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DOE OSTI2022

Application of SCALE to Molten Salt Fueled Reactor Physics in Support of Severe Accident Analyses

As part of a US Nuclear Regulatory Commission–sponsored project to assess the modeling and simulation capabilities for accident progression, source term, and consequence analysis for advanced reactor technologies with SCALE and MELCOR, SCALE was used for the modeling and simulation of a molten salt-fueled reactor (MSR). SCALE capabilities for the modeling of MSR physics were demonstrated based on the Molten Salt Reactor Experiment (MSRE). Of primary interest were the determination of the system’s nuclide inventory, as well as the inventories in the various regions of the loop, considering that the fuel is continuously pumped through the system. This report contains discussions on the following: 1. Determination of the system-average fuel salt inventory considering fission gas removal in the off-gas system and noble metal removal through plating out at the heat exchanger using recent enhancements in SCALE’s depletion sequence TRITON, 2. Assessment of the nuclide spatial distribution throughout the loop using SCALE’s depletion solver ORIGEN, 3. Calculation of the core’s power profile, flux profile, temperature reactivity coefficients, and xenon reactivity using full-core calculations with SCALE’s Monte Carlo code KENO-VI. The results obtained with SCALE were post-processed to provide the MELCOR team with the core inventory and decay heat of the system, as well as the inventory and decay heat of individual regions in the loop, a zone-wise power profile, temperature feedback coefficients, and the xenon worth.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

Review and Modeling of Integrated Energy Systems with Nuclear Reactor Coupled Desalination and District Heating

Detailed reviews of a past advanced nuclear reactor based integrated energy system, as well as other nuclear reactor and fossil fuel based integrated energy systems have been performed for this work. Review of the utilization of heat from nuclear reactors for various applications and cogeneration has been done. The heat can be utilized by extraction of the steam from the turbine while the steam is still at a desired temperature. While use of nuclear process heat for district heating in countries like Finland, France, China, Poland, and elsewhere is discussed, more focus of the review has been given on nuclear desalination processes. Integrated energy systems (IES) where distinct types of reactors like PWR, BWR, sodium cooled fast reactor, heavy water reactor and other advanced reactors are coupled with various nuclear desalination processes like multi-effect distillation (MED), multi-stage flashing (MSF) and reverse osmosis (RO) methods have been discussed. The nuclear desalination plant at Aktau has been discussed in more detail due to its decades of successful operation. The IES of the Aktau plant coupled with 5-effect MED desalination plant has been taken as a reference for modeling the Open Modelica (OM) based IES of this work. Here, the OM IES model shows good agreement with the MED plant output of Aktau and can be extended for future applications of IES.

42 ENGINEERING↗

DOE OSTI2021

Bimodal particle distributions with increased thermal conductivity for solid particles as heat transfer media and storage materials

Solid particles are being considered in several high temperature thermal energy storage systems and as heat transfer media in a variety of advanced power generation systems, particularly in concentrated solar power plants. The downside of such an approach is the low overall heat transfer coefficients caused by the inherently low thermal conductivity values of the low-cost solid media when coupled to heat exchanger for the power cycle working fluid. Choosing the right particle size distribution, emittance, and material of the solid media can all make a substantial difference in packed bed thermal conductivity. Current research though exclusively focuses on continuous unimodal distributions of particles. Here, in this work, we propose the use of a binary particle system with a bimodal size distribution to significantly increase packed bed thermal conductivity by reducing packed bed porosity. This is the first study related to ceramic solid particle heat transfer that has considered the thermal conductivity of non-unimodal size distributions at room and elevated temperatures. The following study found that for the binary particle system using Carbo particles CP 16/30 – CP 70/140 where the large particle volume fraction was 50% there was an 17–47% increase in packed bed thermal conductivity when compared with a nearly unimodal particle size distribution of CP 16/30 between 50 and 300 °C. Two different porosity and effective thermal conductivity models were studied, with one providing better prediction of porosity but both effective thermal conductivity models providing less predictive capacity. Importantly this approach can have a substantial impact of thermal performance, with little to no impact on the particle cost.

