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DOE OSTI2022

AST Development in M2FCT (ASTWG and iDWG) Update to 21CTP [Slides]

Accelerated Stress Tests (ASTs) are required to evaluate fuel cell component durability in a reasonable time. Current DOE and FCTT ASTs are light duty focused with 5000 – 8000 hour durability requirements. Heavy duty ASTs need to reflect the 25000+ hour durability requirement. Interim solution is to extend the duration of the current light duty ASTs: Catalyst AST has been extended from 30,000 cycles to 90,000 cycles (From 50 hours to 150 hours). We need to understand Heavy duty stressors and tailor ASTs for heavy duty applications: Longer lifetimes; Higher efficiencies – Higher loadings - Potentially higher operating temperatures and voltages; Heat rejection during low speed hill climbs – Higher operating temperature; Longer Idling times – Higher operating voltages and drier operation; Take into account different hybridization strategies (Vary size of battery).

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2024

Drop Analysis of a Department of Energy Standard Canister Containing Fort Saint Vrain SNF– 24138

DOE manages over 300 types of SNF, many of which are located at the INL site. Managing this large variety of SNF for storage, transportation, and disposal poses a challenge to DOE. The Idaho Cleanup Project and INL are collaborating on the DOE SNF Road-Ready Demonstration (“Road-Ready Demonstration”), which will develop and demonstrate the designs, technology, processes, and regulatory framework for packaging DOE-managed SNF for “road-ready dry storage.” Road-ready dry storage (RRDS) is an SNF management concept in which SNF is packaged into dry, sealed canisters that are then placed in on-site storage in anticipation of later transport and disposition. The forward-looking goal of the Road-Ready Demonstration is to establish the foundation for a large-scale RRDS program at the INL site. One critical aspect of RRDS is the ability to certify the DOE Standard Canister and its associated transportation package in accordance with 10 CFR 71 for offsite transportation. Depending on the SNF type and transportation strategy, DOE Standard Canisters may be required to maintain structural integrity under hypothetical accident scenarios (e.g., drop events). The DOE Standard Canisters have been tested and analyzed under various SNF loading configurations and accident drop events in support of the Idaho Spent Fuel Facility and other DOE programs; however, no analysis has yet been completed in support of the recently initiated Road-Ready Demonstration. This paper presents preliminary results from a finite element analysis of the Ø45.7 cm × 4.6 m (Ø18 in. × 15 ft) DOE Standard Canister under the 9 m drop at 80 degrees off-vertical drop scenario considered in previous INL tests and analyses. It considers the Fort St. Vrain spent nuclear fuel loading configuration proposed for the Road-Ready Demonstration, uses updated material properties, and applies the strain-based acceptance criteria established in ASME Boiler and Pressure Vessel Code’s Section III, Division 3 rules for storage and transportation spent nuclear fuel containments. This updated analysis is compared to previous DOE Standard Canister drop analyses. Preliminary results from the updated analysis show that certain regions of the containment exceed the allowable limits during the accidental drop event. However, these regions are limited to components performing a non-structural function. While further work on this analysis will be pursued, this analysis serves as the foundation for formal calculations used to support applicable certification efforts of the RRDS system at INL.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2024

Drop Analysis of a Department of Energy Standard Canister Containing Fort Saint Vrain SNF

