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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 1,063 records · Page 59
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Temperature Homogeneity under Selective and Localized Microwave Heating in Structured Flow Reactors

Selective heating of different phases of multiphase systems via microwaves can result in energy savings and suppression of side reactions. However, materials properties and operating conditions that maximize temperature gradients are poorly understood. Here we utilize computational fluid dynamics (CFD) computations and temperature measurements in structured flow reactors (monoliths) in a monomodal microwave cavity to assess the temperature difference between the walls and the fluid and develop a simple lumped model to estimate when temperature gradients exist. We also explore the material’s thermal and electrical properties of structured reactors for isothermal catalyst conditions. We propose that CFD simulations can be used as a nonintrusive, predictive tool of temperature homogeneity. Importantly, we demonstrate that localized heating in the bed under several conditions rather than selective heating is responsible for the selectivity enhancement. Furthermore, our results indicate that structured beds made of high thermal conductivity materials avoid arcing and enable temperature homogeneity and low electrical conductivity materials allow microwaves to penetrate the domain.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Advanced manufacturing for electrosynthesis of fuels and chemicals from CO 2

Advanced manufacturing (AM) represents an appealing approach for creating novel electrochemical systems for chemicals synthesis. In this work, we demonstrate AM for rapid development and testing for improved performance for the carbon dioxide reduction reaction across an evolution of vapor-fed reactor designs. In our final design, we observe activation- and mixed-control regimes for a variety of operating conditions via inlet CO 2 flow rate and electrochemical potential. Furthermore, we define a dimensionless number (Da) to identify mass transport regimes by exploring the impact of hypothesized underlying mass transport mechanisms, including consumption of CO 2 via OH - , increased local temperatures, and partial penetration of electrolyte into gas diffusion layer. The accelerated pace of reactor design and development led to high geometric current densities (500 mA cm -2 ), heightened selectivity (85.5% FE C 2+ products), and increased carbon dioxide conversion (16.6%) and cathodic energy efficiency (49.6% CO 2 R). Using AM vapor-fed reactors, we attain high ethylene (3.67%) and record ethanol (3.66%) yields compared to the literature. Finally, this work underscores the promise of AM for accelerating reactor design, understanding of governing phenomena, and improving the performance of catalytic systems.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Simultaneous stabilization and control of the n = 1 and n = 2 resistive wall mode

Abstract DIII-D experiments demonstrate simultaneous stability measurements and control of resistive wall modes (RWMs) with toroidal mode numbers n = 1 and n = 2. RWMs with n > 1 are sometimes observed on DIII-D following the successful feedback stabilization of the n = 1 mode, motivating the development of multi- n control. A new model-based multi-mode feedback algorithm based on the VALEN physics code has been implemented on the DIII-D tokamak using a real-time GPU installed directly into the DIII-D plasma control system. In addition to stabilizing RWMs, the feedback seeks to control the stable plasma error field response, enabling compensation of the typically unaddressed DIII-D n = 2 error field component. Experiments recently demonstrated this algorithm’s ability to simultaneously control n = 1 and n = 2 perturbed fields for the first time in a tokamak, using reactor relevant external coils. Control was maintained for hundreds of wall-times above the n = 1 no-wall pressure limit and approaching the n = 1 and n = 2 ideal-wall limits. Furthermore, a rotating non-zero target was set for the feedback, allowing stability to be assessed by monitoring the rotating plasma response (PR) while maintaining control. This novel technique can be viewed as a closed-loop extension of active MHD spectroscopy, which has been used to validate stability models through comparisons of the PR to applied, open-loop perturbations. The closed-loop response measurements are consistent with open-loop MHD spectroscopy data over a wide range of β N approaching the n = 1 ideal-wall limit. These PR measurements were then fit to produce both VALEN and single-mode stability models. These models allowed for important plasma stability information to be determined and have been shown to agree with experimentally observed RWM growth rates.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

