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DOE OSTI2014

Opportunities in SMR Emergency Planning

Using year 2014 cost information gathered from twenty different locations within the current commercial nuclear power station fleet, an assessment was performed concerning compliance costs associated with the offsite emergency Planning Standards contained in 10 CFR 50.47(b). The study was conducted to quantitatively determine the potential cost benefits realized if an emergency planning zone (EPZ) were reduced in size according to the lowered risks expected to accompany small modular reactors (SMR). Licensees are required to provide a technical basis when proposing to reduce the surrounding EPZ size to less than the 10 mile plume exposure and 50 mile ingestion pathway distances currently being used. To assist licensees in assessing the savings that might be associated with such an action, this study established offsite emergency planning costs in connection with four discrete EPZ boundary distances, i.e., site boundary, 2 miles, 5 miles and 10 miles. The boundary selected by the licensee would be based on where EPA Protective Action Guidelines are no longer likely to be exceeded. Additional consideration was directed towards costs associated with reducing the 50 mile ingestion pathway EPZ. The assessment methodology consisted of gathering actual capital costs and annual operating and maintenance costs for offsite emergency planning programs at the surveyed sites, partitioning them according to key predictive factors, and allocating those portions to individual emergency Planning Standards as a function of EPZ size. Two techniques, an offsite population-based approach and an area-based approach, were then employed to calculate the scaling factors which enabled cost projections as a function of EPZ size. Site-specific factors that influenced source data costs, such as the effects of supplemental funding to external state and local agencies for offsite response organization activities, were incorporated into the analysis to the extent those factors could be representatively apportioned.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2015

Green Gasoline from Wood using Carbona Gasification and Topsoe TIGAS Process

This final report presents the results of a four-year technology demonstration project carried out by a consortium of companies sponsored in part by a $25 million funding by the Department of Energy (DOE) under the American Recovery and Reinvestment Act (ARRA). The purpose of the project was to demonstrate a new, economical technology for the thermochemical conversion of woody biomass into gasoline and to demonstrate that the gasoline produced in this way is suitable for direct inclusion in the already existing gasoline pool. The process that was demonstrated uses the Andritz-Carbona fluidized-bed steam-oxygen gasification technology and advanced tar reforming catalytic systems to produce a clean syngas from waste wood, integrated conventional gas cleanup steps, and finally utilizes Haldor Topsoe’s (Topsoe) innovative Topsoe Improved Gasoline Synthesis (TIGASTM) syngas-to-gasoline process. Gas Technology Institute (GTI) carried out the bulk of the testing work at their Flex Fuel development facility in Des Plaines, Illinois; UPM in Minnesota supplied and prepared the feedstocks, and characterization of liquid products was conducted in Phillips 66 labs in Oklahoma. The produced gasoline was used for a single-engine emission test at Southwest Research Institute (SwRI®) in San Antonio, TX, as well as in a fleet test at Transportation Research Center, Inc. (TRC Inc.) in East Liberty, Ohio. The project benefited from the use of existing pilot plant equipment at GTI, including a 21.6 bone dry short ton/day gasifier, tar reformer, Morphysorb® acid gas removal, associated syngas cleanup and gasifier feeding and oxygen systems.

09 BIOMASS FUELS↗

DOE OSTI2014

Dynamical systems probabilistic risk assessment

Probabilistic Risk Assessment (PRA) is the primary tool used to risk-inform nuclear power regulatory and licensing activities. Risk-informed regulations are intended to reduce inherent conservatism in regulatory metrics (e.g., allowable operating conditions and technical specifications) which are built into the regulatory framework by quantifying both the total risk profile as well as the change in the risk profile caused by an event or action (e.g., in-service inspection procedures or power uprates). Dynamical Systems (DS) analysis has been used to understand unintended time-dependent feedbacks in both industrial and organizational settings. In dynamical systems analysis, feedback loops can be characterized and studied as a function of time to describe the changes to the reliability of plant Structures, Systems and Components (SSCs). While DS has been used in many subject areas, some even within the PRA community, it has not been applied toward creating long-time horizon, dynamic PRAs (with time scales ranging between days and decades depending upon the analysis). Understanding slowly developing dynamic effects, such as wear-out, on SSC reliabilities may be instrumental in ensuring a safely and reliably operating nuclear fleet. Improving the estimation of a plant's continuously changing risk profile will allow for more meaningful risk insights, greater stakeholder confidence in risk insights, and increased operational flexibility.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2015

