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All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Evacuations: Reva Hurwitz, The Red Cross, and Operation Crossroads

On April 1, 1946, an earthquake off Unimak Island, Alaska, generated a tsunami that raced across the Pacific. One of the islands in danger was Kwajalein, the logistical hub for Operation Crossroads. Commodore Ben Wyatt, the U.S. naval commander of the Marshall Islands, ordered the evacuation of “10 Red Cross workers, 19 USO women, 17 native women, 16 male [hospital] patients, four tiny babies, one small boy, and two navy doctors,” to the USS Rockbridge, which then steamed in deep water off the atoll until the danger passed. One of the Red Cross workers, Reva Hurwitz, played bridge in the ship’s wardroom until 2 a.m., a luxury since the island curfew, strictly enforced, was 10:30 pm. The tsunami bypassed Kwajalein, and everyone returned to the island less than twenty-four hours after being evacuated. Although the evacuation proved unnecessary, the women were grateful, said Hurwitz, because they had the opportunity “to use hot water and eat fresh fruit.”

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2017

Review and Future Perspective of Central Receiver Design and Performance

Concentrating solar power (CSP) technology provides a commercial solar option to the utility-scale electricity market. CSP is unique in its ability to include low-cost thermal storage; thus, it can generate electricity when the sun is not available and dispatch electricity to meet varying load requirements. Within the suite of CSP technologies, the central receiver design represents the state-of-the-art technology, promising low cost, high performance, and dispatchable energy production. Current total capacity of central receiver plants worldwide is about 1.0 gigawatt (electric) with operating plants in Spain and the United States, as well as projects under construction in Asia, the Middle East, and North Africa. Central receiver technology has been under development since the 1950s, and a variety of central receiver designs have been explored. A distinguishing feature is the heat transfer medium. Central receiver designs exist that use dense fluids, gases, and solid particles in this role. Water/steam and molten salt receivers have been adopted in current commercial plants and are often coupled with a steam-Rankine power cycle with an operating temperature of less than 600 degrees C. Many new central receiver concepts, such as the volumetric air, supercritical carbon dioxide (sCO2), solid particle, and liquid-metal receiver designs, are under active research and development (R&D). New designs target operating temperatures generally higher than 700 degrees C-800 degrees C -- and even above 1000 degrees C -- so that higher-performance power cycles such as the sCO2-Brayton cycle or air-Brayton/steam-Rankine combined cycle can be used to promote greater overall system efficiency. Central receiver thermal storage provides dispatchability unavailable from variable-output renewables such as solar photovoltaic and wind power. Case study analysis of the California grid shows that there is a limit on the amount of non-dispatchable renewable generation that the grid can accommodate, beyond which overgeneration, spillage, and instability may occur. Energy storage may well become a necessity in some areas in order to maintain reliability. Next-generation central receiver technologies will have higher operating temperatures and additional features that allow higher-efficiency power generation and deliver other cost-performance advantages. The underlying innovations will come from areas such as multi-physics modeling, high-temperature materials, novel power cycles and heat exchanger designs, and collector field sensing and performance monitoring technologies. Technology innovation is expected to improve the cost and performance of central receiver designs. To deliver value as a generation and storage option, central receiver technology must also be supported by flexible and robust financial models and comprehensive energy and ancillary service markets justifying the capital-intensive investment. Progress in these areas will position CSP central receiver technology for future deployment.

14 SOLAR ENERGY↗
DOE OSTI2014

Energy 101: Geothermal Energy

See how we can generate clean, renewable energy from hot water sources deep beneath the Earth's surface. The video highlights the basic principles at work in geothermal energy production, and illustrates three different ways the Earth's heat can be converted into electricity.

