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DOE OSTI2021

Economic solution for low carbon process heat: A horizontal, compact high temperature gas reactor

In 2018, nuclear energy generated 55% of United States’ and one third of the world’s carbon free electricity, making nuclear energy a key tool in efforts to mitigate climate change before 2050. However, the current nuclear technology, light water reactors (LWRs), is limited to 300°C, so it cannot be used to decarbonize industrial process heat which accounts for 12% of US greenhouse gas emissions. High temperature gas reactors (HTGRs) can meet the high temperature demand with carbon free nuclear heat. The estimated cost of HTGRs, such as the Next Generation Nuclear Plant (NGNP), are even higher than state-of-the-art LWRs. In this paper, we expanded our nuclear cost estimating tool to include HTGRs and find that the NGNP overnight capital costs were 32% higher than an advanced LWR per unit capacity. The higher cost will naturally result in larger risk to cost overrun as recently experienced by larger LWRs in western nations. With a design-to-build mindset to minimize cost and construction risk, we introduce the horizontal, compact HTGR (HC-HTGR). The reactor core and steam generator are mounted horizontally on rails and in-line with one another, decreasing the size of the reactor building relative to the power capacity four times when compared to traditional HTGRs. The HC-HTGR reduced overnight civil structure costs by 42%, indirect costs by 38%, and total capital costs by 20% from NGNP. We discussed the required engineering of new systems for the HC-HTGR including vessel supports, the reactor cavity cooling system, and steam generator design. Finally, we estimated the fuel and operations costs of the HC-HTGR, and a survey of low-carbon industrial process heat technology showed the HC-HTGR can deliver a highly competitive levelized cost of heat in the range of $6.13–12.48/GJ.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2024

The RAPTR furnace: a rapid heating and cooling sample furnace for in situ X-ray scattering studies of temperature-induced reactions

In situX-ray scattering provides valuable insights into the mechanisms and kinetics of reactions and structural transformations. For reactions and structural transformations primarily driven by temperature, and not coupled to chemical/electrochemical triggers, our ability to initiate and quench processes thermally is a practical limit for probing fast reactive phenomena. Meaningful quantitative analysis requires the dynamic phenomena to be triggered on fast time scales relative to the reaction/transformation kinetics. This article describes a new sample furnace, the Rapid-Actuating Pneumatic Thermal Reactor or RAPTR, for time-resolvedin situX-ray scattering studies initiated by temperature. The RAPTR quickly heats and cools samples by translating them into and out of a pre-heated hot zone. Using diffraction thermometry, it is shown that the samples can be heated/cooled in 10 s or less, with temperatures up to ∼1000°C being accessible. The application of the RAPTR furnace is demonstrated by exploring a fast solid-state reaction: the synthesis of scheelite-type lead tungstate, PbWO 4 , from PbO and WO 3 for which Pb 3 WO 6 is identified as a previously unrecognized reaction intermediate.

Chemistry↗

DOE OSTI2023

Process Variability Effects on Tensile Response in Injection Molded, Fluorinated Thermoplastics

The mechanical properties of fluorinated thermoplastics (i.e., tensile strength and elongation) can vary with changes in injection molding processing parameters. Four fluoropolymers are examined: poly(vinylidene fluoride) (PVDF) and random poly(vinylidene fluoride-co-chlorotrifluoroethylene) (PVDF-CTFE) with three CTFE concentrations. Dog bones were manufactured with various cylinder dwell times and mold cooling times to assess the manufacturing sensitivity to the tensile response. Dwell and cooling times increasingly impact mechanical performance as CTFE concentration increases. Specimens exhibit higher tensile strength as a function of injection order. The first injected specimen exhibits the lowest tensile strength and highest elongation in all copolymers. This trend becomes more pronounced among fluoropolymers with higher CTFE concentration and lower weight-averaged molecular weight. Parallel plate rheology was used to obtain the zero-shear viscosity as a function of material type, process, and injection order. We found that in the copolymers, the first injected sample exhibited a lower zero-shear viscosity than the next, which indicates a lower molecular weight in the first injected specimen. This phenomenon was not presented for the PVDF homopolymer. Copolymer mechanical uncertainties are hypothesized to result from the shorter molecular weight chains extruding out of the specimens' sides as a flash due to higher mobility with CTFE segments.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Evaluating the energy impact potential of energy efficiency measures for retrofit applications: A case study with U.S. medium office buildings

