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All sourcesNASA NTRSDOE OSTI
DOE OSTI2012

Alumina-Forming Austenitics: A New Approach to Thermal and Degradation Resistant Stainless Steels for Industrial Use

A series of developmental AFA alloys was selected for study based on: 25 Ni wt.% (alloys A-F), 20 wt% Ni (alloys G-H), and 12 Ni wt.% (alloys I-L). An emphasis in this work was placed on the lower alloy content direction for AFA alloys to reduce alloy raw material cost, rather than more highly alloyed and costly AFA alloys for higher temperature performance. Alloys A-D explored the effects of Al (3-4 wt.%) and C (0.05-0.2 wt.%) in the Fe-25Ni-14Cr-2Mn-2Mo-1W-1Nb wt.% base range; alloys E and F explored the effects of removing costly Mo and W additions in a Fe-25Ni-14Cr-4Al-2.5Nb-2Mn-0.2C base, alloys G and H examined Nb (1-2.5wt.%) and removal of Mo, W in a Fe-20Ni-14Cr-3Al-2Mn-0.2 C wt.% base; and alloys I-L examined effects of C (0.1-0.2 wt.%) and Mn (5-10 wt.%) on a low cost Fe-14Cr-12Ni-3Cu-2.5Al wt.% base (no Mo, W additions). Creep testing resulted in elemental trends that included the beneficial effect of higher carbon and lower niobium in 20-25%Ni AFA alloys and, the beneficial of lower Mn in 12%Ni AFA alloys. Corrosion tests in steam and sulfidation-oxidation environments showed, in general, these alloys were capable of a ten-fold improvement in performance when compared to conventional austenitic stainless steels. Also, corrosion test results in metal-dusting environments were promising and, warrant further investigation.

36 MATERIALS SCIENCE↗
DOE OSTI2012

Summary Report on Solid-oxide Electrolysis Cell Testing and Development

Idaho National Laboratory (INL) has been researching the application of solid-oxide electrolysis cells (SOECs) for large-scale hydrogen production from steam over a temperature range of 800 to 900°C. From 2003 to 2009, this work was sponsored by the United States Department of Energy Nuclear Hydrogen Initiative, under the Office of Nuclear Energy. Starting in 2010, the high-temperature electrolysis (HTE) research program has been sponsored by the INL Next Generation Nuclear Plant Project. This report provides a summaryof program activities performed in Fiscal Year (FY) 2011 and the first quarter of FY-12, with a focus on small-scale testing and cell development activities. HTE research priorities during this period have included the development and testing of SOEC and stack designs that exhibit high-efficiency initial performance and low, long-term degradation rates. This report includes contributions from INL and five industry partners: Materials and Systems Research, Incorporated (MSRI); Versa Power Systems, Incorporated (VPS); Ceramatec, Incorporated; National Aeronautics and Space Administration - Glenn Research Center (NASA - GRC); and the St. Gobain Advanced Materials Division. These industry partners have developed SOEC cells and stacks for in-house testing in the electrolysis mode and independent testing at INL. Additional fundamental research and post-test physical examinations have been performed at two university partners: Massachusetts Institute of Technology (MIT) and the University of Connecticut. Summaries of these activities and test results are also presented in this report.

08 HYDROGEN↗
DOE OSTI2012

Packed-Bed Reactor Study of NETL Sample 196c for the Removal of Carbon Dioxide from Simulated Flue Gas Mixture

An amine-based solid sorbent process to remove CO 2 from flue gas has been investigated. The sorbent consists of polyethylenimine (PEI) immobilized onto silica (SiO 2 ) support. Experiments were conducted in a packed-bed reactor and exit gas composition was monitored using mass spectrometry. The effects of feed gas composition (CO 2 and H 2 O), temperature, and simulated steam regeneration were examined for both the silica support as well as the PEI-based sorbent. The artifact of the empty reactor was also quantified. Sorbent CO 2 capacity loading was compared to thermogravimetric (TGA) results to further characterize adsorption isotherms and better define CO 2 working capacity. Sorbent stability was monitored by periodically repeating baseline conditions throughout the parametric testing and replacing with fresh sorbent as needed. The concept of the Basic Immobilized Amine Sorbent (BIAS) Process using this sorbent within a system where sorbent continuously flows between the absorber and regenerator was introduced. The basic tenet is to manipulate or control the level of moisture on the bent as it travels around the sorbent circulation path between absorption and regeneration stages to minimize its effect on regeneration heat duty.