42 ENGINEERING↗

DOE OSTI2023

Enhanced Component Performance Study: Emergency Diesel Generators 1998–2022

This report presents an enhanced performance evaluation of the emergency power system (EPS) and high-pressure core spray (HPCS) emergency diesel generators (EDGs) at U.S. commercial nuclear power plants. This report evaluates component performance over time using (1) Institute of Nuclear Power Operations (INPO) Industry Reporting and Information System (IRIS) data from 1998 through 2022 and (2) maintenance unavailability performance data from Mitigating Systems Performance Index (MSPI) Basis Document data from 2002 through 2022. The objective is to show estimates of current failure probabilities and rates related to EDGs, trend these data on an annual basis, determine if the current data are consistent with the probability distributions currently recommended for use in Nuclear Regulatory Commission (NRC) probabilistic risk assessments, show how the reliability data differ for different EDG manufacturers and for EDGs with different ratings; and summarize the subcomponents, causes, detection methods, and recovery associated with each EDG failure mode. The EDG failure modes considered are fail to start (FTS), fail to load and run (FTLR), and fail to run after one hour of operation (FTR>1H). Engineering analyses were performed with respect to time-period and failure mode without regard to the actual number of EDGs at each plant. The factors analyzed include subcomponent, failure cause, detection method, recovery, manufacturer, and EDG rating. The following increasing trends were identified for EDGs for the most recent 10-year period: (1) HPCS EDG FTS failure probability, (2) EPS and HPCS EDG frequency of start demands (demands per reactor year), and (3) EPS and HPCS EDG frequency of FTLR demands. The following decreasing trends were identified for EDGs for the most recent 10-year period: (1) EPS EDG FTS failure probability, (2) EPS EDG FTLR failure probability, (3) EPS EDG unavailability, and (4) EPS and HPCS EDG frequency of FTLR events (failures per reactor year).

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

Transient Optimization of the Cryogenic Moderator System Controller at the Spallation Neutron Source for Improved Performance

The high-energy neutron beam generated at the Spallation Neutron Source (SNS) at Oak Ridge National Laboratory is moderated to use cold (slow) neutrons for scientific discoveries. The Cryogenic Moderator System (CMS) removes heat from the neutron beam using cryogenic hydrogen (H 2 ) moderators connected via heat exchangers to a helium (He) refrigeration loop that dissipates heat using a compressor-brake system. However, the CMS is affected by sporadic losses in beam power, referred to as "beam trips," as these events generate significant disturbances in cooling requirements. To accommodate the heat load transients during beam trips, the CMS uses a decentralized control strategy consisting of four flow valves and one electric heater adjusted by independent proportional-integral (PI) controllers. During the CMS’s initial commissioning, the PI gains were calibrated based only on tracking performance, overlooking their effectiveness in disturbance rejection. A data-driven, control-oriented closed-loop model was developed to recalibrate the PI gains and minimize the transient disturbances caused by beam trips. The model consists of three main components: (1) a physics-based model of the He refrigeration loop, (2) a machine-learning model of the cryogenic H 2 cooling trains, and (3) the control logic used for feedback set-point tracking. Experimental results showed that the recalibrated gains obtained in this study improved the CMS’s transient response during beam trips.

Maldonado Puente, Bryan↗

DOE OSTI2024

Offshore Wind Turbine Blade (85 to120meters ultra-long blade) static and fatigue test

Offshore blades are not just longer, they are wider, heavier and more flexible. These longer blades are a key component of larger wind turbines and for turbines to be more efficient in low wind speeds. These longer blades help reduce the LCOE further and make offshore wind even more competitive. As described earlier, it is essential for the blades to be fully tested to verify and validate the blade designs and manufacturing processes to ensure a reliable product is installed in the field. Through this project WTTC developed and procured new testing equipment required to test longer blades with larger deflections and higher loads. R&D’s BCDA system commissioned was the largest fatigue test exciter system in the world and set the bar for other blade testing facilities worldwide.

17 WIND ENERGY↗

DOE OSTI2024

Ultra-High-Speed X-ray Tomography: Bridging the Gaps to See the Unknown

Rapid, time-varying, three-dimensional physics underpin numerous engineering challenges. Often, these physics occur within opaque environments, internal to a component, severely limiting applicable diagnostics. Development of novel diagnostics is necessary to understand and predict transient three-dimensional (3D) phenomena within opaque environments. This report highlights progress in four key areas leading to advancements in high-speed X-ray radiography and tomography. The first area is enabling MHz-rate imaging of energetics at the Advanced Photon Source at Argonne National Laboratory. The second is modeling a high-flux, rotating-anode X-ray source to understand the heat loads on the anode. The third effort was to develop a novel reconstruction algorithm that is validated by ground experimental tomography data and synthetic tomography data. The fourth is the development of a novel approach to two-color X-ray imaging.

