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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 757 records · Page 42
All sourcesNASA NTRSDOE OSTI
DOE OSTI2014

Reversible Bending Fatigue Testing on Zry-4 Surrogate Rods

Testing high-burnup spent nuclear fuel (SNF) presents many challenges in areas such as specimen preparation, specimen installation, mechanical loading, load control, measurements, data acquisition, and specimen disposal because these tasks are complicated by the radioactivity of the test specimens. Research and comparison studies conducted at Oak Ridge National Laboratory (ORNL) resulted in a new concept in 2010 for a U-frame testing setup on which to perform hot-cell reversible bending fatigue testing. Subsequently, the three-dimensional finite element analysis and the engineering design of components were completed. In 2013 the ORNL team finalized the upgrade of the U-frame testing setup and the integration of the U-frame setup into a Bose dual linear motor test bench to develop a cyclic integrated reversible-bending fatigue tester (CIRFT). A final check was conducted on the CIRFT test system in August 2013, and the CIRFT was installed in the hot cell in September 2013 to evaluate both the static and dynamic mechanical response of SNF rods under simulated loads. The fatigue responses of Zircaloy-4 (Zry-4) cladding and the role of pellet pellet and pellet clad interactions are critical to SNF vibration integrity, but such data are not available due to the unavailability of an effective testing system. While the deployment of the developed CIRFT test system in a hot cell will provide the opportunity to generate the data, the use of a surrogate rod has proven quite effective in identifying the underlying deformation mechanism of an SNF composite rod under an equivalent loading condition. This paper presents the experimental results of using surrogate rods under CIRFT reversible cyclic loading. Specifically, monotonic and cyclic bending tests were conducted on surrogate rods made of a Zry-4 tube and alumina pellet inserts, both with and without an epoxy bond.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2015

Advanced Multiphysics Thermal-Hydraulics Models for the High Flux Isotope Reactor

Engineering design studies to determine the feasibility of converting the High Flux Isotope Reactor (HFIR) from using highly enriched uranium (HEU) to low-enriched uranium (LEU) fuel are ongoing at Oak Ridge National Laboratory (ORNL). This work is part of an effort sponsored by the US Department of Energy (DOE) Reactor Conversion Program. HFIR is a very high flux pressurized light-water-cooled and moderated flux-trap type research reactor. HFIR s current missions are to support neutron scattering experiments, isotope production, and materials irradiation, including neutron activation analysis. Advanced three-dimensional multiphysics models of HFIR fuel were developed in COMSOL software for safety basis (worst case) operating conditions. Several types of physics including multilayer heat conduction, conjugate heat transfer, turbulent flows (RANS model) and structural mechanics were combined and solved for HFIR s inner and outer fuel elements. Alternate design features of the new LEU fuel were evaluated using these multiphysics models. This work led to a new, preliminary reference LEU design that combines a permanent absorber in the lower unfueled region of all of the fuel plates, a burnable absorber in the inner element side plates, and a relocated and reshaped (but still radially contoured) fuel zone. Preliminary results of estimated thermal safety margins are presented. Fuel design studies and model enhancement continue.

COMSOL↗
DOE OSTI2013

Expert Meeting Report: Cladding Attachment Over Exterior Insulation (BSC Report)

The addition of insulation to the exterior of buildings is an effective means of increasing the thermal resistance of both wood framed walls as well as mass masonry wall assemblies. The location of the insulation to the exterior of the structure has many direct benefits including better effective R-value from reduced thermal bridging, better condensation resistance, reduced thermal stress on the structure, as well as other commonly associated improvements such as increased air tightness and improved water management (Hutcheon 1964, Lstiburek 2007). The intent of the meeting was to review the current state of industry knowledge regarding cladding attachment over exterior insulation with a specific focus on: 1. Gravity load resistance, 2. Wind load resistance. The presentations explore these topics from an engineering design, laboratory testing, field monitoring, as well as practical construction perspective. By bringing various groups together (who have been conduction research or have experience in this area), a more holistic review of the design limits and current code language proposals can be completed and additional gaps identified. The results of which will help inform design standards and criteria.