58 GEOSCIENCES↗
DOE OSTI2012

Assessment of Geothermal Resource Potential at a High-Priority Area on the Utah Testing and Training Range–South (UTTR–S)

Field investigations conducted during 2011 support and expand the conclusion of the original Preliminary Report that discovery of a viable geothermal system is possible in the northwestern part of the Utah Testing and Training Range-South (UTTR-S), referred to henceforth as Focus Area 1. The investigations defined the southward extent of the Wendover graben into and near Focus Area 1, enhanced the understanding of subsurface conditions, and focused further geothermal exploration efforts towards the northwestern-most part of Focus Area 1. Specifically, the detailed gravity survey shows that the Wendover graben, first defined by Cook et al. (1964) for areas north of Interstate Highway 80, extends and deepens southwest-ward to the northwest corner of Focus Area 1. At its deepest point, the intersection with a northwest-trending graben there is favorable for enhanced permeability associated with intersecting faults. Processing and modeling of the gravity data collected during 2011 provide a good understanding of graben depth and distribution of faults bounding the graben and has focused the interest area of the study. Down-hole logging of temperatures in wells made available near the Intrepid, Inc., evaporation ponds, just north of Focus Area 1, provide a good understanding of the variability of thermal gradients in that area and corroborate the more extensive temperature data reported by Turk (1973) for the depth range of 300-500 m. Moderate temperature gradients in the northern part of the Intrepid area increase to much higher gradients and bottom-hole temperatures southeastward, towards graben-bounding faults, suggesting upwelling geothermal waters along those faults. Water sampling, analysis, and temperature measurements of Blue Lakes and Mosquito Willey's springs, on the western boundary of Focus Area 1, also show elevated temperatures along the graben-bounding fault system. In addition, water chemistry suggests origin of those waters in limestone rocks beneath the graben in areas with temperatures as high as 140 C (284 F). In conclusion, all of the field data collected during 2011 and documented in the Appendices of this report indicate that there is reasonable potential for a viable geothermal resource along faults that bound the Wendover graben. Prospects for a system capable of binary electrical generation are especially good, and the possibility of a flash steam system is also within reason. The next steps should focus on securing the necessary funding for detailed geophysical surveys and for drilling a set of temperature gradient wells to further evaluate the resource, and to focus deep exploration efforts in the most promising areas.

15 GEOTHERMAL ENERGY↗
DOE OSTI2012

Texas Hydrogen Highway Fuel Cell Hybrid Bus and Fueling Infrastructure Technology Showcase (Final Scientific/Technical Report)

