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All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Assessment of Flow-Enhanced Electrochemical Sensor Testing and Deployments for MSRs

This report serves as the deliverable for Milestone M3RS-23AN0401061 that is part of Work Package RS-23AN040106 (Flow Enhanced Sensors for MSRs – ANL). The goal of this milestone was to determine performance of the flow enhanced electrochemical sensor (FEES) and modular flow instrumentation testbed (MFIT) in safeguards relevant scenarios. Flow enhanced electrochemical sensors are a type of electroanalytical sensor that has been developed at Argonne National Laboratory to be installed directly into MSR flow conduits to make measurements of the salt composition. These sensors represent a significant improvement in capabilities compared to earlier electroanalytical sensors that instead can only be operated in quiescent conditions. Previous work has focused on testing of the FEES in flowing conditions provided by the MFIT to assess the accuracy and precision of the sensor measurements. To further improve this capability, in FY23 we undertook a campaign of safeguards relevant scenarios in molten salt containing a range of uranium chloride concentrations (0 to 3 wt%). All the testing carried out in FY23 was aided by a control system designed to automatically actuate flow conditions and collect data. This new automation system is estimated to have increased experimental throughput by a factor of four and enabled testing in a variety of complex conditions. The advancements in throughput and repeatability led to improved quantification of actinide concentrations using the in-flow sensors, with a reduction of the mean absolute relative error from 5.6% in FY22 to 3.1% in FY23. In addition to safeguards scenarios run in the MFIT, FY23 work included deployment of a FEES at a partner institution where it will be tested in a flowing salt loop. The FEES was successfully integrated into that loop and is being tested prior to loop startup. In FY23, work also continued on the smaller flow system that we have named the mini-MFIT. This smaller system is capable of rapid prototyping of new sensor designs prior to installation in the larger MFIT radiological flow system. Work was carried out to test this new system in non-radiological molten salts in a separate glovebox. This work is helping us to enhance the accuracy of our salt monitoring capabilities through the integration of multiple types of sensors. The high degree of accuracy required by 10 CFR 74 represents a significant challenge, and further design evolution and integration of the sensors into multimodal sensing frameworks will be needed to further push the measurement accuracy to the needed level.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Flow Enhanced Electrochemical Sensor Performance in Complex Salt Systems

To advance MSR MC&A practices, Argonne National Laboratory developed and optimized robust flow enhanced electrochemical sensors (FEES) and multielectrode array voltammetry sensors (MAVS) which provide accurate near-real time measurements of actinides in molten salts. Flow-enhanced electrochemical sensors are installed directly into MSR flow conduits for inline salt chemistry measurement, while MAVS are deployed in quiescent salt conditions enabling online species concentration determination in stationary salt vessels. This report summarizes efforts to improve electrochemical sensor technological readiness through (1) sensor testing in complex, high concentration molten salt systems to demonstrate low uncertainty actinide measurements in MSR-representative solutions and (2) demonstrations of sensor performance in challenging real-world conditions in collaboration with partner MSR institutions.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Synthesis and Thermophysical Property Determination of NaCl-PuCl3 Salts

Currently, a knowledge gap exists in the available data and understanding of thermophysical properties relating to fresh fuel salts, especially those containing plutonium. Determination of this data is necessary for the design and construction of test reactors, as well as the licensing of future commercial molten salt reactors. Thermophysical properties such as melting temperature, salt stability, density, and heat capacity were determined on synthesized eutectic NaCl-PuCl3 and a more sodium rich composition containing 25 mol% PuCl3. These measurements document the baseline properties of the salt as a function of temperature for future experiments on irradiated fuel salt which will provide a holistic perspective on the change of thermophysical properties during reactor operations. It was determined that the NaCl-PuCl3 ingot synthesized for this study contained 63.4 mol% NaCl, 36.3 mol% PuCl3, and was 99.7% pure. Upon heating it was shown that the NaCl- PuCl3 eutectic was stable at temperatures of 800°C. The onset of melting occurred at 541°C and the enthalpy of fusion was determined to be 140.7 ± 8.4 J/g. Specific heat capacity measurements showed a slightly decreasing trend with respect to temperature in the liquid phase ranging from 0.67 to 0.57 J/g·K, with an average value of 0.637 ± 0.03 J/g·K (104 ± 5 J/mol·K) between 500 to 720°C. Three independent trials of the molten NaCl-PuCl3 eutectic salt found the density to be ?(T) = 3.8589 – 9.5342·10-4 T(°C), validated between 500 to 800°C. In addition to salt synthesis and experimentally determining thermodynamic properties, Ab Initio molecular dynamic (AIMD) simulations were used to calculate density and heat capacity values.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Understanding Ionizing Radiation-Induced Speciation, Chemistry, and Transport in Nuclear Materials

