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All sourcesNASA NTRSDOE OSTI
DOE OSTI2016

Packed Bed thermal storage for compact Light water-cooled Small Modular Reactors

Nuclear power plants (NPPs) have less flexibility to follow grid load demand than their natural-gas fueled counterparts. Most of the natural-gas power plants can supply peak-loads by adding more fuel, and thus, can generate far more revenue during those peak hours. On the other hand, use of NPPs for peak load following is quite complex due to technical constraints associated with reactor behavior. These technical challenges include the adequate handling of reactivity swings caused by time-varying fuel and moderator temperatures, a higher fuel-failure probability due to thermal-structural cycling, and spatial variations in xenon concentration. Although there are presently some reactors around the world that are operating with flexible load-following capabilities, such operation is restricted to slowly-varying powers, 2-3 times a day, and only up to 80% of the fuel cycle. Thus, a more convenient and effective method to facilitate load following by NPPs would be to integrate energy storage Authors have previously developed models and performed exergy analysis for integrating liquid type TES with LWRs and SMRs. These exergy based models show that technical feasibility index of integrating thermal energy storage is very high. But most of these previous studies include integration based on existing layout of NPPs with heat exchange between storage Heat Transfer Fluid (HTF) and Reactor Coolant (RC). However, most of the Light Water-cooled Small modular reactor (LW-SMR) based NPP designs can not accommodate additional heat exchange equipment. Although power production is only reduced to 1/20 scale, the containment volume in thus NuScale LW-SMR is reduced to {approx} 1/170 scale. As steam is the secondary or working fluid which exits out of the reactor containment in LW-SMRs, the simplest and most practical way to integrate thermal storage with LW-SMRs is to directly store the energy from steam. Indirect heat exchange between steam and another heat transfer fluid during the storage process, and then heat recovery again via indirect heat exchange is inefficient process due to heat transfer resistance. This inefficiency is due to what is called as 'Pinch point' which occurs whenever there is indirect heat transfer between two media where one undergoes phase change and other undergoes change in sensible heat. Another existing popular option is to use a steam accumulator which stores dry or wet steam directly inside the pressure vessels, however, due to large volumetric requirements it is not a viable option. This work proposes a new method of integrating packed bed TES systems with LW-SMRs, where steam produced in the secondary side of LW-SMRs can be injected into the packed bed of inert particles with sufficient thermal conductivity and capacity to efficiently store energy with high energy density. The changes in the load demand will not effect the LWSMR operation and the excess steam will be diverted to TES. When the demand increases this stored energy in hot packed beds can be recovered by injecting cold pressurized water. Although there are some existing packed bed TES designs and models which consider steam as HTFs, these models have not been extended for wide range of process parameters important for this integration. Authors have previously developed a packed bed thermal model for steam injection and validated it using experimental data. This thermal model is extended to assess behavior of packed bed thermal energy storage (TES) system under storage and recovery cycles. Steam is the only heat transfer fluid (HTF) which exits the reactor vessel, so any application such as process heat or TES integration should be evaluated with steam as process fluid. This project will develop a process system integration model of LW-SMR with packed bed type TES using steam as HTF. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2020

Quarterly Technical Progress Report Piperazine Advanced Stripper (PZAS™) Front End Engineering Design

EXECUTIVE SUMMARY This document summarizes the status of Cooperative Agreement DE-FE0031844, “Piperazine Advanced Stripper (PZAS™) Front-End Engineering Design,” during the reporting period of January 1 through March 31, 2020. The objective of this project is to develop accurate installed costs by conducting a Front-End Engineering Design (FEED) of PZAS™ at Golden Spread Electric Cooperative’s (GSEC) Mustang Station located in Denver City, TX. Complementary benefits include positioning the technology for a commercial project with the 45Q tax credits, qualifying PZAS™ for use on a Natural Gas Combined Cycle (NGCC) Cogen facility, and to provide cost detail to optimize PZAS™ and help guide R&D of second-generation solvent CO2 capture technologies. Results from the FEED will be used to evaluate the economic feasibility of the process at Mustang Station. This project is funded by the U.S. DOE National Energy Technology Laboratory under the aforementioned Cooperative Agreement. Exxon, Total, Chevron, UOP-Honeywell, and the University of Texas (UT) are project co-funders. AECOM and Trimeric are project team members; UT is the prime contractor. Summary of Progress Cooperative Agreement DE-FE0031844 was established in October 2019. The current reporting period, January 1 through March 31, 2020, is the second technical progress reporting period for the project. Several milestones were accomplished during this reporting period, including: • Kickoff Meeting with DOE on February 3, 2020. • Kickoff Meeting with GSEC on March 30, 2020. (Note: Due to Covid-19 travel restrictions and shelter-in-place guidelines, the kickoff meeting was conducted remotely via videoconferencing. See attached notes from that telecon.) • Updated Project Management Plan March 2020, submitted with this quarterly report Other activities during the quarter included progress on contracting and other legal agreements (e.g., non-disclosure agreements), internal kickoff meetings at both AECOM and Trimeric, and development of a Technical Implementation Plan (TIP). The TIP will help the team to make critical, early process decisions and, ultimately, to develop a project and process design basis. Note that all agreements between project team participants are complete as of this submittal, except the vendor agreement with Kiewit (steam cycle modeling). Plans for Next Reporting Period Activities during the next reporting period (April 1, 2020 through June 30, 2020) include: the completion of the Project Design Basis and progress towards the Process Design Basis/Process Design Package (PDP). The Project Design Basis is due as a deliverable and milestone during the next reporting period.

