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DOE OSTI2020

Grimsel Test Site - A Successful International Underground Research Laboratory for Many Decades - 20429

For more than 35 years, Nagra and its partners from around the world have been conducting underground research projects at the Grimsel Test Site (GTS, www.grimsel.com) to contribute to the development and confirmation of safe geological disposal concepts and for the characterization of suitable host rock formations. Over the years, the results of this internationally recognized research program have been, and continue to be, incorporated directly into exploration programs, modelling, safety, and engineering feasibility studies on options for deep geological repositories. Each project of the GTS program involves field-testing, laboratory studies, design and modelling tasks, and integrates all scientific and technical aspects. Each project phase is planned with a duration of three to five years to facilitate practical and administrative aspects and allow flexibility for updating the overall project plans with the latest findings. Scientific and engineering interaction among the different projects is ensured via an international steering committee meeting. Hosting an IAEA level C radiation- controlled zone, which allows use of radionuclides, including actinides such as thorium, uranium, neptunium, plutonium and americium, in in-situ experiments is one of the reasons why GTS also developed as a center of excellence for work with radioactive tracers under realistic in-situ boundary conditions. Last year, a new five-year program (2019 to 2023) started which includes projects with a planning horizon of decades. The new five-year program includes a new phase of in-situ experiments using radionuclides such as migration experiments in the Colloid Formation and Migration project (CFM), the Long-Term Diffusion experiment (LTD) and the newly established C-14 and I-129 Migration in cement project (CIM). The 'High Temperature effects on Bentonite' (HotBENT) project is starting in the current phase and is studying the effects of elevated temperatures (>175 deg. C) on bentonite materials. As a generic underground research laboratory (URL) it is expected that the GTS will provide in the coming years a platform for international collaboration, knowledge development and knowledge transfer for the next generation of scientists and engineers in the area of radioactive waste disposal and geosciences. A key role regarding knowledge transfer and training is provided by the well-established Grimsel Training Center (GTC), which (beside many URL related issues) also covers many general aspects of radioactive waste management. In this paper we provide an overview of the current program at the GTS, focusing on the experiments that study the migration of radionuclides through engineered barrier materials and the geosphere. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2024

Temporal and Spatial Evolution of Non-Elastic Strain Accumulation in Stanstead Granite During Brittle Creep

Understanding the long-term behavior of brittle rocks requires fundamental consideration of time-dependent strain evolution and brittle creep processes. Previous studies have evaluated sub-critical crack growth during time-dependent deformation and damage evolution in brittle rocks; however, there is an incomplete knowledge of how damage evolves spatially and temporally within the body of intact rocks, where distributed regions of damage interact and coalesce during creep. This paper presents laboratory research focusing on evaluating brittle creep damage processes in Stanstead granite (SG) using 2-dimensional digital image correlation (2D-DIC). In the laboratory, the prismatic SG specimens were loaded beyond an estimated Crack Damage stress threshold (CD) level and then maintained a constant stress to initiate the creep process. DIC was used to characterize full-field spatiotemporal strain evolution, which was then interpreted in the context of local regions of “damage”, determined according to a strain-based criterion. Here, a method was proposed for identifying “existing” and “new” damage regions over specified intervals during the test, followed by spatial clustering of these regions to assess their spatiotemporal evolution. The clustering analysis results demonstrated the extension of existing damage regions was the main damage process during brittle creep, which is consistent with existing models of sub-critical crack growth. In addition, temporal analysis of tensile and shear strains on a point-by-point basis revealed both new damage formation and the strain concentration within existing damaged regions significantly contribute to overall specimen strain during primary creep. In contrast, during secondary creep, increases in specimen deformation are influenced by the accumulation of strains within already damaged regions.

