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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 1,477 records · Page 82
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Life-Cycle Analysis Datasets for Regionalized Plastic Pathways

The carbon intensity (CI) of producing five different resins – polyethylene terephthalate (PET), high-density polyethylene (HDPE), low-density polyethylene (LDPE), polypropylene (PP), and polyvinyl chloride (PVC) – in four different international regions – United States of America (USA), Western Europe, Middle East and Northern Africa (MENA), and China – is calculated on a cradle-to-gate basis using the Greenhouse Gases, Regulated Emissions, and Energy Use in Transportation (GREET) model. The list of factors that can potentially vary the CI of the five resins in different international regions include the CI of electricity and natural gas (NG) production, steam cracking feedstock mix, propylene sourcing technology mix, terephthalic monomer (TM) mix, use of hydrogen co-product from steam cracking process, and vinyl chloride monomer (VCM) production technology mix.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Sand Thermal Energy Storage Pilot Design (Final Report)

This report summarizes work done on developing a 10-MWhe pilot of the sand-based thermal energy storage (SandTES) technology at Alabama Power’s Plant Gaston Unit 5, an operating, supercritical coal power unit. The system will be integrated to the unit, obtaining steam to heat the sand through an air-blown fluidized-bed heat exchanger, then storing the water to be reused during discharging to produce steam that will then be vented. An electrical particle heater will also be included to provide part of the heat to the sand to provide data and learnings for commercial systems that will be fully electrically heated. Hot sand is contained in one bunker, while cold sand is housed in the other bunker, and standard solids handling equipment moves the sand around. This pilot would advance the SandTES technology to Technology Readiness Level 6 and position it for commercial readiness by 2030. This work was done in two phases: Phase I performed a conceptual study that provided Association for the Advancement of Cost Engineering (AACE) Class 5 costs and estimated performance, and then Phase II, which also involved a design update, performed a more detailed pre-front-end engineering and design study that elicited AACE Class 4 costs. Work was also done to provide estimated costs for commercial applications of the technology, assess its gaps, create its technology maturation and commercialization plans, and finally perform an Environmental Information Volume for the pilot site as a first step in the National Environmental Policy Act process.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2024

Cost and Performance Estimates for State-of-the-Art and Advanced 1×1 H-Class Natural Gas-Fired Power Plants

As an extension of NETL's Fossil Energy Baseline for Electricity Generating Units Volume 1: Coal and Natural Gas to Electricity (FEB Rev 4a, this study develops cost and performance estimates for analogous NGCC cases using a state-of-the-art 2023 vintage H-Class CT in a 1×1 configuration, where a single combustion turbine and heat recovery steam generator are coupled to a single steam turbine on a common shaft. These 1×1 H-Class cases are used to develop cost and performance estimates of X-Class 1×1 NGCC cases with advanced performance characteristics, analogous to NETL’s cost and performance projections report.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2019

Tailored Syngas via High Temperature H2O-CO2 Co-Electrolysis

This project has developed a new testing capability at PNNL and has evaluated solid oxide electrolysis cell (SOEC) materials for the ability to co-electrolyze carbon dioxide and steam to produce synthesis gas. CO 2 -H 2 O co-electrolysis, the simultaneous electrochemical reduction of carbon dioxide and steam, was performed on the porous Ni-based electrodes in high temperature SOECs. Experiments were conducted using small button cells and the rate of the electrochemical reactions was measured at 750°C for varied reactant compositions: 10-98%CO 2 and 5-50% H 2 O, also in the presence of some H 2 and CO to ensure reducing environment and avoid Ni oxidation.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Capturing O2 Desorption Through Isoconversional Kinetics for CFD Application

The present work examines desorption mechanisms and kinetics of the calcium-doped strontium perovskite at 25% calcium content (i.e., Sr_0.75 Ca_0.25 FeO_(3-δ)). Laboratory-scale, low inventory, fixed bed redox cycle experiments were developed and conducted in both dry and steam-based environments for three isothermal temperatures, 450, 500 and 550C. The temporal evolution of the conversion extent of the material sample over the redox cycles were obtained through the analysis of the gaseous products of the redox reactions. Using subsequently isoconversional differential methods, it was found that the activation energy exhibits a strong dependence on the extent of conversion during the desorption of this perovskite. In addition, the reconstruction of the reaction model showed that the desorption kinetics are controlled by a three-step mechanism. A successful a priori verification of the isoconversional desorption kinetics against the dry and steam-based environment desorption experimental data are shown.

