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At least 1,351 records · Page 75

Conceptual Design of A 20 T Dipole Based on Hybrid REBCO/Nb 3 Sn Cos-theta Coil

This paper presents a design concept of an HTS/LTS hybrid dipole with 50 mm aperture and 20 T nominal field based on a cos-theta coil and a cold iron yoke. The HTS part of magnet coil uses REBCO Twisted Stacked Tape cable. The LTS part is graded and made of two Nb3Sn Rutherford cables. Due to high sensitivity of HTS/LTS coils to large stresses and strains at high fields, a Stress Management (SM) concept combined with the cos-theta coil geometry is used. The results of magnet magnetic analysis are presented and discussed.

43 PARTICLE ACCELERATORS↗

UT-GOM2-2 Preliminary Report: Terrebonne Basin Northern Gulf of Mexico, 30 July-28 September 2023

In the summer and fall of 2023, the Gulf of Mexico Deepwater Hydrate Coring Expedition (UT-GOM2-2) drilled, cored, made downhole measurements, and analyzed samples from the seafloor to the base of the gas hydrate stability zone in one location (Site H, WR313) in the Terrebonne basin, deepwater Gulf of Mexico. Analyses of data and samples from the expedition will inform biological, geochemical, and geomechanical models to constrain the role of gas hydrates in the carbon cycle and the potential for gas hydrates as an energy resource. Pressure and conventional cores were collected continuously to a depth of 155.1 meters below the seafloor (mbsf). At deeper depths, cores were taken periodically from hydrate-bearing sands and their bounding muds to a total depth of 861.3 mbsf. 162.6 m of conventional core and 54.8 m of pressure core were obtained. Twelve temperature measurements were made between 27.1 and 144.5 mbsf to determine the geothermal gradient. At the seafloor, more than 4 m of sandy silt of unknown origin was encountered. Beneath this sand, to a depth of ~200 mbsf, the section was composed of interbedded mud and biogenic carbonate ooze. The biogenic ooze correlated to low density and high porosity intervals observed in the previously acquired logging while drilling (LWD) data and as measured. Calcareous nannofossil biostratigraphy constrains the entire record to the Pleistocene (< 0.91 million years) with a pronounced increase in sedimentation rate with depth. Beneath 200 mbsf, the section was predominantly composed of mud with two thicker, hydrate-bearing coarse-grained intervals, which are commonly known as the Blue and Orange sands. The dissolved gas concentration was quantified from pressure cores. In the shallow section, dissolved methane concentration increased below the sulfate-methane transition zone (SMTZ) and reaches saturation (the limit of solubility for methane) at 147 mbsf. Gas expansion was very common in conventional and depressurized pressure (conventionalized) cores below the SMTZ. At deeper depths, the methane concentration within muds bounding the Blue and Orange reservoirs was generally found to be less than saturation. The dissolved and hydrate gas composition is consistent with a microbial source, containing greater than 99.99% methane and only trace concentrations of ethane, propane, and butane. The methane to ethane ratio (C 1 /C 2 ) and the methane to ethane plus propane (C 1 /(C 2 +C 3 )) decrease with depth down to at least 678 mbsf, mainly driven by the increase in ethane with depth. It is unclear if this trend continues through the Orange sand interval. The δ 13 C isotopic signature of methane ranges between -69.9 and -78.5 ‰ Vienna Pee Dee Belemnite (VPDB). Pressure core recovery of all sandy intervals was poor. However, pressure core logs of the Orange sand show intervals of low density and high velocity, which are indicative of high hydrate saturation. One core from within the Orange sand was composed of interbedded graded sandy silt and mud. The sandy silts from this core are composed of mainly quartz and feldspar with some lithics. Most of the recovered pressure core samples are maintained at near in-situ pressure and temperature (within the hydrate stability field) at the University of Texas Pressure Core Center awaiting analysis. In the shallow section, samples will be used to determine the flux of organic carbon through the basin system, find the rate at which that carbon was consumed, and understand the microbial population responsible for these processes. In the deeper section, samples from in and around the hydrate reservoirs will be used to determine the petrophysical properties of the reservoir and bounding seals in these systems.

