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At least 1,693 records · Page 94

All sources NASA NTRS DOE OSTI

DOE OSTI2023

Assessment of Process Modeling Tools for Determining Variability in Additively Manufactured Parts

The Advanced Materials and Manufacturing Technologies (AMMT) program aims to accelerate the development, qualification, demonstration, and deployment of advanced materials and manufacturing technologies to enable reliable and economical nuclear energy However, the unique aspects of additive manufacturing (AM) materials in terms of their processing history, microstructure, and properties, are a major barrier for qualification and certification of nuclear components. Much of this challenge may be attributed to component scale variations in microstructure and properties that are driven by local influences of process conditions and geometry on thermal history, melt pool dynamics, and corresponding microstructure evolution. Computational modeling tools may be helpful in this regard to aid in predicting and controlling this level of variability. The purpose of this report is to review the current state-of-the-art for process modeling with regards to metal AM. For this purpose, we consider specifically the case study of laser powder bed fusion (LPBF) processing of SS316, a family of alloys that are both commonly used in nuclear energy applications and suitable for AM processing. The report first introduces the necessary components of a process modeling workflow, followed by a review of the current status of each. At the end, application of these modeling tools to understanding variability in AM process given their current state are considered, and recommendations for future development are proposed

36 MATERIALS SCIENCE↗

DOE OSTI2022

Hydrogen Storage for Load-Following and Clean Power: Duct-firing of Hydrogen to Improve the Capacity Factor of NGCC Plants (Final Report, Phase I Conceptual Study)

The 12-month Feasibility study in Phase I study was completed and confirmed the system is feasible and the proposed system is an improvement over alternate low carbon dispatchable power options. Our demonstration will include 54 MWh of hydrogen storage. CO 2 capture inherent to the CHG process can capture 90% of the CO 2 (with upgrades to >98%) in a commercial system (~300 MWth) for sequestration or other uses. The hydrogen will be utilized in a duct burner in a Heat Recovery Steam Generator (HRSG) integrated with the existing Southern Company fossil asset. Here, the firing rate of the duct burner is varied to let the plant respond to fluctuations of electrical load. However, H 2 production is relatively constant by storing H 2 , and revenues are improved by arbitrage between use of low-cost off-peak variable electricity generation or use of stored H 2 under peak demand. The study enabled the fidelity of the concept to be improved and allowed identification of the requirements for the system. Defining the individual system and component requirements was performed via system requirements review with the whole team. These requirements were then incorporated into/iterated with our Heat & Mass Balance models and process flow diagrams were generated to reflect the overall system. This information was then used to complete the TEA and show economic feasibility. Our system generates power at 17.4% lower cost than other low carbon approaches for the H 2 generation, H 2 compression and storage, carbon sequestration, and HRSG added electricity production for a large-scale duct-fired system. Our team recommends completing the Phase II Pre-FEED study for the proposed system as the next step for the project and its tasks will achieve the overall objective and be ready to launch the FEED. The Pre-FEED tasks include updating the requirements, Concept of Operations, plant scope/process description, component modeling, system modeling, performance estimates, emission estimates, block flow diagrams, fluid/process conditions (PFD), utility usage, and facility sizing/definition. The approach will be to complete these updates in a greater level of detail for the selected site. The approach for developing the EIV is to use the updated results, including model outputs, for carbon dioxide and waste streams.

03 NATURAL GAS↗

NASA NTRS1979

An expanded system simulation model for solar energy storage (technical report), volume 1

The simulation model for wind energy storage (SIMWEST) program now includes wind and/or photovoltaic systems utilizing any combination of five types of storage (pumped hydro, battery, thermal, flywheel and pneumatic) and is available for the UNIVAC 1100 series and the CDC 6000 series computers. The level of detail is consistent with a role of evaluating the economic feasibility as well as the general performance of wind and/or photovoltaic energy systems. The software package consists of two basic programs and a library of system, environmental, and load components. The first program is a precompiler which generates computer models (in FORTRAN) of complex wind and/or photovoltaic source/storage/application systems, from user specifications using the respective library components. The second program provides the techno-economic system analysis with the respective I/0, the integration of system dynamics, and the iteration for conveyance of variables.