The research to be presented will cover an overview of three projects supported by the United States Department of Energy Office of Science Solar Photochemistry Program: (i) Radiation-Induced Late Actinide Redox Chemistry (2019–2022); (ii) Understanding Radiation-Induced Iodine Speciation, Chemistry, and Transport in High Temperature Molten Salts (2022–2025); and (iii) Radiation-Induced Chemistry of Nuclear Materials (2023–2026). The overarching aim of these distinct projects is to develop a deep fundamental mechanistic understanding of ionizing-radiation-induced processes occurring in solutions over multiple time and length scales. Investigated solutions range from aqueous to organic to molten salt liquids in the presence and absence of ligands and various redox-active ions and molecules, including the actinides. The ultimate goal of these projects is to utilize the new foundational knowledge gained to construct quantitative multiscale computer models with the capacity to predict radiation-induced behavior in complex systems of relevance to nuclear energy technologies and beyond.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
DOE OSTI2024

Special Considerations for the Removal and Disposal of Micro-Reactor Experiments

Idaho National Laboratory (INL) is preparing to host several microreactor experiments through 2030 and beyond. Two new test beds currently under development will operate as microreactor or nuclear system experiment user facilities. Test bed experiments will be performed in series, with each nuclear experiment installed, operated, and removed before installation of the subsequent experiment. The necessarily brief transition period between experiments introduces unique equipment removal and radioactive waste disposal challenges. This paper evaluates equipment removal and radioactive waste management topics associated with tight sequencing of nuclear experiments and presents some of the solutions and approaches currently planned to meet these special considerations for one such experiment, the Molten Chloride Reactor Experiment (MCRE), slated for operation at INL’s Laboratory for Operation and Testing in the United States (LOTUS). The MCRE project is a collaboration between Southern Company Services, TerraPower, and INL, among others, to provide integral nuclear data that will advance molten salt fast reactor technology. MCRE will be the first critical fast-spectrum circulating fuel system ever operated and the first experiment operated in the LOTUS test bed. The experiment will nominally operate at zero power with planned low power excursions as part of operational planning for MCRE has been to minimize at-power operations to limit fission product formation while still achieving experimental objectives. After the experiment is complete, MCRE will be allowed to radioactively decay for a short period (nominally 90 days) prior to system defueling, flushing, removal, and disposal of all MCRE equipment, readying the test bed for the next nuclear experiment. Equipment removal and radioactive waste disposal have been integral to MCRE project planning since the Cooperative Research and Development Agreement was formalized in 2021. Due to requirements for future use of the test bed, the MCRE system, of necessity, must be removed in a much shorter time frame than typical for historic reactor decommissioning projects at INL. This results in minimal time for radioactive decay, resulting in not only elevated radiation dose rates but also the presence of short-to-medium-lived isotopes not typically encountered in the reactor decommissioning and radioactive waste management space. Additional unique constraints placed on the project include lack of intrinsic remote-operations capabilities in the test bed, space constraints in the test bed once MCRE has been installed, and contamination minimization requirements to return the test bed to as-found conditions to enable future use. This paper discusses planned solutions to these challenges. Approaches for implementing remote or semi-remote technologies in a non-hot cell environment with limited space availability are discussed. The paper also summarizes the systems engineering approach for concept development and design of equipment removal systems, which are being implemented concurrent with the MCRE design phase, providing feedback to system designers to incorporate features enabling efficient and safe equipment removal approaches. The timing of this paper at a relatively early phase of the project is meant to highlight the importance of early planning for nuclear system decommissioning while reactor design is ongoing to allow design feedback on componentry driven from decommissioning system needs. As new, innovative nuclear reactor technologies enter the nuclear market sector, reactor experiments are crucial for providing new integral nuclear data that establish safe operational margins for technology advancement. Microreactor experiments at INL will require safe, effective, and timely decommissioning approaches, which in turn require nuclear systems designed to expedite decommissioning. In addition to the advancement of nuclear reactor technologies, these nuclear experiments provide an opportunity to demonstrate, deploy, and test new removal and disposal capabilities to support the next generation of nuclear reactor technology.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2023

