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At least 793 records · Page 44

Multiphysics Modeling of Microreactors with NEAMS codes, and Validation Based on KRUSTY Reactivity Insertion

The NEAMS Multiphysics Applications team continues to assess code usability and functionality for microreactor design and safety analyses, while demonstrating that NEAMS tools capture both steady-state and transient behavior across distinct microreactor concepts. In FY2025, the team advanced full-core, high-fidelity, multiphysics models that solve more complex problems and strengthen verification/validation for several microreactor systems: heat-pipe microreactor (HPMR), gas-cooled microreactor (GCMR), and the KRUSTY experiment. These models employ the MOOSE MultiApp/Transfers architecture with Griffin for neutronics, BISON for heat conduction/thermomechanics, Sockeye for heat pipes, SAM/THM for coolant channels and loops, and SWIFT for hydride behavior, with meshes generated via the MOOSE Reactor Module. The graphite models available in the Grizzly code were also investigated for future analyses. For the HPMR, a Na-HPMR variant was constructed to align with recently validated heat-pipe experiments and Sockeye’s LCVF capability, enabling mechanistic heat-pipe transients and startup modeling. The Na-HPMR will serve as the primary model for HPMR investigations in upcoming tasks. The load-following and single heat-pipe failure scenarios (Griffin/BISON/Sockeye), which were previously modeled for the K-HPMR, were replicated for the Na-HPMR, showing strong negative temperature feedback and highly localized thermal effects, respectively, while the startup case captured vapor-front progression and heat-removal activation. Solid mechanics was added to the previously built K-HPMR full-core model in BISON, showing minimal impact on steady-state reactivity yet enabling stress-field predictions that prepare the path for full-core TRISO performance analyses. For the GCMR, automated steady-state and four transient scenarios were executed using Griffin/BISON/SAM/SWIFT. Results confirm robust inherent safety: power collapses promptly in loss-of-cooling events, the inlet-temperature drop settles to a new equilibrium, and a single-channel blockage yields only a ~30 K local fuel-temperature rise with <0.4% power decrease. SWIFT-predicted hydrogen redistribution affects reactivity during both steady-state and transient conditions, underscoring its importance. A Brayton-cycle balance of plant (BOP) model in SAM/THM demonstrated stable startup behavior, and xenon-driven reactivity during load following was analyzed. To improve TRISO-compact temperature fidelity, a fast multiscale Heat Source Decomposition (HSD) treatment was implemented. Against heterogeneous benchmarks, HSD reduces underprediction of kernel temperatures and lowers predicted peak powers in reactivity-insertion transients compared to previous homogenized models. KRUSTY warm-critical validation progressed from FY2024 baselines: the 15Ȼ insertion shows excellent agreement in peak power (~2% high) and temperature trends, and the 30Ȼ case was automated via a feedback controller that maintained power near 3 kW for ~150 s with close agreement to data. The successful modeling of the warm critical tests has laid a strong foundation for simulating more complex nuclear system tests in the years ahead. Throughout FY2025, developer feedback was provided (e.g., MOOSE batch mesh generation, distributed pre-split meshes, Griffin sweeper on displaced meshes), several new models were contributed to the Virtual Test Bed, and an OECD-NEA WPRS multiphysics benchmark based on the HPMR was initiated to enable broader cross-comparison and best-practice development with the nuclear community at large.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

High Power FPC Progress for EIC ESR Cavities

Electron-Ion Collider (EIC) is a next generation particle accelerator to be built at Brookhaven National Laboratory, in partnership with Thomas Jefferson National Accelerator Facility. In Electron Storage Ring (ESR), 18 single-cell 591 MHz SRF cavities are required to compensate for up to 10 MW energy loss due to synchronic radiation. Two high power FPCs for each cavity are used to deliver up to 800 kW power to the beam. The high power FPC were designed and reviewed. The FPC prototypes will be ready for high power test around mid-2026. This paper presents the latest development of FPC prototyping and path forward for FPC conditioning.

