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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 1,225 records · Page 68
All sourcesNASA NTRSDOE OSTI
DOE OSTI2015

Fabrication, Welding, and Inspection Techniques in Preparation for In-Reactor Testing of Accident Tolerant Fuels

After the Fukushima events in 2011, DOE-NE in collaboration with nuclear industry shifted R&D emphasis to accident performance of LWR fuels under extended loss of active cooling and steam exposure. DOE-NE has created a roadmap for the “Development of Light Water Reactor Fuels with Enhanced Accident Tolerance.” The mission of the Accident Tolerant Fuel (ATF) Roadmap is to develop the next generation of LWR fuels with improved performance, reliability, and safety characteristics during normal operations and accident conditions and with reduced waste generation. The ultimate goal of the ATF roadmap is to support the insertion of lead fuel rods (LFRs) or lead fuel assemblies (LFAs) of an Accident Tolerant Fuel into a commercial LWR within 10 years (i.e., by the end of FY-2022). As a step toward this goal, an irradiation test series has been developed to assess the performance of proposed ATF concepts under normal LWR operating conditions. Data generated by this test program will be used to establish the feasibility of certain aspects of proposed ATF concepts, as well as provide information to support screening among concepts; as such, it is an integral part of Phase I: Feasibility Assessment and Down-Selection outlined in the ATF Roadmap. This irradiation test series is planned to be performed as a series of drop-in capsule tests to be irradiated in the Advanced Test Reactor (ATR) operated by the Idaho National Laboratory (INL), and it has been designated as the ATF-1 test series. Current fission reactors use zirconium-based fuel cladding because of its extremely low macroscopic thermal neutron absorption cross-section, good high temperature strength, and decent corrosion resistance. However, advanced, innovative materials may provide these same benefits while increasing reactor safety margin, core power density, and fuel utilization. These advanced fuel cladding systems will allow revolutionary cladding performance and enhanced fuel mechanical designs, however, challenges exist in design, analysis and fabrication of innovative, never before tested, fuel cladding systems for in-reactor testing. This paper highlights the challenges associated with design, fabrication and welding, and inspection of innovative materials and actions taken to address those challenges in preparation for the Phase I ATR irradiation testing. The lessons learned from Phase I of this experiment can be used to guide researchers for design and analysis of future in-reactor testing of advanced fuel cladding systems.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2014

Evolution of titanium residue on the walls of a plasma-etching reactor and its effect on the polysilicon etching rate

The variation in polysilicon plasma etching rates caused by Ti residue on the reactor walls was investigated. The amount of Ti residue was measured using attenuated total reflection Fourier transform infrared spectroscopy with the HgCdTe (MCT) detector installed on the side of the reactor. As the amount of Ti residue increased, the number of fluorine radicals and the polysilicon etching rate increased. However, a maximum limit in the etching rate was observed. A mechanism of rate variation was proposed, whereby F radical consumption on the quartz reactor wall is suppressed by the Ti residue. The authors also investigated a plasma-cleaning method for the removal of Ti residue without using a BCl{sub 3} gas, because the reaction products (e.g., boron oxide) on the reactor walls frequently cause contamination of the product wafers during etching. CH-assisted chlorine cleaning, which is a combination of CHF{sub 3} and Cl{sub 2} plasma treatment, was found to effectively remove Ti residue from the reactor walls. This result shows that CH radicals play an important role in deoxidizing and/or defluorinating Ti residue on the reactor walls.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2015