Warren, A. W.↗

DOE OSTI2024

Preliminary Results on Process Modeling Tools for Determining Variability in Additively Manufactured Stainless Steel 316 Parts

The Advanced Materials and Manufacturing Technologies program aims to accelerate the development, qualification, demonstration, and deployment of advanced materials and manufacturing technologies to enable reliable and economical nuclear energy. However, the distinct characteristics of additive manufacturing (AM) materials, stemming from their unique processing history, microstructure, and properties, pose significant challenges for the qualification and certification of nuclear components. These challenges primarily arise from component-scale variations in microstructure and properties influenced by local process conditions and geometry, which affect thermal history, melt pool dynamics, and microstructure evolution. Computational modeling tools can play a crucial role in predicting and controlling this variability. This report presents preliminary results on process modeling tools designed to predict microstructure variability in additively manufactured stainless steel 316 parts. It details the software packages and physical modeling approaches employed to simulate an AM component within an automated process modeling workflow. Initial results are demonstrated through comparisons between predicted microstructures and experimental measurements across various representative processing conditions. The report concludes by discussing the challenges inherent in process modeling of AM components and outlines a plan for future development needs.

36 MATERIALS SCIENCE↗

NASA NTRS2016

Kickstarting a New Era of Lunar Industrialization via Campaign of Lunar COTS Missions

To support the goals of expanding our human presence and current economic sphere beyond LEO, a new plan was constructed for NASA to enter into partnerships with industry to foster and incentivize a new era of lunar industrialization. For NASA to finally be successful in achieving sustainable human exploration missions beyond LEO, lessons learned from our space history have shown that it is essential for current program planning to include affordable and economic development goals as well as address top national priorities to obtain much needed public support. In the last 58 years of NASA's existence, only Apollo's human exploration missions beyond LEO were successful since it was proclaimed to be a top national priority during the 1960's. However, the missions were not sustainable and ended abruptly in 1972 due to lack of funding and insufficient economic gain. Ever since Apollo, there have not been any human missions beyond LEO because none of the proposed program plans were economical or proclaimed a top national priority. The proposed plan outlines a new campaign of low-cost, commercial-enabled lunar COTS (Commercial Orbital Transfer Services) missions which is an update to the Lunar COTS plan previously described. The objectives of this new campaign of missions are to prospect for resources, determine the economic viability of extracting those resources and assess the value proposition of using these resources in future exploration architectures such as Mars. These missions would be accomplished in partnership with commercial industry using the wellproven COTS Program acquisition model. This model proved to be very beneficial to both NASA and its industry partners as NASA saved significantly in development and operational costs, as much as tenfold, while industry partners successfully expanded their market share and demonstrated substantial economic gain. Similar to COTS, the goals for this new initiative are 1) to develop and demonstrate cost-effective, cis-lunar commercial services, such as lunar transportation, lunar mining and lunar ISRU operations; 2) enable development of an affordable and economical exploration architecture for future missions to Mars and beyond; and 3) to incentivize the creation of new lunar markets through use of lunar resources for economic benefit to NASA, commercial industry and the international community. These cost-effective services would not only enable NASA to economically and sustainably achieve its human exploration missions to the Moon, Mars and beyond but it would also kickstart a new era of lunar industrialization. This paper will describe the goals, objectives and approach for implementing this new campaign of missions. It will also describe the potential benefits and progress that can be accomplished with these low-cost, Lunar COTS missions. Lastly, a preliminary economic analysis approach is proposed for understanding the cost and potential return on investment in the use of lunar resources to reach the goal of lunar industrialization and an expanded and sustainable human presence into cis-lunar space and beyond.

Lunar Exploration↗

DOE OSTI2021

Improvement of the $\mathrm{BISON U_3Si_2}$ modeling capabilities based on multiscale developments to modeling fission gas behavior

Uranium silicide (U 3 Si 2 ) is a concept explored as a potential alternative to UO 2 fuel used in light water reactors (LWRs) since it may improve accident tolerance and economics due to its higher thermal conductivity and increased uranium density. U 3 Si 2 has been previously used in research reactors in the form of dispersion fuel, but operated at lower temperatures than commercial LWRs. The research reactor data illustrated that significant gaseous swelling occurs as the fuel burnup increases. Therefore, it is imperative to understand the fission gas behavior of U 3 Si 2 under higher temperature LWR operating conditions. In this work, molecular dynamics and phase-field modeling techniques are used to reduce the uncertainty in select modeling assumptions made in developing the fission gas behavior model for U 3 Si 2 in the BISON fuel performance code. These lower length scale informed models are then utilized in the validation of BISON U 3 Si 2 modeling capabilities to simulate the ATF-1 experiments irradiated in the Advanced Test Reactor (ATR). Sensitivity analysis (SA) and uncertainty quantification (UQ) are included as part of the validation process to identify where further experiments and lower length scale modeling would be beneficial. Here, the multiscale modeling approach utilized in this work can be applied to new fuel concepts being explored for both LWRs and advanced reactors (e.g., uranium nitride, uranium carbide).

