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At least 73 records · Page 4

A Reinforcement Learning Approach to Augment Conventional PID Control in Nuclear Power Plant Transient Operation

The ability of nuclear reactors to operate their power conversion cycles more flexibly will enhance their value to energy grids with variable pricing. Current nuclear control systems are typically classical controllers that are often based on proportional-integral-derivative (PID) control. This paper presents a method of augmenting the existing PID control for difficult transient operations in nuclear power plants using a reinforcement learning–derived feedforward signal applied in real time. The agents, which are trained on a test thermal load-following problem, are designed to improve steam generator outlet temperature control for a range of fast load-following scenarios covering ramp rates from 9%/min to 15%/min. Several reinforcement learning algorithms were initially investigated for the training of the feedforward agents with deep Q-learning (DQN) and proximal policy optimization (PPO) networks, which were found to be the most promising. The DQN controllers utilize discrete actions, giving them a better disturbance rejection at steady state but inconsistent response to initial temperature deviations. In contrast, PPO-trained agents, which take continuous actions except for a dead zone around zero, were shown to have the best combination of high disturbance rejection at steady state and good tracking of the desired temperature value. The ability of the PPO agent was also examined, with the average time of decision making found to be on the order of 1 ms. The fault properties of the controller under the loss of the reinforcement learning agent feedforward signal were also examined. The controller showed strong performance in situations of “no-signal” faults. but was less good at handling “stuck-at” faults, where the feedforward signal remains at a set value. In both cases, however, the PID was able to successfully maintain stability, eventually returning the system to a steady state. It is hoped that this work will allow for the proposed control architecture to be examined for more difficult control problems such that it may eventually be used to adapt existing nuclear plants for more aggressive load-following on grids of the future.

22 GENERAL STUDIES OF NUCLEAR REACTORS

Technical and Economic Assessment and Gap Analysis of Advanced Nuclear Reactor Integration with a Reference Oil Refinery

Efforts to identify the most-economic methods to decarbonize several sectors of the U.S. economy are underway. Industrial processes such as crude-oil refining rely heavily on energy-dense and easily stored and transported fossil fuels for powering their operations. Refineries use large amounts of energy, primarily derived from fossil sources to separate crude-oil components, break down heavier hydrocarbons into lighter compounds, remove impurities, reform hydrocarbon molecules, and generate steam and electricity for pumps and compressors and other various auxiliary systems. Crude-oil refining operations such as distillation, cracking, desulfurization, reforming, utilities systems and some offsite facilities collectively account for most of the energy consumption. Other operations such as hydrocracking or hydrotreating also require hydrogen for developing hydrogenation reactions which involve substantial heating to keep the reactors at high-temperature and pressure levels. All heat and energy demands are typically provided by natural gas (NG), oil, or other fuels, which makes refinery industry one of the most-difficult sectors to decarbonize. Nuclear power is a viable and energy-dense source of clean electricity, heat, and hydrogen to provide the large, sustainable energy supply that the refining industry demands. The U.S. Department of Energy’s (DOE’s) Integrated Energy Systems (IES) program is working to perform research and development, design, economic siting, and risk analysis. This state-of-the-art work will enable the first on-site demonstrations and commercial deployments of advanced small modular nuclear reactors (SMNRs) integrated with industries such as chemical production, refining, iron and steel making, and more. IES seeks to demonstrate the ability of advanced nuclear reactors to meet the heat and power demands of these industries while reducing carbon emissions in a sustainable and cost-competitive way. The primary objective of this research effort is to analyze industrial-scale SMNR integration intended to decarbonize refining facilities. The foreseen outcome is the provision of reliable, cost-competitive, and sustainable clean energy, alongside a reduction of carbon emissions. Specifically, the focus of this work lies on meeting the reference facilities’ heat and electricity demands with nuclear power while also supplying clean hydrogen via integrated high-temperature steam electrolysis (HTSE). This report presents a comprehensive technical and economic assessment of the integration of advanced nuclear reactors into a reference refinery, leveraging financial incentives from the Inflation Reduction Act (IRA). The evaluation aims to explore the potential economic benefits and challenges associated with incorporating advanced nuclear reactors into refinery operations, particularly in terms of energy efficiency, economic implications and environmental impact. By examining both the technical feasibility and economic viability, this analysis seeks to identify existing gaps and propose solutions for successful nuclear integration implementation. The findings are intended to provide valuable insights for stakeholders considering the adoption of advanced nuclear reactors in the refining sector. A refinery reference-plant was developed, using an open-source refinery model, Petroleum Refinery Lifecycle Inventory Model (PRELIM) and expert assessment, as a base case for comparison with various nuclear integration options. The capacity of 100 kbd/day (KBD) of heavy crude-oil feed was selected to represent a general coking-type refinery with deep conversion capabilities (incorporating heavy-oil upgrading with FCC, coking, and associated hydrotreating process units), using a heavy crude-oil feed, which represents about 70% of U.S. refineries configurations. A summary of all cases considered in this study is shown in Table 1.

