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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 775 records · Page 43
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Li-rich cathodes for rechargeable Li-based batteries: reaction mechanisms and advanced characterization techniques

Due to their high specific capacities beyond 250 mA h g -1 , lithium-rich oxides have been considered as promising cathodes for the next generation power batteries, bridging the capacity gap between traditional layered-oxide based lithium-ion batteries and future lithium metal batteries such as lithium sulfur and lithium air batteries. However, the practical application of Li-rich oxides has been hindered by formidable challenges. To address these challenges, the understanding of their electrochemical behaviors becomes critical and is expected to offer effective guidance for both materials and cell development. This work aims to provide fundamental insights into the reaction mechanisms, electrochemical challenges and modification strategies of lithium-rich oxides. We first summarize the research history, the pristine structures, and the classification of lithium-rich oxides. Then we review the critical reaction mechanisms that are closely related to their electrochemical features and performances, such as lattice oxygen oxidation, oxygen vacancy formation, transition-metal migration, layered to spinel transitions, ‘two-phase mechanism’, and lattice evolution. These discussions are coupled with state-of-the-art characterization techniques. As a comparison, the anionic redox reactions of layered sodium transition metal oxides are also discussed. Finally, after a brief overview of the correlation among the aforementioned mechanisms, we provide perspectives on the rational design of lithium-rich oxides with high energy densities and long-term cycling stability.

25 ENERGY STORAGE↗
DOE OSTI2020

Using waste CO 2 from corn ethanol biorefineries for additional ethanol production: life‐cycle analysis

Abstract Corn ethanol plants generate high‐purity carbon dioxide (CO 2 ) while producing ethanol. If that CO 2 could be converted into ethanol by carbon capture and utilization technologies it would be possible to increase ethanol production more than 37% without additional corn grain inputs. Gas fermentation processes use microbes to convert carbon‐containing gases into ethanol and so have the potential to be used with the CO 2 from biorefineries for this purpose. However, as CO 2 utilization technologies for converting thermodynamically stable CO 2 are typically energy intensive, it is necessary to evaluate the related life‐cycle greenhouse gas (GHG) emissions (carbon intensities or CIs) to see whether there are actual emission reduction benefits. In this study, we evaluate the CIs of ethanol produced from high‐purity CO 2 in corn ethanol plants by gas fermentation plus electrochemical reduction. Our analysis shows that the sources of electricity and hydrogen are key drivers of CO 2 ‐based ethanol's GHG emissions. With wind electricity, the design cases show the potential of near‐zero CI ethanol (1.1 g CO 2 e/MJ), but that can increase to up to 331–531 g CO 2 e/MJ when today's U.S. Midwest electricity mix is used. To avoid the renewable electricity intermittency issue, we considered a power purchase agreement option using wind electricity 40% of the time and using the regional mix for the rest, which provides a 42% GHG emission reduction from the CI of gasoline. © 2020 The Authors and UChicago Argonne, LLC, Operator of Argonne National Laboratory. Biofuels, Bioproducts and Biorefining published by Society of Chemical Industry and John Wiley & Sons, Ltd.

09 BIOMASS FUELS↗
DOE OSTI2021

BETO 2021 Peer Review - Electrocatalytic CO2 Utilization

The goal of the ChemCatBio DataHub project is to accelerate the catalyst and process development cycle by developing transformational tools for prediction and collaboration in catalyst R&D. The project is currently focused on the development of the Catalyst Property Database (CPD), a free and public resource released in September 2020. The CPD was designed to advance the state of the art for application of computational data. When computational data, such as computed reaction energetics, is used in catalyst design, it is almost always generated by the researchers seeking to use it, even if similar data has been published previously. One barrier to data reuse that results in this duplication of effort is the difficult process of finding and applying published data, which can be slow, error-prone, and manual. The CPD seeks to overcome these challenges by creating a centralized, searchable database of quality catalyst property data. At present, the CPD contains computed adsorption energies for intermediates along catalytic pathways. During FY21 and FY22, development of the CPD continues with a focus on external users and meeting their requirements. A batch upload capability, training and curation procedures, user interviews, and a demonstration of the CPD's utility in accelerating catalyst research are planned. Overall, the Data Hub project and CPD aim to reduce the time and cost of catalyst research by harnessing the power of data in catalyst discovery.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2020

