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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Evaluation of Tungsten—Steel Solid-State Bonding: Options and the Role of CALPHAD to Screen Diffusion Bonding Interlayers

Critical aspects of innovative design in engineering disciplines like infrastructure, transportation, and medical applications require the joining of dissimilar materials. This study investigates the literature on solid-state bonding techniques, with a particular focus on diffusion bonding, as an effective method for establishing engineering bonds. Welding and brazing, while widely used, may pose challenges when joining materials with large differences in melting temperature and can lead to mechanical property degradation. In contrast, diffusion bonding offers a lower temperature process that relies on solid-state interactions to develop bond strength. The joining of tungsten and steel, especially for fusion reactors, presents a unique challenge due to the significant disparity in melting temperatures and the propensity to form brittle intermetallics. Here, diffusion characteristics of tungsten–steel interfaces are examined and the influence of bonding parameters on mechanical properties are investigated. Additionally, CALPHAD modeling is employed to explore joining parameters, thermal stability, and diffusion kinetics. The insights from this research can be extended to join numerous dissimilar materials for specific applications such as aerospace, automobile industry, power plants, etc., enabling advanced and robust design with high efficiency.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Advanced Reactors Integrated Energy System: Thermal Energy Storage Island Design

The main topic of this research is integrated energy systems (IES) designed for pairing industrial thermal energy loads with advanced reactors (ARs). The Idaho National Laboratory (INL) Crosscutting Technology Development IES program and the National Reactor Innovation Center (NRIC) are seeking to develop, design, and construct an AR-IES demonstration platform that couples the thermal output from an AR operating at the INL/NRIC Demonstration of Microreactor Experiments (DOME) test bed in the Experimental Breeder II dome to a variable capacity load emulator (i.e., air-cooled radiator) and sensible thermal energy storage (TES) via a molten salt thermal energy transfer fluid. In the rapidly evolving landscape of energy supply and distribution, flexibility has emerged as a prized attribute, surpassing the traditional notions of stability and baseload generation capability. This shift in priorities is particularly evident in the context of nuclear power plants (NPPs), where adaptability over constant output is becoming more important. As our energy infrastructure and resources embraces the rise of distributed energy generation, the inherent variability in net demand continues to grow. Moreover, the use of nuclear energy as a source of heat for decarbonizing the industrial sector is becoming a very pressing topic. In such environment, advanced NPPs are poised to enter a more competitive energy market, delivering both, flexible electricity and heat. This shift motivates the exploration of TES systems, designed to empower NPPs with nimble responsiveness to market fluctuations, flexible heat delivery capabilities, and redefine their role in the energy field. TES systems offer the unique advantage of storing nuclear energy in its original form as heat, thereby affording unparalleled flexibility in its subsequent utilization.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2024

ION Work Reduction Opportunity Realization Demonstration

The purpose of this research was to realize one of the advanced training work reduction opportunities first presented in the Idaho National Laboratory (INL) report, “Process for Significant Nuclear Work Function Innovation Based on Integrated Operations Concepts” (INL/EXT-21-64134) [1], with a nuclear power plant (NPP) research partner. Researchers modernized two trainings: (1) an accredited instructor-led training (ILT) overview course on Westinghouse DS 480-volt (V) circuit breakers to a multimedia-focused computer-based-training (CBT) learning module, and (2) an on-demand chaptered video on how to properly rack and un-rack a Westinghouse DS 480-V circuit breaker. These modernized work products were developed and implemented in a manner consistent with the industry guidelines found in Institution of Nuclear Power Operations (INPO) Teaching and Learning 23-001 [2]. Researchers calculated that the modernized accredited training course reduced the time necessary to prepare and deliver the training material by a factor of 8:1. The amount of time learners spend in class could be reduced by this same factor. In other words, if a course took 8 hours to deliver a class, the new CBT instruction would take just over 1 hour. The researchers noted that the requirement for any practicum training by the learners with the instructor(s) would remain in place. But through interviews with new and experienced learners, the researchers discovered that the confidence of these learners in performing the racking and un-racking of the circuit breaker improved as a result of using the new modernized CBT process. Additionally, the learners who tested the modernized work products enjoyed the modernized CBT and the learning video significantly more than current in-class learning methods. These are encouraging results for the nuclear industry, as this modernization of training can be applied to other classes and is scalable across the industry. In line with the Integrated Operations for Nuclear (ION) model, positive workload analysis supports the investment of resources in modernizing NPP training processes and infrastructure. Implementation of the advanced training technologies in this report is likely to result in substantive long-term workload benefits to instructors and learners and result in hard-dollar savings on contractor spends. Additionally, investment in these modernized training processes will result in improved learner proficiency. The results of this research can be applied to additional operator, technical, and general training topics to provide additional workload and learning benefits in addition to what was explored.