Development of Non-Nuclear Microreactor Experimental Capability

Microreactors, or small, transportable reactors with a capacity of 20 MWTH or less, are sought to provide heat and power for myriad applications in remote areas, military installations, emergency operations, humanitarian missions, and disaster relief zones. These small, transportable reactor designs, while offering many advantages, are largely untested and unproven. A non-nuclear system and component testing capability is needed to demonstrate to regulators that these designs are safe and to convince customers that the systems are robust, reliable, and efficient. Idaho National Laboratory has constructed the microreactor agile non-nuclear experimental test bed (MAGNET) to assist with the development, demonstration, and validation of microreactor components and systems. MAGNET will support microreactor technology maturation to reduce uncertainty and risk relative to the operation and deployment of this unique class of systems. Stakeholders for this test bed include microreactor developers, energy users, and regulators. Regulators will be engaged early in the design and testing to expedite regulatory approval and licensing.

42 ENGINEERING↗
DOE OSTI2021

Proposed Risk-Informed Regulatory Framework for Approval of Microreactor Transportation Packages

Microreactors are very small nuclear reactors with a power output of about 20 megawatts electric or less that are designed to be factory-built, modular in nature, and highly portable. These compact reactors will be small enough to be transported by truck or even air and could help solve energy challenges in a number of areas, ranging from remote commercial or residential locations to military bases. Pacific Northwest National Laboratory is tasked to develop and evaluate transportation licensing options for microreactors. The work is funded by the National Reactor Innovation Center a National Department of Energy program led by Idaho National Laboratory for the Office of Nuclear Energy Research and Development which support demonstration of microreactor technology. Key transportation steps include the (1) initial movement of high-assay low enriched uranium fresh fuel, (2) transportation of an intact, but never-operated microreactor, and (3) transportation of an intact, previously-operated microreactor. The deliverables on the project consists of a documentation of applicable regulations and regulatory authority for transportation. The objective of this report is to propose a risk-informed regulatory framework for the licensing of the transportation of microreactors, including the transportation of irradiated nuclear fuel that is assumed to be an integral component of the microreactor transportation package. The framework lays out a viable regulatory pathway, including decision points for regulatory options and the supporting technical evaluations for those options in phases from near to long term. This report includes discussion of the (1) general microreactor design concepts including representative microreactor source terms, (2) options for regulatory approval of microreactor transportation based on current regulation and historical precedence, (3) regulatory basis for including risk information in microreactor transportation licensing activities, and (4) description of a risk-informed regulatory framework.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2021

Proposed Risk-Informed Regulatory Framework for Approval of Microreactor Transportation Packages

Microreactors are very small nuclear reactors with a power output of about 20 megawatts electric or less that are designed to be factory-built, modular in nature, and highly portable. These compact reactors will be small enough to be transported by truck or even air and could help solve energy challenges in a number of areas, ranging from remote commercial or residential locations to military bases. Pacific Northwest National Laboratory is tasked to develop and evaluate transportation licensing options for microreactors. The work is funded by the National Reactor Innovation Center a National Department of Energy program led by Idaho National Laboratory for the Office of Nuclear Energy Research and Development which support demonstration of microreactor technology. Key transportation steps include the (1) initial movement of high-assay low enriched uranium fresh fuel, (2) transportation of an intact, but never-operated microreactor, and (3) transportation of an intact, previously-operated microreactor. The deliverables on the project consists of a documentation of applicable regulations and regulatory authority for transportation. The objective of this report is to propose a risk-informed regulatory framework for the licensing of the transportation of microreactors, including the transportation of irradiated nuclear fuel that is assumed to be an integral component of the microreactor transportation package. The framework lays out a viable regulatory pathway, including decision points for regulatory options and the supporting technical evaluations for those options in phases from near to long term. This report includes discussion of the (1) general microreactor design concepts including representative microreactor source terms, (2) options for regulatory approval of microreactor transportation based on current regulation and historical precedence, (3) regulatory basis for including risk information in microreactor transportation licensing activities, and (4) description of a risk-informed regulatory framework.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2021

Predicting structural material degradation in advanced nuclear reactors with ion irradiation