Particle formation and its control in dual frequency plasma etching reactors

The behavior of a particle cloud in plasma etching reactors at the moment when radio frequency (RF) power changes, that is, turning off and transition steps, was observed using the laser-light-scattering method. Two types of reactors, dual-frequency capacitively coupled plasma (CCP) and the hybrid CCP/inductively coupled plasma (ICP), were set up for experiments. In the hybrid CCP/ICP reactor (hereafter ICP reactor), the position and shape of the cloud were strongly dependent on the RF frequency. The particle cloud becomes larger and approaches the electrode as the RF frequency increases. By turning the lower frequency power off later with a small delay time, the particle cloud is made to move away from the electrode. Maintaining lower frequency RF power only was also helpful to reduce the particle cloud size during this transition step. In the ICP reactor, a sufficient bias power is necessary to make a particle trap appear. A similar particle cloud to that in the CCP reactor was observed around the sheath region of the lower electrode. The authors can also use the low-frequency effect to move the particle cloud away from the substrate holder if two or more bias powers are applied to the substrate holder. The dependence of the particle behavior on the RF frequencies suggests that choosing the proper frequency at the right moment during RF power changes can reduce particle contamination effectively.

42 ENGINEERING↗
DOE OSTI2022

Machine learning and atomic layer deposition: Predicting saturation times from reactor growth profiles using artificial neural networks

In this work, we explore the application of deep neural networks to the optimization of atomic layer deposition (ALD) processes. In particular, we focus on a one-shot optimization problem, where we try to predict the optimal dose time that leads to saturation everywhere in the reactor based on thickness values measured at different points of an ALD reactor after a single trial growth. In order to tackle this problem, we introduce a dataset designed to train neural networks to predict saturation times based on these inputs for a cross-flow ALD reactor. Here, we then explore the predictive ability of artificial neural networks of different depths and sizes using a separate testing dataset to evaluate their accuracies. The results obtained show that networks trained using stochastic gradient descent methods can accurately predict saturation times without requiring any additional information on the surface kinetics. This provides a viable approach to minimize the number of experiments required to optimize new ALD processes in a known reactor, and it highlights the way machine learning can be leveraged for thin film growth and manufacturing. While the datasets and training procedure depend on the reactor geometry, the trained neural networks provide a general surrogate model connecting thickness values and trial dose times with optimal saturation times that can be reused for different ALD processes within the same reactor.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Competitiveness Assessment of Decarbonizing Electricity and Process Heat Supply to a Campus with a Small Nuclear Reactor

This paper analyzes the competitiveness of siting a small nuclear reactor to support decarbonization of sites requiring tens of MW of electricity and/or process heat to support centralized heating and cooling system. This paper focuses on campuses as representative of sites with collections of buildings and research facilities with decarbonization needs represented by buildings heating, and electricity consumption by electrical loads which may include cooling via chilled water (e.g., for air conditioning and to cool down computer clusters). A nuclear reactor can be considered to decarbonize a site’s high-temperature steam generation used mostly for building heating needs, climate control, and hot water, by supplying process heat capabilities, while electricity decarbonization would be achieved mostly by the grid. However, a secondary application can be considered to maximize reactor utilization and avoid ramping down the reactor if the steam demand varies significantly throughout the year. Chilled water generation through steam-driven systems was identified as an attractive secondary option for the site analyzed, due to potential for plant design simplification, while electricity generation could be considered as well to reduce electricity purchases for a wider range of site applications. For a campus with peak 60MW thermal power demand, a small nuclear reactor with similar thermal power rating would almost eliminate CO2 emissions from steam generation and reduce electricity imports for chilled water production. A preliminary techno-economic feasibility study shows that a small nuclear reactor design that is optimized to support process heat can represent an economically feasible option when compared with other decarbonization alternatives.