42 ENGINEERING↗
DOE OSTI2023

Second Report of the Nuclear Data Subcommittee of the Nuclear Science Advisory Committee

The central importance of the nuclear data curated by the US Nuclear Data Program (USNDP) for clean energy generation, national security, nonproliferation, medical applications, and space exploration as well as basic science was described in a prior report issued by the DOE/NSF Nuclear Science Advisory Committee subcommittee on Nuclear Data (NSAC-ND) in September 2022. In this report, we present a set of fourteen (14) recommendations that will enhance and advance DOE-NP's stewardship of nuclear data. The first three recommendations focus on the existing core USNDP capabilities, namely: 1) Support the nuclear structure evaluation workforce to improve the currency, consistency, and accessibility of the Evaluated Nuclear Structure Data File (ENSDF); 2) Enhance nuclear reaction evaluation within the USNDP in support of the Evaluated Nuclear Data File (ENDF) through expansion of the workforce and integration of high-performance computing, automation, and machine learning and; 3) Continue atomic mass evaluation in support AME and NUBASE databases. This is followed by eight (8) recommendations representing new cross-cutting initiatives involving both measurement and evaluation to address outstanding nuclear data needs. These new initiatives require a highly trained, diverse workforce that includes personnel with expertise from both inside and outside the nuclear physics community from which evaluators have traditionally been recruited. As such, many of these initiatives are accomplished via a Topical Nuclear Data Collaborations (TNDC). A TNDC is made up of domestic and international stakeholders, subject matter and nuclear data experts, and nuclear data evaluators and features a workforce development plan to ensure that nuclear data evaluators maintain currency in the relevant applications and are seen as equity partners in the endeavor. These include: 1) Establish a coordinated effort to improve evaluation and modeling in nuclear astrophysics for stellar dynamics, multi-messenger astronomy and nucleosynthesis; 2) Initiate a TNDC to develop and maintain nuclear structure evaluation beyond discrete states, including nuclear level densities, photon strength functions and photonuclear data for improved reaction modeling, and exploring nuclear structure at finite temperature; 3) Create a TNDC to perform correlated fission data evaluation, including cross sections, fragment yields, v(A), v(E n ) for nuclear energy, national security, nonproliferation and basic science; 4) From a panel of subject matter experts to establish and annually update a roster of key decay data to nurture its accelerated dissemination including both measurement and evaluation for targeted high-value nuclides for national security, nonproliferation and medical applications; 5) Comprehensive, consistent neutron-induced structure and reaction data for nuclear energy, national security, nonproliferation and planetary nuclear spectroscopy; 6) Charged-particle stopping powers for detector design, space effects and ion beam therapy; 7) High-energy reactions for space exploration and medical nuclide production, and; 8) The creation of an infrastructure for open data and data preservation for use by the entire nuclear physics community. All told, these initiatives require approximately $6.5M increase in NP support of the USNDP in fiscal year 2023 dollars and would require at least 3-5 years to carry out due to the length of time needed to recruit and train new nuclear data researchers. This relatively modest investment would help ensure that the fruits of the nuclear data research carried out by DOE-NP and its collaborators would be brought to bear to address some of the most important needs of our nation and the world. To ensure effective execution of this plan, we present an overview of recruitment, training, and retention goals for the USNDP, the centerpiece of which is a mutually agreed upon code of conduct. Finally, we identify the facility and instrumentation needed to perform the recommended experimental activities. This includes a short review of target fabrication capabilities, reactors, neutron beam, light- and heavy-stable ion, gamma-ray, high-energy and radioactive ion beam facilities. Lastly, a more complete appendix of experimental facilities previously compiled is included with new input provided for 6 facilities.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2021

Digital Infrastructure Migration Framework Report

This document presents a full-scope Digital Infrastructure implementation and associated lifecycle support recommendations that enable a plant life of 80+ years. Specific technologies and software applications are researched, developed, selected, implemented, and then integrated by utilities to enhance safety, reliability, and economic performance such that the result provides much more than the sum of its parts. Specific selection of these technologies is driven by business case analyses which are utility, station, and unit specific.