58 GEOSCIENCES↗

DOE OSTI2022

Numerical modeling and parametric study of a dual purpose underground thermal battery

We report integrating thermal energy storage with building energy systems can enable flexible building electric demands at buildings to help mitigate the mismatch between electricity supply and demand. A novel building heating and cooling system that integrates a dual-source heat pump with hybrid thermal storage named dual-purpose underground thermal battery (DPUTB) has been developed for reshaping building electric demands. The proposed DPUTB integrated geothermal heat pump system is an original innovation that enables Grid-interactive Energy Efficient buildings. This paper focuses on the study of the novel DPUTB. The DPUTB works as both a thermal storage tank (an inner tank) and a ground heat exchanger (an outer tank separated from the inner tank by the insulation material). High fidelity and computationally effective models are needed to predict the performance of the novel DPUTB. This study has developed a simplified dynamic model for the DPUTB according to heat transfer and energy conservation principles and validated it by using experimental data obtained from testing a small-scale DPUTB apparatus. A parametric study was conducted to identify a design that can achieve the target thermal storage performance of load shift and energy efficiency. The parametric study results show that the inner tank shell thermal conductivity and the phase change material's melting point are the two most influencing factors on the performance of the DPUTB. One single full-size DPUTB with the identified design could provide 1-ton cooling (3.51 kW) with the supply temperature lower than 11 °C for 4 hours in summer after being fully charged in 8 hours. The inner tank filled with phase change material is for cooling thermal storage as a latent tank in the design. However, its capacity can be as high as 60 MJ as a sensible water tank for heating storage in winter. In the future study, the DPUTB model will be incorporated into the dual-source heat pump system for evaluating the overall system performance of demand side management in the long term.

25 ENERGY STORAGE↗

DOE OSTI2026

Chemical and morphological evolution of hybrid conversion coatings in low-Earth orbit space environment

Understanding how protective coatings respond to the harsh low-Earth orbit (LEO) environment is essential for ensuring the safety, longevity, and cost-effectiveness of spacecraft. In particular, identifying environmentally friendly, non-chromate alternatives that can maintain performance under such conditions has both technological and regulatory significance. This study investigates the environmental stability of zirconium-based hybrid conversion coatings with Cu additives (Cu10 and Cu20) applied to cold-rolled steel, tested in the Materials International Space Station Experiment (MISSE) outside the International Space Station (ISS). Chemical and morphological analyses were carried out using a combination of electron microscopy and X-ray spectroscopy techniques, including scanning electron microscopy (SEM), scanning transmission electron microscopy with energy-dispersive X-ray spectroscopy (STEM-EDS), X-ray photoelectron spectroscopy (XPS), and X-ray absorption near-edge structure (XANES) spectroscopy. After exposure outside the ISS, all coatings remained structurally intact, with all exhibiting a uniform Zr-rich matrix and embedded Cu-rich clusters, while a thin Si-rich surface layer developed from interaction with space environments. Depth-resolved XPS showed a layered structure with CuO on the surface, Cu 2 O, and partial Zr(IV) reduction near Cu-rich sites, evidence of Atomic Oxygen (AO)-driven surface oxidation. These results demonstrate that Cu–Zr coatings maintain their chemical integrity and microstructure in harsh space environments, offering a non-chromate alternative for long-term aerospace protection. These insights provide valuable guidance for developing next-generation protective coatings that combine environmental sustainability with the reliability required for future aerospace and orbital applications.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Measure the effect of molten halide salt exposure on creep rupture lifetime

Recent resurgence in the research and commercial interests in molten salt reactors (MSRs) as a viable advanced reactor concept to achieve the short- and long-term climate goals has resulted in ongoing efforts to demonstrate their commercial potential. These are relying on a combination of the extensive legacy knowledge from the molten salt reactor experiment (MSRE) and relatively recent data on materials compatibility of structural materials of interest such as 316H in molten salts environments. However, there is a critical lack of data on the mechanical behavior of alloys of interest for MSRS such as 316H, 617 and 709 in molten fluoride (FLiNaK or FLiBe) or chloride (NaCl-MgCl 2 ) salts. Limited legacy data from the molten salt reactor experiment (MSRE) program showed a significant reduction in creep rupture strength of a Ni-base alloy (Ni-15Cr-7Fe wt.%) in the molten fluoride NaF-ZrF4-UF4 (50-46-4 mol.%) salt. With ongoing efforts to commercialize different molten salt reactor concepts, the industry can considerably benefit from quantitative information on the impact of molten halide salts on the engineering properties such as creep and fatigue strength of materials of interest. Creep tests for 316H were conducted with fluoride (FLiNaK) and chloride (NaCl-MgCl 2 ) salts tat 650°C/150 MPa while alloys 709 and 617 were tested with FLiNaK at 700C/158 MPa and 750C.146 MPa respectively. Baseline tests were conducted in air to assess the impact of the molten salts on the creep behavior.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