Stauff, Nicolas E.↗
DOE OSTI2011

Core and Refueling Design Studies for the Advanced High Temperature Reactor

The Advanced High Temperature Reactor (AHTR) is a design concept for a central generating station type [3400 MW(t)] fluoride-salt-cooled high-temperature reactor (FHR). The overall goal of the AHTR development program is to demonstrate the technical feasibility of FHRs as low-cost, large-size power producers while maintaining full passive safety. This report presents the current status of ongoing design studies of the core, in-vessel structures, and refueling options for the AHTR. The AHTR design remains at the notional level of maturity as important material, structural, neutronic, and hydraulic issues remain to be addressed. The present design space exploration, however, indicates that reasonable options exist for the AHTR core, primary heat transport path, and fuel cycle provided that materials and systems technologies develop as anticipated. An illustration of the current AHTR core, reactor vessel, and nearby structures is shown in Fig. ES1. The AHTR core design concept is based upon 252 hexagonal, plate fuel assemblies configured to form a roughly cylindrical core. The core has a fueled height of 5.5 m with 25 cm of reflector above and below the core. The fuel assembly hexagons are {approx}45 cm across the flats. Each fuel assembly contains 18 plates that are 23.9 cm wide and 2.55 cm thick. The reactor vessel has an exterior diameter of 10.48 m and a height of 17.7 m. A row of replaceable graphite reflector prismatic blocks surrounds the core radially. A more complete reactor configuration description is provided in Section 2 of this report. The AHTR core design space exploration was performed under a set of constraints. Only low enrichment (<20%) uranium fuel was considered. The coated particle fuel and matrix materials were derived from those being developed and demonstrated under the Department of Energy Office of Nuclear Energy (DOE-NE) advanced gas reactor program. The coated particle volumetric packing fraction was restricted to at most 40%. The pressure drop across the core was restricted to no more than 1.5 atm during normal operation to minimize the upward force on the core. Also, the flow velocity in the core was restricted to 3 m/s to minimize erosion of the fuel plates. Section 3.1.1 of this report discusses the design restrictions in more detail.

Holcomb, David Eugene↗
DOE OSTI2012

Design, Test and Demonstration of Saturable Reactor High-Temperature Superconductor Fault Current Limiters

Zenergy Power has successfully designed, built, tested, and installed in the US electrical grid a saturable reactor Fault Current Limiter. Beginning in 2007, first as SC Power Systems and from 2008 as Zenergy Power, Inc., ZP used DOE matching grant and ARRA funds to help refine the design of the saturated reactor fault current limiter. ZP ultimately perfected the design of the saturated reactor FCL to the point that ZP could reliably design a suitable FCL for most utility applications. Beginning with a very basic FCL design using 1G HTS for a coil housed in a LN2 cryostat for the DC bias magnet, the technology progressed to a commercial system that was offered for sale internationally. Substantial progress was made in two areas. First, the cryogenics cooling system progressed from a sub-cooled liquid nitrogen container housing the HTS coils to cryostats utilizing dry conduction cooling and reaching temperatures down to less than 20 degrees K. Large, round cryostats with warm bore diameters of 1.7 meters enabled the design of large tanks to hold the AC components. Second, the design of the AC part of the FCL was refined from a six legged spider design to a more compact and lighter design with better fault current limiting capability. Further refinement of the flux path and core shape led to an efficient saturated reactor design requiring less Ampere-turns to saturate the core. In conclusion, the development of the saturable reactor FCL led to a more efficient design not requiring HTS magnets and their associated peripheral equipment, which yielded a more economical product in line with the electric utility industry expectations. The original goal for the DOE funding of the ZP project Design, Test and Demonstration of Saturable Reactor High-Temperature Superconductor Fault Current Limiters was to stimulate the HTS wire industry with, first 1G, then 2G, HTS wire applications. Over the approximately 5 years of ZP's product development program, the amount of HTS wire employed per FCL and its cost as a percentage of the total FCL product content had not dropped substantially from an unsustainable level of more than 50% of the total cost of the FCL, nor had the availability increased (today the availability of 2G wire for commercial applications outside of specific partnerships with the leading 2G wire manufacturers is extremely limited). ZP had projected a very significant commercial potential for FCLs with higher performance and lower costs compared to the initial models built with 1G wire, which would come about from the widespread availability of low-cost, high-performance 2G HTS wire. The potential for 2G wires at greatly reduced performance-based prices compared to 1G HTS conductor held out the potential for the commercial production of FCLs at price and performance levels attractive to the utility industry. However, the price of HTS wire did not drop as expected and today the available quantities of 2G wire are limited, and the price is higher than the currently available supplies of 1G wire. The commercial option for ZP to provide a reliable and reasonably priced FCL to the utility industry is to employ conventional resistive conductor DC electromagnets to bias the FCL. Since the premise of the original funding was to stimulate the HTS wire industry and ZP concluded that copper-based magnets were more economical for the foreseeable future, DOE and ZP decided to mutually terminate the project.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2012