Rochelle, Gary T.↗
DOE OSTI2021

Development of a Modular, Crushed-Rock Thermal Energy Storage Pilot Design

The goal of this project, primarily funded by the U.S. Department of Energy, is to design a next-step pilot to advance near-term energy storage integrated with a fossil plant to provide a facility capable of being viable and effective in a market with growing penetration of variable renewable energy (VRE). Thermal energy storage (TES) represents an ideal technology for this purpose. The current effort will complete a feasibility study to prepare for the Phase II pre-front end engineering design (pre-FEED) for implementing a crushed-rock TES system integrated with a natural gas combined cycle (NGCC) plant. The crushed rock storage technology, which is being developed by Brenmiller Energy, is a modular TES system termed bGen™, which can accommodate both thermal and electrical inputs and output steam, hot water, or hot air. For this application, the estimated efficiency is 80% thermal to thermal. The TES technology is being designed to operate on a slipstream from NYPA’s Eugene W. Zeltmann Power Project (Zeltmann) natural gas combined cycle (NGCC) plant. The projected size of the system will be up to 4 MWe with at least 4 hours of storage duration, or 16 MWh-e total. Final sizing is being determined during the ongoing feasibility study. The next-step pilot being designed as part of the current project will represent a 5-fold increase in scale for this TES technology, and will be used to validate the technology’s ability to provide effective and economical energy storage. This pilot would represent the next-to-last demonstration scale before the technology could be commercial ready at GWh-e scales in the 2030 timeframe. This project is expected to design the critical next-step pilot, which will be undertaken in real-world operating conditions to better determine the crushed rock TES technology’s ability to be integrated with an NGCC plant and assess degradation over transient cycling at rates befitting various marketplaces. The crushed-rock TES pilot design is a technically feasible next step in the development of the technology and is built upon years of prior testing and demonstration. The proposed TES technology was developed by Brenmiller over the last 8 years and has been tested in 3 generations of demonstration units at various sites, globally. During this field testing, different characteristics and performance of the technology were validated, including the following key features: energy storage capacity, energy storage charge/discharge rate, energy storage loses, energy storage mechanical testing. This presentation will provide an update on the results of the conceptual design study for the modular crushed-rock TES system, integrated with a NGCC power plant.

03 NATURAL GAS↗
DOE OSTI2024

Co-synthesis of Hydrogen and High-Value Carbon Products from Methane Pyrolysis

The ARPA-E Methane Pyrolysis Project successfully developed a scalable technology for hydrogen production with low-CO x emission through methane pyrolysis, co-producing high-value carbon nanotubes (CNTs). The project focused on optimizing reactor design, enhancing catalyst performance, and assessing techno-economic feasibility to create a commercially viable and environmentally sustainable process. The fluidized bed reactor achieved over 90% methane (CH 4 ) conversion by using a 5% CO 2 co-feed, which stabilizes carbon yields and minimizes catalyst deactivation. This setup allowed for continuous operation across ten cycles, each consisting of a 14-minute pyrolysis phase followed by a 10-minute dislodging phase to remove a fraction of the accumulated carbon, resulting in stable performance and high-quality CNT production. In parallel, monolith reactors coated with Fe demonstrated a sustained methane conversion of 73% while producing CNTs with high crystallinity. Although promising for continuous operation, monolith reactors face challenges in coating durability and scalability, highlighting areas for further optimization in commercial applications. Catalyst formulation played a key role in enhancing process efficiency. The core catalyst used was 5%Fe/Al 2 O 3 (wt%), optimized through wet impregnation, which improved CNT morphology, yielding longer and more uniform CNTs. The catalyst's performance was further enhanced by adding promoters: 2.5 wt% Ni increased methane conversion close to the thermodynamic limit, while 2.5 wt% Mn improved CNT alignment and crystallinity, and 1.5 wt% NaCl boosted CNT morphology but slightly lowered methane conversion. These adjustments allowed the reactor to maintain high methane conversion while producing high-quality CNTs, enabling stable performance over multiple cycles. To address carbon buildup and ensure uninterrupted operation, a pneumatic conveying tube was implemented for effective carbon dislodging in the fluidized bed configuration. CO 2 and H 2 O co-feeds were also introduced to enhance carbon removal, with CO 2 boosting CNT yield by approximately 15%. This setup enabled stable reactor operation across multiple cycles, preventing clogging and minimizing catalyst wear, making the process suitable for industrial scaling. Techno-economic analysis (TEA) projected hydrogen production costs between $\$$1.00 and $\$$1.64 per kilogram, with CNT values assumed at $\$$375/ton and $\$$100/ton. The life cycle assessment showed that CO 2 emissions could be as low as 0.64 kg CO 2 e/kg H 2 at 95% methane conversion assuming an electricity input of 50 kg CO 2 e/MWh. Even at 50% methane conversion, emissions remained below 1 kg CO 2 e/kg H 2 , demonstrating the process's low-emission potential and making it a viable alternative to traditional steam methane reforming. Overall, the results from this project demonstrate the feasibility of a pyrolysis process where carbon is continuously removed from the catalyst surface and hydrogen is continuously produced until a catalyst regeneration step is required to fully clean the catalyst surface and renew catalyst performance. Major open challenges are related to avoiding the loss of catalyst material in the dislodged carbon during fluidized bed conditions, since our best result demonstrated a carbon purity of ~70 wt. % (rest being iron and alumina). A monolith reactor was used to favor dislodgement of carbon compared to fluidized bed conditions but our results do not demonstrate an advantage of the monolith configuration. Catalyst performance was similar to fluidized bed conditions with slower deactivation rates overall, but we could not observe carbon dislodging in any of the tens of experiments that were run at Stanford. Our results show that the most relevant areas of improvement are related to the fundamental understanding of the iron-carbon interface for dislodging, and the development of catalyst that can produce CNTs via a base-growth mechanism such that catalyst is not lost in the dislodgement steps. The final report documents all findings and methodologies in detail, providing a valuable resource for the scientific community. By building on these results, researchers can further advance methane pyrolysis technology, moving toward a more sustainable, scalable pathway for hydrogen production. This work lays the foundation for future research and commercial efforts to reduce emissions in hydrogen production while generating valuable carbon products.

