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Fabrication and Testing of Solid-Solution Strengthened Corrosion Resistant Alloys For Service in Molten Fluoride Environments

The demand for higher system thermal efficiencies requires the operation of power generation cycles and heat conversion systems at progressively higher temperatures. As the system operating temperature increases, existing materials may not provide adequate mechanical properties or environmental compatibility or both. There is an increasing commercial interest in the development and deployment of liquid-fueled Molten Salt Reactors (MSRs). Hastelloy®N, the highest performing candidate MSR structural alloy, is not capable of operations at temperatures above 700°C, thus limiting the performance of these systems. Using an Integrated Computational Materials Engineering (ICME)-approach and small laboratory scale heats, ORNL developed a class of patented alloys covered by U.S. Patent 9,435,011 B2, “Creep-resistant, Cobalt-free alloys for high temperature, liquid-salt heat exchanger systems,” similar to Hastelloy®N in that they are primarily solid solution strengthened. In contrast to precipitation strengthened alloys, the microstructure of solid solution alloys and hence the high temperature mechanical properties are stable for extended periods of time allowing long reactor operating life. The new alloys have shown to possess good resistance to liquid fluorides at temperatures up to 850°C and have significantly improved creep properties when compared to Hastelloy®N. The purpose of the CRADA project was for ORNL to collaborate with Haynes International- a materials producer, MetalTek International- a foundry, and Kairos Power – an advanced reactor developer – to scale-up selected alloys, evaluate their properties, and identify one solid solution strengthened alloy that can meet the property requirements for the reactor being developed by Kairos Power and other similar liquid fluoride-salt cooled reactors. As part of the project, eight alloys were down-selected and fabricated in larger industrial scale heats by Haynes International. Resistance to molten salt was evaluated in flowing FLiNaK and FLiBe by Kairos Power using their Rotating Cage Loop (RCL) system. Accounting for iron deposition during these tests, the new alloys displayed very low net mass change showing excellent corrosion performance in molten salt. Creep properties evaluated at ORNL were found to be better than that of Hastelloy®N and 316 stainless steel. Long-term stabilities of the alloys evaluated by Haynes International showed that these alloys have excellent thermal stability in the temperature range 704.4-815.6°C, with the change in strength and ductility being less than 10-15% after a 4000-hour exposure at 815.6°C. Autogenously Gas Tungsten Arc Welding (GTAW) welded samples showed less than 10% change in yield strength / ultimate tensile strength / total elongation compared to the basemetal, indicating that the alloys have excellent weldability. Three parts were successfully investment-cast using one alloy with very little voiding showing feasibility of fabricating parts using the casting process. This project enabled extensive interaction between the material producer Haynes International, casting supplier MetalTek, and reactor developer Kairos Power. This facilitated testing of materials and components produced using the newly developed alloys by the end-user. This allowed the generation of critical dataset required for down-selection of a few promising alloys for further development. This data is also currently being shared with other reactor designers for them to evaluate the suitability of this alloy for their reactor design. The availability of this alloy will ultimately enable the design and development and deployment of MSRs with increased temperature of operation and thus, improved efficiencies.

36 MATERIALS SCIENCE↗

Environmental and Economic Implications of Emerging Plastic Recycling Technologies

Recycling will play a crucial role in mitigating plastic pollution and promoting a circular economy for polymers. Quantitative analysis can help guide the optimization and implementation of these plastic management strategies, enabling increased circularity while minimizing costs, energy use, greenhouse gas emissions, and other environmental impacts. This talk will outline the Bio-Optimized Technologies to keep Thermoplastics out of Landfills and the Environment (BOTTLE) Consortium's approach to analysis-guided plastic recycling research. Stringent process modelling, life cycle assessment, and techno-economic analysis are used to benchmark the technical feasibility, environmental impacts, and costs of chemical and biological recycling technologies in comparison to conventional fossil fuel-based plastic manufacturing. Across emerging recycling strategies, several key challenges become apparent - including plastic feedstock pretreatment requirements, high energy or chemical use, and recycled plastic yields and quality - highlighting opportunities for future innovation. Through this consistent and in-depth analysis approach, BOTTLE aims to provide the plastics community with key metrics and insights to drive plastic recycling innovation towards a more sustainable and circular economy.