Quantifying the energy savings of various energy efficiency measures (EEMs) for an energy retrofit project often necessitates an energy audit and detailed whole building energy modeling to evaluate the EEMs; however, this is often cost-prohibitive for small and medium buildings. In order to provide a defined guideline for projects with assumed common baseline characteristics, this paper applies a sensitivity analysis method to evaluate the impact of individual EEMs and groups these into packages to produce deep energy savings for a sample prototype medium office building across 15 climate zones in the United States. We start with one baseline model for each climate zone and nine candidate EEMs with a range of efficiency levels for each EEM. Three energy performance indicators (EPIs) are defined, which are annual electricity use intensity, annual natural gas use intensity, and annual energy cost. Then, a Standard Regression Coefficient (SRC) sensitivity analysis method is applied to determine the sensitivity of each EEM with respect to the three EPIs, and the relative sensitivity of all EEMs are calculated to evaluate their energy impacts. For the selected range of efficiency levels, the results indicate that the EEMs with higher energy impacts (i.e., higher sensitivity) in most climate zones are high-performance windows, reduced interior lighting power, and reduced interior plug and process loads. However, the sensitivity of the EEMs also vary by climate zone and EPI; for example, improved opaque envelope insulation and efficiency of cooling and heating systems are found to have a high energy impact in cold and hot climates.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

Understanding solidification of near eutectic alloy using Cellular Automata (CA)

The solidification microstructure of an alloy strongly influences the mechanical properties. Dendritic and eutectic solidification are two important pathways of alloy solidification. The formation of phases, and their size and distribution depend on which pathway to take. In contrast to the Scheil model that has been widely used in describing the solidification pathways of alloys manufactured from conventional casting approach, more sophisticated solidification models are required to describe the state-of-the art manufacturing processes, such as additive manufacturing where distinctly different phase morphology, size and distribution than conventional casting can form, due to the vast difference in cooling conditions. Therefore, this work is to develop a computational Cellular Automata framework which includes the modeling of nucleation and growth of dendritic and eutectic solidification, as well as their competition as a function of alloy composition, undercooling and cooling rate. Further, after individual solidification models were validated against analytical solutions, the models were then combined to predict the competition between dendritic and eutectic solidification in alloys with off-eutectic compositions. This work predicts increased cooling rates suppress the dendritic solidification and promote eutectic solidification. Although quantitative validation is needed, this finding is consistent with qualitative observation in literature.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Assessing Low-Temperature Geothermal Play Types: Relevant Data and Play Fairway Analysis Methods

This data catalog contains information on low temperature geothermal play types. The U.S. Department of Energy (DOE) Geothermal Technologies Office (GTO) supports the Geothermal Heating and Cooling Geospatial Datasets and Analysis project, conducted by the National Renewable Energy Laboratory (NREL). This project is part of a broader effort to demonstrate the multifaceted value of integrating geothermal power and geothermal heating and cooling technologies into national decarbonization strategies and community energy plans. There is a need to establish baseline low-temperature geothermal resource data sets and evaluate methods for deploying these technologies. This project aims to reduce exploration risk of low temperature geothermal systems by collecting baseline datasets that can be used for Play Fairway Analysis methodologies. This data catalog contains links to publicly available datasets from different sources that can be relevant for the low temperature geothermal systems. This submission contains data catalogs for Alaska, Hawaii, and the Conterminous United States, as well as a technical report on the methods used to classify and asses the geothermal play types.

15 GEOTHERMAL ENERGY↗

DOE OSTI2023

Process Variability Effects on Tensile Response in Injection Molded, Fluorinated Thermoplastics

The mechanical properties of fluorinated thermoplastics (i.e., tensile strength and elongation) can vary with changes in injection molding processing parameters. Four fluoropolymers are examined: poly(vinylidene fluoride) (PVDF) and random poly(vinylidene fluoride-co-chlorotrifluoroethylene) (PVDF-CTFE) with three CTFE concentrations. Dog bones were manufactured with various cylinder dwell times and mold cooling times to assess the manufacturing sensitivity to the tensile response. Dwell and cooling times increasingly impact mechanical performance as CTFE concentration increases. Specimens exhibit higher tensile strength as a function of injection order. The first injected specimen exhibits the lowest tensile strength and highest elongation in all copolymers. This trend becomes more pronounced among fluoropolymers with higher CTFE concentration and lower weight-averaged molecular weight. Parallel plate rheology was used to obtain the zero-shear viscosity as a function of material type, process, and injection order. We found that in the copolymers, the first injected sample exhibited a lower zero-shear viscosity than the next, which indicates a lower molecular weight in the first injected specimen. This phenomenon was not present for the PVDF homopolymer. Copolymer mechanical uncertainties are hypothesized to result from the shorter molecular weight chains extruding out of the specimens’ sides as a flash due to higher mobility with CTFE segments.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Feasibility and strategic implications of deploying nuclear power reactors in Africa