Irradiation Programs and Test Plans to Assess High-Fluence Irradiation Assisted Stress Corrosion Cracking Susceptibility.

. Irradiation assisted stress corrosion cracking (IASCC) is a known issue in current reactors. In a 60 year lifetime, reactor core internals may experience fluence levels up to 15 dpa for boiling water reactors (BWR) and 100+ dpa for pressurized water reactors (PWR). To support a safe operation of our fleet of reactors and maintain their economic viability it is important to be able to predict any evolution of material behaviors as reactors age and therefore fluence accumulated by reactor core component increases. For PWR reactors, the difficulty to predict high fluence behavior comes from the fact that there is not a consensus of the mechanism of IASCC and that little data is available. It is however possible to use the current state of knowledge on the evolution of irradiated microstructure and on the processes that influences IASCC to emit hypotheses. This report identifies several potential changes in microstructure and proposes to identify their potential impact of IASCC. The susceptibility of a component to high fluence IASCC is considered to not only depends on the intrinsic IASCC susceptibility of the component due to radiation effects on the material but to also be related to the evolution of the loading history of the material and interaction with the environment as total fluence increases. Single variation type experiments are proposed to be performed with materials that are representative of PWR condition and with materials irradiated in other conditions. To address the lack of IASCC propagation and initiation data generated with material irradiated in PWR condition, it is proposed to investigate the effect of spectrum and flux rate on the evolution of microstructure. A long term irradiation, aimed to generate a well-controlled irradiation history on a set on selected materials is also proposed for consideration. For BWR, the study of available data permitted to identify an area of concern for long term performance of component. The efficiency of hydrogen water chemistry mitigation technology may decrease as fluence increases for high-stress intensity factors. This report describes a program plan to determine the efficiency of hydrogen water chemistry as a function of the stress intensity factor applied and fluence. The use of existing, available, materials and the generation of additional materials via irradiation in a research reactor are considered.

36 MATERIALS SCIENCE↗

DOE OSTI2015

Online Monitoring of Concrete Structures in Nuclear Power Plants: Interim Report

The existing fleet of nuclear power plants in the United States have initial operating licenses of 40 years, and many of these plants have applied for and received license extensions. As plant structures, systems, and components age, their useful life—considering both structural integrity and performance—is reduced as a result of deterioration of the materials. Assessment and management of aging concrete structures in nuclear plants require a more systematic approach than simple reliance on existing code-based design margins of safety. Structural health monitoring is required to produce actionable information regarding structural integrity that supports operational and maintenance decisions. The online monitoring of concrete structures project conducted under the Advanced Instrumentation, Information, and Control Technologies Pathway of the Light Water Reactor Sustainability program at Idaho National Laboratory is seeking to develop and demonstrate capabilities for concrete structures health monitoring. Through this research project, several national laboratories and Vanderbilt University propose to develop a framework of research activities for the health monitoring of nuclear power plant concrete structures that includes the integration of four elements—damage modeling, monitoring, data analytics, and uncertainty quantification. This report briefly discusses activities in this project during October-December, 2014. The most significant activity during this period was the organizing of a two-day workshop on research needs in online monitoring of concrete structures, hosted by Vanderbilt University in November 2014. Thirty invitees from academia, industry and government participated in the workshop. The presentations and discussions at the workshop surveyed current activities related to concrete structures deterioration modeling and monitoring, and identified the challenges, knowledge gaps, and opportunities for advancing the state of the art; these discussions are summarized in this report

