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DOE OSTI2024

Molten Salt Loop Operational Experience and Test Campaigns in FY24

The Facility to Alleviate Salt Technology Risks (FASTR) at the US Department of Energy (DOE) Oak Ridge National Laboratory (ORNL) was developed to demonstrate technology for high-temperature chloride salt systems (Figure 1). FASTR is primarily constructed using alloy C-276 and is designed to operate at temperatures of up to 725°C. The facility is loaded with 250 kg of NaCl-KCl-MgCl 2 salt. This salt provides a relevant test environment for de-risking technology while avoiding the costs and hazards associated with beryllium-based or uranium-bearing salts. The facility’s major components include a centrifugal pump for salt circulation, an air-based heat exchanger to reject heat, a suite of instrumentation, and trace heating to prevent salt freezing. The salt was purified in 2020 and 2022, and the pumped loop first operated in December 2022. FASTR is a unique US capability for high-temperature molten halide salt testing. FASTR’s scale, co located purification system, and relatively large power (465 kW) differentiates it from other testing systems. Furthermore, access to the DOE-supported facility and efficient communication of results— which are generally disseminated publicly—distinguish FASTR as being broadly significant throughout the molten salt reactor community. FASTR is similar to ORNL’s Liquid Salt Test Loop (LSTL), although FASTR contains chloride-based salt instead of the fluoride-based salt (LiF-NaF-KF) found in LSTL. Furthermore, FASTR is approximately 2× larger than LSTL in terms of pipe size and length, power, salt volume, flow rate, and number of thermocouples. The LSTL first operated in 2016. At the end of FY23, there was a suspected gas leak in the LSTL that halted operation. At the start of FY24, a leak in the LSTL pump’s tank gas space was confirmed. Because the gas-space leak prevented operation of LSTL, FY24 efforts were focused on operation of FASTR. This report summarizes the progress made during FY24 in support of the DOE Office of Nuclear Energy (DOE-NE) work package, AT-24OR070202 Salt Loop and Capability for Testing Sensors and Off Gas Components.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2025

Operation of Argonne's Liquid Salt-Liquid Metal Separation Testbed for U/TRU Product Processing

Argonne National Laboratory has constructed a liquid salt-liquid metal separation testbed for use in the development and advancement of cathode processing of U/TRU co‑deposits generated by pyroprocessing of used nuclear fuel. The U/TRU product recovered from the electrorefiner contains adhered and entrained salt that must be removed prior to consolidation of the U/TRU alloy for use in advanced reactor fuel fabrication. The bottom pour operation utilizes the low melting points of U/TRU co‑deposits and higher densities of molten metals compared to molten salts to separate and consolidate the U/TRU product. Argonne’s testbed is designed to support the development and optimization of bottom-pouring configurations for batch and semi-continuous operations, integration of process monitoring and control technologies, and determination of operational requirements for implementing in an industrial setting. Scoping tests were performed to demonstrate operational aspects of the testbed, including operation using single-pour spout and dual-pour spout configurations, effectiveness of salt containment and extent of salt vaporization, and the use of sensor probes to detect the location of the interface between the metal and salt phases during pouring. Recommendations for process optimization testing for further development of bottom pour processing to separate U/TRU alloys from adhered salt were made based on the results of scoping tests. Completing the recommended activities will increase the technical readiness level (TRL) of the liquid salt-liquid metal separation operation and consolidation of U/TRU alloys to support industrialization of pyroprocessing.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

Characterization of Inlet Guide Vane Performance for Discharge Compressor Operation near the Dome of an sCO 2 Pumped Heat Energy Storage

Southwest Research Institute® (SwRI®) developed and tested a Variable Inlet Guide Vane (IGV herein) assembly on an integrally-geared sCO 2 compressor (IGC) to demonstrate compressor operation at both the compressor design point and near the dome and to define the operating limits of the compressor by monitoring for two-phase flow, flow turbulence from the IGVs, and compressor choke and surge as the CO 2 inlet temperature is varied. Performance testing was conducted on an existing integrally-geared, two-stage main compressor designed for near-critical-point operation with CO 2 . This testing campaign validated the IGV design and operation, as well as improved the understanding and confidence in operating compressors and predicting performance characteristics near the critical point where fluid properties change rapidly with temperature. In addition to improving the robust operating limits of an sCO 2 compressor, the development of an IGV for the IGC system improved off-design compressor efficiency by 12%.