Measure the effect of molten halide salt exposure on creep rupture lifetime

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2020

Physical and hydrodynamic properties of deep sea mining-generated, abyssal sediment plumes in the Clarion Clipperton Fracture Zone (eastern-central Pacific)

The anthropogenic impact of polymetallic nodule harvesting in the Clarion-Clipperton Fracture Zone is expected to strongly affect the benthic ecosystem. To predict the long-term, industrial-scale impact of nodule mining on the deep-sea environment and to improve the reliability of the sediment plume model, information about the specific characteristics of deep-sea particles is needed. Discharge simulations of mining-related fine-grained (median diameter ≈ 20 µm) sediment plumes at concentrations of 35–500 mg L –1 (dry weight) showed a propensity for rapid flocculation within 10 to 135 min, resulting in the formation of large aggregates up to 1100 µm in diameter. The results indicated that the discharge of elevated plume concentrations (500 mg L –1 ) under an increased shear rate (G ≥ 2.4 s –1 ) would result in improved efficiency of sediment flocculation. Furthermore, particle transport model results suggested that even under typical deep-sea flow conditions (G ≈ 0.1 s –1 ), rapid deposition of particles could be expected, which would restrict heavy sediment blanketing (several centimeters) to a smaller fall-out area near the source, unless subsequent flow events resuspended the sediments. Planning for in situ tests of these model projections is underway.

42 ENGINEERING↗

DOE OSTI2024

Updated sustainability status of cadmium telluride thin‐film photovoltaic systems and projections

This paper provides a comprehensive assessment of the up-to-date life-cycle sustainability status of cadmium-telluride based photovoltaic (PV) systems. Current production modules (Series 6 and Series 7) are analyzed in terms of their energy performance and environmental footprint and compared with the older series 4 module production and current single-crystalline Silicon (sc-Si) module production. For fixed-tilt systems with Series 6 modules operating under average US irradiation of 1800 kWh/m 2 /year, the global warming potential (GWP) is reduced from 16 g CO 2eq /kWh in Series 4 systems to 10 CO 2 eq /kWh in Series 6 systems. For operation in US-SW irradiation of 2300 kWh/m 2 /year, the GWP is reduced from 11 to 8 CO 2eq /kWh and for 1-axis tracking systems operating in Phoenix, Arizona, with point-of array irradiation of 3051 kWh/m 2 /year the GWP is reduced to 6.5 CO 2eq /kWh. Similar reductions have happened in all environmental indicators. Energy payback times (EPBT) of currently installed systems range from 0.6 years for fixed–tilt ground–mounted installations at average US irradiation at latitude tilt installations to 0.3 years for one-axis trackers at high US-SW irradiation, considering average fossil-fuel dominated electricity grids with fuel to electricity conversion efficiency of 0.3. The resulting energy return on energy investment (EROI) also depends on the conversion efficiency of the electricity grid and on the operation life expectance. For a 30-year operational life and grid conversion efficiency of 0.3, EROI ranges from 50 (at US average irradiation) to 70 for US-SW irradiation. The EROI declines with increased grid conversion efficiency; for CdTe PV operating in south California with grid conversion efficiency of 49%, the EROI is about 50 and is projected to fall to 30 when the state's 2030 target of 80% renewable energy penetration materializes. Material alternatives that show a potential of further reductions in degradation rates and materials for enhanced encapsulation that would enable longer operation lives have also been investigated. A degradation rate of 0.3%/year, which has been verified by accelerated testing, is assumed in 30-year scenarios; this is projected to be reduced to 0.2%/year in the near-term and potentially to 0.1%/year in the longer term. With such low degradation rates and enhanced edge-sealing, modules can last 40- to 50-years. Consequently, all impact indicators will be proportionally reduced while EROI will increase. This detailed LCA was conducted according to ISO standards and IEA PVPS Task 12 guidelines. Furthermore, the study revealed that the choices of system models, methods and temporal system boundaries can significantly impact the results and points out to the need to include assumptions regarding these choices in the “transparency in reporting” requirements listed in the IEA PVPS Task 12 Guidelines.

