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All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

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↗
DOE OSTI2020

Nek5000 developments in support of industry and the NRC

This year, the Nuclear Energy Advanced Modeling Simulation program (NEAMS) thermal-hydraulics verification and validation (V&V) work has focused in three areas of Nek5000 V&V-driven development. First, in a close collaborative effort with the U. S. Nuclear Regulatory Commission (NRC) staff, we have continued V&V efforts for the HYMERES-2 project using the OECD/NEA sponsored testing in the PSI PANDA facility. This year’s focus of ANL-NRC collaboration involves Nek5000 setups and validation for a range of problems relevant to and including the HYMERES-2 benchmark from PSI. The primary outcome of this year efforts is a more efficient geometry and inlet modeling simplification after a careful sensitivity study of the inlet profiles and pipe geometries. The resulting modeling choice of a short recycling/fully-developed turbulent inlet is within the experimental uncertainty estimate. This finding simplifies the next step of the cross-V&V HYMERES-2 project. In addition, the ANL team continue to provide assistance to the NRC staff in the form of Nek5000 application support in general and on the use of the HPC platforms of ALCF and INL in particular. This supports the NRC’s assessment of Nek5000 for use with the NRC Blue CRAB code suite. Second, we have implemented and tested more robust model of URANS, namely the k – τ model, a variant of the k-ω model, along with other improvements to RANS Nek5000 modeling in general. Because of its demonstrated robustness and stability, the k – τ model is the only RANS model that has been implemented in the new GPU version of the Nek5000 code, nekRS. Lastly, we report the initial implementation of Jacobian-free Newton Krylov approach to the direct Newton method for steady fluid solvers aimed at acceleration of RANS modeling and at IC improvement for LES campaigns. Also leveraging the Exascale Computing Project (ECP) ANL/CEED & SMR team’s software development effort to support NEAMS problems at large scale of the advanced computing architectures, NekRS, a GPU variant of Nek5000, built on top of kernels from libParanumal using OCCA for portability, has been successfully run on the full system of Summit (4608 nodes, 27648 GPUs).

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Options for Achieving Cost Reduction in Advanced Reactors through Open Architecture

A key contributor to high capital costs and schedule overruns for new nuclear power plants is lack of standardization, driven by site-specific customization and construction of multiple designs by competing vendors rather than commitment to a single standardized program. While advanced reactor vendors typically individually target repeat construction of standardized units, the many competing designs could exacerbate the problem. “Open Architecture”, the open specification of requirements and interfaces for structures, systems and components (SSCs), has been proposed as a means of promoting standardization, by facilitating existing non-nuclear suppliers to enter the industry and/or allowing SSCs to be configured for more than one reactor within the same technology type. Contracting mechanisms that facilitate information sharing and alignment of incentives between stakeholders may complement such an approach. A preliminary scheme is presented for selection of SSCs for which such strategies could be adopted, based on a vendor make/buy decision model and stakeholder interviews. SSCs are categorized according to number of suppliers and their contribution to the reactor’s competitive edge. SSCs with many potential suppliers and a high contribution to competitive edge may be attractive for widening the supply chain via open specification of system requirements and interfaces, e.g., SSCs in the power island. SSCs with few suppliers and low contribution to competitive edge may be potential avenues for common system specification between vendors, e.g., some of the auxiliary SSCs. Potential cost reductions from such strategies will depend upon the size of the build program and the reactor type.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Nuclear Materials Packaging, Transportation, and Systems Analysis Group Software Quality Assurance Plan: ANSYS Mechanical Finite Element Analysis Software Version 2023R1