08 HYDROGEN↗
DOE OSTI2019

Dynamic Earth Energy Storage: Terawatt-Year, Grid-Scale Energy Storage using Planet Earth as a Thermal Battery (GeoTES): Seedling Project Final Report

Grid-scale energy storage has been identified as a needed technology to support the continued build-out of intermittent renewable energy resources. As of April 2017, the U.S. had approximately 24.2 GW of energy storage on line, compared to 1,081 GW of installed generation capacity (Litynski et al. 2006, Hellstrom 2003). This represents a large shortfall of the storage needed to stabilize the U.S. grids with the rising penetration of renewable energy. Our team proposed to address this shortfall through the storage of excess energy as geothermal brine in deep geologic formations. This concept, known as geologic thermal energy storage (GeoTES), relies on the storage of thermal energy in geologic formations for recovery and use in large-scale direct use geothermal applications. As such, GeoTES has the potential to play a significant role in meeting the energy storage shortfall in the coming decades by assisting with peak demand ramping, easing stress on transmission, providing regional storage to support sustainable direct use geothermal applications, and providing a variety of grid stabilization benefits due to renewable outages or inaccurate forecasting and rotor stability.

15 GEOTHERMAL ENERGY↗
DOE OSTI2016

Subtask 2.18 - Advancing CO 2 Capture Technology: Partnership for CO 2 Capture (PCO 2 C) Phase III

Industries and utilities continue to investigate ways to decrease their carbon footprint. Carbon capture and storage (CCS) can enable existing power generation facilities to meet the current national CO 2 reduction goals. The Partnership for CO2 Capture Phase III focused on several important research areas in an effort to find ways to decrease the cost of capture across both precombustion and postcombustion platforms. Two flue gas pretreatment technologies for postcombustion capture, an SO 2 reduction scrubbing technology from Cansolv Technologies Inc. and the Tri-Mer filtration technology that combines particulate, NOx, and SO 2 control, were evaluated on the Energy & Environmental Research Center’s (EERC’s) pilot-scale test system. Pretreating the flue gas should enable more efficient, and therefore less expensive, CO 2 capture. Both technologies were found to be effective in pretreating flue gas prior to CO 2 capture. Two new postcombustion capture solvents were tested, one from the Korea Carbon Capture and Sequestration R&D Center (KCRC) and one from CO 2 Solutions Incorporated. Both of these solvents showed the ability to capture CO 2 while requiring less regeneration energy, which would reduce the cost of capture. Hydrogen separation membranes from Commonwealth Scientific and Industrial Research Organisation were evaluated through precombustion testing. They are composed of vanadium alloy, which is less expensive than the palladium alloys that are typically used. Their performance was comparable to that of other membranes that have been tested at the EERC. Aspen Plus® software was used to model the KCRC and CO 2 Solutions solvents and found that they would result in significantly improved overall plant performance. The modeling effort also showed that the parasitic steam load at partial capture of 45% is less than half that of 90% overall capture, indicating savings that could be accrued if 90% capture is not required. Modeling of three regional power plants using the Carnegie Mellon Integrated Environmental Control Model showed that, among other things, the use of a bypass during partial capture may minimize the size of the capture tower(s) and result in a slight reduction in the revenue required to operate the capture facility. The results reinforced that a one-size-fits-all approach cannot be taken to adding capture to a power plant. Laboratory testing indicated that Fourier transform infrared spectroscopy could be used to continuously sample stack emissions at CO 2 capture facilities to detect and quantify any residual amine or its degradation products, particularly nitrosamines. The information gathered during Phase III is important for utility stakeholders as they determine how to reduce their CO 2 emissions in a carbon-constrained world. This subtask was funded through the EERC–U.S. Department of Energy (DOE) Joint Program on Research and Development for Fossil Energy-Related Resources Cooperative Agreement No. DE-FC26-08NT43291. Nonfederal funding was provided by the North Dakota Industrial Commission, PPL Montana, Nebraska Public Power District, Tri-Mer Corporation, Montana–Dakota Utilities Co., Basin Electric Power Cooperative, KCRC/Korean Institute of Energy Research, Cansolv Technologies, and CO 2 Solutions, Inc.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2016