14 SOLAR ENERGY↗

DOE OSTI2026

Complete Phase Transformation of Ir Nanowire Network into Defect-Rich Oxide Catalyst for High-Performance PEM Water Electrolysis

Iridium-based catalysts remain the most reliable option for the oxygen evolution reaction (OER) in proton exchange membrane water electrolyzers (PEMWEs). However, their high cost and limited performance represent critical barriers to the commercialization of this green hydrogen production technology. Herein, we report the creation of a metallic Ir nanowire network (IrNWN), which exhibits superior OER performance through its in-situ transition into an oxide structure with high intrinsic activity. At a low loading of 0.25 mgIr/cm2 in PEMWEs, IrNWN achieved a current density of 3.13 A/cm2 at a cell voltage of 1.8 V, outperforming the commercial Ir-based catalyst and surpassing the Department of Energy (DOE) 2026 technical target. Moreover, the high activity of IrNWN was maintained for 900 hours in a durability test at 2 A/cm2, showing a low degradation rate of 0.042 mV/hour. Structural analysis of the electrochemically oxidized IrNWN revealed the presence of mixed Ir oxidation states and a high density of surface terminal oxygen groups (μ1-O), which contributed to a reduced energy barrier for the rate-determining O-O coupling step.

oxygen evolution reaction↗

DOE OSTI2020

The Catalytic Reduction of Dinitrogen Under Mild Conditions (Final Report)

In order to use molecular hydrogen as an alternative to fossil fuels, large quantities of hydrogen (or protons and electrons) would have to be generated from water using a method based on solar energy and stored as a molecule in which hydrogen is a high weight percentage. The hydrogen must then be generated as needed from the form in which it is stored. An attractive molecule for this purpose is ammonia (~17% hydrogen by weight). Among the many problems that must be addressed for a successful implementation of this approach in the long term is the reduction of nitrogen catalytically to ammonia with protons and electrons under mild conditions, a goal that is addressed in this proposal. The first abiological catalytic reduction of N 2 to NH 3 by protons and electrons under mild conditions (22 °C and 1 atm) employed molybdenum catalysts, [(HIPTNCH 2 CH 2 ) 3 N]Mo (HIPTN 3 N 3- ), where HIPT (hexaisopropylterphenyl) is 3,5- (2,4,6-i-Pr 3 C 6 H 2 ) 2 C 6 H 3 . A total of approximately four turnovers (to give a maximum of eight equivalents of ammonia) along with approximately one equivalent of hydrogen per N 2 reduced, were found. A limitation of this catalytic approach is loss of the ligand from the metal. This project is aimed at developing a complex that contains a ligand that will not be removed from the metal. A macrocyclic TREN-based ligand of this type has been synthesized recently. The project is aimed at making similar ligands and molybdenum complexes that contain them and testing the new catalysts for catalytic reduction of dinitrogen. The results of these investigations will help guide further design of ligands for more efficient reduction of nitrogen to ammonia and ultimately an integrated device in which protons and electrons are generated using solar energy and employed to reduce nitrogen to ammonia using molybdenum catalysts.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Field Test and Thermal Performance Comparison of a Novel Underground Thermal Battery with a Single U-tube Borehole Heat Exchanger for Geothermal Heat Pump Application

Geothermal Heat Pumps (GHP) are a proven technology to electrify and decarbonize space heating and cooling by utilizing the thermally consistent underground as a heat sink or source. However, the high drilling costs of conventional borehole heat exchangers (BHEs) associated with GHP systems and subsurface heterogeneity have been two major challenges to their widespread adoption. In this paper, we present results from a field-scale pilot of an Underground Thermal Battery (UTB) as a potential alternative to a conventional BHE. To benchmark the UTB performance, a side-by-side field test was conducted to compare the UTB with a conventional BHE installed at the same site. The UTB was installed in a 7.01-meter-deep borehole having a diameter of 0.9 meter, whereas the conventional BHE (with single U-tube loop) is in a borehole with 36.6-meter depth and 0.15-meter diameter. Both are integrated into a GHP system to meet the thermal energy demands of office space at the Illinois Energy Farm on the University of Illinois Urbana-Champaign campus. The system’s performance is compared in terms of heat transfer rate, outlet temperatures, and contributions to the overall thermal power of the GHP system under varying thermal demands and in different heat pump operation modes: heating only, cooling only, and hybrid (alternative, diurnal heating and cooling). Results to date indicate that the UTB delivers a more consistent response under during a time period of varying thermal demands. Its operational performance is better during short-term with higher thermal demands, while the conventional BHE performs better under continuous, long-term thermal demands.