ANSYS Inc. develops and markets engineering simulation software and services used in the aerospace, automotive, manufacturing, electronics, biomedical, energy, defense, and many other industries. ANSYS is dedicated to engineering simulation and is the world’s leading software provider. ANSYS was founded in 1970 and is headquartered in Canonsburg, Pennsylvania. ANSYS provides an engineering analysis tool combining structural, thermal, computational fluid dynamics, acoustic, and electromagnetic simulation capabilities. ANSYS has two main programs, which use the same solvers: (1) Mechanical APDL (ANSYS Design Parametric Language), a Fortran-based coding platform, and (2) ANSYS Workbench, which uses a graphical user interface to aid in finite element analysis implementation. This plan covers both APDL and Workbench. The ANSYS computer program is a large-scale, multipurpose finite element program that can be used to solve several classes of engineering analyses. The analysis capabilities of ANSYS include the ability to solve static and dynamic structural analyses, steady-state and transient heat transfer problems, mode-frequency and buckling eigenvalue problems, static or time-varying magnetic analyses, and various types of field and coupled-field applications. The program contains many special features that allow nonlinearities or secondary effects such as plasticity, large strain, hyperelasticity, creep, swelling, large deflections, contact, stress stiffening, temperature dependency, material anisotropy, and radiation to be included in the solution. As ANSYS has been developed, other special capabilities such as substructuring, submodeling, random vibration, kinetostatics, kinetodynamics, free convection fluid analysis, acoustics, magnetics, piezoelectrics, coupled-field analysis, and design optimization have been added to the program. These capabilities contribute further to making ANSYS a multipurpose analysis tool for varied engineering disciplines. The ANSYS program has been in commercial use for over 50 years and has been used extensively in the aerospace, automotive, construction, electronic, energy services, manufacturing, nuclear, plastics, oil, and steel industries. Additionally, many consulting firms and hundreds of universities have used ANSYS for analysis, research, and educational purposes. ANSYS is recognized worldwide as one of the most widely used and capable programs of its type. Ansys design analysis software is the first created within a quality system with ISO 9001 certification, the internationally accepted quality standard. Product development, testing, maintenance and support processes also meet the United States Nuclear Regulatory Commission's quality requirements, as they have for nearly four decades. The Quality Assurance Service Agreement is suitable for the customers working in the nuclear industry who need to meet specific federal regulations including 10CRF50 Appendix B and provisions of 10CFR21. ANSYS has retained its original International Organization for Standardization (ISO) 9001 accreditation certificate since1995-05-04, It’s current certificate is valid until 2027-05-29.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

First Report of the Nuclear Data Subcommittee of the Nuclear Science Advisory Committee

Accurate, reliable nuclear data is essential for the success of Federal missions such as nonproliferation, nuclear forensics, homeland security, national defense, space exploration, clean energy generation, and scientific research. Data access is also key to innovative commercial developments such as new medicines, automated industrial controls, energy exploration, energy security, nuclear reactor design, and isotope production. The United States Nuclear Data Program (USNDP) is the domestic custodian of nuclear data. In its April 2022 meeting, the DOE/NSF Nuclear Science Advisory Committee was charged with preparing two reports on nuclear data. In this first report, we review recent accomplishments of the USNDP and discuss complementary and collaborative international efforts. Detailed descriptions of nuclear data needs for basic science, nonproliferation, national security, nuclear energy together with medical and space applications are also presented. Lastly, a set of specific cross-cutting nuclear data needs with relevance for multiple applications areas are also identified for further discussion in a follow-on report planned for release at the end of January 2023.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2026

A Framework for Building Security into the Design Process

This report presents guidance to support the implementation of security objectives during the design process for nuclear facilities using an organization’s quality management system. The guidance in this document is intended for design vendors and operators of nuclear power facilities. Additionally, this guidance document can be beneficial to regulatory bodies, industry partners, customers, and other stakeholders within the nuclear power market. This report aims to ensure security consequences are identified before designs are completed, which may lead to reduced costs and higher security effectiveness and efficiency.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2026

A Framework for Building Security into the Design Process

This report presents guidance to support the implementation of security objectives during the design process for nuclear facilities using an organization’s quality management system. The guidance in this document is intended for design vendors and operators of nuclear power facilities. Additionally, this guidance document can be beneficial to regulatory bodies, industry partners, customers, and other stakeholders within the nuclear power market. This report aims to ensure security consequences are identified before designs are completed, which may lead to reduced costs and higher security effectiveness and efficiency.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2020

