Results for “Drying technology” — Page 7

DOE OSTI2025

Pathways of Photocatalytic Oxidation of Formic Acid on Dry and Hydrated Anatase TiO 2 Surfaces

The photocatalytic oxidation of formic acid (FA), which is one of the most abundant volatile organic compounds, is a promising air remediation technology inspired by nature. However, the detailed mechanism of this photocatalytic reaction on the surface of TiO 2 , a typical photocatalyst, is not yet well-understood. In this work, we present a computational mechanistic study of the thermal vs photocatalytic oxidation of FA on dry and hydrated anatase TiO 2 (101) surfaces, based on periodic hybrid density functional theory (DFT) calculations, in which the photooxidation is treated as an excited-state process in a constrained triplet spin state. We first compare the adsorption modes of FA on the anatase (101) surface in the ground and excited states, followed by identification of the corresponding reaction intermediates that lead to the formation of CO 2 . We unveil the pivotal role of photogenerated holes localized at surface under-coordinated oxygen sites in mediating the C−H bond cleavage, thereby promoting CO 2 formation through a highly stable intermediate and an exergonic reaction step. Further investigation of the effect of coadsorbed water molecules shows that hydrogen bonding with water stabilizes FA in a monodentate configuration. This is favored over the unreactive bidentate structure that is the most stable under dry conditions, thus providing insight into the experimentally observed increase of the reaction rate in the presence of water.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2022

Corrosion-Resistant Coatings on Spent Nuclear Fuel Canisters to Mitigate and Repair Potential Stress Corrosion Cracking (FY22 Status)

This report summarizes the activities performed by Sandia National Laboratories in FY22 to identify and test coating materials for the prevention, mitigation, and/or repair of potential chloride-induced stress corrosion cracking in spent nuclear fuel dry storage canisters. This work continues efforts by Sandia National Laboratories that are summarized in previous reports in FY20 and FY21 on the same topic. The previous work detailed the specific coating properties desired for application and implementation to spent nuclear fuel canisters (FY20) and identified several potential coatings for evaluation (FY21). In FY22, Sandia National Laboratories, in collaboration with four industry partners through a Memorandum of Understanding, started evaluating the physical, mechanical, and corrosion-resistance properties of 6 different coating systems (11 total coating variants) to develop a baseline understanding of the viability of each coating type for use to prevent, mitigate, and/or repair potential stress corrosion on cracking on spent nuclear fuel canisters. This collaborative R&D program leverages the analytical and laboratory capabilities at Sandia National Laboratories and the material design and synthesis capabilities of the industry collaborators. The coating systems include organic (polyetherketoneketone, modified polyimide/polyurea, modified phenolic resin), organic/inorganic ceramic hybrids (silane-based polyurethane hybrid and a quasi-ceramic sol-gel polyurethane hybrid), and hybrid systems in conjuncture with a Zn-rich primer. These coatings were applied to stainless steel coupons (the same coupons were supplied to all vendors by SNL for direct comparison) and have undergone several physical, mechanical, and electrochemical tests. The results and implications of these tests are summarized in this report. These analyses will be used to identify the most effective coatings for potential use on spent nuclear fuel dry storage canisters, and also to identify specific needs for further optimization of coating technologies for their application on spent nuclear fuel canisters. In FY22, Sandia National Laboratories performed baseline testing and atmospheric exposure tests of the coating samples supplied by the vendors in accordance with the scope of work defined in the Memorandum of Understanding. In FY23, Sandia National Laboratories will continue evaluating coating performance with a focus on thermal and radiolytic stability.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

Site-specific Design Case Study for Wet Waste Hydrothermal Liquefaction and Biocrude Upgrading to Hydrocarbon Fuels

