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At least 235 records · Page 13

FY26 Progress on Demonstration of a Multiphysics Steady State Capability for Modeling Core Radial Expansion in SFRs

Under the U.S. Department of Energy Office of Nuclear Energy Advanced Modeling and Simulation (NEAMS) Program, an integrated multiphysics approach is being developed to model the core bowing phenomena important to liquid metal-cooled fast reactors. Core bowing is an important passive safety mechanism in liquid metal-cooled fast reactors and involves multiphysics effects including radiation transport, fluid flow, heat transfer, and mechanical response to temperature and flux gradients. This report summarizes recent progress on developing a multiphysics, MOOSE-based workflow to predict core bowing and associated reactivity feedback. Significant new capabilities in the reactor physics code Griffin - sodium backfill and pin power reconstruction for deformed geometries - were applied in this effort. This year’s work included verification, code comparisons, sensitivity studies, and coupled demonstrations that advance the state of MOOSE-based core bowing workflow. Griffin’s sodium backfill capability was verified by demonstrating that its automated treatment of geometry expansion and material-density updates reproduces manual calculations exactly, confirming solid mass conservation and proper coolant backfilling in expanded geometries. Reconstructed pin powers were compared for Griffin’s ductheterogeneous and ring-heterogeneous treatments in single-, seven-, and nineteen-assembly cases, with best agreement observed in lower-leakage configurations and the duct-heterogeneous approach offering substantially lower computational cost. Thermal-hydraulic sensitivity sensitivities showed that MOOSE SCM, SAM, and CFD are expected to produce similar deformation predictions despite variances in their temperature predictions, and that explicit treatment of inter-assembly flow becomes increasingly important as gap flow rate increases. Finally, coupled demonstrations on small multi-assembly configurations using Griffin, MOOSE Solid Mechanics, MOOSE SCM, and Heat Conduction produced physically consistent reactivity feedback from thermal expansion and bowing. The coupled demonstrations simulated grid plate expansion as well as resultant core bowing at full power conditions. Simplifications were made in current workflow, namely the assumption of instantaneous full power conditions following hot zero power, and pre-expanding the Griffin geometry axially due to lack of an axial fuel pin expansion model and temperature feedback to Griffin.

Wozniak, Nicholas↗

Deep learning multiphysics network for imaging CO 2 saturation and estimating uncertainty in geological carbon storage

Multiphysics inversion exploits different types of geophysical data that often complement each other and aims to improve overall imaging resolution and reduce uncertainties in geophysical interpretation. Despite the advantages, traditional multiphysics inversion is challenging because it requires a large amount of computational time and intensive human interactions for preprocessing data and finding trade-off parameters. These issues make it nearly impossible for traditional multiphysics inversion to be applied as a real-time monitoring tool for geological carbon storage. In this paper, we present a deep learning (DL) multiphysics network for imaging CO 2 saturation in real time. The multiphysics network consists of three encoders for analysing seismic, electromagnetic and gravity data and shares one decoder for combining imaging capabilities of the different geophysical data for better predicting CO 2 saturation. The network is trained on pairs of CO 2 label models and multiphysics data so that it can directly image CO 2 saturation. Here we use the bootstrap aggregating method to enhance the imaging accuracy and estimate uncertainties associated with CO 2 saturation images. Using realistic CO 2 label models and multiphysics data derived from the Kimberlina CO 2 storage model, we evaluate the performance of the deep learning multiphysics network and compare its imaging results to those from the deep learning single-physics networks. Our modelling experiments show that the deep learning multiphysics network for seismic, electromagnetic, and gravity data not only improves the imaging accuracy but also reduces uncertainties associated with CO 2 saturation images. Our results also suggest that the deep learning multiphysics network for the non-seismic data (i.e., electromagnetic and gravity) can be used as an effective low-cost monitoring tool in between regular seismic monitoring.