42 ENGINEERING↗

DOE OSTI2024

UEDGE modeling of plasma detachment of CFETR with ITER ‐like divertor geometry by external impurity seeding

Abstract Efficient handling of high heat flux on the plasma‐facing components, particularly the divertor targets, poses a significant challenge for the Chinese Fusion Engineering Testing Reactor (CFETR) with fusion power of Gigawatt. This work investigates the divertor plasma detachment of CFETR with a standard ITER‐like divertor geometry by neon (Ne) or argon (Ar) impurity seeding using UEDGE code. The cross‐field drifts terms are switched off, and fluid neutral models and a “fixed‐fraction” impurity model are applied to enable efficient simulations for the study of CFETR detachment. In order to reduce the heat load on the divertor targets below the acceptable level (<10 MW/m 2 ), the impurity fraction ( f ), pumping speed ( S ), and upstream density are varied to identify the suitable operations window during Ne seeding. The effects of Ne and Ar impurities on the plasma detachment are compared. It is found that with the power across the core‐edge interface P SOL = 200 MW and separatrix density of 2.8 10 19 , Ne impurity fraction ≥1.7%, and Ar impurity fraction ≥0.24% can achieve the partial detachment. Achieving similar total radiation power (˜148 MW), the Ne fraction is 2.3% and the Ar fraction is 0.24%. Moreover, the simulation results indicate that Ar exhibits better power radiation efficiency and core compatibility compared with Ne.

Zhang, M. Z.↗

DOE OSTI2023

Ultrasonic measurement of temperature distributions in extreme environments: Electrical power plants testing in utility-scale steam generators

Thermal heterogeneities within energy conversion and storage, material processing, nuclear processes, aerospace, and military applications are often inaccessible to characterization by insertion sensors. When sensor deployment is possible, conventional pointwise temperature probes quickly degrade when inserted into harsh environments typical of such processes. We developed spatially-resolved ultrasonic thermometry to noninvasively measure the spatial distributions of thermal properties in such applications, even when sizable thermal gradients are present. Our method divides the path of ultrasonic propagation into segments bound by echogenic features, which create echoes in pulse-echo mode, encoding the information about interior temperature distributions. We use the acquired ultrasonic responses to estimate the internal temperature distributions by solving an inverse problem or concatenating segmental estimates. This work describes the implementation and industrial testing of the developed method at a coal-fired electrical power generation plant. We inserted an echogenically segmented Inconel 625 waveguide into the combustion zone of the utility-scale boiler and continuously acquired ultrasonic data while keeping sensitive components away from the damaging combustion environment. The accuracy of the time-dependent temperature distributions reconstructed from the ultrasonic measurements was comparable to that of thermocouples. The resiliency of ultrasonic thermometry to harsh combustion conditions was far superior to conventional insertion sensors. The measurements obtained during plant operation captured daily steam generation cycles in response to changing customer demand and intermittent contributions of renewable power sources to the power grid. These measurements have revealed new insights into the relationship between the dynamic power generation load and the conditions inside the steam generator. As a result, the successful industrial testing of spatially-resolved ultrasonic thermometry in solids indicates that the developed technology has matured to become an attractive alternative to conventional sensing in solving challenging problems of long-term thermal characterizations in extreme environments.

42 ENGINEERING↗

DOE OSTI2020

Variations of Stress Parameters in the Southern California Plate Boundary Around the South Central Transverse Ranges

We examine the stress field in Southern California with a focus on the region near the South Central Transverse Ranges (SCTR), using a refined stress inversion methodology. We independently invert declustered and aftershocks focal mechanisms from the years 1981 to 2017. Comparisons between the stress field orientations and the stress ratios from these inversions provide information on local sources of the stress field. Regionally, the SHmax tends to be toward NNE and the stress ratios vary from transtensional stress regime near the Eastern California Shear Zone (ECSZ), to strike-slip faulting near the SCTR, and toward transpression near the Western Transverse Ranges. Detailed analysis of stress parameters near the SCTR indicates deviations from the regional strike-slip faulting including the following: (1) The San Bernardino Mountain area shows S Hmax direction toward NNW and transpressional stress components likely associated with the motions of the San Andreas Fault and ECSZ; (2) the Cajon Pass and San Gorgonio Pass show transpressional stress regime near the bottom of the seismogenic zone likely associated with the elevated topography; and (3) in Crafton Hills, rotation of the principal stress plunges and SHmax direction and transtensional stress regime below ~10 km, along with lower estimated apparent friction coefficient, suggest a weak fault possibly associated with deep creep. The performed multiscale analysis resolves effects of regional and local loadings. The average stress parameters in the analyzed 37 years do not show significant temporal variations of stress field near the SCTR region.

