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DOE OSTI2022

Self-powered Through-wall communication for dry cask storage monitoring

Many nuclear facilities, such as spent fuel storage dry casks and nuclear reactor pressure vessels, are entirely sealed by metal layers to prevent harmful radiation. For safety and security operations, the temperature, pressure, radiation, and humidity inside the vessel needs to be closely monitored. However, no practical technology is currently available to realize the through-wall data communication and monitoring for these vessels due to the inside harsh environment of high temperature and nuclear radiation. In this paper, an innovative self-powered wireless through-wall data communication system for the nuclear environment is presented, which demonstrates a successful solution to such challenges. The presented system is composed of four modules, i.e., energy harvester with power management circuits, ultrasound wireless communication using high-temperature piezoelectric transducers, electronic circuits for sensing and data transmission, and radiation shielding for electronics. Here, constitutive functions of each module were firstly designed and followed by the system integration. Experiments were conducted subsequently to validate the designed functions and evaluate the performance of the integrated system. Results showed that the average power of over 40 mW was harvested from the thermal flow inside the nuclear spent fuel canisters which could provide enough energy to operate the sensing and data communication systems. The gamma radiation test results showed that the thermoelectric energy harvester and ultrasound transceivers can withstand radiation dosing over 100 Mrad. Furthermore, temperature shock tests demonstrated that the entire system including the shielded electronics can survive and maintain their functionalities at temperatures as high as 195°C. Under the in-lab mocked-up high temperature conditions and radiation shielding, the proposed system is foreseen to survive and operate stably for fifty years inside a nuclear spent fuel canister, and send the frequency modulated data out of the canister for 3 s in every 10 min.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

Effects of a refractory metal protective barrier on uranium carbonitride ceramic–metallic composites exposed to a high temperature hydrogen environment

Uranium nitride has been under consideration at NASA and the Department of Energy for nuclear thermal propulsion applications intended for deep space exploration vehicles. It is critical to the success of the technology development that the behavior of the fuel system is properly characterized in operational environments. This body of work fabricated ceramic metal composites consisting of uranium ceramic fuel in a molybdenum and molybdenum–tungsten metal matrix, both with and without an exterior molybdenum barrier. Specimens were introduced to a high temperature hydrogen environment and characterized through x-ray diffraction, scanning electron microscopy, and energy dispersive spectroscopy to identify characteristic changes. A portion of the specimens was fabricated with a 1.27 mm thick molybdenum barrier in order to isolate the material from the hydrogen environment. Instability of the uranium nitride occurred as low as 2073 K, leading to aggressive instability approaching 2658 K. Carbon reactions with the metal matrix were observed as well as alloying between the uranium and metal matrix constituents. The liquid uranium resulting from the instability of the uranium nitride was observed to attack the grain boundaries of the refractory metal, resulting in the formation of a liquid uranium molybdenum eutectic melt. Specimens encased in a barrier experienced similar results. The authors conclude this is a significant challenge to applications of this cermet at these temperatures. Alternate configurations with resilient hermetic seals or lower temperature applications such as power reactors may have more success.

36 MATERIALS SCIENCE↗

DOE OSTI2022

On the thermal oxidation of nuclear graphite relevant to high-temperature gas cooled reactors

Thermal oxidation of nuclear graphite components is highly undesirable because it can cause structural and property degradation that negatively affect a reactor's intended operation. In this work, the body of knowledge of nuclear graphite oxidation is highlighted, including when O 2 , H 2 O, and/or CO 2 are the oxidant. Oxidation conditions relevant to high-temperature gas-cooled reactors (i.e., when oxidation could occur either as an acute or chronic phenomenon) are emphasized. Here, the objective is to summarize graphite oxidation data in a practical and accessible way to inform future research and regulatory requirements. Although each grade of nuclear graphite is different, the oxidation mechanism has underlying commonalities. Although oxidation behavior is grade dependent, the general temperature dependence is well described by a sequence of elementary steps which become rate limiting. Because the regime transition temperature depends on sample microstructure, size, and oxidant supply rate, extrapolating results beyond the experimental range should be done cautiously. Gravimetric oxidation rate measurements generally replicate well. However, caution must be exercised when rates are estimated by other methods or for samples that deviate significantly in size. Air oxidation data for IG-110, NBG-18, and PCEA graphite is critically reviewed to emphasize this point. Despite the amount of experimental data, gaps remain. Sample size and shape effects are not fully explained. Data on the oxidant penetration depth are insufficient. Analytical assessments demonstrate that lower temperature oxidation does not necessarily imply that oxidation is uniform throughout the bulk. Oxidation occurs faster at higher temperature but is more localized to the exposed surface. Paradoxically, at equal mass loss percentage, low temperature oxidation leads to greater property degradation than at high temperature. The isolated effect of oxidation is important; however, a gap remains in the systematic understanding of any potential effect of neutron irradiation on graphite structure and reactivity.

