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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Small Business Voucher Program: Scaling-Up of Bio-Based C5 Building Block Production: Cooperative Research and Development Final Report, CRADA Number CRD-16-00611

Visolis, Inc. is an early stage industrial biotechnology company developing next generation of processes for producing building blocks for bulk polymers and fuels. The company is developing low-cost routes to the chemicals of the future in support of DOE, EERE and BETO goals to grow the U.S. bioeconomy. NREL has capabilities in scale-up of fermentation processes from bench top through pilot scales and also has expertise and technologies related to production of lignocellulosic sugars from cellulosic feedstocks. NREL's Integrated Biorefinery Research Facility (IBRF) houses multiple fermentation vessels/systems ranging in size from 0.5 to 9,000 L along with ancillary capabilities in compositional analysis, separations, and purification. NREL's role will be to scale-up the Visolis process to produce an intermediate product, mevalonic acid, from both dextrose and biomass derived sugars. The goals of the project are to: 1) transfer and reproduce one of Visolis's proprietary fermentation processes at bench top and pilot scale at NREL's IBRF using dextrose as the feedstock, 2) carry out bench-scale fermentations using Visolis's organism and cellulosic sugars, and 3) produce mevalonic acid from the bench top and pilot scale runs for catalyst lifetime testing and conversion to isoprene.

09 BIOMASS FUELS↗
DOE OSTI2025

Cataloging Legacy Data from the Tritium Systems Test Assembly Program

The Tritium Systems Test Assembly (TSTA) at Los Alamos National Laboratory, operational from 1984 to 2001, was critical in advancing fusion fuel cycle technologies, including tritium storage, gas separation, and pumping. TSTA’s contributions, particularly in safe tritium operations, have influenced subsequent fusion projects. This paper discusses the ongoing effort to digitize and catalog TSTA’s historical data to create a searchable resource for the fusion research community. While the long-term objective is to develop a relational database for structured data management, the project remains in the early phase, with current efforts focused on scanning and indexing physical documents. Initial plans for database implementations are also presented, outlining key considerations for structure, query indexing, and standardization. As digitization progresses, future discussions will refine these implantation details to ensure an efficient and comprehensive system. This initiative aims to preserve critical legacy data, enhance the design of tritium system facilities, and support the next generation of fusion energy research.

42 ENGINEERING↗
DOE OSTI2023

Application of Principal Component Analysis to Electrochemical Reprocessing PM and NMAC

In this report, data from an electrorefiner (ER) for nuclear fuel reprocessing is evaluated for process monitoring (PM) conclusions. This data comes from tests performed at the Idaho National Laboratory in 2022. Multivariate approaches utilizing methods of Principal Component Analysis (PCA) is applied. This is based off established work in process monitoring for fault detection in industrial facilities. This report will discuss the background, methods, and results of the application and some of the conclusions and applications that can be drawn from them. PCA is applied to two different electrorefiner (ER) operations that occurred at Idaho National Laboratory between August and October 2022. The first operation occurred with little incident while the second had several noted faults in the equipment in operational logs. The data from the first run was used to train the data for “normal” operations and applied to both sets of data to determine when operations were in an “off-normal” condition and identify where the fault occurs through PCA. PCA was able to identify off-normal events and identify the cause for off-normal operations. These identified off-normal events matched with the events and their causes in the operational logs. However, small amounts of variance in the data led to false detection of “off-normal” events. Thus, careful selection of training data and a-posteriori conclusions based off operator assessments will both be required for application of PCA to PM applications. This work demonstrated that multivariate approaches and latent variables are applicable to pyroprocessing PM applications and can be further expanded in future work as quality variables such as salt concentration from sensors and sampling become available.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2026

Quality Assurance of Legacy Post-Irradiation Examination Data for Metallic Fuels

The U.S. DOE-NE’s Advanced Reactor Technologies (ART) Fast Reactor Program (FRP) and the NE-4 Advanced Fuels Campaign (AFC) have jointly undertaken the qualification of the legacy post-irradiation examination (PIE) data held in the Fuels Irradiation & Physics Database (FIPD), covering metallic fuel experiments conducted in the Experimental Breeder Reactor II (EBR-II) and the Fast Flux Test Facility (FFTF). In FY26 this effort reached a milestone: six major types of PIE data—contact profilometry, isotopic gamma scan, fission gas chemistry, fission gas release, laser profilometry, and neutron radiography—have been qualified for all available experiments in FIPD, and the U.S. nuclear industry can now draw on them with confidence in licensing activities for metallic fuel-based advanced fast reactors. This report documents the qualification process and the resulting status of the PIE data.