43 PARTICLE ACCELERATORS↗

TEAMER – Enhanced Flow Measurement for Aquantis Tidal Turbine Test

The AQ10 is a floating, two-bladed, passive yawing tidal turbine developed by Aquantis that has a 10-meterrotor diameter, 160 kW rating, and employs reliable off-the-shelf powertrain and power conversion hardware. Aquantis is planning on-water turbine power performance and loads (blade loading and thrust)testing, where the turbine will be pushed through still water up to 4 knots and placed in a ‘station keeping’ tow in a tidal race up to its rated speed. On-water testing will be conducted using vessels and floating platforms on the sea surface to improve ease of testing and reduce disturbance to the environment. In this TEAMER project, Pacific Northwest National Laboratory (PNNL) will conduct water velocity and turbulence measurements in front of the turbine during on-water testing using acoustic Doppler instrumentation. By measuring both the tidal current flowing past the turbine and the resulting electrical power output, test results will provide a power curve (power vs flow speed) for the turbine up to rated power. Measurements of turbulence and velocity shear in front of the rotor will also provide information to assess the structural response of the rotor blades. With this analysis, Aquantis can use the performance and loads data to validate Tidal Bladed and OpenFAST simulations of the measured operating conditions. Measuring the power performance of a prototype turbine is a valuable step to improving device development and conducting a complete power performance assessment to IEC/TS 62600-200 standards in the future.

16 TIDAL AND WAVE POWER↗

Testing and Expertise for Marine Energy (TEAMER) Program Support (CRADA Final Report)

Virginia Tech (VT) had previously developed a 50 kW AC to DC power converter that is specifically designed to improve the performance and efficiency of wave energy converters (WECs). Through this CRADA, NLR will test the VT power converter via a coupled dynamometer and power electronics test platform. The NLR test platform will be comprised of (1) a rotary dynamometer that will drive a VT provided gearbox and generator, (2) one or more DC regenerative power supplies that provide input power to and take power from the VT supplied power electronics, and (3) a data acquisition system for measurement. NLR will work with VT to develop a test plan, set up the test platform and integrate the test article, perform the testing, and assist in the data analysis.

16 TIDAL AND WAVE POWER↗

System Analysis of an Internal Combustion Engine (ICE) - Solid Oxide Fuel Cell (SOFC) Hybrid Cycle

The variability of renewable energy sources poses challenges for reliable grid operation. Conventional thermal power sources, though reliable, often lack operational flexibility. Hybrid energy systems that integrate Solid Oxide Fuel cells (SOFC) with Internal Combustion Engines (ICE) offer a promising solution by achieving relatively higher efficiency and grid-following capability. This study investigates performance of a 100-kW pressurized SOFC-ICE hybrid cycle. In this configuration, unutilized SOFC fuel is used to drive the engine, with a turbocharger providing air supply and an external reformer generating syngas. System components were numerically modeled using MATLAB/SIMULINK for the SOFC and reformer, and EBSILON® for the ICE and balance of plant. Parametric studies varied fuel utilization (70-90%), reformer temperature (600 – 1000K), anode off-gas recirculation (0 – 70%), and current density (0.2 – 0.55 A/cm2). Results show that the SOFC and ICE operate as thermally independent topping and bottoming cycles, achieving peak efficiency of 62% under optimized conditions.