Konan, Ndri A.↗
DOE OSTI2024

Technical and Economic Assessment and Gap Analysis of Advanced Nuclear Reactor Integration with a Reference Oil Refinery

Efforts to identify the most-economic methods to decarbonize several sectors of the U.S. economy are underway. Industrial processes such as crude-oil refining rely heavily on energy-dense and easily stored and transported fossil fuels for powering their operations. Refineries use large amounts of energy, primarily derived from fossil sources to separate crude-oil components, break down heavier hydrocarbons into lighter compounds, remove impurities, reform hydrocarbon molecules, and generate steam and electricity for pumps and compressors and other various auxiliary systems. Crude-oil refining operations such as distillation, cracking, desulfurization, reforming, utilities systems and some offsite facilities collectively account for most of the energy consumption. Other operations such as hydrocracking or hydrotreating also require hydrogen for developing hydrogenation reactions which involve substantial heating to keep the reactors at high-temperature and pressure levels. All heat and energy demands are typically provided by natural gas (NG), oil, or other fuels, which makes refinery industry one of the most-difficult sectors to decarbonize. Nuclear power is a viable and energy-dense source of clean electricity, heat, and hydrogen to provide the large, sustainable energy supply that the refining industry demands. The U.S. Department of Energy’s (DOE’s) Integrated Energy Systems (IES) program is working to perform research and development, design, economic siting, and risk analysis. This state-of-the-art work will enable the first on-site demonstrations and commercial deployments of advanced small modular nuclear reactors (SMNRs) integrated with industries such as chemical production, refining, iron and steel making, and more. IES seeks to demonstrate the ability of advanced nuclear reactors to meet the heat and power demands of these industries while reducing carbon emissions in a sustainable and cost-competitive way. The primary objective of this research effort is to analyze industrial-scale SMNR integration intended to decarbonize refining facilities. The foreseen outcome is the provision of reliable, cost-competitive, and sustainable clean energy, alongside a reduction of carbon emissions. Specifically, the focus of this work lies on meeting the reference facilities’ heat and electricity demands with nuclear power while also supplying clean hydrogen via integrated high-temperature steam electrolysis (HTSE). This report presents a comprehensive technical and economic assessment of the integration of advanced nuclear reactors into a reference refinery, leveraging financial incentives from the Inflation Reduction Act (IRA). The evaluation aims to explore the potential economic benefits and challenges associated with incorporating advanced nuclear reactors into refinery operations, particularly in terms of energy efficiency, economic implications and environmental impact. By examining both the technical feasibility and economic viability, this analysis seeks to identify existing gaps and propose solutions for successful nuclear integration implementation. The findings are intended to provide valuable insights for stakeholders considering the adoption of advanced nuclear reactors in the refining sector. A refinery reference-plant was developed, using an open-source refinery model, Petroleum Refinery Lifecycle Inventory Model (PRELIM) and expert assessment, as a base case for comparison with various nuclear integration options. The capacity of 100 kbd/day (KBD) of heavy crude-oil feed was selected to represent a general coking-type refinery with deep conversion capabilities (incorporating heavy-oil upgrading with FCC, coking, and associated hydrotreating process units), using a heavy crude-oil feed, which represents about 70% of U.S. refineries configurations. A summary of all cases considered in this study is shown in Table 1.

13 HYDRO ENERGY↗
DOE OSTI2024

STAT7 v1.2 User Guide: The STAT7 Code for Statistical Propagation of Uncertainties in Steady-State Thermal Hydraulics Analysis of Plate-Fueled Reactors