The Texas Hydrogen Highway project has showcased a hydrogen fuel cell transit bus and hydrogen fueling infrastructure that was designed and built through previous support from various public and private sector entities. The aim of this project has been to increase awareness among transit agencies and other public entities on these transportation technologies, and to place such technologies into commercial applications, such as a public transit agency. The initial project concept developed in 2004 was to show that a skid-mounted, fully-integrated, factory-built and tested hydrogen fueling station could be used to simplify the design, and lower the cost of fueling infrastructure for fuel cell vehicles. The approach was to design, engineer, build, and test the integrated fueling station at the factory then install it at a site that offered educational and technical resources and provide an opportunity to showcase both the fueling station and advanced hydrogen vehicles. The two primary technology components include: Hydrogen Fueling Station: The hydrogen fueling infrastructure was designed and built by Gas Technology Institute primarily through a funding grant from the Texas Commission on Environmental Quality. It includes hydrogen production, clean-up, compression, storage, and dispensing. The station consists of a steam methane reformer, gas clean-up system, gas compressor and 48 kilograms of hydrogen storage capacity for dispensing at 5000 psig. The station is skid-mounted for easy installation and can be relocated if needed. It includes a dispenser that is designed to provide temperature compensated fills using a control algorithm. The total station daily capacity is approximately 50 kilograms. Fuel Cell Bus: The transit passenger bus built by Ebus, a company located in Downey, CA, was commissioned and acquired by GTI prior to this project. It is a fuel cell plug-in hybrid electric vehicle which is ADA compliant, has air conditioning sufficient for Texas operations, and regenerative braking for battery charging. It uses a 19.3 kW Ballard PEM fuel cell, will store 12.6 kg of hydrogen at 350 Bar, and includes a 60 kWh battery storage system. The objectives of the project included the following: (a) To advance commercialization of hydrogen-powered transit buses and supporting infrastructure; (b) To provide public outreach and education by showcasing the operation of a 22-foot fuel cell hybrid shuttle bus and Texas first hydrogen fueling infrastructure; and (c) To showcase operation of zero-emissions vehicle for potential transit applications. As mentioned above, the project successfully demonstrated an early vehicle technology, the Ebus plug-in hybrid fuel cell bus, and that success has led to the acquisition of a more advanced vehicle that can take advantage of the same fueling infrastructure. Needed hydrogen station improvements have been identified that will enhance the capabilities of the fueling infrastructure to serve the new bus and to meet the transit agency needs. Over the course of this project, public officials, local government staff, and transit operators were engaged in outreach and education activities that acquainted them with the real world operation of a fuel cell bus and fueling infrastructure. Transit staff members in the Dallas/Ft. Worth region were invited to a workshop in Arlington, Texas at the North Central Texas Council of Governments to participate in a workshop on hydrogen and fuel cells, and to see the fuel cell bus in operation. The bus was trucked to the meeting for this purpose so that participants could see and ride the bus. Austin area transit staff members visited the fueling site in Austin to be briefed on the bus and to participate in a fueling demonstration. This led to further meetings to determine how a fuel cell bus and fueling station could be deployed at Capital Metro Transit. Target urban regions that expressed additional interest during the project in response to the outreach meetings and showcase events include San Antonio and Austin, Texas. In summary, the project objectives were achieved in the following ways: Through presentations and papers provided to a variety of audiences in multiple venues, the project team fulfilled its goal of providing education and outreach on hydrogen technology to statewide audiences. The project team generated interest that exists well beyond the completion of the project, and indeed, helped to generate financial support for a subsequent hydrogen vehicle project in Austin. The University of Texas, Center for ElectroMechanics operated the fuel cell-electric Ebus vehicle for over 13,000 miles in Austin, Texas in a variety of routes and loading configurations. The project took advantage of prior efforts that created a hydrogen fueling station and fuel cell electric-hybrid bus and continued to verify their technical foundation, while informing and educating potential future users of how these technologies work.