36 MATERIALS SCIENCE↗

DOE OSTI2022

CityBES v2021

City Buildings, Energy, and Sustainability (CityBES) is a web-based data and computing platform, focusing on energy modeling and analysis of a city's building stock to support district or city-scale building energy efficiency programs. CityBES uses an international open data standard, CityGML, to represent and exchange 3D city models. CityBES employs EnergyPlus to simulate building energy use and savings from energy efficient retrofits. Other CityBES features include energy benchmarking, district heating and cooling system modeling, rooftop PV analysis, building performance visualization, heat resilience modeling, as well as urban scale mapping of microclimate and heat vulnerability at census tract level. Different from other tools, CityBES uses integrated open and standard 3D city building data and models each individual building using EnergyPlus. CityBES can be used by urban planners, city energy managers, building owners, utilities, energy consultants and researchers.

Hong, Tianzhen↗

DOE OSTI2020

Power Grid Simulation Testbed for Transactive Energy Management Systems

To effectively engage demand-side and distributed energy resources (DERs) for dynamically maintaining the electric power balance, the challenges of controlling and coordinating building equipment and DERs on a large scale must be overcome. Although several control techniques have been proposed in the literature, a significant obstacle to applying these techniques in practice is having access to an effective testing platform. Performing tests at scale using real equipment is impractical, so simulation offers the only viable route to developmental testing at scales of practical interest. Existing power-grid testbeds are unable to model individual residential end-use devices for developing detailed control formulations for responsive loads and DERs. Furthermore, they cannot simulate the control and communications at subminute timescales. To address these issues, this paper presents a novel power-grid simulation testbed for transactive energy management systems. Detailed models of primary home appliances (e.g., heating and cooling systems, water heaters, photovoltaic panels, energy storage systems) are provided to simulate realistic load behaviors in response to environmental parameters and control commands. The proposed testbed incorporates software as it will be deployed, and enables deployable software to interact with various building equipment models for end-to-end performance evaluation at scale.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2021

A two-phase three-field modeling framework for heat pipe application in nuclear reactors

Heat pipes and two-phase thermosyphons are highly efficient heat transfer devices utilizing continuous evaporation and condensation of working fluid for two-phase heat transport in closed systems. Because of the nearly isothermal and fully passive phase-change heat transfer mechanism, heat pipes and thermosyphons have found many applications in nuclear engineering, space technologies, and other energy systems. High-temperature heat pipes are used in nuclear microreactors to remove fission power from the primary system and are coupled with power conversion systems or process heat applications. Modeling of the two-phase flow phenomena inside a heat pipe is essential to its design and safety analysis. In this study, a comprehensive one-dimensional two-phase three-field flow model has been developed for the analysis of heat pipes in normal operation conditions and transients. The conservation or field equations of mass, momentum, and energy were developed for the liquid film, vapor, and droplet. In addition, constitutive models or correlations were reviewed thoroughly and provided for the closure of the three-field equations. Specific constitutive equations regarding interfacial mass and heat transfer at two interfaces, namely film-gas interface and gas-droplet interface, were reviewed for droplet entrainment and deposition rates as well as film and droplet evaporation rates. Furthermore, mechanistic correlations of annular flow film thickness were recommended for the modeling of the thermosyphons without a wick as a critical constitutive correlation. Furthermore, experimental data needs from new experiments using a prototype working fluid or surrogate fluids for the model validation of high-temperature heat pipes in microreactors were recommended for future research.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2021

Thermophysical Properties Experimentally Tested for NaCl-KCl-MgCl 2 Eutectic Molten Salt as a Next-Generation High-Temperature Heat Transfer Fluids in Concentrated Solar Power Systems

