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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 OSTI2024

Addressing Failures in Molten Salt Thermal Energy Storage Tank for Central Receiver Concentrating Solar Power Plants

The thermal energy storage (TES) system is a critical component in concentrated solar power (CSP) plants that increases the plant's capacity factor and economic competitiveness by reducing the levelized cost of energy (LCOE) while simultaneously increasing the value of the delivered energy. Failures including molten-salt leaks and diverse localized cracking after several months to a few years of operation have been reported in hot tanks for CSP plants operating around the world. A model of a molten salt thermal energy storage tank was developed and validated to analyze the impact of different tank design features on the temperature and stress distributions as a function of typical plant operation conditions. Design features included the floor plate thicknesses, friction coefficients between the tank floor and the foundation, and the sparger ring location. Maximum stresses in the tank floor frequently surpassed the yield point of the material during operation, leading to a detriment of the tank's lifetime. Recommendations on design features to improve the reliability of new molten salt tanks for CSP plants are provided.

concentrating solar power↗
DOE OSTI2024

Online Molten Salt and Gas Monitoring Using Combined Spectroscopic Methods

The nonproliferation of nuclear material and the development of safeguards technologies to sample and analyze fuel salt is a challenge for molten salt reactor (MSR) developers. We seek online monitoring using combined spectroscopic methods of two distinct material phases from MSR’s. Molten salt transformed to aerosol phase allows for Light Induced Breakdown spectroscopy (LIBS) without adverse splashing (ARPA-E). Vaporized used nuclear fuel through chlorine-based volatility (CBV) allows for uranium separation based on boiling point differences

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗
DOE OSTI2024

Methods, materials systems, and devices for inhibiting infiltration and penetration of molten salts into solid materials

Methods, materials systems, and devices for inhibiting the infiltration and penetration of molten salts into solid materials, including porous materials at temperatures above the solidus temperature of the molten salt. The methods, materials systems, and devices utilize a non-wetted solid that is introduced into pores having entrances at an exterior surface of a porous solid material adapted to contact the molten salt.

Sandhage, Kenneth Henry↗
DOE OSTI2025

Development for Integrated System-Level Analysis Capabilities in SAM for Molten Salt Reactors

In recent years, there has been renewed interest in Molten Salt Reactors (MSRs) for their potential advantages compared to reactors that rely on solid fuel. In response to such interest, many methods and codes have been developed to capture the unique features of MSRs. Among them, the System Analysis Module (SAM) is a modern system analysis tool that provides fast-running, modest-fidelity, whole-plant transient analysis capabilities, essential for fast-turnaround design scoping and engineering analyses of advanced reactor concepts. For liquid-fuel MSRs, the complex physics and chemistry involved in MSR operation—such as reactor kinetics, fluid flow, heat transfer, and salt composition dynamics—pose significant challenges for system-level modeling. Specific modeling capabilities are needed for system-level transient simulation. This paper presents recent advancements in SAM capability enhancements for system-level modeling of MSRs, focusing on improved simulation fidelity, computational efficiency, and multi-physics integration. Key enhancements include the development of species transport, Delayed Neutron Precursor (DNP) drift, modified Point Kinetics Equations (PKE), decay heat modeling, key fission product behavior, salt corrosion, and thermal-hydraulic coupling, as well as code robustness and performance enhancements for MSR applications. The code enhancement allows for better predictive accuracy in safety analysis, transient behavior, and operational optimization, thus supporting the design and licensing of next-generation MSRs. Results from case studies are presented to demonstrate the benefits of these enhancements in accurately capturing key reactor transient behaviors.