Building America↗
DOE OSTI2014

Enhanced Cover Assessment Project:Soil Manipulation and Revegetation Tests

The U.S. Department of Energy Office of Legacy Management is evaluating methods to enhance natural changes that are essentially converting conventional disposal cell covers for uranium mill tailings into water balance covers. Conventional covers rely on a layer of compacted clayey soil to limit exhalation of radon gas and percolation of rainwater. Water balance covers rely on a less compacted soil “sponge” to store rainwater, and on soil evaporation and plant transpiration (evapotranspiration) to remove stored water and thereby limit percolation. Over time, natural soil-forming and ecological processes are changing conventional covers by increasing hydraulic conductivity, loosening compaction, and increasing evapotranspiration. The rock armor on conventional covers creates a favorable habitat for vegetation by slowing soil evaporation, increasing soil water storage, and trapping dust and organic matter, thereby providing the water and nutrients needed for plant germination, survival, and sustainable transpiration. Goals and Objectives Our overall goal is to determine if allowing or enhancing these natural changes could improve cover performance and reduce maintenance costs over the long term. This test pad study focuses on cover soil hydrology and ecology. Companion studies are evaluating effects of natural and enhanced changes in covers on radon attenuation, erosion, and biointrusion. We constructed a test cover at the Grand Junction disposal site to evaluate soil manipulation and revegetation methods. The engineering design, construction, and properties of the test cover match the upper three layers of the nearby disposal cell cover: a 1-foot armoring of rock riprap, a 6-inch bedding layer of coarse sand and gravel, and a 2-foot protection layer of compacted fine soil. The test cover does not have a radon barrier—cover enhancement tests leave the radon barrier intact. We tested furrowing and ripping as means for creating depressions parallel to the slope contour, bringing soil up into the rock riprap layer, and loosening and blending compacted fine soil with coarse sand and gravel layers. Objectives of these manipulations include (1) enhancing root growth, (2) increasing seed-soil contact, (3) catching runoff water for plant germination and growth, (4) increasing soil water storage capacity, and (5) enhancing deep drying by disrupting the capillary barrier at the interface of the bedding and protection layers.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2017

Understanding the Reliability of Solder Joints Used in Advanced Structural and Electronics Applications: Part 2 - Reliability Performance.

Whether structural or electronic, all solder joints must provide the necessary level of reliability for the application. The Part 1 report examined the effects of filler metal properties and the soldering process on joint reliability. Filler metal solderability and mechanical properties, as well as the extents of base material dissolution and interface reaction that occur during the soldering process, were shown to affect reliability performance. The continuation of this discussion is presented in this Part 2 report, which highlights those factors that directly affect solder joint reliability. There is the growth of an intermetallic compound (IMC) reaction layer at the solder/base material interface by means of solid-state diffusion processes. In terms of mechanical response by the solder joint, fatigue remains as the foremost concern for long-term performance. Thermal mechanical fatigue (TMF), a form of low-cycle fatigue (LCF), occurs when temperature cycling is combined with mismatched values of the coefficient of thermal expansion (CTE) between materials comprising the solder joint “system.” Vibration environments give rise to high-cycle fatigue (HCF) degradation. Although accelerated aging studies provide valuable empirical data, too many variants of filler metals, base materials, joint geometries, and service environments are forcing design engineers to embrace computational modeling to predict the long-term reliability of solder joints.

42 ENGINEERING↗
DOE OSTI2017

A NEW THERMIONIC RF ELECTRON GUN FOR SYNCHROTRON LIGHT SOURCES

A thermionic RF gun is a compact and efficient source of electrons used in many practical applications. RadiaBeam Systems and the Advanced Photon Source at Argonne National Laboratory collaborate in developing of a reliable and robust thermionic RF gun for synchrotron light sources which would offer substantial improvements over existing thermionic RF guns and allow stable operation with up to 1A of beam peak current at a 100 Hz pulse repetition rate and a 1.5 μs RF pulse length. In this paper, we discuss the electromagnetic and engineering design of the cavity and report the progress towards high power tests of the cathode assembly of the new gun.

