Demonstration of the Triple Bubbler for Pyrochemical Nuclear Safeguards Applications
NA
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
SEARCH · Search NASA
Results for “Molten materials”
Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.
The Development and Testing of an Oxide Reduction Voltammetry Sensor
N/A
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
Overview of Pyroprocessing
This is a PPT presentation on the spent fuel treatment operations in the Fuel Conditioning Facility at MFC.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
Technical Performance of Refractory Liners for Molten Chloride Salt Thermal Energy Storage Systems
A chloride-based molten-salt system that uses a ternary blend of MgCl2/KCl/NaCl is investigated to provide higher temperature thermal energy storage capability. Despite higher thermal stability, molten chlorides present several unique challenges, including the design of internal refractory-ceramic liners to prevent the corrosion and thermal stress of alloy tank shells. This work discusses issues and potential solutions related to containment of molten chloride salt, specifically the optimization of the refractory material at the molten salt interface (hot face). The down-selected hot face candidate limits permeation of salt through the material and forms a highly stable secondary surface phase in equilibrium with the molten salt. A mortar is created using the corrosion resistant hot face brick. Brick and mortar composite are subjected to mechanical stress/strain analysis, in order to calculate composite material properties and better inform thermomechanical models. The U.S. Department of Energy Generation 3 (DOE Gen3) program seeks to develop higher efficiency CSP plants that can provide cost-competitive, flexible power in the U.S. electric grid. The proposed Gen3 Liquid Pathway CSP plant closely resembles the configuration of current nitrate salt power towers with two-tank storage (Gen2). The differences between Gen2 and Gen3 include the types of compatible materials used in salt storage tank construction. Stainless steel loses strength at Gen3 temperatures, and although nickel superalloys would be capable of withstanding sustained high temperatures, these materials are prohibitively expensive at scale. Uninsulated tank shells also pose a significant risk as common steels are highly susceptible to chemical attack from molten chloride salt. To address these concerns, refractory-ceramic based containment materials are proposed to line the inside of the hot and cold storage tanks. In doing so, stainless or carbon steel shells may be used in construction depending on the level of insulation provided. The composition of the internal liner requires careful consideration to maximize the efficacy of multiple parameters including corrosion resistance, strength at operating temperature, durability, and cost. This is particularly true for the material at the interface with the salt, known as the "hot face", which is responsible for protecting the insulating layers between the tank shell and the hot face brick layer. The molten salt in this system is superheated over 300 °C above its freeze temperature. Therefore, unlike other industrial processes which use refractory-lined vessels, it is not expected that a freeze plane will develop in the hot face. Therefore, the hot face must be designed to withstand chemical corrosion and inhibit permeation of molten salt into the insulating layers. A down selection was performed to identify a hot face candidate best equipped to maintain thermal, mechanical, and chemical integrity when exposed to molten salt over extended periods of time. Long-duration chemical capability experiments were conducted with the down selected hot face refractory fully immersed in molten chloride salt for up to 3000 hours. The average salt penetration does not exceed 100 microns. When extrapolated to 20 and 30 years of continuous exposure, the expected salt penetration depth is approximately 2.0 mm and 2.9 mm, respectively. A magnesium-rich secondary phases develops at the salt/refractory interface. X-ray diffraction identifies the material as forsterite (Mg2SiO4), which is reported to form synthetically in molten chloride salt solutions. These results suggest the selected hot face will adequately inhibit salt permeation. While there is optimism that the hot face brick will inhibit salt permeation, mortar joints are typically the weakest point of a refractory brick liner. From a thermochemical perspective, differing thermal expansion coefficients may result in the mortar and brick to grow independent of each other, creating gaps through which molten salt can penetrate. To address this issue, NREL has developed an in-house mortar composed of the down selected hot face brick that has been shown to be compatible with the salt. Compressive stress/strain analyses have been performed on the brick/ mortar composites to generate stress/strain curves. Modulus of elasticity and Poisson's ratio of the composite may be calculated from the stress/strain curves, in order to provide more representative data to finite element mechanical models for accurate approximation of stress on the tank shell and the amount of thermal expansion expected within the tank liner.
41 EE - Solar Energy Technologies Office (EE-4S)↗
Safeguards Material Control And Accountancy Considerations For Molten Salt Reactors
Molten salt reactors are a class of nuclear reactor designs with features and operational characteristics that vary significantly. Variations in design features include the physical, chemical, and isotopic composition of fresh and irradiated fuel, neutron energy spectrums, breeding ratios, and the design’s plans for chemical processing. Specific designs within these variations affect the material control and accountancy approaches implemented by both domestic and international nuclear safeguards. This paper identifies safeguards-relevant design features for molten salt reactors and describes how each feature might influence both domestic and international nuclear safeguards implementation. Additionally, this paper describes two potential general categories of material control and accountancy approaches that may be appropriate for molten salt reactors: a black box material-balance approach with measurements on the feed and waste streams combined with robust containment and surveillance on the nuclear material within the reactor or an approach that aims to quantify the nuclear material throughout the reactor (i.e., a process monitoring approach). This paper describes the benefits and challenges of these approaches to meet technical safeguards objectives and identifies gaps in current technologies.