15 GEOTHERMAL ENERGY↗
DOE OSTI2017

Reducing Reaction Temperature, Steam Requirements, and Coke Formation During Methane Steam Reforming Using Electric Fields: A Microkinetic Modeling and Experimental Study

In this study, we approach several common problems with the Ni-catalyzed methane steam reformation reaction (MSR) using a two-pronged approach combining density functional theory (DFT) calculations with experimental work. Specifically, we look at the deactivation of a Ni catalyst due to coke formation, its high operating temperature requirements, and the high steam-to-methane (H 2 O/CH 4 ) ratio needed for proper MSR operation. A DFT-based microkinetic model was developed in the presence and absence of electric fields and the results were compared with experimental results. The microkinetic model shows that under various electric fields, the most favorable MSR mechanism changed slightly. It also shows that the presence of a positive electric field decreases the surface coverage of carbon, increases the water coverage, accelerates the rate-limiting step of the C-H bond cleavage in methane, and increases the desorption rates of the syngas product (CO + H 2 ) during MSR. Consequently, for a given methane conversion, a positive electric field allows for significantly lower H 2 O/CH 4 ratio and operating temperatures as compared to systems without an electric field. These findings correspond well with experimental tests under a variety of operating conditions. In addition, improvement in the catalytic activity due to the presence of a positive electric field remained significant even at industrially relevant applied pressures improving the hydrogen yield greatly. Overall, we find that an applied electric field can play a significant role in improving the catalytic activity of heterogeneous reactions. Here, this information can guide the design of heterogeneous reactions in the presence of an electric field. By utilizing the electric field generated by various renewable energy sources, electric field assisted heterogeneous reactions can open up a paradigm in future energy research.

03 NATURAL GAS↗
NASA NTRSDate not supplied

Foreign Object Damage in Yb 2 Si 2 O 7 Environmental Barrier Coatings

Environmental Barrier Coatings (EBCs) have been developed as an enabling technology for silicon carbide based ceramic matrix composites in gas turbine engines. Two of the key failure mechanisms identified in EBC systems are foreign object damage (FOD) and the oxidative growth of a SiO 2 thermally grown oxide (TGO) layer that can lead to premature coating spallation. Previously the effects of FOD on NASA’s second generation Ytterbium Disilicate EBC were studied and recently it was shown that the addition of oxide modifiers resulted in improved oxidation resistance in the EBC. This work will compare FOD of the baseline Ytterbium Disilicate EBC to the that of the modified EBC. FOD was performed at room temperature using a 1.59 mm hardened steel ball with projectile velocities of 50-300 m/s. Additionally, the effects of oxidation via cyclic steam exposure prior to impact were investigated.

environmental barrier coatings (EBCs)↗
DOE OSTI2023

FWP FEAA149: “Next Generation Environmental Barrier Coatings”

Environmental barrier coatings (EBCs) are required coatings for utilization of SiC/SiC ceramic matrix composite (CMC) components in gas turbines, where the EBC represents the life-limiting factor for such components. EBC/CMC systems have shown success in aero-engine applications with increased turbine inlet temperatures and improved efficiencies, which are achieved through higher temperature stability, lower density, and decreased reliance on cooling air compared to traditional superalloys. While industrial gas turbines (IGTs) do not currently utilize SiC/SiC CMCs, the current shift towards low-carbon or carbon-free fuel sources for power generation could result in a need for EBC/CMC components with higher temperature capabilities. In this work, three tasks were outlined to improve understanding of EBC lifetimes to encourage use in IGTs with carbon-free fuel such as hydrogen: 1. Define the bond coating oxidation kinetics and EBC failure criteria, 2. Measure thermal expansion coefficients of each layered material, and 3. Perform advanced characterization and modeling to assess EBC lifetimes. Cyclic steam oxidation tests were conducted on various EBC/Si/SiC chemistries and EBC/SiC architectures to define substrate oxidation kinetics and EBC failure modes. An open-source code was developed to quantify the undulating thermally grown oxide thickness with thousands of measurements from specimen cross-section images. Bond coating oxidation kinetics were determined and used to develop a kinetic and thermodynamic model for predicting EBC lifetimes. High-temperature Raman spectroscopy was utilized for determining the SiO 2 thermally grown oxide phase transformation as the life-limiting feature for EBCs. Model efforts supported the claim that the SiO 2 phase transformation causes elevated stress during thermal cycling with associated cracking that decreases the adhesion strength of the EBC, eventually resulting in coating spallation. The finite element model subroutine will be made publicly available upon internal review. Further development of an EBC lifetime model for IGTs involves definition of a critical SiO 2 thickness for EBC spallation and must also consider both environmental (gas velocity, pressure, etc.) and specimen (EBC dopants, layer architectures, etc.) effects into predicted bond coating oxidation kinetics for long-lifetime components.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Thermal Integration of Advanced Nuclear Reactors with a Reference Refinery, Methanol Synthesis, and a Wood Pulp Plant (Rev.1)