hybrid↗

MEMS RF accelerators for nuclear energy and advanced manufacturing

Energetic ions are widely used to develop radiation hard structural materials and fuels for advanced nuclear energy. Ion beams are also used to generate neutrons for nuclear materials testing, as well as in a series of high impact, high value adding manufacturing processes (ranging from doping of semiconductors to hardening of materials against wear and to increase bio-compatibility of materials). But to date, high power beams of high energy ions are simply too expensive because they are delivered from large single beam accelerators. We have recently demonstrated that MEMS technology enables massively parallel, low cost batch fabrication of ion beams. We propose to scale intense ion accelerators based on MEMS (micro-electro mechanical systems) to high beam power (>10 kW). With our approach, hundreds to thousands of ion beamlets will be densely packed on silicon wafers. Ions are injected and accelerated across gaps formed in stacks of wafers, leading to uniquely high current densities for intense ion accelerators with variable kinetic energy (0.1 to 10 MeV) and variable ion species. Our team brings together experts in high power ion accelerators from Lawrence Berkeley National Laboratory and leading experts in MEMS technology from Cornell University. We will deliver a disruptive technology of low cost, flexible and massively scalable ion accelerators that will enable the rapid development of radiation hard nuclear materials for advanced nuclear energy and enable new applications in manufacturing.

43 PARTICLE ACCELERATORS↗

Advancing Conduction-Cooled 650 MHZ SRF Technology for Industrial Accelerators at Fermilab S IARC

The National Nuclear Security Administration (NNSA) funds the Illinois Accelerator Research Center (IARC) at Fermilab in developing a high-power, conduction-cooled Superconducting Radio Frequency (SRF) accelerator tailored for industrial applications requiring robust and efficient operation. A 650 MHz, 1.6 MeV, 20 kW SRF accelerator is currently under development, employing a conduction cooling approach to simplify cryogenic requirements and enhance accessibility for industrial use. The accelerator's control system is implemented on the Blinky Lite platform, selected for its open-source architecture, secure remote access capabilities, and operational flexibility attributes advantageous for industrial deployment and sustained operation. A dedicated beamline is designed to measure essential beam parameters and test the integrated performance of the accelerator and control systems, thereby validating their operational readiness for intended applications.

Ji, Yichen [Fermilab]↗

First Results from A $Nb_3Sn$-Coated 1.5-Cell 650MHZ SRF Cavity for Cryogen-Free Industrial Accelerators

Fermilab is advancing the development of a compact, high-power electron beam accelerator using superconducting radio frequency (SRF) technology as a non-radioactive alternative to traditional radiological sources. The current design targets continuous-wave (CW) operation at \SI{1.6}{MeV} and \SI{20}{kW}. To ensure suitability for industrial environments, the system is being designed for cryogen-free operation, driving the adoption of a novel Nb$_3$Sn-coated 1.5-cell SRF cavity operating at \SI{650}{MHz}. This contribution reports on the fabrication, surface preparation, and Nb$_3$Sn coating process of the cavity, as well as first results from vertical test stand (VTS) measurements performed in a liquid helium bath. These initial tests mark a key milestone toward demonstrating the viability of conduction-cooled Nb$_3$Sn SRF cavities for industrial-scale deployment.

Tagdulang, Nikki Diala [Fermilab]↗

Defining Power Efficient Residential Electric Appliances and Equipment

While the long-established concept of "energy efficiency" has successfully reduced energy consumption and bills in homes, it is no longer sufficient to address the modern challenges of electrical load growth, infrastructure upgrades and associated affordability challenges. We introduce the concept of “power efficiency” for household appliances and equipment, providing a framework to support affordable home modernization and grid management. Energy efficiency is the measure of energy used (kWh) to provide comfort/conveniences, power efficiency is the measure of power used (kW) to provide those same comforts/conveniences. Energy efficiency was needed because energy is a limited resource and expensive. Now power efficiency is needed because power delivery into a building is a limited resource and expensive. We propose a new set of metrics for defining and measuring power efficiency by investigating how current appliance nameplate ratings are established, and assessing the availability and use of existing data.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Effects of turbulence-radiation coupling in pressurized oxy-combustion