The STAT7 software was developed to perform steady-state, single-phase thermal hydraulics analysis of plate-fueled reactors based on statistical propagation of uncertainties. Application of the software is for non-power research and test reactors, including conversion to low-enriched uranium fuel of U.S. High-Performance Research Reactors such as Massachusetts Institute of Technology Research Reactor. Since it can be necessary to repeat analysis during fuel reloading, STAT7 accommodates flexibility in analyzing many realistic aspects of reactor fuel management. STAT7 uses a Monte Carlo approach to model uncertainty in common fuel fabrication parameters and other key reactor operating parameters required for thermal hydraulics analyses of research and test reactors. These safety calculations are ultimately intended to protect against high fuel plate temperatures due to critical heat flux, or onset of flow instability. STAT7 supports water properties based on the IAPWS-IF97 functions (The International Association for the Properties of Water and Steam Industrial Formulation 1997 for the Thermodynamic Properties of Water and Steam) in addition to the fit functions. STAT7 predicts axial profiles of fuel, cladding, and coolant temperature along a lateral stripe that runs the full length of the fuel plate from the bottom to the top. STAT7 can simultaneously analyze all of the axial nodes of all of the fuel plates and all of the coolant channels for one latera stripe of a fuel element. Power splits are calculated for each axial node of each plate to determine how much of the power goes out each face of the plate. By running STAT7 multiple times, full core analysis can be performed by analyzing the margin to onset of nucleate boiling and onset of flow instability for each axial node of each stripe of each plate of each fuel element in the core.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Deer Park Energy Center Natural Gas Combined Cycle Carbon Capture System Front-End Engineering Design Study (Final Scientific/Technical Report – Unlimited)

Calpine Texas CCUS Holdings, LLC (Calpine), Shell Catalysts & Technologies (SCT), Technip Energies (TEN), and Sargent & Lundy, LLC (S&L) have conducted a Front-End Engineering Design (FEED) Study to integrate a new carbon capture system at Calpine’s Deer Park Energy Center (DKEC). The DKEC facility is a nominal 1200 MW gas-fired co-generation power plant situated at the Shell Chemical Manufacturing (Shell) Facility located in Deer Park, Texas. Steam is produced for use by the adjacent Shell Chemical Manufacturing Facility as well as by the onsite steam turbine for electrical generation. The power output from DKEC is provided to the Electric Reliability Council of Texas (ERCOT) operated power grid. DKEC provides power to industrial and commercial customers via this interconnection.

03 NATURAL GAS↗
DOE OSTI2024

Technoeconomic Analysis of Kraft Pulp Mill Integration with an Advanced Nuclear Reactor

This study focuses on post-combustion capture and oxy-fuel combustion for the boilers at the mill, as well as steam integration with the nuclear power plant. The primary goal of the research outlined in this report is to design, analyze, and document the integration of industrial-scale HTGR with a reference Kraft Pulp Mill. The purpose is to deliver reliable, cost-effective, and sustainable clean energy alternatives while reducing CO2 emissions. Specifically, this study focuses on 6 different scenarios that include carbon capture equipment and some of them use nuclear power to meet the heat and electricity needs of the reference plant. Also, 2 of these scenarios are created while also producing clean hydrogen through integrated High-Temperature Steam Electrolysis (HTSE). This report offers a detailed techno-economic assessment of different scenarios for a Kraft Pulp Mill, including an analysis of tax credits (section 45V, 45Q, and 48E) provided by the Inflation Reduction Act (IRA) of 2022. The evaluation explores the potential economic benefits and challenges of incorporating different configurations, including nuclear energy, into Kraft Pulp Mill operations, with particular attention to energy efficiency, economic implications, and environmental impact. By assessing both the technical feasibility and economic viability, this analysis aims to identify existing gaps and propose solutions for the successful implementation of nuclear integration. The findings are intended to provide valuable insights for stakeholders considering the adoption of advanced nuclear reactors in the pulp and paper industries.

08 HYDROGEN↗
DOE OSTI2024

A Multidisciplinary Approach to Integrated Energy Systems: Advanced Nuclear Plants with Thermal Storage for Dynamic and Flexible Operation in Diverse Markets