03 NATURAL GAS↗

Aluminum Ultra-conductors for Energy-Efficient Aerospace Busbar Applications (Abstract)

In this project, we will develop aluminum ultra-conductors with graphene additives demonstrating enhanced electrical conductivity at 90 °C compared to electric grade aluminum alloy AA1100 (43% IACS at 90 °C). While ultra-conductivity has been developed in copper and copper alloys, it is yet to be reported extensively in aluminum-based materials. This project will scale initial work done at PNNL on aluminum ultra-conductors using shear-assisted processing and extrusion (ShAPETM), a novel solid phase processing technique. Ultra-conductors are an emerging class of composites, comprised of a metal substrate with small quantities of nanocrystalline additives such as graphene or carbon nanotubes that demonstrate enhanced conductivity at relevant operating temperatures. Aluminum ultra-conductors can improve efficiency and power density while reducing the demand for copper in a wide range of applications, such as power transmission cables and electric motors. Busbars are an important component in aerospace systems that require lightweight and high-current power distribution including both future electric vertical take-off and landing (eVTOL) aircrafts and current aircraft electrical systems. We will accelerate aluminum ultra-conductor composite formulation development using combinatorial synthesis and testing methods aided by process/microstructure modeling, developed previously at PNNL. Eaton will test the properties of the ShAPE aluminum ultra-conductor feedstock (used to make the busbars) in relevant operating conditions (20 – 90 °C), predict the improvement in busbar performance when manufactured with ultra-conductors over commercial conductors (such as AA1100), and perform technoeconomic analysis to evaluate the potential for commercialization of ShAPE aluminum ultra-conductors. The project is expected to have a budget of $\$375$K, with $\$300$K in federal funding and $\$75$K in-kind cost-share contribution from Eaton over a period of performance of 24 months. Of the $\$300$K of federal funds, $\$140$K is allocated for CRADA activities that generate intellectual property (IP), and the remaining $\$160$K is reserved for modeling, material testing, characterization, travel, and reporting-related activities.

36 MATERIALS SCIENCE↗

Simplified inelastic constitutive models for ASME Section III, Division 5 design by inelastic analysis

This report describes the development of simplified, universal constitutive model that captures the high temperature monotonic and cyclic behavior of a range of commonly-used high temperature materials. The goal of the work is to provide a simple, universal constitutive model to replace the current bespoke models for Grade 91, 316H, and Alloy 617 included in Nonmandatory Appendix HBB-Z of the ASME Boiler & Pressure Vessel Code, and to extend this model to cover Alloy 800H. We initiated this work in response to feedback from reactor vendors and other Code users requesting simplified models, compared to the current models, that are easier to implement and use in commercial finite element analysis software. This report describes the completion of this effort by developing a model to correct the defects in standard model forms presently used for high temperature material modeling, described in past work, developing and implementing new numerical methods to train this model against test data, and then actually training the model for the four materials. The report provides a complete mathematical description of the model along with the tabulated material coefficients for the four materials. The final step will be to formulate an ASME Code change to introduce the new models into the Code.

