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Papadias, D. D.

Publications and source records attributed to Papadias, D. D..

Performance and cost of fuel cells for off-road heavy-duty vehicles

Hydrogen fuel cell-powered off-road vehicles can replace hydrocarbon-powered off-road vehicles to reduce carbon dioxide and criteria pollutant emissions in the agriculture, construction, and mining industries. Vehicle manufacturers and customers recognize health and environmental benefits of emissions reductions but are ultimately compelled by the total cost of ownership of their vehicles. In this study, we conduct a technoeconomic evaluation for three hallmark off-road vehicles, tractors, wheel loaders, and excavators, comparing vehicles with hydrogen fuel cell + battery hybrid powertrains to traditional diesel powertrains. Stakeholder-valued performance metrics include fuel cell engine power, engine durability, hydrogen consumption rate, hydrogen storage system volume, and energy-regenerative drivetrain efficiency. The total cost of ownership includes capital, operating and maintenance, fuel, and fuel storage costs. State-of-the-art fuel cell powered wheel loaders and excavators are currently cost competitive with diesel platforms. If targeted improvements to cost, performance, and durability improvements of fuel cell stacks and storage systems are achieved, fuel cell systems would be cost competitive for tractors and significantly lower total cost of ownership options for wheel loaders and excavators.

33 ADVANCED PROPULSION SYSTEMS↗

Bulk Storage of Hydrogen

The technical aspects and economics of bulk hydrogen storage in underground pipes, lined rock caverns (LRC) and salt caverns are analyzed. Hydrogen storage in underground pipes is more economical than in geological caverns for useable amounts <20-t-H2. However, because the pipe material is a major cost factor, the capital and operating costs for this storage method do not decrease appreciably with an increase in the amount of stored H2. Unlike underground pipes, the installed capital cost of salt caverns decreases appreciably from ~$95/kg-H2 at 100 t-H2 stored to <$19/kg-H2 at 3000 t-H2 stored. Over the same scale, the annual storage cost decreases from ~$17/kg-H2 to ~$3/kg-H2. Like salt caverns, the installed capital cost of lined rock caverns decreases from ~$160/kg-H2 at 100 t-H2 stored to <$44/kg-H2 at 3000 t-H2 stored. Storing >750-t useable H2 requires multiple caverns. The cost of salt caverns scales more favorably with size because the salt caverns are larger than lined rock caverns and need to be added at a slower rate as the storage capacity is increased.

Bulk storage of hydrogen↗

Toluene-Methylcyclohexane as Two-Way Carrier for Hydrogen Transmission and Storage

Recognizing the potential role of liquid hydrogen carriers in overcoming the inherent limitations in transporting and storing gaseous and liquid hydrogen, a complete production and use scenario is postulated and analyzed for a two-way carrier. MCH is produced at commercially viable scales in a central location in Texas (TX) by hydrogenation of toluene and transmitted by rail or chemical tankers to northern California (CA), see Fig. 1. MCH is dehydrogenated near city gates to generate fuel-cell quality hydrogen, and toluene is transmitted back to TX.

08 HYDROGEN↗

TREAT LEU Conversion Analyses Performed 2016-2018

TREAT is an experimental nuclear reactor designed to produce high neutron flux transients for the testing of reactor fuels and other materials. After more than 20 years of non-operational standby, TREAT has been restarted under the U.S. Department of Energy’s Resumption of Transient Testing Program. The conversion of TREAT from its current highly enriched uranium fuel to a low enriched uranium fuel is being pursued in keeping with the mission of the Department of Energy National Nuclear Security Administration’s Material Management and Minimization Reactor Conversion Program. This report documents additional analyses performed over the timeframe of 2016 to early 2018 to evaluate the LEU Conceptual Design for the TREAT reactor, following the initial design studies documented in the 2016 Conceptual Design Report. The analyses documented in this report include neutronic and thermal hydraulic sensitivity studies to evaluate the effect of key design parameters on predicted core behaviors, as well as a simple investigation into the effect of fuel thermal expansion.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Durability of Pt-Co Alloy Polymer Electrolyte Fuel Cell Cathode Catalysts under Accelerated Stress Tests