03 NATURAL GAS↗
DOE OSTI2012

Center for Integrated Nanotechnologies 2011 Annual Report

We are pleased to share with you this 2011 edition of the Annual Report from the Center for Integrated Nanotechnologies (CINT) and the growing excitement we feel around cementing our brand as a leader in integration nanoscience. This can be seen most readily in the momentum we have achieved in our signature Integration Focus Activities (IFAs). These efforts unite our scientists across our four scientific Thrust areas with our users to concentrate research on larger-scale nanoscience integration challenges for specific classes of nanomaterials, systems, and phenomena. All three of our current IFAs (p. 10) now have a full head of steam, and nearly 30% of our current user projects map in some meaningful way to one of these IFAs. As part of our redoubled effort to increase our industrial user base, we are also looking to leverage these IFAs to build a stronger link to and spur recruitment within our industrial user community. We believe that the IFAs are a natural community-building tool with an intrinsic value proposition for industry; an R&D pipeline that can lead to more mature, more commercially well-positioned technologies. Finally, as nanoscience and nanotechnology are maturing, we as a research community are beginning to see our efforts extend in many exciting new directions. Our focus on nanoscience integration positions us very well to capitalize on new opportunities including the emerging Mesoscale Initiative within the DOE Office of Science. Many aspects of mesoscale science are embodied in the integration of nanoscale building blocks. We are equally proud of our continuing strong performance in support of our user program. We have fully transitioned to our new user proposal database providing enhanced convenience and flexibility for proposal submission and review. In our two regular proposal calls this year we received a total of 225 proposals, an increase of 10% over our 2010 performance. Our official count on number of users for the period remains at {approx}350 and continues to reflect full engagement of our scientific staff. We are also seeing a steady increase in our industrial user base, with the number of industrial proposals (including Rapid Access proposals) doubling in 2011. We attribute this in part of our outreach efforts including our focused industrial session in each of our past two annual User Conferences. The Center for Integrated Nanotechnologies (CINT) is a Department of Energy/Office of Science Nanoscale Science Research Center (NSRC) operating as a national user facility devoted to establishing the scientific principles that govern the design, performance, and integration of nanoscale materials. Jointly operated by Los Alamos and Sandia National Laboratories, CINT explores the continuum from scientific discovery to use-inspired research, with a focus on the integration of nanoscale materials and structures to achieve new properties and performance and their incorporation into the micro- and macro worlds. Through its Core Facility at Sandia National Laboratories and its Gateway Facility at Los Alamos National Laboratory, CINT provides open access to tools and expertise needed to explore the continuum from scientific discovery to the integration of nanostructures into the micro- and macro worlds. In its overall operations, CINT strives to achieve the following goals common to all Nanoscale Science Research Centers: (1) Conduct forefront research in nanoscale science; (2) Operate as a user facility for scientific research; (3) Provide user access to the relevant BES-supported expertise and capabilities at the host national laboratory; and (4) Leverage other relevant national laboratory capabilities to enhance scientific opportunities for the nanoscience user community. These additional goals are specific to the unique CINT mission: (5) Establish and lead a scientific community dedicated to solving nanoscale science integration challenges; and (6) Create a single user facility program that combines expertise and facilities at both Los Alamos and Sandia National Laboratories. The CINT user program provides the international scientific community with open access to world-class scientific staff and state-of-the-art facilities for theory and simulation, nanomaterials synthesis and characterization, and unique capabilities for nanoscale materials integration, from the level of nanoscale synthesis to the fabrication of micro- and macroscale structures and devices. The staff of CINT includes laboratory scientists, postdocs and technical support staff who are leaders in the nanoscience research programs in CINT scientific thrust areas: (1) Nanoscale Electronics and Mechanics, (2) Nanophotonics and Optical Nanomaterials, (3) Soft, Biological and Composite Nanomaterials, and (4) Theory and Simulation of Nanoscale Phenomena.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2012

Evaluating the Effects of Fly Ash Exposure on Fish Early Life Stages: Fathead Minnow Embryo-Larval Tests

On December 22, 2008, a dike containing fly ash and bottom ash in an 84-acre complex of the Tennessee Valley Authority's (TVA) Kingston Steam Plant in East Tennessee failed and released a large quantity of ash into the adjacent Emory River. Ash deposits extended as far as 4 miles upstream (Emory River mile 6) of the Plant, and some ash was carried as far downstream as Tennessee River mile 564 ({approx}4 miles downstream of the Tennessee River confluence with the Clinch River). A byproduct of coal burning power plants, fly ash contains a variety of metals and other elements which, at sufficient concentrations and in specific forms, can be toxic to biological systems. The effects of fly ash contamination on exposed fish populations depend on the magnitude and duration of exposure, with the most significant risk considered to be the effects of specific ash constituents, especially selenium, on fish early life stages. Uptake by adult female fish of fly ash constituents through the food chain and subsequent maternal transfer of contaminants to the developing eggs is thought to be the primary route of selenium exposure to larval fish (Woock and others 1987, Coyle and others 1993, Lemly 1999, Moscatello and others 2006), but direct contact of the fertilized eggs and developing embryos to ash constituents in river water and sediments is also a potential risk factor (Woock and others 1987, Coyle and others 1993, Jezierska and others 2009). To address the risk of fly ash from the Kingston spill to the reproductive health of downstream fish populations, ORNL has undertaken a series of studies in collaboration with TVA including: (1) a field study of the bioaccumulation of fly ash constituents in fish ovaries and the reproductive condition of sentinel fish species in reaches of the Emory and Clinch Rivers affected by the fly ash spill; (2) laboratory tests of the potential toxicity of fly ash from the spill area on fish embryonic and larval development (reported in the current technical manuscript); (3) additional laboratory experimentation focused on the potential effects of long-term exposures to fly ash on fish survival and reproductive competence; and (4) a combined field and laboratory study examining the in vitro developmental success of embryos and larvae obtained from fish exposed in vivo for over two years to fly ash in the Emory and Clinch Rivers. These fish reproduction and early life-stage studies are being conducted in conjunction with a broader biological monitoring program administered by TVA that includes a field study of the condition of larval fish in the Emory and Clinch Rivers along with assessments of water quality, sediment composition, ecotoxicological studies, terrestrial wildlife studies, and human and ecological risk assessment. Information and data generated from these studies will provide direct input into risk assessment efforts and will also complement and help support other phases of the overall biomonitoring program. Fish eggs, in general, are known to be capable of concentrating heavy metals and other environmental contaminants from water-borne exposures during embryonic development (Jezierska and others 2009), and fathead minnow embryos in particular have been shown to concentrate methylmercury (Devlin 2006) as well as other chemical toxicants. This technical report focuses on the responses of fathead minnow embryos to simple contact exposures to fly ash in laboratory toxicity tests adapted from a standard fathead minnow (Pimephales promelas) 7-d embryo-larval survival and teratogenicity test (method 1001.0 in EPA 2002) with mortality, hatching success, and the incidences of developmental abnormalities as measured endpoints.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2012

