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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Direct internal recycling fractions approaching unity

Direct internal recycling (DIR) refers to the process of recovering pure hydrogen isotopes (D/T) from helium and other impurities in the fusion plasma exhaust and directing them back to the fuel injection system. Increasing the exhaust fraction purified through DIR significantly reduces the size and cost of the tritium plant and provides additional benefits including reduced requirements for both the tritium startup inventory and tritium breeding ratio. Metal foil pumps (MFPs) are the dominant technology for this separation, relying on the concept of superpermeation. We recently demonstrated that PdCu foils operated at low temperature provide both exceptional flux and resilience to helium absorption as the DIR fraction is increased. Herein we design and demonstrate continuous and semi-batch DIR processes using PdCu MFPs. Under continuous processing, stable performance was observed for DIR fractions up to 92 %. In addition, we demonstrate a semi-batch process capable of extending the DIR fraction to unity (> 99.8 %). Under the experimental conditions described within a PdCu MFP area of ~22 m 2 would be sufficient to process the fusion exhaust with 92 % DIR fraction at expected flowrates of 100 Pa·m 3 ·s -1 for a future fusion power plant.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Preliminary Testing of a Continuous Cryopump for Primary Fusion Device Pumping and Direct Internal Recycling

Here, the concept of directly recirculating fusion machine exhaust gas, bypassing the tritium plant, to make fuel pellets was proposed in the 1990s and later termed direct internal recycling (DIR). In the DIR concept, the residual fusion fuel in the machine exhaust stream is separated from impurities locally and diverted directly to the fueling systems, bypassing isotopic separation and other processing equipment, and therefore significantly reducing the required size of the fuel processing plant, reducing plant inventory, and thus increasing the economic viability of fusion as an energy source. One concept for DIR consists of a series of cryogenic pumps to separate the impurities from the machine exhaust gas using different triple point temperatures and saturation curves of exhaust constituents. In this concept, the plasma exhaust is initially passed through an impurity trap operating at ~25–30 K to desublimate impurities such as hydrocarbons, argon, oxygen, and nitrogen. The resulting process stream will consist of DT fuel and helium. The process stream is then pumped by a continuous cryopump known as a “snail pump.” This pump is a steady-state continuous cryopump that desublimates all remaining exhaust gas constituents while allowing helium, a byproduct of the fusion reaction, to pass through. The helium is pumped to the tritium plant for processing while the desublimated material is continuously scraped off, heated up, and transported to the fueling system. This article will present the cryogenic DIR concept and outline the design and operation of the snail pump, along with results from preliminary testing. Tests to assess pumping and separation efficiency found that at D2 flows below 50.7 Pa ⋅ m3/s with 1% helium, the pump is capable of pumping and separating the gas with a resulting DIR fraction of >99%, with no helium entrained in the primary fuel exhaust stream. The main limitation is due to the thermal performance of the cryogenic circuits of the pump, which will be addressed in future testing.

Gebhart III, Trey E. [Oak Ridge National Laborator↗
DOE OSTI2025

The impact of argon addition on hydrogen superpermeation through palladium alloy metal foil pumps during direct internal recycling

Metal foil pumps (MFPs) are a leading technology for the direct internal recycling (DIR) of hydrogen isotopes from the plasma exhaust of fusion devices. MFPs rely on the concept of superpermeation, where plasma-generated atomic hydrogen absorbs into the metal foil, rapidly diffuses, and desorbs downstream. To date, studies of superpermeation have predominantly employed pure hydrogen or in some cases trace levels of impurities. In practice the plasma exhaust may contain significant levels of plasma enhancement gases such as argon, an inert gas with metastable states that can enhance the plasma. In this work, we systematically study the impact of Ar addition on the performance of PdCu and PdAg MFPs at low temperature. Performance was strongly dependent on the DIR fraction. At negligible DIR levels Ar addition did not significantly improve the flux over dilution effects. However, under appreciable DIR operation the flux was enhanced up to 90 % relative to pure H 2 , with the optimal concentration range being 5–10 % Ar exiting the system. Beyond 15 % addition plasma enhancement benefits were offset by dilution. Performance correlated with the atomic H emission, and benefits were more pronounced for PdAg than PdCu. Operation at significant DIR levels dramatically alters the flow dynamics resulting in concentration gradients near the MFP, creating plasma conditions that promote H 2 dissociation.

