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Furthering Advancements to Shorten the Time (FAST) to Commissioning for Pumped Storage Hydropower (PSH) Prize (Penn State-PNNL): Cooperative Research and Development Final Report, CRADA Number CRD-19-00842

The National Renewable Energy Laboratory (NREL) initiated a Prize with support from Argonne National Laboratory (ANL), Oak Ridge National Laboratory (ORNL), and Pacific Northwest National Laboratory (PNNL), and sponsored by the U.S. Department of Energy Water Power Technologies Office (DOE WPTO) to encourage ideas to reduce the time to commissioning for PSH projects. As a result, nine finalists have been chosen to develop their concepts in advance of the FAST Prize Pitch Contest to be held on October 7, 2019. The national labs will provide technical and business advisement to the noted FAST Prize finalists in preparation for this Pitch Contest.

13 HYDRO ENERGY↗

Study of Additive Manufacturing Applications to Geothermal Technologies Final Project Report

This report summarizes work performed to assess the potential for utilizing additive manufacturing (AM) to substantially improve either the availability, performance or cost basis for tools and components that are required for geothermal energy production. A systematic cataloging of geothermal activities, associated technologies, and current manufacturing methods was first undertaken. This included literature reviews as well as interviews with subject matter experts, service companies and OEMs. An industry workshop was held as part of this portion of the project to obtain input and concerns from a broad range of OEMs, service providers and end users. This workshop was also used to gage the current level of AM activity in industry, receptiveness to the use of AM manufactured parts, and any up front concerns that may exist. A summary of the workshop is presented in this report. Representative components and assemblies and their current manufacturing methods were then analyzed by additive manufacturing experts at a company called Senvol to determine the feasibility and required steps for producing parts by additive manufacturing. A step by step description of conventional manufacturing of the parts was also performed to establish a manufacturing baseline for comparison purposes. This analysis also considered and described the benefits of additively manufacturing the parts in terms of specific AM systems, material availability for AM, dimensional requirements and potential economic advantages. Details of the manufacturability assessment were summarized in a report which is included as a chapter in this document. The analysis of the AM subject matter experts was then be used by techno-economic analysts to perform a comparative economic evaluation of the manufacturing of select technologies by AM and conventional approaches. This activity leveraged ORNL expertise and prior experience in other applications. A framework based on assessing cost, volume production considerations, and time to manufacture was created to more easily discern the advantages or disadvantages of additive versus conventional manufacturing methods. The report concludes with a general assessment of the current applicability of AM for geothermal technologies, AM gaps and needs related to typical geothermal hardware, and the potential benefits and impacts of AM to geothermal energy production.

15 GEOTHERMAL ENERGY↗

Early Phase Molten Salt Reactor Safety Evaluation Considerations

This report documents rationale to develop analytical tools and data applicable to the safety and design of advanced molten salt power reactors. This report represents early steps in the implementation of the tasks defined by Oak Ridge National Laboratory (ORNL) in 2018 in the following sections of A Safety and Licensing Roadmap to identify the Research and Development Gaps of Commercial Molten Salt Reactors

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Furthering Advancements to Shorten the Time (FAST) to Commissioning for Pumped Storage Hydropower (PSH) Prize: Cooperative Research and Development, CRADA Number CRD-19-00837 (Final Report)

The National Renewable Energy Laboratory (NREL) initiated a Prize with support from Argonne National Laboratory (ANL), Oak Ridge National Laboratory (ORNL), and Pacific Northwest National Laboratory (PNNL), and sponsored by the U.S. Department of Energy Water Power Technologies Office (DOE WPTO) to encourage ideas to reduce the time to commissioning for PSH projects. As a result, nine finalists have been chosen to develop their concepts in advance of the FAST Prize Pitch Contest to be held on October 7, 2019. The national labs will provide technical and business advisement to the noted FAST Prize finalists in preparation for this Pitch Contest.