System Evaluations and Life-Cycle Cost Analyses for High-Temperature Electrolysis Hydrogen Production Facilities

This report presents results of system evaluations and lifecycle cost analyses performed for several different commercial-scale high-temperature electrolysis (HTE) hydrogen production concepts. The concepts presented in this report rely on grid electricity and non-nuclear high-temperature process heat sources for the required energy inputs. The HYSYS process analysis software was used to evaluate both central plant designs for large-scale hydrogen production (50,000 kg/day or larger) and forecourt plant designs for distributed production and delivery at about 1,500 kg/day. The HYSYS software inherently ensures mass and energy balances across all components and it includes thermodynamic data for all chemical species. The optimized designs described in this report are based on analyses of process flow diagrams that included realistic representations of fluid conditions and component efficiencies and operating parameters for each of the HTE hydrogen production configurations analyzed. As with previous HTE system analyses performed at the INL, a custom electrolyzer model was incorporated into the overall process flow sheet. This electrolyzer model allows for the determination of the average Nernst potential, cell operating voltage, gas outlet temperatures, and electrolyzer efficiency for any specified inlet steam, hydrogen, and sweep-gas flow rates, current density, cell active area, and external heat loss or gain. The lifecycle cost analyses were performed using the H2A analysis methodology developed by the Department of Energy (DOE) Hydrogen Program. This methodology utilizes spreadsheet analysis tools that require detailed plant performance information (obtained from HYSYS), along with financial and cost information to calculate lifecycle costs. There are standard default sets of assumptions that the methodology uses to ensure consistency when comparing the cost of different production or plant design options. However, these assumptions may also be varied within the spreadsheets when better information is available or to allow the performance of sensitivity studies. The selected reference plant design for this study was a 1500 kg/day forecourt hydrogen production plant operating in the thermal-neutral mode. The plant utilized industrial natural gas-fired heaters to provide process heat, and grid electricity to supply power to the electrolyzer modules and system components. Modifications to the reference design included replacing the gas-fired heaters with electric resistance heaters, changing the operating mode of the electrolyzer (to operate below the thermal-neutral voltage), and considering a larger 50,000 kg/day central hydrogen production plant design. Total H2A-calculated hydrogen production costs for the reference 1,500 kg/day forecourt hydrogen production plant were $\$$3.42/kg. The all-electric plant design using electric resistance heaters for process heat, and the reference design operating below the thermal-neutral voltage had calculated lifecycle hydrogen productions costs of $\$$3.55/kg and $\$$5.29/kg, respectively. Because of its larger size and associated economies of scale, the 50,000 kg/day central hydrogen production plant was able to produce hydrogen at a cost of only $\$$ 2.89/kg.

08 HYDROGEN↗
DOE OSTI2012

Evaluation of Manual Ultrasonic Examinations Applied to Detect Flaws in Primary System Dissimilar Metal Welds at North Anna Power Station

During a recent inservice inspection (ISI) of a dissimilar metal weld (DMW) in an inlet (hot leg) steam generator nozzle at North Anna Power Station Unit 1, several axially oriented flaws went undetected by the licensee's manual ultrasonic testing (UT) technique. The flaws were subsequently detected as a result of outside diameter (OD) surface machining in preparation for a full structural weld overlay. The machining operation uncovered the existence of two through-wall flaws, based on the observance of primary water leaking from the DMW. Further ultrasonic tests were then performed, and a total of five axially oriented flaws, classified as primary water stress corrosion cracking (PWSCC), were detected in varied locations around the weld circumference.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2012