Swelling associated with the formation and growth of cavities is among the most damaging of radiation-induced degradation modes for structural materials in advanced nuclear reactor concepts. Ion irradiation has emerged as the only practical option to rapidly assess swelling in candidate materials. For decades, researchers have tried to simulate the harsh environment in a nuclear reactor in the laboratory at an accelerated rate. Here we present the first case in which swelling in a candidate alloy irradiated ~ 2 years in a nuclear reactor was replicated using dual ion irradiation in ~ 1 day with precise control over damage rate, helium injection rate, and temperature and utilize physical models to predict the effects of radiation in reactors. The capability to predict and replicate the complex processes surrounding cavity nucleation and growth across many decades of radiation dose rate highlights the potential of accelerated radiation damage experiments. More importantly, it demonstrates the capability to predict the swelling evolution and the possibility to predict other features of the irradiated microstructure evolution that control material property degradation required to accelerate the development of new, radiation-tolerant materials.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Benchtop-Scale High Temperature Molten Salt Electrochemical Reactors: Experimental Setup and Considerations

Molten salt electrochemical reduction (MSER) is the dominant production method for aluminum and titanium, and emerging technologies for producing other commodity metals with these highly electrified techniques have demonstrated promising results. However, the scale up of MSER of materials such as iron and silicon are limited by the challenging issues of materials compatibility and impurity control. This work describes an experimental MSER setup using both chloride and carbonate salts. This setup is designed for operations outside of a glovebox, which is practical from an industrial perspective, but creates unique challenges. This work serves as a practical guide to discuss some key operational difficulties such as temperature control, air and humidity, material compatibility, developing strong electrical measurements and techniques, and safety.

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

Equipment List Comparing Balance of Plant Containing a Heat Pump against a Reference Electricity Generating Plant

Approximately two-thirds of U.S. energy consumption in the industrial and transportation sectors relies on fossil fuels. These sectors require high-quality heat, i.e., thermal energy at very high temperatures, for molecular transformation processes. The Integrated Energy Systems (IES) program aims to assess the economic potential of utilizing nuclear-grade heat from Advanced Reactors (ARs) to meet the high-quality heat demands. By having industrial processes (IPs) supplied with nuclear-generated heat, manufacturers could benefit from more stable and potentially lower energy costs, reducing reliance on volatile fossil fuel markets. The main outcome of the FY24 research was the thermodynamic assessment and gap analysis of steam generation for IP applications. The study completed in June 2024 demonstrated that the required steam temperatures could be achieved by integrating a heat pump into an AR power plant. After identifying the thermal demands of target IPs, multiple balance of plant configurations for the Xe-100 reactor by X-energy, incorporating a heat pump, were analyzed. Their technical feasibilities were assessed, including the design of suitable axial compressors for these applications. Comparative performance analysis showed that thermal efficiency alone is insufficient to evaluate system suitability. To address this, a new indicator (heat factor) was introduced in the report released in September 2024 to quantify the low-quality thermal power needed to produce one unit of high-quality heat for the IP. Results showed that integrating heat pumps into Rankine cycles enables higher steam temperatures, though at the expense of increased thermal energy input. This report builds upon and completes the foundational work previously undertaken. It focuses on the design of two Balance of Plant (BOP) configurations, both based on Rankine energy conversion cycles: “Case 1”, which involves electricity generation only, and “Case 2”, which combines electricity and high-temperature heat generation for industrial use. For each configuration, a comprehensive equipment list was developed, detailing all major components such as turbines, compressors, heat exchangers, pumps, and control systems. These lists will serve as the basis for future comparative cost analyses, with the goal of assessing the number and type of components required to integrate a heat pump into the Rankine cycle and to establish a heat transport system capable of delivering thermal energy from the nuclear plant to an industrial facility. Using the constitutive equations presented in the June 2024 milestone, the operating conditions of all BOP components for both “Case 1” and “Case 2” were evaluated. These parameters—such as temperature, pressure, mass flow rate, and steam quality—served as the basis for calculating the associated thermal and mechanical power flows. The net power required from the heat pump to raise the steam temperature to the target level was also determined. The thermodynamic performance of the configuration was then assessed using the heat factor metric. The key outcome of this analysis is a comparative table that presents the equipment that was used in the “Case 1” and “Case 2” configurations. This study offers a preliminary comparison of the two designs, providing insight into the impact of integrating a heat pump in terms of component requirements and thermal efficiency. This equipment list, together with the evaluated operating conditions, also serves as a foundation for the economic analyses scheduled for the current fiscal year.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2026