70 - PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

The impact of helium on plasma-driven hydrogen permeation and implications for direct internal recycling in the fusion fuel cycle

Abstract Metal foil pumps (MFPs) are the leading technology for direct internal recycling (DIR) of hydrogen isotopes from the plasma exhaust in future fusion plants. MFPs rely on the concept of superpermeation, where superthermal H atoms directly absorb into the metal foil, rapidly diffuse, and desorb downstream. To date, studies of superpermeation have predominantly employed either pure hydrogen or in some cases trace levels of impurities. The plasma exhaust is expected to contain just ∼1% helium, but in DIR the source gas would be enriched in helium as hydrogen isotopes are extracted. In this work, we explore the impact of helium on hydrogen superpermeation at low temperature (75 °C–200 °C) using Pd-based foils. To first order, the flux scaled linearly with the hydrogen mole fraction. Stable permeation was observed until the helium fraction reached ∼80%, where the flux began to decline slowly with time. In addition, short term (1–5 min) exposure to pure helium plasma significantly attenuated subsequent hydrogen plasma permeation, and the degree was more dramatic at elevated temperature. This attenuation was correlated with He retention in the foils, which was detected by time-of-flight secondary ion mass spectrometry at low levels (<0.1 at. %) and limited to the near surface (<10 nm). Similar trends were observed among all alloys (Pd, PdAg, PdCu), and the foils were restored to full performance with an Ar + sputter clean. The potential for helium plasma exposure to impact MFP performance under these conditions has not been previously reported, and these findings have significant implications to the design and implementation of practical DIR systems.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2026

Separation of Hydrogen Using Pd/Ag Membranes: Experimental and Modeling Results with Potential Application to Direct Internal Recycle

Implementation of fusion energy requires processing the deuterium-tritium (D-T) mixture used to fuel the reaction, and separation of hydrogen isotopes from other gases is imperative. Specifically, the separation of hydrogen isotopes from helium is a matter of importance to the fusion fuel cycle community. Initial testing with a palladium-silver (Pd-Ag) membrane indicates that even moderate vacuum (~100 torr permeate pressure) can provide a high degree of separation (>90%) at a high ratio of H 2 to He. Given the presence of He in many fusion systems, a high technology readiness level (TRL) for Q 2 /He (where Q represents any isotope of hydrogen) separations is needed. This study demonstrates the efficacy of H 2 removal from He via permeation and potential applications for direct internal recycle. Modeling will accompany the experimental campaign to generate a predictive capability and quantify the separation performance. Modeling from previous hydrogen permeation studies has demonstrated that the typical Sieverts’ law fails to predict the measured permeation rates at high hydrogen fluxes. Existing models are being refined to integrate the effects of surface phenomena into permeation predictions, which have been expanded to account for mixtures with large ranges of Q 2 concentrations. These data will improve the TRL of permeators as a separation technology for the fusion fuel cycle.

08 HYDROGEN↗
DOE OSTI2025

Evaluating the Impact of Tritium Permeation Membrane Performance and Direct Internal Recycling on Fusion Fuel Cycle Efficiency Using TMAP8

An efficient fuel cycle is vital to sustainable and cost-effective energy generation in fusion systems. Since tritium is not widely available, fusion systems must breed their own tritium for sustainable fusion deuterium-tritium reactions. An inefficient fuel cycle increases the tritium inventory needed for operations, which increases costs, constraints on tritium management systems, and safety concerns. A fuel cycle model is a powerful tool for understanding tritium inventories and flow rates across all systems in the fuel cycle. By simplifying the technical details into time-dependent tritium flow rates and inventories, the model can simulate the entire fuel cycle with high computational efficiency, even for technologies that are still under development. It can therefore quantify the impact of new tritium management technologies on fuel cycle efficiency. To evaluate the impact of key components on reducing tritium inventory, we are using and expanding an existing fuel cycle models based on latest advancements in fuel cycle research. The new model integrates Tritium Permeation Membrane (TPM) and Direct Internal Recycling (DIR) to enhance tritium transport from blanket breeders and plasma exhaust. These fuel cycle models are implemented in TMAP8 (Tritium Migration Analysis Program, version 8), a MOOSE-based open-source application designed to provide cutting-edge capabilities for tritium transport and fuel cycle modeling. The study aims to demonstrate the extensibility of existing fuel cycle modeling capability in TMAP8 and to offer a proof-of-principle design for future fusion plant systems. The presentation will cover the performance of fuel cycle modeling capabilities available in TMAP8, highlight advancements in fuel cycle research, and present a sensitivity analysis of these models. The results underline potential approaches and technology solutions to lower tritium inventory requirements, highlighting their role in shaping the future of fusion energy.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Effects of Target Protium Content on SteadyState Isotope Rebalancing and Protium Removal Distillation Column Operation