The present report is intended to provide process flow diagrams (PFDs) and energy and mass balance data sheets for a U.S. industrial sector subset with which nuclear heat and power could be integrated—a subset that includes the oil refining, methanol and pulp and paper industries. Coupling options for integrating nuclear energy into these industries are quantitatively outlined for reference systems, and future work will extend this analysis in greater detail. Opportunities for integrating small modular nuclear reactors (SMNRs) were investigated for each of the industrial process configurations. Aspen HYSYS and Cycle-Tempo models for a high-temperature gas-cooled reactor were developed to evaluate the proposed integration. This introductory evaluation provides a general description and assessment of the operating principles, reactor coolant core outlet temperature, and reactor size to be integrated with industry. The industrial processes of oil refining and the production of methanol, pulp and paper were simulated by using Aspen HYSYS, Aspen Plus, and the PRELIM (Petroleum Refinery Life Cycle Inventory Model) tool to develop process details. Cycle-Tempo models then extend the process modeling results to obtain net energy demands (e.g., heat, steam, and electricity) when accounting for process steam and waste heat recovery. This information is intended to foster the analysis of integrating an SMNR to decarbonize industrial facilities. The SMNR would provide reliable, competitive, and sustainable clean energy while reducing carbon emissions and other environmental impacts, such as water withdrawals, consumption, and contamination. The refining industry, exhibited in Figure ES1, is a leading consumer of fossil -fuel-based heat, power, and hydrogen in the U.S. industrial sector, generating over 164 million metric tons (MMT) of CO 2 emissions in 2023. The overall mass and energy pertaining to a generalized complex refinery in the United States is reflected in Figure ES1, along with energy metrics regarding integration with a nuclear power plant (NPP). Data sheets were developed to indicate the energy requirements for the overall refinery and each refinery process. The data sheet for the overall refinery is shown in Table ES2.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2020

Process Heating Assessments Using DOE’s Manufacturing Energy Assessment Software for Utility Reduction (MEASUR) Tool Suite

Process heating is the most energy-intensive manufacturing process for most sectors of industry. To quantify energy savings from various energy conservation measures, the Department of Energy (DOE) sponsored the development of the Process Heating Assessment and Survey Tool (PHAST) and similar tools for other industrial systems in the early 2000s. It has been used extensively in the Save Energy Now Program’s Energy Savings Assessments and the Better Plants Program’s In-Plant Trainings. Since the initial development of the legacy tools, both computer operating systems and software development have evolved significantly. Thus, DOE has invested in the modernization of PHAST and other legacy software tools to create the Manufacturing Energy Assessment Software for Utility Reduction (MEASUR) tool suite. MEASUR offers a collection of software tools that can aid manufacturing facilities in improving the efficiency of energy systems and equipment (specifically pumps, fans, steam, and process heating) and in conducting “Energy Treasure Hunts”. Eventually, the tool will also add compressed air and process cooling systems. The Process Heating Assessment (PHA) module of MEASUR is an upgrade of the PHAST tool. PHA provides the means to model fuel-fired, steam-based, and electric process heating systems, covering process heating for most industrial plants in manufacturing sector. It also includes several key upgrades, including the ability to consider multi-component charge loads and account for several different areas of energy losses. The new tool includes a comprehensive flue gas calculator to quantify available heat and heat loss for various gaseous, liquid, and solid fuels and new heat loss calculators. It generates a report and a dynamic Sankey diagram to show the energy consumption in various areas of energy use. MEASUR has significantly improved the user experience by adopting a modern software design. This paper details the structure and workflow of PHA and presents a real-world case study to demonstrate energy savings quantification and MEASUR’s outstanding reporting capabilities.