Design Optimization of Liquid Fueled High Velocity Oxy- Fuel Thermal Spraying Technique for Durable Coating for Fossil Power Systems

High-velocity oxy–fuel (HVOF) thermal spraying was developed in 1930 and has been commercially available for twenty-five years. HVOF thermal spraying has several benefits over the more conventional plasma spray technique including a faster deposition rate which leads to quicker turn-around, with more durable coatings and higher bond strength, hardness and wear resistance due to a homogeneous distribution of the sprayed particles. HVOF thermal spraying is frequently used in engineering to deposit cermets, metallic alloys, composites and polymers, to enhance product life and performance. HVOF thermal spraying system is a highly promising technique for applying durable coatings on structural materials for corrosive and high temperature environments in advanced ultra-supercritical coal- fired (AUSC) boilers, steam turbines and gas turbines. HVOF thermal spraying is the preferred method for producing coatings with low porosity and high adhesion. HVOF thermal spray process has been shown to be one of the most efficient techniques to deposit high performance coatings at moderate cost. Variables affecting the deposit formation and coating properties include hardware characteristics such as nozzle geometry and spraying distance and process parameters such as equivalence ratio, gas flow density, and powder feedstock. In the spray process, the powder particles experience very high speeds combined with fast heating to the powder material melting point or above. This high temperature causes evaporation of the powder, dissolution, and phase transformations. Due to the complex nature of the HVOF technique, the control and optimization of the process is difficult. In general, good coating quality with suitable properties and required performance for specific applications is the goal in producing thermal spray coatings. In order to reach this goal, a deeper understanding of the spray process as a whole is needed. Although many researchers studied commercial HVOF thermal spray systems, there exists a lack of fundamental understanding of the effect of hardware characteristics and operating parameters on HVOF thermally sprayed coatings. Motivated by these issues, this study is devoted to investigate the effect of hardware characteristics (e.g. spraying distance) and operating parameters (e.g. combustion chamber pressure, equivalence ratio, and total gas flow rate) on HVOF sprayed coatings using Inconel 718 alloy. The current study provides extensive understanding of several key operating and process parameters to optimize the next generation of HVOF thermally sprayed coatings for high temperature and harsh environment applications. A facility was developed to support this endeavor in a safe and efficient way, including a HVOF thermal spray system with a Data Acquisition and Remote Controls system (DARCS). The coatings microstructure and morphology were examined using X-Ray Diffraction (XRD), Scanning Electron Microscope (SEM) and Nanoindentation.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2020

Multi-Gas Sensors for Enhanced Reliability of SOFC Operation

GE Research, in partnership with SUNY Polytechnic Institute (SUNY Poly), designed, built, and tested gas sensors for in situ monitoring of H 2 and CO anode tail gases produced with on-site steam reforming in solid oxide fuel cell (SOFC) systems. The knowledge of the H 2 /CO ratio of these anode tail gases should allow accurate determination and control of the efficiency of the reforming process in the SOFC system and should deliver a lower operating cost for SOFC customers. The project objectives were to achieve multi-gas monitoring capability with a single multivariable sensor, and to sustain this performance in the presence of gaseous interferences and a potential poison for the sensor. The duration of the project was 24 months with the project structure that included three technical tasks such as (1) development of design rules of photonic nanostructures for H 2 and CO gas detection, (2) laboratory validation of photonic nanostructures for selective H 2 and CO gas detection, and (3) validation of photonic nanostructures for initial stability and poison-resistance against H 2 S. To build multivariable sensors for selective H 2 and CO gas detection in the presence of interferences, we expanded our earlier knowledge of multi-gas sensors into new fabrication and functionalization methodologies as well as into new methodologies for the spectral data analysis of multi-gas responses. We have advanced our design rules of the three-dimensional (3D) photonic nanostructures that allowed detection of H 2 and CO at high temperatures as individual gases and as their mixtures and rejection of interferences such as CO 2 , H 2 O, CH 4 , and other hydrocarbons for SOFC applications. Our advanced design rules should be attractive for building the new generation of cost-effective industrial sensors. Stability and poison resistance of our 3D photonic nanostructures was tested in the laboratory conditions. While initially we utilized conventional machine learning data analysis tools, we have found that they were unable to correct for the sensor drift. Thus, we have implemented new methods of machine learning for the analysis of our spectral data. These learnings pave the way to move the future studies into advanced testing of effects of interferences, aging and field tests. In future, our work will continue to advance our sensing designs to operate in conditions with known and unknown interferences by implementing nanostructures with enhanced spectral diversity of responses to gaseous species of interest and interferences. Our systematic reduction of technical risks in this completed project and in future studies will ensure transition of this sensing technology to commercialization.