Hydrothermal liquefaction (HTL) is a thermal process that converts wet biomass to renewable hydrocarbon fuel blendstocks (i.e., renewable naphtha, renewable diesel, and sustainable aviation fuel (SAF)). It can utilize a wide range of pure and blended wet feedstocks, including sewage sludge from water resource recovery facilities (WRRF), food and agriculture wastes, algae, fats, oils and greases (FOG) and blends of dry and wet wastes/feedstocks. Historically, techno-economic analysis (TEA) and annual state of technology (SOT) assessments with standard economic assumptions used by the Bioenergy Technologies Office (BETO) were conducted for the wet waste HTL pathway leveraging experimental data collected from Pacific Northwest National Laboratory’s (PNNL) continuous flow reactor systems. The objective of the SOT assessment has been to guide and track progress of BETO’s HTL research and development (R&D) toward reduced cost and greenhouse gas (GHG) emissions for the pathway. However, gaps exist between BETO’s traditional SOT updates and the needs of key external stakeholders that – if addressed – will accelerate technology adoption. This Business Case Study aims to bridge this gap by providing an updated design, TEA, and LCA based on PNNL’s FY23 R&D with added analyses and information that provide enhanced relevance for stakeholders of the HTL technology. This includes specific siting, regional wet waste resource inventory and transportation cost analyses, fuel market information, sustainable fuel policy impacts, economic metrics of net present value (NPV) and internal rate of return (IRR), greenhouse gas (GHG) emissions analysis, and statistical analysis of cost and technical uncertainties of the HTL plant design. The study focuses on the “Detroit combined statistical area (CSA)” region for siting of a wet waste HTL plant adjacent to the Great Lakes Water Authority (GLWA) facility with guidance from industry participants. Regional resource and siting analyses were conducted to identify feedstock availability, scale, and cost, as well as a beneficial site location. TEA with detailed rigorous capital cost estimation for the specific site application was conducted to evaluate the key economic metrics of most value to industrial partners. These include total capital investment, operating costs, minimum fuel selling price (MFSP) of the biocrude and fuel blendstock, and NPV and internal rate of return IRR with sustainable fuel credits. Life cycle analysis was conducted to evaluate the supply chain greenhouse gas (GHG) emissions for the wet waste HTL process as compared with petroleum derived diesel. This study is also informed by years of R&D and process de-risking learnings and was conducted with a basic engineering HTL plant design and costing that akin to a “first-of-a-kind” plant economics. This differs from our conventional “nth plant ” SOT assessments. Specifically, the HTL process model has been updated with more operationally reliable methods for feed heating and phase separations. Further, we have implemented additional spare equipment for redundancy, a more rigorous installed equipment cost estimation approach, and additional costs associated with feed formatting and delivery, building, piping and site development. An Excel-based cost sheet based on the basic engineering design is also released alongside the report that allows users to conduct customized TEA with their own feed composition and financial assumptions.

09 BIOMASS FUELS↗

DOE OSTI2024

Supporting data for Site-specific Design Case Study for Wet Waste Hydrothermal Liquefaction and Biocrude Upgrading to Hydrocarbon Fuels

