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DOE OSTI2023

Transient Efficiency, Flexibility, and Reliability Optimization of Coal-Fired Power Plants - Final Report

This program developed an advanced model-based monitoring and model-predictive control algorithms for a coal fired power plant (CFPP), and deployed these algorithms in a real-time platform to demonstrate performance benefits for transient flexibility and plant operation efficiency. More specifically, the objectives were successfully achieved through a combination of (i) developing a high-fidelity transient plant model in Apros, which was used as a high-fidelity plant simulation between $100-50\% TMCR$ where TMCR denotes the turbine maximum continuous rating, i.e., baseload, (ii) developing a very fast physics-based reduced-order model (ROM) of the plant, which ran more than $100\times$ faster than real-time, enabling its use as real-time embedded model for model-based estimation (MBE) and model predictive control (MPC) (iii) implementing a real-time MBE based on ROM using a robust unscented Kalman filter (UKF) to continuously tune the ROM to match the measurements from high-fidelity Apros plant model despite significant plant-model mismatch, and thus, obtain a Digital Twin of the plant (iv) designing and implementing a real-time MPC with dual objectives of transient plant load tracking with high ramp rates and minimizing coal consumption, i.e., improving plant efficiency in the baseload-partload operation range of $100-50\% TMCR$. Each key element above was developed and tested individually, and has been reported in corresponding Topical Reports. Finally, all the individual elements were integrated in an overall closed-loop system, that was successfully tested in desktop Simulink test harness simulations with ROM or high-fidelity model as the plant. Thereafter, the Simulink implementation was used to auto-generate C-code and deploy as real-time Docker microservice containers in Linux, and validate that they can run in real-time in the hardware-in-the loop (HIL) setup and produce the same results as in Simulink. The results of the integrated simulation tests in Simulink as well as the real-time HIL deployment are documented in this final report, showing good load tracking for load ramps at $3-4\%/min$ ramp rates, and achieving up to $5.5\%$ reduction in coal relative to baseline operation at $50\% TMCR$ load. The desktop and HIL simulations show successful performance of the overall model based estimation and control solution and achieve the key objectives of the program for flexible, efficient and reliable operation of subcritical coal fired power plants.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2012

ALTERNATIVES OF MACCS2 IN LANL DISPERSION ANALYSIS FOR ONSITE AND OFFSITE DOSES

In modeling atmospheric dispersion to determine accidental release of radiological material, one of the common statistical analysis tools used at Los Alamos National Laboratory (LANL) is MELCOR Accident Consequence Code System, Version 2 (MACCS2). MACCS2, however, has some limitations and shortfalls for both onsite and offsite applications. Alternative computer codes, which could provide more realistic calculations, are being investigated for use at LANL. In the Yucca Mountain Project (YMP), the suitability of MACCS2 for the calculation of onsite worker doses was a concern; therefore, ARCON96 was chosen to replace MACCS2. YMP's use of ARCON96 provided results which clearly demonstrated the program's merit for onsite worker safety analyses in a wide range of complex configurations and scenarios. For offsite public exposures, the conservatism of MACCS2 on the treatment of turbulence phenomena at LANL is examined in this paper. The results show a factor of at least two conservatism in calculated public doses. The new EPA air quality model, AERMOD, which implements advanced meteorological turbulence calculations, is a good candidate for LANL applications to provide more confidence in the accuracy of offsite public dose projections.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2016

Bulk Electrical Cable Non-Destructive Examination Methods for Nuclear Power Plant Cable Aging Management Programs

