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DOE OSTI2024

Technoeconomic Evaluation of Microreactor Using Detailed Bottom-up Estimate (Rev.1)

Microreactors are a novel class of nuclear reactors that are expected to be factory produced, transportable, and self-regulating. They are expected to be several orders of magnitude smaller in size than traditional reactors (with power outputs in the 1–20 MWe range typically). They are primarily envisaged to target niche, remote markets that are difficult to access and where energy costs are high. There has been a scarcity of technoeconomic assessment for these types of reactors due to the scarcity of designs without proprietary restraints (e.g., those that include balance of plants and building layouts) and cost estimates. The primary objective of this report was to develop a transparent, detailed, bottom-up cost estimate for a microreactor. While there is a high degree of uncertainty associated with the projected costs, this work provides a foundation that can built upon and improved to better model the economics of microreactors. The Microreactor Applications Research, Validation, and Evaluation (MARVEL) microreactor was selected for this analysis. This Department of Energy–sponsored demonstration was chosen because (1) its final design was recently completed and (2) a detailed class-3 cost-and-schedule estimation was conducted for it. This provided a strong technical basis for further analysis.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

High Yield Xray Imager Final Design Review

The High Yield Xray Imager (HYXI) is a new NIF target diagnostic system currently under development. The goal of HYXI is to provide high-fidelity, high temporal resolution x-ray imaging capability on high yield NIF implosions at 10MJ and above. The HYXI instrument design concept is based on the combination of two technologies that have been successfully utilized at the NIF on previous instruments, electron pulse-dilation and hybrid-CMOS sensor imaging. The combination of these two techniques will give HYXI sufficient data quality to ascertain differences in hot spot formation dynamics between high and low yield implosions. This information will highlight the critical hot spot conditions needed for ignition and burn. The HYXI design leverages the successful operation of the PDIXI x-ray imager at the NIF on multi MJ yield shots. A new radiation tolerant CMOS imaging array (HYPERION) is being developed to eliminate the significant background noise which limits the data quality of PDIXI. We successfully placed the contract with Advanced hCMOS Systems (AHS) to develop the HYPERION sensor, which fulfils our criteria to place long lead time item procurements by end of FY24. The HYXI Final Design Review was completed at the end of Q4 FY24 (Sep 24 th and Sep 30 th ). The HYXI project is a multi-year effort with a phased approach to be bring up system functionality over time in parallel with the development and fabrication effort of the HYPERION CMOS imaging array. In Phase 1, time-integrated x-ray images on NIF DT experiments will be collected starting in Q3 FY25. In Phase 2 of the project, time-resolved imaging with HYXI utilizing a spare microchannel plate detector back-end will begin in Q3 FY26. Phase 3 concludes the project with the installation of the HYPERION sensor array and the final performance qualification of the HYXI instrument which is scheduled for Q3 FY27 as discussed in the PDR and MRT report on this project in FY23.

42 ENGINEERING↗

DOE OSTI2025

Fermilab PIP-II CDS & CM Cryogenic Controls System

Details on Final design for Cryogenic Electrical & Controls System for Fermilab' s next-gen particle accelerator PIP-II. Electrical Controls System includes instrumentation and controls of Cryogenics Distribution System and Cryomodules. Design includes Siemens PCS7 Controls System with 26 Remote IO Rittal Cabinets and 48 Relay Racks for Temperature Readouts, Valve Positioners, Level, Heater Controls etc. Electrical Drawings and Design have been completed with focus now on fabrication of the 26 Rittal Cabinets and 48 Relay Racks. All materials have been procured. EPICS will be used as a SCADA system communicating to S7 Controllers via OPC UA.