A new eutectic chloride molten salt, MgCl 2 -KCl-NaCl (wt% 45.98–38.91–15.11), has been recognized as one of the most promising high-temperature heat transfer fluids (HTF) for both heat transfer and thermal storage for the third-generation concentrated solar power (CSP) systems. For the first time, some essential thermophysical properties of this eutectic chloride molten salt needed for basic heat transfer and energy storage analysis in the application of concentrating solar power systems have been experimentally tested and provided as functions of temperature in the range from 450 °C to 700 °C. The studied properties include heat capacity, melting point, heat of fusion, viscosity, vapor pressure, density, and thermal conductivity. The property equations provide essential database for engineers to use to calculate convective heat transfer in concentrated solar receivers, heat exchangers, and thermal storage for concentrated solar power plants.

14 SOLAR ENERGY↗

DOE OSTI2025

Electrical and Thermal Load Impacts of Three District Heating and Cooling Designs for an Existing Community in Washington, DC

District energy systems that provide building heating and cooling are a promising option to provide low-cost, energy efficient heating and cooling solutions for communities. As some buildings move to electrified heating designs, there may be significant increases in electric grid demand, particularly in the winter. District energy systems may be able to help reduce these high electrical demands on the electric grid, while also providing decreased overall energy consumption with an increased flexibility in electrical energy usage. To evaluate and compare district options for district-based heating and cooling, an existing neighborhood of Washington, DC consisting of 35 existing buildings was selected as a case study. This study models and compares a fourth generation (4G) district heating and cooling systems that provide hot and chilled water from a central plant directly to each prosumer and a fifth generation (5G) district heating and cooling systems that provide near-ambient water via geothermal boreholes to interface with an energy transfer station with a heat pump at each prosumer. These district systems are compared against a baseline of the non-connected buildings with their self-contained and current HVAC systems. The neighborhood was selected as a good candidate for a district system for its diversity of loads (mix of different commercial and property types) and the availability of building characteristics. URBANopt District Energy Systems (DES) was used to model the buildings and create initial Modelica models for the district systems. Finally, the DES models were tuned and simulated in Dymola, and the outputs were post-processed for verification and to calculate the electrical and thermal grid impact metrics. This is the first documentation of this workflow and its complete analysis. The three designed systems are compared via their grid metrics including: total energy consumption, electrical demand peak loads, daily peak-to-valley ratios, and system ramping. A detailed discussion is provided about how each system impacts and interacts with the electric grid.

15 GEOTHERMAL ENERGY↗

DOE OSTI2020

Heat treatment to anneal residual stresses during additive manufacturing

An additive manufacturing system having a heat source for melting powder particles in a desired shape and pattern to produce a product. A secondary heat source is used for heat treating the product to achieve heat treatment. The secondary heat source is used to peen or anneal residual stresses caused by the additive manufacturing process.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Material Selection and Heat Transfer Model for PTUHS Device

The Path to Ultimate Heat Sink Device (PTUHS) is a passive safety system that utilizes a radiative heat transfer valve to control the rate at which heat is removed from a nuclear reactor pressure vessel (RPV) and dispersed into surrounding soil. The material selection for the PTUHS device is investigated, where the thermophysical properties are either maximized or minimized bases on what section of the PTUHS that material is being used for. Final recommendations of material choice are then presented. The heat transfer model of the PTUHS device is solved in ABAQUS, where a normal operating conditions and SCRAM conditions are solved. These temperature maps and heat flux of the system show the system's ability, where minimal heat is lost during normal operating conditions and system failure in a SCRAM scenario due to temperatures that were reached.

