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At least 883 records · Page 49

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DOE OSTI2022

Hybrid Hydraulic-Electric Architecture (HHEA) for Mobile Machines (Final Report)

Traditionally, off-road mobile machines such as excavators and wheel loaders are primarily powered by hydraulics, and throttling valves are used to control their work circuits. In recent years, two general trends are towards more energy efficient systems and electrification. With electrification, both efficiency and control performance can be improved by the elimination of throttling losses and the use of high-bandwidth inverter control. Electrification is generally accomplished with Electro-hydraulic actuators (EHA) but they are limited to lower powered systems due to the high cost of electric machines capable of high power or high torque. This project proposes a new system architecture for off-road vehicles - Hybrid Hydraulic Electric Architecture (HHEA) to improve efficiency and control performance without requiring large electric machines. The widely applicable architecture combines hydraulic power and electric power in such a way that the majority of power is provided hydraulically while electric drives are used to modulate this power. In particular, HHEA utilizes multiple common pressure rails to transmit the majority of power and small electric machines to modulate the power. The energy-saving potential of the the HHEA has been validated for the work circuits of a variety of mobile machines, from small 5-ton excavators to medium sized 20-ton excavators and wheel loaders, and representative duty cycles to reduce energy input by 50-80% compared to the commercial state-of-art load-sensing systems. In addition, the corner power requirements of the electrical machines can be downsized by 85% compared to the EHA approach. Various tradeoff studies have also been conducted, including sensitivities to individual components performances, controllers, accumulator sizes, and variations of the system architecture etc. A control strategy has been developed to maintain or exceed the motion control precision compared to current systems. The motion control strategy consists of a nominal controller, based on a passivity-based backstepping design, and a transition controller, based on least-norn feedforward design. The nominal controller is used in between common pressure rail switches whereas the transition controller compensates for any disturbance that common pressure rail switchings inflict on the system. The control strategy has been experimentally validated on both a medium pressure (200bar) hardware-in-the-loop (HIL) testbed and a high pressure (300+bar) HIL testbed. An efficient and power-dense integrated electric-hydraulic machine consisting of an axial flux electric machine and a radial hydrostatic piston hydraulic machine has been designed, constructed and tested. The machine has an active material power density of 6.1kW/kg, a rated speed of 12500 RPM, and a design efficiency of 85%. This is among the highest power density electric machines using conventional materials. While the integrated machine was designed for modulating the hydraulic power within the HHEA, it can also be used in other applications.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2020

Aquifer Hydraulic Testing and Characterization Plan for the Ringold Formation Unit A in the Hanford 200-ZP-1 Groundwater Operable Unit and Vicinity

This document presents a plan for testing and characterizing the hydraulic properties of the Ringold Formation, member of Wooded Island – unit A (Rwia) in the 200-ZP groundwater operable unit. The testing approach includes multiple field methods and associated analyses designed to investigate and understand aquifer hydraulic properties over a range of scales. Testing was designed to achieve specific testing objectives identified previously in the 200 ZP-1 Groundwater Operable Unit Ringold Formation Unit A Characterization Sampling and Analysis Plan (Ringold A SAP). The test plan provides necessary technical and operational detail for writing subsequent field test instruction documents specific to each testing location. Hydraulic characterization activities will proceed in a phased manner focusing on areas identified to have knowledge gaps and also critical for remedy modifications and/or selection. These activities are designed to minimize impact to pump-and-treat (P&T) operations and to use existing P&T injection and extraction wells as stress wells, and include use of the new Rwia monitoring wells installed for Ringold A SAP activities. ZP-1 hydraulic testing will include slug testing in new Rwia wells, shutdown-recovery tests in multiple Rwia and composite Ringold Formation member of Wooded Island – unit E (Rwie)-Rwia aquifer test locations, installation of new Automated Water Level Network stations in Rwia monitoring wells, characterization of P&T and barometric responses, identifying the vertical distribution of hydraulic conductivity in the Rwia and Rwie units using electromagnetic borehole flowmeter tests, and single-well tracer testing in select Rwia monitoring wells. Slug testing to be conducted during drilling is described under the Ringold A SAP. The remaining testing activities are to be conducted after well drilling and completion and are described in this test plan.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2023

Improving to the neutron fluence rate monitor measurement system at the Advanced Test Reactor