36 MATERIALS SCIENCE↗

DOE OSTI2025

The Effect of Operational Temperature on the Performance and Durability of Solid Oxide Fuel Cells and Solid Oxide Electrolysis Cells

Solid oxide fuel cells (SOFC) and solid oxide electrolysis cells (SOEC) have received great interest due to their highly effective reversibility as power generation and H2 production system without releasing any greenhouse gases into environment. The LSCF electrode exhibits a higher structural and performance stability under both SOFC and SOEC operation due to its mixed ionic and electronic conductivity, and there is no immediate delamination taking place during the initial several hundred hours operation. However, the LSCF based air electrode still presents significant performance degradation (with the increased resistance) over the prolonged operation, such as over 1000 hours of operation under SOFC and SOEC. The influence factors for the cell’s performance and stability need to be optimized to improve the power generation for SOFC and H2 production for SOEC. The effects of operational temperature on the performance and durability for both SOFC and SOEC are electrochemical operation dependent. The performance and performance durability for the first 1500h were currently studied under optimized operational temperature for reversible SOFC/SOEC.

Fan, Yueying [NETL Site Support Contractor, Nation↗

DOE OSTI2024

Reaction Pathways and Energy Consumption in NH 3 Decomposition for H 2 Production by Low Temperature, Atmospheric Pressure Plasma

Pathways for NH 3 decomposition to N 2 and N 2 H 4 by atmospheric pressure nonthermal plasma are analyzed using a combination of molecular beam mass spectrometry measurements and zero-dimensional kinetic modeling. Experimental measurements show that NH 3 conversion and selectivity towards N 2 formation scale monotonically with the specific energy input into the plasma with ~ 100% selectivity to N 2 formation achieved at specific energy inputs above 0.12 J cm −3 (3.1 eV (molecule NH 3 ) −1 ). The kinetic model recovers these trends, although it underpredicts N 2 selectivity at low specific energy input. These discrepancies can be explained by the underestimation of reaction rate coefficients for reactions that consume N 2 H x species in collisions with H radicals and/or radial nonuniformities in power deposition, gas temperature, and species concentrations that are not represented by the plug flow approximation used in the model. The kinetic model shows that N 2 formation proceeds through N 2 H x decomposition pathways rather than NH x decomposition pathways in low temperature, atmospheric pressure plasma. Higher selectivity toward N 2 production can be achieved by operating at higher NH 3 conversion and with a higher gas temperature. Furthermore, the high energy cost of NH 3 decomposition by atmospheric pressure nonthermal plasma found in this work (25–50 eV (molecule NH 3 converted) −1 ; 17–33 eV (molecule H 2 formed) −1 ) is a result of the energy requirement for electron-impact dissociation of NH 3 and the significant re-formation of NH 3 by three-body recombination reactions between NH 2 and H.

Nonthermal plasma↗

DOE OSTI2021

Net Electronic Charge as an Effective Electronic Descriptor for Oxygen Release and Transport Properties of SrFeO 3 -based Oxygen Sorbents

Perovskite oxides, as oxygen sorbents, exhibit excellent potential in thermochemical redox applications such as chemical looping air separation (CLAS), resulting from their excellent redox properties and high tunability. The structural and compositional flexibility of perovskites, while making these mixed oxides highly versatile, also poses challenges for their design and optimization. Moreover, the elevated operating temperature and dynamic oxygen partial pressure swings during redox processes add additional complications for oxygen sorbent design. From a fundamental standpoint, finding simple yet effective descriptors for the effect of cation substitutions on oxygen sorbents’ redox and oxygen transport properties are of significant importance for rational optimization of perovskite-based oxygen sorbents. In the present study, a series of A/B-site-doped SrFeO 3-δ perovskites are investigated using density functional theory (DFT) + U simulations. From these simulations, an effective electronic structural descriptor, the net electronic charge (Δe) of oxygen anions, is extracted based on its excellent correlations with vacancy formation energy, experimentally derived oxygen capacity, and oxygen vacancy migration barrier. Overall, these findings provide an effective tool to correlate the oxygen sorbents’ redox performances with a simple yet physically meaningful descriptor for rational design and optimization of perovskites in the context of CLAS.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2021

Survey of Advanced Generation IV Reactor Parameters for Integrated Energy System Modeling Capabilities