This report assesses the feasibility and strategic implications of deploying nuclear power reactors, including large-scale plants, advanced small modular reactors (SMRs), and microreactors, in African countries. Case studies focus on South Africa, Egypt, Kenya, Ghana, and Nigeria, examining nuclear energy’s role in Africa’s rapidly evolving energy landscape, marked by fast-growing demand, significant electricity access gaps, increasing renewable penetration, and strong policy commitments to industrialization and energy security. Several U.S. reactor technologies and designs are considered based on their development status and readiness for deployment. The analysis finds that nuclear power can provide reliable, clean baseload and flexible generation, as well as high-temperature process heat for desalination, hydrogen production, and industrial applications. However, suitability is highly country-specific, depending on grid size and stability, transmission capacity, cooling water availability, regulatory readiness, and fuel supply chains. Near-term deployment opportunities are strongest for light-water reactors (such as NuScale, BWRX-300, AP300, and SMR-300) that use low-enriched uranium and build on proven technology. More advanced concepts, including gas-cooled, sodium-cooled, molten-salt cooled reactors, and microreactors, will likely be relevant for African deployment in the 2030s or later, contingent on demonstration projects, high-assay low-enriched uranium (HALEU) fuel availability, and mature international licensing frameworks. Economic analysis shows that SMRs are capital-intensive, with projected overnight costs for 300 MWe units in 2025 ranging from approximately 1.4 to 2.6 billion USD per module. The levelized cost of electricity (LCOE) is highly sensitive to the weighted average cost of capital (WACC). Given typically higher financing costs and utility balance-sheet weaknesses in many African countries, bankable project structures will require sovereign guarantees, robust offtake arrangements, and layered financing from export credit agencies, development finance institutions, and vendor nations. Comparisons with recent large nuclear projects in the United Arab Emirates (UAE) and Egypt underscore the central role of state-backed loans, long tenors, and concessional terms. Country case studies illustrate a spectrum of readiness and opportunity. South Africa operates two 920 MWe pressurized light water reactors (totaling 1,840 MWe) at Koeberg and has the most mature regulatory and industrial base, positioning it as a prime candidate for both large reactors and SMRs to replace coal, support desalination, and anchor industrial hubs. Egypt is constructing four VVER-1200 units at El Dabaa with strong state leadership and could later complement this fleet with SMRs for coastal and industrial applications. Kenya and Ghana are advancing through IAEA Milestones with growing institutional capacity and clear interest in SMRs that match their smaller grids and industrialization plans. Nigeria has the largest demand potential but faces acute constraints in grid reliability, project bankability, and regulatory capacity; targeted deployments of large reactors and SMRs near coastal or industrial sites could have high impact if accompanied by major grid upgrades and institutional reforms. The report identifies cross-cutting challenges such as financing, political continuity, public acceptance, nonproliferation and security, waste and back-end management, regulatory capacity, grid adequacy, and long deployment timelines for first-of-a-kind designs, and ANL/NSE-26/3 ii proposes broad directions for resolution. These include stronger multifaceted financing for nuclear, long-term national energy strategies that transcend electoral cycles, proactive stakeholder engagement, strengthened regional and national regulators, and systematic workforce development through centers of excellence and expanded training. The United States should develop partnerships with African countries and offer end-to-end nuclear package similar to those used effectively by competitors: coordinated project development, state-backed financing, long-term fuel services, and durable in-country support through regional offices and sustained workforce/regulatory training. With timely planning, sustained political commitment, and appropriate financing and institutional support, nuclear energy, both large reactors and advanced SMRs, can become a meaningful, though not dominant, pillar of Africa’s future power mix, enhancing energy security, enabling industrial growth, and supporting climate goals.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2026

Understanding the Thermal Physics and Metallurgy of Metal Big Area Additive Manufacturing