This Pacific Northwest National Laboratory milestone report describes progress to date on the investigation of nondestructive test methods focusing particularly on bulk electrical test methods that provide key indicators of cable aging and damage. The work includes a review of relevant literature as well as hands-on experimental verification of inspection capabilities. As nuclear power plants consider applying for second, or subsequent, license renewal to extend their operating period from 60 years to 80 years, it is important to understand how the materials installed in plant systems and components will age during that time and develop aging management programs to assure continued safe operation under normal and design basis events (DBE). Normal component and system tests typically confirm the cables can perform their normal operational function. The focus of the cable test program, however, is directed toward the more demanding challenge of assuring the cable function under accident or DBE. The industry has adopted 50% elongation at break (EAB) relative to the un-aged cable condition as the acceptability standard. All tests are benchmarked against the cable EAB test. EAB, however, is a destructive test so the test programs must apply an array of other nondestructive examination (NDE) tests to assure or infer the overall set of cable’s system integrity. Assessment of cable integrity is further complicated in many cases by vendor’s use of dissimilar material for jacket and insulation. Frequently the jacket will degrade more rapidly than the underlying insulation. Although this can serve as an early alert to cable damage, direct test of the cable insulation without violating the protective jacket becomes problematic. This report addresses the range of bulk electrical NDE cable tests that are or could be practically implemented in a field-test situation with a particular focus on frequency domain reflectometry (FDR). The FDR test method offers numerous advantages over many other bulk electrical tests. Two commercial FDR systems plus a laboratory vector network analyzer are used to test an array of aged and un-aged cables under identical conditions. Several conclusions are set forth, and a number of knowledge gaps are identified.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2013

Summary of Large Concrete Samples

Materials issues are a key concern for the existing nuclear reactor fleet as material degradation can lead to increased maintenance, increased downtime, and increased risk. Extending reactor life to 60 years and beyond will likely increase susceptibility and severity of known forms of degradation. Additionally, new mechanisms of materials degradation are also possible. The purpose of the U.S. Department of Energy Office of Nuclear Energy’s Light Water Reactor Sustainability (LWRS) Program is to develop technologies and other solutions that can improve the reliability, sustain the safety, and extend the operating lifetimes of nuclear power plants beyond 60 years. The intent of this LWRS Concrete nondestructive evaluation (NDE) roadmap is to define Research & Development (R&D) actions to address gaps between available NDE concrete techniques and the technology needed to make quantitative measurements to determine the durability and performance of concrete structures on our current nuclear power plant (NPP) fleet. A multitude of concrete-based structures are typically part of a light water reactor (LWR) plant to provide foundation, support, shielding, and containment functions. Concrete has been used in the construction of NPPs because of three primary properties: its inexpensiveness, its structural strength, and its ability to shield radiation. Examples of concrete structures important to the safety of LWR plants include containment building, spent fuel pool, and cooling towers. This use has made its long-term performance crucial for the safe operation of commercial NPPs. With respect to the concrete structures, age-related degradation may affect engineering properties, structural resistance/capacity, failure mode, and location of failure initiation that in turn may affect the ability of a structure to withstand challenges in service. In order to ensure the safe operation of NPPs, it is essential that the effects of potential degradation of the plant structures, as well as systems and components, be assessed and managed during both the current operating license period as well as subsequent license renewal periods. In contrast to many mechanical and electrical components, replacement of many concrete structures is impractical. Therefore it is necessary that safety issues related to plant aging and continued service of the concrete structures are resolved through sound scientific and engineering understanding.

concrete↗

DOE OSTI2022

Stress Intensity Thresholds for Development of Reliable Brittle Materials

Brittle material failure in high consequence systems can appear random and unpredictable at subcritical stresses. Gaps in our understanding of how structural flaws and environmental factors (humidity, temperature) impact fracture propagation need to be addressed to circumvent this issue. A combined experimental and computational approach composed of molecular dynamics (MD) simulations, numerical modeling, and atomic force microscopy (AFM) has been undertaken to identify mechanisms of slow crack growth in silicate glasses. AFM characterization of crack growth as slow as 10 -13 m/s was observed, with some stepwise crack growth. MD simulations have identified the critical role of inelastic relaxation in crack propagation, including evolution of the structure during relaxation. A numerical model for the existence of a stress intensity threshold, a stress intensity below which a fracture will not propagate, was developed. This transferrable model for predicting slow crack growth is being incorporated into mission-based programs.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Environmental and Operational Performance of CO2-EOR as a CCUS Technology: A Cranfield Example with Dynamic LCA Considerations