Concerns over climate change have led to numerous efforts in developing low-carbon energy technologies. Pressurized oxy-combustion (POC) is a promising candidate to reduce carbon emission in power generation. Due to the strong impact of pressure on thermal radiation, heat transfer in POC differs significantly from the situation of conventional atmospheric pressure combustion. Thus thermal radiation in POC needs to be investigated to aid new combustor development. The present computational work is a step in this direction, initiating a systematic analysis of thermal radiation and heat transfer in a pilot-scale POC combustor, which has been developed at Washington University in St. Louis (WUSTL). In a POC process, pulverized coal is burned under elevated pressure and O2-CO2 environment. While most previous computational works on flame radiation focused on atmospheric pressure condition, this work considered a pressurized flame. Specifically, a 15-bar POC combustor of power 50 kW is modeled employing the Ansys FLUENT commercial platform, using both Reynolds-averaged Navier-Stokes (RANS) modeling and large-eddy simulation (LES). A recently published and validated global radiation model is used to predict the radiative property of the flue gas. The discrete ordinates (DO) radiation model is chosen to solve the radiative transport equation. Incident radiation on the walls of the combustor is identified and investigated. It is revealed that for this pilot-scale, pressurized combustor, thermal radiation exhibits similar patterns in the RANS and LES models. However, the magnitudes of radiation are different in both models, presumably because interactions between radiation and turbulence are embedded in the LES model but not in the RANS model. This difference thereby underlines the major goal of this research: investigating the impact of such turbulence-to-radiation coupling on thermal radiation in a pilot-scale POC setting. Most previous studies on turbulence-to-radiation interactions focused on bench-scale, atmospheric pressure flames. This work is the first effort to extend this study to a pilot-scale, pressurized flame.

Li, Lei↗

The Evolving Role of Demand Charges in Retail Electricity Rates

Retail electricity demand charges refer to a type of retail rate that is based on a metric of kilowatt (kW) demand rather than kilowatt-hour (kWh) energy usage. Demand charges are widely used in the commercial and industrial (C&I) electricity sectors to recover significant portions of utility revenue and are also used in residential rates in a modest but growing number of locations. This paper explores the historical context of and motivations for demand charges, describes their implementation and impacts in today's context, and uses a variety of opinions collected from relevant parties through semi-structured interviews to inform how demand charges align with four widely accepted rate design principles. This project is funded by the Department of Energy's Office of Electricity, which is interested in conducting research to understand the current state of affairs related to demand charges and how the future U.S. electricity grid will help to define retail rates.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

SHOTEAM: Superalloy Heat exchangers Optimized for Temperature Extremes and Additive Manufacturability (Final Technical Report)

UCLA developed an extreme-condition heat exchanger technology targeted to ultra-high efficiency hybrid aviation power cycles. The heat exchanger targeted operation at 50 kW (thermal) at supercritical CO 2 pressures of 80 and 250 bar (1160 and 3626 psi) in hot and cold streams, respectively and at a hot-stream inlet temperature of 800°C (1472°F). A metallic superalloy capable of withstanding high temperature and pressure was used to fabricate a microtube shell-and-tube-based design supplemented with 3D-printed tube augmentations. The optimized design enhanced overall heat transfer while maintaining a small overall form factor and low weight. This class of heat exchanger could dramatically improve efficiency, power density, and cost effectiveness for new hybrid aviation power cycles, thus enabling economically feasible routes to air vehicle propulsion with substantially less CO 2 emissions to the environment.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

FINAL PROJECT REPORT SBIR Phase II Next Generation Power Converters for Distributed Wind Applications

Intergrid, LLC, based in Temple, New Hampshire, conducted an 24-month DOE SBIR Phase II research program to develop next-generation electronic power inverters and converters for the United States distributed wind (DW) market. The distributed wind segment is defined as turbines rated from 10 kW to 1 MW, a market segment that has been almost entirely blocked by the absence of UL1741-certified, commercially available inverters.

17 WIND ENERGY↗

Design of a high power 8 MeV electron beam injector for the LERF

We present the beamline design for a high power 8 MeV electron injector to be installed at the Low Energy Recirculator Facility (LERF). The injector is designed to provide beam power of up to 80 kW for testing positron source target candidates. We discuss the results of beam dynamics simulations conducted using the General Particle Tracer (GPT) software, where electromagnetic beamline elements were optimized using multi-objective genetic algorithm tools. Additionally, we present preliminary studies on secondary particle generation from both rotating solid and free surface liquid metal jet targets described elsewhere in this workshop.