American Recovery & Reinvestment Act: Fuel Cell Hybrid Power Packs and Hydrogen Refueling for Lift Trucks

HEB Grocery Company, Inc. (H-E-B) is a privately-held supermarket chain with 310 stores throughout Texas and northern Mexico. H-E-B converted 14 of its lift reach trucks to fuel cell power using Nuvera Fuel Cells’ PowerEdge™ units to verify the value proposition and environmental benefits associated with the technology. Issues associated with the increasing power requirements of the distribution center operation, along with high ambient temperature in the summer and other operating conditions (such as air quality and floor surface condition), surfaced opportunities for improving Nuvera’s PowerEdge fuel cell system design in high-throughput forklift environments. The project included on-site generation of hydrogen from a steam methane reformer, called PowerTap™ manufactured by Nuvera. The hydrogen was generated, compressed and stored in equipment located outside H-E-B’s facility, and provided to the forklifts by hydrogen dispensers located in high forklift traffic areas. The PowerEdge fuel cell units logged over 25,300 operating hours over the course of the two-year project period. The PowerTap hydrogen generator produced more than 11,100 kg of hydrogen over the same period. Hydrogen availability at the pump was 99.9%. H-E-B management has determined that fuel cell forklifts help alleviate several issues in its distribution centers, including truck operator downtime associated with battery changing, truck and battery maintenance costs, and reduction of grid electricity usage. Data collected from this initial installation demonstrated a 10% productivity improvement, which enabled H-E-B to make economic decisions on expanding the fleet of PowerEdge and PowerTap units in the fleet, which it plans to undertake upon successful demonstration of the new PowerEdge reach truck product. H-E-B has also expressed interest in other uses of hydrogen produced on site in the future, such as for APUs used in tractor trailers and refrigerated transport trucks in its fleet.

08 HYDROGEN↗
DOE OSTI2015

RELAP-7 Progress Report. FY-2015 Optimization Activities Summary

This report summarily documents the optimization activities on RELAP-7 for FY-2015. It includes the migration from the analytical stiffened gas equation of state for both the vapor and liquid phases to accurate and efficient property evaluations for both equilibrium and metastable (nonequilibrium) states using the Spline-Based Table Look-up (SBTL) method with the IAPWS-95 properties for steam and water. It also includes the initiation of realistic closure models based, where appropriate, on the U.S. Nuclear Regulatory Commission’s TRACE code. It also describes an improved entropy viscosity numerical stabilization method for the nonequilibrium two-phase flow model of RELAP-7. For ease of presentation to the reader, the nonequilibrium two-phase flow model used in RELAP-7 is briefly presented, though for detailed explanation the reader is referred to RELAP-7 Theory Manual [R.A. Berry, J.W. Peterson, H. Zhang, R.C. Martineau, H. Zhao, L. Zou, D. Andrs, “RELAP-7 Theory Manual,” Idaho National Laboratory INL/EXT-14-31366(rev. 1), February 2014].

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2016

DTK C/Fortran Interface Development for NEAMS FSI Simulations

This report documents the development of DataTransferKit (DTK) C and Fortran interfaces for fluid-structure-interaction (FSI) simulations in NEAMS. In these simulations, the codes Nek5000 and Diablo are being coupled within the SHARP framework to study flow-induced vibration (FIV) in reactor steam generators. We will review the current Nek5000/Diablo coupling algorithm in SHARP and the current state of the solution transfer scheme used in this implementation. We will then present existing DTK algorithms which may be used instead to provide an improvement in both flexibility and scalability of the current SHARP implementation. We will show how these can be used within the current FSI scheme using a new set of interfaces to the algorithms developed by this work. These new interfaces currently expose the mesh-free solution transfer algorithms in DTK, a C++ library, and are written in C and Fortran to enable coupling of both Nek5000 and Diablo in their native Fortran language. They have been compiled and tested on Cooley, the test-bed machine for Mira at ALCF.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2016

Implementation of flowsheet change to minimize hydrogen and ammonia generation during chemical processing of high level waste in the Defense Waste Processing Facility