The research goal of this EPSCoR-DOE partnership is to mitigate defects in parts made using a new type of additive manufacturing (AM) process called metal Big Area Additive Manufacturing (m-BAAM). To realize this goal, the PIs will detect and correct defects in the part as it is being printed by combining fundamental knowledge of the thermal physics and metallurgy of m-BAAM with in-process sensor data. Developed at the DOE-funded Manufacturing Demonstration Facility at Oak Ridge National Laboratory, the m-BAAM process involves one or more robots working together to produce a part by fusing metal wire layer-by-layer using arc welding. The process can print large metal parts such as turbine blades, which is not possible using other AM processes. In addition, m-BAAM production rates are more than ten times faster than other AM processes while requiring one-tenth of the material cost. Despite their potential to become a critical force multiplier in the energy generation industry, m-BAAM parts may fail to print accurately due to retention of heat and uneven cooling. Overheating and anomalous cooling rates in turn can cause inconsistencies in the microstructure, leading to sudden failure when used in safety-critical applications. In other words, flaw formation in m-BAAM parts is governed by the thermal history – intensity and spatial distribution of heat inside the part during printing. The thermal history is a complex function of the part shape and process settings such as welding energy, path taken by the welding torch for deposition (tool path), wire feed rate, among others.

36 MATERIALS SCIENCE↗

NASA NTRS1974

Neutrino reactions in strong magnetic field

Presentation of the energy losses due to several neutrinos processes: (1) synchrotron neutrinos, (2) pair annihilation neutrinos, (3) plasmon neutrinos, and (4) photoneutrinos in the presence of a superstrong magnetic field. Numerical results are tabulated and illustrated for several values of densities and temperatures. In the low density regime, the presence of a magnetic field decreases the luminosity, whereas the opposite is true at higher densities. This last effect is, however, almost entirely due to the existence of a new process, the synchrotron neutrinos that disappear when H goes to zero. Even though the overall effect can only be quantitatively ascertained after a complete cooling computation is performed, one should however expect a much lower temperature for neutron star surface than the one computed in the case where H is zero.

Canuto, V.↗

NASA NTRS1976

Ceramic thermal-barrier coatings for cooled turbines

Coating systems consisting of a plasma sprayed layer of zirconia stabilized with either yttria, magnesia or calcia over a thin alloy bond coat have been developed, their potential was analyzed and their durability and benefits evaluated in a turbojet engine. The coatings on air cooled rotating blades were in good condition after completing as many as 500 two-minute cycles of engine operation between full power at a gas temperature of 1644 K and flameout, or as much as 150 hours of steady state operation on cooled vanes and blades at gas temperatures as high as 1644 K with 35 start and stop cycles. On the basis of durability and processing cost, the yttria stabilized zirconia was considered the best of the three coatings investigated.

Liebert, C. H.↗

NASA NTRS1976

Ceramic thermal-barrier coatings for cooled turbines

Ceramic thermal-barrier coatings on hot engine parts have the potential to reduce metal temperatures, coolant requirements, cost, and complexity of the cooling configuration, and to increase life, turbine efficiency and gas temperature. Coating systems consisting of a plasma-sprayed layer of zirconia stabilized with either yttria, magnesia or calcia over a thin alloy bond coat have been developed, their potential analyzed and their durability and benefits evaluated in a turbojet engine. The coatings on air-cooled rotating blades were in good condition after completing as many as 500 two-minute cycles of engine operation between full power at a gas temperature of 1644 K and flameout, or as much as 150 hours of steady-state operation on cooled vanes and blades at gas temperatures as high as 1644 K witn 35 start and stop cycles. On the basis of durability and processing cost, the yttria-stabilized zirconia was considered the best of the three coatings investigated.

Liebert, C. H.↗

NASA NTRS1978

Fractional crystallization of iron meteorites, an experimental study

Measurements of the distribution coefficients of various elements (Ni, Co, P, Pt, Ir, Ge, Cr, and Au) between solid and liquid phases were made for FeNi alloys. A high thermal gradient crystal growing furnace was employed in order to promote plane front solidification, rapid mixing in the liquid and a minimum of diffusion in the solid. Eight measurements of the nickel distribution coefficient gave an average value of 0.91 plus or minus 0.03 and this value was independent of the Ni concentration in the range 5.5 to 8.75 wt. % Ni. Equilibrium distribution coefficients were also calculated by correcting for the diffusion boundary layer present in the liquid. These values are within 20% of the measured distribution coefficient values. Except for Co and Ni, all the measured distribution coefficient values are closer to 1.0 than those calculated by Scott (1972) for the IIIAB irons. Using the experimental values and the calculated equilibrium values for ternary additions to FeNi melts, it appears that fractional crystallization processes will not explain the observed chemical variations in the major iron meteorite groups. Alternative explanations are suggested which also recognize the fact that cooling rates vary widely in several chemical groups.