13 HYDRO ENERGY

Field Validation of Electrocoagulation Treatment for Oily Wastewater at a Steel Mill

Oily wastewater is a significant byproduct across various industries, including steel production, posing environmental and health risks. Steelmaking is particularly water-intensive, with an estimated 75,000 gallons required to produce 1 ton of steel, although recycling reduces this to 13,000–23,000 gallons per ton.1 Water serves multiple purposes in steelmaking, including equipment cooling, scale removal, steam generation, lubrication, and pollution control.

54 ENVIRONMENTAL SCIENCES

Status of SPCA-ANL Software Development, Software Quality Assurance, and Application (FY2025)

SPCA-ANL is a simulation tool used to perform deterministic analyses of sodium spray and pool fires. Development of the SPCA-II (Spray Pool Combustion Analysis) code began in the mid- 1980s as part of the Clinch River Breeder Reactor (CRBR) Project. At that time, development of SPCA-II, which was led by Rockwell International, was focused on treatment of large-scale sodium spray, stream, and pool fires that were anticipated to be prototypic of the steam generator building cells in CRBR. Under more recent DOE NE programmatic activities, the SPCA-II code was recovered from existing literature and underwent minor modifications to generate a stable executable. This recovered version of the code was not formally released. As part of the Versatile Test Reactor (VTR) Project in the 2010s, the SPCA-II code underwent key modifications to improve stability, address modeling deficiencies, improve consistency between the code manual and software, and address numerous bugs. At this point, SPCA-II was renamed SPCA-ANL. Given that SPCA-II served as the original basis for SPCA-ANL, both codes share an integrated history. Following termination of the VTR Project, the DOE NE Fast Reactor Program resumed support of the software with the goal of building and maintaining software infrastructure that can enable commercial-grade dedication of SPCA-ANL by an end user. Version 1.0, the first external release of SPCA-ANL, was generated in June 2024. This report summarizes the development and maintenance activities completed for SPCAANL in FY2025. This year’s work was focused on improving quality and usability of the code. The provisional Software Quality Assurance (SQA) program has been established and was used to test the procedures for infrastructure improvements, code development, bug fixes, and code releases, as described in the following sections of this report. A code Version 1.0.1 was released in FY25, as described in Chapter 4.

97 MATHEMATICS AND COMPUTING

Chevron Natural Gas Carbon Capture Technology Testing Project (Final Technical Report)

The objective of this project was to design, construct, commission, and operate an engineering scale post combustion carbon capture system to validate the technical maturity, operability, and scalability of Svante’s VeloxoTherm™ solid sorbent carbon capture technology under representative flue gas conditions. The project was executed at Chevron’s Kern River oil field in the San Joaquin Valley of California and evaluated carbon capture performance using slipstream flue gas from natural gas fired once through steam generators (OTSG), including indicative coal and natural gas combined cycle (NGCC) operating scenarios.