Patel, Pratik [Fermilab]↗

DOE OSTI2025

Modular Processing of Flare Gas for Carbon Nanoproducts

This project demonstrated the technical viability and economic promise of a modular system for converting flared natural gas into valuable carbon nanoproducts (CNPs) through catalytic chemical vapor deposition (CVD). All major project milestones were successfully completed, including reactor design and commissioning, catalyst development, process optimization, technoeconomic analysis, and application testing in concrete systems. The overarching goal was to create a scalable, field-deployable process that valorizes stranded methane by producing high-value carbon materials for use in cementitious composites. At the lab scale, the team designed and built a fluidized bed reactor optimized for use with silica fume-supported nickel catalysts synthesized via atomic layer deposition (ALD). A statistically designed sintering study enabled precise tuning of nickel nanoparticle size, identifying the influence of oxygen partial pressure, time, and temperature on catalyst morphology and performance. These insights allowed the team to target catalyst conditions that maximize carbon nanofilament growth. Subsequent CVD experiments achieved up to 31.8 wt% carbon deposition under optimized conditions, with TEM confirming the presence of nanofilament structures and sustained hydrogen evolution during reaction. Reactor upgrades and empirical fluidization studies supported the development of reliable, repeatable experimental protocols. The modular pilot-scale skid reactor was fully constructed, instrumented, and commissioned. Capable of operating at 675–800°C and pressures up to 290 psig, the system was designed for continuous operation at a carbon production rate of 1 kg/hr. Initial demonstration runs confirmed solids handling, thermal control, and system leak-tightness, although a critical reactor component (the downfeed tube) was inadvertently omitted during final assembly. This omission limited gas–solid contact and prevented meaningful carbon deposition during pilot-scale CVD runs. Nonetheless, the system operated safely under design conditions, and the root cause of performance limitations was clearly identified. Complementary work on UHPC formulations demonstrated that small additions of carbon nanoproducts, including those derived from flare gas, can significantly enhance mechanical performance while preserving workability. A comprehensive study of CNF dispersion techniques and mix design optimization led to a clear protocol for integrating these nanomaterials into concrete. Incorporation of CNPs improved flexural toughness and reduced porosity, supporting their use in high-performance infrastructure applications. A technoeconomic analysis (TEA) confirmed that this process can produce CNP-loaded catalyst material at a levelized cost below $\$$7/kg across a range of catalyst loadings and reaction yields. With estimated market values for the carbon composite product ranging from $\$$14 to over $\$$60/kg, and the ability to blend CNPs into concrete at sub-percent levels with less than 10% added cost, the system presents a compelling economic case. While additional engineering work is needed to optimize fluidization and heat transfer at scale, this project establishes a strong foundation for commercial development. The process is not only technically sound but also economically promising, representing a viable pathway for flare gas mitigation through modular carbon nanomaterial production.

03 NATURAL GAS↗

DOE OSTI2025

Net-Zero Lime Kiln and Carbon Removal Facility

The final scientific/technical report for DE-FE0032248. The Project Objective for DE-FE0032248, Net-Zero Lime Kiln and Carbon Removal Facility, was to execute and complete the initial design of a commercial-scale, advanced carbon capture system that separates CO2 with at least 95% capture efficiency from process streams at the Carmeuse Kentucky (KY) lime plant that will be retrofitted to utilize sustainably sourced biomass (SSB) alone or in combination with natural gas, and/or coal, with at least a 20-year available feedstock supply and remaining asset life.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2022

Biochemical responses of hairgrass (Deschampsia caespitosa) to hydrological change

Plant growth and development are closely related to water availability. Water deficit and water excess are detrimental to plants, causing a series of damage to plant morphology, physiological and biochemical processes. In the long evolutionary process, plants have evolved an array of complex mechanisms to combat against stressful conditions. In the present study, the duration-dependent changes in ascorbate (AsA) and glutathione (GSH) contents and activities of enzymes involved in the AsA-GSH cycle in hairgrass ( Deschampsia caespitosa ) in response to water stress was investigated in a pot trial using a complete random block design. The treatments were as follows: (1) heavily waterlogging, (2) moderate waterlogging, (3) light waterlogging, (4) light drought, (5) moderate drought, (6) heavily drought, and (7) a control (CK) with plant be maintained at optimum water availability. The hairgrass plants were subjected to waterlogging or drought for 7, 14, 21 and 28 days and data were measured following treatment. Results revealed that hairgrass subjected to water stress can stimulate enzymatic activities of ascorbate peroxidase (APX), glutathione peroxidase (GPX), glutathione reductase (GR), dehydroascorbate reductase (DHAR), monodehydroascorbate reductase (MDHAR) and L-galactono-1, 4-lactone dehydrogenase (GalLDH), switched on the ascorbate-glutathione (AsA-GSH) cycle and the L-galactose synthesis, up-regulated the contents of AsA and GSH, and maintained higher ratios of ascorbate to dehydroascorbate (AsA/DHA) and reduced glutathione to oxidized glutathione (GSH/GSSG) to alleviate potential oxidative damage. However, the light waterlogging did not induce hairgrass under stress to switch on the AsA-GSH pathway. In general, the critic substances and enzyme activities in AsA-GSH metabolic pathway increased as the increase of water stress intensity. As the increase of exposure duration, the critic antioxidant substances content and enzyme activities increased first and then maintained a relatively stable higher level. Our findings provide comprehensive information on biochemical responses of hairgrass to hydrological change, which would be a major step for accelerating ecological restoration of degradation alpine marshes in the Qinghai-Tibetan Plateau.