Mo, Kun↗
DOE OSTI2025

IER 516 - Zirconium Test Assembly (ZTA) Preliminary Experimental Design [Slides]

Zirconium present in large quantities in criticality safety applications such as fuel manufacturing and processing facilities, and in commercial thermal nuclear reactors. ICSBEP lacks benchmarks optimized for zirconium sensitivity to validate zirconium evaluations. Evaluators lack isotopic differential nuclear data in regions of high importance to fission systems.

K-PSO 2.0↗
DOE OSTI2023

Scale-up Testing of Advanced Polaris Membrane in CO2 Capture Technology

This final technical report describes work conducted by Membrane Technology and Research, Inc. (MTR) for the U.S. Department of Energy (DOE), National Energy Technology Lab (NETL) on the scale-up and testing of advanced Polaris™ membrane CO2 capture technology at the Technology Centre Mongstad (TCM) under award number DE-FE0031591. The work was performed from August 1, 2018 through January 31, 2023. The overall goal of this project was to design, build and operate an advanced Polaris membrane CO2 capture system at TCM. MTR was assisted in this project by Trimeric Corporation (Trimeric), an engineering design services company, the Carbon Capture Simulation for Industry Impact (CCSI2), a partnership among national laboratories, industry, and academic institutions, and the Technology Centre Mongstad (TCM), who provided the host site for the slipstream field test. This report details the work conducted to scale-up MTR’s second-generation (Gen-2) Polaris membrane and advanced planar membrane modules to a final form factor optimized for commercial use; validate their performance in an engineering-scale field test at TCM; and to show the potential of the MTR process to meet DOE CO2 capture targets from large source point emitters. Work for this project included membrane optimization and scale-up, advanced planar module design and fabrication, design and fabrication of an engineering-scale field test membrane skid, operation of the field test skid processing Residue Fluid Catalytic Cracker (RFCC) industrial flue gas at TCM, and a detailed techno-economic analysis (TEA) of the MTR membrane post-combustion process for CO2 capture. This project validated recent membrane technology advancements at the engineering-scale, moves the MTR advanced post-combustion capture technology to TRL-6, and mitigates risk in future Large Pilot or Demonstration scale-up activities.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2020

Verification and Validation of the STAT7 Code

This document presents the verification and validation of the STAT7 Version 1.0 code which has been developed to perform the steady-state thermal hydraulic safety calculation of the MIT Research Reactor required upon conversion of the reactor from high enrichment uranium fuel to low enrichment uranium fuel. The key capabilites of the code including the statistical processing, water property generation, and thermal hydraulic solution are verified independently. While the first two capabilites are checked using statistical tests and NIST data tables, each component of the thermal hydraulic solution is verified using simple geometry test problems. The comparison between results obtained by the code and hand calculations on these problems shows that each of these components work correctly. Additionally, a comprehensive comparison between STAT7 Version 1.0 and PLTEMP/ANL Version 4.2 calculations for a five-channel test problem is performed for the validation. The good agreement between the obtained results for all thermal hydraulic parameters belonging to the fuel core region is achieved. An issue in bypass flowrate calculation was detected when both fin-friction and bypass flow claculations are involved. This problem can be corrected in a later version of the code, however, does not affect the application of STAT7 code as it has been used to date where the flow distribution in the core region and bypass channel is specified as an input parameter.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2020

Verification and Validation of the STAT7 Code

This document presents the verification and validation of the STAT7 Version 1.0 code which has been developed to perform the steady-state thermal hydraulic safety calculation of the MIT Research Reactor required upon conversion of the reactor from highly enriched uranium fuel to low- enriched uranium fuel. The key capabilities of the code including the statistical processing, water property generation, and thermal hydraulic solution are verified independently. While the first two capabilities are checked using statistical tests and NIST data tables, each component of the thermal hydraulic solution is verified using simple geometry test problems. The comparison between results obtained by the code and hand calculations on these problems shows that each of these components work correctly. Additionally, a comprehensive comparison between STAT7 Version 1.0 and PLTEMP/ANL Version 4.2 calculations for a five-channel test problem is performed for the validation. The good agreement between the obtained results for all thermal hydraulic parameters belonging to the fuel core region is achieved. An issue in bypass flowrate calculation was detected when both fin-friction and bypass flow calculations are involved. This problem can be corrected in a later version of the code. However, it does not affect the application of STAT7 as it has been used to date where the flow distribution in the core region and bypass channel is specified as an input parameter.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2024