Hu, Rui (ORCID:0000000237712920)↗
DOE OSTI2022

Ab initio molecular dynamics (AIMD) simulations of NaCl, UCl 3 molten salts

Ab initio molecular dynamics (AIMD) simulations are used to calculate select thermophysical and thermodynamic properties of NaCl, UCl and NaCl-UCl 3 molten salts. Following established approaches, the AIMD simulations include a model for Van der Waals interactions. The Langreth & Lundqvist (vDW-DF2), DFT-D3, and density-dependent energy correction (DFT-dDsC) dispersion models are first tested for molten NaCl in order to assess their accuracy for density and heat capacity predictions across a range of temperatures. Based on the NaCl results, the vdW-DF2 and DFT-dDsC methods are extended to the UCl 3 system and compared to available experimental data. Next, mixtures of NaCl-UCl 3 are investigated and analyzed with respect to the deviation from ideal solution behavior. For the DFT-dDsC simulations, density deviates by up to 2% from an ideal mixture, with the maximum occurring close to the eutectic composition. The mixing energy also deviates from an ideal solution and exhibits a minimum of about -0.074 to eV per formula unit, again close to the eutectic composition. Finally, the compressibility and species diffusivity of the pure and mixed salt systems are calculated. The diffusivities are slightly reduced in the mixed compared to the pure systems and the compressibilities loosely follow a linear correlation as a function of the UCl 3 composition. The trends observed for mixing properties are rationalized by correlating them to the coordination chemistry, which emphasizes the importance of maintaining the extended network formed by U and Cl ions as the NaCl concentration increases. The concentration at which breakdown of the extended network occurs, roughly coincides with the minimum of both the mixing energy and the deviation from ideal solution behavior for density.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Salt and ion transport in a series of crosslinked AMPS/PEGDA hydrogel membranes

Salt permeability and ionic conductivity are critical properties for membranes in water purification and energy applications. Both properties depend on individual ion sorption and diffusion coefficients, which are significantly influenced by polymer chemical and physical parameters such as fixed charge concentration and membrane water content. However, systematic studies connecting polymer structure to ion transport properties are still lacking. In this study, a series of uncharged and charged membranes were synthesized using poly(ethylene glycol) diacrylate (PEGDA) as a cross-linker and 2-acrylamido-2-methyl-1-propanesulfonic acid (AMPS) as a charged monomer. Membrane fixed charge concentration and water uptake were systematically varied by adjusting AMPS content in the pre-polymerization mixture. Salt sorption and permeability coefficients and ionic conductivity of these membranes were measured as a function of NaCl solution concentration (0.01–1 M). Combining the solution-diffusion model and Nernst-Planck equation, individual ion diffusion coefficients were calculated. Experimental Na + diffusion coefficients for all materials were well described by the Mackie and Meares tortuosity model, highlighting the strong influence of water content on ion diffusivity in both uncharged and charged polymers. Model predictions for Cl – diffusion coefficients agree reasonably well with experimental values, with some deviations occurring in more highly charged membranes. Finally, this discrepancy might result from interactions not captured by the Mackie and Meares model (e.g., fixed charge-ion interactions).

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Thermodynamic properties of ZrCl 4 with LiCl, NaCl, KCl, CsCl, MgCl 2 , and UCl 3 for molten salt reactor applications

Here, a set of self-consistent Gibbs energy functions has been developed to describe the thermochemical behavior of the major reactive fission product ZrCl 4 with key components in chloride molten salt reactors (MSRs): LiCl–ZrCl 4 , NaCl–ZrCl 4 , KCl–ZrCl 4 , CsCl–ZrCl 4 , MgCl 2 –ZrCl 4 and UCl 3 –ZrCl 4 . Low ZrCl 4 concentration phase equilibria most relevant to MSR applications have been confirmed via differential scanning calorimetry for NaCl–ZrCl 4 , and X-ray diffraction analysis performed on equilibrated samples of NaCl–ZrCl 4 , KCl–ZrCl 4 , MgCl 2 –ZrCl 4 , and UCl 3 –ZrCl 4 . Within the framework of the modified quasi-chemical model in the quadruplet approximation, extrapolations of pseudo-binary models were generated to represent KCl–MgCl 2 –ZrCl 4 , KCl–NaCl–ZrCl 4 , and MgCl 2 –NaCl–ZrCl 4 , which show agreement with phase equilibria data where available without the use of ternary interaction parameters. The optimized thermodynamic descriptions for these systems and others are available in the open-source compendium Molten Salt Thermal Properties Database – Thermochemical (MSTDB–TC).