circular economy↗

An Adaptable and Comprehensive Project Assessment Tool

Most companies, agencies, and other real property owners require capital asset projects to pass some type of scrutiny before budgets and authority to expend funds for the design, construction and eventual operations are approved. This process typically involves management approval of key/critical decision(s) or a project’s passage through gates (or critical decisions). Cost, functionality, safety, and risk are just some of the factors typically considered during project assessment processes. This paper describes a tool that was developed and is used by the Department of Energy to facilitate this project assessment process. There are three versions of this tool for construction, decontamination and decommissioning (D&D), and environmental restoration/cleanup project types. The tool’s elements and associated criteria are tailored for each project type; although some elements, such as cost estimating and scheduling, are used in common. The tool is easy to use, requiring little or no training. It provides a common assessment tool for project self-appraisals and independent project reviews. It promotes efficiency and reduces disagreements and unnecessary effort. A comprehensive array of elements covers the gamut of cost, schedule, scope/technical, and safety/security ensuring that no important project attributes are overlooked. The tool is adaptable for use by any organization.

97 MATHEMATICS AND COMPUTING↗

A rapid embodied carbon assessment tool for priority materials

Embodied carbon limits within building materials are a driving factor in global trade, generating new research and analysis tools in industry. These product assessments, which require utilizing life-cycle assessment (LCA) across broad supply chains, can be expensive, time and data-intensive, and subject to significant variations. Existing methods and tools, such as specific environmental product declarations, typically do not capture these variations and dynamics in supply and manufacturing. Moreover, models and tools must enable stakeholders to assess customized supply chains and future scenarios. In this study, we present the Rapid Embodied Carbon Assessment and Target-setting for Emissions-intensive Materials (REDuCE) tool for building materials. We developed a tool that allows users to select production technologies, transportation mode and distances, concrete carbonation, fuel sources, and regional electricity mixes to supply customization for cement and concrete produced and consumed in California. We generated and integrated a material demand model using residential building stock projections. We provide the user with a wide range of mitigation alternatives through low-carbon production pathways, material use efficiency, transportation modes, and projected electricity grid mixes. In a case study application through four mitigation scenarios, we find emission savings up to 80% by maximizing user mitigation alternatives, primarily driven by reductions in material use intensities. This work represents a foundation for expanding LCA and embodied carbon tools to better enable stakeholders to rapidly and accurately assess customized supply chains while meeting trade requirements.

building materials↗

Solving the sample size problem for resource selection functions

Abstract Sample size sufficiency is a critical consideration for estimating resource selection functions (RSFs) from GPS‐based animal telemetry. Cited thresholds for sufficiency include a number of captured animals and as many relocations per animal N as possible. These thresholds render many RSF‐based studies misleading if large sample sizes were truly insufficient, or unpublishable if small sample sizes were sufficient but failed to meet reviewer expectations. We provide the first comprehensive solution for RSF sample size by deriving closed‐form mathematical expressions for the number of animals M and the number of relocations per animal N required for model outputs to a given degree of precision. The sample sizes needed depend on just 3 biologically meaningful quantities: habitat selection strength, variation in individual selection and a novel measure of landscape complexity, which we define rigorously. The mathematical expressions are calculable for any environmental dataset at any spatial scale and are applicable to any study involving resource selection (including sessile organisms). We validate our analytical solutions using globally relevant empirical data including 5,678,623 GPS locations from 511 animals from 10 species (omnivores, carnivores and herbivores living in boreal, temperate and tropical forests, montane woodlands, swamps and Arctic tundra). Our analytic expressions show that the required M and N must decline with increasing selection strength and increasing landscape complexity, and this decline is insensitive to the definition of availability used in the analysis. Our results demonstrate that the most biologically relevant effects on the utilization distribution (i.e. those landscape conditions with the greatest absolute magnitude of resource selection) can often be estimated with much fewer than animals. We identify several critical steps in implementing these equations, including (a) a priori selection of expected model coefficients and (b) regular sampling of background (pseudoabsence) data within a given definition of availability. We discuss possible methods to identify a priori expectations for habitat selection coefficients, effects of scale on RSF estimation and caveats for rare species applications. We argue that these equations should be a mandatory component for all future RSF studies.