Nimbalkar, Sachin U.↗
DOE OSTI2017

Orificed Flow Results for a Two-Phase Natural Circulation Loop

Researchers at University of Wisconsin - Madison have constructed a 1/4 scaled experimental facility to study the operation of a two-phase natural circulation decay heat removal system. The Reactor Cavity Cooling System (RCCS) is a decay heat removal safety system designed for high temperature generation IV reactors. The system removes decay heat by encircling the outside of the walls of the pressure/containment vessel with cooling channels. These channels are filled with either air in an open loop configuration or water in a closed loop configuration. Radiative and convective heat loads from the pressure vessel induce a buoyancy driven flow in the risers. In accident conditions, the water-based system reaches saturation and the resulting steam is vented off further removing heat until the water inventory is depleted. The water based system has been under investigation at University of Wisconsin - Madison for variations in performance under various flow restriction cases.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2020

Update on the United States Advanced Ultra-Supercritical Program with Full Scale Component Fabrication to Develop Utility Scale Power Plants with 760°C Steam Temperature

Following the successful completion of a 15-year effort to develop and test materials that would allow coal-fired power plants to be operated at advanced ultra-supercritical (A-USC) steam conditions, a United States-based consortium is presently engaged in Phase 2 of a project which includes an advanced manufacturing effort to complete US-based supply chain development for full commercial scale (800-850 MWe) A-USC components made of nickel-based alloys, components operating at up to 760°C. The project, funded under U.S. Department of Energy Award No. DE-FE0025064, falls under the US DOE overall goal to Develop cost-effective, reliable technologies to improve the efficiency of new and existing coal-fired power plants. A-USC steam cycles have the potential to improve cycle efficiency, reduce fuel costs, and reduce greenhouse gas emissions. Current development and demonstration efforts are focused on enabling the construction of A-USC plants, operating with steam temperatures as high as 1400°F (760°C) and steam pressures up to 5000 psi (35 MPa), which can potentially increase cycle efficiencies to 47% HHV (higher heating value), or approximately 50% LHV (lower heating value), and reduce CO 2 emissions by roughly 25%, compared to today’s U.S. fleet. A-USC technology provides a lower-cost method to reduce CO 2 emissions, compared to CO 2 capture technologies, while retaining a viable coal option for owners of coal generation assets. Among the specific goals of Phase 2 of the ComTest Project are to: validate that components made from advanced nickel-based alloys can operate and perform under A-USC conditions accelerate the development of a U.S.-based supply chain for the full complement of A-USC components close the remaining gaps and reduce the risks for manufacturing components from advanced materials for commercial demonstration fabricate full-scale versions of selected key components made of nickel-based alloys validate a qualified U.S. supply chain, to provide greater cost certainty for components obtain American Society of Mechanical Engineers (ASME) code approval for new materials, components and processes Additional benefit: Manufacturing technology will be applicable to other advanced fossil energy high temperature cycles, and can support increased flexibility of existing power plants The ComTest project is managed by Energy Industries of Ohio, and technically directed by the Electric Power Research Institute, Inc., with General Electric designing the A-USC components. As stated earlier, the current phase of the effort is primarily funded by the U.S. Department of Energy, through the National Energy Technology Laboratory. This presentation outlines the motivation for the project, explains the project’s structure and schedule, and provides some of the technical details on the design of the ComTest components.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2020

Update on the United States Advanced Ultra-Supercritical Program with Full Scale Component Fabrication to Develop Utility Scale Power Plants with 760°C Steam Temperature

