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DOE OSTI2022

Reducing the Overnight Capital Cost of Advanced Reactors Using Equipment-Level Seismic Protective Systems

Consideration of the effects of earthquake shaking on the design and construction of nuclear power plants adds substantially to the overnight capital cost, with anecdotal estimates as high as 35+%, attributed to additional construction materials, need for one-off and sub-optimal designs of equipment due to conflicting design choices, the high cost of seismic qualification of equipment, and regulatory review. Safety-critical equipment in large light water reactors is designed and qualified for seismic demands imposed by the supporting reactor building, optimal mechanical designs are not possible, and designs of a given piece of equipment may vary with height above grade. Similar negative impacts are expected for advanced reactors unless the seismic design paradigm is changed. The overarching goal of this transformational MEITNER project, which involved a multidisciplinary engineering team and designers of three fundamentally different advanced reactors, was to adapt proven seismic isolation and damping technologies to operationalize modular protective systems for safety-class equipment inside advanced reactor buildings. Such seismic protective systems would be tightly integrated into design development for reactor support systems and balance-of-plant construction. The adoption of the technology, which is widely used in non-nuclear sectors, would simplify plant design, enable the use of standardized equipment and buildings, optimized for operational performance, and reduce plant size and weight. The need for site-specific equipment would be eliminated, enabling identical equipment to be used across multiple plants sited across the US and economies of scale, and catalyzing new interest and investment. The equipment-based protective systems would allow siting of advanced reactors in regions of high seismic hazard.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

Toward digital design at the exascale: An overview of project ICECap

High performance computing has entered the Exascale Age. Capable of performing over 1018 floating point operations per second, exascale computers, such as El Capitan, the National Nuclear Security Administration's first, have the potential to revolutionize the detailed in-depth study of highly complex science and engineering systems. However, in addition to these kind of whole machine “hero” simulations, exascale systems could also enable new paradigms in digital design by making petascale hero runs routine. Currently, untenable problems in complex system design, optimization, model exploration, and scientific discovery could all become possible. Motivated by the challenge of uncovering the next generation of robust high-yield inertial confinement fusion (ICF) designs, project ICECap (Inertial Confinement on El Capitan) attempts to integrate multiple advances in machine learning (ML), scientific workflows, high performance computing, GPU-acceleration, and numerical optimization to prototype such a future. Built on a general framework, ICECap is exploring how these technologies could broadly accelerate scientific discovery on El Capitan. In addition to our requirements, system-level design, and challenges, we describe some of the key technologies in ICECap, including ML replacements for multiphysics packages, tools for human-machine teaming, and algorithms for multifidelity design optimization under uncertainty. As a test of our prototype pre-El Capitan system, we advance the state-of-the art for ICF hohlraum design by demonstrating the optimization of a 17-parameter National Ignition Facility experiment and show that our ML-assisted workflow makes design choices that are consistent with physics intuition, but in an automated, efficient, and mathematically rigorous fashion.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2022

Minimum feature size control in level set topology optimization via density fields

A level set topology optimization approach that uses an auxiliary density field to nucleate holes during the optimization process and achieves minimum feature size control in optimized designs is explored. The level set field determines the solid-void interface and the density field describes the distribution of a fictitious porous material using the solid isotropic material with penalization. These fields are governed by two sets of independent optimization variables which are initially coupled using a penalty for hole nucleation. The strength of the density field penalization and projection is gradually increased during the optimization process to promote a 0-1 density distribution. In addition, a second penalty regulates the evolution of the density field in the void phase. The treatment of the density field combined with the second penalty mitigate the appearance of small design features. The minimum feature size of optimized designs is controlled by the radius of the linear filter applied to the density optimization variables. The structural response is predicted by the extended finite element method, the sensitivities by the adjoint method, and the optimization variables are updated by a gradient-based optimization algorithm. Numerical examples investigate the robustness of this approach with respect to algorithmic parameters and mesh refinement. The results show the applicability of the combined density level set topology optimization approach for both optimal hole nucleation and for minimum feature size control in 2D and 3D. This comes, however, at the cost of a more complex problem formulation and additional computational cost due to an increased number of optimization variables.