Street, Garrett M.↗

Marine carbon dioxide removal (mCDR) test site needs: A joint PNNL-PMEL workshop report

This workshop report summarizes testing and capability needs for marine Carbon Dioxide Removal (mCDR) research identified by researchers from DOE’s Pacific Northwest National Laboratory (PNNL) and NOAA’s Pacific Marine Environmental Laboratory (PMEL) as essential to advancing the state of the science and technology. A one-day workshop was held for 36 hybrid participants on June 2, 2023 at PNNL’s Marine and Coastal Sciences Laboratory in Sequim, WA. The workshop began with DOE and NOAA leadership offering perspectives on the mission alignment and long-term implementation of mCDR research within NOAA’s Office of Ocean and Atmospheric Research (OAR), DOE’s Water Power Technologies Office (WPTO), and DOE’s Office of Fossil Energy and Carbon Management (FECM). As identified by the participants and by program leadership at both agencies, many mCDR strategies are in early stages of development making it difficult to reliably estimate their impact. The essential next step in proving the efficacy, safety, and sustainability of these solutions and identifying market potential requires studies under field-relevant conditions.

13 HYDRO ENERGY↗

Vadose and Saturated Zone Flow and Transport Calculations for the Active Trenches of the Low-Level Burial Grounds, Hanford Site, Washington

The purpose of the fate and transport modeling described in this environmental calculation file (ECF) is to evaluate the impacts to groundwater associated with waste disposal operations at Mixed Waste Low-Level Burial Ground (LLBG) Trenches 31 and 34 to satisfy requirements in DOE O 435.1, Radioactive Waste Management. The model integrates the flow and transport in the vadose zone beneath the active trenches with the saturated zone downgradient of the trenches to predict the radionuclide concentration at the point of assessment (POA). DOE M 435.1-1, Radioactive Waste Management Manual, defines the POA as the point of highest projected dose or concentration beyond a 100 m (328 ft) buffer zone surrounding the disposed waste. The modeling is conducted in accordance with the DOE G 435.1, Implementation Guide for Use with DOE M 435.1-1, performance assessment (PA) guidelines. The modeling involves evaluation of the groundwater concentrations and radionuclide arrival times during the 1,000-year compliance and 10,000-year sensitivity-uncertainty periods per DOE O 435.1 and DOE M 435.1. This analysis does not consider radionuclide release during facility operations, only the post-closure impacts of the radionuclides to the environment. The evaluation of potential radiological dose to groundwater receptors caused by releases from a closed facility containing radioactive waste typically includes the following: (1) Release of radionuclides from that facility (2) Transport of those radionuclides through the environment, and (3) Exposure to humans to environmental concentration levels of those radionuclides The fate and transport three-dimensional (3D) model analysis involves the post-closure impacts to the environment of the technetium-99, iodone-129, and uranium (all isotopes in the waste). The residual inventory estimates include several radionuclides, but technetium-99 is typically responsible for almost all of the beta-gamma dose equivalent associated with groundwater (water resources) protection per 40 CFR 141, “National Primary Drinking Water Regulations” (e.g., see the results in WCH-520, Performance Assessment of Environmental Restoration Disposal Facility, Hanford Site, Washington; hereinafter referred to as the ERDF PA), and iodone-129 can also be a significant dose contributor for some waste (e.g., RPP-RPT-59958, Performance Assessment for the Integrated Disposal Facility, Hanford Site, Washington; hereinafter referred to as the IDF PA). Uranium does not typically factor significantly into the impacts to groundwater, even during the 10,000-year sensitivity-uncertainty period, but always remains of interest as a contaminant. This ECF does not address vadose and saturated zone modeling for Trench 94 of the 200 East Area LLBG. Current information confirms the validity of the low corrosion rate of the naval reactor plant carbon steel (HY-80), and the even lower corrosion rate of the nickel-iron-chromium alloy reactor vessel (Inconel Alloy 600) presented in DOE/EIS-0259, Final Environmental Impact Statement on the Disposal of Decommissioned, Defueled Cruiser, Ohio Class, and Los Angeles Class Naval Reactor Plants. Based on these low corrosion rates, the time to breach the reactor vessel to allow release of radionuclides from the activated metal of the reactor vessel internal structure is at least 10,000 years. This time to breach precludes the need to evaluate the vadose and saturated zone transport of contaminants released from the reactor compartment disposal packages in the 200 East Area LLBGs PA (CP-63826, Waste Release Model Package Report for the Active Trenches of the Low-Level Burial Grounds, Hanford Site, Washington).