42 ENGINEERING↗
DOE OSTI2022

WIRE-21 Sensor Irradiation Experiment Ready for HFIR Insertion

The ability to deploy new nuclear fuels for current or future reactor concepts requires a wealth of data regarding fuel performance during normal operation, anticipated operational occurrences, and design-basis accidents. Most of these data have historically been collected during experiments in materials test reactors, ideally with online instrumentation to collect as much data as possible. However, advanced instrumentation could also allow for in situ monitoring of fuel operating conditions during commercial reactor operation to maximize fuel utilization, reduce unnecessary conservativism in design margins, and improve operator understanding of limiting peaking factors. The latter approach would complicate fuel handling, particularly during refueling, unless the instrumentation could be placed inside the fuel rods and transmitted wirelessly to a receiver located outside the fuel’s primary pressure boundary. To this end, Westinghouse Electric Company (WEC) developed wireless sensors based on inductive coupling that can transmit information regarding fuel centerline temperatures and rod internal pressures wirelessly from within a fuel rod to a nearby instrument thimble. After testing these sensors in lower-power university research reactors, the next step is to perform high neutron fluence testing to characterize the performance of these wireless sensors under conditions that are more representative of the intended application—in this case, light-water reactors (LWRs). The removable Be (RB) positions of the High Flux Isotope Reactor (HFIR) at Oak Ridge National Laboratory (ORNL) provide the neutron flux, experiment volume, and access to instrument leads required to achieve these sensor testing goals. This report summarizes the design, analysis, and assembly of the Wireless Instrumented RB Experiment 2021 (WIRE-21). This is the most highly instrumented irradiation experiment ever performed in HFIR. The experiment will use seven different sensing techniques to measure temperature, pressure, neutron flux, and neutron fluence during reactor operation. In addition to WEC’s wireless temperature and pressure sensors, WIRE-21 includes an array of thermocouples, self-powered neutron detectors, spatially distributed fiber optic temperature sensors, passive SiC temperature monitors, and flux wires. The design of WIRE-21 and the cabling that was installed in HFIR also provide the infrastructure to enable accelerated, economical testing of advanced sensor technologies while leveraging the extremely high neutron flux that is available in HFIR. The containment for WIRE-21 is similar to previous RB irradiation vehicles but includes a few modifications, most notably the use of integrated compression seals to pass a larger number of sensor leads through the experiment’s pressure boundary. In addition to the sensor leads, inert gas lines are passed into the experiment to enable active temperature control and the ability to pneumatically actuate a bellows-driven pressure sensor. WIRE-21 is targeting component temperatures (300–350°C) and neutron fluence levels (~10 22 n/cm 2 ) that would be expected in the plenum region of LWR fuels, except for the active sensing region of the wireless temperature sensor, which is targeting LWR fuel centerline temperatures (~800–1,100°C). WIRE-21 was successfully assembled, passed all nondestructive examination, and was delivered to HFIR for insertion during upcoming cycle 498 (April 2022).

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Plan for a Data Base Approach to Evaluating LWR Plant Integration with Hydrogen and Industrial Facilities

The purpose of this report is to provide an outline and scope of a database tool that could be used to identify the most beneficial locations to site a hydrogen, chemical facility or other industrial facility that would be powered by nuclear energy. This energy may be in the form of electricity produced by the plant, heat in the form of steam or both. In addition, this siting tool should consider factors such as economics, geography, industries, residences, geological hydrogen storage, and key infrastructure. The infrastructure to be considered could include pipelines or other storage and transportation facilities to carry the created products from the production facility to the end user. Also considered should be infrastructure that could deliver needed chemicals or gasses to allow the production of desired products such as ammonia or biofuels. This data base tool should allow a screening study of all U.S. nuclear plants to identify opportunities and barriers to creating hydrogen hubs around nuclear power plants. For this effort, it has been decided that the Siting Tool for Advanced Nuclear Development (STAND) would be used to conduct this screening study which is a follow-on research project to this present effort. Currently, plans are being developed to modify the STAND tool to provide the capability necessary to perform screening of each US commercial nuclear plant to identify the best locations to site hydrogen or chemical production facilities. Many features of the current STAND tool will be employed to meet this objective, but additional infrastructure data (such as the location of pipelines) may need to be added to allow these locations to be fully vetted. In addition, new analysis capabilities may need to be added so economic considerations can be understood

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

Research Requirements to Move the Bar forward Using Aqueous Formate Salts as H 2 Carriers for Energy Storage Applications

In this perspective on hydrogen carriers, we focus on the needs for the development of robust active catalysts for the release of H 2 from aqueous formate solutions, which are non-flammable, non-toxic, thermally stable, and readily available at large scales at reasonable cost. Formate salts can be stockpiled in the solid state or dissolved in water for long term storage and transport using existing infrastructure. Furthermore, formate salts are readily regenerated at moderate pressures using the same catalyst as for the H 2 release. There have been several studies focused on increasing the activity of catalysts to release H 2 at moderate temperatures, i.e., < 80 °C, below the operating temperature of a proton exchange membrane (PEM) fuel cell. One significant challenge to enable the use of aqueous formate salts as hydrogen carriers is the deactivation of the catalyst under operating conditions. In this work we provide a review of the most efficient heterogeneous catalysts that have been described in the literature, their proposed modes of deactivation, and the strategies reported to reactivate them. We discuss potential pathways that may lead to deactivation and strategies to mitigate it in a variety of H 2 carrier applications. We also provide an example of a potential use case employing formate salts solutions using a fixed bed reactor for seasonal storage of energy for a microgrid application.