42 ENGINEERING↗

DOE OSTI2022

Comparison of CCM- and CRM-Based Boost Parallel Active Power Decoupler for PV Microinverter

Single-phase inverter or rectifier systems often make use of an active power decoupler (APD) to balance the mismatch between constant dc power and fluctuating ac power. This article deals with the comparison of continuous conduction mode (CCM) and critical conduction mode (CRM) operation-based design of a parallel boost-type APD for photovoltaic microinverter applications. From a design perspective, multiobjective analysis of efficiency, volume, and cost is explored within a decision space including planar inductors, gallium nitride based devices, film capacitors, switching frequency, and modulation (CCM vs. CRM). The theoretical study analyzes all possible design configurations within CCM and CRM and identifies Pareto-optimal designs, from which the selected CRM design can achieve reduced system volume and lower cost with the use of smaller inductor core, while operating with similar California Energy Commission efficiency drop as the selected CCM design. From a control perspective, a pulsewidth modulation based control strategy is proposed to implement closed-loop CRM modulation that does not rely on zero-crossing detection. Furthermore, closed-loop systems are designed for the optimal CCM and CRM realizations, and the final system characteristics are compared. Experimental results, obtained using two separate 40-V, 400-W hardware prototypes for CCM and CRM, are presented to verify the analyses.

42 ENGINEERING↗

DOE OSTI2012

Characteristics of miniature electronic brachytherapy x-ray sources based on TG-43U1 formalism using Monte Carlo simulation techniques

Purpose: The goal of this study is to determine a method for Monte Carlo (MC) characterization of the miniature electronic brachytherapy x-ray sources (MEBXS) and to set dosimetric parameters according to TG-43U1 formalism. TG-43U1 parameters were used to get optimal designs of MEBXS. Parameters that affect the dose distribution such as anode shapes, target thickness, target angles, and electron beam source characteristics were evaluated. Optimized MEBXS designs were obtained and used to determine radial dose functions and 2D anisotropy functions in the electron energy range of 25-80 keV. Methods: Tungsten anode material was considered in two different geometries, hemispherical and conical-hemisphere. These configurations were analyzed by the 4C MC code with several different optimization techniques. The first optimization compared target thickness layers versus electron energy. These optimized thicknesses were compared with published results by Ihsan et al.[Nucl. Instrum. Methods Phys. Res. B 264, 371-377 (2007)]. The second optimization evaluated electron source characteristics by changing the cathode shapes and electron energies. Electron sources studied included; (1) point sources, (2) uniform cylinders, and (3) nonuniform cylindrical shell geometries. The third optimization was used to assess the apex angle of the conical-hemisphere target. The goal of these optimizations was to produce 2D-dose anisotropy functions closer to unity. An overall optimized MEBXS was developed from this analysis. The results obtained from this model were compared to known characteristics of HDR {sup 125}I, LDR {sup 103}Pd, and Xoft Axxent electronic brachytherapy source (XAEBS) [Med. Phys. 33, 4020-4032 (2006)]. Results: The optimized anode thicknesses as a function of electron energy is fitted by the linear equation Y ({mu}m) = 0.0459X (keV)-0.7342. The optimized electron source geometry is obtained for a disk-shaped parallel beam (uniform cylinder) with 0.9 mm radius. The TG-43 distribution is less sensitive to the shape of the conical-hemisphere anode than the hemispherical anode. However, the optimized apex angle of conical-hemisphere anode was determined to be 60 deg. For the hemispherical targets, calculated radial dose function values at a distance of 5 cm were 0.137, 0.191, 0.247, and 0.331 for 40, 50, 60, and 80 keV electrons, respectively. These values for the conical-hemisphere targets are 0.165, 0.239, 0.305, and 0.412, respectively. Calculated 2D anisotropy functions values for the hemispherical target shape were F(1 cm, 0 deg.) = 1.438 and F(1 cm, 0 deg.) = 1.465 for 30 and 80 keV electrons, respectively. The corresponding values for conical-hemisphere targets are 1.091 and 1.241, respectively. Conclusions: A method for the characterizations of MEBXS using TG-43U1 dosimetric data using the MC MCNP4C has been presented. The effects of target geometry, thicknesses, and electron source geometry have been investigated. The final choices of MEBXS design are conical-hemisphere target shapes having an apex angle of 60 deg. Tungsten material having an optimized thickness versus electron energy and a 0.9 mm radius of uniform cylinder as a cathode produces optimal electron source characteristics.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2022

