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All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Evaluation of the Potential for Precipitation of Solids during Storage of Non-Aluminum SNF Solutions

Non-aluminum clad spent nuclear fuels (NASNF) stored in the L-Area basin will be dissolved in H-Canyon using the 6.3D electrolytic dissolver. The solutions will be stored in either the hot or warm canyon until the preparation of a sludge batch for the Defense Waste Processing Facility. Spent nuclear fuel solutions could be stored for 1-2 years before transfer to the H-Area Tank Farm depending on the interval between sludge batches. The solution level in the storage tanks will be maintained; therefore, precipitation of solids due to evaporation is not an issue. However, the precipitation of solids from completely dissolved SNF due to solution instabilities has been observed during intermediate storage of solutions generating hydrated oxides.The presence of fissile material in these solids is generally associated with zirconium molybdate, which is known to act as a host lattice for Pu and can carry the actinides upon precipitation. The formation of zirconium molybdate solids which carry fissile material is a potential concern for the storage of NASNF solutions. To address this concern, the Savannah River National Laboratory performed a literature review to identify knowledge gaps which may require experimental work to determine if the formation of solids is a concern during storage of these solutions. Based on the literature review, the precipitation of zirconium molybdate solids from the Campaign 1 NASNF solutions during intermediatestorage is expected. This conclusion is supported by the identification of zirconium molybdate solids found on the H-Canyon 6.1D Dissolver MK-12 insert spacer. The formation of the zirconium molybdate solids is attributed to hydrolysis and radiolytic processes in the nitric acid solution. As the molybdate solids form, U and Pu can substitute for Zr in the crystal lattice resulting in co-precipitation. Generally, the Pu substitutes directly into the crystal lattice during precipitation while the U associated with the molybdate solids more likely absorbs from the solution. The U in the NASNF solutions is present as uranyl nitrate, a 2+ cation which will not substitute as easily into the molybdate crystal lattice for the Zr 4+ ion.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

Key Degradation Products in Nitroplasticizer Thermal Aging

Upon thermal aging, nitroplasticizer (NP) can thermally degrade and release numerous degradation products depending on aging conditions. In this report, we summarize our recent findings, a library of key degradation products in the NP thermal aging is provided. The library contains 25 identified species with their corresponding MS/MS spectrum and intensity profiles, which are derived from our 44-month thermal aging experiment of NP conducted in air, nitrogen, and water at room temperature (RT), 38, 45, 55, and 64°C. To provide a comprehensive yet simplified overview of NP degradation, we summarized the proposed mechanisms of HONO elimination and decomposition, acid generation, PBNA nitrosation and nitration, acid-catalyzed hydrolyses of NP and polynitrated PBNAs, as well as the formation of NP degradants. As the last part of a series of publications and reports on the investigation of NP degradation mechanisms, this work further unfolds complex chemistry that occurs in the entire aging process of NP.

36 MATERIALS SCIENCE↗
DOE OSTI2024

LCO Synthesis by Sol-Gel Method

The synthesis of Lanthanum Cobalt Oxide (LCO) via Sol-Gel method provides a potentially low-cost method of production for a P-type photocatalytic. LCO was prepped from Lanthanum and Nitrate Precursors in Aqueous solution. After a significant amount of water is evaporated, the solution is deposited onto SiO2 substrate via spin-deposition method. After annealing, the samples produce thin film LCO that display thickness of sub-500 nanometers. The samples material profile is confirmed by both Raman spectroscopy and X-Ray Diffraction spectroscopy (XRD). Additionally, two-point probing tested the conductivity of the samples. The thin film samples display characteristics of a P-type photocatalytic and may potentially be used in the formation of a P-N junction for user in water-splitting applications.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Simultaneous Thermal Analysis of Anion and Cation Exchange Resins

The decomposition reactions of one anion exchange resin (Bio-Rad AG MP-1) and one cerium-loaded cation exchange resin (DOWEX 50W-X8), both in nitrate form, were analyzed using simultaneous thermal analysis methods. Thermogravimetric analysis, dynamic scanning calorimetry, and evolved gas analysis were deployed in combination to probe the temperature profiles, reaction enthalpies, and off-gases from these resins under process-relevant temperature ranges. Analysis indicates that both resins undergo three clear phases during heating. The first is a dehydration step with prominent off-gassing of water, the second is a decomposition step with evolution of several gaseous species, and lastly is a combustion step with a large release of CO 2 . The temperature at which combustion ends varies slightly between AG MP-1 and DOWEX 50W: combustion completed at ~690°C and ~810°C, respectively. For the DOWEX cation resin, the combustion reaction showed greater sensitivity to the availability of oxygen under the test conditions. Both resins displayed broad exotherms during the combustion step of the decomposition, but the DOWEX cation resin demonstrated a 4.5 times higher specific enthalpy than that of the AG MP-1.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Characterizing Bioavailable Soil Nutrients Across Coastal Systems: Western Lake Erie and Chesapeake Bay