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2022

Metabolic flux modeling of Gluconobacter oxydans enables improved production of bioleaching organic acids

Bioleaching with organic acids is an option for recovery of rare earth elements (REE) and or other valuable metals from consumer or industrial wastes. Biohydrometallurgy can play an economically and environmentally sustainable role in REE recycling, particularly if agriculture or food wastes are used as the carbon substrates for production of the bioleaching agents. A challenge for organic acid based REE bioleaching is the incomplete conversion of the carbon substrate to an optimal organic acid mixture with high REE extraction capability. To help meet this challenge a metabolic flux model was developed for Gluconobacter oxydans to identify options for improving sugar conversion to chelating organic acids. Here, model predictions were consistent with laboratory data for the microbial consumption of glucose and production of gluconic acid and suggested that providing growth conditions with relatively high carbon to nitrogen molar ratios could result in production of lower pH biolixiviant and thus improve REE bioleaching yields.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2025

A dynamic 2D Borehole Thermal Energy Storage (BTES) model for enhanced computational efficiency

Progressing toward a future increasingly reliant on renewable energy sources, the development of effective, durable energy storage solutions becomes essential to balance supply and demand fluctuations. Borehole Thermal Energy Storage (BTES) is a long-duration thermal energy storage technology that captures excess heat generated from renewable energy sources and stores it underground for later use, enabling the efficient utilization of sustainable energy. This approach is particularly valuable in district energy networks when integrated with Ground Source Heat Pumps (GSHP) to provide stable heating and cooling. However, traditional three-dimensional (3D) numerical models of BTES systems demand extensive computational resources, limiting their practicality for real-time and large-scale applications. This study introduces a novel two-dimensional (2D) modeling approach that reduces computational costs while maintaining high accuracy. By employing a radial ring-based discretization method, the model simulates heat injection, retention, and retrieval dynamics over seasonal cycles. A new thermal-mass weighted-average temperature parameter is introduced to evaluate the performance of BTES systems. Model validation against FEFLOW simulations demonstrates a 17-fold improvement in computational speed compared to traditional Computational Fluid Dynamics (CFD) models while achieving a mean absolute percentage error (MAPE) of 2 % during charging and 4 % during discharging. Additionally, a trade-off analysis between computational efficiency and accuracy is conducted, ensuring the model's applicability for real-world scenarios. The findings of this research contribute to the development of computationally efficient BTES models, facilitating better optimization, control, and integration into renewable energy systems. This work provides a foundation for further studies in techno-economic analysis, multi-year performance evaluation, and real-time operational strategies for BTES applications, supporting a more sustainable energy future.

2D modeling↗

DOE OSTI2025

Front-of-Meter Model Results

These files contains aggregations of key variables from the NREL Distributed Wind Futures Study using full parcel level data. These variables describe total technical and economic potential for distributed wind turbine deployment. Aggregations are available at the (1) county, (2) zipcode (zip code tabulation area or zcta), and (3) US Census block group level. Each scenario is coded with the scenario name (e.g., baseline) and year (e.g., 2022). Those files postfixed with 'econpot' contain results for only those parcels that are economically viable while the files postfixed with 'techpot' include results for all parcels that are technically feasible. Hence these correspond to technoeconomic and technical potential respectively. The data are available as CSV or Geopackage. Columns in the files are as follows: * geoid: geographic identifier (FIPS code or similar) * min_techpot_sum_kw: technical potential for all parcels in kW using turbines downsized to demand when appropriate * max_techpot_sum_kw: technical potential for all parcels in kW without downsizing turbines * aep_sum_kwh: annual energy production estimate in kWh * cf_mean_ratio: mean capacity factor * lcoe_mean_cents_per_kwh: mean levelized cost of energy for parcels in geography in cents per kWh * lcoe_std_cents_per_kwh: standard deviation of the above * parcel_area_sum_acres: total area of viable parcels in acres * n_turbines: number of cited turbines (one per viable parcel currently) Note: These are preliminary results from the full-parcel 2024 update of the Distributed Wind Energy Futures study. Please take care when making use of the data, and feel free to contact the team with any questions. Full documentation in support of these data is in progress and will follow.