A knowledge gap analysis for transient CHF prediction within RELAP5-3D

Here we compare several experimental pool and flow boiling critical heat flux experiments with corresponding computational models developed with RELAP5-3D. Encompassed within this paper are several sensitivity analyses for the boiling heat transfer correlations, critical heat flux (CHF) prediction within RELAP5-3D and the thermal properties of the cladding for experiments in the Transient Reactor Test Loop (TRTL) and Transient Reactor Test (TREAT) facilities. The sensitivity analyses were consistent in determining that there is a large contribution from the critical heat flux multiplier which in this application, accounts for the effects of power transient critical heat flux. Comparison to experimental results of both the TREAT CHF-SERTTA experimental campaign and a University of New Mexico (UNM) pool boiling experimental campaign demonstrate both the under-prediction of transient CHF and nucleate boiling heat transfer. To address the gaps in knowledge regarding the transient heating effect for both boiling heat transfer and CHF prediction, we present an experimental test matrix for the TRTL facility that will isolate the power transient effect under PWR relevant operational conditions. The test matrix will incorporate 6 power pulses with a constant energy deposition and a timescale that spans over several orders of magnitude, including a steady state test with an exponential period of 10 s.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Active and Stable PtPd Diesel Oxidation Catalysts under Industry‐Defined Test Protocols

Nanoparticle-supported Pt and Pd catalysts are employed industrially to convert CO and hydrocarbon residue from incomplete diesel fuel combustion into more environmentally-benign products. However, these catalysts deactivate over time due to sintering, especially for Pt nanoparticles which readily generate volatile species under high operating temperatures. Here, we turned the detrimental vapor-mediated sintering of Pt into an advantage by using a physical mixture of Pt and Pd catalysts prepared using a raspberry-colloid-templating (RCT) method. The RCT method produced Pt/Al 2 O 3 and Pd/Al 2 O 3 catalysts with partially embedded NPs to inhibit surface-mediated sintering pathways. As validated using an industry-defined emission control test protocol, aging a physical mixture of Pt/Al 2 O 3 and Pd/Al 2 O 3 at high temperature produced an alloyed PtPd/Al 2 O 3 catalyst that outperformed the fresh catalyst mixture and both individual catalysts for hydrocarbon conversion, while exhibiting high catalytic stability and resistance to sintering and to SO 2 poisoning. X-ray photoelectron spectroscopy revealed that in the aged catalyst mixture, half of the Pd content existed in the more active metallic state, compared to the less active oxide forms in the fresh mixture and both individual catalysts, explaining the unusual activity enhancement. Our results represent a practical approach to producing active and stable PtPd/Al 2 O 3 diesel oxidation catalysts for emission control applications.

Lim, Kang Rui Garrick [Harvard University, Cambrid↗
DOE OSTI2024

Description of FY25 Theory and Simulation Performance Target: Development of an integrated modeling framework for fusion reactor design and assessment

The urgency to deliver fusion power is growing now more than ever, with increasing pressure for both public programs and private companies to meet milestones timelines and overcome significant remaining technical challenges to ensure growth of a nascent fusion industry in time to meet rapidly growing clean energy demands. With incredible advancements in computation and years of investment in fusion model development and validation, integrated modeling is poised to fill a key role in accelerating the timeline to a fusion pilot plant (FPP). Future fusion pilot plants will operate in regimes far beyond current experience, and device design will rely on physics-based prediction and extrapolation. Many concepts will also rely on simulation to assess safety (shielding, tritium management, materials activation and lifetimes), economics and scalability before the decision to build. Importantly, integrated simulation can be used to reveal and solve the complexities of system integration that may otherwise not be apparent in physical components or models developed in isolation. New experimental test facilities that produce relevant conditions to validate and resolve key technical challenges for various subsystems (materials, blankets, fuel cycle, etc.) have been repeatedly called for by the fusion community but are not yet realized. Integrated modeling has an important role in identifying realistic load conditions (thermal, electromagnetic, plasma, neutron and photon loads, etc.) and defining the components and experiments for these test facilities in order to ensure meaningful validation that sufficiently reduces modeling uncertainties and technical risk for the full integrated reactor. The Fusion REactor Design and Assessment (FREDA) SciDAC project is building a component-based integrated modeling framework & data structure to enable self-consistent, multi-fidelity, iterative optimization workflows for the fusion reactor design process. FREDA aims to shorten the time to viable designs by providing a set of flexible workflows to support the various stages of the design process using an integrated model hierarchy, ranging from the simple analytic descriptions to the highest fidelity, theory-based plasma and engineering modeling developed by the fusion and fission communities. These tools are expected to be needed for timely support of FPP design in the milestone program and in the FIRE collaboratives. The plasma simulation backbone of FREDA is IPS-FASTRAN with newly developed coupled Core-Edge Pedestal-SOL (CESOL) workflows, which is being extended to the far-SOL region up to the plasma facing components. FREDA incorporates the FERMI engineering modeling suite and will enable self-consistent evaluation of the thermal shields, limiters, blanket, magnets, and other surrounding structures with predictions of temperatures, erosion, dpa, activation, tritium generation and transport, creep, corrosion, material degradation, etc. Parametric generation of 3D CAD enables rapid iteration of component geometry in response to plasma and loading specifications.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Micro-Tensile Properties of Irradiated AGR-2 TRISO Fuel Pyrolytic Carbon (PyC) and Silicon Carbide (SiC) Coatings