03 NATURAL GAS↗
DOE OSTI2021

Wyandotte Integrated Renewable Energy Strategy (WIRES 2) (Final Technical Report)

Wyandotte Municipal Services (WMS), a Michigan Municipal Utility offering electric generation, transmission & distribution, water filtration & distribution and Broadband/Video sought to deploy a set of renewable energy projects for their Electric Utility that contributed to reducing the City’s environmental and energy impact, provided examples that would encourage businesses and citizens to adopt cleaner energy practices and help WMS meet the required renewable energy standards of the State of Michigan (10% in 2015, 15% in 2021). WMS generates and delivers roughly 280,000 megawatt hours (MWh) of electricity annually to more than 10,000 homes and 1,000 businesses within the City of Wyandotte. The Wyandotte Integrated Renewable Energy Strategy – WIRES 2 resulted in deployment of a set of community-scale micro-wind turbines, evaluation and installation of energy-efficient and low-maintenance light-emitting diode (LED) street lights and park lights in highly visible locations in the City and expansion of the geothermal heating and cooling district that already included residential geothermal systems, to include larger scale business/institutional systems at the Utility’s largest electric customer and at the City Library. Finally, WMS identified the need for job training in energy efficiency and renewable energy technologies to further develop a local skilled workforce in these areas. Partially funded by the grant, the wind turbine project provides a benchmark for WMS, local businesses and residents in the evaluation of utility-scale wind v. micro-wind in an urban environment as a renewable energy strategy. Also partially funded by the grant, the LED project benefited the City of Wyandotte by reducing load on the electric system for the public utility but also reduced City costs for streetlighting, parking lot lighting and park lighting without a compromise in security. The project also resulted in a visual success that has led to additional approvals for non-Grant related LED lighting installations resulting in further reduction in the electric load in the City. Commercial Geothermal installations resulted in the Utility being able to eliminate steam customers who formerly utilized the byproduct of steam from WMS electric production. Due to the reduction in natural gas prices and the overall reduction in market purchased power, it was no longer feasible for WMS to operate its Power Plant as a base load plant and to only operate on a market dispatch philosophy when market prices dictated that WMS could produce electricity cheaper than the market purchase price. This has resulted in fewer operating days for the WMS Power Plant, resulting in less environmental impact. WMS has now completely exited the steam business and the ability to offer a geothermal option to two (2) former steam customers (BASF-Wyandotte and the Bacon Memorial Library) allowed for that. In addition, peak loads have been shaved for these two (2) large customers due to the consistent temperature offered by geothermal heating and cooling, reducing the swings associated with thermostat changes caused by outside temperature changes during extreme high and low temperatures. Finally, energy efficiency and renewable energy college-level classes at Wayne County Community College allowed a group of interested students to pursue studies in those technologies through grant provided tuition, books and course materials. This effort provided a foundation of potential future employees not only for WMS but other energy efficiency/renewable energy employers such as Franklin Energy, a partner with WMS in energy optimization efforts with Wyandotte businesses.

17 WIND ENERGY↗
DOE OSTI2017

Performance of a Steel/Oxide Composite Waste Form for Combined Waste Steams from Advanced Electrochemical Processes

The results of electrochemical corrosion tests and modeling activities performed collaboratively by researchers at the University of Illinois at Chicago and Argonne National Laboratory as part of workpackage NU-13-IL-UIC-0203-02 are summarized herein. The overall objective of the project was to develop and demonstrate testing and modeling approaches that could be used to evaluate the use of composite alloy/ceramic materials as high-level durable waste forms. Several prototypical composite waste form materials were made from stainless steels representing fuel cladding, reagent metals representing metallic fuel waste streams, and reagent oxides representing oxide fuel waste streams to study the microstructures and corrosion behaviors of the oxide and alloy phases. Microelectrodes fabricated from small specimens of the composite materials were used in a series of electrochemical tests to assess the corrosion behaviors of the constituent phases and phase boundaries in an aggressive acid brine solution at various imposed surface potentials. The microstructures were characterized in detail before and after the electrochemical tests to relate the electrochemical responses to changes in both the electrode surface and the solution composition. The results of microscopic, electrochemical, and solution analyses were used to develop equivalent circuit and physical models representing the measured corrosion behaviors of the different materials pertinent to long-term corrosion behavior. This report provides details regarding (1) the production of the composite materials, (2) the protocol for the electrochemical measurements and interpretations of the responses of multi-phase alloy and oxide composites, (3) relating corrosion behaviors to microstructures of multi-phase alloys based on 316L stainless steel and HT9 (410 stainless steel was used as a substitute) with added Mo, Ni, and/or Mn, and (4) modeling the corrosion behaviors and rates of several alloy/oxide composite materials made with added lanthanide and uranium oxides. These analyses show the corrosion behaviors of the alloy/ceramic composite materials are very similar to the corrosion behaviors of multi-phase alloy waste forms, and that the presence of oxide inclusions does not impact the corrosion behaviors of the alloy phases. Mixing with metallic waste streams is beneficial to lanthanide and uranium oxides in that they react with Zr in the fuel waste to form highly durable zirconates. The measured corrosion behaviors suggest properly formulated composite materials would be suitable waste forms for combined metallic and oxide waste streams generated during electrometallurgical reprocessing of spent nuclear fuel. Electrochemical methods are suitable for evaluating the durability and modeling long-term behavior of composite waste forms: the degradation model developed for metallic waste forms can be applied to the alloy phases formed in the composite and an affinity-based mineral dissolution model can be applied to the ceramic phases.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2012