Luo, Qiaoyu↗

DOE OSTI2020

Petrophysical and geomechanical properties of gas hydrate-bearing sediments recovered from Alaska North Slope 2018 Hydrate-01 Stratigraphic Test Well

Knowledge of petrophysical and geomechanical properties of gas hydrate-bearing sediments are essential for predicting reservoir response due to gas production from gas hydrate reservoirs. That information will be critical parameters for designing production well completion such as specification of depressurization pump, water storage tank, and mesh size of sand screen. In December 2018, Stratigraphic Test Well Hydrate-01 was drilled in the western part of the Prudhoe Bay Unit, Alaska North Slope as part of the technical planning effort for a future long-term production test by collaborative team of DOE/NETL, USGS, and MH21-S (Boswell et al., 2020, Collett et al., 2020, Okinaka et al., 2020). Data set of logging-while-drilling (LWD) were acquired (Haines et al., 2020, Suzuki et al., 2019) and core sampling depth was determined on-site.Side-wall pressure coring was conducted to recover gas hydrate-bearing sediments from two reservoir sections named Unit-B and Unit-D. A total of 34 cores were successfully recovered by 5 runs of a wire-line deployed pressure corer (CoreVault® System - Halliburton). Core analysis scheme of this project are shown in Figure 1. All cores were quenched in liquid nitrogen while at high pressure in the laboratory of Stratum Reservoir, LLC. at Anchorage (Figure 1, a)). And the cores were removed from the pressure corer autoclave with temperature support of dry ice and stored under liquid nitrogen at atmospheric pressure. 19 damaged cores were processed to index property measurements directly such as grain size, grain density. 4 of another 17 cores were depressurized and trimmed for making a plug to analyze petrophysical properties of host sediments. Unsteady-state permeability test was conducted to obtain relative water permeability to gas and core scale NMR T2 distribution measurement was performed for evaluating pore size distribution at Houston (Figure 1, b)). Remained high quality 13 cores were preserved with gas hydrate for advanced laboratory analysis. National Institute of Advanced Industrial Science and Technology, as a part of the Japanese National Hydrate Research Program (MH21-S, funded by Ministry of Economy, Trade and Industry), received the samples at Sapporo, Japan for advanced core analysis. High-resolution X-ray CT was used to analyze the quality of the samples, which showed undisturbed lithological layers. Cores were lathed into cylindrical shape and distributed for multi property measurements (Figure 1, c)).<p>As a result, sediment from Unit-D is categorized as silty sand at ~37% porosity with ~80% gas hydrate saturation. An average hydration number n = 6.16 was measured by Raman spectroscopy. An average intrinsic permeability of ~400 mD and in situ effective permeability (with hydrate) on the order of ~10 mD. The Unit B recovered cores consisted of well sorted sand at ~40% porosity with ~95% gas hydrate saturation. An average intrinsic permeability of ~1 Darcy and in situ effective permeability on the order of ~30 mD was measured for the Unit B cores. There was a small permeability reduction due to porosity loss with increasing effective stress that simulated consolidation behavior along with depressurization in the highly permeable sandy sediment. The apparent minimum change in porosity and permeability may be caused by the low compressibility of quartz sand grains in the recovered cores. XRD and thermal conductivity analysis also suggested high quartz content. Triaxial compression tests established internal friction angles based on the Mohr-Coulomb's failure criterion, which are 40° for hydrate-bearing sediment and 29.8° for hydrate free sediment.</p>