Terrestrial Aquatic Interfaces (TAIs), defined as where land meets water, exhibit important hydrological, biological, and biogeochemical dynamics and play a critical role in the Earth’s carbon cycle. Current Earth System Models improperly represent this role due to the complexity of these systems and the disproportionally large impact TAIs have relative to their area. To improve our predictive capacity of coastal system dynamics, a better understanding of carbon and nutrient cycling across TAI’s is needed. Coastal Observations, Mechanisms, and Predictions Across Systems and Scales (COMPASS) aims to achieve this through field observations and laboratory incubations throughout the Western Lake Erie and Chesapeake Bay regions. Here, we report on preliminary results from a soil characterization experiment across the WLE and CB regions. This experiment was conducted as part of the 2-year field, measurements, and experiments (FME) pilot study portion of COMPASS to provide initial baseline data for the sites and to characterize the spatial variability of our analytes. Soil samples were collected from three locations along the TAI transect (upland forest, transitional forest, and wetland) and analyzed for bioavailable nutrients using three types of extractions: (a) water extractions, (b) 2M KCl extractions, and (c) 1M NH4Cl extractions to analyze (a) water soluble organic carbon (WSOC), (b) ammonium and nitrate, and (c) base cations, including Ca, Mg, Na, K, and Fe. These analyses, in conjunction with other bulk physicochemical analyses, will help establish baseline understanding of these sites to drive future research and design focused experiments that will ultimately improve our predictive understanding of these freshwater and marine coastal TAIs and their response to short and long-term changes.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

PM2.5 Active Aerosol Collection Field Campaign Report

The long-range transport of aerosols can affect local air quality as well as contribute elements and constituents to mountain watersheds that have potentially positive (e.g., nitrate) and negative (e.g., heavy metals) effects to the local ecosystem. Isotopic analysis of aerosols can be a powerful tool for deconvolving the relative contributions of far-distant and local sources to the composition of collected aerosols. Our field campaign involved the week-long collection of PM2.5 (i.e., particulate matter with an aerodynamic diameter of about 2.5 microns) aerosols on filters, which were returned to the laboratories at Lawrence Berkeley National Laboratory (LBNL) for analysis. The sampling sites were located at the Gothic, Colorado Surface Atmosphere Integrated Field Laboratory (SAIL) Atmospheric Radiation Measurement (ARM) and the Mt. Crested Butte, Colorado SAIL ARM sites. The original intention was to measure the lead (Pb) and strontium (Sr) isotopic compositions of the collected aerosols at high precision to provide constraints on source portioning and attribution, as well as analyze the chemical compositions and nitrogen and carbon isotopic compositions. However, severe blank issues arose that prevented the planned isotopic analyses of Sr, Pb, C, and N and severely affected the analyses of the bulk chemical compositions of the collected aerosols, resulting in the failure of the study. The issue is described in Section 2.0.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

Salt Tank Testbed: a Test Site Designed to Replicate Floor Buckles Observed in Commercial TES Tanks

A test site has been designed and is under construction to replicate the buckling failure ob-served in several in-service storage tanks for nitrate salts operating up to 565°C. In commercial tanks multiple factors have been identified that influence the floors susceptibility to buck-ling, including: the as-manufactured shape of the floor, high compressive stresses due to thermal gradients and/or friction, fluid inventory and absolute temperature. Based on exten-sive modeling analysis it was determined that similar buckles can be reproduced in a scaled test tank (approximately 9x smaller than a representative commercial tank design). To buckle the scaled tank a radial thermal gradient is generated in the tank with a low fluid level, the fluid level is then increased while maintaining the thermal gradient; based on the modeling results just one of these cycles can plastically deform the tank floor. The test site which is under construction is designed to replicate this damaging cycle at lower temperatures. The goal of testing will be to reproduce this damaging cycle and buckle the scaled test tank floor, allowing proper model validation and a methodology for comparing different tank designs at a smaller (and less costly) scale.