This study evaluates the potential of carbon dioxide-enhanced oil recovery (CO2-EOR) to reduce greenhouse gas emissions without compromising oil production goals. A novel, dynamic carbon lifecycle analysis (d-LCA) was developed and used to understand the evolution of the environmental impact (CO2 emissions) and mitigation (geologic CO2 storage) associated with an expanded carbon capture, utilization and storage (CCUS) system, from start to closure of operations. EOR operational performance was assessed through CO2 utilization rates, which relate usage of CO2 to oil production. Because field operational strategies have a significant impact on reservoir engineering parameters that affect both CO2 storage and oil production (e.g., sweep efficiency, flood conformance, fluid saturation distribution), we conducted a scenario analysis that assessed the operational and environmental performance of four common and novel CO2-EOR field development strategies. Each scenario was evaluated with and without stacked saline carbon storage, an EOR/storage combination strategy where excess CO2 from the recycling facility is injected into an underlying saline aquifer for long-term carbon storage. The dynamic interplay between operational and environmental performance formed the basis of our CCUS technology analysis. The results showed that all CO2-EOR evaluated scenarios start operating with a negative carbon footprint and, years into the project, transitioned into operating with a positive carbon footprint. The transition points were significantly different in each scenario. Water-alternating-gas (WAG) was identified as the CO2 injection strategy with the highest potential to co-optimize EOR and carbon storage goals. The results provide an understanding of the evolution of the system’s net carbon balance in all four field development strategies studied. The environmental performance can be significantly improved with stacked storage, where a negative carbon footprint can be maintained throughout the life of the operation in most of the injection scenarios modelled. This information will be useful to CO2-EOR operators seeking value in storing more CO2 through a carbon credit program (e.g., the 45Q carbon credit program in the USA). Most importantly, this study serves as confirmation that CO2-EOR can be operationally designed to both enhance oil production and reduce greenhouse gas emissions into the atmosphere.

58 GEOSCIENCES↗

DOE OSTI2012

Advanced Composite Wind Turbine Blade Design Based on Durability and Damage Tolerance

The objective of the program was to demonstrate and verify Certification-by-Analysis (CBA) capability for wind turbine blades made from advanced lightweight composite materials. The approach integrated durability and damage tolerance analysis with robust design and virtual testing capabilities to deliver superior, durable, low weight, low cost, long life, and reliable wind blade design. The GENOA durability and life prediction software suite was be used as the primary simulation tool. First, a micromechanics-based computational approach was used to assess the durability of composite laminates with ply drop features commonly used in wind turbine applications. Ply drops occur in composite joints and closures of wind turbine blades to reduce skin thicknesses along the blade span. They increase localized stress concentration, which may cause premature delamination failure in composite and reduced fatigue service life. Durability and damage tolerance (D&DT) were evaluated utilizing a multi-scale micro-macro progressive failure analysis (PFA) technique. PFA is finite element based and is capable of detecting all stages of material damage including initiation and propagation of delamination. It assesses multiple failure criteria and includes the effects of manufacturing anomalies (i.e., void, fiber waviness). Two different approaches have been used within PFA. The first approach is Virtual Crack Closure Technique (VCCT) PFA while the second one is strength-based. Constituent stiffness and strength properties for glass and carbon based material systems were reverse engineered for use in D&DT evaluation of coupons with ply drops under static loading. Lamina and laminate properties calculated using manufacturing and composite architecture details matched closely published test data. Similarly, resin properties were determined for fatigue life calculation. The simulation not only reproduced static strength and fatigue life as observed in the test, it also showed composite damage and fracture modes that resemble those reported in the tests. The results show that computational simulation can be relied on to enhance the design of tapered composite structures such as the ones used in turbine wind blades. A computational simulation for durability, damage tolerance (D&DT) and reliability of composite wind turbine blade structures in presence of uncertainties in material properties was performed. A composite turbine blade was first assessed with finite element based multi-scale progressive failure analysis to determine failure modes and locations as well as the fracture load. D&DT analyses were then validated with static test performed at Sandia National Laboratories. The work was followed by detailed weight analysis to identify contribution of various materials to the overall weight of the blade. The methodology ensured that certain types of failure modes, such as delamination progression, are contained to reduce risk to the structure. Probabilistic analysis indicated that composite shear strength has a great influence on the blade ultimate load under static loading. Weight was reduced by 12% with robust design without loss in reliability or D&DT. Structural benefits obtained with the use of enhanced matrix properties through nanoparticles infusion were also assessed. Thin unidirectional fiberglass layers enriched with silica nanoparticles were applied to the outer surfaces of a wind blade to improve its overall structural performance and durability. The wind blade was a 9-meter prototype structure manufactured and tested subject to three saddle static loading at Sandia National Laboratory (SNL). The blade manufacturing did not include the use of any nano-material. With silica nanoparticles in glass composite applied to the exterior surfaces of the blade, the durability and damage tolerance (D&DT) results from multi-scale PFA showed an increase in ultimate load of the blade by 9.2% as compared to baseline structural performance (without nano). The use of nanoparticles lead to a delay in the onset of delamination. Load-displacement relationships obtained from testing of the blade with baseline neat material were compared to the ones from analytical simulation using neat resin and using silica nanoparticles in the resin. Multi-scale PFA results for the neat material construction matched closely those from test for both load displacement and location and type of damage and failure. AlphaSTAR demonstrated that wind blade structures made from advanced composite materials can be certified with multi-scale progressive failure analysis by following building block verification approach.