This paper is to categorize and characterize advanced Generation IV nuclear reactors that are not water based according to the key parameters for the Integrated Energy Systems (IES) project[1]. A key goal of the IES project is to assess the economic viability of including an advanced nuclear reactor into an IES. The landscape of advanced reactors is heterogeneous: several unique designs with different heat profiles are currently being studied and designed. This report provides a high-level perspective of advanced reactor concepts, including primary loop nuclear output temperatures and operation schemes that could affect secondary side power production or storage. For example, this report addresses the type of thermodynamic system (Brayton, supercritical CO 2 [S-CO 2 ], etc.) and the various pressures and temperatures on the secondary side that are expected to be provided by the various primary side reactor types. Based on these characteristics, it may be possible to determine which type of nuclear power plant could be the most economical for analysis in the IES framework for power production coupled with energy storage and waste heat utilization. The results of this effort will serve as input for model development of various secondary side components, concentrating on off-the-shelf capabilities for current and near future secondary side power generation and heat rejection as simulated in TRANSFORM. Generic models can be created which are agnostic of the nuclear energy supply without violating intellectual property rights of the developer. These models can be used to make informed decisions on the economics of integrating various energy system components with nuclear plant designs. Once complete, conclusions may be drawn regarding (1) the economics, efficiency, and reliability of certain nuclear reactors, (2) certain industry processes and energy storage systems, and (3) prioritization of certain reactor types with the studied industry types.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

Hourly dynamic line ratings for existing transmission across the contiguous United States (preliminary results) [Slides]

The thermal rating of a transmission line depends on the rate at which heat generated by current flow through the line can be dissipated into the environment by convective and radiative cooling, keeping the conductor below a maximum operating temperature. Static or seasonal line ratings assume nearly-worst-case weather conditions (high ambient air temperature, high solar irradiance, and low wind speed), resulting in a low risk of "overrating" a line (i.e., allowing more current to flow than the line is designed for) but a high fraction of time when the line is "underrated" (i.e., able to flow more current while staying below the maximum temperature). Dynamic transmission line ratings (DLR) use real-time measurements of weather conditions, line sag, or line temperature to determine the thermal rating of transmission lines at hourly or higher time resolution, allowing for increased ratings during some (cold, windy, and/or dark) periods and correcting for overrating during other (hot, calm, and/or sunny) periods. Many studies have explored the benefits of DLR, but typically for small collections of transmission lines under a limited sample of weather conditions, leaving open the question of how widely applicable the benefits of DLR might be over diverse geographies and weather conditions. Here, we combine geospatial data on tens of thousands of transmission line routes across the contiguous United States with high-resolution hourly historical weather data for 2007-2013 to estimate the impact of DLR and other weather-adjusted rating systems. We compare static and dynamic line ratings to intermediate ratings adjusted by ambient temperature, day/night irradiance, clear-sky irradiance, and/or measured irradiance, illustrating the benefits of incorporating progressively more detailed weather data into the calculated line ratings. Moving from nighttime-adjusted ratings to clear-sky-adjusted ratings provides more benefit than moving from clear-sky-adjusted ratings to measured-irradiance-adjusted ratings. Depending on the assumed static windspeed for irradiance-adjusted-ratings, DLR either corrects for overrated hours or provides substantially increased ratings in the majority of hours on the majority of lines.

14 SOLAR ENERGY↗

DOE OSTI2025

Large area transparent refractory aerogels with high solar thermal performance

Application of transparent silica aerogels in low-temperature solar thermal systems has led to major improvements in performance. In high temperature concentrating solar thermal (CST) systems, aerogels have yet to demonstrate the necessary scalability, durability, and performance to support their widespread deployment. Here, large-area transparent refractory aerogel tiles are synthesized and shown to achieve a record-high receiver figure-of-merit (FOM) at high temperatures. The work leverages a scaled-up process for sol–gel synthesis to control the density of the aerogels for improved solar transmittance and adapts a previous atomic layer deposition (ALD) technique with the aid of predictive reaction-transport modeling. After aging for 10 days at 700 °C, the large-area tiles exhibit a solar-weighted transmittance of 95.6 % and a thermal emittance of 0.31, corresponding to a FOM of 80 % at 100 suns and 700 °C. The observed sintering rates at 700 °C are comparably low to earlier one-inch aerogels, suggesting long-term stability under relevant operating conditions. Furthermore, the study indicates that refractory aerogels are scalable materials for efficient photothermal conversion at high temperatures.