42 - ENGINEERING↗

DOE OSTI2021

A System of Agents for Supporting Optimization and Control of a Connected Community

The residential sector consumes a significant portion of the electricity sold in the United States. Above 60% of the energy used in the sector is used to operate heating, ventilation, and air conditioning (HVAC) systems and water heating (WH) systems. With the increase of intelligence in the grid and the new decision and control options enabled by the Internet of Things; control of these devices can be used to support the grid. Therefore, this article presents a scalable multiagent system for optimizing HVAC and WH systems while maintaining comfort. It allows a utility to orchestrate the shifting of energy from critical periods without direct control, but instead by using a price signal. The architecture, optimization formulation, implementation strategy and results from an implementation project are discussed.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2022

Material Plasma Exposure eXperiment (MPEX) High Heat Flux Bellows for Component Alignment in High Microwave Environment

The Material Plasma Exposure eXperiment (MPEX) device is a linear plasma device developed to perform plasma material interaction experiments under the conditions prototypic of a fusion reactor divertor. MPEX has multiple systems that must be precisely aligned to the plasma axis, including an electron cyclotron heating system that emits up to 400 kW of microwave power into the vacuum vessel. Five distinct systems require precise alignment on the MPEX device, thus requiring four bellows, all of which are adjacent to the plasma at a relatively high heat flux of approximately 47 kW/m2 and microwave power regions. The MPEX high heat flux bellows (HHFB) is designed to deliver 6 degrees of freedom positioning. The HHFB includes titanium–zirconium–molybdenum (TZM) inserts that are brazed into a Glidcop AL-15 body using a high-temperature braze alloy, thus blocking direct line of sight to an edge-welded bellows from the plasma and microwave screen to block microwaves from the bellows. Further, a custom ConFlat knife edge is machined into the Glidcop AL-15, so the vacuum flanges do not need a braze or weld joint on the vacuum interface. Fingerstock or copper mesh is used to restrict microwave power from entering the interstitial space between the water-cooled Glidcop AL-15 body and edge-welded bellows. Glidcop AL-15 was selected as the material of choice for the water-cooled body because it can maintain mechanical integrity at elevated temperatures, and it also allows for a high-temperature braze. TZM was selected for its machinability and compatibility with vacuum and plasma requirements. A test article is also being considered for a similarly shaped component, the MPEX limiter, that will demonstrate the integrity of the braze joint under high thermal load. Results from this testing will be extrapolated to deduce the lifetime and integrity of the HHFB design.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2021

System and method for small, clean, steady-state fusion reactors

According to some embodiments, a system for widening and densifying a scrape-off layer (SOL) in a field reversed configuration (FRC) fusion reactor is disclosed. The system includes a gas box at one end of the reactor including a gas inlet system and walls of suitable heat bearing materials. The system further includes an exit orifice adjoining the gas box, wherein the exit orifice has a controllable radius and length to allow plasma to flow out from the gas box to populate the SOL with the plasma. The system may also include fusion products, which decrease in speed in the plasma in the SOL, allowing energy to be extracted and converted into thrust or electrical power and further allowing ash to be extracted to reduce neutron emissions and maintain high, steady-state fusion power.

Cohen, Samuel A.↗

DOE OSTI2022

System and method for small, clean, steady-state fusion reactors

Cohen, Samuel A.↗

DOE OSTI2022

Slides for MS&T2022: Carbon-Carbon Composites from 3D Printed Preforms Graphitized by Electric Field Assisted Sintering

Formation of Carbon-Carbon (C-C) composite materials requires putting a carbon fiber preform through a cycle of densification, carbonization, and graphitization. This cycle is then repeated until the desired properties are achieved. The graphitization phase is particularly energy demanding as it involves heating the components to in excess of 2000°C. In traditional furnaces this is also quite time consuming as typical heating rates are low, and the actual heat treatment may be limited by component dimensions, as heat is conducted throughout the part primarily by thermal diffusion. Joule heating by means of Electric Field Assisted Sintering (EFAS) systems enables high heating rates and causes the part to be heated from the inside, which eliminates the thermal diffusion time constraint. In our process, C-C composites are formed by pyrolyzation of 3D-printed carbon fiber preforms, vacuum infiltration of naphthalene based mesophase pitch, and carbonization. The part is then graphitized in the EFAS system. By this method graphitization of the composite matrix was achieved in less than an hour. A part density of greater than 1.6g/cc (up to 1.9g/cc demonstrated) was achieved after only two rounds of infiltration and a single graphitization. Overall the process took less than a week which is significantly faster than traditional methods. Optical microscopy and XRD results are discussed to elucidate the internal porosity and characterize the degree of graphitization. Testing was performed showing the impact on fiber direction to electrical and thermal properties of the final part.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Control rod drive mechanism with heat pipe cooling