Testing was completed to develop a chemical processing flowsheet for the Defense Waste Processing Facility (DWPF), designed to vitrify and stabilize high level radioactive waste. DWPF processing uses a reducing acid (formic acid) and an oxidizing acid (nitric acid) to rheologically thin the slurry and complete the necessary acid base and reduction reactions (primarily mercury and manganese). Formic acid reduces mercuric oxide to elemental mercury, allowing the mercury to be removed during the boiling phase of processing through steam stripping. In runs with active catalysts, formic acid can decompose to hydrogen and nitrate can be reduced to ammonia, both flammable gases, due to rhodium and ruthenium catalysis. Replacement of formic acid with glycolic acid eliminates the generation of rhodium- and ruthenium-catalyzed hydrogen and ammonia. In addition, mercury reduction is still effective with glycolic acid. Hydrogen, ammonia and mercury are discussed in the body of the report. Ten abbreviated tests were completed to develop the operating window for implementation of the flowsheet and determine the impact of changes in acid stoichiometry and the blend of nitric and glycolic acid as it impacts various processing variables over a wide processing region. Three full-length 4-L lab-scale simulations demonstrated the viability of the flowsheet under planned operating conditions. The flowsheet is planned for implementation in early 2017.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2017

Multi-Scale Ordered Cell Structure for Cost Effective Production of Hydrogen by HTWS

Production of hydrogen using an electrochemical device provides for large scale, high efficiency conversion and storage of electrical energy. When renewable electricity is used for conversion of steam to hydrogen, a low-cost and low emissions pathway to hydrogen production emerges. This project was intended to demonstrate a high efficiency High Temperature Water Splitting (HTWS) stack for the electrochemical production of low cost H2. The innovations investigated address the limitations of the state of the art through the use of a novel architecture that introduces macro-features to provide mechanical support of a thin electrolyte, and micro-features of the electrodes to lower polarization losses. The approach also utilizes a combination of unique sets of fabrication options that are scalable to achieve manufacturing cost objectives. The development of HTWS process and device is guided by techno-economic and life cycle analyses.

08 HYDROGEN↗
DOE OSTI2018

Final Report for Project 13-4791: New Mechanistic Models of Creep-Fatigue Crack Growth Interactions for Advanced High Temperature Reactor Components

This project developed and validated a novel, multi-scale, mechanism-based model to quantitatively predict creep-fatigue crack growth and failure for Ni-based Alloy 617 at 800°C. Alloy 617 is a target material for intermediate heat exchangers in Generation IV very high temperature reactor designs, and it is envisioned that this model will aid in the design of safe, long lasting nuclear power plants. The technical effectiveness of the model was shown by demonstrating that experimentally observed crack growth rates can be predicted under both steady state and overload crack growth conditions. Feasibility was considered by incorporating our model into a commercially available finite element method code, ABAQUS, that is commonly used by design engineers. While the focus of the project was specifically on an alloy targeted for Generation IV nuclear reactors, the benefits to the public are expected to be wide reaching. Indeed, creep-fatigue failure is a design consideration for a wide range of high temperature mechanical systems that rely on Ni-based alloys, including industrial gas power turbines, advanced ultra-super critical steam turbines, and aerospace turbine engines. It is envisioned that this new model can be adapted to a wide range of engineering applications.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Development of Novel Functionally Graded Transition Joints for Improving the Creep Strength of Dissimilar Metal Welds in Nuclear Applications

Steam generators of the small modular Very High Temperature Reactor (VHTR) will require use of Alloy 800 and 2.25Cr-1Mo steel in different regions depending on temperature and corrosion resistance requirements. As a result, Dissimilar Metal Welds (DMWs) between these two materials are critical for design, development, and manufacturing of the VHTR. DMWs are also used in many other applications in the power generation and petrochemical industries. Experience has demonstrated that failures of such DMWs can occur prematurely well below the expected creep life of either base metal, and these failures have significant consequences in terms of plant reliability, safety, and economic impact. These DMWs failures are caused by the abrupt change in composition that occurs at the weld interface between the two alloys. In this research, the concept of developing and optimizing Graded Transition Joints (GTJ) was developed through an integrated modeling and experimental approach. With GTJs, the composition is gradually graded between the two alloys, thus eliminating the sharp change in composition that causes failure. Microstructural modeling was first conducted to identify the optimum grade length required for improved resistance to carbon diffusion that is largely responsible for premature failure. Next, GTJs were fabricated and characterized in detail to understand how the microstructure evolves during fabrication and long term aging. Finally, the creep behavior of the GTJs was investigated and compared to that of conventional DMWs to demonstrate the superior creep strength of the GTJs. The results of this research provide significant insight into design, fabrication, microstructural evolution, and resultant performance of GTJs that can be used for reducing or eliminating DMW failures in a number of high temperature applications. The results also demonstrate that the GTJs can be readily fabricated with either conventional or additive manufacturing processes, and detailed guidelines are provided on the length of grades needed for optimal performance. The results of this research benefits the general public by improving the reliability of power generation and petrochemical plants that rely on DMWs for safe and reliable operation to deliver power and other products.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2018