RF↗
DOE OSTI2017

Non-Destructive Evaluation of the Bondline Interface between Carbon Fiber Reinforced Laminated Composites and Metal Materials via Ultrasonic Inspection Methods

Woven fiber, laminated composites allow the design engineer to create high strength parts, but the effectiveness of the final processed part is greatly diminished through weak or nonexistent bonds between the composite and the substrate to which it is bonded. Additionally, these layered laminates are commonly made by curing the resin infused carbon fiber fabrics in predefined layers and then bonding them to another composite or a metallic structure using either a pre-cure or a co-cure method. The focus of this study is the identification of the defect caused by a disbond or a delamination located at the interface between a composite laminate stack and the substrate to which it is bonded. We present a nondestructive approach using various ultrasonic methods to identify the existence of the bond between composite and composite-to-metal interface. This paper explores contact and immersion ultrasound methods using pulse-echo for evaluating the composite material and adhesive bondline and the signal attenuation undergone by the wave as it propagates through the composite. Finally, a summary of the detection and analysis techniques developed to identify disbonds, including Fast Fourier Transform analysis of the immersion data, is presented. Lastly, each of the methods evaluated in this study is able to detect the transition from bonded to unbonded sections at the bondline from either side of the bonded part, with the immersion technique providing a significantly higher resolution of the edge of the bondline.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Examining the Climate-Energy Nexus for CO2-Enhanced Oil Recovery - LCAXVII

This work was presented at the American Center for Life Cycle Assessment (ACLCA) LCAXVII Conference in Portsmouth, NH on October 4, 2017. An existing LCA model of hydrocarbon fuels produced via CO2-EOR systems is enhanced to more precisely characterize the energy flows alongside the GHG emissions profile. Process energy and material flows are developed based on engineering design principles, the existing unit processes, EOR field parameters, and open source life cycle models including the Petroleum Refinery Life Cycle Inventory Model (PRELIM) and the Oil Production GHG Emissions Estimator (OPGEE). A combinatorial approach is employed to systematically evaluate the energy and environmental profiles of CO2-EOR systems, consisting of permutations of discrete variables: CO2 source, powerplant type, and primary fuel combusted.

Skone, Timothy J.↗
DOE OSTI2021

Pilot-Scale Testing of an Integrated Circuit for the Extraction of Rare Earth Minerals and Elements from Coal and Coal Byproducts Using Advanced Separation Technologies