25 ENERGY STORAGE↗
DOE OSTI2021

Phase Stability of Yttrium Titanium Oxide

This proposed study aims at elevating Idaho National Laboratory (INL)’s portfolio in nuclear material research on two major fronts: 1) expanding INL’s material characterization capabilities to provide holistic microstructural and microchemical characterization ranging from atomic scale to millimeter scale, and 2) filling the knowledge gap on the effect of microstructural evolution on material phase stability at extreme conditions resembling those inside nuclear reactors, using Yttrium-Titanium-Oxide (YTO) as a model material. Previous research indicated the kinetics of phase transition of YTO materials varies between bulk samples and powder samples, suggesting that microstructural characteristics such as defect, micro-strain, and crystallite size could play a significant role in phase transition. The effect of crystallite size on the thermodynamics of phase transition has been well documented for other ceramic materials at nanometer crystallite size, with potential impacts from surface and strain energy and defects. In this proposed study, we will perform microstructural (micro-strain, crystallite size, defects, phase) and microchemical (elemental mapping) analyses through in-situ high temperature measurements using X-ray diffraction (XRD; at millimeter scale for powder and bulk samples) and transmission electron microscopy (TEM, at nanometer scale and atomic scale for powder and thin foil samples), to provide a comprehensive view of the effect of microstructural and microchemical evolution on phase transition and phase stability of YTO materials. These findings will also establish a roadmap and provide new insights on the phase stability of other materials that are critical to nuclear energy and other renewable energy infrastructure. Besides advancing our understanding of this fundamental material science question, this project will also enable the development of state-of-the-art material characterization capabilities at INL/MFC for microstructural and microchemical analysis at high temperature conditions. The new collaboration between the High-Resolution Materials Characterization group at INL and the Electron Microscopy group at the University of Florida (UF) in this project will open the possibilities for more fruitful and synergetic cutting-edge nuclear material research in the future.

36 MATERIALS SCIENCE↗
NASA NTRSDate not supplied

Space Transformation -- Localizing the Remote and Connecting the Isolated

In motivating the Space Transformation theme for this year’s 4S symposium, the organizers provided the following context, “Transformation of economies are driven by a change in values and accelerated by new technologies.” These words rang particularly true when I read them at the beginning of the holiday season. Like so many others, I was in the early phases of my Christmas shopping procrastination campaign, and I’d just been reflecting on how Amazon Prime was the transformational tool I’d been waiting for. Basic limiting principles of time and space, supply and demand, were all but erased by the Amazon Prime phenomenon. Coupled with emerging 3D printing and other adaptive manufacturing technologies, a transformation from deliberate planning to “think it … have it” had occurred, empowering me to procrastinate longer than I’d ever dreamed possible. The organizers went on to ponder, “Will space transformation also affect society?”, just as our team at the Air Force Research Lab’s (AFRL) Center for Rapid Innovation (CRI) were working alongside partners within our larger Integrated Capabilities Directorate, NASA’s Flight Opportunities and Small Spacecraft Technology programs, and DARPA’s Luna-10 program to develop technologies and execute demonstration missions that leverage the space domain to genuinely connect even the most remote and austere domains on the timeline of need. Picking apart the miracle that is Amazon prime, where does the model fail, and why? More relevantly to the theme of this year’s symposium, how can the space domain be used to overcome its limitations and minimize its weaknesses? Perhaps it is best assessed in the context of Use Cases. What are the Amazon delivery cost, schedule, and cargo limiters to the Amundsen-Scott South Pole Research Station, or the Lunar South Pole Research Station? This paper will explore enabling infrastructure that allows Amazon prime to thrive and assess the transformational enabling technologies that would be necessary to extend that miracle to the truly remote or the truly austere. Localizing the Remote • First, it will evaluate the ability of the on-going AFRL Rocket Cargo and Space Initiatives Ringside Seats systems, coupled with Astrobotic’s Xodiak and Xogdor capabilities, developed to support the NASA Flight Opportunities Program (FOP), to supply orbital/suborbital delivery to both improved and austere sites on the Earth and Moon. • Then, it will add the surface terminal distribution leg, with an examination of Lunar Outpost’s Mobile Autonomous Prospecting Platform (MAPP), equipped with Mobile Autonomous Robotic Swarm (MARS) software, and Intuitive Machine’s Hopper, developed with support of AFRL and NASA’s Commercial Lunar Payload Services (CLPS) program. Connecting the Isolated From there, it will focus on the destination, asking what implied destination services are required to support highly assured autonomous delivery. • Specifically, it will highlight Astrobotic’s Skymage mesh-networked publish and subscribe communication and navigation service, as well as AFRL’s on-going developments of radioisotope and reactor nuclear-sourced thermoelectric power generation and distribution systems under development under the Joint Emergent Technology Supplying On-orbit Nuclear Power (JETSON) program by Lockheed Martin, Westinghouse, Intuitive Machines, and Zeno Power, to provide the power service to locations well off the grid. • Finally, the paper will connect to the “human machine”. What connects the remote or in-situ human consumer to the remote domain? What connects the diverse international government and commercial services to each other? The former will focus on AFRL’s OraCloud feeding their Space Defense Control and Characterization System (SDCCS) and Lunar Station’s MoonHacker systems, while the latter will focus on the BlueHalo/Tensor LunX Technology Platform for the Cislunar Commodity Marketplace. In 1984, Krafft Ehricke famously remarked that, “If God wanted man to become a spacefaring species, He would have given man a Moon.” This paper is not about the Moon, but is about humans as a spacefaring species, shedding the pesky land/air limitations of the Amazon Prime model … so that we can all live a procrastinator’s “think it … have it” existence.