Design of a Multi-Monochromatic X-ray Imager (MMI) for Kr K-shell line emission

We report the Multi-Monochromatic X-ray Imager (MMI) is a time-gated spectrometer used in implosion experiments at the OMEGA laser facility. From the data, electron temperature and density spatial distributions can be obtained at different implosion times. Previous MMI designs used Ar K-shell emission (3–6 keV) as a spectroscopic tracer and provided a spectral resolution of around 20 eV. However, Ar K-shell line emission becomes less useful at electron temperatures above 2 keV due to over-ionization. Kr K-shell (12–16 keV) has been shown to be an attractive alternative to diagnose hot implosion cores in recent publications. The purpose of this paper is to show a new point design that allows the MMI to detect this higher photon energy range with suitable spectral resolution. The algorithm used to find the optimal design couples a ray-tracing code and an exhaustive parameter space search. This algorithm may be useful as a tool to find optimal MMI designs for other purposes, i.e., other spectral regions for other spectroscopic tracers. So, the main change between the two designs is the replacement of the multi-layer mirror with a flat Bragg Ge (220) crystal. The final Kr K-shell MMI design has a photon energy range from 12 to 16.1 keV.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2022

MISPR : an open-source package for high-throughput multiscale molecular simulations

Computational tools provide a unique opportunity to study and design optimal materials by enhancing our ability to comprehend the connections between their atomistic structure and functional properties. However, designing materials with tailored functionalities is complicated due to the necessity to integrate various computational-chemistry software (not necessarily compatible with one another), the heterogeneous nature of the generated data, and the need to explore vast chemical and parameter spaces. The latter is especially important to avoid bias in scattered data points-based models and derive statistical trends only accessible by systematic datasets. Here, we introduce a robust high-throughput multi-scale computational infrastructure coined MISPR (Materials Informatics for Structure–Property Relationships) that seamlessly integrates classical molecular dynamics (MD) simulations with density functional theory (DFT). By enabling high-performance data analytics and coupling between different methods and scales, MISPR addresses critical challenges arising from the needs of automated workflow management and data provenance recording. The major features of MISPR include automated DFT and MD simulations, error handling, derivation of molecular and ensemble properties, and creation of output databases that organize results from individual calculations to enable reproducibility and transparency. In this work, we describe fully automated DFT workflows implemented in MISPR to compute various properties such as nuclear magnetic resonance chemical shift, binding energy, bond dissociation energy, and redox potential with support for multiple methods such as electron transfer and proton-coupled electron transfer reactions. The infrastructure also enables the characterization of large-scale ensemble properties by providing MD workflows that calculate a wide range of structural and dynamical properties in liquid solutions. MISPR employs the methodologies of materials informatics to facilitate understanding and prediction of phenomenological structure–property relationships, which are crucial to designing novel optimal materials for numerous scientific applications and engineering technologies.

36 MATERIALS SCIENCE↗

DOE OSTI2011

Present Status of the ILC Project and Development

The Technical Design of the International Linear Collider (ILC) Project will be finished in late 2012. The Technical Design Report (TDR) will include a description of the updated design, with a cost estimate and a project plan, and the results of research and development (R & D) done in support of the ILC. Results from directed ILC R & D are used to reduce the cost and risk associated with the ILC design. We present a summary of key challenges and show how the global R & D effort has addressed them. The most important activity has been in pursuit of very high gradient superconducting RF linac technology. There has been excellent progress toward the goal of practical industrial production of niobium sheet-metal cavities with gradient performance in excess of 35 MV/m. In addition, three purpose-built beam test facilities have been constructed and used to study and demonstrate high current linac performance, electron-cloud beam dynamics and precision beam control. The report also includes a summary of component design studies and conventional facilities cost optimization design studies.

43 PARTICLE ACCELERATORS↗

DOE OSTI2022

Machine Learning Software for Cylindrical Battery Design and Performance Prediction

A software that delivers optimal design parameters and performance predictions for cylindrical cells, which can range in size from micro batteries to EV batteries, is developed. The Cylindrical battery design V1.0 is comprised of three types of cylindrical batteries, Micro battery (Primary), Micro battery (Secondary) and 18650/21700/xxxxx cylindrical battery. The software was developed in MATLAB. The software has the capability to output the cell design with the capacity ranges from several mAh to several million Ah. The software utilizes machine learning and includes a graphical user interface to enable rapid prototyping to accelerate energy storage research, development, and manufacturing.