25 ENERGY STORAGE↗

DOE OSTI2024

U.S. Department of Energy-National Lab Equity Summit: Grid Planning and Operations (Workshop Report)

This report summarizes the U.S. DOE and national laboratories equity summit that was held on February 5, 2024, and focused on grid planning and operations. The objectives of the summit were to connect DOE and lab researchers working on grid-related equity issues, share information on current and planned grid-related equity projects and initiatives, and inspire and educate participants by hearing from our panelists about solutions and challenges to integrating equity in grid planning and operations. The summit included two panels of industry leaders. The first was a state and community perspectives panel that included representatives from a state public utility commission (Oregon Public Utility Commission), a state energy office (Washington Department of Commerce), a state utility consumer advocate (Connecticut Consumer Counsel), and industry consultants (Elevated Engagement and ArkSpring Consulting). Panelists shared successes they have seen, critical challenges related to equity and grid planning and operations, and other considerations. The second panel addressed utility perspectives and included representatives from two utilities (Commonwealth Edison and Tacoma Power), the National Rural Electric Cooperative (NRECA), and a former utility employee and legal consultant. Panelists discussed the role of the utility concerning equity, the most significant technical and data modeling needs and opportunities, and the role the labs could help advance equity in grid planning and operations. There was also a session on partner organization presentations. Argonne National Laboratory made a short presentation on the Grid Modernization Laboratory Consortium (GMLC) project they are leading on equity-informed power system planning. NARUC, NASEO, and the Clean Energy States Alliance, as partners of the GMLC project also shared updates on relevant activities and resources. During the summit, there were two rounds of lightning presentations by national labs and DOE highlighting research that addresses equity and grid planning and operations (Tables 5 and 6 and slides in the Appendix). The goal of the lightning rounds was to share information between participants to encourage collaboration and leverage ongoing research at labs and DOE. The summit included two interactive exercises where summit participants shared their perspectives on relevant equity projects and initiatives (Table 2), key challenges regarding equity and grid planning and operations (Table 3), and promising innovations or progress (Table 4). At the end of the session, participants were asked to share essential insights from the event (Table 7) and an action they plan to take as a result of the event. Participants agreed that the event was useful in helping them share and learn from each other. The project team plans to use the information from the summit as a starting point to help inform future research and technical assistance. In 2026, another Equity Summit will be held (virtually or in person) as part of the same project to help raise awareness and disseminate research and resources completed during the project's duration.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2019

On Computation of Koopman Operator from Sparse Data

In this paper, we propose a novel approach to compute the Koopman operator from sparse time series data. In recent years there has a considerable interest in operator theoretic methods for data-driven analysis of dynamical systems and existing techniques for the approximation of the Koopman operator require rich enough data-sets. However, in many applications, the data set may not be rich enough to approximate the operators to acceptable limits. In this paper, using ideas from robust optimization, we propose an algorithm to compute the Koopman operator from sparse data. In particular, we enrich the sparse data set with artificial data points and use robust optimization techniques to obtain the transfer operator. We illustrate the efficiency of our proposed approach in three different dynamical systems, namely, a linear system, a nonlinear system and a dynamical system governed by a partial differential equation.

