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All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Understanding Subsidies to Achieve Diesel Powertrain Financial Parity for Heavy-Duty Fuel Cell Electric Vehicles

The development of a long-term sustainable hydrogen energy economy for commercial vehicle transportation will need to overcome key critical technical and logistics considerations in the near term. As compared to zero-emission powertrains, fossil-fuel-based powertrains provide mission flexibility and high uptime at a comparatively low total cost of ownership (TCO). While the incumbent carbon-intensive powertrains suffer from poor efficiency and are not sustainable to support global climate change initiatives in transportation decarbonization, techno-economic challenges continue to create complex barriers to the large-scale displacement of these with highly electrified powertrains architectures. Here, this article specifically addresses opportunities that well-targeted subsidies would afford in achieving fuel cell electric powertrain financial parity with diesel powertrains in heavy-duty trucks (HDTs). It shows that a rigorous assessment of system TCO factors will be critical in designing a viable subsidy strategy. Based on powertrain component and fuel price points, subsidy variations (for both capital expenses and operating fuel expenses) are assessed and quantified to determine where and how much subsidies should be leveraged to accelerate achieving diesel system financial parity. It shows that subsidies on hydrogen fuel expenses (and associated constituents) will play an important role in achieving this goal while subsidies on capital expenses (the more typical subsidy formulation) may not always be the preferred subsidy strategy. The results provide subsidy agencies with clear guidance and a database approach to characterize and implement viable HDT hydrogen powertrain system subsidy strategies. The approach may be readily tailored for other applications and system architectures.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2018

Developing Design Criteria for Safeguards Seals for Spent Fuel Transportation Casks

Current designs for spent fuel transportation casks cannot ensure a cask's integrity during shipment, nor is there any verifiable means of maintaining continuity of knowledge (CoK) on a cask's contents. Spent fuel destined for encapsulation plants or geological repositories requires additional containment and surveillance (C/S) measures during shipment. Following final safeguards accountancy measurements on spent fuel assemblies, the shipment of verified assemblies will require unprecedented reliance on maintaining CoK on the fuel inside transport casks. Such increased reliance is due to the lack of reverification of spent fuel following encapsulation into disposal canisters and by meeting the requirement of dual C/S measures during such fuel shipments according to recommendations made by the Application of Safeguards to Geological Repositories (ASTOR) International Atomic Energy Agency (IAEA) expert group. By designing spent fuel transportation casks with effective seals integrated into their design, CoK can be more effectively maintained than by ad hoc C/S measures because seal integration ensures that a cask has not been tampered with. Externally applied seals might not be able to provide such assurance for currently designed spent fuel transportation casks, although some combination of seals, detectors, and/or a technology that can verify canister integrity might provide this assurance. This paper examines the design criteria for integrating safeguards seals into transportation casks and provides recommendations for near-term applications.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Flowsheet Development for the University of Tokyo YAYOI (UTY) Fuel

The Savannah River National Laboratory (SRNL) was requested by H-Canyon Engineering to determine the flowsheet parameters needed to dissolve and store the YAYOI Material Test Reactor (MTR) uranium fuel safely and efficiently. In response to this request, a literature review of existing SRNL MTR dissolution flowsheets and general fuel dissolution literature in the nuclear fuel processing industry was performed to evaluate chemical dissolution parameters required to dissolve the YAYOI fuel and the tin-plated carbon steel product cans (PC). Based on past dissolutions of similar fuel in the H-Canyon and open literature reviews on chemical dissolution of spent nuclear fuel (SNF), the following conclusions and flowsheet recommendations were made.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Diversion Path Analysis: A Proposed Methodology to Develop an MC&A Approach for Liquid-Fueled Molten Salt Reactors