Aerogels↗

DOE OSTI2025

Employing a Hardware-in-the-Loop Approach to Realize a Fully Homomorphic Controller for a Small Modular Advanced High Temperature Reactor

This paper addresses the cybersecurity challenges of advanced nuclear reactors by integrating fully homomorphic encryption (FHE) into their control systems, enabling encrypted processing of control signals without compromising functionality. Advanced nuclear reactors, including Small Modular Reactors (SMRs) and microreactors, aim to achieve autonomous and remote operations, reducing costs and enhancing competitiveness. However, these advancements expand the attack surface for cyberattacks, particularly in autonomous and remote operation scenarios. Cyberattacks can exploit vulnerabilities to manipulate physical processes, causing shutdowns, asset damage, or public harm. Such attacks begin with passive reconnaissance, where adversaries intercept communications or observe behaviors to gather information, which is then leveraged to execute cyber-physical attacks by injecting malicious commands. Nuclear power must adopt cybersecurity protection measures to secure the integrity and availability of their digital control systems. This paper demonstrates the application of FHE to secure operations by enabling encrypted processing of sensitive signals and parameters -- ensuring privacy without exposing data. FHE supports secure mathematical operations on encrypted data without requiring decryption. Using a hardware-in-the-loop (HIL) approach, this paper implements an FHE-integrated controller on a BeagleBone Black (BBB) controlling a simulation of the Small Modular Advanced High Temperature Reactor (SmAHTR). By doing so, the encrypted controller protects the integrity of critical set points and control signals during transmission and processing. Thus, FHE-integrated controllers enhance secure operations of advanced nuclear reactors while maintaining functionality.

control systems↗

DOE OSTI2021

Melting rate correlation with batch properties and melter operating conditions during conversion of nuclear waste melter feeds to glasses

The rate of conversion of nuclear waste melter feed to glass is affected by the selection of melter feed materials and by melter design and operation. The melting rate correlation (MRC) is an equation that relates the glass production rate with two types of variables: (1) feed and melt properties: conversion heat, cold-cap bottom temperature, and glass melt viscosity; and (2) melter design and operation parameters: melter geometry, melter operating temperature, and gas bubbling rate. The MRC shows good agreement for an extended melting-rate data set of high-level waste (HLW) melter feeds and a data set generated for low-activity waste (LAW) melter feeds. Laboratory observation of heated melter feed samples is often used to assess the cold-cap bottom temperature of HLW melter feeds (moderately foaming feeds), but this technique appears inadequate for LAW melter feeds (vigorously foaming feeds). For LAW feeds, an adequate assessment of the cold-cap bottom temperature was achieved using evolved gas analysis, which allows identification of the collapse of primary foam for oxidized feeds. This assessment shows that the cold-cap bottom temperature for vigorously foaming LAW feeds is higher than that for moderately foaming HLW feeds. When the results of MRC are compared, LAW feeds are generally less sensitive to the bubbling rate and melt viscosity, and more sensitive to the cold-cap bottom temperature than HLW feeds. The MRC qualifies as a promising tool to support the selection of melter feed materials and melter operating conditions, which is determined from expensive independent scaled melter experiments, and sophisticated mathematical models.

Lee, Seung Min↗

DOE OSTI2021

Iron-iminopyridine complexes as charge carriers for non-aqueous redox flow battery applications

Non-aqueous redox flow batteries (RFBs) have been gaining increased attention in the energy storage arena. Some of their attractive features include the promise for high energy densities, wider voltage windows compared to aqueous systems, as well as wider operating temperature ranges. One of the major challenges in the development of these systems is the lack of electroactive materials that can undergo reversible redox events within the larger potential window of organic solvents. In this paper, we present the design, synthesis, and measurement of electrochemical properties of some iron-based imine- and iminopyridine complexes as promising candidates for RFB applications. Synthesized complexes afforded three reversible redox couples over a ~3 V range. The redox events were also computationally explored and are in good agreement with experimental data. Theoretical calculations show that the redox event at the positive potential can be characterized as metal-centered event corresponding to Fe 3+ → Fe 2+ reduction, while the two redox events at negative potentials are associated with the consecutive reductions of iminopyridine or diimine moieties. This work has led to the identification of a promising anolyte material, [tris(imino)pyridine)Fe][OTf] 2 (1), which is soluble in acetonitrile and is synthesized in two simple steps. This species shows outstanding performance when cycled between 1.0 V and 2.35 V, with 93% coulombic efficiency, 84% energy efficiency, and a capacity decay rate of 0.61% per cycle at 5 mA cm –2 . Further modifications to this kind of charge carrier may lead to the development of high energy density materials for grid scale energy storage applications.