Energy supply, distribution, and demand are continuously evolving in accordance with the integration of new power generation sources. In the United States, there is a progressive shift toward incorporating fluctuating energy sources such as wind and solar into the energy mix, alongside the distributed generation. Simultaneously, we are seeing a revolution in consumer technologies such as electric vehicles, energy devices for both residential and commercial use, and industrial processes—all contributing to a fundamental change in energy consumption dynamics. These scenarios have led to huge demand for enhanced flexibility from nuclear power plants (NPPs), requiring them to operate with unprecedented adaptability. Furthermore, advanced NPPs (A-NPPs) could potentially apply to scenarios in which power generation flexibility is prioritized over its current and conventional baseload generation capacity for traditional demand patterns. The present work covers several configurations for coupling nuclear energy production with thermal energy storage (TES). Previous work evaluated systems entailing a simple nuclear-TES configuration that used steam as a heat source for the TES of three different advanced reactors (ARs), but its heat diversion ratio (HDR) for charging was limited. The present work proposes a new configuration that features full decoupling of the nuclear reactor and the power cycle, using reactor coolant (i.e., gas) as a heat source for the TES and offering a theoretically unlimited HDR. This configuration is, however, more complex, as both high- and low-temperature TES (HT-TES and LT-TES) systems are required in order to cover the extended temperature range. Although this configuration imposes certain limitations on the discharge system configuration, it also presents the opportunity to design a more efficient system. For this case in particular, a steam reheat cycle is advantageous. Conventional TES systems take advantage of nominal efficiency when discharging, whereas the reheat cycle in the fully decoupled TES system affords a significant efficiency increase over conventional cases. Material selection, component/equipment sizing, and costing analyses were performed, followed by economic dispatch and size optimization. Dynamic models were developed for the decoupled system in order to generate insights into aspects of off design operation (e.g., drops in cycle efficiency), and these models enable exploration of potential mitigation strategies for addressing such drops. The models also highlight the need to design fail-safes that ensure continuous operational stability and minimize the impact of power ramping on the reactor parameters.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2024

Creep Degradation of Austenitic Steels in CO2 Environments

Steels have a proven track record of safe operation in steam power plants for decades. Interest in developing supercritical CO2 power cycles as a more efficient and sustainable alternative to steam cycles has driven a need to understand steel performance in these new environments. In particular, the potential of the high temperature CO2 environment to influence the creep behavior of the steel must be determined. Prior research on this topic between the 1960s and 1980s found conflicting conclusions, but nevertheless raised the possibility that carburization during CO2 exposure may strongly affect the creep behavior. This raises concerns particularly for thin-sectioned components such as compact heat exchangers, where even small rates of carburization can become problematic over long operating lifetimes. To shed light on this issue, this research investigates the creep behavior of austenitic stainless steel 347H and 309H (a higher Cr alternative) at 650°C. Specimens of 0.5, 1.0, and 2.0 mm thickness were tested to further assess the effect of steel thickness. Both steels show a reduction in creep life in CO2 relative to air, with 309H showing slightly better performance than 374H. Analysis is ongoing to determine the reason for degraded creep properties.

Rozman, Kyle A.↗
DOE OSTI2024

Thermal Integration of Advanced Nuclear Reactors with a Reference Refinery, Methanol Synthesis, and a Wood Pulp Plant (Rev.1)

The present report is intended to provide process flow diagrams (PFDs) and energy and mass balance data sheets for a U.S. industrial sector subset with which nuclear heat and power could be integrated—a subset that includes the oil refining, methanol and pulp and paper industries. Coupling options for integrating nuclear energy into these industries are quantitatively outlined for reference systems, and future work will extend this analysis in greater detail. Opportunities for integrating small modular nuclear reactors (SMNRs) were investigated for each of the industrial process configurations. Aspen HYSYS and Cycle-Tempo models for a high-temperature gas-cooled reactor were developed to evaluate the proposed integration. This introductory evaluation provides a general description and assessment of the operating principles, reactor coolant core outlet temperature, and reactor size to be integrated with industry. The industrial processes of oil refining and the production of methanol, pulp and paper were simulated by using Aspen HYSYS, Aspen Plus, and the PRELIM (Petroleum Refinery Life Cycle Inventory Model) tool to develop process details. Cycle-Tempo models then extend the process modeling results to obtain net energy demands (e.g., heat, steam, and electricity) when accounting for process steam and waste heat recovery. This information is intended to foster the analysis of integrating an SMNR to decarbonize industrial facilities. The SMNR would provide reliable, competitive, and sustainable clean energy while reducing carbon emissions and other environmental impacts, such as water withdrawals, consumption, and contamination. The refining industry, exhibited in Figure ES1, is a leading consumer of fossil -fuel-based heat, power, and hydrogen in the U.S. industrial sector, generating over 164 million metric tons (MMT) of CO 2 emissions in 2023. The overall mass and energy pertaining to a generalized complex refinery in the United States is reflected in Figure ES1, along with energy metrics regarding integration with a nuclear power plant (NPP). Data sheets were developed to indicate the energy requirements for the overall refinery and each refinery process. The data sheet for the overall refinery is shown in Table ES2.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Defect Thermodynamics and Transport Properties of Proton Conducting Perovskite Electrode and Electrolyte Materials Evaluated Based on Density Functional Theory Modeling