Pokhrel, Sajjan [ORNL] (ORCID:0000000228523749)↗

DOE OSTI2021

Mining and Validating Social Media Data for COVID-19–Related Human Behaviors Between January and July 2020: Infodemiology Study

Background: Health authorities can minimize the impact of an emergent infectious disease outbreak through effective and timely risk communication, which can build trust and adherence to subsequent behavioral messaging. Monitoring the psychological impacts of an outbreak, as well as public adherence to such messaging, is also important for minimizing long-term effects of an outbreak. Objective: We used social media data from Twitter to identify human behaviors relevant to COVID-19 transmission, as well as the perceived impacts of COVID-19 on individuals, as a first step toward real-time monitoring of public perceptions to inform public health communications. Methods: We developed a coding schema for 6 categories and 11 subcategories, which included both a wide number of behaviors as well codes focused on the impacts of the pandemic (eg, economic and mental health impacts). We used this to develop training data and develop supervised learning classifiers for classes with sufficient labels. Classifiers that performed adequately were applied to our remaining corpus, and temporal and geospatial trends were assessed. We compared the classified patterns to ground truth mobility data and actual COVID-19 confirmed cases to assess the signal achieved here. Results: We applied our labeling schema to approximately 7200 tweets. The worst-performing classifiers had F1 scores of only 0.18 to 0.28 when trying to identify tweets about monitoring symptoms and testing. Classifiers about social distancing, however, were much stronger, with F1 scores of 0.64 to 0.66. We applied the social distancing classifiers to over 228 million tweets. We showed temporal patterns consistent with real-world events, and we showed correlations of up to –0.5 between social distancing signals on Twitter and ground truth mobility throughout the United States. Conclusions: Behaviors discussed on Twitter are exceptionally varied. Twitter can provide useful information for parameterizing models that incorporate human behavior, as well as for informing public health communication strategies by describing awareness of and compliance with suggested behaviors.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2020

Impact of Laboratory-Accelerated Aging Methods to Study Alkali–Silica Reaction and Reinforcement Corrosion on the Properties of Concrete

This study focuses on two separate investigations of the main aging mechanisms: alkali–silica reactivity (ASR) and the corrosion of reinforcing steel (rebar) concrete, both of which may result in a premature failure to meet the serviceability or strength requirements of a concrete structure. However, these processes occur very slowly, spanning decades. The impact of direct chemical additives to fresh concrete to accelerate ASR and the corrosion of reinforcing steel on the fresh and hardened properties of the ensuing material are investigated to inform the potential use of chemicals in large-scale studies. The deterioration of reinforced concrete (RC) is determined by means of expansion, cracking, bulk diffusivity and surface resistivity measurements, and compressive, split tensile and flexural strength tests. The results indicate that the addition of sodium hydroxide and calcium chloride can effectively accelerate the crack formation and propagation in concrete due to ASR and the corrosion of rebar, respectively. The ASR-induced cracks maintained a constant crack width from 0.05 mm to 0.1 mm over the measurement period regardless of the intensity of aging acceleration. Adding 4% chloride by weight of cement for accelerating rebar corrosion resulted in an average crack that was 82% larger than in the case of ASR accelerated with the addition of sodium hydroxide. The addition of alkali resulted in an increase in early-age (7-day) strength. At a total alkali loading of 2.98 kg/m3, 3.84 kg/m3 and 5.57 kg/m3, the 28-day compressive strength of concrete decreased by 3%, 10% and 24%, respectively. Similarly, a higher early-age strength and a lower later-age strength was observed for the concrete in the presence of corrosive calcium chloride. The results from this research are expected to inform future studies on the long-term performance of RC structures under accelerated ASR and corrosion.