• SRNL Fusion Fuel Cycle Research • SRNL Fuel Cycle Tritium Inventory Optimization Approaches • RHINO/Aspen • CODFISH • Direct Internal Recycling • IFE Fuel Cycle Overview • Direct Internal Recycling Applied to IFE • CODFISH Isotope Rebalancing and Protium Removal Column Optimization • RHINO Fuel Cycle Analysis • Conclusions and Future Work

Somers, Alex [Savannah River National Laboratory (↗
DOE OSTI2025

An optimization approach for cryogenic distillation-based protium removal systems in magnetic fusion energy fuel cycles

Tritium inventory reduction for fusion power plants is central to the successful adoption of fusion energy. The advent of direct internal recycling in deuterium-tritium fusion fuel cycle design has led to significant reduction in startup tritium inventory estimates for fusion power plants but requires an isotope rebalancing and protium removal (IRPR) system to ensure acceptable isotopic fuel composition. Cryogenic distillation is a potential solution for near-term deployment in an IRPR system due to its demonstrated performance in similar operating regimes. Using protium removal in the fuel cycle as the primary performance metric, this paper presents an optimization methodology for a single-column continuous cryogenic distillation-based IRPR system for a 500 MW fus magnetic fusion device. Distillation column optimization was performed using the CryOgenic Distillation For Isotopic Separation of Hydrogen (CODFISH) code developed at Savannah River National Laboratory. The distillation column design presented maximizes direct recycling of hydrogen isotopes from the fusion chamber exhaust to the fueling system while minimizing IRPR system steady-state tritium inventory. The optimized IRPR distillation column presented achieves direct recycling of 60 % of the hydrogen isotopes in the fusion chamber exhaust with an estimated steady-state system tritium inventory <30 g. In conclusion, the optimized IRPR distillation column operation was then used to estimate the design requirements for a detritation column to treat the IRPR system effluent stream.

CryOgenic distillation↗
DOE OSTI2025

Computational Study of a Cryopump Design for Fusion Exhaust Gas Purification Using Direct Simulation Monte Carlo

Cryopump-based direct internal recycling (DIR) of fusion fuel is an attractive prospect because it provides pumping of helium ash from a reactor along with separation of helium and other impurities from the fuel. Previous studies have demonstrated a continuously regenerating cryopump, referred to as the Snail pump, that separates helium ash from fusion fuel for reactor-relevant flow rates. Here, in this study, a conceptual cryopump was designed as a proof-of-principle study to target other impurities, besides helium ash, from the fusion exhaust that would complement the Snail pump. The impurity-removal cryopump consists of four sets of chevron fins, two sets operating at 80 K and the other two at 30 K. A computational study using direct simulation Monte Carlo (DSMC) was performed with a gas mixture of 96.5% D2, 2.0% He, and 0.5% each of CO2, N2, and CH4. In this configuration, 80 K chevron fin sets are capable of capturing CO2 and 30 K sets capable of capturing CO2, N2, and CH4. The computational study showed that the cryopump is capable of reducing the impurity content by more than two orders of magnitude from the flow.