Sinha, Subhrajit↗

DOE OSTI2025

Block-Structured Operator Inference for Coupled Multiphysics Model Reduction

This work presents a block-structured formulation of Operator Inference as a way to learn structured reduced-order models for multiphysics systems. The approach specifies the governing equation structure for each physics component and the structure of the coupling terms. Once the multiphysics structure is specified, the reduced-order model is learned from snapshot data following the nonintrusive Operator Inference methodology. In addition to preserving physical system structure, which in turn permits preservation of system properties such as stability and second-order structure, the block-structured approach has the advantages of reducing the overall dimensionality of the learning problem and admitting tailored regularization for each physics component. The numerical advantages of the block-structured formulation over a monolithic Operator Inference formulation are demonstrated for aeroelastic analysis, which couples aerodynamic and structural models. For the benchmark test case of the AGARD 445.6 wing, block-structured Operator Inference provides an average 20% online prediction speedup over monolithic Operator Inference across subsonic and supersonic flow conditions in both the stable and fluttering parameter regimes while preserving the accuracy achieved with monolithic Operator Inference.

42 ENGINEERING↗

DOE OSTI2022

Improving Microalgal Biomass Productivity Using Weather-Forecast-Informed Operations

The operation of microalgal cultivation systems, such as culture dilution associated with harvests, affects biomass productivity. However, the constantly changing incident light and ambient temperature in the outdoor environment make it difficult to determine the operational parameters that result in optimal biomass growth. To address this problem, we present a pond operation optimization tool that predicts biomass growth based on future weather conditions to identify the optimal dilution rate that maximizes biomass productivity. The concept was tested by comparing the biomass productivities of three dilution scenarios: standard batch cultivation (no dilution), fixed-rate dilution (harvest 60% of the culture every three days), and weather-forecast-informed dilution. In the weather-forecast-informed case, the culture was diluted daily, and the dilution ratio was optimized by the operation optimization tool according to the future 24 h weather condition. The results show that the weather-forecast-informed dilution improved the biomass productivity by 47% over the standard batch cultivation and 20% over the fixed-rate dilution case. These results demonstrate that the pond operation optimization tool could help pond operators to make decisions that maximize biomass growth in the field under ever-changing weather conditions.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2018

Capacity Optimization of a Centralized Charging Station in Joint Operation with a Wind Farm

In the context of large-scale wind power integration and rapid development of electric vehicles (EVs), a joint operation pattern was proposed to use a centralized charging station (CCS) to address high uncertainties incurred by wind power integration. Additionally, this would directly remove the significant indeterminacy of wind power. Because the CCS is adjacent to a wind power gathering station, it could work jointly with wind farms to operate in power system as an independent enterprise. By combining the actual operational characteristics of the wind farm and the CCS, a multidimensional operating index evaluation system was created for the joint system. Based on the wind farm’s known capacity, a multi-target capacity planning model was established for CCS to maximize the probability of realizing diverse indices of the system based on dependent-chance goal programming. In this model, planning and dispatching are combined to improve the feasibility of results in the operational stage. This approach takes the effects of randomness into account for wind power and battery swapping. The model was solved through combining Monte Carlo simulation and a genetic algorithm (GA) based on segmented encoding. Finally, as shown in the simulation results, the proposed model could comprehensively include factors such as initial investment, wind power price, battery life, etc., to optimize CCS capacity and to ultimately improve the operating indices of the joint system.

17 WIND ENERGY↗

DOE OSTI2018

Development of 80- and 100- Mile Work Day Cycles Representative of Commercial Pickup and Delivery Operation

When developing and designing new technology for integrated vehicle systems deployment, standard cycles have long existed for chassis dynamometer testing and tuning of the powertrain. However, to this day with recent developments and advancements in plug-in hybrid and battery electric vehicle technology, no true 'work day' cycles exist with which to tune and measure energy storage control and thermal management systems. To address these issues and in support of development of a range-extended pickup and delivery Class 6 commercial vehicle, researchers at the National Renewable Energy Laboratory in collaboration with Cummins analyzed 78,000 days of operational data captured from more than 260 vehicles operating across the United States to characterize the typical daily performance requirements associated with Class 6 commercial pickup and delivery operation. In total, over 2.5 million miles of real-world vehicle operation were condensed into a pair of duty cycles, an 80-mile cycle and a 100-mile cycle representative of the daily operation of U.S. class 3-6 commercial pickup and delivery trucks. Using novel machine learning clustering methods combined with mileage-based weighting, these composite representative cycles correspond to 90th and 95th percentiles for daily vehicle miles traveled by the vehicles observed. In addition to including vehicle speed vs time drive cycles, in an effort to better represent the environmental factors encountered by pickup and delivery vehicles operating across the United States, a nationally representative grade profile and key status information were also appended to the speed vs. time profiles to produce a 'work day' cycle that captures the effects of vehicle dynamics, geography, and driver behavior which can be used for future design, development, and validation of technology.