25 ENERGY STORAGE↗

DOE OSTI2024

Designing Operationally Flexible Diafiltration Membrane Systems for Critical Mineral Separations

This talk presents the design of operationally flexible diafiltration membrane systems for Li/Co recovery, and applies robust optimization methodologies using these flexible systems to generate optimal designs immune to membrane manufacturing variability and uncertain process inlet conditions. The results highlight the use of robust optimization to find design strategies and insights that may reduce technical risks arising from model uncertainties.

Yao, Jason↗

DOE OSTI2024

Treatment and Mineral Recovery from Combustion Residual Leachate and Produced Water

Able, Chad↗

DOE OSTI2019

Assessment of Existing Capabilities and Future Needs for Designing Networked Microgrids

This is a review of existing microgrid design tool capabilities, such as the Microgrid Design Tool (MDT), LANL PNNL NRECA Optimal Resilience Model (LPNORM), Distributed Energy Resource-Customer Adoption Model (DER-CAM), Renewable Energy Optimization (REopt), and the Hybrid Optimization Model for Multiple Energy Resources (HOMER). Additionally, other simulation and analysis tools which may provide fundamental support will be examined. These will include GridLAB-DTM, OpenDSS, and the hierarchical Engine for Large-scale Infrastructure Co-Simulation (HELICS). Their applicability to networked microgrid operations will be evaluated, and strengths and gaps of existing tools will be identified. This review will help to determine which elements of the proposed optimal design and operations (OD&D) tool should be formulated from first principles, and which elements should be integrated from past DOE investments.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2022

Crosslink V.0.11.x User Manual

CrossLink is a novel two-dimensional and three-dimensional geometry and mesh generation software package developed by the Simulation Tools team at Los Alamos National Laboratory. This software represents the third generation of topology-based mesh generation technology developed by the Department of Defense and the Department of Energy with a special focus on complex multi-material hydrodynamic applications, mesh scalability, and high-order element mesh generation. The topology-based meshing approach offered by CrossLink enables users to quickly and easily mesh complex geometries in a repeatable and robust manner. CrossLink’s topology-based meshing approach is well-suited for parametric design studies, parametric design optimization, damage scenario assessment, and iterative design modification (i.e. feature addition and/or removal). CrossLink’s python API allows workflow scripting of the geometry creation and mesh generation process for traceability, repeatability, data provenance, and version control. CrossLink consists of three main components: a graphical user interface (GUI), a geometry creation and mesh generation engine, and a python API that provides a workflow scripting interface to the geometry and meshing functions.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2025

Preliminary System Interface Failure Mode Analysis for Two Advanced Reactors

This study explores two distinct Balance of Plant (BOP) configurations: the Rankine cycle for a sodium-cooled fast reactor (SFR) and the Brayton cycle for a gas-cooled reactor (GCR). As representative designs, the Power Reactor Innovative Small Module (PRISM) by GE Hitachi Nuclear Energy was selected for the SFR, while the Gas Turbine Modular Helium Reactor (GT MHR) by General Atomics was chosen for the gas-cooled reactor. Both configurations were adapted to deliver high-quality heat for industrial applications. A Failure Modes and Effects Analysis (FMEA) was conducted for each system to identify critical failure modes affecting key components. This study marks the first phase of a two-step design optimization approach, integrating FMEA into the design process. Based on the analysis, design modifications and mitigation strategies were proposed to enhance system resilience. The second phase, to be detailed in a subsequent report, will focus on the role of the control system in mitigating these failures. The FMEA serves as a foundation for defining the control topology, ensuring system resilience against component failures that could compromise essential functions, such as electricity and heat production.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2025

Project FELICIA - A probe to survey the RHIC magnet beampipe diameter for EIC beam screen insertion

The Electron Ion Collider (EIC) Hadron Storage Ring (HSR) will reuse many of the existing superconducting (SC) magnets of the RHIC storage rings. To comply with the beamline vacuum requirements in more demanding operational scenarios, the beampipe of the RHIC SC magnets will be equipped with low surface impedance, low secondary electron yield (SEY) beam screens. The installation of these beam screens will be done with the SC magnets as installed today, thus making it a critical operation for a timely EIC installation. The beam screen inner dimensions must be maximized to retain enough aperture to the beam. On the other hand, keeping enough clearance between the screen and the beampipe is critical to ensure a smooth beam screen installation. A survey probe was designed and built to measure the inner diameter of several RHIC SC magnets in-situ and provide critical data for the beam screen design optimization. This paper reports on the design of the probe and the results from the survey campaign.