The primary objective of this project was to develop and demonstrate an integrated pilot-scale circuitry for recovering high-value rare earth elements (REEs) from coal and coal byproducts. The target performance was to produce a mixed REE product with content of at least two percent by weight on a dry mass basis in a cost-effective and environmentally benign manner. During the first nine months of the project period (Phase 2 Budget Period 2), pilot plant construction was completed including all field site startup activities such as permitting, engineering design, procurement/bidding, unit fabrication, site construction, equipment installation, module assembly, safety training, and circuit shakedown. During the remaining 21 months of project period (Phase 2 Budget Period 3), detailed field-testing activities were performed including feedstock sample collection and preparation, exploratory testing, circuit modification, detailed parametric study, and performance optimization. A detailed techno-economic analysis was performed based on the pilot plant testing findings which provided various scenarios for REE production. The project successfully accomplished the proposed target performance by producing mixed rare earth oxide (REO) with greater than 90% purity by weight in a continuous pilot scale operation from two distinctly different coarse refuse materials (i.e., West Kentucky No. 13 and Fire Clay coal seams), and at least three secondary sources (i.e., heap leach process and naturally formed acid mine drainage system). Project partners included the University of Kentucky, Virginia Tech, West Virginia University, Alliance Coal, Blackhawk Mining, Mineral Refining Company, and Mineral Separation Technologies. The pilot scale test facility was constructed at a former mining complex owned by Alliance Natural Resource Partners (Alliance Coal). The site was rehabilitated to accommodate the equipment installation, construction and fabrication, electrical power requirement, water line management and containment. The process units constructed and installed included X-ray sorting unit, crushing and grinding unit, physical separation unit, acid leaching unit, solvent extraction unit, and wastewater management unit. A rare earth mineral concentration unit was constructed as a standalone unit for flexible operation. A detailed environmental assessment and control plan was carried out to identify and quantify any potential impacts of the pilot-scale processing circuitry on the human and eco-system health and well-being. Corresponding mitigation strategies and control measures were provided. A conceptual flowsheet was developed to effectively remove thorium and uranium from high purity rare earth oxide mix or any potential radionuclide enriched stream. The two distinct feedstock materials were secured from the Blackhawk Mining Complex in eastern Kentucky where the Fire Clay (Hazard No. 4) seam is processed. The West Kentucky No. 13 (Baker) coarse refuse material was collected from an active process stream at an Alliance coal preparation plant located in western Kentucky. Characterization analysis indicated that both of feed materials generated from the two sources contained >300 ppm of TREEs on a dry whole mass basis which met the requirements for a qualified feed stock. The two feedstocks were further upgraded using a dual x-ray sorter to prepare the feed material for hydrometallurgical circuit. Thermal treatment on feed material prior to leaching was found to: 1) improve the leaching recovery of REEs, 2) increase the leaching kinetics, and 3) allow the leaching reaction to occur at lower acidity. Roasting at 600°C was selected as the pre-treatment condition for both West Kentucky No. 13 and Fire Clay coarse refuse material. Over 40% of leaching recovery was achieved by roasting West Kentucky No. 13 material having a top particle size of 3 mm in the pilot scale operation using 1.2M sulfuric acid leaching at 75OC. Initial pilot scale testing involved continuous operation of the pilot plant for 94 hours. The leaching unit was operated at solid-to-liquid ratio of 1 to 10 (w/v) using 0.5M sulfuric acid solution at a temperature of 75°C. The continuous solvent extraction circuit utilized rougher and cleaner units with DEHPA and TBP as the extractants. An innovative stripping circuit was developed to accumulate the REE concentration in the stripping solution to a level above 600 ppm. A bleed stream from the recycled strip solution was treated using oxalic acid precipitation which produced a high grade rare earth oxalate. The oxalate product was roasted to remove the oxalate which produced a rare earth oxide product having a purity greater 90%. Due to high concentrations of contaminant ions in the pregnant leach solution (PLS), a modified flowsheet was developed that involved pre-concentration of the REEs using multiple stages of precipitation and redissolution. The advantage of this process was improved removal of contamination before the downstream purification process and a significant cost reduction relative to the circuit that utilized the solvent extraction process. The modified circuitry included processes involving leaching, multistage precipitation, redissolution, and oxalate precipitation followed by roasting of the oxalate product. The circuit produced a mixed REO that was 92.96% pure from the initial test. A detailed parametric test plan was carried out which involved varying key parameters including solids feed rate, acid flowrate, acid concentration, multistage precipitation pH, redissolution pH, oxalate precipitation dosage and pH. The response variables included REE recovery, contaminant recovery, REO product grade and overall chemical consumption. Test results indicated that the acid-to-solid ratio is the key parameter to leaching efficiency as performance deteriorated with an increase in solids concentration. The optimal pH determined for REE precipitation and redissolution was 6.5 and 2.5, respectively. Additional tests were conducted to further improve the flowsheet. Recirculating a portion of the PLS to the feed of the leach tanks improved the leaching performance by lowering the pH of the leaching system and reducing the contamination recovery by shortening the residence time. Moreover, the removal of Al prior to REE precipitation significantly reduced the oxalic acid consumption in the oxalate precipitation circuit. The modified circuit produced over 90% grade REO by weight from both West Kentucky No. 13 and Fire Clay coarse refuse material in pilot scale continuous test programs. A case analysis model was developed to project the REE and major contaminants concentration in each PLS stream based on the leaching condition, pH cut point, and oxalic acid dosage. A correlation was established using empirical and semi-empirical models. Using the models, chemical consumption required for each stage was predicted based on the projected performance of the hydrometallurgy circuit. After identifying the optimum conditions, validation tests were carried out for the treatment of both West Kentucky No. 13 and Fire Clay coarse refuse materials in the pilot plant. The actual circuit performance and chemical consumptions were very close to the model predictions. Other than the two coarse refuse sources, several secondary feedstocks were also tested in the pilot plant facility. A “heap leach” system was constructed using the coarse refuse material generated from cleaning the West Kentucky No. 13 seam coal. Using the two stage SX rougher and cleaner circuit, a concentrate with a grade >90% REO was produced while recovering >97% of the REEs from the heap leach PLS. Naturally generated acid mine drainage (AMD) from West Kentucky No.13 mine was processed using the multistage precipitation circuit in the pilot plant in a test conducted for a period of 32 hours. The final grade of the mix RE oxide produced from the AMD was 90.84% with an overall circuit recovery of 64%. The primary source of REE was the selective precipitation steps involving iron and aluminum rejection. The hydrophobic-hydrophilic separation (HHS) process was proven to effectively recover coal from fine waste materials. For REM recovery, the HHS process was able to produce concentrates at grades of approximately 1.8% REE on an ash basis; however, recovery values were typically low, <10%, under the optimal conditions determined in the laboratory-scale testing. Staged testing of the pilot-scale HHS process for coal recovery and semi-continuous laboratory testing for REM testing showed that a total concentration ratio of more than 15x was observed for the REM recovery process. A circuit simulation package was developed for REE extraction and purification using a spreadsheet-based platform (Microsoft Excel). The REESim circuit simulation package is configured to track the mass and volume flows of components passing through a series of unit operations specified and configured by the user. The mass rates can then be utilized by the user to determine important performance indicators such as product mass yields, concentrate purity levels, element-by-element recoveries, and so forth. The techno-economic analysis showed that the roasting and leaching operations were the most expensive capital items, each contributing approximately 30% to the total capital cost. One notable contributor to the high production costs was the low REE recovery observed in the pilot scale trials. The product basket price was shown to have a strong influence on the economic viability of the scenarios, with the scandium price being the most significant influencer. Operating cost was shown to be extremely sensitive to REE recovery, REE feed grade, and leaching acid consumption. An analysis of ten different scenarios for a 500 t/h commercial operation revealed that three were economically favorable, producing internal rates of return varying from 27.7% to 33.1% and payback periods of 4 to 5 years. The project successfully developed and demonstrated a process to recover REEs from coal and coal byproducts in a pilot-plant operation which consistently produced over 90% grade REO mix from varies types of feedstocks. Commercialization analysis showed that the technology readiness level successfully achieved TRL 6 at the end of the project and demonstrated the need and the potential for scaling the process to further advance the technologies toward the goal of providing a domestic supply of REEs at a commercial scale.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2021