Tristructural isotropic (TRISO) coated nuclear fuel particles are emerging as a versatile option for new reactor designs, with the silicon carbide (SiC) layer crucial for retaining fission products. However, the mechanical properties of TRISO coating layers, particularly after irradiation, are not fully understood due to their small size and high radioactivity. Recent in situ micro-tensile testing of various TRISO layers aims to better understand the SiC layer's failure mechanisms, advancing TRISO fuel qualification. These micro-tensile results will be presented.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

Sensors for measuring thermal conductivity and related methods

A sensor for measuring thermal conductivity includes an insulator, a test material over the insulator, a conductor over the test material, and a gas within an open volume adjacent the test material and the conductor. An electrical source is configured to provide an alternating current through the conductor to heat the test material. Leads are connected to the conductor and configured to connect to a voltmeter. A method of measuring thermal conductivity includes disposing the sensor in a reactor core in which a nuclear fuel undergoes irradiation and radioactive decay. An alternating current is provided from the electrical source through the conductor to heat the test material. A voltage is measured as a function of time at the leads connected to the conductor. A thermal conductivity of the test material is calculated based on the voltage measured as a function of time. Methods of forming a sensor are also disclosed.

Daw, Joshua↗
DOE OSTI2023

Uncertainty analysis for techno-economic and life-cycle assessment of wet waste hydrothermal liquefaction with centralized upgrading to produce fuel blendstocks

Wet waste hydrothermal liquefaction is a promising technology for producing transportation fuels with much lower greenhouse gases emissions than petroleum-based fuels. However, its techno-economic and life cycle assessment are primarily based on laboratory scale testing data, subject to considerable uncertainties, and even bias, due to knowledge gaps. Here, a preliminary uncertainty analysis of key economic measures was conducted based on the 2019 state-of-technology model for biocrude production. Building on the preliminary analysis, this work presents a comprehensive uncertainty analysis in both economic and environmental measures of the entire supply chain of wet waste hydrothermal liquefaction to fuel blendstocks including biocrude upgrading based on the 2021 state-of-technology model. The analysis includes the most recent developments in hydrothermal liquefaction and biocrude upgrading technologies and Monte Carlo simulation based on an integrated model system including an improved reactor yield model, reduced-order process model, discounted cash flow economic model and simplified life-cycle assessment model. The estimated biocrude yield ranges from 42.2% to 52.4% with a median of 47.3%. The estimated fuel yield ranges from 34.7% to 42.7% with a median of 38.7%. The estimated minimum fuel selling price ranges from $\$ $2.28/gge to $\$ $3.45/gge with a median of $\$ $2.80/gge. Relative to petroleum-derived diesel, the estimated reduction in supply chain greenhouse gas emissions ranges from 73.4% to 81.8% with a median of 77.7%. Compared to the 2019 state-of-technology analysis, a significant improvement in biocrude selectivity and economic measures and reduction in uncertainties were achieved due to the incorporation of additional continuous experimental data sets, technology development and de-risking, and improvement in model accuracy.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Full Length Assembly Testing in PELICAN (Final Report)