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Exopolysaccharide is required for motility, stress tolerance, and plant colonization by the endophytic bacterium Paraburkholderia phytofirmans PsJN

Paraburkholderia phytofirmans PsJN is an endophytic bacterium and has been shown to promote the growth and health of many different plants. Exopolysaccharide (EPS) plays important roles in plant-bacteria interaction and tolerance to environmental stresses. However, the function of EPS in PsJN and its interaction with plants remain largely unknown. In this study, a deletion mutation of bceQ gene, encoding a putative flippase for the EPS biosynthesis, was introduced in the genome of PsJN. The ΔbceQ mutant produced a significantly lower level of EPS than the wild type strain in culture media. Compared to the wild type PsJN, the ΔbceQ mutant was more sensitive to desiccation, UV damage, salt (NaCl) and iron (FeCl 3 ) stresses, and bacteriophage infection. More importantly, the mutation of bceQ decreased the endophytic colonization of PsJN in camelina (Camelina sativa) and pea (Camelina sativa) under plant drought stress conditions. To the best of our knowledge, this is the first report that EPS production is required for the maximal colonization of an endophytic bacterium in the plant tissues under stress conditions.

59 BASIC BIOLOGICAL SCIENCES↗

Chronic Cardiotoxicity Assays Using Human Induced Pluripotent Stem Cell-Derived Cardiomyocytes (hiPSC-CMs)

Cardiomyocytes (CMs) differentiated from human induced pluripotent stem cells (hiPSCs) are increasingly used in cardiac safety assessment, disease modeling and regenerative medicine. A vast majority of cardiotoxicity studies in the past have tested acute effects of compounds and drugs; however, these studies lack information on the morphological or physiological responses that may occur after prolonged exposure to a cardiotoxic compound. In this review, we focus on recent advances in chronic cardiotoxicity assays using hiPSC-CMs. We summarize recently published literature on hiPSC-CMs assays applied to chronic cardiotoxicity induced by anticancer agents, as well as non-cancer classes of drugs, including antibiotics, anti-hepatitis C virus (HCV) and antidiabetic drugs. We then review publications on the implementation of hiPSC-CMs-based assays to investigate the effects of non-pharmaceutical cardiotoxicants, such as environmental chemicals or chronic alcohol consumption. We also highlight studies demonstrating the chronic effects of smoking and implementation of hiPSC-CMs to perform genomic screens and metabolomics-based biomarker assay development. The acceptance and wide implementation of hiPSC-CMs-based assays for chronic cardiotoxicity assessment will require multi-site standardization of assay protocols, chronic cardiac maturity marker reproducibility, time points optimization, minimal cellular variation (commercial vs. lab reprogrammed), stringent and matched controls and close clinical setting resemblance. A comprehensive investigation of long-term repeated exposure-induced effects on both the structure and function of cardiomyocytes can provide mechanistic insights and recapitulate drug and environmental cardiotoxicity.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Creep of MARBN-type 9Cr martensitic steel in gaseous CO 2 environment