Following the successful completion of a 15-year effort to develop and test materials that would allow coal-fired power plants to be operated at advanced ultra-supercritical (A-USC) steam conditions, a United States-based consortium is presently engaged in Phase 2 of a project which includes an advanced manufacturing effort to complete US-based supply chain development for full commercial scale (800-850 MWe) A-USC components made of nickel-based alloys, components operating at up to 760°C. The project, funded under U.S. Department of Energy Award No. DE-FE0025064, falls under the US DOE overall goal to Develop cost-effective, reliable technologies to improve the efficiency of new and existing coal-fired power plants. A-USC steam cycles have the potential to improve cycle efficiency, reduce fuel costs, and reduce greenhouse gas emissions. Current development and demonstration efforts are focused on enabling the construction of A-USC plants, operating with steam temperatures as high as 1400°F (760°C) and steam pressures up to 5000 psi (35 MPa), which can potentially increase cycle efficiencies to 47% HHV (higher heating value), or approximately 50% LHV (lower heating value), and reduce CO 2 emissions by roughly 25%, compared to today’s U.S. fleet. A-USC technology provides a lower-cost method to reduce CO 2 emissions, compared to CO 2 capture technologies, while retaining a viable coal option for owners of coal generation assets. Among the specific goals of Phase 2 of the ComTest Project are to: validate that components made from advanced nickel-based alloys can operate and perform under A-USC conditions accelerate the development of a U.S.-based supply chain for the full complement of A-USC components close the remaining gaps and reduce the risks for manufacturing components from advanced materials for commercial demonstration fabricate full-scale versions of selected key components made of nickel-based alloys validate a qualified U.S. supply chain, to provide greater cost certainty for components obtain American Society of Mechanical Engineers (ASME) code approval for new materials, components and processes Additional benefit: Manufacturing technology will be applicable to other advanced fossil energy high temperature cycles, and can support increased flexibility of existing power plants The ComTest project is managed by Energy Industries of Ohio, and technically directed by the Electric Power Research Institute, Inc., with General Electric designing the A-USC components. As stated earlier, the current phase of the effort is primarily funded by the U.S. Department of Energy, through the National Energy Technology Laboratory. This presentation outlines the motivation for the project, explains the project’s structure and schedule, and provides some of the technical details on the design of the ComTest components.

01 COAL, LIGNITE, AND PEAT↗
NASA NTRS2008

Nondestructive Evaluation of Metal Fatigue Using Nonlinear Acoustics

Safe-life and damage-tolerant design philosophies of high performance structures have driven the development of various methods to evaluate nondestructively the accumulation of damage in such structures resulting from cyclic loading. Although many techniques have proven useful, none has been able to provide an unambiguous, quantitative assessment of damage accumulation at each stage of fatigue from the virgin state to fracture. A method based on nonlinear acoustics is shown to provide such a means to assess the state of metal fatigue. The salient features of an analytical model are presented of the microelastic-plastic nonlinearities resulting from the interaction of an acoustic wave with fatigue-generated dislocation substructures and cracks that predictably evolve during the metal fatigue process. The interaction is quantified by the material (acoustic) nonlinearity parameter extracted from acoustic harmonic generation measurements. The parameters typically increase monotonically by several hundred percent over the fatigue life of the metal, thus providing a unique measure of the state of fatigue. Application of the model to aluminum alloy 2024-T4, 410Cb stainless steel, and IN100 nickel-base superalloy specimens fatigued using different loading conditions yields good agreement between theory and experiment. Application of the model and measurement technique to the on-site inspection of steam turbine blades is discussed.

