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DOE OSTI2022

Semi-Annual Report for Modular Integrated Gas High Temperature Reactor Development during Performance Period April 2022 - September 2022

Horizontal Compact High Temperature Gas Reactor (HC-HTGR) is being designed by a multidisciplinary team of nuclear, mechanical, and structural engineers under the support of a DOE-NE Advanced Reactor Demonstration Program’s Advanced Reactor Concepts-20 (ARC-20) award. The objective of this ARC-20 project is to deliver a conceptual design for the proposed HC-HTGR in 3 years and support its commercialization as a safe, low-cost HTGR. Argonne National Laboratory (Argonne) is responsible for the design and analysis of the reactor cavity cooling system (RCCS) as a safety system for passive decay heat removal of the reactor concept. Additionally, Argonne is providing analysis of the primary coolant system to ensure temperatures within the core remain below safety margins during steady-state and potential accident scenarios. This second semi-annual report summarized the progress made at Argonne on the two tasks during the second half of FY22. As a part of the RCCS design task, a scoping calculation in estimating HVAC capability for the HC-HTGR reactor building was performed. A water panel modeling study was first performed with the test case, which confirms the capability of the RELAP5-3D modeling approach to explore various design options of the HC-HTGR RCCS under consideration. Then, a reference RELAP5-3D model for the unit geometry of the preliminary design of the HC-HTGR RCCS was developed. A preliminary performance analysis was conducted to evaluate the performances of a single-phase natural circulation and panel conduction in various operating conditions. For the primary coolant system analysis task, preliminary thermal hydraulic analysis of the HC-HTGR core design was performed with a high resolution 1D fluid-3D solid coupled model using the System Analysis Module (SAM) to assess the assembly coolant channel and bypass flow mass flow rate distribution. Some preliminary work on the development of a full core reduced order model was discussed following the assembly level model to predict the core wide coolant flow distribution and to model certain operational and accidental transients.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2011

2011 Remediation Effectiveness Report for the U.S. Department of Energy Oak Ridge Reservation, Oak Ridge, Tennessee - Data and Evaluations

Under the requirements of the Oak Ridge Reservation (ORR) Federal Facility Agreement (FFA) established between the U.S. Department of Energy (DOE), the U.S. Environmental Protection Agency, (EPA) and the Tennessee Department of Environment and Conservation (TDEC) in 1992, all environmental restoration activities on the ORR are performed in accordance with the Comprehensive Environmental Response, Compensation, and Liability Act of 1980 (CERCLA). Since the 1990s, the environmental restoration activities have experienced a gradual shift from characterization to remediation. As this has occurred, it has been determined that the assessment of the individual and cumulative performance of all ORR CERCLA remedial actions (RAs) is most effectively tracked in a single document. The Remediation Effectiveness Report (RER) is an FFA document intended to collate all ORR CERCLA decision requirements, compare pre- and post-remediation conditions at CERCLA sites, and present the results of any required post-decision remediation effectiveness monitoring. First issued in 1997, the RER has been reissued annually to update the performance histories of completed actions and to add descriptions of new CERCLA actions. Monitoring information used in the 2011 RER to assess remedy performance was collected and/or compiled by DOE's Water Resources Restoration Program (WRRP). Only data used to assess performance of completed actions are provided. In addition to collecting CERCLA performance assessment data, the WRRP also collects baseline data to be used to gauge the effectiveness of future actions once implemented. These baseline data are maintained in the Oak Ridge Environmental Information System and will be reported in future RERs, as necessary, once the respective actions are completed. However, when insufficient data exist to assess the impact of the RAs, e.g., when the RA was only recently completed, a preliminary evaluation is made of early indicators of effectiveness at the watershed scale, such as contaminant trends at surface water integration points (IFs). Long-term stewardship (LTS) information used in this report is collected, compiled, and tracked by the WRRP in conjunction with the Bechtel Jacobs Company LLC (BJC) Surveillance and Maintenance (S&M) program, the BJC Radiation Protection Organization at East Tennessee Technology Park (ETTP), ETTP Environmental Compliance Program, B&W Y-12 Liquid Waste Treatment Operations, and UT Battelle Facilities Management Division. Additionally, documentation verifying the implementation of administrative land use controls (LUCs) [i.e., property record restrictions, property record notices, zoning notices, and excavation/penetration permit (EPP) program] is also obtained from many sources throughout the fiscal year (FY), including County Register of Deeds offices for property record restrictions and property record notices, City Planning Commission for zoning notices, and BJC project engineers for EPP program verification. Copies of this documentation are obtained by the WRRP and maintained with the project RER files.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2016