Both electron-rich and electron-poor perovskite oxides have been used in solid oxide cell applications as electrode and electrolyte materials. The rich oxygen defect chemistry and its coupling to temperature, hydrogen-steam or oxygen-steam gas pressure, or to the applied potentials creates enormous complexities for modeling performance and degradation of the materials. Herein, density functional theory-based thermodynamic modeling was carried out to describe the defect chemistry and transport properties of the proton-conducting electrolyte BaZr1-xYxO3-δ (x≤0.1) and of the triple-conducting perovskite (La,Ba)(Fe,M)O3-δ (M=Y and Zr). The defect thermodynamics of intrinsic point defects and the hydrogen-related defect reactions were solved in integrated defect models and further used to predict the Brouwer diagram and the transport properties of the functional perovskites. For the electron-poor electrolytes BaZr0.9Y0.1O3-δ, the developed model has been used to describe the experimental transport properties in the SOC operating conditions. Specifically, the roles played by the acceptor-bound holes and the intrinsic and hydrogen point defects upon the conductivities of holes, protons, and oxygen vacancies under the hydrogen-rich and oxygen-rich conditions at various humidity levels were demonstrated. A defect modeling tool was also developed for the triple-conducting perovskite (La,Ba)(Fe,M)O3-δ (M=Y and Zr) to examine magnetic effects and hydride defects in defect equilibria.

defect thermodynamics↗
DOE OSTI2025

Rapid Bayesian High Entropy Alloy Designs Fabricated via Wire Arc Additive Manufacturing