25 ENERGY STORAGE↗
DOE OSTI2025

Reinventing wastewater treatment plants: energy neutral treatment and enhanced fertilizer production through a novel resource recovery center

Wastewater treatment plants (WWTPs) are typically energy intensive, mainly due to the secondary treatment processes such as activated sludge (AS) for treatment of organics as well as nutrients like nitrogen. Nitrogen removal presents a big problem for WWTPs. The main form of nitrogen in wastewater is ammonium, and an AS process uses oxygen to convert ammonium into nitrite and nitrate which is then converted to nitrogen through denitrification process. During anaerobic digestion (AD), organic nitrogen gets degraded, resulting in an effluent stream (centrate) with a high nitrogen content, mostly in the form of ammonium. This contributes 15-30% of total nitrogen to the wastewater influent which further increases energy consumption for aeration. The project aims to transform this conventional municipal WWTPs into energy-neutral, resource-recovering facilities by integrating three core technologies: • Cloth Media Filtration (CMF) to replace conventional primary sedimentation (CPS) and increase the diversion of organics from the energy intensive secondary treatment to AD. This results in reduced energy demand for aeration in the secondary process while simultaneously increasing the biogas production in the anaerobic digesters. • Anerobic Digester to increase biogas and ammonia production. • Membrane Evaporation (ME) to recover ammonia from AD centrate and produce marketable fertilizer. The benefits of proposed WWTP process modifications were evaluated using techno economic analysis (TEA) and life cycle assessment (LCA). For CMF portion of the research a statistical analysis was employed to develop data-driven tools that could be used to enhance and optimize its performance in terms of energy savings and effluent quality. The main objective of this project is to reduce the energy demand for secondary treatment at municipal WWTPs by at least 50%, increase anaerobic digester (AD) biogas and ammonia production by 100% and 120%, respectively, and recover 90% of ammonia from the AD. Integrated CMF, AD, and ME was shown to work synergistically toward achieving these decarbonization targets through energy-positive treatment and fertilizer recovery techniques.

42 ENGINEERING↗
DOE OSTI2025

Fractionation of Filamentous Algae from Mixed Biofilms

Filamentous algae, which grow in long, hair-like filaments within biofilms, play a crucial role in wastewater treatment due to their ability to produce significant biomass and their resistance to predation compared to traditional microalgal treatments. These algae can effectively uptake and utilize pollutants, particularly excessive nitrogen (ammonia, nitrate, nitrite) and phosphorus (phosphate), making filamentous algae valuable for wastewater treatment, as well as bioethanol and biodiesel production due to high lipid productions. However, each algal species possesses different capacities, necessitating a thorough genetic identification and understanding of each community. A major challenge in accurately assessing these communities is the lack of coverage in large sequencing databases which can lead to misrepresentation of the true composition and abundance of organisms and overall sequencing bias. To address this, I evaluated chemical and physical techniques for separating filamentous algae from mixed biofilms to achieve clean genetic sequencing results. I employed pH washing (0.001M HCl, 0.001M HCl, DiH2O, 0.0001M HCl, 0.001M HCl) for chemical treatment, followed by physical separation through centrifugation (5000rpm, 6500rpm) or filtration (2mm, 250um, 75um). The most successful method was deionized water washing, which yielded clear differences across stacked filters; the 2mm filtrate showed high levels of filamentous algae, with microalgae eluting in the 75um filtrate or remaining within agglutinations of algae larger filters. Base washing eluted the highest concentrations of microalgae, with larger filter sizes retaining more filamentous algae, indicating the breakdown of extracellular polymeric substances (EPS). Our downstream plans include sending the high-throughput next-generation sequencing to confirm the purity and ratios of filamentous and non-filamentous algae, as well as bacteria present, thereby validating the success of our treatments. Potential applications include creating community-based fractions for analysis, refining current sequencing data with clearer isolations, and generating designer biofilms to enhance our understanding of community interactions.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2025

Ammonia Decomposition Catalyst Development for Palladium Membrane Reactor

Conclusions and Questions • Tritiated ammonia is a persistent problem in tritium operations. • Tritiated ammonia can be completely converted to nitrogen and tritium using a permeation membrane reactor. • Ruthenium trimetallic catalysts are highly active at PdAg temperatures. • Catalysts from nitrate precursors are more active than from chloride. • Nickel-based catalysts are potential replacements for ruthenium catalysts.