Yoneda, Jun↗

DOE OSTI2025

Integrated Molten Salt Reactor Modeling Capabilities in NEAMS Thermal Hydraulics Tools

The DOE neams program supports a full range of computational thermal fluids analysis capabilities and code developments for a broad range of advanced reactor concepts. The research and development approach under the thermal fluids technical area synergistically combines three length and time scales in a hierarchical multi-scale approach. To enable multi-scale thermal fluids capability using these codes, a key joint effort has been underway to develop an integrated system- and engineering-scale thermal fluids analysis capability, through integration of SAM and Pronghorn codes, both based on the MOOSE framework. This report summarizes recent advances in developing an integrated system- and engineering-scale modeling capability for the msr concept, which has gained significant interest in recent years. A consistent framework was established by coupling Pronghorn and SAM through the Saline interface, with thermophysical properties provided by the Molten Salt Thermal Property Database (MSTDB-TP). Further improvements were made to the coupling schemes and domain-overlapping strategies, enhancing the stability and robustness of multi-code simulations. Verification and validation efforts demonstrate the accuracy of this integration across a range of benchmark problems, including one-dimensional heated pipe flows, three-dimensional natural convection loops with evolving isotopic compositions, and \gls{msre} demonstration cases. Within Pronghorn, new capabilities were introduced to model corrosion and noble-metal plating phenomena, supported by an extended thermal-hydraulics framework and refined turbulence treatments. To capture two-phase flow behavior, a multiphase Euler–Euler model was implemented in Pronghorn, including advanced closure relations, high-resolution advection techniques, and capillary force reconstruction. Preliminary verification cases confirm the fidelity of the approach, while planned validation efforts target canonical multiphase benchmarks and application to msr components such as the msre pump bowl. Finally, updates to SAM’s msr mass transfer modeling were extended to consider noble gas migration into porous structures like graphite. The point kinetics model was updated to include reactivity feedback contributions from any defined species, such as xenon. The gas transport model was expanded for applicability to gas mixtures, bubble efflux phenomena, and species transport between liquid and gas phases. A selection of multi-scale Sherwood number correlations from MOSCATO/NekRS and multi-phase correlations from literature have been added for improved accuracy in calculating mass transfer coefficients. A companion effort on developing system-level redox corrosion has also been incorporated into SAM. Collectively, these enhancements strengthen the predictive capability of SAM and Pronghorn for simulating MSR thermal-hydraulics, corrosion, multiphase behavior, and fission-product transport, providing a more complete toolset for design, safety analysis, and licensing support of next-generation \gls{msr}s.

42 - ENGINEERING↗

DOE OSTI2025

Fermilab PIP-II CDS and CM Cryogenic Controls System

Patel, Pratik [Fermilab]↗

DOE OSTI2020

Pre-Commercial Scale-Up of a Gas-Fired Absorption Heat Pump

The project sought to advance the maturity of SMTI’s 80 kBTU/hr residential space and water heating GAHP from the engineering prototype stage (TRL-7) to pre-production readiness by addressing manufacturing, balance of system design and installation, cost, reliability, and field application questions. As part of this project, the project team has: (1) Matured the design package for a commercially ready product (2) Demonstrated compliance with relevant ANSI standards (3) Completed manufacturing and assembly process specifications (4) Completed total production cost estimates and capital equipment requirements (5) Initiated component and system level reliability assessments (6) Completed a small field demonstration including measured performance, installation requirements and expected costs, and customer/key stakeholder feedback. (7) Completed a Techno-economic analysis for representative applications and climate zones, including justification for utility incentive programs. (8) Completed a market intelligence report. Scope of Work: A multi-faceted project was completed that included: (a) design for manufacturing tasks for both the sealed system and balance of system, (b) development and trial of key manufacturing processes and techniques, (c) evaluation of component and system level reliability, (d) exploration of make/buy decisions including impact on cost and required capital. Additionally, (e) installation and monitoring of a small number of field test units was completed to demonstrate energy savings and collect customer/installer feedback, and (f) a focused market research task was completed to explore potential barriers and improve market introduction plans. These tasks addressed many of the remaining technical risks regarding long-term reliability, verification of manufacturing cost estimates and identification of cost concerns, identify installation and balance of system design criteria necessary to achieve energy savings and installed cost goals, and identify market barriers and strategies prior to product market introduction.