Hydrothermal liquefaction (HTL) is a thermal process that converts wet biomass to renewable hydrocarbon fuel blendstocks (i.e., renewable naphtha, renewable diesel, and sustainable aviation fuel (SAF)). It can utilize a wide range of pure and blended wet feedstocks, including sewage sludge from water resource recovery facilities (WRRF), food and agriculture wastes, algae, fats, oils and greases (FOG) and blends of dry and wet wastes/feedstocks. Historically, techno-economic analysis (TEA) and annual state of technology (SOT) assessments with standard economic assumptions used by the Bioenergy Technologies Office (BETO) were conducted for the wet waste HTL pathway leveraging experimental data collected from Pacific Northwest National Laboratory’s (PNNL) continuous flow reactor systems. The objective of the SOT assessment has been to guide and track progress of BETO’s HTL research and development (R&D) toward reduced cost and greenhouse gas (GHG) emissions for the pathway. However, gaps exist between BETO’s traditional SOT updates and the needs of key external stakeholders that – if addressed – will accelerate technology adoption. This Business Case Study aims to bridge this gap by providing an updated design, TEA, and LCA based on PNNL’s FY23 R&D with added analyses and information that provide enhanced relevance for stakeholders of the HTL technology. This includes specific siting, regional wet waste resource inventory and transportation cost analyses, fuel market information, sustainable fuel policy impacts, economic metrics of net present value (NPV) and internal rate of return (IRR), greenhouse gas (GHG) emissions analysis, and statistical analysis of cost and technical uncertainties of the HTL plant design. The study focuses on the “Detroit combined statistical area (CSA)” region for siting of a wet waste HTL plant adjacent to the Great Lakes Water Authority (GLWA) facility with guidance from industry participants. Regional resource and siting analyses were conducted to identify feedstock availability, scale, and cost, as well as a beneficial site location. TEA with detailed rigorous capital cost estimation for the specific site application was conducted to evaluate the key economic metrics of most value to industrial partners. These include total capital investment, operating costs, minimum fuel selling price (MFSP) of the biocrude and fuel blendstock, and NPV and internal rate of return IRR with sustainable fuel credits. Life cycle analysis was conducted to evaluate the supply chain greenhouse gas (GHG) emissions for the wet waste HTL process as compared with petroleum derived diesel. This study is also informed by years of R&D and process de-risking learnings and was conducted with a basic engineering HTL plant design and costing that akin to a “first-of-a-kind” plant economics. This differs from our conventional “nth plant ” SOT assessments. Specifically, the HTL process model has been updated with more operationally reliable methods for feed heating and phase separations. Further, we have implemented additional spare equipment for redundancy, a more rigorous installed equipment cost estimation approach, and additional costs associated with feed formatting and delivery, building, piping and site development. An Excel-based cost sheet based on the basic engineering design is also released alongside the report that allows users to conduct customized TEA with their own feed composition and financial assumptions.

Li, Shuyun↗

DOE OSTI2020

Electrochemical Deposition of Aluminum-Based Coatings From Aqueous Systems

The electroplating of aluminum has represented a challenge for the coatings industry for decades. The reactivity of aluminum metal leads to a very negative reduction potential. This leads to abundant gas evolution instead of aluminum reduction in water. Current aluminum deposition technology overcomes this limitation by excluding oxygen and water from the process with rigorously dry solvent and airtight plating tanks. These adaptations yield metallic aluminum depositions with significant impurities affecting its properties. In addition, this approach requires a great capital investment and cost of process maintenance. An alternative approach to Al electrodeposition has been developed based on the the use of organic ligands to stabilize the Al3+ ion in water-based solutions. By using a ligation approach, we can create aluminum species that remain stable in water while lowering the reduction potential of the aluminum complex by 0.5V. This improvement in reduction potential gives the possibility for the deposition of aluminum without significant competition from hydrogen evolution. With this platform we can deposit highly adherent aluminum-based layers on metal surfaces. The aluminum/aluminum oxide layers appear as thin, coherent and highly adherent coatings. This aluminum/alumina layer can then be chemically treated to achieve desirable surface properties which were previously inaccessible. For example, the coating can be made hydrophobic, highly adherent to different polymer coatings or even dyed using common anodizing dyes.