17 WIND ENERGY↗

DOE OSTI2020

3-D Radiological Data Acquisition, Visualization and Modeling - 20211

The U.S. Army Corps of Engineers (USACE) was tasked to investigate and remediate low activity radiological contamination from research and production of the nation's first nuclear weapons at the former DuPont Chambers Works Formerly Utilized Sites Remedial Action Program (FUSRAP) site (DuPont). The DuPont site had several buildings used for the Manhattan project that were demolished in the 1940's and 1950's apparently using heavy earthmoving equipment. Some of the contaminated rubble from the demolition appears to have been spread out by this equipment resulting in somewhat random scattering of radiologically contaminated soil and debris along with aqueous spills. Traditional investigative methods such as soil borings, test pits and 2-dimensional gamma walkovers were only partially successful in delineating the radiological contamination at the site. It was feared that even 'chasing' the contamination during remediation would miss contamination if the demolition resulted in discontinuous trails of radiologically contaminated soils. In evaluating the data generated over the interceding decades, the USACE determined that a better method to collect and process the remedial action radiological data was needed to enable the project team to optimize predictive planning and meet documentation expectations. The purpose of this paper is to provide an overview of the effort and progress to combine and organize radiological survey methods into a highly flexible sampling, modeling, and decision analysis approach that emphasizes the quality of decision-making during remediation. This innovative system blends multiple tools to develop a methodology that can extend MARRSIM [1] into the subsurface and provide tools that can be applied to other sites. (authors)

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2016

Ultra-High-Performance Concrete And Advanced Manufacturing Methods For Modular Construction