The existing fluence monitor wire scanning system at the Advanced Test Reactor (ATR) was designed and installed for use in the Engineering Test Reactor (ETR) when it began operation in 1958. The wire scanner was operated in ETR for over 20 years until ATR began operation, when it was moved to the ATR west canal area in 1971 and subsequently moved to the west canal in 2006 where it presently resides. With a continued service life of 65 years the system is well beyond the typical design life of 20 years for these types of systems. The need to update the data acquisition and control system was identified, and the benefits of replacing the existing sodium iodide (NaI) detector with an electronically cooled high-purity germanium (HPGe) detector are discussed.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2023

Molten Salt Tritium Transport Experiment: A Versatile Fluoride Salt Loop for Validation of Tritium Transport Phenomena

Tritium is generated in Molten Salt Reactors (MSRs) from neutron capture by lithium and other constituents of the molten salt FLiBe. Tritium is a unique radionuclide as it readily permeates through hot structural materials. Thus, any material in contact with tritium laden molten salt is a potential pathway for release. Understanding tritium transport and devising adequate control strategies is necessary for the safe operation of MSRs. The Molten Salt Tritium Transport Experiment (MSTTE) is a forced-convection fluoride salt loop with the capability to inject hydrogen isotopes into flowing molten salt and to measure transport phenomena such as permeation through metals and evolution from free-surfaces. MSTTE is designed to be versatile to test potential control technology in future campaigns. This report focuses on the current design and analysis of MSTTE. Custom designed and fabricated experiment components such as the hydrogen injection system, permeation test section, diagnostics, and gas distribution system are discussed in detail. System-level tritium transport modeling using the System Analysis Module investigates experiment parameters such as hydrogen source terms, salt flow rate, and salt temperature. Computational fluid dynamics of the salt flow in the permeation test section informs design choices to establish fully developed flow in the measured permeation zone.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

Acceptance criteria for in situ surveillance of MSR materials based on thermally-loaded mechanical test articles

This report describes practices and acceptance test procedures for designing, running, and maintaining a material surveillance program in a future operating molten salt reactor. The programs described here rely on test data from passively actuated mechanical test articles inserted into critical regions of the reactor and periodically removed for out-of-reactor testing. The report defines definite acceptance procedures, based on the results of these tests, to determine whether a component can continue to operate accounting for the accumulation of environmentally-assisted mechanical damage in the component materials to date, and extrapolated out through the next inspection period. Additionally, the report describes work on a software tool implementing many of the surveillance methods and procedures described here and progress on simplified methods for inferring damage accumulation in the test articles, based on out-of-reactor thermal cycling, that do not rely on sophisticated numerical analysis.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Safeguards by Design Projects (Final Report-FY-22)

This University Engagement project challenged engineering students at universities, that do not have Bachelor degree programs in nuclear engineering but do have research reactors and some nuclear engineering coursework, to incorporate Safeguards by Design concepts into their Senior Capstone Design Project. This University Engagement project was part of the U. S. Department of Energy’s (DOE) National Nuclear Security Administration (NNSA), Office of Defense Nuclear Nonproliferation, Office of International Nuclear Safeguards, Next Generation Safeguards Initiative (NGSI), Human Capital Development (HCD): University Engagement Program. This program exposed university students with Mechanical Engineering majors and Nuclear Engineering minors to the concepts of international nuclear safeguards. In FY22, three teams at the University of Rhode Island and two teams at the University of Texas - Austin participated in researching, designing, building, and testing projects to support international nuclear safeguards measurements or verification. The projects involved engaging in activities at the university’s research reactors. All the projects engaged students with prototyping a design and/or tool for application at the Universities’ reactor. At the end of the course, most of the students expressed the experience was positive and they learned more about international nuclear safeguards and applying requirements than they had previously encountered. This school year the projects were further complicated by the COVID-19 pandemic. Both universities had limited in classes on campus, still relying on Zoom classes, and limited direct student/professor interactions. Furthermore, Los Alamos National Laboratory (LANL) greatly restricted travel, therefore making it impossible to visit the students at the end of the semester for the review of their design projects. The final design and review meeting for the projects happened via meetings over the internet. Additionally, the teams did build and test some prototypes but could only do so in a limited capacity.