Nuclear material control and accounting (MC&A) is a critical element of both the US Nuclear Regulatory Commission (NRC) and US Department of Energy (DOE)’s domestic safeguards and security requirements. NRC licensees are required, under Title 10 of the Code of Federal Regulations (10 CFR) Part 74 to establish and maintain an MC&A program that captures and records the quantities and locations of special nuclear material (SNM) at the facility. Along with physical protection, MC&A is a key element of domestic nuclear material safeguards that enables the NRC to ensure that SNM is controlled and accounted for. SNM, per 10 CFR Part 74, refers to plutonium, 233 U, and uranium enriched in the isotope 233 U or 235 U, but does not include source material. Periodic physical inventories, coupled with material balance evaluations, are effective and demonstrated tools to account for and detect theft or diversion of SNM in facilities containing SNM in bulk material form (i.e., not in discrete, countable items). Historically in the United States, these types of facilities have included fuel fabrication, conversion, and enrichment facilities. In comparison, reactors have relied on item counting of assemblies and control of SNM while in containment (e.g., a sealed reactor pressure vessel) because, to date, reactor fuel has been in item form. In liquid-fueled molten salt reactors (MSRs), unlike traditional light water reactors (LWRs) or bulk facilities, bulk SNM quantities can change significantly during operation as a result of depletion and transmutation. This introduces challenges to the use of traditional periodic physical inventories and material balance evaluations to detect theft or diversion of SNM in reactors that use SNM in bulk material form. Liquid-fueled (i.e., salt-fueled) MSR facilities are MSRs that use SNM within a salt eutectic as the fuel. The SNM is in a bulk material form any time it is outside of fresh or spent fuel storage containers. Some examples of when SNM will be in bulk form in the facility are during addition of fuel to the reactor system, while fuel is circulating in operation, and while fuel is in a drain tank. Periodic physical inventories and material balance evaluations can likely be effectively applied to many portions of an MSR facility, including all areas where depletion and transmutation are not significantly changing the quantities of SNM within the control area. Within an MSR facility, this would include fresh fuel receipt and loading, waste streams that may contain SNM, irradiated fuel storage outside of the reactor core, and any irradiated fuel processing that may happen after SNM has been removed from the reactor. All of these process steps could rely on measurements of SNM quantities compared with documented inventories. Any discrepancies from predicted (i.e., book) inventories and measured inventories could be quantified as inventory differences, consistent with traditional MC&A guidance from the NRC (e.g., in NUREG-1065 Revision 2, NUREG-2159 Revision 1, and RG 5.29 Revision 2). Within the reactor system, additions and removals to the book inventory include depletion of the SNM (e.g., fission of 235 U), which complicates the use of physical inventories. SNM control, however, can also likely be effectively applied to detect theft of SNM throughout a liquid-fueled MSR facility. To complement these approaches, prior technical reports have identified that a diversion path analysis may be a useful, risk-informed, and performance-based tool to determine suitable elements of an MC&A approach for the reactor system within a liquid-fueled MSR facility.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2018

Subtask 1.3 – Integrated Carbon Capture and Storage for North Dakota Ethanol Production

Presentation for Mastering the Subsurface Through Technology Innovation, Partnerships and Collaboration: Carbon Storage and Oil and Natural Gas Technologies Review Meeting, Pittsburgh, Pennsylvania, August 13–16, 2018. The goal of this project is to implement a small‑scale (<200,000 metric tons of CO₂ per year) commercial carbon capture and storage (CCS) system at an industrial fuel production facility to produce reduced‑carbon ethanol eligible for low‑carbon fuel programs. Objectives include developing a framework for CCS deployment at small facilities, evaluating the full carbon life cycle of fuel production with CCS, and assessing the viability of CCS pathways for meeting Low Carbon Fuel Standard (LCFS) requirements. The project also seeks to validate the Broom Creek Formation, an aeolian reservoir, as a viable regional geologic storage target for CO 2 .

09 BIOMASS FUELS↗
DOE OSTI2025

Development of Powder Production Methods for Advanced LEU Fuel Concepts

A set of novel fuel concepts has been proposed for use in advanced low-enriched uranium (LEU) systems that utilize powder metallurgical methods for fabrication of the fuel forms. Preliminary tests demonstrated the ability to produce powder but did not yield the desired quality to be used as feedstock in these applications. This study seeks to establish an improved powder production method for uranium-based alloys and evaluate the parameters required to refine the particles produced by size and morphology. Powder samples were fabricated via atomization and analyzed for particle morphology utilizing sieving methods and scanning electron microscopy (SEM). Surrogate testing displayed improved performance in producing small (<250 µm) spherical particles, and initial tests demonstrated the initial capability to atomize uranium. Further work is required to refine the atomization process to produce high quality uranium microspheres.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS1971

Development of a full-length external-fuel thermionic converter for in-pile testing.

Description of an external-fuel thermionic converter which utilizes a thoriated-tungsten fuel-emitter body. Performance in out-of-pile tests was comparable to that of an arc-cast tungsten emitter body, with 400-eW output power (about 5 W/sq cm) at 10.8% efficiency. Maximum fuel clad temperature averaged from 1650 to 1700 C during the 300-hour test. This converter has been processed for in-pile testing. The various processing steps, including the installation of six emitter thermocouples, encapsulation in the secondary container, and joining to the fission-gas collection system, are described in detail. In addition to the converter assembly, a doubly contained fission gas collection assembly with radiation-hardened differential pressure transducers was fabricated. The experiment support plate required for the in-pile test, containing electrically insulated instrumentation feedthroughs and coolant line feedthroughs to the vacuum test chamber, was also fabricated.