BETO 2021 Peer Review - FCIC Task 6: High Temperature Conversion

The impacts of feedstock variability on pyrolysis processes are significant but poorly defined. Current engineering designs are based on empirical guidelines, useful only over a narrow range of feedstock properties. The objectives of this project are to (1) Develop science-based knowledge of how feedstock attributes and operational parameters impact pyrolysis process reliability and product quality; and (2) Build an experimental and computational toolset that predicts these outcomes, enabling processes to optimize reliability and product quality. Biomass is a complex feedstock. Controlling for and testing the effects of individual attributes is very challenging. This project couples multiscale experimentation and modeling to accurately capture the fundamental physics and chemistry of biomass flow and conversion behavior in feeding and pyrolysis reactor operations. Our focus is on pine residue attributes – anatomical fraction (bark, needles, wood), particle morphology (size/shape distribution, density, porosity), and chemical composition (extractives, biopolymers, alkali metals) – that impact product quality for downstream catalytic upgrading. Because detailed pyrolysis product characterization is limited, cutting-edge analytical techniques are being developed to reveal impactful product attributes. The tools and knowledge developed here will enable integrated pyrolysis-based processes that are more robust, flexible, and market-responsive with respect to feedstock variability.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2021

Scalable Approaches to Selecting Key Entities in Large Networked Infrastructure Systems

This work aims at bringing advances in discrete optimization algorithms to solving practical engineering problems at scale. Often times, in many engineering design problems, there is a need to select a small set of influential or representative elements from a large ground set of entities in an optimal fashion. Submodular optimization provides for a formal way to solve such problems. Common examples with infrastructure systems involve sensor placement and identification of key entities with certain objectives. However, scaling these approaches to large infrastructure systems can be challenging because of the high computational complexity of the overall framework that include the optimization algorithms as well as high-complexity compute-oracles that provide the necessary objective function values. In this work, we explore a well-studied and widely-applicable paradigm, namely leader-selection in a multi-agent networked setting in the context of scalable methodologies. We demonstrate novel frameworks that utilize variations of accelerated submodular optimization algorithms along with linear-algebraic methods that can help accelerate the oracle computations. We further explore this combination in conjunction with graph partitioning paradigms to take advantage of the accelerated algorithms in a distributed setting. Finally we demonstrate the key findings on a practical problem in an operational setting. For this, we leverage an example road network with approximately 18k nodes and 27k edges in a traffic control application, where we seek a limited number of k=200 key intersections. This problem can be solved in a serial setting in just under 5 hours providing more than 2 orders of magnitude speed-up over methods that do not consider acceleration techniques.