58 GEOSCIENCES↗

Multiphysics Coupling Methods for Molten Salt Reactor Modeling and Simulation in VERA

New multiphysics coupling capabilities for molten salt reactor (MSR) analysis have been developed in the Virtual Environment for Reactor Applications (VERA). This development consisted of two main efforts. First, a generic species transport module was added in the CTF code, which is the thermal-hydraulics (TH) code for VERA. This module uses the velocity fields for which CTF solves during the TH calculation to transport species through the core and around the primary loop. Additionally, a gas sparging model has been added to CTF to model the movement of certain species, namely, fission products such as xenon gas, to transport between the molten salt and gas bubbles present in the salt. The second effort in this development was coupling this capability to VERA’s neutron transport code MPACT. This effort focused on coupling the detailed TH transport models in CTF to MPACT to account for feedback effects in the neutron transport calculations. Finally, the thermochemistry code Thermochimica has also been coupled to VERA. Thermochimica performs pointwise calculations for chemical potential and Gibbs free energy and determines what phases are produced by the temperature, pressure, and elemental concentrations at different locations in the primary loop. These capabilities are demonstrated using a model of the Molten Salt Reactor Experiment (MSRE). Furthermore, this reactor operated at Oak Ridge National Laboratory in the 1960s, providing sources of experimental data that were used to develop the model. Various combinations of species were modeled using VERA’s new multiphysics coupling capabilities. Species distributions and reactivity effects behaved as expected for the MSRE model, demonstrating that the coupling is behaving correctly and causing appropriate feedback. The results of these calculations show the potential for VERA to be used for a wide variety of MSR analyses.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Providing Experimental Infrastructure for Accelerating Advanced Reactor Demonstrations through the National Reactor Innovation Center

A suite of experimental infrastructure projects has been developed by the National Reactor Innovation Center to accelerate advanced reactor demonstrations and facilitate their development, addressing crucial gaps in data, materials characterization, and modeling. First, the Molten Salt Thermophysical Examination Capability (MSTEC) provides a specialized platform for post-irradiation characterization of molten salt reactor fuel, coolant salts, and structural materials, essential for supporting the design and operation of advanced reactors and future commercial molten salt reactor development and licensing. The Virtual Test Bed (VTB) complements these efforts by leveraging advanced modeling and simulation tools to evaluate reactor performance and safety. Serving as a library of reference models, the VTB offers a database of multiphysics reactor models, facilitating rapid safety evaluations and includes continuous software quality assurance, crucial for accelerating deployment while maintaining reliability. Additionally, the Helium Component Test Facility (HeCTF) addresses the need for high-temperature helium-cooled reactor component testing. As the first-of-its-kind facility in the United States, HeCTF emulates high-temperature gas reactor conditions, reducing time and cost associated with component validation, thereby accelerating reactor development. Finally, In-cell Thermal Creep Frames provide a unique solution for obtaining thermal creep data from irradiated materials, critical for materials qualification and licensing. Developed by the National Reactor Innovation Center, these compact frames enable the examination of previously irradiated materials, overcoming traditional limitations and enhancing the understanding of mechanical properties crucial for reactor development. Collectively, these experimental infrastructure projects form a comprehensive framework aimed at expediting advanced reactor demonstrations, fostering innovation, and ensuring the viability of next-generation nuclear energy solutions.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

The Role of Interfacial Thermal Resistance in Li-Ion Battery Thermal Management: Preprint

Temperature critically affects the performance, life and safety of lithium-ion batteries. Therefore, it is essential to understand heat generation and dissipation within individual battery cells and battery packs to plan a proper thermal management strategy. One of the key challenges is that interfacial heat transfer of a battery unit is difficult to quantify. The steady-state absolute method and the transient laser-flash-diffusivity method were employed to measure heat conductivities of battery layer stacks and individual battery layer separately. Results show flash diffusivity method gives higher thermal conductivity at both cross-plane and in-plane directions. The difference is primarily caused by interfacial thermal resistance so that it can be estimated by steady-state and transient measurements. To investigate the effects of interfacial thermal transport beyond individual cell level, a multiphysics battery model is used. The model is built upon a multi-scale multi-domain modeling framework for battery packs that accounts for the interplay across multiple physical phenomena. Benefits of a battery module using thermal management materials are quantified through numerical experiments. During a thermal runaway event, it is found interfacial thermal resistance can mitigate thermal runaway in a battery module by significantly reducing heat transfer between cells.