Purpose: This project seeks to demonstrate a new high-throughput (rapid) alloy design technique applied to creating new high entropy alloys (HEAs) for extreme environments. High entropy alloys shift the design paradigm from being focused on a single principal element (e.g. nickel-based alloys) to target alloys that include high atomic fractions (X >10%) of multiple elements. These HEA materials can exhibit sluggish diffusion and enhanced corrosion resistance, ideal for potential applications in advanced ultra supercritical (A-USC) steam cycles for power generation. Scope: The addition of multiple elements in high atomic fractions creates an enormous design space that cannot easily be investigated by traditional material design strategies such as designed of experiments (DOE). This project utilizes a Bayesian machine learning algorithm that has been modified to work with calculation of phase diagrams (CALPHAD) software. This Bayesian algorithm reduces manual inputs and increase the likelihood of achieving an optimal solution. Compositional inputs to this algorithm will be assessed using existing material property models for high temperature strength and corrosion resistance. The target for alloy performance will be a 15% (~100 ⁰C) increase in allowable service temperature beyond heat-resistant stainless steels while maintaining or improving alloy cost and corrosion resistance. Haynes 230 was selected as a baseline, which is 57 wt% Ni with 22 wt% Cr 14 wt% W, and 2 wt% Mo as solid solution strengtheners. In addition to rapid design via Bayesian machine learning, the alloys were rapidly fabricated using a multi-wire arc additive manufacturing (mWAAM) technique which allows for precise control of alloy composition and assessing of alloy design “windows” to study composition effects. Build speeds for wire-arc additive processes are among the highest for additive technologies enabling rapid and reliable sample fabrication when compared to conventional methods such as arc button melting. The mWAAM samples will be rapidly characterized via instrumented indentation for room temperature modulus and strength and for elevated temperature strength via hot hardness tests. After being screened with hardness testing, potential alloys will be further evaluated with conventional microscopy techniques including scanning electron microscopy (SEM) and transmission electron microscopy (TEM) to assess agreement with modeling results. The most promising compositions will also be evaluated by printing full sized tensile specimens for mechanical behavior tests at elevated temperatures. Results: Bayesian machine learning of a single performance function was initially used to optimize five performance metrics: 1) single phase stability, 2) yield strength, 3) creep resistance (low diffusion coefficient), 4) freezing range (weldability), and 5) material cost. The single performance function was suboptimal as assumptions had to be made about the results while formulating the optimization. A goal-oriented Bayesian optimization strategy (Hanaoka, 2021) was implemented with CALPHAD for use with the five metrics above. This multi-objective Bayesian optimization (MOBO) enabled the design of NiCrCoFe alloys with V and W additions. A base composition of NiCoCr was selected as Ni provides a stable FCC matrix, Cr aids corrosion/oxidation resistance, and Co is a solid-solutions strengthener that also improves creep by increasing the activation energy. Fe helps reduce diffusion coefficients and cost. Finally, V and W were selected for their reasonable solubility and high atomic misfit to aid in solid solution strengthening. Cracking of the mWAAM specimens was an early issue, and the Easton solidification cracking model (Easton et al., 2014a) was selected for addition to the MOBO function. High performing alloys fabricated by mWAAM included Ni 28 Cr 25 Co 26 Fe 15 V 8 and Ni 62 Cr 18 Co 1 Fe 3 W 15 . It was observed that even after adapting the mWAAM process for W, the W did not fully dissolve. To fully evaluate the Ni 62 Cr 18 Co 1 Fe 3 W 15 composition, a cored wire (80-20 NiCr sheath/powder core) was manufactured and printed via WAAM, and HIP’ing was utilized to homogenize and densify the printed alloy. The V and W alloys produced met metrics 1 (solid solution), 4 (solidification cracking), and 5 (cost). However, an unmodeled mechanism of thermal stress cracking was identified in the WAAM produced materials, perhaps exacerbated by the lack of grain boundary strengthening elements (B, C). Conclusions & Recommendations: A high-throughput (rapid) alloy design technique was applied to designing and manufacturing new high entropy alloys (HEAs) for extreme environments utilizing MOBO and mWAAM. The developed process was rapid and effective in addressing the mechanisms included in the model. The lack of grain boundary strengthening element additions (e.g., B, C) was a simplification that likely produced thermal stress cracking that turned into a large part of the investigation. Additions on the order of 0.005 wt% B and 0.05 wt% C likely would have minimized thermal stress grain boundary cracking. Overall, the high throughput design strategy is promising for rapid design of metrics-driven alloys for advanced ultra supercritical (A-USC) steam cycles for power generation. The MOBO and mWAAM process could be commercialized to accelerate metrics-driven alloy design. In addition, the cored-wire process utilized for scale-up is a promising high-volume process for WAAM alloy development and scale-up.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Field Validation of a Pilot-scale Black Liquor Membrane for Water Removal at Ahlstrom-Munksjö Paper Mill in Mosinee, WI

Project Background: The Industrial Technology Validation (ITV) program aims to identify and demonstrate the performance of new, emerging, and underutilized technologies in the industrial sector to help inform decisions towards accelerating commercialization and deployment. Pulp and paper is considered one of the most energy-intensive industries in the manufacturing sector. There are several methodologies for converting wood into pulp in the paper-making industry. The kraft process is a chemical method for producing wood pulp. The kraft process generates black liquor as a byproduct of pulp production. Traditionally, water is evaporated from the liquor by a set of multi-effect evaporators (MEEs), which concentrate weak black liquor (WBL) into strong black liquor (SBL) to support efficient combustion in a recovery boiler. Concentrating black liquor is an energy-intensive step in recovering pulping chemicals and generating high-pressure steam from dissolved wood solids. About 7% of pulp and paper energy usage, or nearly 164 trillion Btu, is used to remove water from black liquor in U.S. kraft pulp mills per year. The U.S. DOE’s IEDO is interested in the black liquor membrane technology evaluated in this report because it offers the potential for a more energy-efficient and less carbon-intensive kraft pulping process across 99 kraft pulp mills in 24 states (Agenda 2020 Technology Alliance 2016). This ITV project validates an innovative black liquor membrane technology for kraft pulp mills to understand its impact and benefits. Via Separations is a technology vendor that developed a graphene oxide membrane system to remove water from WBL before entering the evaporator set. High-pressure positive displacement (HPR) pumps move the black liquor through membranes that separate water and create a more concentrated black liquor. The vendor claims their pre-commercial technology reduces evaporator steam consumption by dewatering WBL before entering the evaporators. They also claim their technology has non-energy benefits such as enhanced soap collection and improved pulp throughput. This evaluation focuses on validating the energy and carbon dioxide (CO 2 e) emissions benefits associated with the membrane system.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Comprehensive Life Cycle Analysis of Methanol Production and Methanol-to-Diesel Conversion