Visweswara Sathanur, Arun↗
DOE OSTI2022

Techno-Economic Evaluation of Strategies to Approach Net-Zero Carbon Sustainable Aviation Fuel via Woody Biomass Gasification and Fischer-Tropsch Synthesis

Reducing the carbon dioxide (CO2) emissions from the transportation industry is a key target for achieving global net-zero carbon goals. Wide-spread electrification, efficient engine design, and alternative fuel implementations have been introduced for light-duty vehicles and are projected to significantly reduce light-duty emissions in the near future. Conversely, the aviation sector contributes considerably towards transportation-based carbon emissions, but current projections do not show substantial reductions in carbon emissions over time. Challenges for the aviation sector include low compatibility with electrification, relative inflexibility to variations in fuel properties, and requirement of high energy density fuels. Thus, identifying pathways to decarbonize the aviation sector via liquid low- or net-zero carbon biofuels that are compatible with current aviation infrastructure is crucial. This work investigates the economic feasibility of approaching net-zero carbon sustainable aviation fuel (SAF) from woody biomass via gasification and Fischer-Tropsch synthesis. In doing so, this assessment identifies the economic opportunities and trade-offs of several carbon mitigation strategies coupled with renewable resource interventions required to approach net-zero carbon fuels via biomass. Renewable natural gas and green hydrogen utilization strategies are assessed to examine the impact of fuel yield improvements versus renewable resource cost. Additionally, both carbon capture and sequestration (CCS) and carbon capture and utilization (CCU) are considered in this analysis to help mitigate carbon loss to the atmosphere. Each scenario was assessed on cost, carbon efficiency, energy efficiency, and overall technology-readiness level (TRL). The results of this analysis show that renewable natural gas, green hydrogen, and CCS can be viewed as a low-cost, near-term carbon abatement strategies. However, in the long-term, deployment of more expensive and less technologically mature CCU technologies can make use of point sources of CO2 to boost overall fuel production.

aviation fuel↗
DOE OSTI2022

Material Compatibility of 3D Printed Polymer Composites with Low GWP Refrigerants

The recent development of 3D printing brings numerous opportunities to develop polymer heat exchangers with desired configurations and allows access to the new complex engineering design for better performance. To be used in the HVAC&R system, the compatibility of these materials to refrigerants needs to be thoroughly investigated and understood. This study tested the material compatibility of the printed polymer composites according to the ASHRAE Guideline 38 using metal pressure vessels. These printed parts were tested with R-134A, R-1234YF, R-1234ZE, R-1233ZD(E), and 32-3 MAF POE (10 wt.%) was used as the lubricants. The change in volume, mass, hardness, and mechanical properties was studied in detail. Different compatibility of the composites with refrigerants was observed when the composition of the composite changed. After exposure to refrigerants, the morphological and thermal properties were studied with the scanning electron microscope, thermogravimetric analysis, and differential scanning calorimetry to further reveal the influence of these refrigerants.