Small modular reactors (SMR) allow for less onsite construction, increase nuclear material security, and provide a flexible and cost-effective energy alternative. SMR can be factory-built as modular components, and shipped to desired locations for fast assembly. This project successfully developed a new class of ultra-high performance concrete (UHPC), which features a compressive strength greater than 22 ksi (150 MPa) without special treatment and self-consolidating characteristics desired for SMR modular construction. With an ultra-high strength and dense microstructure, it will facilitate rapid construction of steel plate-concrete (SC) beams and walls with thinner and lighter modules, and can withstand harsh environments and mechanical loads anticipated during the service life of nuclear power plants. In addition, the self-consolidating characteristics are crucial for the fast construction and assembly of SC modules with reduced labor costs and improved quality. Following the UHPC material development, the capacity of producing self-consolidating UHPC in mass quantities was investigated and compared to accepted self-consolidating concrete standards. With slightly adjusted mixing procedure using large-scale gravity-based mixers (compared with small-scale force-based mixer), the self-consolidating UHPC has been successfully processed at six cubic yards; the product met both minimum compressive strength requirements and self-consolidating concrete standards. Steel plate-UHPC beams (15 ft. long, 12 in. wide and 16 in. deep) and wall panels (40 in. X 40 in. X 3 in.) were then constructed using the self-consolidating UHPC without any external vibration. Quality control guidelines for producing UHPC in large scale were developed. When the concrete is replaced by UHPC in a steel plate concrete (SC) beam, it is critical to evaluate its structural behavior with both flexure and shear-governed failure modes. In recent years, SC has been widely used for buildings and nuclear containment structures to resist lateral forces induced by severe earthquakes and heavy winds. SC modules have good potential for SMR because of their cost-effectiveness and reduced construction time. However, the minimum shear reinforcement (i.e. cross tie) ratio needs to be determined for the steel plate-UHPC (S-UHPC) beams to exhibit a ductile failure mode. In this project, S-UHPC beams were designed and constructed. The beams were tested to evaluate structural capacity and identify the minimum cross ties ratios. In addition, as the bond between UHPC and steel plate is essential for ensuring structural integrity under shear and flexure, it was measured and examined in this project through digital image correlation system and smart piezoelectric aggregate sensors. Large-scale testing and finite element simulation were also performed on S-UHPC wall panels. New bond slip-based constitutive models of steel plate were developed for S-UHPC, which were used in finite element analysis program to predict S-UHPC behavior under shear. The results were well validated through experimental data. The long-term durability of UHPC were established in this project. UHPC specimens were tested under free shrinkage, restrained shrinkage, elevated temperature, water permeation, chloride diffusion, corrosion, and alkali silica reaction. UHPC has demonstrated significantly improved durability compared with control concrete specimens. This research led to a new generation of steel plate-UHPC modules for SMR that can provide large benefits to the electric power industry. Taking advantage of the high strength and durability of UHPC, their modularity and ease of assembly can address the high cost barriers of typical nuclear power plants.

42 ENGINEERING↗

DOE OSTI2026

Blueprint: Coordinated Vulnerability Disclosure (CVD) Adaption and Adoption Guide for Industry To Create Their Own CVD Program

This guide provides a series of steps and guidance for electric vehicle supply equipment (EVSE) industry members to set up their own coordinated vulnerability disclosure (CVD) program by utilizing the Software Engineering Institute/Computer Emergency Response Team (SEI/CERT)’s CVD how-to guide. Due to the complexity of CVD, and with the existing resources out there, this guide is intended that this portion of the blueprint is an extension of the CVD how-to guide, not meant as a replacement. This guide is meant to outline a process for what to do when you discover a vulnerability on EVSE equipment. It is written for developers, vendors and security researchers as well as management. This is not a technical document. It is meant to be accessible for both technical and non-technical roles.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2022

Node Monitoring as a Fault Detection Countermeasure against Information Leakage within a RISC-V Microprocessor

Advanced, superscalar microprocessors (μP) are highly susceptible to wear-out failures because of their highly complex, densely packed circuit structure and extreme operational frequencies. Although many types of fault detection and mitigation strategies have been proposed, none have addressed the specific problem of detecting faults that lead to information leakage events on I/O channels of the μP. Information leakage can be defined very generally as any type of output that the executing program did not intend to produce. In this work, we restrict this definition to output that represents a security concern, and in particular, to the leakage of plaintext or encryption keys, and propose a counter-based countermeasure to detect faults that cause this type of leakage event. Fault injection (FI) experiments are carried out on two RISC-V microprocessors emulated as soft cores on a Xilinx multi-processor System-on-chip (MPSoC) FPGA. The μP designs are instrumented with a set of counters that records the number of transitions that occur on internal nodes. The transition counts are collected from all internal nodes under both fault-free and faulty conditions, and are analyzed to determine which counters provide the highest fault coverage and lowest latency for detecting leakage faults. We show that complete coverage of all leakage faults is possible using only a single counter strategically placed within the branch compare logic of the μPs.