CALPHAD↗
DOE OSTI2020

Nanoconfinement and Salt Synergistically Suppress Crystallization in Polyethylene Oxide

Suppressing the crystallization of polyether-based solid electrolytes is a widely sought-after strategy to improve ionic conductivity. We report the effects of nanoconfinement on polyethylene oxide electrolytes. We find that neat polyethylene oxide responds to nanoconfinement by adopting a preferred orientation, yet is able to crystallize even in nanoconfinement volumes with widths as small as 8 nm. However the combination of nanoconfinement and salt addition does suppress polymer crystallization at room temperature, even though either factor alone cannot. Such synergistic suppression of crystallization has implications for polymer electrolytes, since amorphous rather than crystalline domains predominantly contribute to ionic conduction. Our results suggest that salts previously discounted due to their inability to suppress crystallinity in bulk materials could be made viable when combined with nanoconfinement, thereby opening new possibilities for high-performance solid polymer electrolytes.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Polyethylene Upcycling to Liquid Alkanes in Molten Salts under Neat and External Hydrogen Source-Free Conditions

Development of facile approaches to convert plastic waste into liquid fuels under neat conditions is highly desired but challenging, particularly without noble metal catalysts and an external hydrogen source. Herein, highly efficient and selective polyethylene-to-gasoline oil (branched C 6 –C 12 alkanes) conversion was achieved under mild conditions (<170 °C) using commercially available AlCl 3 -containing molten salts as reaction media and to provide catalytic sites (no extra solvents, additives, or hydrogen feeding). The high catalytic efficiency and selectivity was ensured by the abundant active Al sites with strong Lewis acidity (comparable to the Al type in acidic zeolite) and highly ionic nature of the molten salts to stabilize the carbenium intermediates. Dynamic genesis of the Al sites was elucidated via time-resolved Al K-edge soft X-ray and 27 Al NMR, confirming the tricoordinated Al 3+ as active sites and its coordination with the as-generated alkene/aromatic intermediates. Further, the carbenium formation and polyethylene chain variation was illustrated by inelastic neutron scattering (INS) and an isotope-labeling experiment. Theoretical simulations further demonstrated the successive hydride abstraction, β-scission, isomerization, and internal hydrogen transfer reaction pathway with AlCl 3 as active sites. This facile catalytic system can further achieve the conversion of robust, densely assembled, and high molecular weight plastic model compounds to liquid alkane products in the diesel range.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Molybdenum-99 from Molten Salt Reactor as a Source of Technetium-99m for Nuclear Medicine: Past, Current, and Future of Molybdenum-99

Technitium-99m ( 99m Tc), a widely used radioisotope, is used in tens of millions of medical diagnostic procedures annually. However, it is hard to store and must be immediately used upon production due to its short half-life (i.e., 6 h); thus, it is currently produced from 99 Mo, which itself is a result of 235 U fission. The majority of 99 Mo supplies to U.S. patients are currently provided by foreign producers and produced using highly enriched uranium (HEU). In order to minimize the proliferation risks of HEU-based medical isotope production, the U.S. Department of Energy’s National Nuclear Security Administration has funded a program to accelerate the development of technologies to produce 99 Mo without the use of HEU. Today, the global supply of 99 Mo depends on a limited number of nuclear reactors, and production has been interrupted unexpectedly since 2009 due to the fleet’s advanced age. Herein, alternative options for 99 Mo production are discussed, and one potential option is to obtain 99m Tc from molten salt reactors (MSRs). A MSR is a nuclear fission reactor that can operate at or close to atmospheric pressure with liquid fuel, which allows for producing isotopes in a timely manner. In this paper, the past and current production of 99 Mo via nuclear reactors is described, and the future of 99 Mo production by MSRs is discussed. The behavior and chemical properties of molybdenum in fluoride salts in MSRs and the possible extraction methods are also examined in addition to the limitation of current studies.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2023