Guin, Tyler [Savannah River National Laboratory (S↗
DOE OSTI2025

Electrochemical Denitration and Caustic Generation (EDCGe) System: Year One Project Report

An advanced electrochemical denitration and caustic generation (EDCGe) system is being developed to process legacy waste through the direct feed high-level waste (DFHLW) flowsheet at Hanford. This system aims to destroy nitrates and organics in DFHLW and potentially DFHLAW feeds, significantly reducing off-gas concerns from both process safety and process flowsheet perspectives. Supported by a multidisciplinary team, this effort includes creating a tandem denitration electrolyzer/off-gas system as part of a broader mission to accelerate waste treatment through fundamental and applied research and development initiatives. The progress for the first year of the three-year program to develop technology for the EDCGe system is described within this document.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2025

Rapid Oxidation of Uranium Steel Alloys: Combustion Synthesis

This project explored the use of combustion synthesis as a rapid, high-temperature method for oxidizing uranium-bearing steel alloys. Traditional laboratory-scale synthesis methods often fail to replicate the thermal and kinetic conditions experienced by real-world particulates, particularly those formed under rapid quenching or high-temperature scenarios. Combustion synthesis offers a promising alternative by enabling fast, localized heating and flexible precursor selection. A series of targeted experiments were conducted using a U 2 NiCrFe 4 alloy as the precursor. The alloy was oxidized using combustion synthesis reactions fueled by uranyl nitrate and glycine, achieving peak temperatures exceeding 1,200 °C. Postreaction analysis using scanning electron microscopy (SEM), elemental mapping, and Raman spectroscopy revealed the formation of iron-based oxides, with limited but detectable evidence of uranium oxide phases such as UO 2 . The results indicate that under the rapid reaction and cooling conditions of combustion synthesis, iron oxides form preferentially, but uranium oxide formation is kinetically limited. These findings validate combustion synthesis as a viable method for simulating the oxidation behavior of uranium steels in extreme environments and lay the groundwork for future studies aimed at enhancing uranium oxide formation through higher temperatures or modified precursor compositions.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Application of Raman Spectroscopy to Determine Uranium Content in ADUN Solution

The work presented in this report is part of the ongoing efforts to address the nuclear material control and accounting needs for advanced reactor fuel fabrication facilities. This work was supported by the Materials Protection, Accounting, and Control Technologies (MPACT) program under the US Department of Energy Office of Nuclear Energy‘s Nuclear Fuel Cycle and Supply Chain program. The activities and engagements under the MPACT program are designed to support a robust US civilian nuclear energy enterprise. In the work described in this report, we supported MPACT objectives by developing measurement techniques that could be used for material accounting and process monitoring and by working with industry partners to identify existing gaps and areas for improvement. Oak Ridge National Laboratory has been working with commercial tristructural isotropic (TRISO) fuel fabricators such as Standard Nuclear to develop technology for rapid and cost-effective uranium content assessment. This work has focused on demonstrating advanced measurement techniques (e.g., Raman spectroscopy) that can be used for rapid, reliable, and cost-effective routine measurements of uranium content in feed solutions and liquid waste streams as well as for monitoring in-line process measurements and product streams. Specifically, this report explores techniques for accurately determining uranium content in acid-deficient uranyl nitrate (ADUN) solutions and detecting low uranium concentrations in ammonia solutions. Developing such measurement techniques will benefit TRISO fuel fabrication facilities, facilities involved in other parts of the fuel cycle that require online monitoring of aqueous solutions, and potentially molten salt fuel reactors. This work supports developing Raman spectroscopy procedures to determine uranium concentrations in ADUN solutions, which are used as feedstock in the sol–gel process for creating TRISO fuel. Some additional benefits of using Raman spectroscopy for uranium quantification in fabrication facilities include enabling online monitoring of the chemical process, which would provide near real-time feedback; eliminating the need for sample transfers, preparation, or dilution; providing nondestructive measurements; and user friendliness. In this fiscal year, FY25, we determined the identity of the unknown Raman band at approximately 853 cm−1 that was discovered in ADUN Raman spectra in FY24, created calibration curves and determined uranium concentrations of two ADUN solutions, and compared the Raman results to results obtained from inductively coupled plasma mass spectrometry and Davies–Gray titration. Furthermore, we have identified focus areas for experimentation in future fiscal years. A key result is that the accuracy of using Raman can provide accuracy comparable to destructive analysist techniques, With a well-developed calibration curve, using standards and a large number of samples (more than five samples), uncertainty on the order of 1%–3% is achievable. Given that the uncertainties achieved by Raman spectroscopy were on the order of the uncertainties achieved using ICP-MS, we conclude that with a well-developed procedure Raman spectroscopy can be used to determine uranium concentrations in ADUN solutions for NMC&A applications. The benefits of such an approach are that the time and effort will be less than that of comparable destructive analysis techniques, with approximately the same level of technical expertise. This will be attractive to operators of fuel fabrication facilities as it will lower costs and improve efficiencies.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Measurements and Analyses to Enable Science for the Eastern Pacific Cloud Aerosol Precipitation Experiment (EPCAPE)