43 PARTICLE ACCELERATORS↗

DOE OSTI2025

Demonstration of a 1820 channel multiplexer for transition-edge sensor bolometers

The scalability of most transition-edge sensor arrays is limited by the multiplexing technology, which combines their signals over a reduced number of wires and amplifiers. Here, in this Letter, we present and demonstrate a multiplexer design optimized for transition-edge sensor bolometers with 1820 sensors per readout unit, a factor of two more than the previous state-of-the-art. The design is optimized for cosmic microwave background imaging applications, and it builds on previous microwave superconducting quantum interference device multiplexers by doubling the available readout bandwidth to the full 4–8 GHz octave. Evaluating the key performance metrics of yield, sensitivity, and crosstalk through laboratory testing, we find an end-to-end operable detector yield of 78%, a typical nearest-neighbor crosstalk amplitude of ∼0.4%, and a median white noise level of 83 pA/$\sqrt{\textrm{Hz}}$ due to the multiplexer, corresponding to an estimated contribution of 4% to the total system noise for a ground-based cosmic microwave background telescope. Additionally, we identify a possible path toward reducing resonator loss for future designs with reduced noise. We expect these developments to alleviate the system complexity, cryogenic requirements, and cost of future large arrays of low temperature detectors.

cosmic microwave background↗

DOE OSTI2020

Seismic Isolation of Major Advanced Reactor Systems for Economic Improvement and Safety Assurance

Advanced reactor concepts currently under development in the United States [e.g., the High-Temperature Gas Reactor (HTGR) of X-Energy and the Molten Chloride Fast Reactor (MCFR) of TerraPower] are striving to improve the economics of nuclear power primarily by using passively and ‘walk-away’ safe technologies in the reactor. The recently published report, ‘Future of Nuclear Energy in a Carbon-Constrained World’ by the Massachusetts Institute of Technology Energy Institute (MIT EI) has shown that a significant contributor to the capital cost of NPPs is the ‘civil works’ i.e., the construction of the balance of plant (BoP: all SSCs except those involved in power generation, e.g., reactor vessel) such as the buildings, containment dome, foundation, etc., which amount to almost half of the overnight capital cost. The report suggests that using advanced construction technologies such as seismic isolation and high-performance concrete to significantly reduce the capital costs of advanced reactors. This report demonstrates the application of two cost-cutting solutions on advanced reactor designs that are currently under development. These solutions include, (1) seismic base isolation, and (2) risk- and cost-based seismic design optimization including seismic isolation of individual components.

42 ENGINEERING↗

DOE OSTI2016

Multi-species Modeling of Molten-Salt Electrochemical Process

Spent nuclear fuel has been produced and stored in over 30 different countries which are operating commercial nuclear power plants. Molten-salt pyroprocessing has been developed for treating both oxide and metal spent nuclear fuels. This process separates long-lived actinide isotopes together as a group from fission products for burning the long-lived isotopes in fast reactors. Main processes of pyroprocessing such as oxide reduction, electrorefining, and electrowinning are based on a concept of electrolytic cell consuming energy to proceed electrochemical reactions. To scale-up the electrochemical processes, the design optimization of the key steps is required to reach high throughput that improves economic competitiveness and reduces an environmental impact. For the optimization, it is significant to compare different unit process designs and find optimum designs and operating conditions. However, this optimization process is very costly if we need to conduct experiments on every case with spent nuclear fuel. Instead, a validated simulation model can help to rapidly calculate and evaluate different case at significantly reduced costs. This paper presents recent development of multi-physics simulation of molten salt electrochemistry for partitioning spent nuclear fuel with limiting factors. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