Cantrell, John H., Jr.↗
DOE OSTI2014

Superficial Carbon Dioxide Brayton Cycle Energy Conversion Research and Development Program

A closed Brayton cycle recirculates the working fluid, and the turbine exhaust is used in a recuperating heat exchanger to heat the turbine feed. A "supercritical cycle' is a closed Brayton cycle in which the working fluid, such as supercritical carbon dioxide (s-0O2), is maintained near the critical point during the compression phase of the cycle. The key property of the fluid near its critical point is its higher gas density, closer to that of a liquid than of a gas, allowing for the pumping power in the compressor to be significantly reduced, which results in thermal efficiency that is significantly improved over the efficiency attainable in an ideal-gas Brayton cycle. Another advantage of using a supercritical cycle is that the overall footprint of the power-conversion system can be significantly reduced, as compared to the same power output of a steam-Rankine cycle, due to the high pressure in the system and resulting low volumetric flow rate. This allows for the heat-rejection heat exchanger and turbine to be orders of magnitude smaller than for similar power output steam-Rankine systems. Other potential advantages are the reduced use of water, not only due to the increased efficiency, but due also to the fact that the heat rejection temperature is significantly higher than for steam-Rankine systems, allowing for significant heat rejection directly to air. In 2006, Sandia National Laboratories (SNL), recognizing these potentially significant advantages of a higher efficiency power cycle, used internal funds to establish a testing capability and began partnering with the U.S. Department of Energy Office of Nuclear Energy to develop a laboratory-scale test assembly to show the viability of the underlying science and demonstrate system performance. Since that time, SNL has generated over 100 kW-hours of energy, verified cycle performance, and developed cycle controls and maintenance procedures. The test assembly has successfully operated in different configurations (simple Brayton, waste heat cycle, and recompression) and tested additives to the s-CO 2 working fluid. However, challenges remain to confirm viability of existing components and suitability of materials, demonstrate that theoretical efficiencies are achievable, and integrate and scale up existing technologies to be suitable for a range of applications.

42 ENGINEERING↗
DOE OSTI2015

A STRONGLY COUPLED REACTOR CORE ISOLATION COOLING SYSTEM MODEL FOR EXTENDED STATION BLACK-OUT ANALYSES

The reactor core isolation cooling (RCIC) system in a boiling water reactor (BWR) provides makeup cooling water to the reactor pressure vessel (RPV) when the main steam lines are isolated and the normal supply of water to the reactor vessel is lost. The RCIC system operates independently of AC power, service air, or external cooling water systems. The only required external energy source is from the battery to maintain the logic circuits to control the opening and/or closure of valves in the RCIC systems in order to control the RPV water level by shutting down the RCIC pump to avoid overfilling the RPV and flooding the steam line to the RCIC turbine. It is generally considered in almost all the existing station black-out accidents (SBO) analyses that loss of the DC power would result in overfilling the steam line and allowing liquid water to flow into the RCIC turbine, where it is assumed that the turbine would then be disabled. This behavior, however, was not observed in the Fukushima Daiichi accidents, where the Unit 2 RCIC functioned without DC power for nearly three days. Therefore, more detailed mechanistic models for RCIC system components are needed to understand the extended SBO for BWRs. As part of the effort to develop the next generation reactor system safety analysis code RELAP-7, we have developed a strongly coupled RCIC system model, which consists of a turbine model, a pump model, a check valve model, a wet well model, and their coupling models. Unlike the traditional SBO simulations where mass flow rates are typically given in the input file through time dependent functions, the real mass flow rates through the turbine and the pump loops in our model are dynamically calculated according to conservation laws and turbine/pump operation curves. A simplified SBO demonstration RELAP-7 model with this RCIC model has been successfully developed. The demonstration model includes the major components for the primary system of a BWR, as well as the safety system components such as the safety relief valve (SRV), the RCIC system, the wet well, and the dry well. The results show reasonable system behaviors while exhibiting rich dynamics such as variable flow rates through RCIC turbine and pump during the SBO transient. The model has the potential to resolve the Fukushima RCIC mystery after adding the off-design two-phase turbine operation model and other additional improvements.