42 ENGINEERING↗

DOE OSTI2021

Tank Side Cesium Removal IXC-150 Cask Detonation Report

A set of experiments were conducted at Los Alamos National Laboratory’s firing point 88 to determine the blast pressure and effects of a stoichiometric gas mixture of Hydrogen (H 2 ) and Nitrous Oxide (N 2 O) on the IXC-150 Storage Pad Vent Stack assemblies. The Lab was asked to design, build, and test the vent stack assemblies using a reaction gas volume of 340 in 3 that mimics the Tank Side Cesium Removal (TSCR) Ion Exchange Column (IXC) assembly. The experimental system with vent stack assembly was designed with input from the Washington River Protection Services (WRPS) to ensure an accurate test setup. The tests were conducted at LANL on the newly built filter/gas assembly at the end of April 2021 timeframe, using WRPS supplied vent stack assemblies and internal HEPA filters. The objective of these tests was to observe that the structural integrity of the vent stack assemblies was maintained and determine the resulting blast overpressures at a distance of 16 and 32 inches from the assembly. All work was performed under the LANL Quality Assurance Program (SD330), using a graded application of ASME NQA-1- 2008/NQA-1a-2009. To ensure that all client quality assurance (QA) expectations were addressed, evaluation of the end data needs was performed and the appropriate controls applied for this work.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2022

Submersible Multistage Centrifugal Pump for Versatile Test Reactor Cartridge Test Loop

Submersible multistage centrifugal pumps are ideal for pumping in narrow confined spaces and achieving necessary head pressures and flow rates. Once a diameter is determined then manipulation of the number of stages and motor speed are all that are required to meet desired flow conditions. The Versatile Test Reactor (VTR) closed loop cartridge systems will need forced convection cooling independent of the main reactor. A multistage centrifugal pump can meet the necessary flow rates and pumping pressures while minimizing space taken. The pump considered for this work was based off a deep well submersible pump, a variation of a multistage centrifugal pump. We experimented with two pump sizes, 5 cm (2 inch) and 7.5 cm (3 inch) diameters. These diameters were chosen to fit into the inner diameter of standard 5 and 7.5 (2 and 3 inch) Schedule 40 pipe, respectively. This made the design for the test loop both simpler and less expensive as the need for an engineered pump housing was eliminated. Initial test cartridge planning indicated space for only a 5 cm (2 inch) diameter pump, though early testing of this size showed the need for an abnormally high-speed and high-power motor. Fine tuning of the cartridge design allowed a pump size increase to 7.5 cm (3 inches), which was the pump size most extensively tested in this work. The test loop is composed of various sizes of PVC and aluminum piping components in a loop configuration. The pump is driven by a Pittman 250 W (1/3 horsepower) electric motor with maximum speed of 3,450 RPM. Testing consisted of running the pump at a constant motor speed while varying a control valve to restrict flow through the loop, with differential pressure and flow rate recorded. This was done for one and two stage configurations for the 5 cm (2 inch) diameter impeller design and one, two, and three stage configurations for the 7.5 cm (3 inch diameter) impeller design, respectively. Due to pumping power requirements, two and three stage 7.5 cm (3 inch) diameter impeller testing at higher flowrates lowered the motor speed substantially. In regions where motor speed could not be maintained constant, the data were discarded. The test loop was also reconfigured to allow for the pump to be tested for pressure drop in a stalled or inoperable (0 RPM) flow condition. Demonstration of adequate natural convection cooling of the test cartridge fuel type is necessary under accident conditions, and this will depend upon the flow resistance through the impeller assembly when the pump is not operating. Thus, accurate knowledge of the effective impeller assembly loss coefficient is important for safety evaluations. The test loop was modified to provide water inlet and outlets on either side of the pump impeller stack, and a metered flow of lab water was provided in order to measure the pressure drop across the cartridges as a function of flowrate. Data from the pump head curve testing developed as part of this work and supported by analysis using pump head affinity laws indicates that a three stage 7.5 cm (3 inch) pump impeller design will meet target requirements for coolant flow within the VTR cartridge sodium cartridge at full power conditions [1] with margin; this corresponds to a flowrate of 45 l/min (12 gpm) at a pressure drop of 6.1 m (20 feet) of water head. The results of the pressure loss measurements across the impeller assembly when the pump is stationary (i.e., at 0 RPM) indicate that the pressure loss coefficient is 0.921 for a two impeller stack configuration; this value is calculated based on the flow velocity through the minimum available flow area within a single stage of the impeller which corresponds to 1.4 cm2.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2021

Experimental Investigation of Melting and Solidification Processes of Phase Change Material Heat Exchanger