Ferroelectricity in Si-Doped Hafnia: Probing Challenges in Absence of Screening Charges

The ability to develop ferroelectric materials using binary oxides is critical to enable novel low-power, high-density non-volatile memory and fast switching logic. The discovery of ferroelectricity in hafnia-based thin films, has focused the hopes of the community on this class of materials to overcome the existing problems of perovskite-based integrated ferroelectrics. However, both the control of ferroelectricity in doped-HfO2 and the direct characterization at the nanoscale of ferroelectric phenomena, are increasingly difficult to achieve. The main limitations are imposed by the inherent intertwining of ferroelectric and dielectric properties, the role of strain, interfaces and electric field-mediated phase, and polarization changes. In this work, using Si-doped HfO2 as a material system, we performed a correlative study with four scanning probe techniques for the local sensing of intrinsic ferroelectricity on the oxide surface. Putting each technique in perspective, we demonstrated that different origins of spatially resolved contrast can be obtained, thus highlighting possible crosstalk not originated by a genuine ferroelectric response. By leveraging the strength of each method, we showed how intrinsic processes in ultrathin dielectrics, i.e., electronic leakage, existence and generation of energy states, charge trapping (de-trapping) phenomena, and electrochemical effects, can influence the sensed response. We then proceeded to initiate hysteresis loops by means of tip-induced spectroscopic cycling (i.e., “wake-up”), thus observing the onset of oxide degradation processes associated with this step. Finally, direct piezoelectric effects were studied using the high pressure resulting from the probe’s confinement, noticing the absence of a net time-invariant piezo-generated charge. Our results are critical in providing a general framework of interpretation for multiple nanoscale processes impacting ferroelectricity in doped-hafnia and strategies for sensing it.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Rapid charging made practical in graphite-based lithium batteries: surface-acoustic wave turbulent electrolyte mixing to overcome diffusion limited charging rates [Final Report]

One of the key limits in rapidly recharging a lithium-ion battery is the depletion of lithium ions within the electrolyte adjacent the anode during charging and long diffusion time to overcome this depletion. It also causes dendrite formation, inefficient use of the lithium, and battery degradation over many charge-discharge cycles. Because the liquid electrolyte remains quiescent and unmixed, this depletion layer’s depth rapidly grows to match the anode-cathode separation distance at even modest charge rates. The solution proposed by PI Prof. James Friend and Co-PI Prof. Ping Liu, both from the University of California, San Diego, is to mix the electrolyte and minimize the Li+ ion concentration gradient during charging. Even in the presence of the separator, the charging rate could then be significantly increased. They propose to accomplish this using surface acoustic wave (SAW)-driven acoustic streaming, a technique employing 10-mW fingernail-sized solid-state devices from the telecommunications industry to drive turbulent mixing to submicron length scales in a manner completely compatible with the typical 20700 and 18650 cells used in electric vehicles. 0.1. Turbulent acoustic streaming mixes the electrolyte during charging—even with separator Our proposed 100-MHz SAW device used to recirculate the electrolyte is compatible with lithium- ion battery electrochemistry, as it is made in our lab of single-crystal lithium niobate. Their solution is straightforward to drive from a DC power source alongside the signal provided during battery charging. The device is only needed during charging and does not consume power dur- ing battery discharge. Uniquely, SAW generates extreme accelerations of over 1 billion meters per second squared in the fluid, driving turbulent mixing from centimeter to submicron length scales, even through the porous separator materials that tend to be used in batteries, all while avoiding interfering with the anode’s solid electrolyte interphase layer that forms during use. By employing novel fluid mechanics, the investigators are proposing a new direction for battery research away from direct use of materials science and electrochemistry. The chemistry agnostic solution may be employed in any battery chemistry that makes use of liquid electrolytes, providing a broader transformative benefit to the battery research community. They are to produce a series of prismatic and 20700-cell sized 2 Ah batteries capable of being charged and discharged at least 500 times without more than 20% loss in battery capacity, and to provide analysis tools useful to the battery research and development community for adopting this approach for other battery chemistries and configurations.