Coastal cities provide the opportunity to characterize the substantial effects of manmade particles on marine cloud properties and processes. La Jolla lies to the north of San Diego, California, but it is often about a day directly downwind of the major pollution sources located in the ports of Los Angeles and Long Beach. The large dynamic range of aerosol particle concentrations combined with the multi-hour to multi-day persistence of stratocumulus cloud layers makes the site ideal for investigating the seasonal changes in cloud and aerosol properties as well as the quantitative relationships between cloud and aerosol properties. The Eastern Pacific Cloud Aerosol Precipitation Experiment (EPCAPE) characterized the extent, radiative properties, aerosol interactions, and precipitation characteristics of stratocumulus clouds in the Eastern Pacific across all four seasons at two coastal sites in La Jolla. This project was designed to enhance and expand the scientific uses of the ARM AMF1 measurements from EPCAPE. The goal was to ensure meaningful observations were collected that would enable science. The project included the following objectives: (1) Reviewing the ARM AMF1 measurements [ARM, 2021a; b] and circulating a summary of the measurements each week, (2) Comparing AMF1 measurements to those provided by collaborators (including filter measurements at the pier), (3) Collecting and analyzing filter samples from Scripps Pier by Fourier Transform Infrared spectroscopy (FTIR) and X-ray Fluorescence (XRF), (4) Assisting in operations of instruments provided by Guest PIs when possible, and (5) Providing an initial compilation of EPCAPE aerosol and cloud seasonal differences. The expected outcomes of these objectives were enhanced proposals and publications using EPCAPE measurements by helping to identify instrument issues, expanded data access and awareness by distributing weekly plots and related summaries, improved source-related attribution of aerosols with elemental tracers, additional observations provided by Guest PIs, and accelerated ACI studies enabled by the compiled seasonal summaries of aerosol and cloud properties. Three examples of the science enabled by this project are findings that (i) aerosol and cloud aqueous production contributes more than half of sulfate particle mass concentration, (ii) upwind sources make chemical composition very similar at nearby sites despite local differences in meteorology, and (iii) most of the large mass concentration of semi-volatile organic components is co-emitted and co-evaporated with nitrate. Together these findings illustrate how ARM extended field campaigns in coastal regions can be used to constrain ACI processes with direct observations. By using the unique ARM suite of cloud radiative products in addition to the measured aerosol properties at a coastal location, we were able to address the more specific question of which aerosol particles cause how much of the effects on clouds. Identifying this signature in coastal areas provides an opportunity to test the representation of aerosol sources by global models in a range of clean and urban-influenced conditions.

Russell, Lynn [Univ. of California, San Diego, CA ↗
DOE OSTI2021

Bismuth-Functionalized Silica Aerogels for Iodine Capture

The U.S. Department of Energy is looking into alternative sorbents for the removal of radioiodine from off-gas streams in a used nuclear fuel reprocessing plant. One class of sorbents considered are bismuth-functionalized silica aerogels which offer an efficient capture of iodine from off-gas streams and are environmentally friendly and lower cost when compared to silver-functionalized sorbents. Two types of bismuth-functionalized silica aerogels were successfully manufactured using a hierarchical synthesis approach:1) The Bi 3+ -aerogel with bismuth oxide nitrate hydroxide hydrate particles and 2) Bi-aerogel with bismuth metal and bismuth sulfide nanoparticles. Both sorbents exhibited high sorption capacity for iodine. However, presence of particles of different composition, size, and distribution on aerogel support resulted in different iodine loadings. The Bi 3+ -aerogel exhibited sorption capacity of 289 mg/g. In contrast, Bi-aerogel exhibited more that 20% higher sorption capacity. The heat-treatment of Bi 3+ -aerogel at 225? under hydrogen atmosphere increased iodine loading capacity to 351 mg/g.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2026