17 WIND ENERGY↗

DOE OSTI2025

Behind-the-Meter Model Results

17 WIND ENERGY↗

DOE OSTI2025

Evaluating advanced nuclear fission technologies for future decarbonized power grids

Advanced nuclear fission, which encompasses various innovative nuclear reactor designs, could contribute to the decarbonization of the United States electricity sector. However, little is known about how cost-competitive these reactors would be compared to other technologies, or about which aspects of their designs offer the most value to a decarbonized power grid. We employ an electricity system optimization model and a case study of a decarbonized U.S. Eastern Interconnection circa 2050 to generate initial indicators of future economic value for advanced reactors and the sensitivity of future value to various design parameters, the availability of competing technologies, and the underlying policy environment. These results can inform long-term cost targets and guide near-term innovation priorities, investments, and reactor design decisions. We find that advanced reactors should cost $\$5.7$–$\$7.3$/W to gain an initial market share (assuming 30 year asset life and 3.5 %–6.5 % real weighted average cost of capital), while those that include thermal storage in their designs can cost up to $\$6.0$/W–$\$7.7$/W (not including cost of storage). Since the marginal value of advanced fission reactors declines as market penetration increases, break-even costs fall ~32 % at 100 GW of cumulative capacity and ~51 % at 300 GW. Additionally, policies that provide investment tax credits for nuclear energy create the most favorable environment for advanced nuclear fission. In conclusion, these findings can inform near-term resource allocation decisions by stakeholders, innovators and investors working in the energy technology sector.

Capacity expansion↗

DOE OSTI2025

Implications of point defect accumulation on UO 2 thermal conductivity and fission gas release under accelerated fuel irradiation

Evaluation of thermal properties is a crucial factor for nuclear fuel performance. During reactor operation, the accumulation of fission products and irradiation-induced lattice defects are responsible for degradation in thermal conductivity. Consequently, it affects fuel temperature and fission gas release (FGR) among other Multiphysics processes important for economics and safety analysis. We analyze the implications of point defects (PD) accumulation described using a rate theory (RT) Model on lattice thermal conductivity of UO 2 . Here, we demonstrate that fission rate-dependent point defect concentrations have the largest impact on in-pile thermal conductivity in the periphery of light water reactor fuels below a temperature threshold governed by the migration barrier of defects. Our analysis provides a mechanistic description of this phenomena which current fuel performance codes treat empirically. The reduction of thermal conductivity in the low -temperature rim region acts as additional thermal resistance and leads to a temperature notably larger than suggested by Lucuta thermal conductivity correlation. These effects are anticipated to have notable impacts when fuels are exposed to accelerated radiation. The impact of such point defect-informed treatment of thermal conductivity on fuel performance is evaluated by a detailed analysis of fission gas behavior and its release. We consider several models capturing different stages of fission gas bubble evolution and fission gas release (FGR). Finally, a new fission rate-dependent correction to the Lucuta correlation is proposed. The results show a significant reduction in thermal conductivity at the fuels’ periphery and an increase in fuel centerline temperature specifically at low burnups. Ultimately a modified LC shows a higher FGR compared to the original LC, while the acceleration process results in a reduction in overall FGR.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2023

Biochemical Conversion of Lignocellulosic Biomass to Hydrocarbon Fuels and Products: 2022 State of Technology and Future Research