Lizarraga-Rubio, Victor [Thomas Jefferson National↗

Cummins PEM Fuel Cell System for Heavy Duty Applications

The motivation for this project was to develop a high-pressure 100+ kW fuel cell stack that can be used in a modular fashion to power HD applications up to 1 MW. One of the issues that was identified during fuel cell system integration was the need for extra space for heat rejection systems(radiators) as well as additional fans and associated energy consumption to compensate for lower operating temperatures of fuel cells compared to internal combustion (IC) engines. To maximize the heat rejection capability of existing water-based coolant systems that are prevalent on IC engine-based systems, fuel cell stack design was developed to withstand and operate at IC engine coolant temperatures or higher, which in turn helps to reduce the radiator size requirement.

08 HYDROGEN↗

High Voltage High Power Traction Inverter Thermal Management

This project develops thermal management solutions for various 530-kW inverter topologies being developed by Oak Ridge National Laboratory (ORNL). The thermal management solutions will provide high thermal performance and be designed to keep inverter components (e.g., power modules, capacitors) within allowable operating temperatures to help meet the project objectives. Steady-state and transient thermal models of the inverter and cooling system will be created and used to predict component temperatures under various drive cycle conditions.

33 ADVANCED PROPULSION SYSTEMS↗

Gas-Gap Calorimeter Sizing and Rating Tools for Heat Pipe Experimentation

Effective gas-gap calorimeter sizing and rating tools are required to design calorimeters that enable well-defined operating conditions, high cooling powers, and accurate calorimetry. The present report describes two tools utilizing Microsoft Excel and MathWorks MATLAB that enable the sizing and rating of gas-gap calorimeters with a He-Ar binary gas mixture in the gap. The Excel tools are two easy-to-use spreadsheets for calculating heat pipe operating temperature or He-Ar mole fractions given the required inputs. The MATLAB tool includes similar models with more robust solution algorithms along with sub-options for full-vacuum, static gas-gap, and forced circulation in the gas-gap. The accuracy of the developed tools were demonstrated by comparing with existing work in literature. The MATLAB tool was used for a parametric study to determine the gas-gap thickness, coolant gap thickness, coolant flow rate, and coolant inlet temperatures for the testing of a 3/4 in outer diameter heat pipe up to powers of 10 kW and temperatures of 1,000°C. The effects of heat pipe and calorimeter inner shell surface emissivities were investigated, considering the inability to control or accurately measure surface emissivities in most applications. It was found that controlling the He-Ar mole fractions provides a wide operating range for gas-gap thicknesses around ~ 0.042--0.090 in (~ 1.07--2.29 mm) for a surface emissivity range of 0.4--0.8, since conduction heat transfer is a significant fraction of the heat transfer across the gas-gap. In addition, it was found that turbulent flow in the coolant gap is needed at high input powers to prevent shell temperatures from approaching the boiling temperature of the water coolant. The parametric study resulted in choosing stainless steel tubes with an outer diameter and thickness of 1 x 0.065 in as the inner shell, and a 1-1/2 x 0.156 in as the outer shell of the calorimeter. Overall, this report presents the necessary information for the sizing and rating of gas-gap calorimeters with He-Ar mixtures for the testing of high-temperature heat pipes (~ 500--1,000°C).

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

Design of a high power 8 MeV electron beam injector for the LERF

Here, we present the beamline design for a high power 8 MeV electron injector to be installed at the Low Energy Recirculator Facility (LERF). The injector is designed to provide beam power of up to 80 kW for testing positron source target candidates. We discuss the results of beam dynamics simulations conducted using the General Particle Tracer (GPT) software, where electromagnetic beamline elements were optimized using multi-objective genetic algorithm tools. Additionally, we present preliminary studies on secondary particle generation from both rotating solid and free surface liquid metal jet targets described elsewhere in this workshop.

Lizarraga-Rubio, Victor Manuel [Thomas Jefferson N↗