Kinetics Modeling and Reactor Design Study of Glucose-to-Terpenes Cell-Free Conversion

Cell-free systems offer many advantages over traditional biological conversion by eliminating biological growth constraints. It also offers easy manipulation and finetuning of the reaction conditions for each individual enzyme. The conversion of cellulosic glucose to Limonene, a terpene, is a promising pathway for producing fuels and chemicals. Recent advances in developing cell-free systems focuses on bench scale optimization of terpene yield and to demonstrate its feasibility towards commercialization [1,2]. There is significant knowledge gap regarding reaction kinetics of these cell-free systems to further study how it will perform at larger scale. We present here, our studies on reaction kinetics and reactor design implications of cell-free glucose to Limonene conversion to facilitate the further development and commercialization of this process. We developed a novel kinetic model based on the metabolic-network structure of the cell-free system with multi-substrate reversible Michaelis-Menten rate law. To estimate kinetic parameters for this system of rate equations, we employed Bayesian optimization to perform global search with the assistance of gaussian processes to balance exploration and exploitation. The model parameters estimated showed good results compared with experimental data. The estimated parameters were used to perform sensitivity analysis. We found that Hexokinase is one of the most critical enzymes that affect the conversion of the glucose. We also observed that abundance of co-factors is also critical to the conversion of glucose to limonene. We investigated packed bed reactors with enzymes immobilized on the surface of particles to convert glucose stream into Limonene for larger scale production. The reactor design such as particle size, enzyme loading, and flow rate are found to be critical for improving yields. [1] Dudley, Q.M., Nash, C.J. and Jewett, M.C., 2019. Synthetic Biology, 4(1), p.ysz003. [2] Korman, T.P., Opgenorth, P.H. and Bowie, J.U., 2017. Nature communications, 8(1), p.15526.

09 BIOMASS FUELS↗
DOE OSTI2023

Summary of INL Integrated Energy Systems Research for the Global National Laboratories Consortium on IES

The DOE Office of Nuclear Energy (DOE-NE) program on Integrated Energy Systems (IES) is led by researchers at Idaho National Laboratory (INL), and work is conducted in partnership with an array of other DOE laboratories, industry, and academia. IES research and development activities are additionally complimented by the DOE-NE Light Water Reactor Sustainability (LWRS) program, where work under the Flexible Plant Operations & Generation pathway supports analysis of opportunities for non-electric applications of current fleet nuclear plants and collaborates with multiple plants on near-term hydrogen production demonstration opportunities. The DOE-NE programs additionally partner with the Hydrogen and Fuel Cell Technologies Office under the DOE Office of Energy Efficiency and Renewable Energy to jointly fund the development of analysis tools, technologies, and nuclear-integrated hydrogen demonstration projects. This document provides a brief, high-level summary of IES work as contribution to the annual report for the Global National Laboratories Consortium on IES.

08 HYDROGEN↗
DOE OSTI2025

Direct Comparison of the Activity and Selectivity of Rh 1 Cu and Ni 1 Cu Single-Atom Alloy Sites for Ethanol Decomposition