36 MATERIALS SCIENCE↗

DOE OSTI2020

ELECTROCHEMICAL DEPOSITION OF ALUMINUM-BASED COATINGS FROM AQUEOUS SYSTEMS

The electroplating of aluminum has represented a challenge for the coatings industry for decades. The reactivity of aluminum metal leads to a very negative reduction potential. This leads to abundant gas evolution instead of aluminum reduction in water. Current aluminum deposition technology overcomes this limitation by excluding oxygen and water from the process with rigorously dry solvent and airtight plating tanks. These adaptations yield metallic aluminum depositions with significant impurities affecting its properties. In addition, this approach requires a great capital investment and cost of process maintenance. An alternative approach to Al electrodeposition has been developed based on the the use of organic ligands to stabilize the Al3+ ion in water-based solutions. By using a ligation approach, we can create aluminum species that remain stable in water while lowering the reduction potential of the aluminum complex by 0.5V. This improvement in reduction potential gives the possibility for the deposition of aluminum without significant competition from hydrogen evolution. With this platform we can deposit highly adherent aluminum-based layers on metal surfaces. The aluminum/aluminum oxide layers appear as thin, coherent and highly adherent coatings. This aluminum/alumina layer can then be chemically treated to achieve desirable surface properties which were previously inaccessible. For example, the coating can be made hydrophobic, highly adherent to different polymer coatings or even dyed using common anodizing dyes.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Validated model of a thermoelectric heat pump clothes dryer using secondary pumped loops

The energy associated with clothes drying makes up 4% of the total residential electrical energy consumption in the US. The cost is high since most clothes dryers use electric resistance heating which is inexpensive but also energy inefficient. State-of-the-art vapor-compression heat pump clothes dryers offer significant energy savings but have limited market penetration in the US. Here, a new configuration of clothes dryer was studied that utilizes a solid-state thermoelectric heat pump with pumped secondary water loops and conventional fin-and-tube water-to-air heat exchangers. Experimental results are presented for the thermoelectric dryer prototype with a combined energy factor of 6.89 lb BDW /kWh (specific moisture extraction rate of 1.71 kg w /kWh) and a dry time of 84 min for a standard load size of 8.45 lb (3.83 kg) with 57.5% starting moisture content. This is a 85% energy efficiency improvement over baseline electric resistance dryers. The efficiency and drying time results achieved are similar to vapor compression heat pump dryers. Compared to previous air-based thermoelectric clothes dryers, the energy efficiency has been increased by 6%, but drying time has been reduced by as much as 47% using secondary pumped loops and separate heat exchangers, which represents a significant advancement in the technology. In addition to the experimental prototype, a model was also developed to study the performance. The model was validated against experimental prototype data and used to identify the range of performance (dry time and efficiency) that could be expected of the design.

42 ENGINEERING↗

DOE OSTI2025

A Comparison of Battery Charge Controller Technologies for Wave Energy Converters

Wave energy is a uniquely challenging field for electrical system designers. High peak and low average power potential with a constantly varying energy input is difficult to harness and control through conventional means. To power the blue economy, low-powered wave energy converters (WECs) need batteries for energy storage. Safely and effectively charging batteries from waves requires a charge controller to properly monitor and control voltage and current going to the battery. Currently, off-the-shelf charge controllers exist for other renewable generation such as wind, hydro, and solar. Two topologies were validated: a buck converter and a pulse width modulation (PWM) charge controller. Using an in-lab dry testbed, wave energy power inputs were simulated to properly validate the effectiveness of existing charge controller technologies, identifying the shortcomings and improvements needed to effectively harness wave energy.

battery storage↗

DOE OSTI2024

High‐Loading Lithium‐Sulfur Batteries with Solvent‐Free Dry‐Electrode Processing

Abstract Lithium‐sulfur (Li‐S) batteries, with their high energy density, nontoxicity, and the natural abundance of sulfur, hold immense potential as the next‐generation energy storage technology. To maximize the actual energy density of the Li‐S batteries for practical applications, it is crucial to escalate the areal capacity of the sulfur cathode by fabricating an electrode with high sulfur loading. Herein, ultra‐high sulfur loading (up to 12 mg cm −2 ) cathodes are fabricated through an industrially viable and sustainable solvent‐free dry‐processing method that utilizes a polytetrafluoroethylene binder fibrillation. Due to its low porosity cathode architecture formed by the binder fibrillation process, the dry‐processed electrodes exhibit a relatively lower initial capacity compared to the slurry‐processed electrode. However, its mechanical stability is well maintained throughout the cycling without the formation of electrode cracking, demonstrating significantly superior cycling stability. Additionally, through the optimization of the dry‐processing, a single‐layer pouch cell with a loading of 9 mg cm −2 and a novel multi‐layer pouch cell that uses an aluminum mesh as its current collector with a total loading of 14 mg cm −2 are introduced. To address the reduced initial capacity of dry‐processed electrodes, strategies such as incorporating electrocatalysts or employing prelithiated active materials are suggested.