25 ENERGY STORAGE↗
DOE OSTI2021

CSP Gen3: Liquid-Phase Pathway to SunShot

The United States Department of Energy (DOE) established the Concentrating Solar Power Generation 3 (CSP Gen3) program to promote the development of advanced CSP systems capable of producing electricity at a levelized cost of energy (LCOE) less than $60/MWh, based on criteria published in the CSP Gen3 Roadmap and a subsequent funding opportunity announcement (Gen3 FOA). This report documents the progress and potential of the “Liquid Pathway” to meet these objectives. The Liquid Pathway proposes the use of low-cost molten chloride salts for energy storage, mated with an operationally flexible solar receiver that employs liquid-metal sodium for heat capture and transfer to the storage salt. This approach leverages molten-salt technology from the current state-of-the-art CSP power towers embodied by plants such as Gemasolar, Crescent Dunes, Noor III, and the DEWA 700 CSP project. Furthermore, the design builds on the knowledge gained over decades of use of liquid-metal sodium as a high-temperature heat transfer fluid (HTF) in solar tests and nuclear-power applications. The commercial representation of the proposed Gen3 design incorporates a high-efficiency sodium receiver operating at ~740°C, with a liquid-liquid heat exchanger feeding a two-tank, molten-chloride salt storage system. Chloride salt is dispatched to a supercritical CO 2 (sCO 2 ) power cycle to provide electric power to the grid. The design integration is a conceptual match for the current sodium receiver → solar salt storage → steam-Rankine power cycle promoted by developer Vast Solar, which may facilitate commercial acceptance and development.

14 SOLAR ENERGY↗
DOE OSTI2024

DASSH-F: Subchannel Based Thermal Analysis

The DASSH thermal analysis code is designed to rapidly allow a reactor design engineer to obtain flow rates requirements that satisfy peak temperature constraints in the domain. The advantage of using DASSH over a hand calculation is that it has a more rigorous treatment of the pin power distribution and coolant heat transfer within an assembly and between assemblies. The advantage of using DASSH over a conventional 3D subchannel code or a computational fluid dynamics code (CFD) is that it can obtain the desired solution in a matter of minutes in serial with minor computer memory needs. The DASSH methodology is virtually identical to SUPERENERGY-2 with additional functionalities taken from follow on work to SUPERENERGY-2 done at ANL in the 1980s. DASSH today is an integral component of the Argonne Fast Reactor analysis suite for reactor design work. DASSH obtains the power distribution from a coupled neutron-gamma heating calculation in GAMSOR (including DIF3D) at each time point of a companion fuel cycle analysis calculation with REBUS. The domain in DASSH assumes a hexagonal grid typical for fast reactors with much of the geometry information taken from the DIF3D model. DASSH assumes the assemblies that are loaded into each grid position are ducted to control the coolant flow. Considerable detail is given on the subchannel formulation of DASSH in this document. Much of the formulation and design of the code builds upon research done by previous authors with little new investigation. Thus the decisions made in developing the subchannel model used in DASSH have their origins over 50 years ago. Much of the heat transfer methodology in DASSH is built upon correlations for both the coolant mixing and heat transfer coefficients for pins and ducts. DASSH is thus not a rigorous treatment of a given problem, but a rapid assessment of the temperature field that has known limitations with respect to an experimental measurement or CFD calculation. The DASSH input and output are detailed along with usage of the software. The DASSH output provides tables of evaluated material properties and key coolant and pin temperature results. DASSH can create Python scripts that generate domain summary pictures. DASSH can also generate assembly temperature maps and VTK output files which allow the DASSH solution to be visualized. As the primary purpose of the DASSH software is to compute the coolant and fuel pin temperature distribution for a given model of a reactor, much of the output focus is giving the user quick summary tables needed to assess the performance of a given orifice flow specification. The present version of DASSH has a crude orifice search capability and an efficient orifice flow search capability. The flow search tries to meet user specified constraints for 1) peak 2-sigma clad midwall temperature, 2) peak coolant temperature, and 3) desired bulk outlet temperature. There are many development shortcomings in DASSH detailed in this document, but this version is functional for modern analysis needs. This document serves as the manual for the Fortran based DASSH software that was developed to replace the Python version of DASSH developed as part of the VTR program.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Methane Mitigation Thermoelectric Generator (MMTEG) (Final Scientific/ Technical Report)