MSR Proliferation Resistance and Physical Protection White Paper

This document represents the status of Proliferation Resistance and Physical Protection (PR&PP) characteristics for the Molten Salt Reactor designs selected by the Generation IV International Forum (GIF) Molten Salt Reactor (MSR) provisional System Steering Committee (pSSC) as representatives of three broad classes of MSRs. The three classes of MSRs are: (1) Liquid-fueled with integrated salt processing, (2) Liquid-fueled without integrated salt processing, (3) Solid-fueled with salt coolant. The intent is to generate preliminary information about the PR&PP merits of the MSR Reactor Technology and to provide insights for optimizing their PR&PP performance for the benefit of MSR system designers. It updates the MSR analysis published in the 2011 report “Proliferation Resistance and Physical Protection of the Six Generation IV Nuclear Energy Systems”, prepared Jointly by the Proliferation Resistance and Physical Protection Working Group (PRPPWG) and the System Steering Committees of the Generation IV International Forum, taking into account the evolution of both the systems and the GIF R&D activities since its publication. The document, prepared jointly by the GIF PRPPWG and the GIF MSR pSSC, follows the high-level paradigm of the GIF Proliferation Resistance and Physical Protection Evaluation Methodology to investigate the Proliferation Resistance and Physical Protection features of the GIF MSR representative designs. For PR, the document analyses and discusses the proliferation resistance aspects in terms of robustness against State-based threats associated with diversion of materials, misuse of facilities, breakout scenarios, and production in clandestine facilities. Similarly, for physical protection, the document discusses the robustness against theft of material and sabotage by non-State actors.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

In situ Monitoring of Lanthanide Reactions with Oxide Species via Combined Absorption Spectroscopy and Electrochemical Methods

Molten salts for engineering scale applications of spent nuclear fuel pyrochemical processing will inevitably have some level of oxygen impurities which can form insoluble oxide and oxychloride species with fission products. This work demonstrates real-time concentration monitoring of two lanthanide (Ln3+) fission products, Nd3+ and Pr3+, and their reactions with oxygen (O2-) impurities to form insoluble products in LiCl-NaCl-KCl eutectic salt. Combined absorption spectroscopy and electrochemical testing were used to track lanthanide concentrations. O2- impurity levels were controlled by adding Li2O to lanthanide-salt solutions. After the introduction of O2- impurities, Ln3+ concentrations were monitored via time-resolved absorption spectroscopy. Concentrations of both Ln3+ species in solution decreased with time as insoluble products formed. The initial impurity concentration controlled whether insoluble products were predominantly oxychlorides or mixtures of oxychlorides and oxides. However, absorption spectroscopy is limited for weakly absorbing species, such as Pr3+, and under conditions of high impurity concentrations where solutions can be turbid. To circumvent this limitation, the concentrations of Pr3+ were monitored with square wave voltammetry (SWV). Reaction rates and extent of Pr3+ removal from solution as monitored by SWV agreed closely with results found from spectroscopic monitoring. This demonstrates that simultaneous electrochemical testing complements the capabilities of absorption spectroscopy to monitor reactions of fission products in molten salts.

absorption spectroscopy↗
DOE OSTI2025

In situ monitoring of lanthanide reactions with oxide species via combined absorption spectroscopy and electrochemical methods