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2014

Economic Impacts Associated with Commercializing Fuel Cell Electric Vehicles in California: An Analysis of the California Road Map Using the JOBS H2 Model

Successful implementation of the California Road Map (the Road Map) for the introduction of hydrogen fueling stations to support a fleet of fuel cell electric vehicles (FCEVs) will produce positive economic impacts. Those impacts include jobs created or retained to develop and operate hydrogen fueling stations, earnings by businesses and workers so employed, and economic output generated by the activities required to develop and operate the stations. This report summarizes an analysis of those impacts as conducted by Argonne National Laboratory and RCF Economic and Financial Consultants for the U.S. Department of Energy’s Fuel Cell Technologies Office (FCTO). The analysis assumes that the cost and technical performance of stations that received awards under the 2014 solicitation of the California Energy Commission are representative of all stations to be deployed under the Road Map (subject to scale effects) and that information supplied by applicants representing the majority of those stations is representative of all. The analysis further assumes that all stations will be of a design similar to those developed in the initial years of the rollout, with additional equipment added as modules to achieve the targeted station capacity specified in the Road Map.

08 HYDROGEN↗

DOE OSTI2015

Irradiation-Accelerated Corrosion of Reactor Core Materials. Final Report

This project aims to understand how radiation accelerates corrosion of reactor core materials. The combination of high temperature, chemically aggressive coolants, a high radiation flux and mechanical stress poses a major challenge for the life extension of current light water reactors, as well as the success of most all GenIV concepts. Of these four drivers, the combination of radiation and corrosion places the most severe demands on materials, for which an understanding of the fundamental science is simply absent. Only a few experiments have been conducted to understand how corrosion occurs under irradiation, yet the limited data indicates that the effect is large; irradiation causes order of magnitude increases in corrosion rates. Without a firm understanding of the mechanisms by which radiation and corrosion interact in film formation, growth, breakdown and repair, the extension of the current LWR fleet beyond 60 years and the success of advanced nuclear energy systems are questionable. The proposed work will address the process of irradiation-accelerated corrosion that is important to all current and advanced reactor designs, but remains very poorly understood. An improved understanding of the role of irradiation in the corrosion process will provide the community with the tools to develop predictive models for in-reactor corrosion, and to address specific, important forms of corrosion such as irradiation assisted stress corrosion cracking.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2015

A New Generation High Density Thermal Battery Based on Advanced Metal Hydride

In a world that is facing an energy crisis and environmental pollution, the development of an electric vehicle (EV) as zero-emission, energy-efficiency mode of transportation has taken on an accelerated pace. Most of major automotive manufacturers have launched aggressive programs to develop new-generation EVs, and some economical EVs have been commercialized. Moreover, market forecasting has suggested that Hybrid Electric Vehicles (HEVs), Plug-in Hybrid Electric Vehicles (PHEVs), and Electric Vehicles (EV), will be a growing component of the US vehicle fleets in the near future. By supplying power to EV, a rechargeable electric battery is one of the most crucial components in EV. However, the capacity and cost of an electric battery represent the highest barriers to wide scale adoption of electric vehicles as the large and expensive batteries needed to provide significant driving range can result in unattractive vehicle design and price points. In addition to the electric energy that has been used in powertrain, a key drain on the electrical battery system of an EV is needed to serve cabin heating and cooling loads. Cabin climate conditioning can significantly reduce the electric range of plug-in and full electric vehicles, by as much as 40% in extreme cases, or inversely and can increase the battery size and cost by a comparable amount for the same range. Therefore, significant reduction in the size/cost of EV batteries or a significant increase in driving range can be enabled by eliminating the need for cabin climate load to draw on the electrical battery system. The work of this project focused on a concept that employs metal hydride materials and chloride-ammonia as energy storage materials to build a new generation thermal battery with sufficient energy density to meet the above requirements. The high-energy density of metal hydride material makes the thermal battery meet the requirements of HVAC system for EB automobiles. The present research focused on a specific on-board application to develop a novel HVAC system for EV. However, the methodology of the thermal battery could be extended to a much broader range of applications, including other transportation vehicles such as long haul trucks, stationary HVAC, solar thermal energy storage systems, and waste heat recovery and storage systems. Multiple prototypes were designed, fabricated, and tested. The results successfully demonstrate the principles of the thermal battery using advanced metal hydrides. The performance of the concept-demonstration-unit showed both high heating/cooling power and high energy densities. Although the feasibility of the “Thermal Battery” has been demonstrated by this project, the commercial applications of this technology remain challenging. Either the volumetric or the gravimetric energy density of the materials used often cannot be both met. The solution to this problem is to work with vehicle HAVC designers to identify design innovations that can take advantages of the thermal battery without compromising the performance of the vehicles.