36 MATERIALS SCIENCE↗

The University of Missouri Research Reactor (MURR) LEU Fuel Element Flow Test Preliminary Design

As part of the U.S. National Nuclear Security Administration’s (NNSA) mission to eliminate or minimize the civilian use of weapons-grade highly enriched uranium (HEU, ≥ 20 wt% U-235) fuels, the NNSA Material Management and Minimization (M3) Office of Reactor Conversion and Uranium Supply is collaborating with six U.S. high performance research reactors (USHPRR), including one critical facility, to convert from the use of HEU to low-enriched uranium (LEU, < 20 wt% U-235) fuel. Primary conversion objectives for the USHPRR are to develop LEU fuel element designs that will ensure safe reactor operations and maintain the existing experimental facilities performance. The work is being conducted through many interrelated activities by stakeholders across organizations.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Spatiotemporal Adaptive Passive Direct Air Capture

Carbon Collect Inc., along with Arizona State University, the Electric Power Research Institute (EPRI), PM Group, and Trimeric Corporation, completed an initial design of a commercial-scale, passive direct air capture (DAC) system termed “carbon trees” that will capture, separate, and store at least 100,000 tonnes/year of carbon dioxide (CO2) from air (net basis). Passive DAC is unique among DAC technologies in that passive air delivery by wind avoids the energy penalty of forced convection. Carbon Collect Inc.’s sorbent-agnostic approach offers the flexibility to choose sorbents for a wide range of climates. A combination of steam, low-grade heat, and vacuum releases the CO2 from the sorbent, which is extracted from the chamber and purified and compressed for geological storage. A commercial carbon tree forest combines the output of several thousand trees for compression and purification with high heat and energy integration. The project team prepared an initial engineering design package for each of three geographically diverse host sites throughout the United States to better understand the effect of local/regional ambient conditions on DAC system performance and project costs. A techno-economic analysis, life cycle analysis, business case analysis, and an environmental, health, and safety risks assessment were also completed for each of the three geographically diverse host sites.

14 SOLAR ENERGY↗

Analysis of Electric Heavy-Duty Driving and Infrastructure Requirements

The analysis discussed in this report was performed as part of DOE award DE-EE0009232 to model the effects of charging Heavy Duty Battery Electric Trucks (HDBETs) on the grid. This project combines best in class freight modeling by the National Renewable Energy Laboratory (NREL) with advanced distribution modeling by EPRI using detailed data from Xcel Energy and Salt River Project to analyze the effects of depot charging and utility-grade transmission modeling by Tri-State Transmission and Generation Association Inc. to analyze the effects of en-route charging.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Design of Defensive Cybersecurity Architectures for High Temperature, Gas-Cooled Reactors

This report presents the design of defensive cybersecurity architectures (DCSAs) for High Temperature, Gas-Cooled Reactors (HTGRs). A DCSA is a cybersecurity design feature that places systems into security zones in a graded approach according to the importance of the functions performed by the systems. DCSA design efforts for advanced reactors may commence as early as the system-level design phase. This design approach is consistent with the draft regulatory guide for advanced reactor cybersecurity programs (DG-5075) and enables advanced reactor designers to consider the effects of security-by-design (SeBD) features on their DCSAs. Integration of DCSA design and other cybersecurity activities with the traditional design process as part of a SeBD framework may enable advanced reactor designers to improve the security posture of their plants while reducing implementation and operating costs. This report provides a DCSA template for an exemplar HTGR and describes a DCSA design process using event tree analysis so that the template may be optimized for a given HTGR design.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Advancements in Development and Testing of Thermal Power Dispatch Simulators