Goldstein, J. I.↗

NASA NTRS1980

Activated solar filaments and flares

Skylab observations have shown that activations and disruptions of dark H-alpha filaments are one of the basic and most important mechanisms of solar activity. The Kopp-Pneuman theory of post-flare loops shows that the process which disrupts a filament opens the magnetic field and causes a greatly enhanced mass flow along the field lines. The open field lines subsequently reconnect, starting from the bottom of the corona and proceeding upwards. This process can last for many hours. Hot loops are first seen in X-rays, then in extreme UV lines, and, after an appropriate cooling time, in H-alpha as the loop prominence systems.

Svestka, Z.↗

NASA NTRS1980

Crystal/liquid partitioning in augite - Effects of cooling rate

The partitioning of major and minor elements between augite and melt was determined as a function of cooling rate for two high-titanium basalt compositions. The results of this study of lunar rock systems 10017 and 75055 were compared with the results of other kinetic studies of augite-liquid partitioning in other rock systems. It was found that the partitioning of major elements (i.e., Ca, Fe, Mg) is essentially rate independent and is insensitive to bulk rock composition and to the nature and order of appearance of coexisting phases for cooling rates of less than 100 C/hr. The partitioning behavior of minor elements (i.e., Al, Cr, Ti) for the same range of cooling rates is complex, being dependent on cooling rate and bulk rock composition. Consideration of these factors is important when augite chemistry and/or partitioning behavior are used in modeling certain magmatic processes or in estimating the thermal history of basaltic rocks.

Gamble, R. P.↗

NASA NTRS1983

New perspectives for advanced automobile diesel engines

Computer simulation results are presented for advanced automobile diesel engine performance. Four critical factors for performance enhancement were identified: (1) part load preheating and exhaust gas energy recovery, (2) fast heat release combustion process, (3) reduction in friction, and (4) air handling system efficiency. Four different technology levels were considered in the analysis. Simulation results are compared in terms of brake specific fuel consumption and vehicle fuel economy in km/liter (miles per gallon). Major critical performance sensitivity areas are: (1) combustion process, (2) expander and compressor efficiency, and (3) part load preheating and compound system. When compared to the state of the art direct injection, cooled, automobile diesel engine, the advanced adiabatic compound engine concept showed the unique potential of doubling the fuel economy. Other important performance criteria such as acceleration, emissions, reliability, durability and multifuel capability are comparable to or better than current passenger car diesel engines.

Tozzi, L.↗

NASA NTRS1984

High-resolution soft X-ray spectra of Scorpius X-1 - The structure of circumsource accreting material

Four observations of Scorpius X-1 with the Objective Grating Spectrometer of the Einstein Observatory have provided high-resolution spectra (lambda/Delta lambda = approximately 20-50) in the wavelength range 7-46 A. The spectra reveal the presence of absorption structure due to oxygen, nitrogen, and iron, and variable emission structure associated with ionized iron and nitrogen. The strengths of these features suggest that the N/O abundance ratio in the absorbing and line emitting gas is anomalously high, which might indicate that these spectral components are associated with processed material, probably accreting matter transferred from the surface of an evolved companion. Constraints on the inclination of the system, however, imply that this cool, dense, accreting material must be well out of the plane of the binary system. Possible models for the origin and nature of this circumsource medium are discussed. An extensive discussion of the calibration of the Objective Grating Spectrometer and of the analysis of spectra acquired by that instrument is also provided.

Kahn, S. M.↗

NASA NTRS1981

Solar Corona Explorer: A mission for the physical diagnosis of the solar corona

Mission objectives and spacecraft requirements for the Solar Corona Explorer (SCE), a proposed free flying, unmanned solar research craft to be tenatively launched in 1987, were defined. The SCE's purpose is to investigate structure, dynamics and evolution of the corona, globally and in the required physical detail, to study the close coupling between the inner corona and the heliosphere. Investigative objectives are: (1) to understand the corona as the source of varying interplanetary plasma and of varying solar X-ray and extreme ultraviolet fluxes; (2) to develop the capabilities to model the corona with sufficient precision to forecast the Earth's variable environment in space, on the scales from weeks to years; (3) to develop an understanding of the physical processes that determine the dynamics and physical state of the coronal plasma, particularly acceleration processes; and (4) to develop insight and test theory on the Sun applicable to stellar coronae and winds, and in particular, to understand why cool stars put such a large fraction of their energy into X-rays. Considered related factors are: (1) duration of the mission; (2) onboard measuring instrumentation; (3) ground support equipment and procedures; and (4) programs of interpretation and modeling.

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