Fuel Salt Information Needed to Support Safety Adequacy Assessment [Slides]

This presentation provides an overview of the information needed to support fuel salt safety adequacy assessment. It provides a discussion of fuel salt qualification and developing a mechanistic source term. This presentation includes discussion the use of total stored energy release as a means to bound potential accidents.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2026

Analysis of Molten Salt Thermal Energy Storage Tank Sizing and Preheating

Molten Salt Thermal energy storage (TES) is essential for concentrating solar power (CSP) plants, enhancing their capacity factor and dispatchability to ultimately reduce electricity costs. This technology is becoming more important for other technologies including nuclear power, thermal-electrical storage, and concentrating solar thermal (CST). While molten salt TES tanks have been successfully deployed in lower-temperature parabolic-trough plants, the current state-of-the-art central receiver systems operating at temperatures up to 565 degrees Celsius have experienced costly and frequent failures. These failures are associated with the immaturity of the technology and problems in tank design, fabrication, commissioning and, sometimes, aggressive operation. A primary contributing factor is the absence of a dedicated technical standard for high-temperature molten nitrate TES tanks; designers must currently rely on existing codes like API 650 and ASME Section II, which are insufficient because they fail to account for the unique demands of high temperatures, thermal cycling, and transient conditions.

25 ENERGY STORAGE↗
DOE OSTI2024

Influence of Carboxymethyl Cellulose as a Thickening Agent for Glauber’s Salt-Based Low Temperature PCM

This work is focused on a novel, promising low temperature phase change material (PCM), based on the eutectic Glauber’s salt composition. To allow phase transition within the refrigeration range of temperatures of +5 °C to +12 °C, combined with a high repeatability of melting–freezing processes, and minimized subcooling, the application of three variants of sodium carboxymethyl cellulose (Na-CMC) with distinct molecular weights (700,000, 250,000, and 90,000) is considered. The primary objective is to optimize the stabilization of this eutectic PCM formulation, while maintaining the desired enthalpy level. Preparation methods are refined to ensure repeatability in mixing components, thereby optimizing performance and stability. Additionally, the influence of Na-CMC molecular weight on stabilization is examined through differential scanning calorimetry (DSC), T-history, and rheology tests. The PCM formulation of interest builds upon prior research in which borax, ammonium chloride, and potassium chloride were used as additives to sodium sulfate decahydrate (Glauber’s salt), prioritizing environmentally responsible materials. The results reveal that CMC with molecular weights of 250 kg/mol and 90 kg/mol effectively stabilize the PCM without phase separation issues, slowing crystallization kinetics. Conversely, CMC of 700 kg/mol proved ineffective due to the disruption of gel formation at its low gel point, hindering higher concentrations. Calculations of ionic concentration indicate higher Na ion content in PCM stabilized with 90 kg/mol CMC, suggesting increased ionic interactions and gel strength. A tradeoff is discovered between the faster crystallization in lower molecular weight CMC and the higher concentration required, which increases the amount of inert material that does not participate in the phase transition. After thermal cycling, the best formulation had a latent heat of 130 J/g with no supercooling, demonstrating excellent performance. This work advances PCM’s reliability as a thermal energy storage solution for diverse applications and highlights the complex relationship between Na-CMC molecular weight and PCM stabilization.