Ethanol is an important source of clean hydrogen, acetaldehyde, acetic acid, acetate esters, and light hydrocarbons. Controlling the divergent reaction pathways to these products requires understanding how different active sites influence the elementary steps involved. Herein, we present a combined surface science, theory, and nanoparticle catalysis study demonstrating how two single-atom dopants (Rh and Ni) in a Cu host can distinctively alter the selectivity of alcohol conversion. Specifically, our model studies reveal that ethanol reacts on Ni 1 Cu single-atom alloys to selectively produce acetaldehyde, whereas methane and CO are also formed on Rh 1 Cu single-atom alloys. Interestingly, these different reactivities are in contrast to the behavior of the pure metals as Ni(111) and Rh(111) surfaces favor methane/CO and surface carbon/CO, respectively. DFT calculations of reaction pathways and simulated product desorption based on microkinetic analyses explain these reactivity differences, demonstrating that C–C cleavage leading to methane formation has a lower barrier on Rh single-atom sites. To test the catalytic relevance of these fundamental results we synthesized and characterized supported Ni 1 Cu and Rh 1 Cu single-atom alloy nanoparticles with dopant:Cu ratios of 1:200. Flow reactor results revealed that both Ni and Rh increased ethanol conversion over Cu and that Ni 1 Cu catalysts were >99.9% selective to acetaldehyde, while Rh 1 Cu also produced 0.6%–2.6% of equimolar methane and CO between 433 and 493 K, demonstrating that C–C bond cleavage is enabled by isolated Rh sites. Furthermore, these catalytic results bridge the pressure and materials gaps, and together, this study provides insights into how different isolated dopant sites promote different catalytic pathways.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

Ion Cyclotron Heating in a Levitated Dipole Fusion Reactor

OpenStar Technologies is pursuing the levitated dipole (LD) as a highly modular, loosely-coupled system that leverages their expertise in high temperature superconductor (HTS) technology. The next generation experiment at OpenStar, Tahi (Ma¯ori for “first”), will demonstrate the generation and confinement of fast ions in a levitated dipole for the first time. Ion cyclotron range of frequency (ICRF) heating is a leading candidate for energetic ion formation in Tahi. A frequency in the 10 MHz range will be used for H minority heating or D majority heating with waves launched from an antenna located above the floating coil. Unlike a tokamak, where the targeted cyclotron resonance is typically a vertical path through the center of the plasma, in a dipole the resonance location follows a C-shaped path from the separatrix to the center of the plasma. The value of B also varies significantly within the confined plasma resulting in a large number of cyclotron harmonics present in the low field region. Furthermore, levitated dipoles contain a “first closed flux surface” surrounding the floating coil, in addition to the traditional separatrix /last closed flux surface. Simulation e ff orts using full-wave ICRF codes show that ICRF heating of a levitated dipole reactor is feasible using a pair of toroidal current straps phased to launch the appropriate parallel ( i.e. poloidal) refractive index.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2023

High-Temperature Sodium System Structural Health Monitoring (SHM) Technologies at the Mechanisms Engineering Test Loop (METL)

This report documents the deployment of non-destructive testing (NDT) technologies at the Mechanisms Engineering Test Loop (METL). METL became operational in September 2018 with the mission to provide an ecosystem for Advanced Reactor Development (ARD). METLs flagship facility’s primary purpose is conducting small to intermediate scale tests for Sodium Fast Reactors (SFR). Its resemblance to a commercial SFR’s intermediate heat transport system, prototypic operating conditions, and industrial construction practices/materials provides the overarching benefit of establishing a proving ground for devices of all technology readiness levels as well as commercial off-the-shelf equipment yet to be demonstrated on a sodium system.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

Continuum Damage Mechanics Modeling of High-Temperature Flaw Propagation: Application to Creep Crack Growth In 316H Standardized Specimens and Nuclear Reactor Components

Predicting creep crack growth (CCG) of flaws found during operation in high-temperature alloy components is essential for assessing the remaining lifetime of those components. While defect assessment procedures are available for this purpose in design codes, these are limited in their range of applicability. This study assesses the application of a local damage-based finite-element methodology as a more general technique for the prediction of CCG at high temperatures on a variety of structural configurations. Numerical results for stainless steel 316H, which are validated against experimental data, show the promise of this approach. This integration of continuum damage mechanics (CDM) based methodologies, together with adequate inelastic models, into assessment procedures can therefore inform the characterization of CCG under complex operating conditions, while avoiding excessive conservatism. This article shows that such modeling frameworks can be calibrated to experimental data and used to demonstrate that the degree of tri-axiality ahead of a growing creep crack affects its rate of growth. The framework is also successfully employed in characterizing CCG in a realistic reactor pressure vessel geometry under an arbitrary loading condition. These results are particularly relevant to the nuclear power industry for defect assessment and inspections as part of codified practices of structural components with flaws in high-temperature reactors.