58 GEOSCIENCES↗

DOE OSTI2022

Combined Normal and Disruption, Electromagnetic Transient, Thermal, and Structural Analysis of COMPASS Upgrade

We report that COMPASS Upgrade is a replacement for the COMPASS device at the Institute of Plasma Physics (IPP) of the Czech Academy of Sciences. It is a cryogenic copper machine with a major radius of 0.89 m, with 5 T at the plasma centerline and 2-MA plasma current. It is intended to develop ITER relevant plasma densities and high power fluxes in the divertor region. The entire vacuum vessel is planned to reach 500 °C. The COMPASS-U TF coil is a bitter plate-like design with radial conductor plates that extend the width of the TF inner leg. Currents redistribute radially based on resistive and inductive effects. This necessitates an electromagnetic (EM) transient analysis of the coil current distribution. For copper coils like COMPASS Upgrade, the solution must be coupled with a thermal solution to properly include the temperature-dependent resistive effects. The EM transient solution includes the TF magnetic loads, and a stress pass on the results produces in-plane loads. The EM solution chosen requires inclusion of all the conducting and nonconducting regions surrounding the TF coil. With the TF current distribution solved, the addition of the poloidal coils and resulting background fields allows the determination of the out-of-plane loads. Integration of the Joule heating produced from the EM solution produces temperature distributions throughout the shot, which can be read in to a structural pass to include thermal stresses in the evaluation. This is true of both TF and PF temperature prediction with appropriate packing fractions. Currents in the PF coils, with computed background fields, produce Lorentz loads. Time transients of the PF currents produce startup eddy currents in the structures included in the model; inclusion of the vessel and other passive structures allows these to be included in a stress pass. The EM transient solution includes all the elements needed for a disruption analysis with prescribed motions and quench of the plasma. From a model originally intended to simulate current diffusion in the TF coil, the analysis can be refined to be used to predict the performance of most of the components of the tokamak or provide boundary conditions for more detailed submodels. In this article, the use of the current diffusion model for bounding assessments of the COMPASS Upgrade TF, PF, vessel, external structure, and disruption analyses will be presented.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2024

Robust Restoration From Cyber-Physical Attacks in Active Distribution Grids With Grid-Edge IBRs

The inverter-based resources (IBRs) have enabled the integration of renewable energy at the grid edge with enhanced control capabilities to support the reliable operation of power grids. Different control frameworks, such as hierarchical or distributed architecture, have been proposed with the expansion of cyber networks for real-time monitoring and control. This evolution of critical infrastructure into cyber-physical systems also brings more vulnerabilities for the broadened attack surfaces, and significantly increases the possibility of physical system failures or outages caused by cyberattacks. Among tremendous efforts in the defense-in-depth approach, it remains challenging to provide prompt detection and accurate location of attack entry points or paths. Therefore, the prevailing restoration framework may struggle to fully consider the cyber-physical interdependence, successfully isolate the compromised cyber and physical components, and safely recover the systems without the potential risks leading to secondary outages. This paper is motivated to develop a cyber-physical restoration framework for distribution grids to recover from cyber attacks by harnessing grid-edge IBRs. The framework is first built on the operational guidelines of IBRs considering the compromised cyber layer. Then, an ambiguity set is established to represent the uncertainty of attack scenarios and their possibility levels. Next, a distributionally robust optimization model is developed to provide the optimal load restoration strategy across all scenarios. The effectiveness of the proposed model is demonstrated through various use cases on the modified IEEE 13-node and 123-node test systems. Finally, simulation results demonstrate the effectiveness and advancement of developed post-attack restoration strategies.