Flexible plant operations and generation (FPOG) offer nuclear power plants (NPPs) the chance to leverage alternative, non-electric revenue streams while ensuring their continued role as reliable, clean, and constant sources of baseload electrical power. The excess thermal energy generated from NPPs during periods of low electricity demand can be channeled as raw materials to numerous industrial processes via a thermal power dispatch (TPD) system. Hydrogen production via high-temperature steam electrolysis (HTSE) is an optimal use case based on technical and economic feasibility. Researchers at Idaho National Laboratory (INL) have conducted previous works that developed and implemented TPD system models within the GSE Solutions Generic Pressurized Water Reactor (GPWR) simulator to support human-in-the-loop (HITL) scenario-based evaluations. The first part of this report documents modifications made to the GPWR TPD model and HMI from the previous iteration in line with a new Sargent and Lundy (S&L) TPD design with an automatic control system. The was done in collaboration with Westinghouse using their three-loop pressurizer water reactor (W3LPWR) simulator which contains an industrial grade automatic control system for the TPD. This was installed in the Human Systems Simulation Laboratory (HSSL) at INL. The second part of the report documents findings from an all-hands-on-deck integration and verification workshop that was conducted in the HSSL over several days. The research team comprised INL human factors and TPD experts, a nuclear engineer from GSE Solutions who implemented the revised TPD model for GPWR, the human-machine interface (HMI) prototyping and human factors team from the University of Idaho, and personnel with operations experience with pressurized water reactors. The workshop provided time and expertise to conduct the final activities to bring the operations, HMI, and simulator into a functional state. The goals of the integration and verification workshop were: 1. to install the revised GPWR TPD model into the HSSL 2. verify the TPD HMI prototype was functional 3. integrate the HTSE Simulink model to GPWR. 3. Issues were identified for resolution, but overall the workshop accomplished its goal to integrated and verify the majority of the intended functional. Future work will resolve the identified issues and use the integrated simulation to support an evaluation and demonstration in the next fiscal year.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Industrial Carbon Capture from a Cement Facility Using the Cryocap™ FG Process

The objective of the project was to execute and complete front-end engineering and design (FEED) studies for commercial-scale, carbon capture projects that separate 95% of the total CO 2 emissions at an industrial facility, producing at least 100,000 metric tonnes/year of CO 2 for sequestration. The industrial facility selected is the Holcim (US) Ste. Genevieve cement manufacturing facility (the largest single kiln line in the world), while the carbon capture system selected is Pressure Swing Adsorption system (PSA) assisted Cryocap™ technology developed by Air Liquide. The industrial host site emits approximately 3 million tonnes CO 2 /year based on plant data from 2020-2022. The captured CO 2 will meet the requirements of transport (Pipeline Grade) and geological storage, and the geological storage facilities within 80 miles of the CO 2 source. The impact of the project on Environmental Justice and the regional economy was also analyzed.

01 COAL, LIGNITE, AND PEAT↗

Upcycling Polyethylene Waste to Advanced Carbon Materials for Energy Storage Applications

Polyethylene is notoriously difficult to upcycle because it decomposes into light gases at approximately 350-400 °C which prevents processing it at higher temperatures to convert it into high-value carbon materials, such as graphene or graphite. We address this challenge by using an air-based, thermo-oxidation process, which heats polyethylene (PE) just below the decomposition point to initiate oxidation and cross-linking of PE alkyl chains. These molecular transformations allow PE to be further graphenized or graphitized at higher temperatures without decomposing. The PE-derived graphene has a specific surface area up to 1,800 m 2/g and Raman ID/IG ratio of 0.85, which enables it to be used as an electrode material for a symmetric supercapacitor with the 1 M H2SO4 electrolyte. The PE-derived graphene material has a comparable electrochemical capacitive performance, such as power density, specific capacitance, and long cycle stability, to the commercial state of art porous carbon electrode. The stabilized PE could also be converted into highly crystalline flake graphite via low-temperature catalytic graphitization. The PE-derived graphite is used for the lithium-ion battery anode, which showed comparable electrochemical battery performance, such as reversible rate performance and long-term cyclic stability, to the current use battery-grade graphite, thus providing a scalable method to upcycle PE plastic waste into high-value carbon material.

Gao, Yuan↗

Integrated Technology for Cost-Effective CO2 Capture and Formic Acid Production: Modeling, Optimization, and Economic Analysis

A novel reactive technology is being investigated that electrochemically converts CO2 into valuable chemicals, particularly formic acid. This work focuses on identifying the optimal design and operation of an integrated membrane-based CO2 capture unit with the electrochemical conversion process. In this setup, the CO2 in the flue gas permeates through a CO2-selective membrane and enters an electrolyzer to produce formic acid, creating an integrated reaction module. To refine the chemical product, gas products from the electrolyzer are directed to a pressure swing adsorption unit, while the liquid product undergoes refinement to achieve commercial-grade formic acid using reactive distillation. A membrane CO2 capture model and an electrochemical conversion model have been developed using the IDAES Integrated Platform (Institute for the Design of Advanced Energy System), facilitating rigorous flowsheet modeling and process design and optimization.