The durability of Pt-Co alloy cathode catalysts supported on high surface area carbon is investigated by subjecting them to accelerated stress tests (ASTs). The catalysts had different initial Co contents and nanoparticle morphologies: a “spongy” porous morphology for the high-Co (H) content catalyst, and a fully alloyed crystalline morphology for the medium-Co (M) and low-Co (L) content catalysts. The specific activity of the catalysts depends on their initial Co content, morphology and nanoparticle size, and remained higher than 1000 μA/cm 2 -Pt after 27–50% Co loss. The H-catalyst electrode showed the smallest kinetic overpotentials (η c s ) due to higher initial Pt loading than the other two electrodes, but it had the fastest increase in ηcs with AST cycling due to lower Co retention; the L-catalyst electrode showed higher η c s due to a lower initial Pt loading, but had a smaller increase in η c s with aging due to higher Co retention; the M-catalyst electrode showed a similar increase in η c s with aging, but this increase was due to the combined effects of Co dissolution and electrochemically active surface area (ECSA) loss. In conclusion, the modeled increase in mass transfer overpotentials with aging correlates with the initial Pt loading, ECSA loss and the initial catalyst morphology

25 ENERGY STORAGE↗

Analysis of the TREAT LEU Conceptual Design

Analyses were performed to evaluate the performance of the low enriched uranium (LEU) conceptual design fuel for the conversion of the Transient Reactor Test Facility (TREAT) from its current highly enriched uranium (HEU) fuel. TREAT is an experimental nuclear reactor designed to produce high neutron flux transients for the testing of reactor fuels and other materials. TREAT is currently in non-operational standby, but is being restarted under the U.S. Department of Energy’s Resumption of Transient Testing Program. The conversion of TREAT is being pursued in keeping with the mission of the Department of Energy National Nuclear Security Administration’s Material Management and Minimization (M3) Reactor Conversion Program. The focus of this study was to demonstrate that the converted LEU core is capable of maintaining the performance of the existing HEU core, while continuing to operate safely. Neutronic and thermal hydraulic simulations have been performed to evaluate the performance of the LEU conceptual-design core under both steady-state and transient conditions, for both normal operation and reactivity insertion accident scenarios. In addition, ancillary safety analyses which were performed for previous LEU design concepts have been reviewed and updated as-needed, in order to evaluate if the converted LEU core will function safely with all existing facility systems. Simulations were also performed to evaluate the detailed behavior of the UO 2 -graphite fuel, to support future fuel manufacturing decisions regarding particle size specifications. The results of these analyses will be used in conjunction with work being performed at Idaho National Laboratory and Los Alamos National Laboratory, in order to develop the Conceptual Design Report project deliverable.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Preliminary Results of Ancillary Safety Analyses Supporting TREAT LEU Conversion Activities

The Transient Reactor Test Facility (TREAT), located at Idaho National Laboratory (INL), is a test facility designed to evaluate the performance of reactor fuels and materials under transient accident conditions. The facility, an air-cooled, graphite-moderated reactor designed to utilize fuel containing high-enriched uranium (HEU), has been in non-operational standby status since 1994. Currently, in support of the missions of the Department of Energy (DOE) National Nuclear Security Administration (NNSA) Material Management and Minimization (M3) Reactor Conversion Program, a new core design is being developed for TREAT that will utilize low-enriched uranium (LEU). The primary objective of this conversion effort is to design an LEU core that is capable of meeting the performance characteristics of the existing HEU core. Minimal, if any, changes are anticipated for the supporting systems (e.g. reactor trip system, filtration/cooling system, etc.); therefore, the LEU core must also be able to function with the existing supporting systems, and must also satisfy acceptable safety limits. In support of the LEU conversion effort, a range of ancillary safety analyses are required to evaluate the LEU core operation relative to that of the existing facility. These analyses cover neutronics, shielding, and thermal hydraulic topics that have been identified as having the potential to have reduced safety margins due to conversion to LEU fuel, or are required to support the required safety analyses documentation. The majority of these ancillary tasks have been identified in [1] and [2]. The purpose of this report is to document the ancillary safety analyses that have been performed at Argonne National Laboratory during the early stages of the LEU design effort, and to describe ongoing and anticipated analyses. For all analyses presented in this report, methodologies are utilized that are consistent with, or improved from, those used in analyses for the HEU Final Safety Analysis Report (FSAR) [3]. Depending on the availability of historical data derived from HEU TREAT operation, results calculated for the LEU core are compared to measurements obtained from HEU TREAT operation. While all analyses in this report are largely considered complete and have been reviewed for technical content, it is important to note that all topics will be revisited once the LEU design approaches its final stages of maturity. For most safety significant issues, it is expected that the analyses presented here will be bounding, but additional calculations will be performed as necessary to support safety analyses and safety documentation. It should also be noted that these analyses were completed as the LEU design evolved, and therefore utilized different LEU reference designs. Preliminary shielding, neutronic, and thermal hydraulic analyses have been completed and have generally demonstrated that the various LEU core designs will satisfy existing safety limits and standards also satisfied by the existing HEU core. These analyses include the assessment of the dose rate in the hodoscope room, near a loaded fuel transfer cask, above the fuel storage area, and near the HEPA filters. The potential change in the concentration of tramp uranium and change in neutron flux reaching instrumentation has also been assessed. Safety-significant thermal hydraulic items addressed in this report include thermally-induced mechanical distortion of the grid plate, and heating in the radial reflector.