Methanol is a strategic chemical and intermediate in the manufacture of synthetic diesel, due to its versatility, diesel’s compatibility with existing infrastructure, and their role in industrial and transport applications. Conventional production methods for methanol, primarily steam methane reforming (SMR), rely on natural gas and are subject to the price variability due to market conditions and geopolitical events. They are also associated with greenhouse gas (GHG) emissions. Methanol and synthetic diesel production could be integrated with nuclear energy to stabilize fuel prices and insulate pricing from outside geopolitical events due to the relative stability of nuclear fuel as compared to natural gas. This could lead to increased transportation fuel security, reliability and resilience. An added benefit is the abatement of emissions when substituting nuclear energy for conventional energy from natural gas. This report presents a comprehensive life cycle analysis(LCA) framework which was developed to evaluate the GHG emissions reduction potential associated with nuclear integrated methanol production, methanol-to-diesel upgrading, and end-use combustion. Gate-to-gate methanol production and cradle-to-grave emissions were evaluated in, starting with a business-as-usual (BAU) SMR-based methanol plant, and then considering stepwise nuclear integration. Methanol-to-diesel (MTD) conversion was evaluated accounting for nuclear energy integration and hydrogen production via high-temperature steam electrolysis (HTSE) using electricity either from the grid or from a dedicated nuclear power system. This multi-step process diverts stable and reliable nuclear energy into the transportation sector by upgrading low energy dense natural gas into liquid fuels fully compatible with existing infrastructure.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Technology for Electrically Enhanced Thermochemical Hydrogen (TEETH)

This is the Final Technical Report for the TEETH project. The TEETH concept couples high-temperature solar-thermochemical water splitting (TCWS) with electrochemical H 2 pumping through a proton conducting membrane (PCM) and capitalizes on the benefits of the individual technologies to synergistically providing new benefits. That is, TEETH is a coupled thermochemical/electrochemical process to produce H 2 from steam using solar energy. This approach is thermodynamically equivalent to other hybrid electrolytic processes but is unique in that the equilibrium of the reaction is driven forward by close coupling an electrically driven proton-conducting-membrane to the H 2 -producing reoxidation step. The process uniquely provides and benefits from the necessary H 2 /steam separation and, also unlike other hybrid processes, benefits thermodynamically from the use of readily generated high pressure steam. The concept also satisfies the objectives of previous concepts: 1) decreasing the reduction enthalpy (the reduction temperature), of the working metal-oxide (MO); 2) eliminating the need for a windowed receiver; and 3) widening the scope of material candidates, while also obviating the need for electrical connections to the working MO and avoiding the use of aqueous electrolytes and hydrated redox species (there is no liquid phase), without increasing mechanical complexity.

08 HYDROGEN↗
DOE OSTI2024

Numerical investigation of the AP1000 response following loss-of-coolant accident using PCTRAN and CFD to support R&D of SMRs

Small Modular Reactors (SMRs) present a promising solution for the future of sustainable energy, offering advantages such as reduced waste generation, advanced passive safety features, and potential cost efficiencies. Ongoing research focuses on the design and development of SMRs, addressing challenges through numerical simulations and experimental test data. Given that many next-generation reactors are first-of-a-kind (FOK), current operational reactors serve as valuable benchmarks for understanding various thermal-hydraulic phenomena during postulated design basis accidents (DBAs), including loss-of-coolant accidents (LOCA), main steam line breaks (MSLB), and steam generator tube ruptures (SGTR). This study employs the AP1000 model Personal Computer Transient Analyzer (PCTRAN) to simulate reactor responses to small-break LOCA scenarios, specifically analyzing break sizes of 2 and 10 inches. Additionally, ANSYS FLUENT software is utilized to assess containment responses to large-break LOCAs, focusing on the quantification of decay heat removal via natural convection. Verification of the PCTRAN results is achieved using Westinghouse data, with CFD results corroborating the findings. The outcomes demonstrate strong agreement with Westinghouse data, confirming the accuracy of the simulations.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