Gas Technology Institute (GTI) has completed a $1.815M (plus $500K cost share), 54-month Co-operative agreement with the Department of Energy’s National Energy Technology Laboratory to develop a Methane Mitigation Thermoelectric Generator (MMTEG) system for gas field applications. This novel system uses fugitive gas to produce electrical power and consists of Thermoelectric Generators (TEG) driven by a linear burner, an air compressor, an accumulator, valves, batteries, and power electronics. The electrical power generated by the system is used to compress air and, in turn, the air is used to operate the pneumatic valves at the well site instead of using natural gas (NG) which would then be vented. The team completed the project objectives which included (1) Design, fabricate and test an integrated 6We nominal MMTEG prototype system, (2) Design a “retrofit kit” MMTEG system capable of being field tested at a gas well production site, and (3) build and test the field MMTEG system in a laboratory environment. Multiple system options were developed prior to selecting a “Passive” system which meets cost, NG savings, and greenhouse gas (GHG) reduction targets although not as efficient as initially planned. The MMTEG system is built primarily from commercial off-the-shelf parts (in some cases re-purposed) including the heat exchanger, heat rejection, electronic components, and also the TEGs. The team developed and implemented a novel system including the control system developed by Morrison Applied Sciences (MAS). The team completed incremental demonstrations of the hardware prior to the MMTEG system demonstration. A one-year simulation of the air delivery and battery charging subsystems was completed prior to the integration into the MMTEG system. In addition, the team simulated two-years of thermal cycles for integrated Burner/TEG/heat rejection subsystem. Finally, the entire MMTEG system was assembled, and troubleshooting was completed over a two-week period. Next, the MMTEG system was tested to simulate over 15 weeks of entire system operation over approximately four weeks in an accelerated test fashion with minimal intervention (such as changing fuel tanks). The MMTEG system met the key goals of a unit cost of under $1500 while saving 97% of NG expended today (including leakage) on average by pneumatic systems venting to the atmosphere. The MMTEG system reduced GHG emissions by 1000X (using the methane intensification factor of 28 relative to CO2). GTI is currently pursuing a field test of the MMTEG system. Interfacing with producers has provided additional insight into system improvements. Planned improvements include additional weather protection and control system improvements including the implementation of a long- range radio capability to notify operators if there is a fault.