42 ENGINEERING↗
DOE OSTI2021

Explicit Modeling of Pebble Temperature in the Porous-medium Framework for Pebble-bed Reactors Applications

In this study, an explicit model for pebble temperature calculations in the framework of a porous-medium approach has been developed and implemented in the SAM code. The solid-phase energy conservation equation, including the explicit modeling of pebble temperature, is a multi-scale model, which can predict the macroscopic (pebble-bed) and microscopic (pebble) temperature distributions under both steady-state and transient conditions. Extensive and successful code verifications and demonstrations have been performed for this newly developed model. By explicitly modeling pebble temperatures, this new model addresses a major deficiency of the previously implemented model, which assumed a local solid-phase thermal equilibrium that is not appropriate for pebble-bed reactor design and safety analysis applications.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2025

A percolating path to green iron

About 1.9 gigatons of steel is produced every year, emitting 8% (3.6 gigatons) of global CO 2 in the process. More than 50% of the CO 2 emissions come from a single step of steel production, known as ironmaking. Hydrogen- based direct reduction (HyDR) of iron oxide to iron has emerged as an emission-free ironmaking alternative. However, multiple physical and chemical phenomena ranging from nanometers to meters inside HyDR reactors alter the microstructure and pore networks in iron oxide pellets, in ways that resist gaseous transport of H 2 /H 2 O, slow reaction rates, and disrupt continuous reactor operation. Using synchrotron nano X-ray computed tomography and percolation theory, we quantify the evolution of pores in iron oxide pellets and demonstrate how nanoscale pore connectivity influences micro- and macroscale flow properties such as permeability, diffusivity, and tortuosity. Our modeling framework connects disparate scales and offers opportunities to accelerate HyDR.

hydrogen↗
DOE OSTI2021

Observation of fully detached divertor integrated with improved core confinement for tokamak fusion plasmas

Integration of divertor detachment with a high-performance (β N ~ 3, β p > 2, H 98 ~ 1.5) core plasma has been demonstrated in DIII-D high-β p (poloidal beta) plasmas associated with a sustained core internal transport barrier (ITB) and an H-mode edge transport barrier (ETB). Such good core-edge integration has been achieved for both neon and nitrogen seeding, for both favorable and unfavorable B-field directions, independently from the impurity puffing locations, though these variations play important roles on divertor characteristics. Compared to the standard H-mode plasmas, the high-β p plasma exhibits a much wider window of detachment compatible with high confinement core. Fully detached divertor plasmas with low plasma temperature (Te < 5 eV), low particle flux, and low heat flux across the entire divertor target plate were obtained by using nitrogen seeding. This detached high-β p plasma is compatible with a newly developed detachment control system which can help optimize the nitrogen gas flow rate. Several features, i.e., the high edge safety factor in the high-β p scenario, impurity injection, closed divertor and reduced heating power requirement due to the high confinement, facilitate the achievement of full divertor detachment at lower density. Instead of degrading global performance, the divertor detachment facilitates the access to an even stronger ITB at large radius with a relatively weak ETB through self-organized synergy between ITB and ETB, leading to sustained high confinement. The strengthening of the large-radius ITB compensates for the ETB degradation associated with divertor detachment. In addition, a weak ETB naturally has smaller edge localized modes (ELMs). In particular, with neon injection, a long-period no-ELM H-mode phase has been achieved simultaneously with high-performance core and partially detached divertor plasmas. Furthermore, these results demonstrate the possibility of integrating excellent core plasma performance with an effective divertor solution, an essential step toward steady-state operation of reactor-grade plasmas.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