Solid Oxide Based Electrolysis and Stack Technology with Ultra-High Electrolysis Current Density (>3A/cm 2 ) and Efficiency

Hydrogen, a valuable commodity gas, is increasingly recognized as an important fuel and energy storage pathway of the future. This project aims to develop an innovative solid oxide based electrolysis cell and stack technology with ultra-high steam electrolysis current (>3A/cm 2 ) for potentially ultra-low-cost, highly efficient hydrogen production from diverse renewable sources. In this project, solid oxide based high power density cells (HiPoD cells) were developed. Those cells demonstrated capability of operating at ultra-high electrolysis current density of 6 A/cm 2 at 1.67V. During a long term steady state electrolysis test, a HiPoD cell was operated for more than 1000 hours at 3 A/cm 2 with a low degradation rate of 1.8% per 1000 hours. A 20-cell electrolysis stack was built using HiPoD cells and an ultra-compact, low-cost stack design platform. This stack was used to explore the boundaries of high current density electrolysis operation and achieved an incredible stack current density of 3 A/cm 2 with an average cell voltage of only 1.493 V. The stack was further operated in steady-state electrolysis at 2 A/cm 2 for more than 1000 hours with an overall degradation of 0.57% per 1000 hours. With an improved understanding of electrolysis operation at ultra-high current density, a new compact stack architecture (CSA) design with scalability up to 55 kW (or 38 kg H 2 per day) was tested. A number of 45-cell CSA stack was built and demonstrated 10 kW and 245 g/hr hydrogen production at 1.8 A/cm 2 electrolysis current density. In addition to cell and stack development, a preliminary system design was developed by integrating the inputs from electrochemistry, cell/stack performance data, and system level implications of configuration and operational parameters. A module design was created based on a circular array of six stacks surrounded in a cool pressure vessel. Further architectural and controls strategies such as stack power control and instrumentation were determined through the development of the module. A comprehensive techno-economic study of an ultra-high current density SOEC system integrated with renewable energy sources has been conducted. To determine the estimated cost of hydrogen for the system, the H2A Current Distributed Hydrogen Production Model version 3.101 was applied. Annual system production cases at both commercial and industrial electricity rates as per the H2A model was analyzed. The option of meeting DOE 2020 Advanced Electrolysis Technologies targets were discussed. Feedstock electricity represents the bulk of projected hydrogen cost with either electricity rate. At an annual production volume of 250 units, H2A hydrogen cost of $2.3/kg can be achieved at electricity cost around 3.5¢/kWh.

08 HYDROGEN↗
DOE OSTI2019

The Northwest Geysers Enhanced Geothermal System Demonstration Project, The Geysers, California (Final Report)

An Enhanced Geothermal System (EGS) Demonstration Project was completed in the northwest portion of The Geysers geothermal field in Northern California. The goal was to demonstrate the feasibility of stimulating a deep, high temperature reservoir (HTR) with measured temperatures up to 750 °F (400 °C). We note that while some of the traditional Hot Dry Rock EGS concepts involves one or a few repeated hydraulically pressurized stimulations, our concept involves continuous injection over a periods of years at relatively low injection flows and at low pressures. Important measures of success are a sustained steam production rate and decreasing noncondensible gas (NCG) concentrations within the EGS Demonstration area. The project was completed in three phases and this Final Report characterizes the EGS reservoir and documents the successful stimulation of the HTR by the continuous injection of treated wastewater under only a gravity pressure head.

15 GEOTHERMAL ENERGY↗