Molten salts for engineering scale applications of spent nuclear fuel pyrochemical processing will inevitably have some level of oxygen impurities which can form various insoluble oxide and oxychloride species with uranium and fission products. This work demonstrates real-time concentration monitoring of two trivalent lanthanide (Ln3+) fission products, Nd3+ and Pr3+, and their reactions with oxygen (O2-) impurities to form insoluble products in LiCl-NaCl-KCl eutectic salt. A combination of high-temperature absorption spectroscopy and electrochemical testing were used to track lanthanide concentrations. O2- impurity levels were controlled in the range of 0.001 M to 0.5 M by adding Li2O to lanthanide-salt solutions. After the introduction of O2- impurities, Ln3+ concentrations were monitored via time-resolved absorption spectroscopy. Concentrations of both Ln3+ species in solution decreased with time as insoluble products formed. The initial impurity concentration controlled whether insoluble products were predominantly oxychlorides (LnOCl) or mixtures of oxychlorides and oxides (Ln2O3). However, absorption spectroscopy is limited for weakly absorbing species, such as Pr3+, and under conditions of high impurity concentrations where solutions can be turbid. To circumvent this limitation, the concentrations of Pr3+ were monitored with square wave voltammetry (SWV). Estimated reaction rates and extent of Pr3+ removal from solution as monitored by SWV agreed to within ~10% of the results found from absorption spectroscopy monitoring. This demonstrates that simultaneous electrochemical testing complements and expands the capabilities of absorption spectroscopy to monitor reactions of fission products in molten salts.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Spectro-electrochemistry of vanadium ions in LiCl-KCl-VCl2,3

Owing to their relatively high thermal conductivity and corrosion resistance, and low radiation heating and embrittlement properties, vanadium (V) alloys are being considered for fusion blanket structural materials. As such, the fundamental behavior of these materials, including the speciation of their corrosion products in molten lithium salts, must be elucidated to enable quantitative lifetime prediction. Yuan et al. [REF#1] demonstrated the reduction and oxidation of vanadium ions in molten LiCl-KCl eutectic salt using a tungsten wire, indicating the possibility of metallic vanadium reduction from V3+ negative potentials

36 - MATERIALS SCIENCE↗
DOE OSTI2025

Development of Surveillance Test Articles for Materials Degradation Management in MSR Environments

Materials in molten salt reactors (MSR) undergo accelerated degradation from corrosion, irradiation, and cyclic loads at elevated temperatures. Establishing a materials surveillance program to enable the assessment of material deterioration is critical to assure structural integrity of MSRs components. This presentation summarizes recent efforts towards the development of surveillance test articles for collecting various damages for monitoring materials degradation. Surveillance test articles with reduced dimensions were designed to capture creep-fatigue damage from cyclic loading at elevated temperatures. The strain evolution of test articles during thermal cycling was analyzed both numerically and experimentally. Out-of-reactor thermal cycling demonstrated successful capture of strain range for materials assessment. Moreover, test articles were subject to both mechanical loads and molten salt exposure, and the damage due to stress and corrosion was investigated. Additionally, damage inference models were developed to predict the remaining life of materials based on the accumulated damage in surveillance test articles.

36 - MATERIALS SCIENCE↗
DOE OSTI2025

In situ monitoring of lanthanide reactions with oxide species via combined absorption spectroscopy and electrochemical methods

Molten salts for engineering scale applications of spent nuclear fuel pyrochemical processing will inevitably have some level of oxygen impurities which can form insoluble oxide and oxychloride species with fission products. This work demonstrates real-time concentration monitoring of two lanthanide (Ln3+) fission products, Nd3+ and Pr3+, and their reactions with oxygen (O2-) impurities to form insoluble products in LiCl-NaCl-KCl eutectic salt. Combined absorption spectroscopy and electrochemical testing were used to track lanthanide concentrations. O2- impurity levels were controlled by adding Li2O to lanthanide-salt solutions. After the introduction of O2- impurities, Ln3+ concentrations were monitored via time-resolved absorption spectroscopy. Concentrations of both Ln3+ species in solution decreased with time as insoluble products formed. The initial impurity concentration controlled whether insoluble products were predominantly oxychlorides or mixtures of oxychlorides and oxides. However, absorption spectroscopy is limited for weakly absorbing species, such as Pr3+, and under conditions of high impurity concentrations where solutions can be turbid. To circumvent this limitation, the concentrations of Pr3+ were monitored with cyclic voltammetry (CV). Reaction rates and extent of Pr3+ removal from solution as monitored by CV agreed closely with results found from spectroscopic monitoring. This demonstrates that simultaneous electrochemical testing complements the capabilities of absorption spectroscopy to monitor reactions of fission products in molten salts.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Chemical Understanding of Actinide Separations