Chemistry↗

DOE OSTI2024

A Comparison of Battery Charge Controller Technologies for Wave Energy Converters: Preprint

Wave energy is a uniquely challenging field for electrical system designers. High peak and low average power potential with a constantly varying energy input is difficult to harness and control through conventional means. To power the blue economy, low-powered wave energy converters (WECs) need batteries for energy storage. Safely and effectively charging batteries from waves requires a charge controller to properly monitor and control voltage and current going to the battery. Currently, off-the-shelf charge controllers exist for other renewable generation such as wind, hydro, and solar. Two topologies were validated: a buck converter and a pulse width modulation (PWM) charge controller. Using an in-lab dry testbed, wave energy power inputs were simulated to properly validate the effectiveness of existing charge controller technologies, identifying the shortcomings and improvements needed to effectively harness wave energy.

battery storage↗

DOE OSTI2021

Preshaping clear glass at low temperatures

Advances in available glass chemistries and glass processing methods have accompanied and enabled some of the biggest technology revolutions, from the development and mass production of light bulbs to low-loss fiber optics and durable smartphone touchscreens. An emerging generation of low-temperature processing technologies aims to continue this important trend and make a broader array of glass components mass producible. In the issue, Mader et al. (1) describe one such innovation in glass processing—the use of low-temperature injection molding to preshape silica particle–filled composites that can later be transformed into transparent fused silica glass objects. Traditionally, transparent glass objects are manufactured in high volume from molten or softened glass, which is floated, drawn, blown, cast, or blow-molded to a desired shape (see the figure, top). The glass composition and processing technique dictate the working temperature, which is usually quite high (near 1000°C) and often restricts the choice of compatible equipment or limits the choice of glass composition. Because geometry-specific capital investment is required for production, drastic or frequent component design changes or small batches may be cost prohibitive. Alternatively, transparent glass components can also be shaped at ambient temperature from solid glass by a series of subtractive processes, including cutting or multiple stages of grinding, followed by slower processing steps, such as polishing or etching. This approach is somewhat less amenable to mass production, and certain geometries containing tool-inaccessible regions cannot be fabricated in this way. Several emerging glass-shaping technologies aim to reduce the required manufacturing temperatures and still provide access to a broader range of glass compositions and component geometries (see the figure). These approaches use a three-step process. First, a desired shape is preformed at low temperature from a glass-forming, organic-inorganic composite. Next, the preform is dried, and organic materials used to bind particles are removed. Finally, the preform is heated (sintered) well below the glass-melting temperature to densify to transparent glass. Although the second and third steps do occur at increased temperatures, only standard, geometry-agnostic driers and furnaces are required. This strategy builds on the well-studied sol-gel approach to forming monolithic glass, where silica network–forming chemical solutions are poured into molds, slowly dried, and condensed into dense glass without melting (2). In a departure from the sol-gel process, these new technologies use solvents, cross-linkers, and polymers to formulate organic-inorganic composites tuned for compatibility with a particular shaping process, with formats ranging from photocurable liquids to shear-thickening pastes to solids. The composite inorganic loadings are also typically higher than those in the pure sol-gel approach, which drastically reduces shrinkage in comparison.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Roadmap for the Completion of the Design and Implementation of a Remote Canister Monitoring System