Wang, Maojian↗

Reduction of Methane Leaks through Corrosion Mitigation Pre-treatments for Pipelines with Field Applied Coatings

Corrosion of buried, coated steel pipelines transporting natural gas is a significant source of methane emissions, from pipeline venting required for maintenance and repairs and from pipeline leaks and incidents. Corrosion of steel under field applied coatings is an important safety concern for the pipeline industry. This project investigates the application of a field applied alloy over girth welds to mitigate external corrosion of buried coated steel pipelines. Various metallic coating options were considered, which were required to meet several criteria: (1) it must resist corrosion under open-circuit or mild cathodic protection conditions, (2) it must protect the substrate steel, and (3) it must not negatively affect the adhesion of the field coating. Finite element models and lab testing were performed of alloy coating compositions to identify promising alloy types underneath disbonded coatings. Polarization curves of coating alloys were generated to provide the boundary conditions for the COMSOL model to compute potential and current distributions around coated areas. Sacrificial and corrosion-resistant metal alloy coatings were evaluated and optimized using corrosion modeling and laboratory electrochemical testing, where aluminum alloy 5356 (5% Mg) and steel alloy B9 (9% Cr) were selected. Corrosion test coupons were designed and fabricated using thermal spray aluminum 5356 and welded B9 steel overlays on API 5L grade X42 line pipe steel. The corrosion test coupons, with simulated pipe coating damage, were tested in a laboratory soil box and a field pipeline site in Texas for 3-months. Corrosion test coupons were then tested for 6-months at field pipeline sites in Texas and Tennessee to quantify corrosion rates and performance of the aluminum and steel alloys under polyethylene tape and 2-part epoxy coatings, various coating holidays, and with and without cathodic protection.

03 NATURAL GAS↗

Develop and Connect TRISO Failure Analysis and Uncertainty Quantification to Fission Product Release Calculation Capability

The U.S. Department of Energy’s Nuclear Energy Advanced Modeling and Simulation (NEAMS) program aims to develop predictive capabilities by applying computational methods to the analysis and design of advanced reactor and fuel cycle systems. This program has been providing engineering-scale support for the development of BISON, a high-fidelity and high-resolution fuel performance tool. Stress-based failure probability has been developed and analyzed to assess the integrity of tri-structural isotropic (TRISO) fuel particles during fuel life cycles. While simple, stress-based approaches to failure probability leveraging the Weibull statistical distribution entails a number of drawbacks when stress concentration occurs near crack tips, including finite element mesh size dependency. In this report, we use an interaction integral approach to the computation of stress intensity factors in functionally graded materials (FGM) for axisymmetric models. The inner pyrolytic carbon (IPyC) cracking induced silicon carbide (SiC) failure is one of the dominated failure modes in TRISO failure analysis. In this study, we consider a crack in the IPyC layer perpendicular to the SiC layer. The interface between these two TRISO layers is considered to be porous, which we simulate considering a transition of mechanical properties over the porous length. These aspects are considered in the computation of stress intensity factor (SIF) from a fracture mechanics approach and compared with the known stress-based failure probability approach.