Rapid development and validation of PCM embedded heat exchangers (PCM-HX) concepts warrant a purpose-built test bench. This paper describes a test facility built for testing various PCM-HX configurations and phase change temperatures that will serve to validate the performance of novel PCM-HX designs. The entire test rig is placed in a temperature-controlled environmental chamber. Inside the PCM-HX containers, up to 48 T-type thermocouples can be spatially distributed on and around the tubes depending on the HX type to capture the phase change process over time. In this paper, a straight tube embedded in PCM having a phase change temperature of 37°C in cylindrical containers is tested. The PCM-HX uses water as an in-tube working fluid. Based on the measured data, the energy balance is analyzed, and its temperature distribution is presented. Here, the maximum deviation between the predicted stored energy and the energy stored calculated from experimental measurements is less than 5%.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Alternative Liquid DSA Containers for Sludge Slurry Storage in the SRNL Shielded Cells

A pending revision of the Documented Safety Analysis (DSA) for the Savannah River National Laboratory (SRNL) defines “DSA containers” for liquid sludge slurries as containers not susceptible to a flashing spray release in a fire and requires that a list of DSA containers be maintained. High Level Waste (HLW) samples are typically received from the Savannah River Site (SRS) tank farm after retrieval from the storage tanks. Glass bottles are preferred for long-term storage of radioactive liquid sludge slurry samples but are not on the DSA container list. An evaluation has been conducted to identify vessel lids for the glass bottles that would vent prior to pressurization and liquid superheating in a fire event. Low melting Field’s Metal eutectic alloy with a melting point of 62 °C has been identified as a preferred material of construction for vessel lids for this application because the material is resistant to puncture and is expected to have good chemical compatibility and radiation stability in the shielded cells environment. A test vessel was designed to evaluate the alloy and confirm that it would melt before the water in the vessel reaches the boiling point. The tests confirmed: 1) that the reported melting point of the alloy was accurate, 2) that a top fashioned from this material will melt creating an open atmosphere in the vessel headspace prior to sample boiling under moderate and fast heating rates, and 3) that nonuniform heating of the bottle from the bottom also results in melting of the alloy prior to boiling. Based on the results, neither an engulfing fire with standing or toppled bottles or a fire producing localized heat at the vessel bottom would result in flashing spray conditions.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2024

Model Formulations: Market clearing models, market design specifications, and dispatch simulation

This document provides various model formulations that will be implemented for the Energy Storage Participation Algorithm pilot competition (ESPA-Comp). This competition will assess the performance of different storage offer algorithms in terms of their ability to maximize the value of storage resources participating under various market designs that vary in the range of complexity of possible storage offers. The model formulations include a general market clearing optimization model and specification to implement it in various market designs. We provide specifications for three market designs to be tested in ESPA-Comp, which we call the two-settlement, multi-settlement, and rolling horizon forward markets. The market designs include different trading frequencies and offer formats. Storage resources participating in the market are provided with primitive values for the resource’s physical capabilities, and they are provided with a storage offer format that their algorithms will be tasked with populating. A detailed physical model is used to assess each storage resource’s ability to maintain its scheduled dispatch according to its state-of-charge, operating temperature, and power conversion efficiency.

25 ENERGY STORAGE↗

DOE OSTI2020

The U.S. Nuclear Test History

This paper describes a desktop application designed to introduce users to unclassified information for the series of nuclear experiments conducted by the United States, colloquially referred to within the nuclear weapons design community as simply, the “Test History.” The application facilitates simple browsing (by name, by date, and MMDD date code), and more complex analyses based on user-defiend relational database queries.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2023

Development and Bench-Scale Testing of a Novel Biphasic Solvent-Enabled Absorption Process for Post-Combustion Carbon Capture (Final Technical Report)