Charles Finley↗
NASA NTRS2018

Electrically Heated Testing of the Kilowatt Reactor Using Stirling TechnologY (KRUSTY) Experiment Using a Depleted Uranium Core

The Kilopower project aims to develop and demonstrate scalable fission-based power technology for systems capable of delivering 1 to 10 kW of electric power with a specific power ranging from 2.5 to 6.5 W/kg. This technology could enable high-power science missions or could be used to provide surface power for manned missions to the Moon or Mars. NASA has partnered with the U.S. Department of Energy's National Nuclear Security Administration, Los Alamos National Laboratory, Nevada National Security Site (NNSS), and Y−12 National Security Complex to develop and test a prototypic reactor and power system using existing facilities and infrastructure. This technology demonstration, referred to as the "Kilowatt Reactor Using Stirling TechnologY (KRUSTY)," will undergo nuclear ground testing by the end of calendar year (CY) 2017 at the NNSS. The 1-kWe variation of the Kilopower system was chosen for the KRUSTY demonstration. The concept for the 1-kWe flight system consists of a 4 kWt highly enriched uranium-molybdenum reactor operating at 800 degC coupled to sodium heat pipes. The heat pipes deliver heat to the hot ends of eight 125-W Stirling convertors producing a net electrical output of 1 kW. Waste heat is rejected using titanium-water heat pipes coupled to carbon composite radiator panels. The KRUSTY test, based on this design, uses a prototypic highly enriched uranium-molybdenum core coupled to prototypic sodium heat pipes. The heat pipes transfer heat to two Advanced Stirling Convertors (ASC−E2s) and six thermal simulators, which simulate the thermal draw of full-scale power conversion units. Thermal simulators and Stirling engines are gas cooled. The most recent project milestone was the completion of nonnuclear system-level testing using an electrically heated depleted uranium (DU) (nonfissioning) reactor core simulator at the NASA Glenn Research Center. System-level testing has validated performance predictions and has demonstrated system-level operation and control in a test configuration that replicates the one to be used at the Device Assembly Facility (DAF) at the NNSS. Fabrication, assembly, and testing of the DU core has allowed for higher fidelity system-level testing at Glenn, and has validated the fabrication methods to be used on the highly enriched uranium core that will supply heat for the DAF KRUSTY demonstration.

Briggs, Maxwell H.↗
NASA NTRS2017

Electrically Heated Testing of the Kilowatt Reactor Using Stirling Technology (KRUSTY) Experiment Using a Depleted Uranium Core

The Kilopower project aims to develop and demonstrate scalable fission-based power technology for systems capable of delivering 110 kW of electric power with a specific power ranging from 2.5 - 6.5 Wkg. This technology could enable high power science missions or could be used to provide surface power for manned missions to the Moon or Mars. NASA has partnered with the Department of Energys National Nuclear Security Administration, Los Alamos National Labs, and Y-12 National Security Complex to develop and test a prototypic reactor and power system using existing facilities and infrastructure. This technology demonstration, referred to as the Kilowatt Reactor Using Stirling TechnologY (KRUSTY), will undergo nuclear ground testing in the summer of 2017 at the Nevada Test Site. The 1 kWe variation of the Kilopower system was chosen for the KRUSTY demonstration. The concept for the 1 kWe flight system consist of a 4 kWt highly enriched Uranium-Molybdenum reactor operating at 800 degrees Celsius coupled to sodium heat pipes. The heat pipes deliver heat to the hot ends of eight 125 W Stirling convertors producing a net electrical output of 1 kW. Waste heat is rejected using titanium-water heat pipes coupled to carbon composite radiator panels. The KRUSTY test, based on this design, uses a prototypic highly enriched uranium-molybdenum core coupled to prototypic sodium heat pipes. The heat pipes transfer heat to two Advanced Stirling Convertors (ASC-E2s) and six thermal simulators, which simulate the thermal draw of full scale power conversion units. Thermal simulators and Stirling engines are gas cooled. The most recent project milestone was the completion of non-nuclear system level testing using an electrically heated depleted uranium (non-fissioning) reactor core simulator. System level testing at the Glenn Research Center (GRC) has validated performance predictions and has demonstrated system level operation and control in a test configuration that replicates the one to be used at the Device Assembly Facility (DAF) at the Nevada National Security Site. Fabrication, assembly, and testing of the depleted uranium core has allowed for higher fidelity system level testing at GRC, and has validated the fabrication methods to be used on the highly enriched uranium core that will supply heat for the DAF KRUSTY demonstration.