Condensation in horizontal heat exchanger tubes

Many innovative reactor concepts for Generation III nuclear power plants use passive safety equipment for residual heat removal. These systems use two phase natural circulation. Heat transfer to the coolant results in a density difference providing the driving head for the required mass flow. By balancing the pressure drop the system finds its operational mode. Therefore the systems depend on a strong link between heat transfer and pressure drop determining the mass flow through the system. In order to be able to analyze these kind of systems with the help of state of the art computer codes the implemented numerical models for heat transfer, pressure drop or two phase flow structure must be able to predict the system performance in a wide parameter range. Goal of the program is to optimize the numerical models and therefore the performance of computer codes analyzing passive systems. Within the project the heat transfer capacity of a heat exchanger tube will be investigated. Therefore the tube will be equipped with detectors, both temperature and pressure, in several directions perpendicular to the tube axis to be able to resolve the angular heat transfer. In parallel the flow structure of a two phase flow inside and along the tube will be detected with the help of x-ray tomography. The water cooling outside of the tube will be realized by forced convection. It will be possible to combine the flow structure measurement with an angular resolved heat transfer for a wide parameter range. The test rig is set up at the TOPLFOW facility at the Helmholtz-Zentrum Dresden-Rossendorf (HZDR), so that it will be possible to vary the pressure between 5 and 70 bar. The steam mass content will be varied between 0 and 100 percent. The results will be compared to the large scaled Emergency Condenser Tests performed at the INKA test facility in Karlstein (Germany). The paper will explain the test setup and the status of the project will be presented. (authors)

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2018

Global Value Chain and Manufacturing Analysis on Geothermal Power Plant Turbines

Currently, geothermal project developers customize the size of the power plant to fit the resource being developed. The turbine is designed and sized to optimize efficiency and resource utilization for electricity production; most often, other power plant components are then chosen to complement the turbine design. These custom turbine designs demand one-off manufacturing processes, which result in higher manufacturing setup costs, longer lead-times, and higher capital costs overall in comparison to larger-volume line manufacturing processes. In contrast, turbines produced in standard increments, manufactured in larger volumes, could result in lower costs per turbine. In this study, we developed a manufacturing cost model to identify requirements for equipment, facilities, raw materials, and labor. Then we used discounted cash flow (DCF) analysis to calculate the minimum sustainable price (MSP). We analyzed three different cases 1) 1 MWe geothermal ORC turboexpander 2) 5 MWe ORC turboexpander and 3) 20 MWe geothermal steam turbine, and calculated the cost of manufacturing the major components, such as the impellers/blades, shaft/rotor, nozzles, inlet guide lanes, disks, and casings. The results showed that MSP could highly vary between 893 /kW and 30 /kW based on turbine size, standardization and volume of manufacturing. The analysis also showed that the economy of scale applies both to the size of the turbine and the number manufactured in a single run. As an example, the unit price of a 5 MW standard design turbine could be 150 /W cheaper than the custom design. Sensitivity analysis indicated that these savings come largely from reduced labor costs for design and engineering and manufacturing setup. In addition to manufacturing cost savings, there is a delivery time saving up to 10 months, which could have a positive effect to construction financing operation time. Another advantage of these standard turbines is their adaptability to different geothermal systems by operating at off-design conditions. We also modeled off-design turbine efficiencies within the commercially-favorable operating range of a standard ORC compared to custom-designed ORC equipment. Than we used these performance calculations and power output capacities in a discounted cash flow (DCF) analysis of plant operations and financing, thereby creating representative techno economic models of a total geothermal power plant. I this scope we used NREL's System Advisor model (SAM) and performed DCF analysis of standard and custom design turbines using results from IPSEpro over range of temperatures of interest. In this scope 63 different off-design cases were analyzed. This helped us to answer the question; 'Can today's capital cost savings compensate the future revenue losses due to lower electricity generation?' The results showed that, the net capital cost savings for the modeled 5 MW case study may reach up to plus 1,298,672. Also, the difference between NPV of standard design and custom design turbine could reach up to 733,940. To sum up, when all the things mentioned above are taken into consideration, it can be said that, the standard turbines are competitive over a wide range of temperatures and flow rates and the give positive NPV differences for certain cases near their design point.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2018

2018 Research Highlight in Manufacturing: Global Value Chain and Manufacturing Analysis on Geothermal Power Plant Turbines