A new class of biphasic solvents was developed, and the concept of the enabled carbon dioxide (CO 2 ) absorption process was tested for post-combustion carbon capture in our previous lab-scale research. The primary goals of this project were to advance the development of the novel biphasic CO 2 absorption process (BiCAP) and validate its technical advantages by testing the integrated technology at a 40 kWe bench-scale with actual coal-derived flue gas in a power plant environment. The project was led by the University of Illinois at Urban-Champaign (UIUC), and Trimeric Corporation served as a sub-awardee providing support in basic design and techno-economic studies. To achieve the project goals and objectives, solvent management studies, process modeling and optimization, bench-scale equipment design, construction and testing, and technical, economic and environmental assessments have been conducted. The two top-performing biphasic solvents developed in our previous research were used in this project. Biphasic solvent emissions and control were investigated in the laboratory. The emissions of the biphasic solvents from the absorber were comparable to or lower than the reference 30 wt% monoethanolamine (MEA) solution, while they could be more effectively removed in the water wash column. Lab-scale testing of solvent degradation reclamation has revealed that vacuum distillation was feasible for biphasic solvent reclamation. Aspen Plus models were used to optimize the BiCAP, and a CO 2 stripping configuration introducing a secondary cold solvent feed to the stripper was identified to be the most energy efficient. A 40 kWe bench-scale, integrated BiCAP system was successfully designed, fabricated, and installed at the UIUC’s Abbott Power Plant. Parametric testing with synthetic flue gas has demonstrated that the two biphasic solvents required a more than 40% lower heat duty for CO 2 desorption as compared to the reference MEA tested on the same bench-scale skid. Slipstream testing with actual coal flue gas for a total of 31 days in two test campaigns has further demonstrated stable operation of the bench-scale skid. During the first campaign targeting 90% CO 2 removal, the heat duty averaged at 2,183 MJ/tonne of CO 2 captured and during the second campaign targeting 95% removal, the heat duty averaged at 2,450 MJ/tonne of CO 2 captured. A techno-economic analysis has revealed that for integration of the BiCAP into a 650-MWe pulverized coal-fired power plant, the parasitic power loss was reduced by ~20%, and the cost of CO 2 capture was reduced by ~21% ($36.3/tonne on a December 2018 dollar basis) compared to the U.S. Department of Energy (DOE)’s baseline Case B12B. As progression from this bench-scale development effort, a new project “Engineering-Scale Testing of the Biphasic Solvent Based CO 2 Absorption Capture Technology at a Covanta Waste-to-Energy Facility” was awarded by the DOE, launched in February 2023, to allow the team to further test the technology and demonstrate its technical and economic advantages at a pilot scale.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2022

Industry Assessment and Initial Adaptive Protection System Design

This report presents the success merits, logic design details, and test plans for adaptive protection schemes for microgrids, secondary distribution networks, and radial distribution feeders. Success merits are presented in terms of challenges and issues which should be mitigated. The challenges and issues were identified during site-specific simulations and analysis presented in a prior report. The adaptive protection logic designs are presented in a vendor-neutral manner to make them readily adaptable to site--specific protection relays and controllers which support custom logic design. Vendor-specific implementations of the logic for the adaptive protection laboratory tests are also presented. The final section of the report presents details of the testing methodology, plans, and documentation for each of the three adaptive protection schemes.

14 SOLAR ENERGY↗

DOE OSTI2025

A Large Bore Conduction Cooled Superconducting Magnet for the Princeton Axion Search

Princeton University (PU) is designing and building a new experiment, called the Princeton Axion Search (PXS), that aims to discover (or exclude) Quantum Chromodynamics (QCD) axions in the 0.8–2 μeV mass range that are the cosmological dark matter. Core elements of the experiment are new, and in particular new to the search for axion dark matter. An essential component of the experiment is a 5 T superconducting magnet with a total bore volume of ~500 L. The Princeton Plasma Physics Laboratory (PPPL), a Department of Energy (DOE) Laboratory managed by Princeton University, has the unique expertise and experimental facilities to design and construct such a solenoid magnet assembled with the cavity resonator for PXS. To support this, PPPL utilizes legacy ITER-Nb3Sn conductors, along with its experimental facilities and expertises to design, build and test low-cost conduction-cooled superconducting solenoid magnets to be integrated into the axion detector. This paper discusses the various coil design and integration challenges in the large bore conduction cooled magnet in support of PXS. In conclusion, the proposed instrumental methods will help optimize the path to future and more ambitious axion searches at lower masses.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2021

Design of high-deflection foils MHK applications - CFD models - RivGen turbine

The Ocean Renewable Power Company's (ORPC's) goal is to design, develop, and test hydrofoils with large deflections. The effects of the deflections on cross-flow turbine performance would be evaluated in order to inform design considerations for full-scale water turbines and other marine hydrokinetic devices. CFD Models OpenFOAM V1912 RivGen turbine

16 TIDAL AND WAVE POWER↗

DOE OSTI2021

Design of high-deflection foils MHK applications - FEA models - RivGen Turbines

16 TIDAL AND WAVE POWER↗

DOE OSTI2021

Design of high deflection foils for MHK applications - CFD files

16 TIDAL AND WAVE POWER↗