25 ENERGY STORAGE↗

DOE OSTI2025

Durable, Ultra-Thin Diaphragms for Liquid Alkaline Water Electrolysis

W. L. Gore & Associates assembled a world class team (De Nora Tech, LLC; New York University; and thyssenkrupp nucera) to develop durable, ultra-low resistance diaphragms that dramatically improve system efficiency, dynamic response, and operational flexibility. To enable the use of ultra-thin diaphragms, an optimized electrode package was chosen as part of an electrode down select study. Ultra-thin diaphragms based on microporous polymer scaffolds imbibed with zirconia nanoparticles were developed and tested. Performance and durability on par with incumbent materials was demonstrated. A transparent electrolyzer to directly observe in-situ diaphragm-bubble interactions was designed and built, and simultaneous optical and electrochemical performance tests were performed. A Pressurized Alkaline Water Electrolysis (PAWE) single cell test station was designed to support advanced R&D in high-pressure electrolysis, particularly for evaluating novel electrode and separator configurations under elevated temperature and pressure operating conditions. Due to early project termination, the original scope could not be fully achieved.

08 HYDROGEN↗

DOE OSTI2026

Design and Commissioning of a Deuterium-Tritium Gas Delivery System for Muon Catalyzed Fusion in a Diamond Anvil Cell

We report the design, commissioning, and operation of deuterium-deuterium (DD) and deuterium-tritium (DT) gas delivery systems developed to load a diamond anvil cell (DAC) beam target for muon-catalyzed fusion (muCF). The DAC approach enables DT fuel to be compressed to GPa pressures at more than twice the liquid density and heated from cryogenic temperatures through 500 K, opening access to a substantially expanded parameter range for muCF kinetics and yield measurements. In this approach, DT is cryo-condensed to a liquid in a minichamber and then compressed in the DAC using a helium-driven pneumatic membrane, achieving high pressures in a millimeter-scale DT sample volume. A DD gas delivery system was designed and used to validate the experimental apparatus, measure the gas quantities needed for filling, develop operational experience, and collect kinetics and yield data with DD targets. The DT gas delivery system adds tritium-specific capabilities for inventory minimization, secondary containment, and activity monitoring. The DT system integrates depleted uranium storage beds and a liquid helium cryogenic condenser used for pressure building and cryopumping. High-purity delivery is provided by a rapid-response palladium permeator. The system is housed in a helium-atmosphere glovebox held at negative pressure with continuous cleanup. We present the process and instrumentation design, a failure modes and effects analysis (FMEA), and data from the experiment's in situ Raman spectrometer, which provides direct confirmation of target loading and composition through the optically clear diamond anvils. The 2024 and 2025 DT campaigns achieved repeatable target fills and operation with no measurable tritium releases to the stack, demonstrating safe, high-purity DT loading at novel density-temperature conditions for muCF studies.

Koukina, Elena [Acceleron Fusion]↗

DOE OSTI2023

HPC-Enabled Optimization of High Temperature Heat Exchangers (CRADA Final Report)

This project was a collaborative effort between Lawrence Livermore National Security, LLC (LLNS) as manager and operator of Lawrence Livermore National Laboratory (LLNL) and Materials Sciences, LLC, to develop a technology for design and optimization of heat exchangers using powerful desktop and laptop computers. The project was originally designated as a 12-month project, and consisted of 3# major tasks and the following 8# major deliverables: 1) CFD models of 3D heat exchangers based on existing and new geometry. 2) Validation against experimental data provided by MSC and published in the literature. 3) CFD models of 3D unit cells based on TPMS. 4) Surrogate models capable of delivering the gradients of the homogenized properties with respect to the parametrization. 5) 3D design methodology using TO algorithms. 6) Conventional reference and topology optimized designs. 7) 3D optimized designs stored in a 3D printer build format. 8) Verification of the improved performance. All of the deliverables for this project were successfully completed with two no-cost time extensions.

36 MATERIALS SCIENCE↗

DOE OSTI2026

HPC-Enabled Optimization of High Temperature Heat Exchangers (CRADA Final Report)

13 HYDRO ENERGY↗

DOE OSTI2021

High Temperature Alloys Session 1

Section III Division 5 overview Code materials VHTR materials 617 and 800H Qualification of additional materials Corrosion effects Operating plant experience Additive/advanced manufacturing Control rod sleeves Pressure Vessel Steels Allowed materials Elevated temperature limits and properties Supply chain Welding Radiation damage

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

Solid state battery system usable at high temperatures and methods of use and manufacture thereof

A battery cells that include sulfide cathodes are described with examples being suitable for operation at elevated temperatures. Also described are methods of making and using these battery cells.

Hu, Liangbing↗