The Office of Environmental Management within the Department of Energy is currently investigating technical issues associated with extended dry storage (50+ years) of aluminum spent nuclear fuel. As part of these efforts, a remote canister-monitoring system (RCMS) has been proposed to collect the real-time data of the environmental conditions in the canisters used for the dry storage of aluminum spent nuclear fuel in the CPP-603 facility at Idaho National Laboratory (INL). The proposed RCMS would provide the opportunity to evaluate the appropriate technologies for monitoring, to collect canister environment conditions as soon as possible, to verify and validate current laboratory-based study results and analytic modeling approaches, and to potentially identify additional dry storage options for aluminum spent nuclear fuel at the INL Site. The document provides a brief update on the progress that has been made toward deploying the RCMS and will present at a high level, the general system design philosophy behind the project and the key future tasks necessary for the completion of the RCMS system design, fabrication of the RCMS prototype, testing, and eventual deployment of the RCMS, and a tentative timeline for these tasks.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2021

Environmental Influence on Fracture and Delamination of Electrically Conductive Adhesives

This paper presents our continued work on developing a degradation model for electrically conductive adhesive (ECA) interconnects in photovoltaic modules. Here, we characterize the fracture mechanics properties of an epoxy based ECA, for both critical and subcritical loading conditions. Emphasis is put on the influence of different environmental conditions such as temperature and humidity. We found that high levels of humidity not only weaken the adhesive joint but also promote subcritical debonding at significantly lower driving forces than in dry environments.

41 EE - Solar Energy Technologies Office (EE-4S)↗

DOE OSTI2024

Fabrication and Testing of DOE Standard Canister Closure Leak Test Assembly

DOE manages over 300 types of spent nuclear fuel (SNF), many of which are located at the Idaho National Laboratory (INL) site. Managing this large variety of SNF for storage, transportation, and disposal poses a challenge to DOE. The Idaho Cleanup Project and INL are collaborating on the DOE SNF Road-Ready Demonstration (“Road-Ready Demonstration”), which will develop and demonstrate the designs, technology, processes, and regulatory framework for packaging DOE-managed SNF for “road-ready dry storage.” Road-ready dry storage is an SNF management concept in which SNF is packaged into dry, sealed canisters that are then placed in onsite storage in anticipation of later transport and disposition. The forward-looking goal of the Road-Ready Demonstration is to establish the foundation for a large-scale road-ready dry storage program at the INL site. In support of establishing a large-scale road-ready dry storage program at the INL site, the Road-Ready Demonstration will first package Fort St. Vrain SNF currently in dry storage at INL into several DOE Standard Canisters (DOESCs). These DOESCs will in turn be loaded into another containment similar to commercial multi-purpose canisters. This multi-purpose canister will then be compatible with a transportation or storage system, such as a storage cask for interim storage or transportation package for offsite transport. These DOESCs will remain sealed over the course of their storage, transportation, and applicable disposal functions. The closure process for the DOESC will include fuel and basket loading, welding, inspection, leak testing, and, if needed, repair. As a follow-up to previous discussions on the design of the DOE Closure Leak Test Assembly (LTA), this report describes recent fabrication and testing efforts performed at INL. DOESCs are sealed by two sequential gas tungsten arc welds, both of which are performed by remotely operated and semiautomatic welding systems. The first weld is a circumferential pipe weld that completes the assembly of the canister body and lid assembly. The second and final closure weld attaches the vent plug to the vent socket via a butt joint. After the second weld is performed, the welds are helium leak tested using an evacuated envelope technique. The LTA was designed for both remote and manual operation. This report describes the fabrication and performance testing associated with the evacuated envelope technique. INL staff designed, fabricated, and tested the LTA at INL facilities. This testing included establishing technique and system sensitivities in accordance with ASME and American National Standards Institute N14.5 requirements. Forthcoming work will cover such areas as design optimization, process and personnel qualification, and implementation in Road-Ready Demonstration operations.