The TRANSCEND University Consortium: Theme 4: Nuclear Materials - 20431

The safe and secure management of Pu is a matter of international concern, with ∼250 t of separated Pu currently stockpiled worldwide. The UK's civil inventory of nuclear materials contains significant stocks of separated Pu from the reprocessing of Magnox and AGR spent fuels. The preferred option for the 138.5 tonnes of Pu is re-use as mixed oxide (MOx) fuel, although 5% is not suitable for re-use and is recommended for direct disposal. However, it will take more than 15 years to implement re-use, requiring that the Pu be kept in interim storage in its current state for that period, i.e. as PuO{sub 2} powder within inert steel storage cans at Sellafield. The focus of the work presented here is thus plutonium storage and the direct disposal of plutonium. The Research and Development needs of both are now pressing: in the case of storage due to it being the current default; in the case of immobilization and disposal because of a comparative lack of Research and Development on Pu conditioning and packaging due to policy uncertainty as to whether it would be disposed of in a Geologic Disposal Facility (GDF). Addressing these needs is complicated by Pu's high radioactivity, decay heat and radiotoxicity, criticality, nuclear safeguard requirements and, for some UK Pu contaminated materials targeted for disposal, poor inventory. Thus, there is also a critical requirement for underpinning research on Pu bearing materials in these two contexts. In response to these needs, the TRANSCEND Consortium (Transformative Science and Engineering for Nuclear Decommissioning, a multi-disciplinary collaboration of 11 universities and 8 key industry partners from across the UK's civil nuclear sector) is seeking to provide technical underpinning to ongoing option development for the UK's civil Pu stockpile. Whilst understanding the behaviour of plutonium during its re-use as MOx is beyond the scope of the TRANSCEND Consortium work plan, the main objectives of the work are: (1) For interim storage: to understand how the surface structure and properties of pristine and radiation damaged PuO{sub 2} change with time in the absence and presence of water; and (2) For immobilization and disposal: to understand the mechanisms of incorporation of Pu into ceramic and glass-ceramic waste-forms, as well as the effect on these of self-induced radiation damage. Each objective is being addressed through separate work packages, the details of which are discussed in this paper. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Consideration of Decabromodiphenyl Ether Flame Retardant in Thermal and Radiation Aging of Crosslinked Polyethylene Cable Insulation

Decabromodiphenyl ether (decaBDE) has been used as a flame-retardant additive in nuclear-grade electrical cable insulation. However, decaBDE has been identified as a persistent, bioaccumulative and toxic (PBT) substance, leading to regulatory scrutiny. On January 6, 2021, the Environmental Protection Agency (EPA) published a final rule to phase out decaBDE. The 2021 rule set a two-year compliance deadline for “processing and distribution in commerce of decaBDE for use in wire and cable insulation in nuclear power generation facilities.” In recognition of industry concerns following a sudden discontinuation of decaBDE-containing Class 1E wire and cable essential for nuclear power operations and the time needed for qualifying the individual components using the alternative insulation technology, an extended compliance deadline was set in the finalized amendments to the 2021 rule as published by the Environmental Appeals Board on November 12, 2024. The 2024 rule set the compliance deadline for processing and distributing decaBDE-containing wire and cable insulation until the end of the service life of these materials. Since decaBDE has long been relied upon as the flame retardant in one of the most common cross-linked polyethylene (XLPE) nuclear cable insulation formulations, RSCC Firewall III insulation, questions have naturally arisen regarding whether changes in cable performance might be expected for XLPE containing a decaBDE alternative, especially for safety-related cables that must perform their safety function in a design basis event such as a loss of coolant accident.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS2001

Space Fission Propulsion Testing and Development Progress

Successful development of space fission systems will require an extensive program of affordable and realistic testing. In addition to tests related to design/development of the fission system, realistic testing of the actual flight unit must also be performed. Testing can be divided into two categories, non-nuclear tests and nuclear tests. Full power nuclear tests of space fission systems we expensive, time consuming, and of limited use, even in the best of programmatic environments. If the system is designed to operate within established radiation damage and fuel burn up limits while simultaneously being designed to allow close simulation of heat from fission using resistance heaters, high confidence in fission system performance and lifetime can be attained through a series of non-nuclear tests. Non-nuclear tests are affordable and timely, and the cause of component and system failures can be quickly and accurately identified. MSFC is leading a Safe Affordable Fission Engine (SAFE) test series whose ultimate goal is the demonstration of a 300 kW flight configuration system using non-nuclear testing. This test series is carried out in collaboration with other NASA centers, other government agencies, industry, and universities. If SAFE-related nuclear tests are desired they will have a high probability of success and can be performed at existing nuclear facilities. The paper describes the SAFE non-nuclear test series, which includes test article descriptions, test results and conclusions, and future test plans.