100 mile↗

DOE OSTI2021

Characterizing the performance of a POPS miniaturized optical particle counter when operated on a quadcopter drone

We first validate the performance of the Portable Optical Particle Spectrometer (POPS), a small light-weight and high sensitivity optical particle counter, against a reference scanning mobility particle sizer (SMPS) for a month-long deployment in an environment dominated by biomass burning aerosols. Subsequently, we examine any biases introduced by operating the POPS on a quadcopter drone, a DJI Matrice 200 V2. We report the root mean square difference (RMSD) and mean absolute difference (MAD) in particle number concentrations (PNCs) when mounted on the UAV and operating on the ground and when hovering at 10 m. When wind speeds are low (less than 2.6 m s –1 ), we find only modest differences in the RMSDs and MADs of 5 % and 3 % when operating at 10 m altitude. When wind speeds are between 2.6 and 7.7 m s –1 the RMSDs and MADs increase to 26.2 % and 19.1 %, respectively, when operating at 10m altitude. No statistical difference in PNCs was detected when operating on the UAV in either ascent or descent. We also find size distributions of aerosols in the accumulation mode (defined by diameter, d, where 0.1 ≤ d ≤ 1 µm) are relatively consistent between measurements at the surface and measurements at 10 m altitude, while differences in the coarse mode (here defined by d > 1 µm) are universally larger. Our results suggest that the impact of the UAV rotors on the POPS PNCs are small at low wind speeds, but when operating under a higher wind speed of up to 7.6 m s –1 , larger discrepancies occur. In addition, it appears that the POPS measures sub-micron aerosol particles more accurately than super-micron aerosol particles when airborne on the UAV. These measurements lay the foundations for determining the magnitude of potential errors that might be introduced into measured aerosol particle size distributions and concentrations owing to the turbulence created by the rotors on the UAV.

47 OTHER INSTRUMENTATION↗

DOE OSTI2021

Coordination and control – limits in standard representations of multi-reservoir operations in hydrological modeling

Abstract. Major multi-reservoir cascades represent a primary mechanism for dealing with hydrologic variability and extremes within institutionally complex river basins worldwide. These coordinated management processes fundamentally reshape water balance dynamics. Yet, multi-reservoir coordination processes have been largely ignored in the increasingly sophisticated representations of reservoir operations within large-scale hydrological models. The aim of this paper is twofold, namely (i) to provide evidence that the common modeling practice of parameterizing each reservoir in a cascade independently from the others is a significant approximation and (ii) to demonstrate potential unintended consequences of this independence approximation when simulating the dynamics of hydrological extremes in complex reservoir cascades. We explore these questions using the Water Balance Model, which features detailed representations of the human infrastructure coupled to the natural processes that shape water balance dynamics. It is applied to the Upper Snake River basin in the western US and its heavily regulated multi-reservoir cascade. We employ a time-varying sensitivity analysis that utilizes the method of Morris factor screening to explicitly track how the dominant release rule parameters evolve both along the cascade and in time according to seasonal high- and low-flow events. This enables us to address aim (i) by demonstrating how the progressive and cumulative dominance of upstream releases significantly dampens the ability of downstream reservoir rules' parameters to influence flow conditions. We address aim (ii) by comparing simulation results with observed reservoir operations during critical low-flow and high-flow events in the basin. Our time-varying parameter sensitivity analysis with the method of Morris clarifies how independent single-reservoir parameterizations and their tacit assumption of independence leads to reservoir release behaviors that generate artificial water shortages and flooding, whereas the observed coordinated cascade operations avoided these outcomes for the same events. To further explore the role of (non-)coordination in the large deviations from the observed operations, we use an offline multi-reservoir water balance model in which adding basic coordination mechanisms drawn from the observed emergency operations is sufficient to correct the deficiencies of the independently parameterized reservoir rules from the hydrological model. These results demonstrate the importance of understanding the state–space context in which reservoir releases occur and where operational coordination plays a crucial role in avoiding or mitigating water-related extremes. Understanding how major infrastructure is coordinated and controlled in major river basins is essential for properly assessing future flood and drought hazards in a changing world.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2024