Adhikari, Nirajan [Oak Ridge National Laboratory (↗
DOE OSTI2024

High Compression in Palladium Alloy Metal Foil Pumps

Metal foil pumps (MFPs) are key components in the direct internal recycling inner fuel cycle loop for the recovery of hydrogen isotopes from deuterium-tritium fusion exhaust. Operating under vacuum conditions, they utilize superthermal hydrogen as the feed gas in a process called superpermeation. A notable feature of MFPs is their ability to pump against a pressure gradient. This study examines the compression capabilities of PdAg and PdCu MFPs at low temperatures with a constant feed pressure of 10 Pa. At 75°C, compression ratios exceeding 200 were readily achieved, with downstream pressures exceeding 4500 Pa using PdCu. For both alloys, net fluxes decreased by only ~15% at downstream pressures of 1000 Pa, which offers potential simplifications for the downstream pump train. Performance declined markedly when the temperature was elevated to 200°C. Pump curves were constructed and advocated as the most appropriate manner to assess MFP performance. Separate pressure-driven-permeation experiments at relevant conditions were conducted, providing a direct measurement of the hydrogen dissociation constant $k$ d , which was found to be in good agreement with the previous literature. Further, these measurements were used to predict pump curves and maximum compression ratios by balancing superpermeation with pressure-driven permeation, achieving excellent agreement with experiment. Last, experiments using asymmetric MFPs revealed the detrimental impact that surface impurities have on performance in this system.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRSDate not supplied

Can water mined on the moon save cost for life support?

The water needed for space life support has been so far provided by direct supply from Earth on most missions or by recycling on the International Space Station (ISS). With the recent reduction in launch cost, Earth resupply has become more attractive than recycling for lunar missions with smaller crews and briefer missions requiring less than 1,000 crew days. The third alternative supply method would use water mined from the lunar regolith. Continuing lunar research suggests that the moon may have more water, more widely distributed than previously expected. The cost of water mined on the moon will depend on its form and concentration, the machinery and operations required, and the overall demand for water. The use of oxygen and hydrogen for propulsion may greatly exceed the need for crew life support. The conditions under which water mined on the moon would be less expensive that water provided by resupply or recycling are described.

Harry W Jones↗
NASA NTRSDate not supplied

Should Oxygen, Hydrogen, and Water on the Moon Be Provided by Earth Supply, Life Support Recycling, or Regolith Mining?

The water needed for space life support has so far been provided by either direct supply from Earth on most missions or by life support wastewater recycling on the International Space Station (ISS). With the recent large reduction in launch cost, Earth resupply has become more attractive, but recycling always costs less than resupply for a large enough crew on a long enough mission. Water is also needed to make up recycling losses and oxygen and hydrogen are needed for propulsion fuel. This paper compares the costs of oxygen, hydrogen, and water on the moon for Earth supply, lunar recycling, and lunar mining. While Earth supply is the most expensive by far, lunar recycling and mining costs are not much different. Life support wastewater provides a large but limited supply, so lunar mining will always be needed. Minor cost reductions may make mining less expensive than recycling.

Harry W Jones↗
NASA NTRS2017

Developing Reliable Life Support for Mars

A human mission to Mars will require highly reliable life support systems. Mars life support systems may recycle water and oxygen using systems similar to those on the International Space Station (ISS). However, achieving sufficient reliability is less difficult for ISS than it will be for Mars. If an ISS system has a serious failure, it is possible to provide spare parts, or directly supply water or oxygen, or if necessary bring the crew back to Earth. Life support for Mars must be designed, tested, and improved as needed to achieve high demonstrated reliability. A quantitative reliability goal should be established and used to guide development t. The designers should select reliable components and minimize interface and integration problems. In theory a system can achieve the component-limited reliability, but testing often reveal unexpected failures due to design mistakes or flawed components. Testing should extend long enough to detect any unexpected failure modes and to verify the expected reliability. Iterated redesign and retest may be required to achieve the reliability goal. If the reliability is less than required, it may be improved by providing spare components or redundant systems. The number of spares required to achieve a given reliability goal depends on the component failure rate. If the failure rate is under estimated, the number of spares will be insufficient and the system may fail. If the design is likely to have undiscovered design or component problems, it is advisable to use dissimilar redundancy, even though this multiplies the design and development cost. In the ideal case, a human tended closed system operational test should be conducted to gain confidence in operations, maintenance, and repair. The difficulty in achieving high reliability in unproven complex systems may require the use of simpler, more mature, intrinsically higher reliability systems. The limitations of budget, schedule, and technology may suggest accepting lower and less certain expected reliability. A plan to develop reliable life support is needed to achieve the best possible reliability.

life support↗
NASA NTRS2017

Would Current International Space Station (ISS) Recycling Life Support Systems Save Mass on a Mars Transit?