A representative cooling system for a nuclear reactor control rod drive mechanism (CRDM) includes an evaporation section located within or next to the CRDM and a condensation section fluidly coupled to the evaporation section. The cooling system includes a set of heat fins coupled to drive coils in the CRDM and heat pipes that extend through the drive coils and heat fins. A fluid evaporates while in the evaporation section of the heat pipes from heat generated by the CRDM and moves out of the evaporation section into the condensation section in the heat fins. The fluid cools and condensates while in the condensation section, recirculating back into the evaporation section. This passive natural circulation cooling system reduces or eliminates the number of water hoses, piping, and other water pumping equipment typically used for cooling a CRDM thereby increasing nuclear reactor reliability and simplifying nuclear reactor operation and maintenance.

Lobscheid, Christian↗

DOE OSTI2024

Multi-fluid, earth battery energy systems and methods

The present disclosure relates to a system for storing and time shifting at least one of excess electrical power from an electrical power grid, excess electrical power from the power plant itself, or heat from a heat generating source, in the form of pressure and heat, for future use in assisting with a production of electricity. An oxy-combustion furnace is powered by a combustible fuel source, plus excess electricity, during a charge operation to heat a reservoir system containing a quantity of a thermal storage medium. During a discharge operation, a discharge subsystem has a heat exchanger which receives heated CO 2 from the reservoir system and uses this to heat a quantity of high-pressure, supercritical CO 2 (sCO 2 ) to form very-high-temperature, high-pressure sCO 2 at a first output thereof. The very-high-temperature, high-pressure sCO 2 is used to drive a Brayton-cycle turbine, which generates electricity at a first output thereof for transmission to a power grid. The Brayton-cycle turbine also outputs a quantity of sCO 2 which is reduced in temperature and pressure to a heat recuperator subsystem. The heat recuperator subsystem circulates the sCO 2 and re-heats and re-pressurizes the sCO 2 before feeding it back to the heat exchanger to be even further reheated, and then output to the Brayton-cycle turbine as a new quantity of very-high-temperature, high-pressure sCO 2 , to assist in powering the Brayton-cycle turbine.

Buschek, Thomas A.↗

DOE OSTI2023

Combined Heat Shield and Solar Thermal Propulsion System for an Oberth Maneuver

As humanity continues its exploration of space, many space missions are enabled by increases in speed. Examples include outer planet and dwarf planet exploration missions and missions that travel through our solar system into interstellar space. For many of these applications speeds of >10 astronomical units per year (AU/yr) are desired. A powered gravity assist around the Sun may offer the best option for reaching this goal; however, current heat shields and kick stages are too heavy or generate too little thrust. Solar thermal propulsion overcomes this tradeoff by converting the heat of the Sun into thrust. By tripling the specific impulse relative to chemical propulsion and by enabling a smaller perihelion through active cooling, this approach nearly doubles the escape velocity. Our team has designed and built working solar thermal propulsion prototypes out of materials that can survive 2700 K at a 30 x 30 cm scale. These benchtop-scale demonstrations have thus far validated the simplifying assumptions that underlie our thermal and propulsion models. Despite growing confidence that a full-scale heat shield/heat exchanger can survive an Oberth maneuver, many questions remain regarding the feasibility of long-term cryogenic storage of hydrogen propellant.

33 ADVANCED PROPULSION SYSTEMS↗