36 MATERIALS SCIENCE↗

DOE OSTI2020

CY2019 Annual Closure Monitoring Report for Corrective Action Unit 98, Frenchman Flat, Underground Test Area, Nevada National Security Site, Nevada (January 2019–December 2019), Revision 1

Three types of monitoring are performed for CAU 98: water quality, water level, and institutional control. These are monitored to determine whether the URs remain protective of human health and the environment, and to ensure that the regulatory boundary objectives are being met. Monitoring data will be used in the future, once multiple years of data are available, to evaluate consistency with the groundwater flow and contaminant transport models because the contaminant boundaries calculated with the models are the primary basis of the UR boundaries. Six wells were sampled for water-quality monitoring in 2019. Contaminants of concern were detected only in the two source/plume wells already known to contain contamination as a result of a radionuclide migration experiment. Tritium concentrations in both of these wells, RNM-2S and UE-5n, remain above the Safe Drinking Water Act maximum contaminant level of 20,000 picocuries per liter but declined in 2019 as compared to measurements in 2018. All other contaminants of concern are below the minimum detection level plus analytical error. The water-level monitoring network includes 16 wells. Depth to water measured in 2019 is generally consistent with recent measurements for all wells. Many wells continue to exhibit a long-term downward trend in water level, though changes from 2018 to 2019 are minimal. The sharp 2016 decline in water level in Well ER-5-3-2 remains unexplained, with the lower level persisting through 2019. Rising water-level trends continue to be observed in Well ER-5-3 deep piezometer and former water supply Well WW-5A. Water supply Well WW-5B experienced a rise in water level as a result of an absence of pumping in the first part of the year (due to a mechanical problem), whereas water levels declined in WW-4 and WW-4A in response to greater pumping in 2019. Institutional control monitoring confirmed the URs are recorded in U.S. Department of Energy and U.S. Air Force land management systems, and that no activities within Frenchman Flat basin are occurring that could potentially affect the contaminant boundaries. Survey of groundwater resources in basins surrounding Frenchman Flat similarly identify no current or pending development that would indicate the need to increase monitoring activities or would otherwise cause concern for the closure decision. The URs continue to prevent exposure of the public, workers, and the environment to contaminants of concern by preventing use of potentially contaminated groundwater.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2024

Estimation of the Thermal-Fluids and Thermal-Structural Performance of Helium-Cooled Modular Finger-Type Divertors

Over the past decade, our group has investigated the thermal-fluid performance of the helium-cooled modular divertor with multiple jets (HEMJ) and a simplified “flat” design of the HEMJ for long-pulse magnetic fusion energy (MFE) reactors. Experimental studies were performed in a helium (He) loop at the prototypical pressure of 10 MPa, nearly prototypical He temperatures and incident heat fluxes using test sections made from stainless steel and tungsten alloys. Correlations for average Nusselt numbers and pressure loss coefficients were developed from the data and are used to validate computational fluid dynamics (CFD) models. Here, this work presents updated thermal-fluids performance curves based on these correlations that estimate the maximum heat flux that can be accommodated by the plasma-facing surface and coolant pumping power requirements at prototypical operating conditions. Thermal-structural performance curves developed from ITER structural design criteria are introduced, which include protection against ductile and non-ductile failure, ratcheting fatigue, and creep fatigue. The performance design curves for these finger-type divertors demonstrate that the “flat” design, with a significantly less complicated geometry than the HEMJ, has thermal-fluid and thermal-structural performance comparable to the original HEMJ concept, and may be superior in terms of non-ductile failure criteria.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2022

Implementation of a Model Predictive Control Strategy to Regulate Temperature Inside Plug-Flow Solar Reactor With Countercurrent Flow

Abstract Solar-driven thermochemical energy storage systems are proven to be promising energy carriers (solar fuels) to utilize solar energy by using reactive solid-state pellets. However, the production of solar fuel requires a quasi-steady-state process temperature, which represents the main challenge due to the transient nature of solar power. In this work, an adaptive model predictive controller (MPC) is presented to regulate the temperature inside a tubular solar reactor to produce solid-state solar fuel for long-term thermal storage systems. The solar reactor system consists of a vertical tube heated circumferentially over a segment of its length by concentrated solar power, and the reactive pellets (MgMn2O4) are fed from the top end and flow downwards through the heated tube. A countercurrent flowing gas supplied from the lower end interacts with flowing pellets to reduce it thermochemically at a temperature range of 1000—1500 °C. A low-order physical model was developed to simulate the dynamics of the solar reactor including the reaction kinetics, and the proposed model was validated numerically by using a 7-kW electric furnace. The numerical model then was utilized to design the MPC controller, where the control system consists of an MPC code linked to an adaptive system identification code that updates system parameters online to ensure system robustness against external disturbances (sudden change in the flow inside the reactor), model mismatches, and uncertainty. The MPC controller parameters are tuned to enhance the system performance with minimum steady-state error and overshoot. The controller is tested to track different temperature ranges between 500 °C and 1400 °C with different particles/gas mass flowrates and ramping temperature profiles. Results show that the MPC controller successfully regulated the reactor temperature within ± 1 °C of its setpoint and maintained robust performance with minimum input effort when subjected to sudden changes in the amount of flowing media and the presence of chemical reaction.