Here, with an interest in moving from steam to supercritical CO 2 as the working fluid in advanced energy systems, it is important to study the mechanical response of structural alloys to CO 2 -containing environments. MARBN-type 9Cr martensitic steel was originally developed for application in boilers for supercritical and ultra-supercritical power plants where the steam temperature reaches 650 °C. In this research, a MARBN-type 9Cr martensitic steel designed and manufactured at NETL was creep tested in a gaseous CO 2 environment (i.e., 0.1 MPa at 650 °C), and the results are directly compared to creep tests conducted in air. It was found that environmentally-assisted cracking facilitated by carbide formation beneath the growing oxide accelerated failure in gaseous CO 2 . This work indicates that creep-oxidation interactions in advanced martensitic steels represent an important consideration for materials selection in supercritical CO 2 power cycles. Furthermore, this work confirms that more oxidation-resistant alloys will be required for the highest temperature portions of these systems.

36 MATERIALS SCIENCE↗

Mapping heat vulnerability in cities: A tale of two california cities

Extreme heat is a major cause of weather-related deaths in the United States. To address this, a heat vulnerability index (HVI) is crucial for assessing heat risk and identifying vulnerable urban areas and populations, supporting city planning and emergency response. Current HVI studies often use Principal Component Analysis (PCA) on environmental, socioeconomic, and medical data to aggregate vulnerability indicators into a single index. However, these fixed aggregation weights struggle to adapt to different use cases, which may require varying focuses. Moreover, existing tools primarily consider outdoor heat exposure, providing an incomplete picture of actual exposure, as people spend most of their time indoors. Our research introduces an HVI web mapping tool that addresses these gaps in the literature by: (1) allowing flexible weights to adapt to different use cases, and (2) uniquely integrating both outdoor and indoor heat exposure by considering building characteristics for a more comprehensive risk assessment. We demonstrated this tool in two California cities with contrasting climates: Fresno (inland, arid, hot summers) and Oakland (temperate coastal). This HVI mapping tool provides essential decision support for policymakers and stakeholders in both short-term heat mitigation and long-term urban planning for building interventions and infrastructure development.

BES↗

Isotopically Selective Quantification by UPLC-MS of Aqueous Ammonia at Submicromolar Concentrations Using Dansyl Chloride Derivatization

Ammonia (NH 3 ) is necessary for food production and is commercially synthesized from nitrogen (N 2 ) and hydrogen (H 2 ) using the Haber–Bosch process. Significant amounts of ammonia are made every year in a reaction that requires high temperatures and pressures, with the Haber–Bosch accounting for ~1.6% of total annual global energy consumption. Electrocatalysts are also being explored to convert in an environmentally friendly manner N 2 to NH 3 at ambient temperature and pressure.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Liquid Fed Pyrolysis of Polyethylene Films: Environmental and Economic Assessments of Co-located and Remotely-Located U.S. Facilities

Polyethylene (PE) films are one of the highest production volume plastic products, but they have very low recycling rates. A novel liquid fed pyrolysis process (LFP) is an advanced recycling technology that can be applied to waste PE films. In this work, two environmental and six economic metrics were evaluated for the LFP process under different scenarios with a baseline production capacity of 8,400 Metric Tons (MT) of pyrolysis products/year. The studied scenarios considered process improvement such as heat integration, changing the final product yields, and location of the LFP process facility (i.e., co-located at a petrochemical facility or located remotely). Results show that producing refined pyrolysis wax in remote areas is the most environmentally favorable and profitable scenario. The LFP process co-located at a petrochemical facility and selling only liquid and gaseous pyrolysis products to the facility would require a capacity of >18,000 MT/year to be economically feasible. Heat integration led to greenhouse gas emission savings of at least 14%, 19%, and 32% for the pyrolysis oil, gas, and wax products, respectively. Fianlly, the LFP process in remote and less populated locations producing a high yield of refined wax may be a feasible solution for increasing recycling rates of PE films.