VanDyke, Melissa↗
DOE OSTI2026

MoNbTi-based Refractory Multi-principal Element Alloy System: A Review of the Thermodynamic Phase Predictions, Formed Microstructures, and Mechanical Properties as a Function of the Fabrication Methods (AM versus SPS versus VAM)

Abstract Multi-principal element alloys, particularly of refractory compositions, are an increasingly popular candidate for extreme-environment applications, including for next-generation nuclear reactors and in other industries, such as biomedical and aerospace, due to their high strength. The ability to achieve solid-solution microstructures provides these alloys with improved mechanical properties; however, these microstructures are heavily composition- and processing-dependent. In this review, the multi-principal element alloy MoNbTi-based system (with Zr, V, and Cr additions) was selected to compare the effects of elemental composition and processing route on the resulting microstructures and mechanical properties. The review provides insight into identifying the optimal alloy composition and processing route for a balance of desired microstructure and mechanical properties.

Krogh, Kara↗
DOE OSTI2026

Reliable statistics-based detection and investigation of anomalies in a SMART valve system

Reliable anomaly detection and diagnosis are critical for the safe operation of complex engineered systems. This study presents a unified framework that integrates statistical, model-based, and data-driven techniques for anomaly detection and investigation, demonstrated on SMART valve systems in hybrid energy applications. Four detection methods—mean deviation, seasonal extreme studentized deviate, ARIMA forecasting, and matrix profiling—were implemented and compared. Matrix profiling was particularly effective in revealing subtle deviations and hidden relationships among variables. Anomaly investigation was performed by analyzing variable-level and grouped signal profiles, with system topology incorporated to distinguish primary faults from propagated effects. Grouping signals by type enhanced interpretability, enabling accurate localization of anomalies across multi-dimensional datasets. Experimental results confirmed the framework's capability to consistently detect and isolate anomalies while providing actionable insights into system interdependencies. The proposed methodology offers a robust, interpretable, and scalable solution for condition monitoring, with potential applications in safety-critical domains such as nuclear energy, aerospace, and process industries.

ARIMA models↗
DOE OSTI2026

Structural dynamics of the renewable energy economy: A longitudinal input-output insights for a resilient transition

As countries accelerate their energy transitions, understanding how renewable energy (RE) systems structurally integrate into national economies is essential. This study presents a longitudinal economic input-output (EIO) analysis of the renewable energy sector in South Korea from 2016 to 2022. We develop a novel EIO-based framework that disaggregates the RE sector both by energy source (thermal, hydro, nuclear and renewable) and by industrial function (manufacturing, generation, and services), allowing for a detailed assessment of production dynamics, value-added creation, and import dependency. By quantifying backward and forward linkages and induced economic effects, the analysis reveals persistent structural vulnerabilities in renewable manufacturing and increasing sectoral interdependencies. Results reveal that while the renewable energy sector's production and value-added shares have increased, critical segments remain highly import-dependent, particularly in equipment manufacturing. The analysis highlights systemic gaps in domestic supply chain resilience and offers sector-specific insights for reducing vulnerability and enhancing energy security. Although applied to South Korea as a case study, the proposed framework is designed to be transferable to other national contexts where renewable energy planning requires economic structural insights. The findings offer policy-relevant guidance for enhancing domestic energy resilience and aligning industrial strategy with long-term decarbonization goals.