13 HYDRO ENERGY↗

Novel GLIDES Technology for Grid Resiliency. Final Report

The transformative Ground Level Integrated Diverse Energy Storage (GLIDES) technology was invented and had early stage success demonstrated at Oak Ridge National Laboratory (ORNL) in 2013–2017. The first proof-of-concept demonstration prototype of GLIDES has been successfully developed. In May 2016, this unique technology was a featured story in the ASHRAE newsletter.1 A detailed thermophysical analysis of this system has also been already published.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Summary of Previous Mechanical Test Data on ODS Alloys 14YWT and OFRAC up to 1000ºC

The Nanostructured Ferritic Alloys (NFA) 14YWT and OFRAC were developed for future fission and fusion nuclear energy reactors requiring high-temperature mechanical properties that are tolerant to extreme neutron irradiation environments. The NFA contain a high concentration of Ti-, Y- and O-enriched nanoclusters (NC) and ultra-fine grains to achieve high temperature strength and creep properties and high sink strength for trapping irradiation induced point defects to minimize hardening and swelling and transmutated He atoms to form intragranular nano-size bubbles that prevent formation of coarse bubbles on grain boundaries that cause embrittlement. The mechanical properties of 14YWT and OFRAC have been acquired from tensile and creep tests conducted in the past at Oak Ridge National Laboratory. The development of 14YWT started in 2000, resulting in the production of numerous heats. Tensile properties were obtained from eleven heats of 14YWT from room temperature to 800ºC. Tensile data for the SM10 heat of 14YWT was extended to 1,000ºC. Initial development of OFRAC occurred in 2016. Tensile tests conducted from room temperature to 800ºC revealed similar properties of OFRAC with those obtained from the newer generation of 14YWT heats. The creep properties of 14YWT-SM10 evaluated using constant stress tensile and load time-to-failure tests at 800ºC showed low minimum creep rates with stresses of 200 and 100 MPa. The single time-to-failure test of 14YWT-SM10 at 800ºC and 100 MPa was terminated after 20,357 hours with no specimen failure and a low creep strain of ~0.24 %. The creep properties of OFRAC determined from strain-rate jump tests at were similar those of 14YWT-SM10. The stress exponent for 14YWT and OFRAC at 800ºC are similar and are consistent with threshold stress behavior. Since both 14YWT and OFRAC are candidates for fuel cladding in future fast reactors, several fabrication studies were recently conducted and have successfully demonstrated that thin wall tubes can be fabricated from 14YWT and OFRAC by cold pilger rolling and high precision tube rolling. The high temperature mechanical properties and feasibility of fabricating thin wall tubes make 14YWT and OFRAC candidates for application as heat pipes in advanced micro-reactors. The purpose of this report is to summarize the previously obtained tensile and creep data at temperatures up to 1000ºC for NFA 14YWT and OFRAC that have been acquired over the past 20 years at ORNL.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

First Experiments: New Science Opportunities at the Spallation Neutron Source Second Target Station (abridged)

This brochure is an abridged version of a more comprehensive companion report. DOE proposes to build a Second Target Station (STS) at SNS to produce beams of cold neutrons with world-leading peak brightness at a repetition rate of 15 Hz, providing broad energy/wavelength ranges that can be used simultaneously. Construction of the STS will provide transformative capabilities that allow thousands of users from national laboratories, universities, and industry to address grand scientific challenges [Hemminger 2015], advance energy research, and accelerate industrial innovations through the combination of cold (long-wavelength) neutrons of unprecedented peak brightness and short neutron pulses with broad ranges of usable wavelengths or energy. The STS Project, now in progress at ORNL, will design, construct, install, and commission the facilities and equipment needed to create a world-leading source of cold neutrons of unprecedented peak brightness at SNS. Key aspects of the STS design, including preliminary descriptions of an illustrative suite of eight instruments, are presented in the section “The STS at SNS.” The capabilities offered by the STS instruments (22 when fully built out) will complement those of the FTS and HFIR, providing the United States with unparalleled resources for neutron scattering at the world’s leading high–peak brightness cold neutron source.