33 ADVANCED PROPULSION SYSTEMS↗

Multiphysics Simulation of KRUSTY Warm Critical Experiments Using MOOSE Tools

A series of critical experiments were performed during the Kilopower Reactor Using Stirling TechnologY (KRUSTY) project, producing valuable and unique data for the validation of corresponding microreactor models. In this paper, the development of a high-fidelity multiphysics model of the KRUSTY microreactor within the MOOSE ecosystem is presented, with a focus on the microreactor configuration during the warm critical experiments. The model was established by coupling a deterministic neutronics model using the Griffin code, with a BISON thermomechanical model. The multiphysics model successfully simulated the KRUSTY 15 ¢ and 30 ¢ warm critical reactivity insertion experiments in satisfactory agreement with the experimental measurement data. In conclusion, the modeling results demonstrated the performance of MOOSE-based multiphysics tools in microreactor simulations, and spotlighted the useful applications of these tools in supporting microreactor design, qualification, and licensing activities.

KRUSTY↗

Survey of Relevant Data from the MSRP to Guide Development of MSR Chemistry Modeling Benchmarks

The Multiphysics Applications technical area of the Nuclear Energy Advanced Modeling and Simulation (NEAMS) program is tasked with assessing, demonstrating, and applying NEAMS tools in solving multiphysics problems of nuclear reactors, such as liquid-fueled molten salt reactors (MSRs), which are the focus of this report. MSRs are actively being pursued as a potential candidate for power and heat generation by the nuclear industry. However, the inherent multiphysics nature of liquid-fueled MSRs, stemming from the strong interrelationship of neutronics, thermal fluids, and chemistry phenomena, provides unique challenges in modeling and simulation (mod/sim). Therefore, it will be important to develop mod/sim tools with varying types of multiphysics coupling that depend on the problem. The current work is focused on the initiation and development of MSR chemistry modeling benchmarks useful for validating current and potential future NEAMS tools. Development of such benchmarks include the following actions: 1) Summarize available chemistry data from the Oak Ridge National Laboratory (ORNL) MSR Program (MSRP) including operation of the Molten Salt Reactor Experiment (MSRE) and design studies for the Molten Salt Breeder Reactor (MSBR) concept; 2) Recommend simulation problems in MSR chemistry mod/sim based on (1); 3) Assess the current state of NEAMS tools that may support (2); 4) Demonstrate and validate the capabilities of the NEAMS tools in (3) while providing iterative feedback on future code development activities. The objective of this report is to initiate this effort by completing actions (1) and (2), which are discussed in Section 2. An overview of the relevant available MSRE experimental data is provided with examples of how this data may be useful in chemistry mod/sim problems, with the caveat that most of this data is over 50 years old, therefore some problem details as well as uncertainty estimates are often not provided. In Section 3, the current state of NEAMS tools is assessed for potential use in these mod/sim problems, with considerations for future code development activities, supporting action (3). Future work supporting this project under NEAMS may include a deeper dive into the specific phenomena discussed here including tasks such as the compilation of additional available data, updates in code development activities, and ultimately the demonstration and validation of these tools, supporting action (4).

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Lattice Design and Advanced Modeling to Guide the Design of High-Performance Lightweight Structural Materials

Lightweight structural materials are required to increase the mobility of fission batteries. The materials must feature a robust combination of mechanical properties to demonstrate structural resilience. The primary objective of this project is to produce lightweight structural materials whose strength-to-weight ratios exceed those of the current widely used structural materials such as 316L stainless steels (316L SS). To achieve this, advanced modeling and simulation tools were employed to design lattice structures with different lattice parameters and different lattice types. A process was successfully developed for transforming lattice-structures models into Multiphysics Object Oriented Simulation Environment (MOOSE) inputs. Finite element modeling (FEM) was used to simulate the uniaxial tensile testing of the lattice-structured parts to investigate the stress distribution at a given displacement. The preliminary results showed that the lattice-structured sample displayed a lower Young’s modulus in comparison with the solid material and that the unit cell size of the lattice had a minimal effect. The novelty here is to apply up-front modeling to determine the best structure for the application before actually producing the sample. The approach of using modeling as a guiding tool for preliminary material design can significantly save time and cost for material development.