03 NATURAL GAS↗
DOE OSTI2023

Flue-Gas Desulfurization Effluent Management using an Innovative Low-Energy Biosorpotion Treatment System to Remove Key Contaminants

Among the most critical water contaminants of concern affecting wide geographical regions and a number of industries and natural systems is selenium. Selenium found in surface, ground and wastewater in originates from natural sources, as well as industrial sources such as petroleum refineries, electronics manufacturing, pesticides, and coal power plants and mining also contribute to selenium contamination in water in the US. At high concentrations, selenium is toxic to human and wildlife. There are a number of technologies that have been used to treat selenium and other similar contaminants in water. Biological treatment of selenium has been used in the past to reduce soluble SeVI and/or SeIV to insoluble Se0, which is then filtered in the same vessel. The insoluble selenium (Se0) is then backwashed from the system and solids are separated for subsequent disposal, if they meet the leaching and water content criteria. In order to promote biological reduction to insoluble Se0, heating of bioreactor is needed in some applications, and excess food source (electron donor) is added so that all selenium can be filtered. An additional disadvantage of these systems is the significant amount of water lost due to extensive and frequent backwash and rinse cycles. When comparing the advantages and energy requirements of the various treatment technologies, RO membrane filtration immediately stands out due to the excessive energy expenditure needed to pump water across the membrane although RO is an effective way to remove selenium. In addition, RO requires extensive pretreatment, such as MF membrane, and frequent maintenance, rendering it an expensive option that may be out of reach for certain applications. In fact, although the performance was good during the pilot testing by the NSMP Working Group for treatment naturally occurring selenium in the surface water, the high electricity requirements and significant reject water stream made it an infeasible alternative. While conventional ion exchange maybe an effective treatment option, it requires frequent regeneration of the resin when applied to highly contaminated water, which leads to several tons of contaminant-laden, high-salinity brine that needs to be disposed off-site each day. One of the water systems in the west coast currently uses ion exchange for selenium treatment and has been trucking selenium laden hazardous brine waste weekly in the last several years. Pneumatic pumping and rinse water pumping required for ion exchange also increase the energy usage. In comparison, adsorption process is a passive treatment system where contaminated water comes in contact with an adsorption media in a vessel. Typically, there is no mixing, backwash, or recycle pumping required, thus significantly reducing the energy usage. A passive single-use adsorption system does not require backwash, thereby generating small amount of process waste, and producing the highest water yield among the alternatives. The energy and water efficiencies, and applicability for SeVI and SeIV are summarized in Table 1. Despite these benefits though, adsorption typically does not work for the most oxidized form of selenium (SeVI). The innovative biosorption process integrates both process to increase the treatment efficiency while minimizing energy, chemical, and time required to treat both SeVI and SeIV. Additional advantages include simple partial biological reduction with reduced on-site waste generation, which lead to water and electricity savings, and less operational need compared to biological treatment alone. This makes biosorption especially suitable for remote areas, where liquid backwash and brine disposal may be cost prohibitive or infeasible.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2020

Sister Rod Destructive Examinations (FY20) Appendix A: Full Length Rod Heat Treatments (FHT)

As a part of the US DOE-NE High Burnup Spent Fuel Data Project, ORNL is performing destructive examinations (DEs) of high burnup (HBU) (>45 gigawatt days per metric ton uranium) spent nuclear fuel (SNF) rods from the North Anna Nuclear Power Station operated by Dominion Energy. The SNF rods, called the “sister rods,” are all HBU and include four different kinds of fuel rod cladding: standard Zircaloy-4, low-tin Zircaloy-4, ZIRLO®, and M5®. The DEs are being conducted to obtain a baseline of the HBU rod’s condition prior to dry storage and are focused on understanding overall SNF rod strength and durability. Both composite fuel and empty cladding are being tested. While the data generated can be used for multiple purposes, a primary goal for obtaining the post-irradiation examination data will support SNF dry storage licensing and relicensing activities.This report documents the status of the ORNL Phase 1 DE activities related to full length rod heat treatments (FHT) applied to selected sister rods in Phase 1 of the sister rod test program. The results of this work and detailed examinations are summarized in the Sister Rod DE Status Report.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Cost Analysis Framework for Comparing AC and DC Design Alternatives for Building Electrical Distribution Systems