25 ENERGY STORAGE↗

DOE OSTI2014

Development of the Mathematics of Learning Curve Models for Evaluating Small Modular Reactor Economics

The cost of nuclear power is a straightforward yet complicated topic. It is straightforward in that the cost of nuclear power is a function of the cost to build the nuclear power plant, the cost to operate and maintain it, and the cost to provide fuel for it. It is complicated in that some of those costs are not necessarily known, introducing uncertainty into the analysis. For large light water reactor (LWR)-based nuclear power plants, the uncertainty is mainly contained within the cost of construction. The typical costs of operations and maintenance (O&M), as well as fuel, are well known based on the current fleet of LWRs. However, the last currently operating reactor to come online was Watts Bar 1 in May 1996; thus, the expected construction costs for gigawatt (GW)-class reactors in the United States are based on information nearly two decades old. Extrapolating construction, O&M, and fuel costs from GW-class LWRs to LWR-based small modular reactors (SMRs) introduces even more complication. The per-installed-kilowatt construction costs for SMRs are likely to be higher than those for the GW-class reactors based on the property of the economy of scale. Generally speaking, the economy of scale is the tendency for overall costs to increase slower than the overall production capacity. For power plants, this means that doubling the power production capacity would be expected to cost less than twice as much. Applying this property in the opposite direction, halving the power production capacity would be expected to cost more than half as much. This can potentially make the SMRs less competitive in the electricity market against the GW-class reactors, as well as against other power sources such as natural gas and subsidized renewables. One factor that can potentially aid the SMRs in achieving economic competitiveness is an economy of numbers, as opposed to the economy of scale, associated with learning curves. The basic concept of the learning curve is that the more a new process is repeated, the more efficient the process can be made. Assuming that efficiency directly relates to cost means that the more a new process is repeated successfully and efficiently, the less costly the process can be made. This factor ties directly into the factory fabrication and modularization aspect of the SMR paradigm—manufacturing serial, standardized, identical components for use in nuclear power plants can allow the SMR industry to use the learning curves to predict and optimize deployment costs. Thus, SMR deployment cost estimates can be modeled using learning curve theory to provide some insight into how and when SMRs would be competitive with both the GW-class reactors and other mutual competitors. However, assuming static learning curve behavior for all aspects of SMR construction is likely an invalid approach—not all components and systems in SMRs will be subject to learning, and those that are subject to learning may not learn at the same rate. A learning curvebased model must be capable of tracking these unique behaviors. At the same time, the behavior of the aggregated and integrated SMR deployment is a more useful metric for discussion and comparison—ultimately, the most useful learning curve information is that which describes power plant deployment as a whole. Therefore, the goal of SMR component and systems learning modeling includes a method to produce an overall power plant learning model. This report describes the mathematics of learning curves that can be used for estimating unit cost in future production for individual components and aggregated systems. All necessary assumptions are provided to support the derivations presented. Future work will demonstrate the implementation of this methodology and provide example calculations of SMR cost

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2015

Effects of High Octane Ethanol Blends on Four Legacy Flex-Fuel Vehicles, and a Turbocharged GDI Vehicle