43 PARTICLE ACCELERATORS↗

High-Resolution 3D Acoustic Borehole Integrity Monitoring (Research Performance Progress Report Q2 2021)

Real-time, in-situ, high spatial resolution (sub-cm) imaging of the near-borehole environment would revolutionize wellbore diagnostics and integrity assessment by direct observation of defects. It is becoming increasingly apparent, that better understanding of the near-wellbore environment is required to meet the safety and operational needs in challenging environments such as those present in subsurface energy extraction (geothermal) and storage (CO2 sequestration) applications. Therefore, it is important to have a more robust ability to image the near-borehole and reliably detect defects. It was proposed to further develop and improve our advanced 3D imaging system to evaluate casing defects (e.g. corrosion) and cement quality in either open- or cased-borehole with the ultimate goal to develop a commercially deployable technology. The system consists of a unique acoustic source (LANL) and advanced inversion techniques for image processing (LANL, ORNL). This system will provide comprehensive borehole integrity monitoring with improved resolution over existing techniques. As an application of this imaging system, we will characterize the effectiveness of next-generation wellbore completion technology (NETL, SNL), and will demonstrate that, unlike current technology, the proposed approach can successfully characterize foamed cements.

15 GEOTHERMAL ENERGY↗

Radiation-Hardened Instrumentation, Sensors and Electronics

To assist the US Department of Energy in defining a course for Office of Nuclear Energy–funded radiation-hardened (rad-hard) electronics research, Oak Ridge National Laboratory (ORNL) will focus on three main tasks in FY21. The first task will investigate the survivability of silicon junction-gate field-effect transistors (Si-JFETs) through a 100 Mrad total ionizing dose (TID) experiment and report the test results. The second task will investigate wide bandgap (WBG)-based JFET devices and sources. The third task is an investigation into commercially available systems and components and will be performed to determine whether a standardized list of devices can be identified for reactor instrumentation application. If the devices are feasible, then this list will provide direction to designers and equipment suppliers for selection of components to meet specific reactor requirements.

42 ENGINEERING↗

Comparing Retrofit Wall Performance Predicted from Hygrothermal Simulations to Measurements

Over the past few years ORNL has been showing that WUFI® can be used to predict the moisture performance of walls when exposed to diffusion of water vapor, convection of moist air through the wall, and solar driven moisture. This is accomplished by comparing the hygrothermal simulation results to carefully instruments walls exposed to these phenomena in a climate chamber. In FY 2018, three stick-built walls were succumbed to typical Chicago, Illinois weather conditions in Oak Ridge National Laboratory’s Heat, Air and Moisture chamber. The measured temperature, relative humidity, and moisture content within these walls were compared with WUFI hygrothermal simulation results. In FY 2019, similar experiments and comparisons with WUFI results were completed with two walls, a structural insulated panel-based wall and a concrete masonry unit-based wall. In FY 2020, experiments were completed for a probable exterior retrofit of a wall which included adding cavity and continuous insulation. Two pairs of walls were tested by exposing them to Chicago winter weather with a positive pressure pushing outside air into the wall. The results from the FY 2020 experiments are reported here.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Ecosystems and Networks Integrated with Genes and Molecular Assemblies (ENIGMA) (Final Scientific/Technical Report, Subcontract Award No. 6953691)