Briggs, Maxwell H.↗
DOE OSTI2025

Modeling and Simulation of Fuel Dispersal During the Loss-of-Coolant Accident

This document is the compilation of the milestone portion to a larger end of project NEUP report. The executive summary of the modeling portion is provided below: In the event of cladding rupture during a postulated LOCA in a pressurized water reactor, fuel particles, along with fission gases, can be expelled into the reactor core from the fractured fuel rod, a phenomenon referred to as fuel dispersal. The initial stage of fuel dispersal is strongly influenced by the high-pressure ejection of fuel fragments, the size and geometry of the ruptured cladding, and the depressurization history of the fuel rod during the postulated LOCA transient. Depending on the location of the burst orifice relative to the quench front, the dispersal event represents an intricate three-phase flow and heat transfer phenomenon, where high-temperature fuel particles carried by the fission gases interact with the coolant within the narrow subchannels of the fuel assemblies, inducing localized phase change. Given the unique multiphysics nature of this phenomena, the current study develops a dedicated computational framework to predict the mass distribution and cooling of dispersing fuel particles, facilitating post-accident assessment and management of the fuel assemblies. Considering the scale of nuclear reactor applications, a continuum three-fluid model is proposed for simulating the transport of solids within the reactor core. With high-temperature fuel fragments within the liquid media, nucleation sites inducing phase changes are dispersed within the flow domain. Coupled with the fact that the transient dispersal event occurs on different time scales than other three-phase flow applications, this study derives a time-averaged three-fluid flow model without losing generality. The assumptions regarding the continuum treatment of the solid phase and the modeling of fuel dispersal behavior are incorporated to simplify the governing equations and derive applicable closure relations. The computational validation of the model was conducted using adiabatic experimental results obtained from ongoing research at Oregon State University, focusing on characterizing fuel dispersal behavior during simulated LOCA conditions. Settlement characteristics of the solids, quantified by the probability distribution of equivalent particles, closely matched the probability density functions reported in experimental studies. The transport of fuel particles within a scaled 5 × 5 lattice of a pressurized-water reactor rod bundle geometry was modeled through a two-fluid Eulerian framework. The required boundary conditions were evaluated from the fuel performance code BISON in a postulated large-break LOCA scenario. The modeling framework considered solid fuel particles as granular matter, interacting with the gaseous dry steam phase and fission gases through the governing interfacial momentum exchange between the participating fluids. The simulation results provided the volume fraction of the solids obtained at the bottom surface of the enclosing tank geometry. Postulated LOCA leading to fuel dispersal phenomena involves the strong coupling between fuel thermomechanics, cladding deformation, thermal-hydraulics, and fuel particle transport. Incorporation of such a strong coupling in numerical simulation is performed by coupling the multiphysics solvers. In the case of fuel dispersal, a strong coupled simulation can be performed by coupling the BISON code for fuel performance, the TRACE code for system-level thermal hydraulics, and fuel particle transport in Multiphysics Object-Oriented Simulation Environment (MOOSE). For such intricate infrastructure, the MOOSE Framework eases the data transfer between codes. The recent version of MOOSE has incorporated the Navier-Stokes module for the fluid flow. An exploratory exercise was done to gain familiarity with finite volume capabilities in the MOOSE framework to incorporate the Spalart-Allmaras (SA) turbulence model. New finite-volume and auxiliary kernels were introduced to assemble the SA transport equation, compute turbulent viscosity, and evaluate wall distance and diagnostic turbulence terms, fully integrated with existing Navier-Stokes modules. A turbulent lid-driven cavity at a Reynolds number of approximately 10,000 is used for verification. MOOSE shows the robust solver convergence and produces the turbulent features. But it underpredicts the velocity profile and turbulent quantities, emphasizing the need to develop improved SA near-wall treatments (e.g., low-Re corrections or wall functions) as a key direction for future work.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Recent Advances and Prospects in Design of Hydrogen Permeation Barrier Materials for Energy Applications—A Review

The hydrogen infrastructure involves hydrogen production, storage and delivery for utilization with clean energy applications. Hydrogen ingress into structural materials can be detrimental due to corrosion and embrittlement. To enable safe operation in applications that need protection from hydrogen isotopes, this review article summarizes most recent advances in materials design and performance characterization of barrier coatings to prevent hydrogen isotopes’ absorption ingress and permeation. Barriers are crucial to prevent hydride formation and unwanted hydrogen effects to increase safety, materials’ lifetime and reduce cost for applications within nuclear and renewable energy. The coating may be applied on a material that requires protection from hydrogen pick-up, transport and hydride formation in hydrogen storage containers, in pipelines, spent nuclear fuel storage or in nuclear reactors. While existing, commercial coatings that have been much in use may be satisfactory for various applications, it is desirable to evaluate whether alternative coating concepts can provide a greater resistance to hydrogen isotope permeation along with other improved properties, such as mechanical strength and thermal resistance. The information presented here is focusing on recent findings within the past 5–7 years of promising hydrogen barriers including oxides, nitrides, carbon, carbide, MAX-phases and metals and their mechanical strength, hydrogen pick-up, radiation resistance and coating manufacturing techniques. A brief introduction to hydrogen permeation is provided. Knowledge gaps were identified to provide guidance for material’s research prospects.