In recent years, in response to the changing nature of building load, direct current (DC) distribution systems for buildings have been proposed as alternatives to traditional alternating current (AC) systems. DC distribution offers a closer match to the types of loads and generation sources found in modern buildings, the majority of which use DC electricity internally either natively or as a power conditioning stage. The proposed benefits of DC distribution compared to AC distribution within buildings include higher efficiency, lower installation cost, lower operating cost, higher reliability, improved communication and control, and simplicity. Most recent DC distribution research has focused on quantifying the efficiency advantage of DC distribution over AC distribution. However, energy savings alone do not guarantee cost savings; a more complete cost accounting is required to establish financial benefit. This report provides a framework for cost analysis and comparison of building electrical distribution systems, including common variants for both AC and DC distribution systems. The framework includes all major cost categories, including up-front costs (capital, installation labor, soft costs) and long-term costs (energy, operations and maintenance).

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2021

Comprehensive process and environmental impact analysis of integrated DBD plasma steam methane reforming

Utilization of electricity generated from renewable sources to obtain hydrogen, H 2 , is of critical importance to decrease the overall carbon footprint. Here in this work, integration of a dielectric discharge barrier (DBD) plasma reactor to convert low calorific value gas, such as landfill gas or coal mine gas into hydrogen, into the existing steam methane reforming (SMR) technology was evaluated using process design considerations. In particular, a DBD-enhanced catalytic SMR reactor was modeled to operate at near atmospheric pressure and 500 °C sequentially with the conventional reformer to obtain ~ 65 kmol/hr H2 for distributed production. This allowed decreasing the size of the conventional reformer albeit at the increased overall electricity consumption. Calculated process economics showed that only at an electricity cost of less than $0.004/kWh does the hybrid DBD plasma process derived H 2 price become competitive with that of the conventional SMR. A Life Cycle Assessment framework was used to compare environmental impacts from the conventional SMR, hybrid DBD SMR and hybrid DBD SMR utilizing only onshore wind-derived electricity. Larger environmental impacts in the plasma reformer were obtained due to the use of electricity for the plasma reforming operation, which was modeled as coming from the typical U.S. grid mix. Utilizing only 100% wind-derived electricity provided certain environmental benefits, except for the ecotoxicity impact where the wind power scenario modeled here only reduced ecotoxicity impacts associated with electricity by 30%.

08 HYDROGEN↗
DOE OSTI2020

Flexibility in the Energy Balancing Network of Photosynthesis Enables Safe Operation under Changing Environmental Conditions

Given their ability to harness chemical energy from the sun and generate the organic compounds necessary for life, photosynthetic organisms have the unique capacity to act simultaneously as their own power and manufacturing plant. This dual capacity presents many unique challenges, chiefly that energy supply must be perfectly balanced with energy demand to prevent photodamage and allow for optimal growth. From this perspective, we discuss the energy balancing network using recent studies and a quantitative framework for calculating metabolic ATP and NAD(P)H demand using measured leaf gas exchange and assumptions of metabolic demand. We focus on exploring how the energy balancing network itself is structured to allow safe and flexible energy supply. We discuss when the energy balancing network appears to operate optimally and when it favors high capacity instead. We also present the hypothesis that the energy balancing network itself can adapt over longer time scales to a given metabolic demand and how metabolism itself may participate in this energy balancing.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2021

Design and Experimental Demonstration of an Additive Manufactured Smart Oxy-Methane Burner for High Pressure and Supercritical Combustion