Brunett, A. J.↗

Overview and Current Status of Analyses of Potential LEU Design Concepts for TREAT

Neutronic and thermal-hydraulic analyses have been performed to evaluate the performance of different low-enriched uranium (LEU) fuel design concepts for the conversion of the Transient Reactor Test Facility (TREAT) from its current high-enriched uranium (HEU) fuel. TREAT is an experimental reactor developed to generate high neutron flux transients for the testing of nuclear fuels. The goal of this work was to identify an LEU design which can maintain the performance of the existing HEU core while continuing to operate safely. A wide variety of design options were considered, with a focus on minimizing peak fuel temperatures and optimizing the power coupling between the TREAT core and test samples. Designs were also evaluated to ensure that they provide sufficient reactivity and shutdown margin for each control rod bank. Analyses were performed using the core loading and experiment configuration of historic M8 Power Calibration experiments (M8CAL). The Monte Carlo code MCNP was utilized for steady-state analyses, and transient calculations were performed with the point kinetics code TREKIN. Thermal analyses were performed with the COMSOL multi-physics code. Using the results of this study, a new LEU Baseline design concept is being established, which will be evaluated in detail in a future report.

Connaway, H. M.↗

Carbon corrosion in PEM fuel cells during drive cycle operation

One of the major contributors to degradation involves the electrocatalyst, including the corrosion of the carbons used as catalyst supports, which leads to changes in the catalyst layer structure. We have measured and quantified carbon corrosion during drive cycle operation and as a variation of the upper and lower potential limits used during drive cycle operation. The amount of carbon corrosion is exacerbated by the voltage cycling inherent in the drive cycle compared with constant potential operation. The potential gap between upper and lower potentials appears to be more important than the absolute operating potentials in the normal operating potential regime (0.40V to 0.95V) as changes in the measured carbon corrosion are similar when the upper potential was lower compared to raising the lower potential. Catalyst layer thinning was observed during the simulated drive cycle operation which had an associated decrease in catalyst layer porosity. This catalyst layer thinning is not due solely to carbon corrosion, although carbon corrosion likely plays a role; much of this thinning must be from compaction of the material in the catalyst layer. As a result, the decrease in catalyst layer porosity leads to additional performance losses due to mass transport losses.

30 DIRECT ENERGY CONVERSION↗

Used nuclear fuel separations process simulation and testing

Recent efforts in separations process simulation at Argonne have expanded from the traditional focus on solvent extraction flowsheet design in order to capture process dynamics and to simulate other components, processing and systems of a used nuclear fuel reprocessing plant. For example, the Argonne Model for Universal Solvent Extraction (AMUSE) code has been enhanced to make it both more portable and more readily extensible. Moving away from a spreadsheet environment makes the addition of new species and processes simpler for the expert user, which should enable more rapid implementation of chemical models that simulate evolving processes. The dyAMUSE (dynamic AMUSE) version allows the simulation of transient behavior across an extractor. Electrochemical separations have now been modeled using spreadsheet codes that simulate the electrochemical recycle of fast reactor fuel. The user can follow the evolution of the salt, products, and waste compositions in the electro-refiner, cathode processors, and drawdown as a function of fuel batches treated. To further expand capabilities in integrating multiple unit operations, a platform for linking mathematical models representing the different operations that comprise a reprocessing facility was adapted to enable systems-level analysis and optimization of facility functions. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