08 HYDROGEN↗
DOE OSTI2023

Evaluation of the Reconstruction Accuracy of the Ultrasound Model–Based Image Reconstruction (U-MBIR) Method for Concrete to Optimize Damage Detection

Reinforced concrete is a critical structural material used to construct nuclear power plants (NPPs). As such, its safety and performance must be thoroughly examined throughout the life cycle of the NPP infrastructure system. Ultrasonic measurements have been an industry standard for both surface and subsurface inspections. To support the development of these techniques, Oak Ridge National Laboratory (ORNL) has researched and developed advanced image reconstruction algorithms to capture internal damage. The results and discussion presented herein summarize the current state of the ultrasonic model–based iterative reconstruction (U-MBIR) algorithm developed at ORNL. In the work documented in this report, the U-MBIR methodology was applied to four sets of ultrasonic data collected from concrete specimens. The results demonstrate that the U-MBIR algorithm can successfully detect defects within the four concrete samples. The reconstruction images help identify the specimen thickness, regions of delamination, and location of rebar embedded within the concrete. The reconstruction images allow engineers and technicians to characterize the internal defects within concrete specimens and structural members. Ultimately, this knowledge can guide engineers in making informed decisions regarding the performance, safety, and reliability of structural materials (i.e., reinforced concrete) throughout the life cycle of NPPs.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Investigating Benefits and Challenges of Converting Retiring Coal Plants into Nuclear Plants

A coal-to-nuclear (C2N) transition means siting a nuclear reactor at the site of a recently retired coal power plant. Three overarching questions from the C2N transition guide this research: where in the United States are retired coal facilities located and what factors make a site feasible for transition; what factors of technology, cost, and project timeline drive investor economics over such a decision; and how will C2N impact local communities? The study team evaluated the siting characteristics of recently retired plants and those operating coal-fired power plant sites run by a utility or an independent power producer utilizing publicly available data to screen U.S. coal power plant sites to nuclear-feasible locations. After screening all retired coal sites to a set of 157 potential candidates and screening operating sites to a set of 237 candidates, the study team estimates that 80% of retired and operating coal power plant sites that were evaluated have the basic characteristics needed to be considered amenable to host an advanced nuclear reactor. For the recently retired plant sites evaluated, this represents a capacity potential of 64.8 GWe to be backfit at 125 sites. For the operating plant sites evaluated, this represents a capacity potential of 198.5 GWe to be backfit at 190 sites. This report evaluates a case study for the detailed impacts and potential outcomes from a C2N transition. Based on the nuclear technology choices and sizes evaluated to replace a large coal plant of 1,200 MWe generation capacity at the case study site, nuclear overnight costs of capital could decrease by 15% to 35% when compared to a greenfield construction project, through the reuse of infrastructure from the coal facility. Nuclear replacement designs can have a lower capacity size because nuclear power plants run at higher capacity factors than coal power plants. In the case study replacing coal capacity with 924 GWe of nuclear capacity, the study team found regional economic activity could increase by as much as $\$275 million$ and add 650 new, permanent jobs to the region of analysis. The evaluated site choice in the report is hypothetical for analysis purposes only and based on available data and documented assumptions. Consequently, the findings only inform at a general level. A community, investor, or other interested stakeholder can use these results to set up a detailed, in-depth analysis for a specific application of interest, such as evaluating a C2N transition of a specific coal power plant and a specific nuclear technology design. The report was subjected to independent peer reviews by experts in systems engineering and regional economic modeling to evaluate analysis and assumptions.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

A Business Case Evaluation of Gas Switching Reforming (GSR) Technology: A Promising Technology for Natural Gas Reforming with Integrated CO2 Capture