The annual State of Technology (SOT) assessment is a key activity for biochemical platform research. It allows the impact of research progress (both directly achieved in-house at the National Renewable Energy Laboratory [NREL] and indirectly extrapolated from available public data) to be quantified in terms of economic improvements in the overall cellulosic biofuel production process for a particular conversion pathway. As such, initial benchmarks can be established for currently demonstrated performance and progress can be tracked toward out-year goals to ultimately demonstrate cost-competitive biofuel technology. Building upon efforts to progress NREL's biochemical platform R&D work toward ultimate 2030 goals to demonstrate less than $2.50/gallon gasoline equivalent (GGE) fuel selling prices, experimental and techno-economic analysis (TEA) activities have primarily focused on "advanced" biochemical processing strategies to fuels and coproducts, guided by TEA modeling to highlight key barriers and priorities toward achieving this goal across a number of potential bioconversion pathways. The purpose of the present effort is to benchmark the latest experimental developments for these pathways as quantified by modeled minimum fuel selling prices (MFSPs), as a measure of current status relative to those final targets. For this SOT, TEA models were run for two separate biological conversion pathways to fuels, based on available data for integrated biomass deconstruction and hydrolysate processing; namely carboxylic acids (primarily butyric acid) and diols (2,3-butanediol [BDO]), reflecting NREL's recently published 2018 biochemical design report focused on those two pathways. The models were run across two scenarios for lignin utilization, namely combustion and conversion to value-added coproducts.

09 BIOMASS FUELS↗

DOE OSTI2025

Bridging the Gap for Powering Data Centers

The rapid expansion of data centers, primarily driven by artificial intelligence, is outpacing the adaptability of the U.S. electric grid. This report, developed by Idaho National Laboratory (INL) , presents a gap analysis of some of the infrastructure challenges associated with large-scale data center deployment. Drawing from a national workshop hosted by INL in October of 2025, the report synthesizes stakeholder insights, survey data, and technical discussions to identify critical barriers and research needs. Key findings highlight the growing preference for behind-the-meter generation, the perceived inadequacy of legacy interconnection processes, and the urgent need for improved coordination between utilities, regulators, and data center developers. Environmental concerns such as water use and noise pollution, as well as economic constraints like equipment lead times and cost allocation, are also explored. The report outlines national lab capabilities in modeling, simulation, and technical assistance, and proposes targeted R&D priorities to support resilient, scalable, and efficient integration of data centers into the grid.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS1979

Economic baselines for current underground coal mining technology

The cost of mining coal using a room pillar mining method with continuous miner and a longwall mining system was calculated. Costs were calculated for the years 1975 and 2000 time periods and are to be used as economic standards against which advanced mining concepts and systems will be compared. Some assumptions were changed and some internal model stored data was altered from the original calculations procedure chosen, to obtain a result that more closely represented what was considered to be a standard mine. Coal seam thicknesses were varied from one and one-half feet to eight feet to obtain the cost of mining coal over a wide range. Geologic conditions were selected that had a minimum impact on the mining productivity.

Mabe, W. B.↗

NASA NTRS1986

Concerning the electrosynthesis of hydrogen peroxide and peroxodisulfates. Section 2: Optimization of electrolysis cells using an electrolyzer for peroxodisulfuric acid as an example

The model is presented of an electrolyzer for peroxodisulfuric acid, and it is analyzed mathematically. Its application for engineering and economic optimization is investigated in detail. The mathematical analysis leads to conclusions concerning the change in position of the optimum with respect to the various target functions due to changes of the individual design-caused and economic parameters.

Schleiff, M.↗

NASA NTRS1992

Utilization of space resources in the space transportation system

Utilization of space resources (i.e., raw materials obtained from nonterrestrial sources) has often been cited as a prerequisite for large-scale industrialization and habitation of space. While transportation of extremely large quantities of material from Earth would be costly and potentially destructive to our environment, vast quantities of usable resources might be derived from the Moon, the asteroids, and other celestial objects in a cost-effective and environmentally benign manner. The primary purpose of the parametric cost model developed as part of this study is to identify the factors that have the greatest influence on the economics of space resource utilization. In the near term, this information can be used to devise strategies for technology development so that capabilities developed will produce cost-effective results.

Simon, Michael C.↗

NASA NTRS1997

Estimating the Effects of the Terminal Area Productivity Program

The report describes methods and results of an analysis of the technical and economic benefits of the systems to be developed in the NASA Terminal Area Productivity (TAP) program. A runway capacity model using parameters that reflect the potential impact of the TAP technologies is described. The runway capacity model feeds airport specific models which are also described. The capacity estimates are used with a queuing model to calculate aircraft delays, and TAP benefits are determined by calculating the savings due to reduced delays. The report includes benefit estimates for Boston Logan and Detroit Wayne County airports. An appendix includes a description and listing of the runway capacity model.

Lee, David A.↗