The oxygen and water are recycled on the International Space Station (ISS) to save the cost of launching their mass into orbit. Usually recycling systems are justified by showing that their launch mass would be much lower than the mass of the oxygen or water they produce. Short missions such as Apollo or space shuttle directly provide stored oxygen and water, since the needed total mass of oxygen and water is much less than that of there cycling equipment. Ten year or longer missions such as the ISS or a future moon base easily save mass by recycling while short missions of days or weeks do not. Mars transit and long Mars surface missions have an intermediate duration, typically one to one and a half years. Some of the current ISS recycling systems would save mass if used on a Mars transit but others would not.

mass↗
NASA NTRS2017

Life Support Goals Including High Closure and Low Mass Should Be Reconsidered Using Systems Analysis

Recycling space life support systems have been built and tested since the 1960s and have operated on the International Space Station (ISS) since the mid 2000s. The development of space life support has been guided by a general consensus focused on two important related goals, increasing system closure and reducing launch mass. High closure is achieved by recycling crew waste products such as carbon dioxide and condensed humidity. Recycling directly reduces the mass of oxygen and water for the crew that must be launched from Earth. The launch mass of life support can be further reduced by developing recycling systems with lower hardware mass and reduced power. The life support consensus has also favored using biological systems. The goal of increasing closure using biological systems suggests that food should be grown in space and that biological processors be used for air, water, and waste recycling. The goal of reducing launch mass led to use of Equivalent System Mass (ESM) in life support advocacy and technology selection. The recent consensus assumes that the recycling systems architecture developed in the 1960s and implemented on ISS will be used on all future long missions. NASA and other project organizations use the standard systems engineering process to guide hardware development. The systems process was used to develop ISS life support, but it has been less emphasized in planning future systems for the moon and Mars. Since such missions are far in the future, there has been less immediate need for systems engineering analysis to consider trade-offs, reliability, and Life Cycle Cost (LCC). Preliminary systems analysis suggests that the life support consensus concepts should be revised to reflect systems engineering requirements.

systems analysis↗
DOE OSTI2025

Review on Preprocessing Strategies, Deactivation, Thermal Safety, and Future Perspectives in Lithium-Ion Battery Recycling

The rapid growth in the use of lithium-ion batteries (LIBs) in electric vehicles, consumer electronics, and renewable energy storage has made effective end-of-life management essential. Recycling LIBs is critical not only for resource recovery and environmental protection but also for ensuring safety and economic viability. This review focuses on the preprocessing technologies that precede typical recovery processes, including disassembly, sorting, discharging, electrolyte removal, dismantling, thermal treatment, separation, and flotation. These steps play a foundational role in determining the efficiency, safety, and environmental impact of LIB recycling. LIBs pose substantial fire and explosion risks due to residual charge, flammable electrolytes, and reactive materials. The conditions and successive progression of the exothermic reactions which lead to thermal runaway has been discussed. It also explores secure deactivation techniques such as external circuit discharge, saline immersion, and thermomechanical methods, alongside fire prevention strategies including the use of flame retardants, elimination of oxidants, and reduction of heat generation and accumulation. Challenges and future directions are outlined, highlighting the need for standardized designs, automation, and safer, more sustainable recycling infrastructure. Furthermore, this review is distinguished by its focused analysis of preprocessing and deactivation steps, with particular attention to the thermal safety engineering aspects of LIB recycling.

Battery deactivation↗
NASA NTRS2017

The Impact of Lower Launch Cost on Space Life Support

The development of commercial launch systems has substantially reduced the cost of space launch. NASA's Space Shuttle had a cost of about $1.5 billion to launch 27,500 kg to Low Earth Orbit (LEO), $54,500/kg. SpaceX's Falcon 9 now advertises a cost of $62 million to launch 22,800 kg to LEO, $2,720/kg. Space launch costs were very high for decades, typically about $20,000/kg, and it was understood that this high launch cost made it necessary for long human missions to recycle water and oxygen to reduce logistics mass. Short missions such as Apollo or Shuttle used stored and resupplied life support materials, but for a much longer mission such as the International Space Station (ISS), recycling saves logistics mass and reduces launch cost. The Life Cycle Cost (LCC) will be computed for resupply logistics and for a recycling system similar to that on the ISS. The LCC includes the costs of development, launch, and operations. The new low launch cost makes open loop life support much cheaper than before. Direct logistics resupply would be less costly than recycling for future human missions, such as a long term moon base, a Mars mission, or a future space station in LEO.

life support↗