Engineering↗

DOE OSTI2023

Review and Summary of Oxide Thickness Data for Aluminum-Clad Spent Nuclear Fuel

The U.S. Department of Energy (DOE) owns a large inventory of aluminum-clad spent nuclear fuel (ASNF) in interim storage pending ultimate disposition, with more being generated by currently operating research reactors. Dry storage in sealed DOE Standard Canisters is being investigated as an approach for long-term interim storage and/or disposition in a repository for ASNF. A primary challenge for ASNF storage is the presence of aluminum (oxy)hydroxide layers formed on the cladding surfaces during water exposure in the reactor and in wet storage, which forms a reservoir of chemisorbed water not readily removed at low (<100°C) drying temperatures. Free, physisorbed, and chemisorbed water are all susceptible to radiolytic breakdown under irradiation and can release hydrogen gas. Identifying the likely range of (oxy)hydroxide loadings on ASNF that may be placed in dry storage will help to ensure that the impact of the (oxy)hydroxide is adequately accounted for while avoiding over conservatism and enable mitigation strategies to be implemented where needed. The current report summarizes information on (oxy)hydroxide thicknesses and characteristics from the literature and from recent measurements taken in the present research campaign. In general, corrosion studies have indicated that the corrosion and oxide buildup on aluminum are affected by numerous conditions, including pH, temperature and heat flux, coolant flowrates, irradiation (in-reactor vs. unirradiated tests), duration of water exposure, and the amount of oxide already on the surface. Some of these factors are interrelated (e.g., the local temperature, heat flux, and coolant flowrate). Observations of the impact of irradiation (in-reactor versus ex-reactor measurements) on corrosion and oxide thickness are mixed, but multiple studies indicate that there is a significant difference between in-reactor and ex-reactor corrosion kinetics, even when other operating conditions such as pH, flowrate, heat flux, etc., simulate those in a reactor.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

Macro-level mechanical interlocking: A rapid joining approach for additively manufactured compression molded composite panels

Composite joining typically involves multiple steps, such as drilling and surface treatment, as part of the manufacturing process, which leads to low throughput and long cycle times. In the present study, we demonstrated a macro-level mechanical interlocking (MI) based, rapid joining technique to assemble additively manufactured compression molded (AMCM) panels, enabling the production of parts larger than the mold dimensions. Composite panels made of 20 wt% short carbon fiber reinforced acrylonitrile butadiene styrene (CF/ABS) were joined using MI features of various geometries, namely tree (TR), dovetail (Dov), rectangle 2 (Rect2), and rectangle 1 (Rect1), and their in-plane strength was evaluated. The resultant strength of the tested MI joints reached up to 74 % of the baseline tensile strength (i.e., the ‘no joint’ case). Observations from optical and scanning electron microscopy revealed inadequate polymer diffusion between the adherends, indicating that the joint strength was primarily derived from mechanical interlocking. Additionally, the fracture surfaces exhibited stress-whitening marks, which were characterized using differential scanning calorimetry (DSC). The increase in melting enthalpy suggested local stretching of polymer chains due to MI. Finite element analysis (FEA) indicated that the Rect1 MI feature, which generated the lowest stress concentration, outperformed the others in terms of joint strength, achieving 42 MPa. As a demonstration of the MI joining method, a battery box tray measuring 108 cm × 34 cm using a mold with an effective dimension of 36 cm × 34 cm successfully manufactured, resulting in a part with an area three times larger than the mold. In conclusion, this study presents a promising approach to improving composite joining techniques while minimizing production complexities.

In-plane joining↗