RCIC↗
NASA NTRS1982

Hybrid fuel cell/diesel generation total energy system, part 2

Meeting the Goldstone Deep Space Communications Complex (DGSCC) electrical and thermal requirements with the existing system was compared with using fuel cells. Fuel cell technology selection was based on a 1985 time frame for installation. The most cost-effective fuel feedstock for fuel cell application was identified. Fuels considered included diesel oil, natural gas, methanol and coal. These fuel feedstocks were considered not only on the cost and efficiency of the fuel conversion process, but also on complexity and integration of the fuel processor on system operation and thermal energy availability. After a review of fuel processor technology, catalytic steam reformer technology was selected based on the ease of integration and the economics of hydrogen production. The phosphoric acid fuel cell was selected for application at the GDSCC due to its commercial readiness for near term application. Fuel cell systems were analyzed for both natural gas and methanol feedstock. The subsequent economic analysis indicated that a natural gas fueled system was the most cost effective of the cases analyzed.

Blazek, C. F.↗
DOE OSTI2017

Fuel-Coolant Interaction Results for High Energy In-Pile LWR Fuels Experiments

Fuel-coolant interaction (FCI) has long been a subject of interest in severe-accident reactor safety applications. Significant chemical interaction also frequently results at the high temperature associated with these events in a water environment. Historical rapid, high energy transient irradiation test results are reviewed for experiments performed in transient experimental reactors in Idaho. Though such events are not credible for any deployed nuclear reactor technology, the pressure waves produced by FCI on surrounding containment structures are of importance to advanced light water reactor designs and for transient experiment design considerations. A brief introduction to steam explosion and related studies is provided in the context of these experiments. Extensive reactivity initiated accident testing programs were carried out in the Transient REActor Test (TREAT) facility, the Special Power Excursion Reactor Test (SPERT) facility, and the Power Burst Facility (PBF) from the 1960’s through the late 1970’s. A variety of fuel forms including waterlogged rods were tested in capsules containing water coolant at standard temperature pressure. A few tests were performed at high pressure and temperature in the water loop of PBF. In many of these experiments, energy deposition was high enough to greatly exceed melting temperatures of the fuel, resulting in some fraction of the fuel being dispersed into the coolant. A purpose of many of these tests was to determine the nuclear-to-mechanical energy conversion ratio as well as the extent of metal-water reaction. Relevant data collected from these tests included transient energy deposition, pressure response of the coolant, water column velocity, total hydrogen generation, and resulting particle size distributions and particle characterization. In this paper, the mechanical configuration of each experiment facility is reviewed and discussed relative to the measured responses. The empirical results for source pressure and extent of metal-water reaction are presented in the context of the experimental conditions. The results of these experiments provide a unique understanding for behavior of fuel under severe accident conditions in a reactor environment.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2016

Experimental and Computational Investigation of High Entropy Alloys for Elevated-Temperature Applications