Cybersecurity↗

DOE OSTI2021

Draft Rules for Alloy 617 Creep-Fatigue Design Using an EPP+SMT Approach

The report describes an improved new creep-fatigue design method for structural components in high temperature nuclear service. The new method uses an integrated elastic-perfectly plastic (EPP) analysis and Simplified Model Test (SMT) approach that greatly simplifies the design process by avoiding the separate evaluation of creep and fatigue damages and eliminating the requirement of stress classification. The report includes draft design rules, presented in a format compatible with an ASME nuclear Code Case, as well as a commentary on the rules and the validation of the rules using pressurized SMT (p-SMT) test data. Areas of potential improvement have been identified for further evaluation. The report also develops EPP+SMT design charts for Alloy 617 at temperatures between 800°C and 950°C by extrapolating high strain range, short hold test data to low strain range and long hold times, typical for structural components in high temperature nuclear service. The design charts are currently limited to 10,000 cycles to avoid excessive extrapolation outside the test database. More robust alternate extrapolation procedures will be considered in future work. The report includes several verification problems comparing the new EPP+SMT design method with current ASME creep-fatigue design methods. The comparison demonstrates that the EPP+SMT method significantly reduces the over-conservatism in current methods. Finally, the report includes a fully-documented sample problem with multiple load cases detailing the application of proposed EPP+SMT design rules.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Sizing ramping reserve using probabilistic solar forecasts: A data-driven method

Ramping products have been introduced or proposed in several U.S. power markets to mitigate the impact of load and renewable uncertainties on market efficiency and reliability. Current methods often rely on historical data to estimate the requirements of ramping products and fail to take into account the effects of the latest weather conditions and their uncertainties, which could lead to overly conservative or insufficient requirements. This study proposes a k-nearest-neighbor-based method to give weather-informed estimates of ramping needs based on short-term probabilistic solar irradiance forecasts. Forecasts from multiple sites are employed in conjunction with principal component analysis to derive numerical classifiers to characterize system-level weather conditions. In addition, we develop a data-driven method to optimize the model parameters in a rolling-forward manner. By using real-world data from the California Independent System Operator, we design two metrics to evaluate method performance: 1) frequency of shortage and 2) oversupply of ramping product. Our proposed method presents advantages in comparison with the baseline and a set of benchmark methods: without compromising system reliability, it reduces system ramping requirements by up to 25%, therefore improving both system reliability and economics.

14 SOLAR ENERGY↗

DOE OSTI2025

Evaluating Autoxidation Radical Scavengers and Additives to Enhance Aminopolymer Sorbent Stability

Solid amine sorbents have shown promise in the removal of ultradilute CO 2 from the atmosphere. Despite being a promising candidate material type for this application, these sorbents are prone to degradation during long-term exposure to environmental components such as CO 2 , O 2 , and H 2 O, with amine oxidation being a particularly challenging problem. In this study, we investigate the potency of different radical scavengers and additives in mitigating the degradation of a model poly- (ethylenimine) (PEI)/Al 2 O 3 sorbent under direct air capture (DAC)-relevant conditions. The results reveal that a 4,4′-bis(α,α- dimethylbenzyl)diphenylamine (BDDPA)-incorporated PEI/Al 2 O 3 sorbent showed the most resistance toward oxidative degradation at varying exposure times and BDDPA loadings under CO 2 -free air (21% O 2 /balance N 2 ) at 120 °C. Interestingly, under humid (∼43% relative humidity (RH) at 26 °C) and dry 0.04% CO 2 -air, the BDDPA/PEI/Al 2 O 3 sorbent showed enhanced sorbent stability both at 70 and 120 °C after 4.5 h of exposure. Under humid CO 2 -free air, at 120 °C, the antioxidant performance slightly declined (in comparison to the dry CO 2 -free air condition) but displayed a much higher stability than the pristine sorbent. Overall, the ability of BDDPA to inhibit sorbent degradation under dry and humid, CO 2 -free and CO 2 -containing (0.04%) air at intermediate (70 °C) and elevated (120 °C) temperatures is promising in prolonging sorbent stability and underscores the importance of performing accelerated oxidation studies in the presence of all species that are expected to be present in DAC processes to identify suitable stabilization treatments for sorbent materials.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Power handling in a highly-radiative negative triangularity pilot plant