Schock, A.↗
NASA NTRS1980

Development and test results of a flight management algorithm for fuel conservative descents in a time-based metered traffic environment

A simple flight management descent algorithm designed to improve the accuracy of delivering an airplane in a fuel-conservative manner to a metering fix at a time designated by air traffic control was developed and flight tested. This algorithm provides a three dimensional path with terminal area time constraints (four dimensional) for an airplane to make an idle thrust, clean configured (landing gear up, flaps zero, and speed brakes retracted) descent to arrive at the metering fix at a predetermined time, altitude, and airspeed. The descent path was calculated for a constant Mach/airspeed schedule from linear approximations of airplane performance with considerations given for gross weight, wind, and nonstandard pressure and temperature effects. The flight management descent algorithm is described. The results of the flight tests flown with the Terminal Configured Vehicle airplane are presented.

Knox, C. E.↗
DOE OSTI2023

THE POTENTIAL FOR REUSE OF PRODUCED WATER IN THE CRITICAL MINERALS SUPPLY CHAIN IN THE POWDER RIVER BASIN OF WYOMING AND MONTANA

The Powder River Basin (PRB) Carbon Ore, Rare Earth, and Critical Minerals (CORE-CM) project is part of the Department of Energy sponsored CORE-CM initiative focused on domestic production of critical minerals and promoting economic development in traditionally fossil fuel producing basins. An important part of this project is regional assessment of waste streams and development of basinal strategies for waste stream reuse within the critical minerals (CM) supply chain. The availability of water for all parts of the CM supply chain is of particular concern in the arid mountain west. In the Wyoming PRB, average annual production of produced water (PW) by the oil and gas industry is more than 16 billion gallons (2015-2022). Through published data and engagement with industry partners, we conducted a preliminary investigation of PW in the PRB to understand volumes, quality, and the potential for use in the CM supply chain. PW was assessed for potential as a direct feedstock and for use in CM processing of a variety of conventional and unconventional feedstocks, including ore from the Bear Lodge Alkaline Complex, coal, and coal byproducts. Preliminary findings suggest that PRB PW contains significantly lower concentrations of rare earth elements (REE) and lithium than would be considered economic at this time. For example, concentrations of REE+Sc measured in PRB PW are <1 ppb (DE-EE0007603), and only seven PRB PW samples reported in the USGS PW database had lithium concentrations ≥50 ppm. However, enrichment of CM in residual brine and sludge from PW evaporation and solidification treatment ponds may yield concentrations of interest over a pond lifetime and should be considered in future studies. Coal bed methane (CBM) PW accounted for 42% of all PW in the Wyoming PRB in 2022. Compared to non-CBM PW, PRB CBM water quality generally meets standards allowing surface discharge and reuse in local industries such as livestock. CBM PW may help to fill water needs within the CM supply chain. Understanding the distribution of CBM PW that is discharged versus reused will help develop basinal reuse strategies.

Jackson, Lily↗
NASA NTRS2026

Mathematical Model of a Regenerative Fuel Cell for System Optimization

This thesis developed a system-level optimization model of a regenerative fuel cell (RFC) system for long-duration, off-world energy storage applications. Prior RFC design studies have typically been limited to reduced parameter sets and simplified constraints due to computational limitations relative to the number of relevant degrees of freedom. As a result, important nonlinear interactions between subsystems have not been fully captured. This work began to address that gap by developing a higher-fidelity, nonlinear optimization framework that incorporates a broader set of design variables and coupled constraints, enabling a multidimensional model that captures the coupled behavior of RFC subsystems and demonstrates the feasibility of applying optimization to such systems. An expanded system-level optimization approach was established that captures interactions between electrochemical performance, structural requirements, and storage design. This enabled a more comprehensive evaluation of trade-offs than conventional formulations. The model integrates four coupled subsystems: a fuel cell, an electrolyzer, reactant gas, and high-pressure storage tanks, and was formulated to accommodate a wide range of mission parameters, including operational time and required output power. It incorporates constraints on available solar array power, reactant mass balance between production and consumption, and pressure-dependent storage requirements. To enable reliable convergence, the optimization problem was reformulated to reduce dimensionality and improve numerical stability, with subsystem models organized for efficient evaluation. Problem dimensionality was reduced by consolidating lower-level design variables into higher-level representative quantities, and subsystem behavior was evaluated within the optimization loop. A multi-start initialization strategy was employed to mitigate sensitivity to local minima and improve solution quality, while nonlinear relationships were solved using robust numerical methods. The results showed that convergence was achieved across a range of required output power values. Specific energy reached a maximum at a critical mission power level, where the electrolyzer power matched the available solar input and operated near its voltage and current density limits. Beyond this point, further increases in required power resulted in less mass-efficient operation, increasing total system mass and reducing overall performance. The developed model represents an advancement in RFC system-level optimization by enabling analysis of a broader and more tightly coupled design space than previous considerations. While convergence behavior and computational cost remain challenges, the methods introduced improve solvability and allow inclusion of additional design variables with minimal loss of physical fidelity. However, the numerical results should not be interpreted as definitive design recommendations, as the model includes simplifying assumptions and omits several higher-order effects. Future work should extend this framework by incorporating additional subsystems and loss mechanisms, such as thermal management, parasitic power consumption, and reactant losses, to improve fidelity and ensure more representative design conclusions.