Hogue, Karen↗
Focused Ion Beam Tomography of Alloy 617 Corroded in Molten Chloride Salt
Materials qualification of reactor structural materials is a critical step in rapid implementation of advanced nuclear reactor technologies, particularly to assess the corrosion performance in these designs. Accelerated qualification of reactor structural materials requires incorporating powerful computational toolsets, such as phase field modelling in the Multiphysics Object-Oriented Simulation Environment (MOOSE) framework, to predict the evolution of structural materials due to corrosion. Accordingly, computational toolsets will require experimental data generated at appropriate length scales to validate accuracy. Focused ion beam (FIB) provides a high degree of control over manipulation of materials for analytical purposes, including capturing data on the evolution in the microstructure and elemental composition of materials at the mesoscale, an appropriate length scale for phase field modelling of intergranular diffusion phenomena using the MOOSE framework. For instance, the FEI Helios G4 UX dual beam plasma FIB microscope at the Irradiated Materials Characterization Laboratory (IMCL) is capable of backscatter diffraction (EBSD) and energy-dispersive x-ray spectroscopy (EDS) documenting the evolution in the microstructure and elemental composition, respectively. The Helios can perform EDS and EBSD three-dimensionally (3D) using tomography, which is then combined using different software packages to visualize 3D volumes correlating elemental composition to microstructural data. The purpose of this investigation was to develop a streamlined characterization and data processing workflow for 3D tomography studies on the FEI Helios G4 plasma FIB. The investigation is segmented into three parts: 1) Optimizing the data collection workflow, 2) identifying appropriate data processing and visualization software (i.e. DREAM.3D, MIPAR, and VGStudioMax), and 3) establishing an infrastructure for public release. The optimization of the data collection workflow is in collaboration with members of the U220 department to setup formal training on the tomography operation of the G4, through ThermoFisher Scientific, and exploring DREAM.3D, MIPAR, and VGStudioMax data processing/visualization software packages. VGStudioMax currently demonstrates the most promise for future use. Optimization of the data collection and processing workflow is still ongoing. A collaboration with INL High Performance Computing (HPC) established an open-source license for expediting the public release of FIB tomography datasets through HPC. FIB tomography data generated by the G4 will provide comprehensive data for validating 3D phase field mesoscale modelling tools within the MOOSE framework for accelerated qualification of reactor structural materials.
Copeland-Johnson, Trishelle↗
Corrosion Response of Ni-19Cr-5Fe in Molten NaCl-MgCl 2 Salt
Ni-based alloys are strong candidates for use in high-temperature molten salt reactors due to their superior corrosion resistance and mechanical stability compared to stainless steels. In this study, the static corrosion behavior of a Ni-19Cr-5Fe model alloy was systematically evaluated in a purified molten NaCl-MgCl 2 salt at 700°C for 30, 240, and 500 h. Post-exposure analyses were conducted to assess microstructural evolution, corrosion depth, and elemental depletion profiles. Corrosion rates, quantified by chromium depletion depth, followed an inverse power-law trend with increasing exposure time, indicating diffusion-limited kinetics. This trend is attributed to limitations in mass transport in the static salt and to the progressive local depletion of reactive chromium species. Coupled electron backscatter diffraction and energy dispersive X-ray spectroscopy analysis further revealed that the grain boundary character significantly influences corrosion susceptibility: high-angle grain boundaries exhibited pronounced Cr depletion and pitting, while low-angle and Σ3 boundaries remained comparatively resistant. These results offer valuable insight into the role of microstructure in corrosion processes and reinforce the importance of time-dependent material evaluation in molten salt environments relevant to advanced reactor designs.
11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
Electrochemical Study on the Kinetic Properties of Fe 2+ /Fe, Ni 2+ /Ni, Cr 2+ /Cr and Cr 3+ /Cr 2+ in Molten MgCl 2 -KCl-NaCl Salts
Here, the fundamental kinetic parameters of corrosion product ions (Fe, Ni and Cr ions) are of significant importance to understand the corrosion mechanisms of the structural materials in the molten salts. In the present study, the fundamental data of Fe 2+ , Ni 2+ , Cr 2+ and Cr 3+ (diffusion coefficient D, exchange current density i 0 , charge transfer coefficient α, limiting current density i L and standard rate constant k0) were measured at different concentrations (1.53 × 10 –6 –7.48 × 10 –4 mol cm –3 ) and temperatures (600 °C–800 °C). The values of D are independent of concentrations and follow Arrhenius law with temperature, which descend in the order of D Cr 2+ > D Fe 2+ > D Cr 3+ > D Ni 2+ with values ranging from 0.94 × 10 –5 to 3.31 × 10 –5 cm 2 s –1 . Both i 0 and k 0 depend on the temperatures, which also follow Arrhenius law.