The overarching objective the Baliga lab is to develop a mechanistic understanding of the field relevant metabolic processes underlying community partitioning of respiration pathways and physiological state shifts. In order to dissect how environmental perturbations influence microbial regulatory networks, we have constructed data-driven models that capture the dynamic interplay between abiotic and biotic factors during laboratory simulations. Specifically, we have developed multiple computational models (i.e., cMonkey2, EGRIN 2.0, and multiple genome-scale metabolic models) connecting environmental influence to genome-encoded regulatory programs. In addition, we have generated new tools such as Live Anaerobic Cell Sorting (LAnCS) and Fluidized Bed Reactors (FBRs) to investigate the dynamics of community partitioning of metabolic processes supporting sulfate or nitrate respiration, which are two critical activities observed from the field site at Oak Ridge National Labs (ORNL). This framework of connecting field phenomena with laboratory simulations and computational modeling has created the Environmental Simulations and Modelling (EnvSim) campaign within ENIGMA. The campaign, which spans multiple laboratories across ENIGMA and is led by the Baliga group, has established synthetic communities (SynComs) to discover, characterize, and dissect key microbial processes relevant to field observations, such as emissions of the greenhouse gas nitrous oxide (N 2 O). For example, the EnvSim campaign so far has deduced four potential mechanisms that may account for the N 2 O emissions at the FRC and are currently being investigated by labs across ENIGMA. Denitrification may be driven by complete denitrifiers, however, their NosZ enzymes, which catalyze the final step in denitrification by converting N 2 O to N 2 , may be sensitive at a lower pH. Additionally, the denitrification process could be partitioned among organisms and some may have pH-sensitive NosZ genes. Another factor contributing to variable N 2 O emissions relates to the metal co-factors involved in the denitrification pathway. For instance, excess Cu, Al, Mn, U, Ni, Co, Cu, and/or Cd may have inhibitory effects on multiple enzymatic steps during denitrification, while the enzymatic production of nitrite, the precursor of N 2 O, can be limited by the essential metal Mo. Lastly, abiotic production of N 2 O may occur as a result of chemodenitrification, in which metals like Fe, Mn, and some organic compounds can drive redox reactions that convert nitrogen cycle intermediates to N 2 O under the right conditions. Current investigations and analyses have generated multiple transcriptomic profiles aiding the refinement of new metabolic and gene regulatory network model for our denitrifying SynCom. In sum, the previous funding cycle has generated 33 peer-reviewed publications spanning predictive network biology to co-operativity of mutualistic interspecies interactions of evolved communities. Our integration of multiple omics datasets and the development of new network modelling tools has revealed important insights that can explain field observed phenomenon and generated new hypotheses to be investigated in the field.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Temperature Effect of Gas Bubble Evolution in UCN Fuel Kernels Irradiated by Swift Xe Ions

UC1-xNx fuel kernels provided by Oak Ridge National Laboratory (ORNL) were irradiated by 84 MeV Xe ions at two different temperatures (450°C & 750°C) at the Argonne Tandem Linac Accelerator System (ATLAS) at Argonne National Laboratory, followed by post-irradiation examination. The primary goal of this study was to understand gas bubble formation (due to accumulation of Xe gas) and corresponding size evolution dependent upon net Xe deposition at the two different temperatures. From the post-irradiation examinations of the samples, it can be concluded at 750°C, with same amount of dose received, the Xe gas bubbles seems to coarsen much more easily compared to 450°C. The results generated for fission gas bubble evolution observed in this study can be used to support fuel performance models for UC1-xNx fuel kernels.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Selection and Characterization of Surrogate Material for Developing Zr Barrier Coatings for Uranium Nitride Particles

In support of UC 1-x N x fuel kernels (~ 800 micrometer diameter) development work ongoing at Oak Ridge national laboratory (ORNL), where the fuel kernels will be embedded inside a possible zirconium based matrix, Argonne National Laboratory (ANL) is contributing to help develop a robust metal diffusion barrier coating. Zirconium nitride (ZrN) and Zirconium oxide (ZrO2) were selected as possible diffusion barrier candidates, and the atomic layer deposition (ALD) has been chosen as a candidate technology to deposit the film. Development of such a barrier coating with the ALD process entails significant number of trials to study relevant parameters. Therefore, to prevent needless wastage, instead of coating directly over fuel kernels, a surrogate candidate with similar dimensions and physical properties were been selected and coated to develop the diffusion barrier coating.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

A Verification and Validation Approach for COMSOL Multiphysics to Support High Flux Isotope Reactor (HFIR)