36 MATERIALS SCIENCE↗

Lattice Structured Lightweight Structural Materials

The development of lightweight structural materials is crucial for enhancing the performance and deployment feasibility of fission batteries. This study aims to produce lightweight structural materials whose strength-to-weight ratios exceed those of current widely used structural materials. To achieve this, advanced modeling and simulation tools were employed to design lattice structures with different lattice parameters and different lattice types. A process was successfully developed for transforming lattice-structured models into Multiphysics Object Oriented Simulation Environment (MOOSE) inputs. Finite element modeling (FEM) was used to simulate the uniaxial tensile testing of the lattice-structured parts to investigate the stress distribution at a given displacement. The modeling results showed that the lattice-structured sample displayed a lower Young’s modulus in comparison to the solid material; the increase in solid shell thickness and blend radius enhances the mechanical performance; and the effect of unit cell size on macro scale stress is minimal. Tensile testing was conducted on the solid and lattice-structured materials fabricated by laser powder bed fusion (LPBF) additive manufacturing. The experimental results agreed well with the model prediction. The approach of using modeling as a guiding tool for preliminary material design can significantly save time and cost for new material development.

lightweight material↗

A Novel Multiphysics Multiscale Multiporosity Shale Gas Transport Model for Geomechanics/Flow Coupling in Steady and Transient States

Summary A novel multiphysics multiscale multiporosity shale gas transport (M3ST) model was developed to investigate shale gas transport in both transient and steady states. The microscale model component contains a kerogen domain and an inorganic matrix domain, and each domain has its own geomechanical and gas transport properties. Permeabilities of various shale cores were measured in the laboratory using a pulse decay permeameter (PDP) with different pore pressure and confining stress combinations. The PDP-measured apparent permeability as a function of pore pressure under two effective stresses was fitted using the microscale M3ST model component based on nonlinear least squares fitting (NLSF), and the fitted model parameters were able to provide accurate model predictions for another effective stress. The parameters and petrophysical properties determined in the steady state were then used in the transient-state, continuum-scale M3ST model component, which performed history matching of the evolutions of the upstream and downstream gas pressures. In addition, a double-exponential empirical model was developed as a powerful alternative to the M3ST model to fit laboratory-measured apparent permeability under various effective stresses and pore pressures. The developed M3ST model and the research findings in this study provided critical insights into the role of the multiphysics mechanisms, including geomechanics, fluid dynamics and transport, and the Klinkenberg effect on shale gas transport across different spatial scales in both steady and transient states.

Engineering↗

Field Laboratory for Emerging Stacked Unconventional Plays in Central Appalachia

The goal of the Field Laboratory for Emerging Stacked Unconventional Plays (ESUP) in Central Appalachia project was to investigate and characterize the resource potential for multi-play production of emerging unconventional reservoirs in Central Appalachia. Project activities included drilling, logging and coring of a vertical characterization well drilled to basement to approximately 15,000 feet in depth. The data from drilling and well logs as well recovered core samples were used by the research team to support characterization of the geology and potential pay zones within the Nora Gas Field of southwestern Virginia and the greater Central Appalachian Basin. This project was led by Dr. Nino Ripepi of the Virginia Center for Coal and Energy Research (VCCER) in close collaboration with EnerVest Operating LLC (EnerVest). VCCER is housed in the Department of Mining and Minerals Engineering at Virginia Tech and was created by an Act of the Virginia General Assembly on March 30, 1977, as an interdisciplinary study, research, information, and resource facility for the Commonwealth of Virginia. EnerVest is a top tier, low-cost oil and natural gas company with a long history of traditional operating relationships with institutional investors as well as public and private companies. This report summarizes two major research activities: 1) Log and Core Analysis and 2) Numerical Modeling. Core analysis comprises the characterization efforts of the ESUP Field Laboratory and includes a discussion of the well logs run in the deep characterization wells, an initial analysis of those, the number, size and location of cores recovered, core testing and analysis done to date as well as plans for future analysis. Numerical modeling is comprised of seven major modeling efforts, including (1) Multiphysics shale transport modeling work, (2) the developed in-house compositional simulator studies, (3) reservoir modeling studies using GEM software, (4) fracture modeling work using EFRAC3D software and (5) numerical modeling efforts with ABAQUS software, (6) Numerical modeling efforts using FLAC3D and PFC3D, and (7) Automatic Machine Learning (AutoML) Studies.