14 SOLAR ENERGY↗
Polymers in molten inorganic salt hydrate phase change materials: solubility and gelation
Inorganic salt hydrates are of interest as phase change materials (PCMs) for thermal energy storage because of their unique properties, such as high latent heats of fusion, moderate melting temperatures, high volumetric energy storage densities, and enhanced thermal conductivities compared to their organic counterparts. Because of the low viscosities of molten salt hydrates, the leakage and settling of solids can easily occur during their application. Polymers are promising candidates for preventing these issues. In addition, the non-flammability, non-volatility, and nontoxicity of many molten salt hydrates make them attractive options as “green” solvents for polymers. However, solutions of polymers in molten salt hydrates have rarely been studied and are poorly understood. The highly ionic environments in these materials created due to a scarcity of hydration water for ions leads to strong ionic interactions, with ramifications for polymer solubility and chain expansion. This Perspective article aims to focus on polymer solutions and gels in inorganic salt hydrates by comparing these systems with existing knowledge of polymers in traditional ionic liquids and aqueous salt solutions. To provide insight into the states of ions and water in molten salt hydrates and the degree of hydration of polymers in these solvents, infrared spectroscopy experiments have been performed, and the data are correlated with the temperature-responsive gelation of poly(vinyl alcohol), one candidate material currently used for the shape stabilization of inorganic PCMs. Finally, the thermal properties of inorganic salt hydrates and ionic liquids are compared and strategies for the shape stabilization of inorganic salt hydrates using polymers, through the formation of physical gels, are discussed.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Reactive matrix infiltration of powder preforms
A reactive matrix infiltration process is described herein, which includes contacting a surface of a preform comprising reinforcement material particles with a molten infiltrant comprising a matrix material, the matrix material comprising an Al—Ce alloy, whereby the infiltrant at least partially fills spaces between the reinforcement material particles by capillary action and reacts with the reinforcement material particles to form a composite material form, the composite material comprising the matrix material, at least one intermetallic phase, and, optionally, reinforcement material particles. A composite material form also is described, which includes a plurality of reinforcement material particles comprising a metal alloy or a ceramic, a matrix material at least partially filling spaces between the reinforcement material particles; and at least one intermetallic phase surrounding at least some of the reinforcement material particles. The reinforcement material particles and intermetallic phase together may form a gradient core-shell structure.
Rios, Orlando↗
Effect of moisture ingression on material performance and particle generation in molten salts
This report summarizes activities conducted to understand and mitigate the negative consequences that moisture ingressions have upon the operations of pyroprocessing equipment. The objectives of the work conducted in FY25 were to characterize (1) the physicochemical properties of particles generated as a result of moisture ingressions, and (2) the corrosion of relevant structural materials with the introduction of moisture. Compositional and morphological analyses of the generated particles were conducted through a suite of characterization technologies, including X-ray diffraction, microscopy, and particle size analysis. The results gathered this year were compared to those obtained in FY24 when studies with oxygen ingressions were conducted on CeCl 3 -LiCl-KCl and UCl 3 -LiCl-KCl systems. Investigations involving performance evaluations of industrially relevant structural alloys were also conducted under moisture ingress conditions. In-line electrochemical monitoring of the bulk salt was augmented with microscopy of alloy samples to quantify the concentration and accumulation of corrosion products in the bulk salt. The results reported in this work provide a more holistic understanding of the effects of atmospheric ingressions on molten chloride salt chemistry such that effective redox control strategies may be implemented.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
Controlled wetting and spreading of metals on substrates using porous interlayers and related articles
The disclosure generally relates to a method of creating patterned metallic circuits (e.g., silver circuits) on a substrate (e.g., a ceramic substrate). A porous metal interlayer (e.g., porous nickel) is applied to the substrate to improve wetting and adhesion of the patterned metal circuit material to the substrate. The substrate is heated to a temperature sufficient to melt the patterned metal circuit material but not the porous metal interlayer. Spreading of molten metal circuit material on the substrate is controlled by the porous metal interlayer, which can itself be patterned, such as having a defined circuit pattern. Thick-film silver or other metal circuits can be custom designed in complicated shapes for high temperature/high power applications. The materials designated for the circuit design allows for a low-cost method of generating silver circuits other metal circuits on a ceramic substrate.