The U.S. Department of Energy (DOE) is supporting engine and vehicle research to investigate the potential of high-octane fuels to improve fuel economy. Ethanol has very high research octane number (RON) and heat of vaporization (HoV), properties that make it an excellent spark ignition engine fuel. The prospects of increasing both the ethanol content and the octane number of the gasoline pool has the potential to enable improved fuel economy in future vehicles with downsized, downsped engines. This report describes a small study to explore the potential performance benefits of high octane ethanol blends in the legacy fleet. There are over 17 million flex-fuel vehicles (FFVs) on the road today in the United States, vehicles capable of using any fuel from E0 to E85. If a future high-octane blend for dedicated vehicles is on the horizon, the nation is faced with the classic chicken-and-egg dilemma. If today’s FFVs can see a performance advantage with a high octane ethanol blend such as E25 or E30, then perhaps consumer demand for this fuel can serve as a bridge to future dedicated vehicles. Experiments were performed with four FFVs using a 10% ethanol fuel (E10) with 88 pump octane, and a market gasoline blended with ethanol to make a 30% by volume ethanol fuel (E30) with 94 pump octane. The research octane numbers were 92.4 for the E10 fuel and 100.7 for the E30 fuel. Two vehicles had gasoline direct injected (GDI) engines, and two featured port fuel injection (PFI). Significant wide open throttle (WOT) performance improvements were measured for three of the four FFVs, with one vehicle showing no change. Additionally, a conventional (non-FFV) vehicle with a small turbocharged direct-injected engine was tested with a regular grade of gasoline with no ethanol (E0) and a splash blend of this same fuel with 15% ethanol by volume (E15). RON was increased from 90.7 for the E0 to 97.8 for the E15 blend. Significant wide open throttle and thermal efficiency performance improvement was measured for this vehicle, which achieved near volumetric fuel economy parity on the aggressive US06 drive cycle, demonstrating the potential for improved fuel economy in forthcoming downsized, downsped engines with high-octane fuels.

09 BIOMASS FUELS↗

DOE OSTI2013

Recovery Act. Solid Oxide Fuel Cell Diesel Auxilliary Power Unit Demonstration

Solid Oxide Fuel Cell Diesel Auxilliary Power Unit Demonstration Project. Summarizing development of Delphi’s next generation SOFC system as the core power plant to prove the viability of the market opportunity for a 3-5 kW diesel SOFC system. Report includes test and demonstration results from testing the diesel APU in a high visibility fleet customer vehicle application.

08 HYDROGEN↗

DOE OSTI2014

Light Water Reactor Sustainability Program Advanced Instrumentation, Information, and Control Systems Technologies Technical Program Plan for 2013

Reliable instrumentation, information, and control (II&C) systems technologies are essential to ensuring safe and efficient operation of the U.S. light water reactor (LWR) fleet. These technologies affect every aspect of nuclear power plant (NPP) and balance-of-plant operations. In 1997, the National Research Council conducted a study concerning the challenges involved in modernization of digital instrumentation and control systems in NPPs. Their findings identified the need for new II&C technology integration.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2014

Benchmark Report on Key Outage Attributes: An Analysis of Outage Improvement Opportunities and Priorities

Advanced Outage Control Center (AOCC), is a multi-year pilot project targeted at Nuclear Power Plant (NPP) outage improvement. The purpose of this pilot project is to improve management of NPP outages through the development of an AOCC that is specifically designed to maximize the usefulness of communication and collaboration technologies for outage coordination and problem resolution activities. This report documents the results of a benchmarking effort to evaluate the transferability of technologies demonstrated at Idaho National Laboratory and the primary pilot project partner, Palo Verde Nuclear Generating Station. The initial assumption for this pilot project was that NPPs generally do not take advantage of advanced technology to support outage management activities. Several researchers involved in this pilot project have commercial NPP experience and believed that very little technology has been applied towards outage communication and collaboration. To verify that the technology options researched and demonstrated through this pilot project would in fact have broad application for the US commercial nuclear fleet, and to look for additional outage management best practices, LWRS program researchers visited several additional nuclear facilities.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2014