42 ENGINEERING↗

Oak Ridge National Laboratory Thermoplastic Composite Joining of Pultruded Continuous Fiber Spars for Multi-Functional Battery Enclosure

Oak Ridge National Laboratory (ORNL) worked with DowAksa Industry to investigate the potential of using PA66 material to produce larger composite parts, transcending the limitations of traditional presses. The project aimed to develop a suitable material for printing battery boxes using Nylon 66 infused with 40 wt.% carbon fiber, compatible with the ORNL Additive Manufacturing and Compression Molding (AM-CM) system. However, even with extensive work, it was concluded that the material is not compatible with the AMCM process and suitable for joining using compression technique. Main reason for the incompatibility were found to be very high crystallinity of the PA66 grade chosen for this work. To improve printability, a modifier (proprietary) was added to decrease crystallinity, but this led to reduced thermal stability and adhesion issues.

36 MATERIALS SCIENCE↗

Technical Basis for Proposed Changes to DOE-STD-1194-2019, Nuclear Material Attractiveness Determination and Categorization

The Department of Energy (DOE)’s Technical Standard DOE-STD-1194-2019 (dated September 2019), Nuclear Materials Control and Accountability, provides key guidance for the determination of Special Nuclear Material (SNM) attractiveness levels. Attractiveness levels are a key component in the security categorization of SNM processed, used, and stored at DOE facilities. Upon review, the writing team identified specific components relating to the determination of attractiveness levels that could be modified to improve clarity, reduce burden on sites, and/or better align with the graded safeguards principle that is central to the DOE’s nuclear security program. The report outlines the original verbiage, issues with implementation of that verbiage, proposed new verbiage, and the expected benefits thus serving as the technical basis for the proposed changes.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗

Saltstone Paddles and Augers Materials of Construction Study

The Saltstone Production Facility (SPF) uses a 10-inch READCO continuous, co-rotating twin-screw mixer to mix the dry premix with the low-level radioactive waste (LLW) salt solution to produce fresh saltstone grout. The paddles and augers within the mixer degrade via erosion in the region where the salt solution is introduced into the mixer. After the paddles/augers erode to a point where the throughput impacts operations, the mixer is disassembled, the effected paddles/augers are replaced, and the mixer is reassembled. Saltstone Engineering indicated that this effort requires an approximately three-week outage. The objective of this task is to assess alternative materials of construction (MOCs) that will provide better erosion characteristics and decrease the frequency in which the paddles and augers need replacement. Previous Astralloy V studies looked only at Charpy Impact and Rockwell Hardness Testing. Each of these will be examined for different alloys as well as Miller Testing (abrasion to determine wear) which will provide a good assessment of an alloy’s erosion/wear characteristics. The following facts concerning the current and proposed alloys for Saltstone Paddles and Augers are provided in this report. • Current Astralloy V material and alloy E52100 had the most favorable Miller Testing Results. • Charpy Impact Testing did not correlate with Miller Testing Results. • Hardness Testing correlated with Miller Testing results meaning that higher hardness will provide more favorable wear resistance. • Further investigation of E52100 and various tool grade steels is recommended for achieving wear resistant properties.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Long-term Moisture Adsorption in Packaged Plutonium Oxide

In 2018, the Department of Energy National Nuclear Security Administration (DOE-NNSA) began implementing dilute and dispose to remove 34 metric tons (MT) of surplus weapons grade plutonium from the US stockpile. Under this plan, surplus plutonium material is converted into plutonium oxide (PuO 2 ) before being stored in metal containers and sent to the DOE Waste Isolation Pilot Plant (WIPP). The dilute and dispose project was implemented as a more cost-effective method for abiding by the Plutonium Management and Disposition Agreement (PMDA) between the USA and Russia, as compared to producing mixed oxide fuel (MOX). The PMDA was originally signed in 2000 and amended in 2010.2 The disassembly of pits and conversion to PuO 2 as part of dilute and dispose is carried out through the Advanced Recovery and Integrated Extraction System (ARIES) developed at Los Alamos National Laboratory (LANL). The dilute portion of dilute and dispose is carried out at Savannah River Site (SRS). With this program in place, it is necessary to ensure the safe, long-term storage of the PuO 2 generated during this process until final disposal at WIPP is accomplished.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