02 PETROLEUM↗

Report of METL Mutual Inductance Level Sensor Development for Use in Liquid Metals – FY2023

A robust mutual inductance level sensor (MILS) for use in high temperature liquid metals has been developed at Argonne National Laboratory (ANL). The current design utilizes mineral insulated cables with a 300-series stainless steel sheath, magnesium oxide insulation, and a single copper conductor. Two coils are wrapped on a common core made of a 300-series stainless steel tube. One coil is energized with an alternating current (AC) source, and this electromagnetically couples with the second coil to generate an induced voltage. The voltage is measured to determine the mutual induction between the coils, and the mutual inductance measurement can be used to determine the level of a nearby liquid metal volume. The MILS can be located in an isolating thimble that is fully sealed to a vessel containing liquid metal for ease of maintenance and replacement. When the primary coil is energized with the AC source, the coil not only electromagnetic (EM) couples with the second coil, but also the surrounding liquid metal. The EM coupling with the surrounding liquid metal reduces the EM coupling with the second coil, producing an inverse-linear relationship between liquid metal level and secondary coil voltage. This has all been demonstrated at the Mechanisms Engineering Test Loop (METL) liquid sodium facility at ANL. The most current iteration of the MILS system is the MILS-MK-II. This sensor system has been commissioned in a non-sodium test stand where calibrations were performed using a sodium analog. The calibrations proved to be highly linear and repeatable. The MILS-MK-II has been installed in the METL expansion tank where high temperature sodium tests have been performed. The MILS-MK-II has been calibrated against a known standard at temperature of 300°C, and the calibrations have proved to be highly linear and repeatable. The calibrated MILS-MK-II has been in operation in the METL facility for several thousands of hours at temperatures around 300°C. The experimental data has been used to develop and validate electromagnetic finite element models in COMSOL Multiphysics, and now these models can be used to advance the development of the sensor system. Next steps will include temperature compensation to allow for operation at various temperatures. Additionally, efforts to incorporate a self-calibration methodology are underway.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Virtual Test Bed (VTB): NRIC FY24 Program Review

NRIC: Deliver successful demonstration and deployment of advanced nuclear energy EBRII Test Bed (DOME) ZPPR Test Bed (LOTUS) Virtual Test Bed (VTB): Accelerate deployment of advanced reactors by leveraging state-of-the-art ModSim tools to evaluate performance and safety Ok, but what is it? Library of Reference Model: database of advanced multiphysics advanced reactor models that users can download, edit, and re-run Continuous Software QA: linking repository to software development to avoid legacy issues while enabling rapid code development Virtual models of the test bed: developing demonstration-relevant models (e.g., candidates for DOME/LOTUS) to accelerate safety evaluations

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

A COUPLED DETERMINISTIC TRANSPORT CALCULATION IN COMSOL USING PROPER ORTHOGONAL DECOMPOSITION

A coupled physics problem consisting of radiation transport and heat transfer was modeled using COMSOL Multiphysics to simulate a criticality accident. Reduced order models (ROM) were created to accelerate the radiation transport calculation through Proper Orthogonal Decomposition (POD). Additionally, on-the-fly neutron cross sections were generated from a non-linear function through a feed forward neural network. The Livelink for MATLAB module allowed for data transfer between an otherwise independent solver and in-house modules. A data driven approach to POD was developed to act as a surrogate model to couple with heat transfer, with the POD module written in MATLAB coupled to an isolated heat transfer solve in COMSOL. A coupled transient solution resulted in a good approximation of the flux and temperature, with the maximum error being 3E-2 and 2.5E-3 respectively.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

FENIX: Towards a Fully Integrated Multiphysics Framework for Plasma Facing Component Modeling