Over the last several decades, many reactors have successfully been converted from high enriched uranium (HEU) to low enriched uranium (LEU) fuels in United States in support of its global non-proliferation objectives. Of the reactors slated for conversion, five high-performance research reactors (HPRRs) remain. The high-flux isotope reactor (HFIR) at Oak Ridge National Laboratory (ORNL) is one of the five. Conversion of HFIR requires the qualification of a new fuel. To aid in the conversion process as well as improve safety margins, COMSOL Multiphysics was chosen to support and eventually supplement the steady-state heat-transfer code (SSHTC). In order to use COMSOL as a supplementary tool, i.e. one used for safety basis calculations, the code needs to undergo a verification and validation process. Verification and validation are important processes for the use of any software; however, physics-based solvers have a unique challenge, in that the validation is much more rigorous and its domain is only applicable to the general scope of the problem. This document details the verification and validation of COMOSL for analysis of HFIR. This report is intended for two different users: (1) current and future users of COMSOL for HFIR and (2) for individuals interested in assessing the scope of the validation of COMSOL for HFIR. This report is divided into six sections. The first of which details the process of verification and validation. Section one provides an overview of key concepts from ASME V&V 10, 20, and 40 and how these concepts are used to provide a validation of any multiphysics software. Section two covers the approach needed in order to validate multiphysics software for a given HFIR analysis. Parts three through five split up the key concepts highlighted in section two. The final section provides concluding remarks which demonstrate the scope and limitations of the validation study and how these may be expanded and improved.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Application of Point Precipitation Frequency Estimates to Watersheds

This report documents work sponsored by the U.S. Nuclear Regulatory Commission (NRC) at the Oak Ridge National Laboratory (ORNL) as part of the RES project, “Application of Point Precipitation Frequency Estimates to Watersheds.” This project was implemented as part of the Probabilistic Flood Hazard Assessment (PFHA) Research Program. The objective of the PFHA Research Program is to develop tools and guidance on the use of PFHA methods to risk-inform NRC’s licensing of new facilities as well as licensing and oversight of currently operating facilities as they relate to flooding hazards. Many nuclear power plants (NPPs) are located on or near rivers so riverine flooding hazards need to be considered in their design and operation. Probabilistic riverine flood models are important tools for realistic assessment of flooding risks. However, these models require areal estimates of the depth, duration, and frequency of rainfall distributed over the watershed, which are not often available. Point precipitation frequency estimates are more widely available. For example, the National Oceanic and Atmospheric Administration (NOAA) has published NOAA Atlas 14, which provides point precipitation frequency estimates for 5-minute through 60-day durations at average recurrence intervals of 1-year through 1,000-year. The research documented in this report addresses areal reduction factors (ARFs), which can be used to convert the widely available point precipitation frequency estimates, to estimates of areal precipitation frequency over a watershed. The most widely used ARF source is Technical Paper 29 (TP-29) published by the then U.S. Weather Bureau in 1958. However, both the methods and the underlying precipitation data used to produce TP-29 are seriously out of date. For example, due to the small gauge network available at the time of TP-29’s compilation, ARF estimates developed are only for watersheds smaller than about 400 square miles. Due to the relatively short record lengths of precipitation data available, frequency considerations could not be accurately determined. Other factors such as regional climate and seasonality were not addressed. Several newer methods have been published since TP-29 was developed and both the type and quantity of precipitation data have increased significantly, along with computational resources and analytical tools such as geographic information systems. This report reviewed and assessed the available precipitation products and methods for conducting ARF analysis. The work applied up-to-date precipitation data products and analysis methods with a novel watershed-based approach to investigate how ARF estimates vary across different methods, data sources, geographical locations, return periods, and seasons. The overall findings reported here regarding basic ARF trends are in line with other recent studies showing that ARFs decrease with increasing area, increase with increasing duration, and decrease with increasing return period. This study found significant differences among the available ARF methods. This work also found a strong geographical variability across different US hydrologic regions, suggesting that the ARF are specific to regional climate patterns and geographical characteristics and should not be applied arbitrarily to other locations. The results also reveal the importance of data record length, especially for high return level ARFs. The work reported in NUREG/CR-7271 will assist NRC staff in assessing different classes of ARF methods in conjunction with available rainfall data sets. It will also support the development of guidance for application of point precipitation data in PFHAs. It should be noted that the ARF values presented in this report for any location or region were developed for the purposes of comparing methods and investigating the factors that influence ARFs. They should not be considered official and should not be used in leu of a site-specific analysis.