42 ENGINEERING↗

DOE OSTI2012

Los Alamos National Laboratory W76 Pit Tube Lifetime Study

A metallurgical study was requested as part of the Los Alamos National Laboratory (LANL) W76-1 life-extension program (LEP) involving a lifetime analysis of type 304 stainless steel pit tubes subject to repeat bending loads during assembly and disassembly operations at BWXT/Pantex. This initial test phase was completed during the calendar years of 2004-2006 and the report not issued until additional recommended tests could be performed. These tests have not been funded to this date and therefore this report is considered final. Tubes were reportedly fabricated according to Rocky Flats specification P14548 - Seamless Type 304 VIM/VAR Stainless Steel Tubing. Tube diameter was specified as 0.125 inches and wall thickness as 0.028 inches. A heat treat condition is not specified and the hardness range specification can be characteristic of both 1/8 and 1/4 hard conditions. Properties of all tubes tested were within specification. Metallographic analysis could not conclusively determine a specified limit to number of bends allowable. A statistical analysis suggests a range of 5-7 bends with a 99.95% confidence limit. See the 'Statistical Analysis' section of this report. The initial phase of this study involved two separate sets of test specimens. The first group was part of an investigation originating in the ESA-GTS [now Gas Transfer Systems (W-7) Group]. After the bend cycle test parameters were chosen (all three required bends subjected to the same amount of bend cycles) and the tubes bent, the investigation was transferred to Terri Abeln (Metallurgical Science and Engineering) for analysis. Subsequently, another limited quantity of tubes became available for testing and were cycled with the same bending fixture, but with different test parameters determined by T. Abeln.

36 MATERIALS SCIENCE↗

DOE OSTI2013

Predicting Backdrafting and Spillage for Natural-Draft Gas Combustion Appliances: Validating VENT-II

VENT-II is a computer program designed to provide detailed analysis of natural draft and induced draft combustion appliance vent-systems (i.e., furnace or water heater). This program is capable of predicting house depressurization thresholds that lead to backdrafting and spillage of combustion appliances; however, validation reports of the program being applied for this purpose are not readily available. The purpose of this report is to assess VENT-II’s ability to predict combustion gas spillage events due to house depressurization by comparing VENT-II simulated results with experimental data for four appliance configurations. The results show that VENT-II correctly predicts depressurizations resulting in spillage for natural draft appliances operating in cold and mild outdoor conditions, but not for hot conditions. In the latter case, the predicted depressurizations depend on whether the vent section is defined as part of the vent connector or the common vent when setting up the model. Overall, the VENTII solver requires further investigation before it can be used reliably to predict spillage caused by depressurization over a full year of weather conditions, especially where hot conditions occur.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2021

Gimballed Tracking Mount Pointing Angle Qualification

Tonopah Test Range (TTR), in support of its testing mission and modernization effort acquired a fleet of new gimballed tracking mounts (GTMs) manufactured by BAE Systems. The new GTMs can be operated remotely during flight tests and provide near real-time target tracking data. Furthermore, test vehicle Time-Space-Position-Information (TSPI) is evaluated using post-test synchronized imagery and pointing angle measurements acquired from each tracking mount. To comply with the Nuclear Enterprise Assurance Program (NEAP), all measurements devices must be certified. In keeping with the NEAP program, qualification of the new GTMs have been assessed to confirm that their pointing angle measurements produce acceptable TSPI results. This study only evaluated the four GTMs as a stand-alone solution and found that the GTMs meet their performance requirement of 0.006 degrees RMS error (or less) for post-processed pointing angles and produced TSPI solution with error volumes on the order of one meter or less. The new GTMs will be utilized in combination with existing optical tracking mounts, which will only improve the accuracy of the resulting TSPI data product. Details regarding the approach, analysis, summary results, and conclusions are presented.