Computational fluid dynamic modeling of fluidized-bed polymerization reactors

Polyethylene is one of the most widely used plastics, and over 60 million tons are produced worldwide every year. Polyethylene is obtained by the catalytic polymerization of ethylene in gas and liquid phase reactors. The gas phase processes are more advantageous, and use fluidized-bed reactors for production of polyethylene. Since they operate so close to the melting point of the polymer, agglomeration is an operational concern in all slurry and gas polymerization processes. Electrostatics and hot spot formation are the main factors that contribute to agglomeration in gas-phase processes. Electrostatic charges in gas phase polymerization fluidized bed reactors are known to influence the bed hydrodynamics, particle elutriation, bubble size, bubble shape etc. Accumulation of electrostatic charges in the fluidized-bed can lead to operational issues. In this work a first-principles electrostatic model is developed and coupled with a multi-fluid computational fluid dynamic (CFD) model to understand the effect of electrostatics on the dynamics of a fluidized-bed. The multi-fluid CFD model for gas-particle flow is based on the kinetic theory of granular flows closures. The electrostatic model is developed based on a fixed, size-dependent charge for each type of particle (catalyst, polymer, polymer fines) phase. The combined CFD model is first verified using simple test cases, validated with experiments and applied to a pilot-scale polymerization fluidized-bed reactor. The CFD model reproduced qualitative trends in particle segregation and entrainment due to electrostatic charges observed in experiments. For the scale up of fluidized bed reactor, filtered models are developed and implemented on pilot scale reactor.

42 ENGINEERING↗
DOE OSTI2013

Design options for a bunsen reactor.

This work is being performed for Matt Channon Consulting as part of the Sandia National Laboratories New Mexico Small Business Assistance Program (NMSBA). Matt Channon Consulting has requested Sandia's assistance in the design of a chemical Bunsen reactor for the reaction of SO2, I2 and H2O to produce H2SO4 and HI with a SO2 feed rate to the reactor of 50 kg/hour. Based on this value, an assumed reactor efficiency of 33%, and kinetic data from the literature, a plug flow reactor approximately 1%E2%80%9D diameter and and 12 inches long would be needed to meet the specification of the project. Because the Bunsen reaction is exothermic, heat in the amount of approximately 128,000 kJ/hr would need to be removed using a cooling jacket placed around the tubular reactor. The available literature information on Bunsen reactor design and operation, certain support equipment needed for process operation and a design that meet the specification of Matt Channon Consulting are presented.

Moore, Robert Charles↗
DOE OSTI2017

Decay Heat Quantification in the High Temperature Test Reactor

The proper calculation of decay heat is necessary for both postulated accidents as well as normal spent fuel repository safety analysis. Since the 1970s, the nuclear industry has primarily relied on the use of the ANSI/ANS-5.1 standard or one of it’s predecessors as the tool for calculating such heat. However, different reactor systems can have substantially different materials, neutron spectrums, operating characteristics, etc.…that lead to vastly different isotopic compositions in the fuel over time. The ANSI/ANS-5.1 standard is specific to Light Water Reactors, and thus may not be well suited for other systems such as high temperature gas reactors. Recent developments in the SCALE 6 code developed at Oak Ridge National Laboratory have allowed for a more accurate treatment of the complexity associated with high temperature reactor TRISO fuel. Also, the standalone isotopic depletion and generation code ORIGEN-S, a module of SCALE, has been validated against experimental data for LWRs for properly characterizing decay heat. And most recently, Japan Atomic Energy Agency has used the ORIGEN code to generate HTGR cross section libraries to be used to quantify the decay heat generated in the High Temperature Engineering Test Reactor at the Oarai Research and Development Center. Given the Idaho National Laboratory’s continued research into the viability of HTGRs as a next generation power reactor, an independent decay heat quantification analysis has been performed for a variety of fuel enrichments, TRISO particle packing fractions, and fuel temperatures using a similar approach. Furthermore, these data are then used as input into the RAVEN code developed at INL. A Reduced Order Model mathematical model in RAVEN is ‘trained’ to create a response mechanism to the various input parameters. Preliminary results demonstrate the potential for using this methodology to accurately predict decay heat generation.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2017