Currently, geothermal project developers customize the size of the power plant to fit the resource being developed. The turbine is designed and sized to optimize efficiency and resource utilization for electricity production; most often, other power plant components are then chosen to complement the turbine design. These custom turbine designs demand one-off manufacturing processes, which result in higher manufacturing setup costs, longer lead-times, and higher capital costs overall in comparison to larger-volume line manufacturing processes. In contrast, turbines produced in standard increments, manufactured in larger volumes, could result in lower costs per turbine. In this study, we developed a manufacturing cost model to identify requirements for equipment, facilities, raw materials, and labor. Then we used discounted cash flow (DCF) analysis to calculate the minimum sustainable price (MSP). We analyzed three different cases 1) 1 MWe geothermal ORC turboexpander 2) 5 MWe ORC turboexpander and 3) 20 MWe geothermal steam turbine, and calculated the cost of manufacturing the major components, such as the impellers/blades, shaft/rotor, nozzles, inlet guide lanes, disks, and casings. The results showed that MSP could highly vary between 893 $/kW and 30 $/kW based on turbine size, standardization and volume of manufacturing. The analysis also showed that the economy of scale applies both to the size of the turbine and the number manufactured in a single run. As an example, the unit price of a 5 MW standard design turbine could be 150 $/W cheaper than the custom design. Sensitivity analysis indicated that these savings come largely from reduced labor costs for design and engineering and manufacturing setup. In addition to manufacturing cost savings, there is a delivery time saving up to 10 months, which could have a positive effect to construction financing operation time. Another advantage of these standard turbines is their adaptability to different geothermal systems by operating at off-design conditions. We also modeled off-design turbine efficiencies within the commercially-favorable operating range of a standard ORC compared to custom-designed ORC equipment. Than we used these performance calculations and power output capacities in a discounted cash flow (DCF) analysis of plant operations and financing, thereby creating representative techno economic models of a total geothermal power plant. I this scope we used NREL's System Advisor model (SAM) and performed DCF analysis of standard and custom design turbines using results from IPSEpro over range of temperatures of interest. In this scope 63 different off-design cases were analyzed. This helped us to answer the question; 'Can today`s capital cost savings compensate the future revenue losses due to lower electricity generation?' The results showed that, the net capital cost savings for the modeled 5 MW case study may reach up to +$1,298,672. Also, the difference between NPV of standard design and custom design turbine could reach up to +$733,940. To sum up, when all the things mentioned above are taken into consideration, it can be said that, the standard turbines are competitive over a wide range of temperatures and flow rates and the give positive NPV differences for certain cases near their design point.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2017

One Step Hydrogen Generation Through Sorption Enhanced Reforming

One-step hydrogen generation, using Sorption Enhanced Reforming (SER) technology, is an innovative means of providing critical energy and environmental improvements to US manufacturing processes. The Gas Technology Institute (GTI) is developing a Compact Hydrogen Generator (CHG) process, based on SER technology, which successfully integrates previously independent process steps, achieves superior energy efficiency by lowering reaction temperatures, and provides pathways to doubling energy productivity with less environmental pollution. GTI’s prior CHG process development efforts have culminated in an operational pilot plant. During the initial pilot testing, GTI identified two operating risks- 1) catalyst coating with calcium aluminate compounds, 2) limited solids handling of the sorbent. Under this contract GTI evaluated alternative materials (one catalyst and two sorbents) to mitigate both risks. The alternate catalyst met performance targets and did not experience coating with calcium aluminate compounds of any kind. The alternate sorbent materials demonstrated viable operation, with one material enabling a three-fold increase in sorbent flow. The testing also demonstrated operation at 90% of its rated capacity. Lastly, a carbon dioxide co-production study was performed to assess the advantage of the solid phase separation of carbon dioxide- inherent in the CHG process. Approximately 70% lower capital cost is achievable compared to SMR-based hydrogen production with CO2 capture, as well as improved operating costs.

08 HYDROGEN↗
DOE OSTI2025

Phase Field Modeling of Chemical Reaction Related Damage Evolution in Environmental Barrier Coatings

The advent of next-generation engines necessitates materials capable of withstanding temperatures beyond the reach of current superalloys. SiC-based ceramic matrix composites, augmented with environmental barrier coatings (EBCs), present a promising materials solution. Given the active search for effective and durable EBCs, there is a pressing need for modeling tools to understand and predict damage evolution in these materials to help accelerate their development. This study introduces a phase-field model (PFM) designed to simulate the thermally grown oxides (TGO) and phase transformation in the degradation and failure of EBCs. The model accounts for the severe volume expansion due to oxidation, alongside phase transformations and porosity evolution during thermal cycling, offering a comprehensive view of the damage processes. Simulation results are validated against experimental findings reported in the literature, establishing the model's potential as a significant tool for understanding and improving the resilience of EBCs in cyclic oxidative environments.

fast-diffusion path↗
DOE OSTI2026

Feedstock/Pretreatment Screening for Bioconversion of Sugars and Lignin Residues

This project will conduct biomass deconstruction (pretreatment and enzymatic saccharification) on two representative biomass feedstocks and four different pretreatment processes, including three high temperature steam/chemical pretreatments and one low temperature chemical/mechanical pretreatment. A third biomass feedstock will undergo biomass deconstruction with three different pretreatment processes, including two high temperature chemical pretreatments and one low temperature chemical/mechanical pretreatment. Several pretreatment conditions will be performed in a screening study using NLR pilot-scale pretreatment equipment to generate a range of pretreated biomass substrates. A selected number of these substrates will be chosen for enzymatic saccharification evaluation, based on standard compositional analysis of the pretreated substrates as a primary indicator of pretreatment efficacy. Resulting enzymatic hydrolysis slurries will be analyzed to determine overall biomass sugar yields. Additional compositional analysis will be performed to determine oligomeric sugar composition and structure, to analyze structural characteristics of solids fractions on native, pretreated, and enzymatically saccharified biomass residues for one of the biomass feedstocks, corn stover. The enzymatically saccharified materials will undergo 2,3-butanediol fermentation in a shaker flask as bench scale. Using relevant process performance data collected in these various conversion steps, technoeconomic analysis activities will be performed to compare the economic potential of the various biomass feedstock and pretreatment processes and to identify key economic drivers and sustainability metrics.