Experimental Operation of a Prototype 750C Advanced Chloride Molten Salt Bellows Valve

To achieve DOE 2030 SunShot targets that reduce the cost of liquid-based solar by an additional 40% to 70% beyond 2018 costs, a more reliable, highly manufacturable flow valve, capable of achieving operational temperatures of >700°C is required [1]. This paper investigates the development of an innovative high-temperature chloride molten salt valve, with operation up to 750°C. This valve is intended to be employed within Gen 3 CSP liquid-based thermal energy storage (TES) systems as well as Gen 4 modular salt reactor (MSR) technologies. This work details the general design and flow testing of a bellows-seal flow control valve (FCV). This design includes an integrated closed-loop thermal control system to ensure robust design for freeze-thaw cycles. The self-contained thermal management STM system, is unique in the salt valve industry since it is an integrated solution to provide a consistent, repeatable alternative to typical heat tracing. Additionally, the design includes the employment of a novel heat pipe valve stem to facilitate enhanced passive thermal management into the valve assembly. This valve stem heat pipe is designed to facilitate natural circulation within the bonnet to ensure robust operation, during both nominal and transient thermal operation. The valve body and trim will be designed using SS316H, consistent with Flowserve Corporation’s existing product base and is code qualified but will utilize clad material for materials corrosion, manufacturing cost reduction and compatibility to ensure design flexibility. A test campaign was performed in this investigation utilizing a novel 750°C ternary chloride (20%NaCl/40%MgCl2/40%KCl by mol. wt. %) molten salt flow loop. A discussion about the design and installation of the valves within this test bed is provided for this investigation. Valve test results from this study assessed Cv curves as well as multiple actuator cycles, under varying thermodynamic and operational mode conditions, which would be characteristic within a commercial molten salt facility. The results indicate nominal operation for the baseline design, though improved performance and reliability is expected with the full designed FCV.

Armijo, Kenneth (ORCID:0000000346832147)↗

DOE OSTI2022

Operator Insights and Usability Evaluation of Machine Learning Assistance for Power Grid Contingency Analysis

Introducing machine learning (ML) assistance into any established process comes with adoption barriers, including entrenched procedures, technological and human readiness levels, human-machine trust, and work culture resistance to change. These barriers are even greater in critical operations such as operating a national or regional power grid, in which both regulatory frameworks and the importance of maintaining reliability levels causes additional resistance to the adoption of new computational support. Developers of future systems and job aides must consider not only technical aspects, but also whether new systems are usable by power system operators. This work presents the methodology and results of a study to evaluate the usability and readiness of a prototype recommender system for power grid contingency analysis. We explore operator cognitive load and evaluate operator performance when solving a collection of scenarios both with and without recommender assistance. We also examine operator trust in the system. We report insights gained on the readiness of the system using a collection of evaluation techniques.

Human-Machine Teaming, Power Systems, usability ev↗

NASA NTRS1972

Effect of commercial and military performance requirements for transport category aircraft on space shuttle booster design and operation

The effect of two sets of performance requirements, commercial and military, on the design and operation of the space shuttle booster is evaluated. Critical thrust levels are established according to both sets of operating rules for the takeoff, cruise, and go-around flight modes, and the effect on engine requirements determined. Both flyback and ferry operations are considered. The impact of landing rules on potential shuttle flyback and ferry bases is evaluated. Factors affecting reserves are discussed, including winds, temperature, and nonstandard flight operations. Finally, a recommended set of operating rules is proposed for both flyback and ferry operations that allows adequate performance capability and safety margins without compromising design requirements for either flight phase.