03 NATURAL GAS

Intracore Natural Circulation Study in the High Temperature Test Facility

The development of the Modular High-Temperature Gas-Cooled Reactor is a significant milestone in advanced nuclear reactor technology. One of the concerns for the reactor’s safe operation is the effects of a loss-of-flow accident (LOFA) where the coolant circulators are tripped, and forced coolant flow through the core is lost. Depending on the steam generator placement, loop or intracore natural circulation develops to help transfer heat from the core to the reactor cavity, cooling system. This paper investigates the fundamental physical phenomena associated with intracore coolant natural circulation flow in a one-sixth Computational Fluid Dynamics (CFD) model of the Oregon State University High Temperature Test Facility (OSU HTTF) following a loss-of-flow accident transient. This study employs conjugate heat transfer and steady-state flow along with an SST k-ω turbulence model to characterize the phenomenon of core channel-to-channel natural convection. Previous studies have revealed the importance of complex flow distribution in the inlet and outlet plenums with the potential to generate hot coolant jets. For this reason, complete upper and lower plenum volumes are included in the analyzed computational domain. CFD results also include parametric studies performed for a mesh sensitivity analysis, generated using the STAR-CCM+ software. The resulting channel axial velocities and flow directions support the test facility scaling analysis and similarity group distortions calculation.

22 GENERAL STUDIES OF NUCLEAR REACTORS

Scheimpflug LIDAR for Gas Sensing at Elevated Temperatures

Localized operating conditions inside boilers, heat recovery steam generators, or other large thermal systems have a huge impact on the efficiency, environmental performance, and lifetime of components. It is extremely difficult to measure species accurately within these systems due to the high temperatures and harsh environments, locally oxidizing or reducing atmospheres, ash, other particulates, and other damaging chemical species. Physical probes quickly suffer damage and are rendered nonfunctional. This work has attempted to adapt the measurement approach based on Scheimpflug light detection and ranging (S-LIDAR) for the remote sensing of gas species inside the high-temperature boiler environment. For a proof-of-concept, the detection of Raman signals of N 2 , O 2 , and CO 2 and their behavior with increasing temperature have been presented.

47 OTHER INSTRUMENTATION

Rocket engine heat transfer and material technology for commercial applications

Liquid fueled rocket engine combustion, heat transfer, and material technology have been utilized in the design and development of compact combustion and heat exchange equipment intended for application in the commercial field. An initial application of the concepts to the design of a compact steam generator to be utilized by electrical utilities for the production of peaking power is described.

Hiltabiddle, J.

Remote sensing of atmospheric SO2 using the differential absorption LIDAR technique

The paper reports an investigation of the capabilities of a UV differential absorption lidar (DIAL) system for remote measurements of sulfur dioxide emissions. Two features of the present DIAL system are an absorption cell permitting the determination of the difference in SO2 absorption coefficients for the two transmitted wavelengths and a calibration cell permitting the linearity and performance of the system to be evaluated. The DIAL technique is described along with the transmitter, receiver, data-adquisition, and data-processing components of the investigated system. Quantitative measurements of the average SO2 concentration in a region surrounding the exhaust stack of a steam-generating plant are discussed which show that the present system has measurement sensitivities of 10 ppb at a range of 0.8 km and 20 ppb at 1.9 km. Based on performance characteristics obtained during a calibration of this system, it is predicted that a measurement sensitivity of less than 4 ppb over a 1-km path will be attained.

Hoell, J. M., Jr.

Material handling systems for the fluidized-bed combustion boiler at Rivesville, West Virginia

The 300,000 lbs/hr steam capacity multicell fluidized-bed boiler (MFB) utilizes complex material handling systems. The material handling systems can be divided into the following areas: (1) coal preparation; transfer and delivery, (2) limestone handling system, (3) fly-ash removal and (4) bed material handling system. Each of the above systems are described in detail and some of the potential problem areas are discussed. A major potential problem that exists is the coal drying system. The coal dryer is designed to use 600 F preheated combustion air as drying medium and the dryer effluent is designed to enter a hot electrostatic precipitator (730 F) after passage through a cyclone. Other problem areas to be discussed include the steam generator coal and limestone feed system which may have operating difficulties with wet coal and/or coal fines.

Branam, J. G.

Conceptual design of thermal energy storage systems for near term electric utility applications. Volume 1: Screening of concepts

Over forty thermal energy storage (TES) concepts gathered from the literature and personal contacts were studied for their suitability for the electric utility application of storing energy off-peak discharge during peak hours. Twelve selections were derived from the concepts for screening; they used as storage media high temperature water (HTW), hot oil, molten salts, and packed beds of solids such as rock. HTW required pressure containment by prestressed cast-iron or concrete vessels, or lined underground cavities. Both steam generation from storage and feedwater heating from storage were studied. Four choices were made for further study during the project. Economic comparison by electric utility standard cost practices, and near-term availability (low technical risk) were principal criteria but suitability for utility use, conservation potential, and environmental hazards were considered.