Hydrogen is essential in the transition to sustainable energy, and developing low-carbon production methods is a key research focus. Traditional steam methane reforming (SMR) dominates the hydrogen industry but contributes substantially to CO2 emissions. In response, Gas Switching Reforming (GSR) has emerged as a novel process that integrates carbon capture and utilizes process heat more efficiently. Unlike other reforming methods, GSR consolidates oxidation and reduction reactions within a single reactor, which minimizes external energy inputs and simplifies scaling. Like conventional steam methane reforming (SMR), GSR can be integrated with water-gas shift and pressure swing adsorption units for pure hydrogen production. This work presents a comprehensive business case analysis of GSR technology based on experimental results in Technology Readiness Level 3, Life Cycle Assessment (LCA) and Techno-Economic (TEA) evaluation incorporating ASPEN Plus process modeling considering different configurations and energy scenarios. The TEA incorporates data from kinetic experiments from various catalysts to evaluate the GSR process under various conditions. The goal of this work is to evaluate GSR’s potential to serve as a low-carbon alternative to SMR, focusing on global warming potential and additional impact categories to evaluate a wide spectrum of environmental impacts. Comparative assessments were conducted with SMR, chemical loop reforming (CLR), and proton exchange membrane (PEM) electrolysis to explore trade-offs across environmental metrics. The environmental impact assessment of this work encompasses the entire hydrogen production lifecycle from raw material extraction to plant decommissioning, using a cradle-to-gate boundary. Preliminary findings highlight that GSR, when integrated with low-carbon energy sources, could significantly reduce environmental impacts, making it a promising candidate for low-carbon hydrogen infrastructure. The insights from this business case evaluation aim to guide industry in scale-up and commercialization of this promising clean energy technology.

03 NATURAL GAS↗
DOE OSTI2022

Demonstrating Advanced Nuclear Energy Solutions for Net Zero

Background/Objectives. The aggressive goals being set by nation states, communities, and private industry for decarbonization of grid electricity, industrial heat sources, and transportation around the world are imperative to mitigating the devastating effects that we are seeing from climate change. Although many of these goals focus on accomplishments by 2035 or 2050, the decisions that we make today won’t just impact the landscape of energy systems for the next 20 or 30 years—they will shape the world’s environment for centuries to come. That means that we can’t just focus on technologies that will get us to 2050, but technologies that will withstand our energy demands over that long-ranging future. Success will require us to utilize all of the clean energy resources that we have available to meet demands for electricity, heat, and steam, and we will need energy carriers such as hydrogen that do not emit additional greenhouse gases at the point of use. Nuclear energy, ranging from technologies in service today to advanced, higher temperature and modular systems that will be in service this decade, will provide a robust complement to renewable energy resources that operate variably. Researchers across the U.S. Department of Energy laboratory complex are working to advance multiple aspects of these clean energy solutions, with many focusing on integrated energy system solutions that leverage all available clean energy assets to meet wide-ranging energy demands. Approach/Activities. Nuclear energy is a proven, zero-emission option during operation that can provide consistent, dispatchable power to meet electricity demands while also providing high-quality heat that can meet energy demands beyond the electricity sector. Energy system design should seek to maximize these assets. As a dispatchable energy source with a small land utilization footprint, nuclear energy can be collocated with renewable resources, and the smaller systems that will be deployed this decade (ranging from a few megawatts to hundreds of megawatts) can be installed right where that energy is needed. Integrated nuclear and renewable systems will enhance power grid reliability and resilience, and they will help stabilize the grid through their increasingly flexible operation. Licensing, installation, and broad adoption of these advanced nuclear energy systems are expected to progress significantly in the 2020s, but this may be longer than desired by some stakeholders wishing to implement impactful clean energy decisions today. However, one must recall that nuclear energy systems will operate for 80 or more years, as is being demonstrated by current fleet nuclear systems. The nuclear community is extremely thorough in reviewing these systems with regard to safety and security; these efforts ensure that the deployed systems will continue to provide reliable, resilient energy over that operational lifetime. That investment of time up front will ensure that we can support energy demands over the centuries to come. While advanced nuclear technologies move through this process, communities and private industry may choose to install renewable generation systems that can later be coupled to the complementary nuclear systems as they become available—thus moving closer to the net zero goals in the near term. Choosing technologies and deployment configurations that allow small modular nuclear powerhouses to be added to these “energy parks” as they become available will ensure that advanced technologies can be readily adopted to support growing demands for clean energy. Results/Lessons Learned. The primary focus of integrated energy systems (IES) research is to assess the technical and economic potential of novel multi-input, multioutput solutions that are expected to enhance energy system flexibility, reliability, and resilience as we pursue a clean energy transition. Various energy applications and product streams beyond electricity are being evaluated, ranging from generation of potable water to production of hydrogen, fertilizers, synthetic fuels, and various chemicals. In early FY23 Idaho National Laboratory (INL) will commission thermal energy generation systems that emulate nuclear fission energy input using electric heating and will allow for integrated system testing with thermal energy storage, hydrogen production via high temperature electrolysis (HTE), and power systems hardware to demonstrate operation of a clean energy park within a microgrid or larger grid infrastructure, supporting up to 450 kW of heat input via electric heating and demonstrating operation of HTE systems at the multi-hundred kW scale. This presentation will highlight the wide array of RD&D being conducted at INL and partner laboratories to develop and deploy nuclear and renewable-based IES that will be key to achieving our net zero goals, including both computational and experimental demonstrations. By working with key collaborators in industry, analytical st

08 HYDROGEN↗