Exe-Guard Project

The exe-Guard Project is an alliance between Dominion Virginia Power (DVP), Sandia National Laboratories (SNL), Dartmouth University, and Schweitzer Engineering Laboratories (SEL). SEL is primary recipient on this project. The exe-Guard project was selected for award under DE-FOA-0000359 with CFDA number 81.122 to address Topic Area of Interest 4: Hardened platforms and Systems. The exe-Guard project developed an antivirus solution for control system embedded devices to prevent the execution of unauthorized code and maintain settings and configuration integrity. This project created a white list antivirus solution for control systems capable of running on embedded Linux® operating systems. White list antivirus methods allow only credible programs to run through the use of digital signatures and hash functions. Once a system’s secure state is baselined, white list antivirus software denies deviations from that state because of the installation of malicious code as this changes hash results. Black list antivirus software has been effective in traditional IT environments but has negative implications for control systems. Black list antivirus uses pattern matching and behavioral analysis to identify system threats while relying on regular updates to the signature file and recurrent system scanning. Black list antivirus is vulnerable to zero day exploits which have not yet been incorporated into a signature file update. System scans hamper the performance of high availability applications, as revealed in NIST special publication 1058 which summarizes the impact of blacklist antivirus on control systems: Manual or “on-demand” scanning has a major effect on control processes in that they take CPU time needed by the control process (Sometimes close to 100% of CPU time). Minimizing the antivirus software throttle setting will reduce but not eliminate this effect. Signature updates can also take up to 100% of CPU time, but for a much shorter period than a typical manual scanning process. Control systems are vulnerable to performance losses if off-the-shelf blacklist antivirus solutions aren’t implemented with care. This investment in configuration in addition to constant decommissioning to perform manual signature file updates is unprecedented and impractical. Additionally, control systems are often disconnected or islanded from the network making the delivery of signature updates difficult. Exe-Guard project developed a white list antivirus solution that mitigated the above drawbacks and allows control systems to cost-effectively apply malware protection while maintaining high reliability. The application of security patches can also be minimized since white listing maintains constant defense against unauthorized code execution. Security patches can instead be applied in less frequent intervals where system decommissioning can be scheduled and planned for. Since control systems are less dynamic than IT environments, the feasibility of maintaining a secure baselined state is more practical. Because upgrades are performed in infrequent, calculated intervals, it allows a new security baseline to be established before the system is returned to service. Exe-Guard built on the efforts of SNL under the Code Seal project. SNL demonstrated prototype Trust Anchors on the project which are independent monitoring and control devices that can be integrated into untrustworthy components. The exe-Guard team started with the lessons learned under this project then designed commercial solution for white list malware protection. Malware is a real threat, even on islanded or un-networked installations, since operators can unintentionally install infected files, plug in infected mass storage devices, or infect a piece of equipment on the islanded local area network that can then spread to other connected equipment. Protection at the device level is one of the last layers of defense in a security-in-depth defense model before an asset becomes compromised. This project provided non-destructive intrusion, isolation and automated response solution, achieving a goal of the Department of Energy (DOE) Roadmap to Secure Control Systems. It also addressed CIP-007-R4 which requires asset owners to employ malicious software prevention tools on assets within the electronic security perimeter. In addition, the CIP-007-R3 requirement for security patch management is minimized because white listing narrows the impact of vulnerabilities and patch releases. The exe-Guard Project completed all tasks identified in the statement of project objective and identified additional tasks within scope that were performed and completed within the original budget. The cost share was met and all deliverables were successfully completed and submitted on time. Most importantly the technology developed and commercialized under this project has been adopted by the Energy sector and thousands of devices with exe-Guard technology integrated in them have now been deployed and are protecting our power systems today

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2014

Embedding Agile Practices within a Plan-Driven Hierarchical Project Life Cycle

Organizations use structured, plan-driven approaches to provide continuity, direction, and control to large, multi-year programs. Projects within these programs vary greatly in size, complexity, level of maturity, technical risk, and clarity of the development objectives. Organizations that perform exploratory research, evolutionary development, and other R&D activities can obtain the benefits of Agile practices without losing the benefits of their program’s overarching plan-driven structure. This paper describes application of Agile development methods on a large plan-driven sensor integration program. While the client employed plan-driven, requirements flow-down methodologies, tight project schedules and complex interfaces called for frequent end-to-end demonstrations to provide feedback during system development. The development process maintained the many benefits of plan-driven project execution with the rapid prototyping, integration, demonstration, and client feedback possible through Agile development methods. This paper also describes some of the tools and implementing mechanisms used to transition between and take advantage of each methodology, and presents lessons learned from the project management, system engineering, and developer’s perspectives.