Automated work packages architecture: An initial set of human factors and instrumentation and controls requirements

The work management process in current fleets of national nuclear power plants is so highly dependent on large technical staffs and quality of work instruction, i.e., paper-based, that this puts nuclear energy at somewhat of a long-term economic disadvantage and increase the possibility of human errors. Technologies like mobile portable devices and computer-based procedures can play a key role in improving the plant work management process, thereby increasing productivity and decreasing cost. Automated work packages are a fundamentally an enabling technology for improving worker productivity and human performance in nuclear power plants work activities because virtually every plant work activity is accomplished using some form of a work package. As part of this year’s research effort, automated work packages architecture is identified and an initial set of requirements identified, that are essential and necessary for implementation of automated work packages in nuclear power plants.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2013

The Western Wind and Solar Integration Study Phase 2

The electric grid is a highly complex, interconnected machine, and changing one part of the grid can have consequences elsewhere. Adding wind and solar affects the operation of the other power plants and adding high penetrations can induce cycling of fossil-fueled generators. Cycling leads to wear-and-tear costs and changes in emissions. Phase 2 of the Western Wind and Solar Integration Study (WWSIS-2) evaluated these costs and emissions and simulated grid operations for a year to investigate the detailed impact of wind and solar on the fossil-fueled fleet. This built on Phase 1, one of the largest wind and solar integration studies ever conducted, which examined operational impacts of high wind and solar penetrations in the West(GE Energy 2010).

14 SOLAR ENERGY↗

DOE OSTI2013

The Western Wind and Solar Integration Study Phase 2 (Executive Summary)

14 SOLAR ENERGY↗

DOE OSTI2015

Transportation Energy Data Book: Edition 34

The Transportation Energy Data Book: Edition 34 is a statistical compendium prepared and published by Oak Ridge National Laboratory (ORNL) under contract with the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, Vehicle Technologies Office. Designed for use as a desk-top reference, the Data Book represents an assembly and display of statistics and information that characterize transportation activity, and presents data on other factors that influence transportation energy use. The purpose of this document is to present relevant statistical data in the form of tables and graphs. The latest edition of the Data Book is available to a larger audience via the Internet (cta.ornl.gov/data). This edition of the Data Book has 12 chapters which focus on various aspects of the transportation industry. Chapter 1 focuses on petroleum; Chapter 2 energy; Chapter 3 highway vehicles; Chapter 4 light vehicles; Chapter 5 heavy vehicles; Chapter 6 alternative fuel vehicles; Chapter 7 fleet vehicles; Chapter 8 household vehicles; Chapter 9 nonhighway modes; Chapter 10 transportation and the economy; Chapter 11 greenhouse gas emissions; and Chapter 12 criteria pollutant emissions. The sources used represent the latest available data. There are also three appendices which include detailed source information for some tables, measures of conversion, and the definition of Census divisions and regions. A glossary of terms and a title index are also included for the reader s convenience.

Air↗

DOE OSTI2015

American Fuel Cell Bus Project Evaluation. Second Report

This report presents results of the American Fuel Cell Bus (AFCB) Project, a demonstration of fuel cell electric buses operating in the Coachella Valley area of California. The prototype AFCB was developed as part of the Federal Transit Administration's (FTA's) National Fuel Cell Bus Program. Through the non-profit consortia CALSTART, a team led by SunLine Transit Agency and BAE Systems developed a new fuel cell electric bus for demonstration. SunLine added two more AFCBs to its fleet in 2014 and another in 2015. FTA and the AFCB project team are collaborating with the U.S. Department of Energy (DOE) and DOE's National Renewable Energy Laboratory to evaluate the buses in revenue service. This report summarizes the performance results for the buses through June 2015.

30 DIRECT ENERGY CONVERSION↗