To create and design novel structural materials with enhanced creep-resistance, fundamental studies have been conducted on high-entropy alloys (HEAs), using (1) thermodynamic calculations, (2) mechanical tests, (3) neutron diffraction, (4) characterization techniques, and (5) crystal-plasticity finite-element modeling (CPFEM), to explore future candidates for next-generation power plants. All the constituent binary and ternary systems of the Al-Cr-Cu-Fe-Mn-Ni and Al-Co-Cr-Fe-Ni systems were thermodynamically modeled within the whole composition range. Comparisons between the calculated phase diagrams and literature data are in good agreement. Seven types of HEAs were fabricated from Al-Cr-Cu-Fe-Mn-Ni and Al-Co-Cr-Fe-Ni systems. The Al x CrCuFeMnNi HEAs have disordered [face-centered cubic (FCC) + body-centered cubic (BCC)] crystal structures, not FCC or BCC single structure. Excessive alloying of the Al element results in the change of both microstructural and mechanical properties in Al x CoCrFeNi HEAs. There are mainly three structural features in Al x CoCrFeNi: (1) the morphology, (2) the volume fractions of the constitute phases, and (3) existing temperatures of all six phases. After homogenization, the Al 0.3 CoCrFeNi material is a pure FCC solid solution. After aging at 700 °C for 500 hours, the optimal microstructure combinations, the FCC matrix, needle-like B2 phase within grains, and granular σ phase along grain boundary, is achieved for Al 0.3 CoCrFeNi. The cold-rolling process is utilized to reduce the grain size of Al 0.1 CoCrFeNi and Al 0.3 CoCrFeNi. The chemical elemental partitioning of FCC, BCC, B2, and σphases at different temperatures, before and after mechanical tests, in Al-Cr-Cu-Fe-Mn-Ni and Al-Co-Cr-Fe-Ni systems are quantitatively characterized by both synchrotron X-ray diffraction, neutron diffraction with levitation, scanning electron microscopy (SEM), advanced atom probe tomography (APT), and transmission electron microscopy (TEM). In-situ neutron diffraction experiments were conducted to study the strengthening effect of B2 phase on tensile properties of Al 0.3 CoCrFeNi HEAs directly. The results shows the creep behavior of Al 0.3 CoCrFeNi is superior to conventional alloys, and the heat treatment introduces secondary B2 phase into the FCC matrix, which increase the yielding strength, decrease the ductility, diminish the serrated flow during compression tests at high temperatures. In summary, the outcomes of the development of the HEAs with creep resistance include: (1) Suitable candidates, for the application to boilers and steam and gas turbines at temperatures above 760 °C and a stress of 35 MPa. (2) Fundamental understanding on the precipitate stability and deformation mechanisms of both single-phase and precipitate-strengthened alloys at room and elevated temperatures, and (3) The demonstration of an integrated approach, coupling modeling [thermodynamic calculations and crystal-plasticity finite-element modeling (CPFEM)] and focused experiments, to identify HEAs that outperform conventional alloys for high-temperature applications, which will be applicable for the discovery and development of other high-temperature materials in the power-generating industry.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Ceramic–metal composites for heat exchangers in concentrated solar power plants

The efficiency of generating electricity from heat using concentrated solar power plants (which use mirrors or lenses to concentrate sunlight in order to drive heat engines, usually involving turbines) may be appreciably increased by operating with higher turbine inlet temperatures, but this would require improved heat exchanger materials. By operating turbines with inlet temperatures above 1,023 kelvin using closed-cycle high-pressure supercritical carbon dioxide (sCO 2 ) recompression cycles, instead of using conventional (such as subcritical steam Rankine) cycles with inlet temperatures below 823 kelvin, the relative heat-to-electricity conversion efficiency may be increased by more than 20 per cent. The resulting reduction in the cost of dispatchable electricity from concentrated solar power plants (coupled with thermal energy storage) would be an important step towards direct competition with fossil-fuel-based plants and a large reduction in greenhouse gas emissions. However, the inlet temperatures of closed-cycle high-pressure sCO 2 turbine systems are limited by the thermomechanical performance of the compact, metal-alloy-based, printed-circuit-type heat exchangers used to transfer heat to sCO 2 . We present a robust composite of ceramic (zirconium carbide, ZrC) and the refractory metal tungsten (W) for use in printed-circuit-type heat exchangers at temperatures above 1,023 kelvin. This composite has attractive high-temperature thermal, mechanical and chemical properties and can be processed in a cost-effective manner. We fabricated ZrC/W-based heat exchanger plates with tunable channel patterns by the shape-and-size-preserving chemical conversion of porous tungsten carbide plates. The dense ZrC/W-based composites exhibited failure strengths of over 350 megapascals at 1,073 kelvin, and thermal conductivity values two to three times greater than those of iron- or nickel-based alloys at this temperature. Corrosion resistance to sCO 2 at 1,023 kelvin and 20 megapascals was achieved by bonding a copper layer to the composite surface and adding 50 parts per million carbon monoxide to sCO 2 . Finally, techno-economic analyses indicate that ZrC/W-based heat exchangers can strongly outperform nickel-superalloy-based printed-circuit heat exchangers at lower cost.

36 MATERIALS SCIENCE↗