Computational tools have a crucial role to play in accelerating the deployment of fusion as a clean, reliable, abundant, and sustainable energy source. Multiphysics, high-fidelity simulation capabilities can help model, study, and predict intricate interactions between materials performance, plasma exposure, neutron irradiation, and engineering processes. As such, they can assist in the resolution of scientific and engineering challenges underpinning design, construction, and commission of fusion power plants. To address these needs, ongoing efforts are leveraging the Multiphysics Object-Oriented Simulation Environment (MOOSE) framework and delivering new computational tools for the fusion community. These tools inherit crucial attributes from MOOSE. They are open-source, modular, integrated with nuclear industry-standard software quality assurance processes, and enable multiphysics, multi-fidelity, fully integrated, zero- to three-dimensional, and massively parallel simulations. After a short overview of these capabilities, we will present the development of Fusion ENergy Integrated multiphys-X (FENIX), a MOOSE-based application designed to enable plasma facing component design and performance evaluation. Throughout their lifetime, plasma facing components are exposed to extreme thermal loads, repeated thermal shocks, and irradiation by plasma ions, neutral particles, and high-energy neutrons. Consequently, designing a plasma facing component with acceptable lifetime degradation is extremely challenging. FENIX aims to model the multiphysics environment in which plasma facing components evolve to accelerate their design studies. To that end, FENIX couples existing MOOSE capabilities such as heat transfer, thermomechanics, and thermal hydraulics, with tritium transport via the MOOSE-based Tritium Migration Analysis Program, Version 8 (TMAP8), with neutronics via the MOOSE-based high-fidelity neutron-photon transport and fluid dynamics code Cardinal, and finally with Particle-in-Cell plasma simulation capabilities being developed in this project. In this study, we present the current FENIX capabilities and preliminary results of its application to model the Tritium Plasma Experiment set up at Idaho National Laboratory.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Computational modeling of graphite degradation in molten salt reactors: Role of infiltration

Molten salt reactors (MSRs) often employ graphite as a moderator and reflector. An important challenge for deploying graphite in these reactors is that, due to limited experimental data, our understanding of graphite’s structural integrity in molten salt environments remains incomplete. Here, this study addresses heat generation from fuel-bearing salt that has infiltrated open pores in the graphite, driven primarily by pressure differentials. This is one of multiple identified physical and chemical mechanisms through which molten salt could potentially degrade graphite. Thermally driven stresses are quantified using the Molten-Salt Reactor Experiment (MSRE) graphite moderator elements as a case study. Finite element simulations predict stress distributions at varying infiltration levels, indicating that thermal stresses increase with higher infiltration. Rare-event simulations using the parallel subset simulation framework identify the combinations and corresponding ranges of input parameters that lead to stresses above a specified threshold. In particular, combinations involving high infiltration amounts, high power density, and low thermal conductivity tend to induce the highest stresses. Under the inputs and assumptions considered in this work, the magnitudes of the thermally driven stresses are quite low, with a very low likelihood of causing failure due to exceeding the graphite’s tensile strength. Additionally, rare-event simulations were performed for two more scenarios: a scaled-up moderator geometry and a localized hotspot in the original geometry. Both cases resulted in increased susceptibility to failure, though not to a detrimental extent. Furthermore, the combined effects of irradiation and infiltration-induced thermal stresses were evaluated. The results showed that thermal stresses from infiltration were negligible compared to those caused by irradiation. The findings of such a study are inherently component-specific, but the methodology presented here could be used for similar assessments of salt-infiltration effects in other graphite components.

36 - MATERIALS SCIENCE↗

Google/Makani Energy Kite Modeling (CRADA CRD-18-00569 Final Report)

In support of Makani’s energy kite development program, Makani engaged with NREL to develop, verify, and document a multiphysics engineering model of a megawatt-scale tethered energy kite (named KiteFAST). After the original development of KiteFAST was completed, Makani further engaged NREL to develop a software enhancement of KiteFAST to enable the dynamics modeling of an energy kite tethered to a floating offshore platform (named KiteFAST-OS). Before this project, the capability to model the aero-hydro-servo-elastic dynamics of an airborne wind energy (AWE) system with electricity generation on the flying device (fly gen) and crosswind flight operation did not exist. Such physics-based modeling capability is needed for loads analysis, structural design, and certification of energy kites. Throughout the project, an exclusive license kept KiteFAST and KiteFAST-OS available only to Makani, NREL, and its counterparts. With the ending of Makani, the KiteFAST and KiteFAST-OS software were merged into a single code base (named KiteFAST), the exclusive license was terminated, and the source code, documentation, and example models were released publicly.

17 WIND ENERGY↗