Pressurized oxy combustion-based systems can improve efficiency by recovering latent heat of the steam in the Flue Gas and achieving 90% CO2 capture. In addition, the novel Directly Heated Supercritical Carbon Dioxide (DH-SCO2) power cycles can achieve high thermal efficiencies and provide nearly full carbon capture. Additionally, due to the reduction of flue gas at higher pressure, smaller system size and capital cost reductions are also possible. Recent thermodynamic analysis of the DH-SCO2 cycle performed by the UTEP research team shows that combustion conditions in the vicinity of 300 bar pressure and 1000-1400 K temperature allow for relatively high system efficiencies while operating within the limit of available combustor materials. However, the realization of a directly heated supercritical power cycle requires combustion systems to operate in supercritical conditions and at temperature far below the blowout limit of conventional flames (above 1500 K). The thermodynamic properties along with the combustion properties and kinetics are unexplored at such conditions. Additionally, the interaction of the supercritical environment with energy components is also unknown. High-pressure combustion tests are performed using a smart burner at some intermediate pressure ranges (<20 bar) to help minimize these knowledge gaps. The knowledge obtained from the high-pressure test will assist in understanding the combustion chamber pressurization mechanism, ignition and flame behavior at the elevated pressure. The obtained data will act as a systematic first step in testing at higher pressures of 100 and 300 bar pressures.The primary purpose of this Dissertation is to demonstrate the operability of a low NOx smart burner for oxy-methane combustion at high pressure (< 20 bar) and scalable up to supercritical conditions. A shear co-axial smart burner is designed with a real-time temperature monitoring capability to understand the burner face interaction at high-pressure conditions. In addition, the burner has four independent injection ports to allow the independent injection of fuel and dilution gases in the combustor. The maximum operating capability of the burner is 575 kWth. The burner was fabricated using a Laser Powder Bed Fusion process with Nickel Alloy 718. A powder removal technology was invented comprising ultrasonic vibration, liquid nitrogen exposure and media blasting to remove powders from internal channels of the burner. The burner operability tests are performed in the high-pressure combustor and the swirl combustor. The high-pressure combustor was used to investigate the burner operability and thermal soak back at different pressurized conditions. The experimental tests in high-pressure combustor up to 275 kWth input resulted in 16.5 bar chamber pressure and 198°C thermal soaks back to the burner. The burner was capable of providing the required thermal input within a 3% deviation range. In addition, soot formation occurred at high-pressure tests. The swirl combustor was used to observe the flame stability of the burner. Flame lift-off was observed for jet velocities above 450 m/s. Additionally, lift-off decreased for low co-flow velocities. CO2 dilution experiments showed increased flame instabilities for all conditions above 50% dilution ratios. At lower thermal inputs, partial flame blow-offs occurred for dilution ratios above 50%. All conditions significantly reduced the flame temperature and increased the flame lift-off height. Finally, a 2nd generation AM smart burner was designed using the knowledge from the 1st generation burner experiments. The 2nd generation burner incorporated two sets of swirlers with 0.9 swirl no. A cooling system was also designed for long-duration tests at higher pressures. The thermal input and division of the burner's power are kept the same as the 1st generation burner. The burner is to be fabricated using nickel-alloy 718 for high-pressure handling capability. The design can sustain at high-pressure conditions up to 100 bar.

Islam, Md Nawshad Arslan↗
DOE OSTI2024

Sister Rod Destructive Examinations (FY23)

As a part of DOE NE High Burnup Spent Fuel Data Project, Oak Ridge National Laboratory (ORNL) is performing destructive examinations (DEs) of high burnup (HBU) (>45 GWd/MTU) spent nuclear fuel (SNF) rods from the North Anna Nuclear Power Station operated by Dominion Energy. The SNF rods, called sister rods or sibling rods, are all HBU and include four different kinds of fuel rod cladding: standard Zircaloy-4 (Zirc-4), low-tin (LT) Zirc-4, ZIRLO, and M5. The DEs are being conducted to obtain a baseline of the HBU rod’s condition before dry storage and are focused on understanding overall SNF rod strength and durability. Composite fuel and defueled cladding will be tested to derive material properties. Although the data generated can be used for multiple purposes, one primary goal for obtaining the post-irradiation examination data and the associated measured mechanical properties is to support SNF dry storage licensing and relicensing activities by (1) addressing identified knowledge gaps and (2) enhancing the technical basis for post-storage transportation, handling, and subsequent disposition. This report provides a cumulative status report of the testing progress, data accumulated, and conclusions reached as a part of the program.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Sodium Extraction from Full-Length Fermi-1 Blanket Assembly