03 NATURAL GAS↗

DOE OSTI2024

SMR Carbon Capture Design and TEA (Final Technical Report)

This project sought to select a process configuration, select a commercial technology offering, and complete an initial engineering design of a carbon capture system that recovers and ultimately would store ~190,000 tonnes per year of CO 2 with 90%+ carbon capture efficiency from an existing steam methane reforming (SMR) plant at Phillips 66’s Rodeo Refinery.

03 NATURAL GAS↗

DOE OSTI2022

Resilience Design Patterns: A Structured Approach to Resilience at Extreme Scale (V.2.0)

Reliability is a serious concern for future extreme-scale high-performance computing (HPC) systems. Projections based on the current generation of HPC systems and technology roadmaps suggest the prevalence of very high fault rates in future systems. The errors resulting from these faults will propagate and generate various kinds of failures, which may result in outcomes ranging from result corruptions to catastrophic application crashes. Therefore, the resilience challenge for extreme-scale HPC systems requires coordination between various hardware and software technologies that are capable of handling a broad set of fault models at accelerated fault rates. Also, due to practical limits on power consumption in future HPC systems, they are likely to embrace innovative architectures, increasing the levels of hardware and software complexities. Therefore, the techniques that seek to improve resilience must navigate the complex trade-off space between resilience and the overheads to power consumption and performance. While the HPC community has developed various resilience solutions, application-level techniques as well as system-based solutions, the solution space of HPC resilience techniques remains fragmented. There are no formal methods to integrate the various HPC resilience techniques into composite solutions, nor are there methods to holistically evaluate the adequacy and efficacy of such solutions in terms of their protection coverage, and their performance & power efficiency characteristics. Additionally, few implementations of current resilience solutions are portable to newer architectures and software environments that will be deployed on future systems. We developed a new structured approach to the management of HPC resilience using the concept of resilience-based design patterns. In general, a design pattern is a repeatable solution to a commonly occurring problem. We identified the well-known solutions that are commonly used to deal with faults, errors and failures in HPC systems. In the initial design patterns specification (version 1.0), we described the various solutions, which address specific problems in the design of resilient HPC environments, in the form of patterns. Each pattern describes a problem caused by a fault, error or failure event in an HPC environment, and then describes the core of the solution of the problem in such a way that this solution may be adapted to different systems and implemented at different layers of the system stack. The catalog of these resilience design patterns provides designers with a collection of design elements. To construct complete resilience solutions using combinations of various patterns, we defined a framework that enhances HPC designers' understanding of the important constraints and the opportunities for the design patterns to be implemented and deployed at various layers of the system stack. The design framework is also useful for establishing interfaces and mechanisms to coordinate flexible fault management across hardware and software components, as well as to consider the trade-off between performance, resilience, and power consumption when constructing a solution. The resilience design patterns specification version 1.1 included more detailed explanations of the pattern solutions, the context in which the patterns are applicable, and the implications for hardware or software design. It also provided several additional examples and detailed case studies to demonstrate the use of patterns to build realistic solutions. In version 1.2 of the specification document, we have improved the pattern descriptions, including graphical representations of the pattern components. These improvements are largely based on critical comments, feedback and suggestions received from pattern experts and readers of the previous versions of the specification. The pattern classification has been modified to further clarify the relationships between pattern categories. This version of the specification also introduces a pattern language for resilience design patterns. The pattern language presents the patterns in the catalog as a network, revealing the relations among the resilience patterns. The language provides designers with the means to explore alternative techniques for handling a specific fault model that may have different efficiency and complexity characteristics. Using the pattern language also enables the design and implementation of comprehensive resilience solutions as a set of interconnected resilience patterns that can be instantiated across layers of the system stack. The overall goal of this work is to provide hardware and software designers, as well as the users and operators of HPC systems, a systematic methodology for the design and evaluation of resilience technologies in HPC systems that keep scientific applications running to a correct solution in a timely and cost-efficient manner despite frequent faults, errors, and failures of various types. Version 2.0 expands the resilience design pattern classification and catalog to include self-stabilization patterns and reliability, availability and performance models for each structural pattern.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2022