In support of the development of the U.S. Department of Energy (DOE) Versatile Test Reactor (VTR), a thermal hydraulics test facility was constructed to generate experimental measurement of the pressure drop across a single full-scale assembly containing prototypic axial reflectors, fuel, and plena components. Constructed and operated at Argonne National Laboratory, the Pressure drop Experimental Loop for Investigations of Core Assemblies in Nuclear reactors (PELICAN) facility was designed to achieve hydraulic conditions identical to those anticipated for a full-scale fuel assembly located in the VTR core in the region with the highest flow rate. Using water as surrogate for liquid sodium, the flow loop was operated at elevated temperatures and pressures to match the thermophysical properties of liquid sodium and ensure matching Reynolds and Euler numbers. The measurement objectives for data generated from this test facility was driven primarily by the validation needs for code calculations and simulations of the reference VTR core. These objectives focused on the need to validate pressure drop results across the various segments of the fuel assembly as they relate directly to the pumping power and safety of the reactor. Presented in this report are experimental results and analytical comparisons based on testing of a full-length assembly in PELICAN. Housed within a hexagonal test section extending 3.4 m in length, the tested assembly features a prototypic lower reflector, grid plates, wire-wrapped rod bundle, upper reflector, and exit region. The rod bundle extends over 1.5 m in length and contains 217 individual wire-wrapped rods with dimensions that best reflect the reference VTR design. The as-tested bundle assembly was fabricated using 316 stainless steel 0.25-inch (6.35-mm) diameter rods wrapped with 0.04-inch (1.016-mm) diameter wire at a helical pitch of 10.51 inch (26.6 cm). Details of the method for in-house wire-wrapping, assembly, and installation are provided later in this report. Experimental measurements of pressure drop at 19 positions along the test assembly were recorded for a range of flow conditions, with special attention paid to key locations within the assembly, including component inlet and outlet, transition, and wire-wrapped rod bundle regions. Testing conditions were based on 110°C water with flow rates ranging from 50 to 450 GPM (3 to 27 kg/s) at the inlet of the test assembly generating Reynolds numbers and velocities up to ~8.0×10 4 and ~7.8 m/s, respectively, within the rod bundle region. Non-dimensional values for the friction factor were then calculated based on these experimental measurements and compared against those predicted by various analytical correlations available from open literature. Predictions by the upgraded Cheng and Todreas, Rehme, and Novendstern correlations fell within 4% to those values measured experimentally.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Dual Mode Intermediate Temperature Fuel Cell: Liquid Fuels and Electricity - CRADA 351 (Abstract)

FuelCell Energy, Inc. (FCE) in collaboration with Pacific Northwest National Laboratory (PNNL), The University of Connecticut (UCONN), The Energy and Environmental Research Center at The University of North Dakota (EERC-UND), and Massachusetts Institute of Technology (MIT), has entered into a co-operative agreement with the U.S. Department of Energy Advanced Research Project Agency – Energy (ARPA-E), agreement number DE-AR0000503, to develop an electrochemical device for conversion of methane gas to a usable liquid product, such as methanol or formaldehyde. The objective of this CRADA is to develop the anode electro-catalyst for the aforementioned electrochemical cell during Q1-Q8. PNNL will utilize thermodynamic modeling, batch-mode reactor screening and button-scale electrochemical testing to develop this anode."

09 BIOMASS FUELS↗
DOE OSTI2021

Exploring the structural uniformity and integrity of protonic ceramic thin film electrolyte using wet powder spraying

Thin protonic ceramic electrolyte contributes to lower ohmic resistance and enhances electrochemical performance of protonic ceramic electrochemical cells. However, manufacturing of large-scale thin electrolyte remains a challenge. Wet powder spraying is an attractive technique to deposit <10 µm thin electrolyte when advanced atomizing techniques and optimized spraying process are integrated. Here ultrasonic atomization is integrated in the wet powder spray technique to reduce the thickness of electrolyte. Moreover, a parametric study is conducted to optimize the wet powder spray process to deposit uniform and crack-free electrolyte film. It is illustrated that tuning of solid loading rates and spray passes can affect the morphology of the as-sprayed electrolyte film, enabling the structural compactness of the sintered electrolyte layer. To maintain chemical stability of the electrolyte layer during sintering, effect of sintering temperature is further investigated to produce a physically thin, structurally dense, and chemically homogeneous electrolyte layer. The protonic ceramic electrochemical cells fabricated with optimized spraying and sintering parameters demonstrate excellent performance under both fuel cell and electrolysis modes. In addition, the cells exhibit remarkable structural integrity during redox and long-term stability tests.

36 MATERIALS SCIENCE↗