42 ENGINEERING↗

DOE OSTI2024

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

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

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2024

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

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

42 ENGINEERING↗

DOE OSTI2023

Fabrication and Testing of DOE Standard Canister Closure Leak Test Assembly – 24139

DOE manages over 300 types of spent nuclear fuel (SNF), many of which are located at the Idaho National Laboratory (INL) site. Managing this large variety of SNF for storage, transportation, and disposal poses a challenge to DOE. The Idaho Cleanup Project and INL are collaborating on the DOE SNF Road-Ready Demonstration (“Road-Ready Demonstration”), which will develop and demonstrate the designs, technology, processes, and regulatory framework for packaging DOE-managed SNF for “road-ready dry storage.” Road-ready dry storage is an SNF management concept in which SNF is packaged into dry, sealed canisters that are then placed in onsite storage in anticipation of later transport and disposition. The forward-looking goal of the Road-Ready Demonstration is to establish the foundation for a large-scale road-ready dry storage program at the INL site. In support of establishing a large-scale road-ready dry storage program at the INL site, the Road-Ready Demonstration will first package Fort St. Vrain SNF currently in dry storage at INL into several DOE Standard Canisters (DOESCs). These DOESCs will in turn be loaded into another containment similar to commercial multi-purpose canisters. This multi-purpose canister will then be compatible with a transportation or storage system, such as a storage cask for interim storage or transportation package for offsite transport. These DOESCs will remain sealed over the course of their storage, transportation, and applicable disposal functions. The closure process for the DOESC will include fuel and basket loading, welding, inspection, leak testing, and, if needed, repair. As a follow-up to previous discussions on the design of the DOE Closure Leak Test Assembly (LTA), this report describes recent fabrication and testing efforts performed at INL. DOESCs are sealed by two sequential gas tungsten arc welds, both of which are performed by remotely operated and semiautomatic welding systems. The first weld is a circumferential pipe weld that completes the assembly of the canister body and lid assembly. The second and final closure weld attaches the vent plug to the vent socket via a butt joint. After the second weld is performed, the welds are helium leak tested using an evacuated envelope technique. The LTA was designed for both remote and manual operation. This report describes the fabrication and performance testing associated with the evacuated envelope technique. INL staff designed, fabricated, and tested the LTA at INL facilities. This testing included establishing technique and system sensitivities in accordance with ASME and American National Standards Institute N14.5 requirements. Forthcoming work will cover such areas as design optimization, process and personnel qualification, and implementation in Road-Ready Demonstration operations.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2026

A Generalized Grain-Scale Model for the Non-Plasma and Plasma-Assisted Hydrogen Direct Reduction of Iron Ore

Direct Reduction of Iron ore using hydrogen (H-DRI) is a promising pathway towards efficient steelmaking and accurate predictive models are a necessity for scale-up and optimization of this technology. However, accurate models of this process remain limited because existing models oversimplify grain-scale phenomena, such as nonlinearity inside grain, self-sufficient porosity, surface reactions, and the role of plasma species. These phenomena are important for flash steelmaking and plasma-assisted H-DRI processes. To address this need, we present a phenomenological model for simulating H-DRI at the scale of a single micron-sized grain of the iron ore. We call this the Transient Reactive Grain Model (TRGM). TRGM incorporates key physical process: gas species transport, a chemical kinetics of material conversion, nanopore structural evolution and, adsorption-desorption surface kinetics at the reactive nanopore surface. The important contribution of this work is that the model provides a dependence on different reductant species, specifically hydrogen atoms versus molecules, so that role of hydrogen plasma reduction can be clarified compared to the use of pure hydrogen gas reduction. TRGM predictions agree well with experimental data for both molecular H2 reduction of Fe2O3 and plasma hydrogen reduction of Fe3O4. Results reveal species concentration gradients with a diffuse reaction zone, and enhanced hydrogen diffusion at the grain outer surface due to evolving porosity. These findings challenge common assumptions in existing models, including sharp reaction fronts, quasi-steady diffusion and kinetics, and the neglect of surface chemistry. As a generalized grain-scale model for H-DRI processes, TRGM has practical applications in flash steelmaking and in-flight reduction using both molecular and plasma hydrogen.

08 HYDROGEN↗