Moving Bed Chemical Looping Combustion Fuel Reactor Modeling and Sensitivity Analysis

Chemical looping combustion (CLC) is a novel, coal-based power generation technology that has currently achieved only small-scale, non-integrated development status, with the fuel reactor being the key developmental component in the CLC process. Both circulating fluidized bed (CFB) and moving bed fuel reactors have been the subjects of ongoing development campaigns. The objective of the effort described in this report is to characterize a moving bed fuel reactor by applying more detailed, reaction kinetics-based models that represent the nature of this reactor with a more fundamental foundation than has previously been reported by developers. This report describes the modeling basis, and a “base” fuel reactor’s design and performance characteristics resulting from the model. A major focus of the evaluation has been placed on studies of the sensitivity of the base moving bed fuel reactor performance, design, and CLC power plant cost implications to the key parameters.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2020

Zeolite Membrane Reactor for Pre-Combustion Carbon Dioxide Capture

Water-gas shift (WGS) reaction followed by carbon dioxide (CO 2 ) separation is a critical step in the integrated gasification combined cycle (IGCC) process for fossil-fuel-fired electrical power generation with CO 2 capture. To intensify the IGCC process hydrogen-permselective zeolite membrane reactor offers promise to replace the conventional energy-intensive fixed-bed reactors and solvent-based CO 2 capture units. The objectives of this project were to develop a bench-scale zeolite membrane reactor (total membrane area: 932 cm 2 for a 21-tube membrane bundle) for the water-gas-shift reaction of raw syngas from an oxygen-blown coal-gasifier for H 2 production with simultaneous CO 2 separation at the capability of about 2 kilograms H 2 per day (equivalent to 2 kW IGCC power plant) and to demonstrate significant progress toward achieving overall performance goal of 90% CO 2 capture rate with 95% CO 2 purity at the cost of electricity 30% less than the baseline carbon capture approaches. This report summarizes results obtained in this project on scaling up the zeolite membrane reactor by a factor of 200 in membrane area, tests of the bench-scale zeolite membrane reactor for the water-gas-shift reaction at high temperature and high-pressure, and techno-economic analysis of the integration of the zeolite membrane reactor in IGCC power plant for the electrical generation with CO 2 capture.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2021

A Pathway for the Development of Advanced Reactor Mechanistic Source Term Modeling and Simulation Capabilities

Source term analysis, or the estimation of the potential radionuclide release to the environment during reactor events, is a central focus of the reactor licensing process and a vital part of risk-informed reactor design approaches. A mechanistic source term (MST) analysis is designed to realistically model the release and transport of radionuclides from the source to the environment for specific scenarios, while accounting for retention or transmutation phenomena and associated uncertainties. The objective of MST analyses, in comparison to bounding or conservative source term assessments, is to provide a non-biased representation of reactor risk and improve the information available for siting, emergency planning, and reactor design decisions. In support of the advanced reactor community in its pursuit of MST analysis capabilities, this work outlines a recommended research pathway for the development of MST modeling and simulation (mod/sim) tools.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2025

Demonstration of the surveillance test article for an advanced reactor surveillance test program

Operational environments in generation IV reactors involve corrosive and irradiative conditions at elevated temperatures. Typical reactor operations consist of transients which impose cyclic loads on reactor components. These cyclic loads, combined with corrosive and irradiative environments, result in synergistic degradation of component materials. However, limited data exists on the coupled damage effects on materials for reactor environments. While the surrogate material surveillance concept has been used in light water reactors to assess irradiation damage, existing material surveillance technologies are not suitable for in-situ monitoring of coupled material degradation. The materials surveillance program focuses on material degradation management and the estimation of remaining life of reactor components through surveillance test articles. This paper presents the design and analysis methodology of a bi-metal surveillance test article, which uses difference in thermal expansion coefficient between two metals to induce in-situ cyclic loads. This report presents the work conducted in FY 25, to test the surveillance test article in air and salt environments. These test specimens were evaluated after thermal cycle exposure and remaining life is measured through creep test.