Advanced recycling↗

Physical and behavioral adaptations to prevent overheating of the living wings of butterflies

The wings of Lepidoptera contain a matrix of living cells whose function requires appropriate temperatures. However, given their small thermal capacity, wings can overheat rapidly in the sun. Here we analyze butterfly wings across a wide range of simulated environmental conditions, and find that regions containing living cells are maintained at cooler temperatures. Diverse scale nanostructures and non-uniform cuticle thicknesses create a heterogeneous distribution of radiative cooling that selectively reduces the temperature of structures such as wing veins and androconial organs. These tissues are supplied by circulatory, neural and tracheal systems throughout the adult lifetime, indicating that the insect wing is a dynamic, living structure. Behavioral assays show that butterflies use wings to sense visible and infrared radiation, responding with specialized behaviors to prevent overheating of their wings. Our work highlights the physiological importance of wing temperature and how it is exquisitely regulated by structural and behavioral adaptations.

59 BASIC BIOLOGICAL SCIENCES↗

Identifying geologic characteristics and operational decisions to meet global carbon sequestration goals

Geologic carbon sequestration is the process of injecting and storing CO 2 in subsurface reservoirs and is an essential technology for global environmental security (e.g., climate change mitigation) and economic security (e.g., CO 2 tax credits). To meet energy, economic, and environmental goals, society will have to identify vast volumes of high-capacity, low-cost, and viable storage reservoirs for sequestering CO 2 . In turn, this requires understanding how major geologic characteristics (such as reservoir depth, thickness, permeability, porosity, and temperature) and design and operational decisions (such as injection well spacing) impact CO 2 injection rates, storage capacity, and economics. Although many numerical simulation tools exist, they cannot repeat the required thousands or millions of simulations to identify ideal reservoir properties and the sensitivity and interaction between geologic parameters and operational decisions. Here, we use SCO 2 T—a fast-running, reduced-order modeling framework—to explore the sensitivity of major geologic parameters and operational decisions to engineering (CO 2 injection rates, plume dimensions, and storage capacities and effectiveness) and costs. Our results show, for the first time, benefits and impacts such as allowing CO 2 plumes to overlap, how different well spacing patterns affect CO 2 sequestration, the effects on costs of including brine treatment and disposal, and the effect of restricting injection rates to 1 MtCO 2 per y based on well limitations. We reveal multiple novel and unintuitive findings including: (i) deeper reservoirs have reduced carbon sequestration costs until injection rates reach 1 MtCO 2 per y, at which point deeper reservoirs become more expensive, (ii) thicker formations allow for increased injection rates and storage capacity, but thickness barely impacts plume areas, (iii) higher geothermal gradients result in reduced sequestration costs, unless brine treatment/disposal costs are included, at which point reservoirs having lower geothermal gradients are more economical because they produce less brine for each unit of injected CO 2 , and (iv) allowing plumes to overlap has a significantly positive impact of increasing storage capacities but has only a small influence on reducing sequestration costs. Altogether, our results illustrate new scientific conclusions to help identify suitable sites to inject and store CO 2 , to help understand the complex interaction between geology and resulting costs, and to help support the pursuit of meeting global sequestration targets.

58 GEOSCIENCES↗

The influence of surface heat fluxes on the growth of idealized monsoon depressions

This study explores the effect of surface sensible and latent heat fluxes on monsoon depressions using a series of idealized convection-permitting simulations. Each experiment is initialized with a small-amplitude wave that is allowed to grow within an environment representative of the South Asian monsoon. Comparing experiments with and without interactive surface heat fluxes, it is found that these fluxes enhance the growth of the simulated vortices. Without interactive surface fluxes, the strengthening period is short and the vortices fail to reach intensities characteristic of stronger monsoon depressions. Using a large set of experiments in which the vertical and meridional shear are systematically varied, it is found that surface heat fluxes enhance intensity the most when the upper-level shear is weak, the lower-level shear and associated moist static energy (MSE) gradient are sufficiently steep, and the lower-level meridional shear is strong. Here, these experiments reveal two different regimes of convection-coupled monsoon depression growth: one in which convection is driven by MSE advection and one in which it is driven by surface heat fluxes and quasigeostrophic forcing for ascent. Both regimes require sufficiently strong meridional shear to achieve initial growth by barotropic instability.

54 ENVIRONMENTAL SCIENCES↗