Enrico Fermi Nuclear Generating Station is a nuclear power plant on the shore of Lake Erie. On October 5, 1966, Fermi 1, a prototype fast breeder reactor, suffered a partial fuel meltdown (no radioactive material was released). As a result, 34 metric tons of sodium-bonded blanket material from the decommissioned Fermi-1 reactor were shipped to and are currently stored at the Idaho Nation Lab (INL). This material is currently awaiting removal from the state of Idaho by 2035. In its current state, the Fermi-1 material is not suitable for disposal due to the reactive characteristic of its bond sodium. This work demonstrates removal of bond sodium from an entire full-length unirradiated Fermi-1 outer radial blanket assembly using a gravity assisted melt-drain-evaporate (MEDE) treatment process. Quantitative and qualitative analyses were performed to characterize the extent of sodium removal from the blanket material following MEDE treatment.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Fast Quasi-Static Time-Series Simulation for Accurate PV Inverter Semiconductor Fatigue Analysis with a Long-Term Solar Profile

Power system simulations with long-term data typically have large time steps varying from one second to a few minutes. However, for PV inverter semiconductors, the minimum thermal stress cycle occurs over the fundamental grid frequency (50 or 60 Hz). This requires the time step of the fatigue simulation to be around 100 µs. This small time step requires long computation times to process yearly power production profiles. This paper proposes a fast fatigue simulation for inverter semiconductors using the quasi-static time series (QSTS) simulation concept. The proposed simulation calculates the steady state of the semiconductor junction temperature by using a Fast Fourier Transform (FFT). The small thermal cycling during a switching period and even over the fundamental waveform is disregarded to further accelerate the simulation speed. The resulting time step of the fatigue simulation is 15 minutes, which is consistent with the solar dataset. The error of the proposed simulation is 0.16% compared to the fatigue simulation results using the complete thermal stress profile. A PV inverter that responds to a Transactive Energy System (TES) is simulated to demonstrate the use of the proposed fatigue simulation. The proposed simulation has the potential to co-simulate with system level simulation tools that also adopt the QSTS concept.

Liu, Yunting↗
DOE OSTI2021

Crack nucleation at forging flaws studied by non-local peridynamics simulations

We present a computational study and framework that allows us to study and understand the crack nucleation process from forging flaws. Forging flaws may be present in large steel rotor components commonly used for rotating power generation equipment including gas turbines, electrical generators, and steam turbines. The service life of these components is often limited by crack nucleation and subsequent growth from such forging flaws, which frequently exhibit themselves as non-metallic oxide inclusions. The fatigue crack growth process can be described by established engineering fracture mechanics methods. However, the initial crack nucleation process from a forging flaw is challenging for traditional engineering methods to quantify as it depends on the details of the flaw, including flaw morphology. We adopt the peridynamics method to describe and study this crack nucleation process. For a specific industrial gas turbine rotor steel, we present how we integrate and fit commonly known base material property data such as elastic properties, yield strength, and S-N curves, as well as fatigue crack growth data into a peridynamic model. The obtained model is then utilized in a series of high-performance two-dimensional peridynamic simulations to study the crack nucleation process from forging flaws for ambient and elevated temperatures in a rectangular simulation cell specimen. The simulations reveal an initial local nucleation at multiple small oxide inclusions followed by micro-crack propagation, arrest, coalescence, and eventual emergence of a dominant micro-crack that governs the crack nucleation process. The dependence on temperature and density of oxide inclusions of both the details of the microscopic processes and cycles to crack nucleation is also observed. The results are compared with fatigue experiments performed with specimens containing forging flaws of the same rotor steel.

97 MATHEMATICS AND COMPUTING↗