36 - MATERIALS SCIENCE↗
DOE OSTI2026

Automatic Volume Balancing for Online Refueling in Molten Salt Reactor Simulations with SCALE

This work introduces recently implemented capabilities in the SCALE code system’s TRITON reactor physics sequence that improve molten salt reactor (MSR) modeling: (1) a volume balancing option, which automatically balances the volumes of the fed material with a corresponding material removal to maintain fixed mixture volumes in the neutron transport model and accurate densities, and (2) continuous feed from mixtures, which enables users to define material feed streams directly from salt mixture definitions rather than individual nuclides. The new capabilities were demonstrated via SCALE/TRITON simulations of two representative MSR concepts. Simulations of the 180 MWth molten chloride fast reactor—a system with a fixed fuel salt volume in the reactor core—applied continuous refueling with fresh fuel salt. The results confirm approximately constant reactivity when the new volume balancing capability is used. Additionally, excellent agreement with a manual feed-and-drain method for volume balancing further verified the new implementation. Simulations of the 400 MWth EIRENE reactor, an integral MSR in which the salt volume may grow over time within the reactor core, demonstrated the capability to represent growing salt volume within the TRITON depletion calculation. Compared with reference solutions, the results show consistent trends in reactivity and isotopic evolution, confirming that these new user-friendly capabilities provide accurate, physically consistent approaches for modeling MSRs in SCALE.

Elzohery, Rabab [ORNL] (ORCID:0000000160043633)↗
NASA NTRS1972

Optimized 4 pi spherical shell depleted uranium-water shield weights for 200 to 550-megawatt reactors

Optimization calculations to determine minimum 4 pi spherical-shell weights were performed at 200-, 375-, and 550-megawatt-thermal reactor power levels. Monte Carlo analyses were performed for a reactor power level corresponding to 375 megawatts. Power densities for the spherical reactor model used varied from 64.2 to 256 watts per cubic centimeter. The dose rate constraint in the optimization calculations was 0.25 mrem per hour at 9.14 meters from the reactor center. The resulting shield weights were correlated with the reactor power levels and power densities by a regression analysis. The optimum shield weight for a 375-megawatt, 160-watt-per-cubic-centimeter reactor was 202,000 kilograms.

Wohl, M. L.↗
NASA NTRS1972

A small, 1400 K, reactor for Brayton space power systems.

An investigation was conducted to determine minimum dimensions and minimum weight obtainable in a design for a reactor using uranium-233 nitride or plutonium-239 nitride as fuel. Such a reactor had been considered by Krasner et al. (1971). Present space power status is discussed, together with questions of reactor design and power distribution in the reactor. The characteristics of various reactor types are compared, giving attention also to a zirconium hydride reactor.

Lantz, E.↗
NASA NTRS1972

Zirconium Hydride Space Power Reactor design.

The Zirconium Hydride Space Power Reactor being designed and fabricated at Atomics International is intended for a wide range of potential applications. Throughout the program a series of reactor designs have been evaluated to establish the unique requirements imposed by coupling with various power conversion systems and for specific applications. Current design and development emphasis is upon a 100 kilowatt thermal reactor for application in a 5 kwe thermoelectric space power generating system, which is scheduled to be fabricated and ground tested in the mid 70s. The reactor design considerations reviewed in this paper will be discussed in the context of this 100 kwt reactor and a 300 kwt reactor previously designed for larger power demand applications.

Asquith, J. G.↗