Electrochemistry↗
DOE OSTI2017

Reliable SOFC Systems

The goal of this U.S. Department of Energy (DOE) sponsored project was to advance the reliability, robustness and endurance of low-cost SOFC technology suitable for ultimate deployment in ≥100 MWe Integrated Gasification Fuel Cell (IGFC) or Natural Gas Fuel Cell (NGFC) systems capable of ≥97% CO2 capture. The ultimate SOFC program goals are ≤ 0.2% per 1000 hours power degradation over a 5-plus year stack life, high-volume (≥ 250 MW/year) stack production cost of ≤$225/kWsystem net AC, and “power block” (exclusive of fuel supply, contaminant removal, and CO2 capture subsystems) capital cost of ≤ 900/kWsystem net AC (in year 2011). To progress towards the ultimate program goals, the specific objectives of this project were to achieve an SOFC stack power degradation rate of ≤1.5% per 1000 hours in a 100 kW (125 kW Peak) Modular Power Block (MPB) stand-alone power system under thermally self-sustained normal operating conditions and to verify the prospects for high volume SOFC stack production cost below the DOE target of ≤ 225/kW. This final technical report summarizes the progress made during the project period of 36 months. Significant progress was made in the areas of cell and stack technology development, Modular Power Block (MPB) development, sub-MW MPB system development, and MW-class SOFC System Development and Costing. The work focused on areas necessary for comprehensive development of an SOFC fuel cell system, including, active cell improvement, contaminant resistance, process engineering, and development of non-repeat module components. Additionally, several custom built balance-of-plant components were designed and fabricated to support the fuel cell system. SOFC cell and stack development focused on improving cell performance and durability. Enhancements were achieved in areas of electrode stability and impurity tolerance. Additionally, several quality control techniques and tools were developed to ensure predictable and repeatable fabrication of SOFC stacks. Module development continued previous development efforts to achieve footprint reduction and higher efficiency by incorporating balance-of-plant functional equipment into the fuel cell containment module. Several improvements were made to prior design. Control and instrumentation hardware was integrated within the module for serviceability and size reduction. The design efforts culminated in a complete SOFC power plant system. The designed plant was constructed and tested at FCE. Stack and system costs were updated, reflecting advances made in this program.

20 FOSSIL-FUELED POWER PLANTS↗
NASA NTRS2004

Evaporator Development for an Evaporative Heat Pipe System

As fossil fuel resources continue to deplete, research for alternate power sources continues to develop. One of these alternate technologies is fuel cells. They are a practical fuel source able to provide significant amounts of power for applications from laptops to automobiles and their only byproduct is water. However, although this technology is over a century old and NASA has been working with it since the early 1960 s there is still room for improvement. The research I am involved in at NASA's Glenn Research Center is focusing on what is called a regenerative fuel cell system. The unique characteristic of this type of system is that it used an outside power source to create electrolysis of the water it produces and it then reuses the hydrogen and oxygen to continue producing power. The advantage of this type of system is that, for example, on space missions it can use solar power to recharge its gas supplies between periods when the object being orbited blocks out the sun. This particular system however is far from completion. This is because of the many components that are required to make up a fuel cell that need to be tested individually. The specific part of the system that is being worked on this summer of 2004 is the cooling system. The fuel cell stack, that is the part that actually creates the power, also produces a lot of heat. When not properly cooled, it has been known to cause fires which, needless to say are not conducive to the type of power that is trying to be created. In order to cool the fuel cell stack in this system we are developing a heat pipe cooling system. One of the main components of a heat pipe cooling system is what is known as the evaporator, and that is what happens to be the part of the system we are developing this summer. In most heat pipe systems the evaporator is a tube in which the working fluid is cooled and then re-circulated through the system to absorb more heat energy from the fuel cell stack. For this system, instead of a tube, the evaporator is made up of a stack-up of screen material and absorbent membranes inside a stainless steel shell and held together by a film adhesive and epoxy. There is an initial design for this flat plate evaporator, however is has not yet been made. The components of the stack-up are known, so all testing is focused on how it will all go together. This includes finding an appropriate epoxy to make the evaporator conductive all the way through and finding a way to hold the required tight tolerances as the stainless steel outer shell is put together. By doing the tests on smaller samples of the stack-ups and then testing the fill size component, the final flat plate evaporator will reach its final design so that research can continue on other parts of the regenerative fue1 cell system, and another step in the improvement of fue1 cell technology can be made.

Peters, Leigh C.↗