42 ENGINEERING↗

DOE OSTI2013

COMMERCIALIZATION OF AN ATMOSPHERIC IRON-BASED CDCL PROCESS FOR POWER PRODUCTION. PHASE I: TECHNOECONOMIC ANALYSIS

Coal Direct Chemical Looping (CDCL) is an advanced oxy-combustion technology that has potential to enable substantial reductions in the cost and energy penalty associated with carbon dioxide (CO2) capture from coal-fired power plants. Through collaborative efforts, the Babcock & Wilcox Power Generation Group (B&W) and The Ohio State University (OSU) developed a conceptual design for a 550 MWe (net) supercritical CDCL power plant with greater than 90% CO2 capture and compression. Process simulations were completed to enable an initial assessment of its technical performance. A cost estimate was developed following DOE’s guidelines as outlined in NETL’s report “Quality Guidelines for Energy System Studies: Cost Estimation Methodology for NETL Assessments of Power Plant Performance”, (2011/1455). The cost of electricity for the CDCL plant without CO2 Transportation and Storage cost resulted in $ $102.67 per MWh, which corresponds to a 26.8 % increase in cost of electricity (COE) when compared to an air-fired pulverized-coal supercritical power plant. The cost of electricity is strongly depending on the total plant cost and cost of the oxygen carrier particles. The CDCL process could capture further potential savings by increasing the performance of the particles and reducing the plant size. During the techno-economic analysis, the team identified technology and engineering gaps that need to be closed to bring the technology to commercialization. The technology gaps were focused in five critical areas: (i) moving bed reducer reactor, (ii) fluidized bed combustor, (iii) particle riser, (iv) oxygen-carrier particle properties, and (v) process operation. The key technology gaps are related to particle performance, particle manufacturing cost, and the operation of the reducer reactor. These technology gaps are to be addressed during Phase II of project. The project team is proposing additional lab testing to be completed on the particle and a 3MWth pilot facility be built to evaluate the reducer reactor performance among other aspects of the technology. A Phase II proposal was prepared and submitted to DOE. The project team proposed a three year program in Phase II. Year 1 includes lab testing and particle development work aimed at improving the chemical and mechanical properties of the oxygen carrier particle. In parallel, B&W will design the 3MWt pilot plant. Any improvements to the particle performance discovered in year 1 that would impact the design of the pilot will be incorporated into the final design. Year 2 will focus on procurement of materials and equipment, and construction of the pilot plant. Year 3 will include, commissioning, start-up, and testing in the pilot. Phase I work was successfully completed and a design and operating philosophy for a 550 MWe commercial scale coal-direct chemical looping power plant was developed. Based on the results of the techno-economic evaluation, B&W projects that the CDCL process can achieve 96.5% CO2 capture with a

Coal Combustion↗

DOE OSTI2022

Multiscale Experiments and Multiphysics Simulation of Multiphase Flow for Transportable Small Modular Reactors

A new type of safe, small, transportable nuclear reactor would address the intense and ever-growing global demand for energy produced via a resilient, carbon-free energy source. In this regard, transportable small modular reactors (SMRs) are being designed and developed for electricity generation within small/micro-grid/off-grid isolated systems, as well as for heat generation in industrial/residential applications. These reactors feature the capability to be fully factory fabricated and then directly transported to utilities’ sites as “plug-and-play” systems. Research and development (R&D) programs are underway at Idaho National Laboratory (INL) to successfully design, develop, and demonstrate such safe-by-design mobile reactor technologies, in collaboration with partner organizations. Multiscale experimental facilities and multiphysics simulation tools are required for reactor design verification and validation (V&V), and licensing. These advanced reactors are intended to feature passive safety systems such as passive containment cooling systems (PCCS), which consist of multiphase flows and multispecies distributions. This seminar talk will focus on designing and analyzing transportable SMR PCCS by using multiscale experiments and multiphysics computational fluid dynamics (CFD) simulations to support reactor licensing and safety. The corresponding research challenges are addressed via supportive verification and validation results generated by the models and simulation tools in combination with selective parametric and uncertainty analysis. This solution approach could blaze the trail for commercial adoption of such technologies. The facilities, simulation capabilities, and research opportunities available at INL in regard to such reactors and the integrated energy systems with which they go hand in hand are also discussed briefly, and may spark interest in deeper research as well as new collaborative projects.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2018