Abstract This work explores detailed power handling solutions for a class of high-field, highly-radiative negative triangularity (NT) reactors based around the MANTA concept (Rutherford et al 2024 Plasma Phys. Control. Fusion ). The divertor design is kept as simple as possible, opting for a standard divertor with standard leg length. FreeGS is used to create an equilibrium for the boundary region, prioritizing a short outer leg length of only ∼50 cm (∼40% of the minor radius). The UEDGE code package is used for the boundary plasma solution to track plasma temperatures and fluxes to the divertor targets. It is found that for P SOL = 25 MW and n sep = 0.96 × 10 20 m −3 , conditions consistent with initial core transport modeling, little additional power mitigation is necessary. For a fixed impurity fraction of just 0.13% Ne in the plasma, the peak heat flux density at the more heavily loaded outer targets falls to 7.8 MW m −2 , while the electron temperature T e remains just under 5 eV. Scans around the parameter space reveal that even at densities lower than in the primary operating scenario, P SOL can be increased up to 50 MW, so long as a slightly higher fraction of extrinsic radiator is used. With less than 1% neon (Ne) impurity content, the divertor still experiences less than 10 MW m −2 at the outer target. Design of the plasma-facing components includes a close-fitting vacuum vessel with a tungsten inner surface as well as FLiBe-carrying cooling channels fashioned into the VV wall directly behind the divertor targets. For the seeded heat flux profile, Ansys Fluent heat transfer simulations estimate that the outer target temperature remains at just below 1550 ∘ C. Initial scoping of advanced divertor designs shows that for an X-divertor, detachment of the outer target becomes much simpler, and plasma fluxes to the targets drop considerably with only 0.01% Ne content.

Miller, M. A. (ORCID:0000000265406533)↗

DOE OSTI2022

Development of a Kollidon 90F-PEG300-Glycerin Binder for PZT 95/5 Ceramic Processing

This SAND Report documents the development of organic binder system for PZT 95/5 consisting of Kollidon 90F, PEG300, and glycerin. Binders are a critical component in the manufacture of ceramic components. Low performing binders can result in poor yield and lower performance of ceramic components. This study sought to develop a well performing binder system for PZT 95/5 ceramics to support Ferroelectric Neutron Generator manufacturing. The study explored the glass transition temperature, powder compaction properties, green strengths, and thermal decomposition over a wide composition range. An optimal composition was found consisting of 1.3 wt.% Kollidon 90F, 0.5 wt.% PEG300, and 0.2 wt.% glycerin, and incorporating humidity conditioning . The results showed that the optimized binder exhibited improved compaction performance and enhanced green strength compared to a baseline binder and at lower loading. Further, sintered PZT 95/5 parts prepared using the optimized binder exhibited ~5% improved polarization performance without alteration to the microstructure.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Investigations of correlation and coherence in turbulence from a large-eddy simulation

Abstract. Microscale flow descriptions are often given in terms of mean quantities, turbulent kinetic energy, and/or stresses. Those metrics, while valuable, give limited information about turbulent eddies and coherent turbulent structures. This work investigates the structure of an atmospheric boundary layer using coherence and correlation in space and time with a range of separation distances. We calculate spatial correlations over entire planes of velocity fluctuations, from which we can evaluate the correlation along different directions at different spacings. Similarly, coherence of the three velocity components over separations in the three directions is also investigated. We apply these analyses to a mesoscale–microscale coupled scenario with time-varying conditions and examine nuances in spatial correlations that are often overlooked. Through these analyses and results, this work highlights important differences observed in terms of coherence when comparing large-eddy simulation data to simpler models and suggests ways to improve these simpler models. We note that such differences are important for disciplines like wind energy structural dynamic analysis, in which blade loading and fatigue depend strongly on the structure of the turbulence. We emphasize the additional wealth of data that can be provided by typical atmospheric boundary layer large-eddy simulation when correlation and coherence analysis is included, and we also state the limitations of large-eddy simulation data, which inherently truncate the smaller scales of turbulence.

17 WIND ENERGY↗