Is Nonflammability of Electrolyte Overrated in the Overall Safety Performance of Lithium Ion Batteries? A Sobering Revelation from a Completely Nonflammable Electrolyte

It has been widely assumed that the flammability of the liquid electrolyte is one of the most influential factors that determine the safety of lithium-ion batteries (LIBs). Following this consideration, a completely nonflammable electrolyte is designed and adopted for graphite||LiFePO 4 (Gr||LFP) batteries. Contrary to the conventional understanding, the completely nonflammable electrolyte with phosphorus-containing solvents exhibits inferior safety performance in commercial Gr||LFP batteries, in comparison to the flammable conventional LiPF 6 -organocarbonate electrolyte. Mechanistic studies identify the exothermic reactions between the electrolyte (especially the salt LiFSI) and the charged electrodes as the “culprit” behind this counterintuitive phenomenon. The discovery emphasizes the importance of reducing the electrolyte reactivity when designing safe electrolytes, as well as the necessity of evaluating safety performance of electrolytes on a battery level.

25 ENERGY STORAGE↗

DOE OSTI2023

Deployable Cryocooler Based Cryomodule

Superconducting Radio Frequency (SRF) linear accelerators (linacs) have shown tremendous promise in extending the intensity frontier of particle accelerator technology. However, they are large and complex systems, requiring a central refrigeration system and complex piping to distribute liquid helium and nitrogen to the accelerating cavities. In response to these problems, RadiaBeam Technologies, LLC. proposes to develop a small mobile cryomodule that can be safely deployed to its planned field location. The scope of this work is to provide RadiaBeam with the specifications for a complete 650 MHz RF cavity model that can be incorporated into a compact SRF accelerator. Fermilab’s contribution will involve sharing contact resistance measurements, design parameters, and solid models. Design parameters will include the cavity frequency and gradient, length of the linac, number of cryocoolers, etc. This will ensure that the design is useful for practical linacs. A complete cryomodule design is envisioned. Radiabeam will design the cryomodule based on input from Fermilab’s experience on conduction cooling and the needs for a compact SRF accelerator.

43 PARTICLE ACCELERATORS↗

DOE OSTI2023

Safety-Related Instrumentation and Control Pilot Upgrade: Conceptual - Detailed Design Phase Report and Lessons Learned

Historically, regulatory barriers have precluded nuclear plant safety-related (SR) Instrumentation and Control (I&C) system modernizations. These barriers have been largely addressed by industry and United States Nuclear Regulatory Commission (NRC) efforts, including development of the License Amendment Request (LAR) Alternate Review (AR) process for digital I&C upgrades. The U.S. Department of Energy (DOE) and the Idaho National Laboratory (INL) are supporting a SR I&C pilot upgrade at the Limerick Generating Station (LGS) to demonstrate this process and capturing associated lessons learned for the benefit of industry. In 2021, a paper summarizing lessons learned as captured in INL/EXT-20-59809, Safety Related Instrumentation & Control Pilot Upgrade Initial Scoping Phase Implementation Report and Lessons Learned was presented at the 12th NPIC & HMIT conference. It is recommended that readers of this paper review reference 1 or the associated Nuclear Journal paper for context. This paper summarizes activities performed and lessons learned for the conceptual design phase and portions of the detailed design phase as captured in INL/RPT-23-XXXX, “Safety-Related Instrumentation and Control Pilot Upgrade: Conceptual - Detailed Design Phase Report and Lessons Learned.” The portions of the effort covered by reference 2 include conceptual design phase activities from December 2020, through completion in November 2021, and detailed design activities through September 2022. These efforts and associated detailed documentation in reference 3 are intended to support similar industry upgrades as a foundation stone for a Digital Transformation that will improve plant safety, reliability, and operational performance while lowering plant total cost of ownership.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2022