09 BIOMASS FUELS↗
DOE OSTI2012

Fish Health Studies Associated with the Kingston Fly Ash Spill, Spring 2009 – Fall 2010

On December 22, 2008, over 4 million cubic meters of fly ash slurry was released into the Emory River when a dike surrounding a solid waste containment area at the Tennessee Valley Authority's (TVA) Kingston Fossil Plant ruptured. One component of TVA's response to the spill is a biological monitoring program to assess short- and long-term ecological responses to the ash and associated chemicals, including studies on fish health and contaminant bioaccumulation. These studies were initiated in early Spring 2009 for the purposes of: (1) documenting the levels of fly ash-associated metals in various tissues of representative sentinel fish species in the area of the fly ash spill, (2) determining if exposure to fly ash-associated metals causes short, intermediate, or long-term health effects on these sentinel fish species, (3) assessing if there are causal relationships between exposure to metals and health effects on fish, (4) evaluating, along with information from other ecological and physicochemical studies, the nature and route of contaminant transfer though food chains into higher level consumers, (5) providing important information for the Ecological Risk Assessment (ERA) for the Kingston fly ash project, and (6) serving as an important technology information transfer or model study focused on how to best evaluate the environmental effects of fly ash (and related environmental stressors), not only at the Kingston site, but also at sites on other aquatic systems where coal-fired generating stations are located. This report presents the results of the first two years of the fish health study. To date, fish health and bioaccumulation studies have been conducted from Spring 2009 though Fall 2011 and includes 6 seasonal studies: Spring 2009, Fall 2009, Spring 2010, Fall 2010, Spring 2011, and Fall 2011. Both the Spring and Fall studies have focused on 3-4 sentinel fish species that represent different feeding habits, behaviors, and home ranges. In addition to fish health and bioaccumulation, the Spring investigations also included reproductive integrity studies on the same fish used for bioaccumulation and fish health. In this report, results of the fish health studies from Spring 2009 through Fall 2010 are presented while an associated report will present the fish reproductive studies conducted during Spring 2009 and Spring 2010. A report on fish bioaccumulation was submitted to TVA in June 2011. The fish health study conducted in conjunction with the bioaccumulation and reproductive study is critical for assessing and evaluating possible causal relationships between contaminant exposure (bioaccumulation) and the response of fish to exposure as reflected by the various measurements of fish health.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2011

RISK-INFORMED BALANCING OF SAFETY, NONPROLIFERATION, AND ECONOMICS FOR THE SFR

A substantial barrier to the implementation of Sodium-cooled Fast Reactor (SFR) technology in the short term is the perception that they would not be economically competitive with advanced light water reactors. With increased acceptance of risk-informed regulation, the opportunity exists to reduce the costs of a nuclear power plant at the design stage without applying excessive conservatism that is not needed in treating low risk events. In the report, NUREG-1860, the U.S. Nuclear Regulatory Commission describes developmental activities associated with a risk-informed, scenario-based technology neutral framework (TNF) for regulation. It provides quantitative yardsticks against which the adequacy of safety risks can be judged. We extend these concepts to treatment of proliferation risks. The objective of our project is to develop a risk-informed design process for minimizing the cost of electricity generation within constraints of adequate safety and proliferation risks. This report describes the design and use of this design optimization process within the context of reducing the capital cost and levelized cost of electricity production for a small (possibly modular) SFR. Our project provides not only an evaluation of the feasibility of a risk-informed design process but also a practical test of the applicability of the TNF to an actual advanced, non-LWR design. The report provides results of five safety related and one proliferation related case studies of innovative design alternatives. Applied to previously proposed SFR nuclear energy system concepts We find that the TNF provides a feasible initial basis for licensing new reactors. However, it is incomplete. We recommend improvements in terms of requiring acceptance standards for total safety risks, and we propose a framework for regulation of proliferation risks. We also demonstrate methods for evaluation of proliferation risks. We also suggest revisions to scenario-specific safety risk acceptance standards, particularly concerning seismic and aircraft impactrelated risks. Most importantly, within the context of the TNF historical SFR safety concerns about energetic core disruptive accidents are seen to be unimportant, but those of rare scenarios mentioned above are seen to be of dominant concern. In terms of proliferation risks the SFR energy system is seen not to be of considerably greater concern than with other nuclear power technologies, providing that highly effective safeguards are employed. We find the economic performance of proposed SFRs likely, due to the problems of using sodium as a coolant, to be inferior to those of LWRs unless they can be credited for services to improve nuclear waste disposal, nuclear fuel utilization and proliferation risk reductions. None of the design innovations investigated offers the promise to reverse this conclusion. The most promising innovation investigated is that of improving the plant's thermodynamic efficiency via use of the supercritical CO{sub 2} (rather than steam Rankine) power conversion system. We were unable to reach conclusions about the economic and proliferation risk implications of competing nuclear fuel processing methods, as available designs are too little developed to justify any such results. Overall, we find the SFR to be a promising alternative to LWRs should the conditions governing the valuation change substantially from current ones.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