54 ENVIRONMENTAL SCIENCES↗

Radiological Monitoring Plan for the Oak Ridge Y-12 National Security Complex: Surface Water

DOE Order 458.1 requires that dose estimates consider contributions from all facilities. In the Y-12 Radiological Monitoring Plan (RMP), surface water is monitored at points that reflect individual facilities, as well as at points that reflect the combined contributions of all facilities. This monitoring plan does not consider other potential routes (i.e., airborne releases and food chains). Thus, a complete determination of total effective dose (TED) cannot be made based on this plan alone. The other routes from Y-12, and all routes from other DOE facilities on the Oak Ridge Reservation (e.g., Oak Ridge National Laboratory (ORNL) and The Heritage Center), must be considered in order to satisfy DOE Order 458.1 requirements. Determination of TED from all sites and pathways is done through the use of dose-assessment models and is documented in the Annual Site Environmental Report. This monitoring plan provides adequate monitoring goals for Y-12 surface water releases to provide input of sufficient sensitivity and accuracy to reliably determine the Y-12 surface water component of the TED. The routine radiological monitoring program is designed to monitor effluents at four types of locations: (1) treatment facilities, (2) other point and area source discharges, (3) instream locations, and (4) production building roof run-off. With this sampling and analysis program, data will be obtained on primary point sources as well as on locations that represent the composite of other potential sources. This plan will be reviewed periodically to determine necessary modifications to the sampling frequencies, parameters, and locations. Modifications, if any, will be based on the analysis of the previous data and its effectiveness in satisfying the objectives of this plan. Appendix A contains graphs of the sum of the DCS fractions for locations and frequencies contained in a previous version of this plan. The data was collected from January 2009 through December 2019. Each sample was analyzed, and each result was divided by the appropriate DCS to compute a DCS fraction. These fractions were summed for all isotopes. According to DOE –STD-1196-2011, the annual average of these sums should be below 1.

54 ENVIRONMENTAL SCIENCES↗

Comparison of mechanical properties measured on multiple scales

FeCrAl alloys are being developed for accident tolerant fuels for current light water reactors. Specifically as fuel claddings with enhanced safety. These alloys are being developed to have excellent corrosion resistance in light water reactor coolant environments and structural integrity for longer durations in the case of a loss of coolant scenario where time is critical for safety. Tensile, shear punch, and Vickers hardness testing was performed on neutron irradiated FeCrAl alloys with three variations in composition. Testing was done at room temperature for comparison of the three techniques. FeCrAl alloys in this report were irradiated at Oak Ridge National Laboratory (ORNL) in the High Flux Isotope Reactor (HFIR) to 7 dpa and at 320 °C.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

A Comparative Study of Direct and Indirect Additive Manufacturing Approaches for the Production of a Wind Energy Component

Additive manufacturing (AM) was developed in the 1980s to create three-dimensional prototypes through layer-wise approaches to fabrication. Since then, these approaches have seen improvements in both materials and processing technologies. To date, there are now 7 types of additive manufacturing processes and hundreds of materials, which can be directly printed – going directly from digital design to fabricated components. In this project, Oak Ridge National Laboratory (ORNL), Vestas Wind Systems, and The National Renewable Energy Laboratory (NREL) collaborated to evaluate the effectiveness of state-of-the-art large-scale AM processes in the production of a structural component for use in a wind turbine nacelle, through both direct and indirect manufacturing approaches. Here, experienced AM design engineers detail techniques for AM design, including topology optimization (TO), support minimization, reverse engineering, and techniques for mitigating poor interlaminar performance. Fabrication of the components is presented, including printing parameters and postprocessing, and followed with full-scale component testing by a 3rd party testing laboratory. To evaluate the potential of the developed approaches, a complete techno-economic analysis is provided which evaluates the cost of these techniques given current and near to long-term projections of AM system capabilities.

17 WIND ENERGY↗