High Temperature Anode Recycle Blower for Solid Oxide Fuel Cell, Phase II (Final Report)

Broad commercialization of solid oxide fuel cells (SOFCs) requires anode offgas recycle blowers (ARCB) that are specifically designed for handling the challenging operating conditions presented by the SOFC process gases. Otherwise, they can be susceptible to frequent maintenance, low reliability, and short life. This report presents details of a DOE-funded Phase II effort conducted by Mohawk Innovative Technology, Inc. (MiTi®) for the development and testing of an oil-free, low cost, high-temperature centrifugal ARCB based on compliant foil bearing (CFB) technology for support of a 100 kW solid oxide fuel cell power plant. This Phase II builds on the results of a successful Phase I development project that resulted in the demonstration of a low TRL-6 prototype, shown in Figure 1. This Phase II final report presents design improvements over the Phase I prototype, presents the assembled test ARCBs, and discusses the advantages of this novel technology, particularly its long life and maintenance-free operation, which are derived from the use of CFBs. Also included are preliminary techno-economic analysis considerations for cost-effective deployment of the technology. The specific objectives of this project, as stated in the statement of program objectives (SOPO) were 1) to follow the methodology of design for manufacturing (or manufacturability) and assembly for implementing improvements identified as part of the Phase I effort with the purpose of reducing cost, enabling mass production, and facilitating the commercialization of a revised ARCB design, and 2) to fabricate four complete ARCB units based on the revised design and demonstrating their performance in both a laboratory setting and in an actual SOFC power plant. Execution of this SOPO would be supported by a number of technical tasks resulting in the fabrication and testing of the prototypes. To this end, MiTi continued the teaming relationship started during Phase I of the program with subcontracting partner FuelCell Energy, Inc. (FCE), which integrated (under a parallel effort funded by DOE Award DE-FE0026199) a modular 200 kWe SOFC power plant. MiTi and FCE coordinated to ultimately incorporate one of MiTi’s ARCB prototypes into one of the 100 kWe SOFC Modular Power Blocks (MPB) that constitute the core of FCE’s SOFC power plant for in-situ long-duration testing. Additionally, MiTi would explore the scalability and extendibility of the technology to other applications, as well as conduct a basic techno-economic analysis.