This work provides a broad overview of the separation processes used to isolate actinides and the experimentally and computationally determined chemical characteristics that define those separations. The redox chemistry of the actinides plays a pivotal role in both aqueous and pyrochemical processing separations. The near-overlapping energies of the 6d and 5f orbitals in the light actinides allow for facile adjustment of actinide oxidation states, which is used in many established separation methods. In contrast, the stable, generally 3+ oxidation states of the mid- and heavy actinides can make it difficult to separate them from the similarly lanthanides(III). In aqueous separations, the tendency of the actinides to form anionic and neutral aqueous complexes with a variety of complexants (especially soft donors) is used to achieve high separation factors between chemically similar elements in both solid–liquid separations and liquid–liquid extraction. This selectivity can be further tuned through the use of specialized organic or solid-phase ligands. Pyroprocessing separations utilize the unique redox behavior of the actinides to adjust their distribution between a molten salt electrolyte and either a solid electrode or molten metal phase. Atomic-level insights into the mechanisms underlying actinide separation processes, with the ultimate goal of predicting separation behavior, can be provided by electronic structure and statistical mechanical-based calculation methods.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

TiO2 Nanocrystal-Framed Li 2 TiSiO 5 Platelets for Low-Voltage Lithium Battery Anode

Titanium-based anode materials are attracting considerable attention for use in high-performance lithium-ion batteries, but the compromised energy density caused by high voltage plateaus and unsatisfactory capacities severely retards their practical applications. Herein, a molten-salt synthesis of Li 2 TiSiO 5 crystalline platelets and a subsequent selective facet modification by in situ growth of TiO 2 nanocrystal frames are facilely achieved. The discharge voltage plateau at around 0.5 V renders the Li 2 TiSiO 5 anode safe compared with graphite and confers a high energy density compared with zero-strain Li 4 Ti 5 O 12 anode. With the optimized size, structure, and content of modified TiO2 nanocrystals associated with the exposed (001) plane of Li 2 TiSiO 5 , the Li 2 TiSiO 5 -based anodes can deliver a capacity of above 300 mAh g -1 , enhanced rate performance, and a capacity retention of 66% after 10 000 cycles. In situ X-ray diffraction and ex situ transmission electron microscopy have demonstrated the structural stability of the anodes upon charge/discharge. Further theoretical calculation reveals 3D migration paths of Li + ions in Li 2 TiSiO 5 . The selective modification of in situ grown TiO2 nanocrystals on certain facets of crystallites opens a new door for the development of electrode materials possessing superior electrochemical properties.

anodes↗
DOE OSTI2020

A High-Performance Na-Al Battery Based on Reversible NaAlCl4 Catholyte

This work demonstrates a high-capacity and safe Na-Al battery pairing sodium metal anode and reversible NaAlCl4 catholyte for grid scale energy storage applications. The energy-rich sodium anode allows the full play of the aluminum cathode, resulting in a full-cell capacity of 308 mAh/g at a discharge voltage of 1.6 V. Benefiting from the use of ??-alumina solid electrolyte (BASE), molten sodium anode and reversible Al deposition/stripping from NaAlCl4 catholyte, the battery presents a stable Coulombic efficiency of 100% and energy efficiency of ~95%. At a rate of C/3 (6.77 mA/cm2), the cell maintains 282 mAh/g (447 Wh/kg) after 200 cycles with an excellent capacity retention of 97.6%. Moreover, we elucidate pathways to build sodium-anode-free cells from the discharged state under dry air, which further extends the feasibility of this battery for stationary storage applications. These findings are expected to provide a new platform for the development of practical Al batteries.