Li, Kai↗
DOE OSTI2022

Start-up and Emergency Shutdown Modeling for a Coal-fired 10MWe sCO₂ Power Plant

As part of a Phase II Front End Engineering Design (FEED) study for the DOE Fossil Fuel Large Scale Pilots program, investigations of novel start-up and emergency shutdown methods for a stoker-fed, coal-fired, 10MWe sCO₂ power plant proposal were performed. These investigations were performed using 1D transient system models of the plant created within the GT-SUITE system modeling platform. The system model components were created using vendor quotation data (heat exchangers), performance maps (turbomachines), or FMU models (fired heater). Previously, Echogen Power Systems (Echogen) has used a sCO₂ power cycle start-up method that fills the system with liquid CO₂ to facilitate easy use of an electrically-driven start pump to transition the system from initial CO₂ fill to turbo-compressor initialization. The novel start-up method presented attempts this transition with a minimal filling of the system with liquid CO₂, to reduce the total CO₂ inventory required. This method leaves the start pump vulnerable to a two phase inlet condition as system pressure is below the CO₂ saturation pressure for the condenser cooling water temperature (Tcw). System model cases at Tcw of 18°C, 26°C, and 32°C, corresponding to cold, design, and hot ambient days, were analyzed to determine if the SP inlet condition could be kept as a subcooled liquid and estimate the CO₂ inventory reduction amount./p> Stoker-fed, coal-fired heaters continue to emit heat for some time even after emergency shutdown from events such as a power failure. This heat emission would lead to a failure of the fired heater, as the metal overheats, if the CO₂ flow is shut off. The emergency shutdown method presented utilizes CO₂ vented by a controllable vent valve (CRV) to provide CO₂ cooling flow to the fired heater. To determine the effectiveness of this method at keeping the fired heater peak tubing metal temperature below the ASME material temperature limit, for pressures below 5 MPa, of 816 °C, system model cases with CRV diameters ranging from 4” to 10”, and an alternative CO₂ vent routing with CRV size of 6”, were investigated./p>

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2023

Effect of Silica and Mixing Time on Microstructures of Porous Polymer Composite by Emulsion Templating

Porous polymer composite with tailored porosity is applied in the myriads of areas such as energy storage, oil/water absorption, bioengineering, and advanced areas of material science. The emulsion templating technology is one of the most popular methods for synthesizing porous polymer composite. It involves solidifying a two-phase mixture of porogen and polymer, then removing porogen to create pores within the continuous emulsion phase by polymerization or curing. The surfactant plays a pivotal role in accomplishing a stable emulsion, a key factor in designing the internal porous structure. This study highlights the effect of silica filler and mixing time on pore morphology, i.e., shape, size, and distribution. on polydimethylsiloxane (PDMS) porous structure utilizing the water-in-oil emulsion templating method. Span® 80 is used as a surfactant to reduce the surface tension between water, silica, and PDMS and simultaneously create a strong foaming effect. Different weight concentrations of silica (1-10 wt%) were chosen while keeping the internal phase, i.e., water (50 wt%) constant. The designed porous structures were further characterized through scanning electron microscopy (SEM). Porous composite specimens fabricated with higher silica content and mixing time consistently exhibit smaller pore sizes than specimens fabricated with lower mixing time and silica content. A breakthrough of pore morphology is seen at silica content higher than 5wt% at 1 min mixing, however, pore morphology drastically changes when mixing time increases from 1 min to 6 min. Variation of finer mixing time beyond 1 min shows stepwise changes in pore morphology from a large single-phase porous structure to a bi-modal porous structure which eventually become a smaller single-mode porous structure. Thus, the emulsion templating technique, in combination with different filler content and mixing time, will effectively aid in designing engineered porous polymer composite with varying stiffness and pore morphology.

Porous polymer, Emulsion templating, Surfactant, P↗
DOE OSTI2023

Industrial Requirements Status Report and Down-Select of Candidate Technologies

The report discusses the potential for implementing Integrated Energy Systems (IES) using advanced nuclear reactors to provide thermal and electrical energy to carbon-emitting industries while reducing their carbon footprint. Nine different industries were reviewed to determine their decarbonization potential, how nuclear power can fit in, and the carbon footprint of each. The report also identifies specific integration points and streams for most processes, including temperature and pressure requirements of integrating nuclear power with industrial processes. The report also provides insights on advanced nuclear reactors and their potential for us in IES for decarbonization. The target audience for the report is broad, but mainly addressed to the industry leads and nuclear reactor developers. The report recommends that in the short term, a few processes should be identified to continue research and investigation so that front end engineering design work can provide technical analysis for integrating nuclear heat and replacing existing carbon-emitting thermal sources. The work emphasized the significant decarbonization opportunity across each of the technologies looked at as well as how novel and useful nuclear integration is to reduce the environmental impact of these significant industries.

02 PETROLEUM↗