03 NATURAL GAS↗

DOE OSTI2021

Solar Steam on Demand

INTRODUCTION: This Report summarizes the research and development project performed by Sunvapor and the subrecipient National Renewable Energy Laboratory (NREL) during the period of 10/01/2018-9/30/2021. The work was aimed at the economic integration of solar steam with an industrial process, and in particular, the advantages that a novel type of thermal energy storage and collector design could bring to the system. The completed work includes experimental research on the storage material, design of the collector, engineering of a complete solar steam plant, and economic analysis. The plant was, in the end, not constructed, due to COVID-19 impacts to the project host. PURPOSE: The purpose of the project was to test the hypothesis that a levelized cost of heat (LCOH) of 2¢/kWh delivered to a steam-consuming process, including energy discharged from storage, could be feasibly achieved. PROJECT OBJECTIVES: For Budget Period 1 our objectives were to engineer a prototype industrial solar steam generation system, and design and test a Latent Heat Energy Storage (LHES) lab-scale system. For Budget Period 2 our objectives were to construct and test the solar steam prototype plant, and to build and factory-test a full LHES module. For Budget Period 3 our objective was to integrate the storage module with the solar steam generator, show successful long duration energy tests of the combined system, and use the results to project the LCOH of delivered steam to a second-generation plant. PROJECT OUTCOMES: Various phase change materials (PCMs) for the LHES were tested for compatibility with industrial steam uses as measured by phase change temperature, stability of latent heat of fusion, and their corrosive effects on steel (the heat exchanger material). Two of these materials (sodium formate and sodium/ potassium) showed potential to meet the technical criteria. The estimated cost of a complete LHES module with these materials did not meet economic targets. The developmental collector design builds from previous work to exploit the potential cost advantages of a spaceframe of lumber construction. Design improvements were achieved in assembly efficiency and structural performance. A complete engineering package was completed for the solar steam system without storage that included the developmental as well as commercial arrays. The plant was permitted for construction. The storage CAPEX for a reference plant was estimate to be greater than $\$ 57$/kWh. The LCOH of the system without storage and with developmental collectors of lumber construction was projected to be 2¢/kWh, assuming a FCR of 8.2% over thirty years. PROJECT MILESTONES: The Milestones fully achieved in the first Budget Period includes obtaining a Letter of Intent from an industrial steam-consuming project host, issuance of a construction permit, and corrosion resistance. The Milestone that was partly achieved was the degradation in the latent heat of fusion. Milestones associated with Budget Periods 2 and 3, related to the construction and operation of the plant were not achieved as a result of the host shutting down the plant due to COVID-19 impacts. CONCLUSIONS: Sunvapor was able to secure an agreement with a host to build a fully engineered and permitted solar steam plant that met the host’s economic goals. As a basis for comparison, the solar field design was comprised of eight commercial collector arrays and one developmental Green Parabolic Trough Collector (GPTC) array. The projected LCOH with a solar field entirely populated with a second generation GPTC met the goal of 2¢/kWh. The experimental program concerning the PCM indicated the feasibility of meeting their technical requirements for industrial steam uses. The cost of the complete LHES exceeded its $\$ 14$/kWh target, and therefore the inclusion of LHES could not be economically justified. Due to COVID-19 impacts on the host, the solar steam plant was not constructed.

14 SOLAR ENERGY↗

DOE OSTI2022

FY2022 Progress Report for Advanced Re-fabrication/Re-instrumentation Capability Development

In support of performing follow-on irradiation experiments with previously irradiated materials, the Halden Reactor Project developed unique and state of the art capabilities to refabricate and re-instrument previously irradiated materials. Such materials were used in in-pile tests at the Halden reactor, and out-of-pile tests for example using furnaces as a heat source. The decision to close the Halden Reactor Project results in the loss of this refabrication and re-instrumentation capability. As a result, the United States (U.S.) Department of Energy (DOE) has determined to develop refabrication and re-instrumentation capability at the unique shielded facilities at Idaho National Laboratory (INL). The development of refabrication capability has been completed and demonstrated. This report focuses on the complementary aspects of reinstrumentation and the progress to-date. Halden spent nearly 30 years developing both refabrication and re-instrumentation. Collaboration with Halden is allowing Idaho National Laboratory (INL) to develop this capability much more rapidly. In FY-21 the results include development of the capability to drill annular center holes in ceramic UO2 fuel pellets, development of fuel rod end caps with feedthroughs for centerline instrumentation inside the rodlet, The procurement of both fuel drilling and welding demonstration equipment from Halden, evaluation of surface thermocouple attachments to support better understanding of temperature measurement uncertainties, and finally, the conceptual design of a new shielded enclosure where advanced refabrication and re-instrumentation equipment can be housed. In FY-22, the results include; Completing set up of the drilling and welding modules procured from Halden, and early experimental trials using that equipment.; Completing set up of an out-of-cell circumferential weld system to allow for further weld development to take place and support fabrication of fuel for fresh fuel experiments.; Evaluation of the Hot Fuel Examination Facility (HFEF) infrastructure to support future installation of advanced re-fabrication/re-instrumentation equipment, specifically related to necessary infrastructure for cryo-drilling.; Developments in dry-drilling alternative. Including experimental studies showing cordierite is the most suitable surrogate for UO 2 for performing drilling studies. That drilling performance is enhanced when a fuel-clad bonding condition is simulated.; Conceptual design completed for attaching surface thermocouples to irradiated fuel in support of TWIST capsule experiments. The authors would like to thank the numerous colleagues at INL and Halden who provided support in accomplishing this work. Their support both material and intellectual is invaluable in advancing the state of the art and establishing the capabilities for refabrication and re-instrumentation at INL.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