Hausz, W.

Cogeneration Technology Alternatives Study (CTAS). Volume 1: Summary report

Large savings can be made in industry by cogenerating electric power and process heat in single energy conversion systems rather than separately in utility plants and in process boilers. About fifty industrial processes from the largest energy consuming sectors were used as a basis for matching a similar number of energy conversion systems that are considered as candidates which can be made available by the 1985 to 2000 time period. The sectors considered included food, textiles, lumber, paper, chemicals, petroleum, glass, and primary metals. The energy conversion systems included steam and gas turbines, diesels, thermionics, stirling, closed-cycle and steam injected gas turbines, and fuel cells. Fuels considered were coal, both coal and petroleum-based residual and distillate liquid fuels, and low Btu gas obtained through the on-site gasification of coal. An attempt was made to use consistent assumptions and a consistent set of ground rules for determining performance and cost in individual plants and on a national level. It was found that: (1) atmospheric and pressurized fluidized bed steam turbine systems were the most attractive of the direct coal-fired systems; and (2) open-cycle gas turbines with heat recovery steam generators and combined-cycles with NO(x) emission reduction and moderately increased firing temperatures were the most attractive of the coal-derived liquid-fired systems.

Gerlaugh, H. E.

Crude oil desulfurization

High sulfur crude oil is desulfurized by a low temperature (25-80 C.) chlorinolysis at ambient pressure in the absence of organic solvent or diluent but in the presence of water (water/oil=0.3) followed by a water and caustic wash to remove sulfur and chlorine containing reaction products. The process described can be practiced at a well site for the recovery of desulfurized oil used to generate steam for injection into the well for enhanced oil recovery.

Kalvinskas, J. J.

Solar Total Energy Project (STEP) Performance Analysis of High Temperature Energy Storage Subsystem

The 1982 milestones and lessons learned; performance in 1983; a typical day's operation; collector field performance and thermal losses; and formal testing are highlighted. An initial test that involves characterizing the high temperature storage (hts) subsystem is emphasized. The primary element is on 11,000 gallon storage tank that provides energy to the steam generator during transient solar conditions or extends operating time. Overnight, thermal losses were analyzed. The length of time the system is operated at various levels of cogeneration using stored energy is reviewed.

Moore, D. M.

Innovation for Pollution Control

Kinetic Controls Inc.'s refuse-fired steam generating facility led to the development of an air pollution equipment control device. The device is currently marketed by two NASA/Langley Research Center employees. It automatically senses and compensates for the changes in smoke composition when refuse is used as a fuel by adjusting the precipitator's voltage and current to permit maximum collection of electrically charged dust particles. The control adapts to any electrostatic precipitator and should have extensive commercial applications.

Source record

Pool Boiling Experiment Has Successful Flights

The Pool Boiling Experiment (PBE) is designed to improve understanding of the fundamental mechanisms that constitute nucleate pool boiling. Nucleate pool boiling is a process wherein a stagnant pool of liquid is in contact with a surface that can supply heat to the liquid. If the liquid absorbs enough heat, a vapor bubble can be formed. This process occurs when a pot of water boils. On Earth, gravity tends to remove the vapor bubble from the heating surface because it is dominated by buoyant convection. In the orbiting space shuttle, however, buoyant convection has much less of an effect because the forces of gravity are very small. The Pool Boiling Experiment was initiated to provide insight into this nucleate boiling process, which has many Earthbound applications, such as steam-generation power plants, petroleum, and other chemical plants. Also, by using the test fluid R-113, the Pool Boiling Experiment can provide some basic understanding of the boiling behavior of cryogenic fluids without the large cost of an experiment using an actual cryogen.

Source record

Altitude Testing of Large Liquid Propellant Engines

Altitude Testing of the J2-X engine at 100,000 feet (start capability). Chemical Steam Generation for providing vacuum. Project Started Mar 07. Test Stand Activation around Late 2010. J-2X Testing around early 2011.

Maynard, Bryon