Economic linkage↗
DOE OSTI2020

Transmission of Images With Ultrasonic Elastic Shear Waves on a Metallic Pipe Using Amplitude Shift Keying Protocol

Transmission of information using ultrasonic elastic waves on existing metallic pipes provides an alternative communication option across physical barriers in a highly partitioned industrial complex, such as a nuclear facility. This work investigates the feasibility of the transmission of digital images over metallic pipes. Ultrasonic communication systems for transmission of images on a nuclear-grade stainless steel pipe were assembled for bench-scale demonstration. Information carriers in this system are refracted shear waves transmitted and received with piezoelectric transducers (PZTs) operating at 2-MHz nominal frequency. The refraction and propagation of ultrasonic shear waves were modeled with COMSOL software. An amplitude shift keying (ASK) communication protocol for image transmission was developed and implemented in the GNURadio software-defined radio (SDR) environment. Digital information was converted to analog ultrasonic signals using Red Pitaya electronic boards. The performance of the ASK protocol is evaluated at the output of every block in the GNURadio program by monitoring the transmission of select characters. Using the ASK communication protocol, the transmission of the 32-KB image was demonstrated at 2-Kbps bitrate across 6-ft-long stainless steel pipe. Finally, preliminary evaluation of ultrasonic communication on the piping of a nuclear facility, such as signal transmission on bent pipes, was performed with COMSOL computer simulations.

42 ENGINEERING↗
DOE OSTI2020

Thermodynamic equilibrium and kinetic fundamentals of oxide dissolution in aqueous solution

Dissolution of oxides in aqueous solutions is fundamentally important for a range of applications and a critical process that determines the chemical durability of industrial ceramics, the performance of nuclear waste forms, and the chemical weathering of minerals. The thermodynamic equilibrium and kinetics of dissolution reactions are key to determining the rate at which oxides dissolve. The increase in collaborative research across disciplines in materials research necessitates a common background to tackle shared scientific problems across different fields. This review selectively examines the fundamentals of dissolution theories that have been developed in chemistry, geochemistry, and materials science, and assembles them into a single collective document for the broader materials science community. Applications of the theories are highlighted using examples from specific areas, but can be similarly applied to other areas. Challenges and future research needs for a predictive-level understanding are discussed in light of the current literature.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

3D Broadband, Noncontact, and Nonlinear Phased Array

Researchers at Los Alamos have developed a 3D broadband, noncontact, and nonlinear ultrasonic phased array technology that enables businesses to characterize and identify cracks and defects using laserbased sensing at ultra-high resolution. It can be applied to a wide range of commercial and industrial markets, e.g., aerospace, aeronautical, nuclear energy, oil and gas, and civil and material engineering and more broadly to those interested in the non-destructive evaluation (NDE) of materials and structures. Traditional phased-array technology for subsurface imaging operate over a narrow frequency range, with a limited number of sensors, using one type of ultrasonic waves which may decrease the likelihood of detecting a structural material crack. This technology fills the information gap by utilizing the potential of laser-based sensing to remove all these limitations. We are seeking a commercialization partner to license the technology or fund us through a Cooperative Research and Development Agreement (CRADA) to further develop a usable product for commercial purposes.

36 MATERIALS SCIENCE↗
NASA NTRS1998

Flight Tests on a Fiber Optic Temperature Sensor

For aircraft engine control, one key parameter to detect on an airplane is the exhaust gas temperature (EGT). Presently, thermocouples are used to perform this measurement. These electrical sensors perform adequately; however, fully utilizing the benefits of optical sensors requires replacing electrical architectures with optical architectures. Part of this requires replacing electrical sensors with optical sensors, such as the EGT sensor chosen for these tests. The objective of the development and testing of this prototype sensor system was to determine the feasibility of operating an optical sensor in a hostile aircraft environment. The fiber optic sensor system was developed to measure temperatures from 20C to 600C in an aircraft environment and was utilized to monitor the EGT of an OV-10D aircraft engine. The sensor has successfully flown over 50 hours and proven to be immune to surface deterioration of the optical element (located inside the sensor head) and able to withstand and operate in normal and sustained severe flight conditions where forces on the airplane exceeded 4 g's. Potential commercial uses for this sensor include monitoring temperature for aeropropulsion system control, military vehicle and naval engine control, conventional and nuclear power plant monitoring and industrial plan monitoring where EMI issues are critical.

Tuma, Margaret L.↗