Pilot Development Progress to Demonstrate Electric Thermal Energy Storage (ETES) Using Low-Cost Particles

The rapid growth of future energy demand increases the need to economically store electrical energy over durations up to several days in long-duration energy storage (LDES) applications. LDES can reduce the grid stress for improving the resilience of the grid. The integration of renewable power and storage has several significant and positive impacts including expanding the renewable energy portion of electricity generation, meeting peak-load demand, and coordinating supply and demand. Several energy storage approaches including mechanical, chemical and electrochemical methods are currently deployed or under development. However, LDES requirements pose unique challenges for scalability, energy capacity, and cost. Thermal energy storage (TES) has the ability to store a large capacity of energy with improved site flexibility compared to incumbent LDES technologies (i.e., pumped hydro) and has attracted significant interest. Our development in TES technology using solid particles as the storage medium has shown feasibility and potential in serving LDES purposes. Particle TES has various advantages over commercialized molten nitrate salt TES and has emerged as a promising storage technology originating from Generation 3 concentrating solar power (CSP) development. Stable, inexpensive silica sand produced in the Midwestern U.S. was identified as a suitable storage medium and has been validated through lab heating and cycling tests. We have successfully developed particle TES for bidirectional electric energy storage to broaden the applications for TES beyond CSP technologies and into standalone electric-thermal energy storage (ETES) systems. Key component designs and performance were verified with prototype testing and model simulations. The ETES system uses high-temperature, low-cost particle thermal energy storage coupled with a unique pressurized fluidized bed heat exchanger that supports a high-efficiency, air-Brayton combined power cycle. At times of low energy demand or high renewable production, an electric particle heater heats large quantities of solid particles to high temperatures in excess of 1100 degrees C. The particles are stored in internally insulated silos. At times of high electricity demand, the hot particles are gravity-fed through the heat exchanger where stored thermal energy is transferred to the power cycle working fluid to drive the gas turbine power generation system, thereby converting the thermal energy back into electricity for the grid. The cold particles leaving the heat exchanger are returned to the storage silos by a well-insulated particle conveyor. This ETES technology using particle TES can be sited anywhere and is predicted to be economic and efficient. Moreover, this ETES technology could be co-located with a retired coal or gas plant to leverage existing power generation and grid infrastructure. Our work has focused on the development of each of the key components (e.g., the electric particle heater, particle storage silos, and the particle-to-gas pressurized fluidized bed heat exchanger) through conceptual designs, prototype testing, and computational modeling. These developments demonstrate technological feasibility and are an important step towards the next phase of development of this promising LDES technology. This presentation will show the progress in developing a pilot demonstration of the ETES system on a commercially relevant scale.

25 ENERGY STORAGE↗
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 OSTI2026

Operational Parameter Database for Molten Salt Thermal Energy Storage Tank Modeling

The second generation of concentrated solar power (CSP) plants is characterized by the use of a central receiver (either cavity or external), two molten nitrate salt tanks (60 wt.% NaNO 3 and 40 wt.% KNO 3 ), and a steam Rankine power-generation cycle connected through a primary heat exchanger. Molten salt thermal energy storage (TES) tanks have been widely deployed in commercial CSP plants worldwide and have been essential for increasing plant dispatchability and capacity factor, while also reducing the levelized cost of electricity (LCOE). These systems enable energy storage at the gigawatt-hour scale, typically providing 6 to 17 hours of storage duration. Despite being a commercial technology, the multiple failures observed after only a few months or years of operation in plants around the world demonstrate the technology's relative infancy and highlight the need for further research to improve its reliability. The National Laboratory of the Rockies (NLR), in collaboration with industry partners and academic and research institutions, has been leading multiple projects funded by the U.S. Department of Energy (DOE). These projects focus on addressing molten salt tank failures by improving tank design and welding fabrication practices, evaluating new alloys and weld fillers, and providing guidelines for tank commissioning and safe operation. In particular, this report presents modeling results on the effect of key tank operation parameters during 60 minutes of operation, including the mass flow rate and temperature of the salt inflow, tank salt inventory temperature, and inventory level for a representative molten salt tank design. These results form a database of tank operation behaviors that captures the effects of each specific parameter during charging, charging/discharging, and discharging processes.

14 SOLAR ENERGY↗