Nicholas, Jason Dale↗
Signature Analysis Utilizing a Dynamic Molten Salt Reactor Model for MC&A
Moving from traditional fixed fuel nuclear reactor systems to a mobile, dynamic fuel system that has dissolved special nuclear material in a molten salt is a paradigm shift in several respects. One major consideration is how to develop effective nuclear material controls and accounting for these novel reactor systems. The Molten Salt Reactor Experiment is one example of a critical molten salt system and provided a significant reference library based on the documented effort. But it was low thermal power that was not intended to reflect a commercial scale electricity production design. Therefore, to facilitate and assist vendors with domestic licensing considerations, research is underway to identify methods that could be used for domestic safeguards approaches for these novel reactor systems. This research presents the results of a signature analysis of data generated from three simulated scenarios using the molten salt demonstration reactor model defined in the Transient Simulation Framework of Reconfigurable Modules. Each scenario provides 1 hour isotope inventories over a 180 day period. The scenarios investigated provide test cases to examine if direct gamma-ray spectroscopy of the fuel can be used to identify changes comparing a base case (no reactivity control and fixed fission contribution) to an insertion of reactivity (10 pcm no change in fission composition) and a change in fission composition. The analysis demonstrates that monitoring the total count rate in a highly collimated high-resolution photon energy spectrum is sensitive to perturbations imposed into the reactor model. The total photon count rate changes ≈2% for the fission composition change and ≈4.5% for the reactivity insertion compared to the base case. However, both scenarios show an increase in the total photon count rate. The total photon count rate can be used to identify changes due to power (number of fissions) but not due to a change in the material undergoing fission. To distinguish between the two cases of increased power, the photon spectrum would require an intensive analysis technique. A photon peak count rate ratio analysis could be used to identify changes in the fissile material fission generation in the core through identification of a static peak that shows little variation to the source of fission and a highly varying peak. The photon peak strength will ultimately be determined by the isotope’s fission yield. A preliminary analysis investigating the coupling of the isotope’s fission yield and its concentration in the fuel salt derived from the modeling has been performed. A ratio analysis of the photon peak count rates of 140 La to 99 Mo demonstrated that the reactivity insertion creates a distinct difference in the ratio compared to the fission composition change scenario.
21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
Fractal textured surfaces for high temperature corrosion mitigation in molten salts
Not provided.
Energy & Fuels↗
Method and apparatus for producing microshells
A method is described for forming hollow particles, or shells, of extremely small size. The shell material is heated to a molten temperature in the presence of a gas that is at least moderately soluble in the shell material, to form a solution of the molten shell material and the soluble gas. The solution is atomized to form a multiplicity of separate droplets that are cooled while in free fall. Cooling of a droplet from the outside traps the desolved gas and forces it to form a gas bubble at the center of the droplet which now forms a gas filled shell. The shell is reheated and then cooled in free fall, in an environment having a lower pressure than the gas pressure in the shell. This causes expansion of the shell and the formation of a shell having a small wall thickness compared to its diameter.
Lee, Mark C.↗
Domestic Safeguards Material Control and Accountancy Considerations for Molten Salt Reactors
Molten salt reactors (MSRs) are a class of nuclear reactor designs with features and operational characteristics that vary significantly more than the class of light water reactors (LWRs). MSR design concepts can be broadly categorized as solid-fueled reactors with molten salt as the coolant, liquid-fueled reactors with fuel dissolved in molten salt coolant and liquid-fueled reactors with fuel dissolved in molten salt that is contained in distinct fuel tubes with a nonfissile coolant. Proposed MSR concepts include features that are specific to each design. MSR concepts vary widely across these design features, including the physical, chemical, and isotopic composition of fresh and irradiated fuel. Operational neutron energy spectrums and breeding ratios also vary significantly across design concepts. Some concepts are burner reactors designed to transmute the spent nuclear fuel from LWRs or pressurized heavy water reactors (PHWRs), while others are breeder reactors designed to breed fissile 233 U from naturally occurring fertile 232 Th. Some MSR concepts are designed to be a part of a once-through fuel cycle, while others involve chemical separation. Those that include plans to recycle the fuel differ by whether the chemical processing would be done onsite, as a process connected to the fuel salt itself, or offsite at a reprocessing facility similar to how LWR or PHWR spent fuel is reprocessed in some countries. Each overall design concept contains various aspects of each of these features to produce a unique facility
22 GENERAL STUDIES OF NUCLEAR REACTORS↗
Experimental and Modeling Studies of Metal Halide Catholyte and Cathode Materials to Enable Low-temperature Molten Sodium Batteries.
Abstract not provided.
Maraschky, Adam↗
Experimental and Modeling Studies of Metal Halide Catholyte and Cathode Materials to Enable Low-Temperature Molten Sodium Batteries .
Abstract not provided.
Maraschky, Adam↗