Bithell, R. A.↗

NASA NTRS1975

Tug fleet and ground operations schedules and controls. Volume 1: Executive summary

This study presents Tug Fleet and Ground Operations Schedules and Controls plan. This plan was developed and optimized out of a combination of individual Tug program phased subplans, special emphasis studies, contingency analyses and sensitivity analyses. The subplans cover the Tug program phases: (1) Tug operational, (2) Interim Upper Stage (IUS)/Tug fleet utilization, (3) and IUS/Tug payload integration, (4) Tug site activation, (5) IUS/Tug transition, (6) Tug acquisition. Resource requirements (facility, GSE, TSE, software, manpower, logistics) are provided in each subplan, as are appropriate Tug processing flows, active and total IUS and Tug fleet requirements, fleet management and Tug payload integration concepts, facility selection recommendations, site activation and IUS to Tug transition requirements. The impact of operational concepts on Tug acquisition is assessed and the impact of operating Tugs out of KSC and WTR is analyzed and presented showing WTR as a delta. Finally, cost estimates for fleet management and ground operations of the DDT&E and operational phases of the Tug program are given.

Source record↗

NASA NTRS1976

Spacelab operations planning

The paper reviews NASA planning in the fields of ground, launch and flight operations and experiment integration to effectively operate Spacelab. Payload mission planning is discussed taking consideration of orbital analysis and the mission of a multiuser payload which may be either single or multidiscipline. Payload analytical integration - as active process of analyses to ensure that the experiment payload is compatible to the mission objectives and profile ground and flight operations and that the resource demands upon Spacelab can be satisfied - is considered. Software integration is touched upon and the major integration levels in ground operational processing of Spacelab and its experimental payloads are examined. Flight operations, encompassing the operation of the Space Transportation System and the payload, are discussed as are the initial Spacelab missions. Charts and diagrams are presented illustrating the various planning areas.

Lee, T. J.↗

NASA NTRS1977

A life cycle cost economics model for projects with uniformly varying operating costs

A mathematical model is developed for calculating the life cycle costs for a project where the operating costs increase or decrease in a linear manner with time. The life cycle cost is shown to be a function of the investment costs, initial operating costs, operating cost gradient, project life time, interest rate for capital and salvage value. The results show that the life cycle cost for a project can be grossly underestimated (or overestimated) if the operating costs increase (or decrease) uniformly over time rather than being constant as is often assumed in project economic evaluations. The following range of variables is examined: (1) project life from 2 to 30 years; (2) interest rate from 0 to 15 percent per year; and (3) operating cost gradient from 5 to 90 percent of the initial operating costs. A numerical example plus tables and graphs is given to help calculate project life cycle costs over a wide range of variables.

Remer, D. S.↗

NASA NTRS1979

Operations of the ATS-6 ion engine

The ion engine experiments on ATS 6 were operated in daylight and eclipse. The effect on particle fluxes to the spacecraft was monitored with the UCSD Auroral Particles Experiment. These data also provide information on the potential of the spacecraft with respect to the ambient plasma and on the local electric fields caused by the charge distribution on the satellite. Daylight operations of the plasma bridge neutralizer and the cesium thruster in fall, 1974, served to hold the spacecraft between -3 and -8 volts with respect to the ambient plasma. Neutralizer operation reduced differential charging effects, while operation of the thruster usually reduced the effects below the detectors sensitivity. Eclipse operations of the neutralizer reduced kilovolt negative potentials to a few volts. Operation of the thruster prevented possible charging of the satellite during substorms, making it possible to study low energy particle spectra which are at times obscured by charging during substorms.

Olsen, R. C.↗