Zhan, Xiaowen↗
DOE OSTI2024

Improving the reliability of machine learned potentials for modeling inhomogeneous liquids

The atomic-scale response of inhomogeneous fluids at interfaces and surrounding solute particles plays a critical role in governing chemical, electrochemical, and biological processes. Classical molecular dynamics simulations have been applied extensively to simulate the response of fluids to inhomogeneities directly, but are limited by the accuracy of the underlying interatomic potentials. Here, we use neural network potentials (NNPs) trained to ab initio simulations to accurately predict the inhomogeneous responses of two distinct fluids: liquid water and molten NaCl. Although NNPs can be readily trained to model complex bulk systems across a range of state points, we show that to appropriately model a fluid's response at an interface, relevant inhomogeneous configurations must be included in the training data. In order to sufficiently sample appropriate configurations of such inhomogeneous fluids, we develop protocols based on molecular dynamics simulations in the presence of external potentials. We demonstrate that NNPs trained on inhomogeneous fluid configurations can more accurately predict several key properties of fluids—including the density response, surface tension and size-dependent cavitation free energies—for liquid water and molten NaCl, compared to both empirical interatomic potentials and NNPs that are not trained on such inhomogeneous configurations. This work therefore provides a first demonstration and framework to extract the response of inhomogeneous fluids from first principles for classical density-functional treatment of fluids free from empirical potentials.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

HRTEM Imaging and Mechanistic Insights Into Carbon Nanotube Nucleation and Growth on Fe Nanocatalysts in a Thermal Plasma

Thermal plasma decomposition of natural gas is a scalable pathway for the production of hydrogen alongside high-value carbon nanotubes (CNTs). Metals evaporate from an electrode and condense to form seed nanoparticles that nucleate and grow CNTs. However, the lack of mechanistic understanding of the CNT nucleation and growth processes in thermal plasma makes control over CNT diameter, chirality, length, and yield difficult. We debundled and separated CNTs from soots produced using iron (Fe) nanocatalysts, and distributed them on monolayer graphene for high-resolution transmission electron microscopy (HRTEM) imaging to gain mechanistic insights. Full graphene encapsulation was found for relatively small Fe nanoparticles that were molten at high temperatures. Zigzag single-wall or double-wall CNTs (SWCNTs or DWCNTs) appeared to have grown out directly from the graphene covering on the conical or cylindrical bodies of small molten Fe nanodroplets with high curvature. Also, SWCNTs likely grew out from H- or O-atom etched single-wall carbon nanocones observed on conical Fe nanoparticles. A SWCNT/DWCNT could also be generated from the cracked opening of the graphene covering on a face-centered cubic (FCC) Fe nanoparticle. A simple, plausible pathway is proposed for the growth of an open, H-passivated, zigzag SWCNT involving reaction of CH 2 and CH radicals at high temperatures.

Fe nanocatalysts↗
DOE OSTI2024

Additive friction stir deposition induced stress ripples in aluminum alloy

In additive manufacturing, modification of the viscosity of softened or molten metal plays a significant role in the development of mechanical properties distribution. Similar to soft polymers, molten or softened metal usually exhibits vastly different viscoelastic properties. During scratching tests, viscoelastic polymers undergo spatiotemporal stress development and relaxation, causing stress ripples to form on their surfaces. Here, it is observed that friction stir-based solid-state manufacturing can yield similar stress ripples on softened aluminum alloys due to the linear motion of the deposition tool. Softened aluminum alloys exhibit viscoelastic and viscoplastic responses similar to polymeric material during the solid-state deposition process. In the final product, residual stress ripples appear on the surface of the metal alloy due to periodic residual stress relaxation, leading to oscillatory behavior from the bulk mechanical properties of the material. The orientation of the in-built stress pattern formed in the bulk of the additively manufactured metal alloy underneath the visually evident onion ring-like surface pattern formation is diametrically in the opposite direction. The experimentally observed results are consistent with analytical calculation and numerical simulations in terms of behaviors.

36 MATERIALS SCIENCE↗