Hanford Double Shell Tank Integrity Inspection - Integration of Customized Robotics - 18400

28 steel, double-shell, million gallon waste storage tanks located at the Hanford site in Washington State store both radioactive and hazardous waste. To monitor their condition and ensure continued viability, these tanks are inspected periodically through a comprehensive integrity program. In 2012, the first leak in a double-shell tank at Hanford was discovered in the 241-AY tank farm (Tank AY-102) and the failure was observed to be from the primary tank bottom. However, the exact failure location and damage mechanism have not been determined. A decision was made to pursue the capability to inspect the primary tank bottom region in order to provide additional tank integrity information. This work is particularly challenging due to the confined space in the double-shell tank annulus region (i.e. the 30 inch space between the primary and secondary tank shells), the limited dimensions of the tank risers that provide access to the annulus space (risers as small as 10 inches in diameter), and also the very small dimensions of the air channels in the concrete refractory pad that the primary waste storage tank rests on (channels are approximately two inches in diameter). Veolia Nuclear Solutions, along with Key Subcontractor Inuktun, were contracted to provide the capability to conduct these tank inspections in support of Hanford's double-shell tank integrity program. The Veolia Nuclear Solutions /Inuktun team designed, built, tested and delivered a tethered miniature robotic crawler system that utilizes the marsupial approach - a larger deployment crawler positions a smaller inspection crawler. The deployment crawler is installed via the tank riser, is magnetically coupled to the side of the tank shell, and drives to the selected deployment location at the end of one of the refractory channels where the small inspection robot is subsequently deployed. Operation of the equipment is controlled from a trailer outside the tank farm (a distance of several hundred feet). The system design includes a custom mechanism that provides for positioning and cable handling as well as the controls interface (laptop connected via control cables). The solution leveraged the Veolia Nuclear Solutions/Inuktun team's experience with delivering similar modular systems for other US and international sites. This simple but innovative solution delivered on an accelerated project schedule underlines the ability to provide effective robotic solutions to the nuclear industry. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2022

Case studies of robots and automation as health/safety interventions in small manufacturing enterprises

This article reviews the experiences of 63 case studies of small businesses (<250 employees) with manufacturing automation equipment acquired through a health/safety intervention grant program. The review scope included equipment technologies classified as industrial robots (n = 17), computer numerical control (CNC) machining (n = 29), or other programmable automation systems (n = 17). Descriptions of workers' compensation (WC) claim injuries and identified risk factors that motivated the acquisition of the equipment were extracted from grant applications. Other aspects of the employer experiences, including qualitative and quantitative assessment of effects on risk factors for musculoskeletal disorders (MSD), effects on productivity, and employee acceptance of the intervention were summarized from the case study reports. Case studies associated with a combination of large reduction in risk factors, lower cost per affected employee, and reported increases in productivity were CNC stone cutting system, CNC/vertical machining system, automated system for bottling, CNC/routing system for plastics products manufacturing, and a CNC/Cutting system for vinyl/carpet. Six case studies of industrial robots reported quantitative reductions in MSD risk factors in these diverse manufacturing industries: snack foods; photographic film, paper, plate, and chemical; machine shops; leather goods and allied products; plastic products; and iron and steel forging. Furthermore, this review of health/safety intervention case studies indicates that advanced (programmable) manufacturing automation, including industrial robots, reduced workplace musculoskeletal risk factors, and improved process productivity in most cases.

42 ENGINEERING↗