25 ENERGY STORAGE↗
DOE OSTI2023

Conceptual Design of a Salt Dechlorination and Vitrification Apparatus

The dechlorination and vitrification apparatus (DeVA) discussed in this report is a prototype conceptualization of a device that could be used to remove halogens from salt-based waste streams so that the remaining salt cations can be converted to oxides and immobilized in a glass-based waste form.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Over-Stoichiometric Metastabilization of Cation-Disordered Rock Salts

Cation-disordered rock salts (DRXs) are well known for their potential to realize the goal of achieving scalable Ni- and Co-free high-energy-density Li-ion batteries. Unlike in most cathode materials, the disordered cation distribution may lead to more factors that control the electrochemistry of DRXs. An important variable that is not emphasized by research community is regarding whether a DRX exists in a more thermodynamically stable form or a more metastable form. Moreover, within the scope of metastable DRXs, over-stoichiometric DRXs, which allow relaxation of the site balance constraint of a rock salt structure, are particularly underexplored. In this work, these findings are reported in locating a generally applicable approach to “metastabilize” thermodynamically stable Mn-based DRXs to metastable ones by introducing Li over-stoichiometry. Further, the over-stoichiometric metastabilization greatly stimulates more redox activities, enables better reversibility of Li deintercalation/intercalation, and changes the energy storage mechanism. The metastabilized DRXs can be transformed back to the thermodynamically stable form, which also reverts the electrochemical properties, further contrasting the two categories of DRXs. This work enriches the structural and compositional space of DRX families and adds new pathways for rationally tuning the properties of DRX cathodes.

25 ENERGY STORAGE↗
DOE OSTI2022

Unveiling Charge Transport and Degradation Mechanisms of Aqueous Zn|α-MoO 3 Batteries in Conventional Concentration and Water-in-Salt Electrolytes: A Multi-Modal In Situ and Operando Study

Herein charge storage and transport properties are elucidated and cell degradation mechanisms of rechargeable aqueous Zn|alpha-MoO 3 batteries in three electrolyte systems (3 m ZnSO 4 , 3 m ZnCl 2 , and 30 m ZnCl 2 [12.5 m] water-in-salt (WIS)) are distinguished by a combination of in situ X-ray diffraction (XRD), in situ X-ray absorption spectroscopy (XAS), operando optoelectrochemistry, and operando energy dispersive X-ray diffraction (EDXRD). In conventional concentration 3 m electrolytes, in situ XRD and XAS, as well as ex situ scanning transmission electron microscopy data collectively support Zn 2+ as the primary charge carrier. In addition, these systems are susceptible to cathode dissolution, Zn corrosion coupled with the hydrogen evolution reaction, and the resultant formation of basic zinc salt phases. The multi-modal in situ and operando experimental analyses validate facile H+ intercalation and extraction in concentrated 30 m ZnCl 2 WIS electrolyte. Via operando EDXRD, reaction front and charge transport limitation during discharge and charge in the viscous WIS electrolyte are spatially tracked. Here this work provides new insight into the stability and degradation mechanisms of aqueous zinc batteries during static storage and upon dynamic cycling, and highlights the utility of in situ and operando techniques in understanding the superior stability of WIS electrolytes.

25 ENERGY STORAGE↗
DOE OSTI2022

Molten-Salt Synthesis of O 3 -Type Layered Oxide Single Crystal Cathodes with Controlled Morphology towards Long-Life Sodium-Ion Batteries

Sodium layered oxides show great promise as affordable alternatives to lithium layered oxides, but their poor cycle life and air stability limit their practical potential. Micron-scale single crystals with greater packing density and lower surface area can overcome these challenges and improve performance compared to the traditional polycrystalline morphology. Herein, the authors present the synthesis of layered O 3 -type Na(Ni 0.3 Fe 0.4 Mn 0.3 )O 2 single-crystals with greatly improved cycle life and air stability. A molten-salt synthesis technique is adopted with excess sodium hydroxide to obtain platelet-like single crystals. Because the main mechanisms of both capacity fade and air degradation occur as a result of surface reactions at the opening of the sodium diffusion channels, particle morphology is found to be a critical metric for materials performance. More important than particle size or total surface area, the smaller proportion of exposed edge planes in the platelet morphology greatly reduces the amount of harmful surface reactions. Furthermore, the molten-salt method is found to eliminate the need for coprecipitated precursors and even form better morphology, starting from metal oxides instead of coprecipitated hydroxides.

25 ENERGY STORAGE↗