Agile Development↗
DOE OSTI2024

Drop Analysis of Department of Energy Standard Canister with Fort Saint Vrain SNF

DOE manages over 300 types of SNF, most of which are located at the INL site. The Idaho Cleanup Project and INL are collaborating on the Road-Ready Capability Demonstration Project, which will develop and demonstrate the designs, technology, processes, and regulatory framework for packaging DOE-managed SNF at the INL site for ?road-ready dry storage?. ?Road-ready dry storage? is a SNF management concept where SNF is packaged into dry and sealed canisters, which are then placed in on-site storage in anticipation of later transportation. The forward-looking goal of the Demonstration is establishing the foundation for a large-scale road-ready dry storage program at the INL site. The Demonstration will first package Fort Saint Vrain SNF currently stored at INL into several DOE Standard Canisters. These Standard Canisters will then be loaded into another commercial transportation or storage containment system (e.g., storage cask or transportation package). The Standard Canister is a class of standardized canisters designed for containing the large variety of DOE-managed SNF during interim storage, transportation and/or disposal at a geological repository. One critical aspect of road-ready dry storage is the ability to license the DOE Standard Canisters and its associated transportation package to 10 CFR 71. Depending on the SNF and transportation strategy, the Standard Canisters may have to maintain structural integrity under normal conditions of transport and hypothetical accident scenarios (i.e., drop events). The Standard Canisters have been tested and analyzed under various SNF loading configurations and accident drop events in support of the Idaho Spent Fuel Facility and other DOE programs. However, no analysis has been completed to support the recent Demonstration. This analysis will consider the Ø0.5 m × 5.1 m Standard Canister under drop scenario(s) considered in previous INL tests and analyses, including the 9 m drop at 80 degree off vertical. However, this analysis will consider the more recent Fort Saint Vrain loading configurations proposed for the Demonstration. This analysis will performed using strain-based acceptance criteria established by the American Society of Mechanical Engineers Boiler and Pressure Vessel Code, Section III, Division 3. It will be compared to previous analyses and form the foundation of further formal calculations that will be used to support licensing efforts of the road-ready dry storage system at INL.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2018

NEAMS Workbench 1.0 Beta

The mission of the US Department of Energy (DOE) Nuclear Energy Advanced Modeling and Simulation (NEAMS) Program is to develop, apply, deploy, and support state-of-the-art predictive modeling and simulation tools for the design and analysis of current and future nuclear energy systems. This is accomplished using computing architectures that range from laptops to leadership-class facilities. The NEAMS Workbench is a new initiative that will facilitate the transition from conventional tools to high-fidelity tools by providing a common user interface for model creation, review, execution, output review, and visualization for integrated codes. The Workbench can use common user input, including engineering scale specifications that are expanded into application-specific input requirements through the use of customizable templates. The templating process enables multi-fidelity analysis of a system from a common set of input data. Additionally, the common user input processor can provide an enhanced alternative application input that provides additional conveniences over the native input, especially for legacy codes. Expansion of the integrated codes and application templates available in the Workbench will broaden the NEAMS user community and will facilitate system analysis and design. Current and planned capabilities of the NEAMS Workbench are detailed here.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2020

NEAMS Workbench Status and Capabilities

The mission of the US Department of Energy’s Nuclear Energy Advanced Modeling and Simulation (NEAMS) program is to develop, apply, deploy, and support state-of-the-art predictive modeling and simulation tools for the design and analysis of current and future nuclear energy systems. This is accomplished by using computing architectures that range from laptops to leadership-class facilities. The NEAMS Workbench is a new initiative that will facilitate the transition from conventional tools to highfidelity tools by providing a common user interface for model creation, review, execution, output review, and visualization for integrated codes. The Workbench can use common user input, including engineering-scale specifications that are expanded into application-specific input requirements through the use of customizable templates. The templating process can enable multifidelity analysis of a system from a common set of input data. Additionally, the common user input processor can provide an enhanced alternative application input that provides additional conveniences compared with native input, especially for legacy codes. Expansion of the integrated codes and application templates available in the Workbench will broaden the NEAMS user community and will facilitate system analysis and design. Current and planned capabilities of the NEAMS Workbench are detailed herein.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2020

Subtask 1.3 – Integrated Carbon Capture and Storage for North Dakota Ethanol Production

The Energy & Environmental Research Center (EERC), in partnership with Red Trail Energy, LLC (RTE), a North Dakota ethanol producer; the North Dakota Industrial Commission (NDIC) Renewable Energy Program (REP); and the U.S. Department of Energy (DOE), conducted a feasibility and implementation study for a commercial carbon capture and storage (CCS) effort. This subtask provided technical support and developed recommended practices of how small-scale industrial CO2 emitters (<1,000,000 tonnes of CO2 emitted annually) may economically deploy CCS. The 64-million-gallon dry mill RTE ethanol facility, emitting an average 180,000 tonnes of CO2 annually, was the subject of the case study. The positive outcome of this research, which shows technical and economic potential for ethanol–CCS in North Dakota, has resulted in RTE acquiring an approved Permit to Drill on December 2, 2019, for a stratigraphic test well in early 2020, a necessary step toward a North Dakota CO2 Storage Facility Permit (SFP) for the RTE CCS effort. Outcomes include 1) validating the Broom Creek Formation as a regional target for CCS, 2) determining the full carbon life cycle of an industrial fuel production facility with CCS, 3) developing a field implementation plan (FIP) for small-scale CCS, and 4) determining the validity and pathway for using CCS to meet low-carbon fuel (LCF) standards. The technical team included the EERC, RTE, Trimeric Corporation, Schlumberger Carbon Services, and Computer Modelling Group (CMG). Findings from activities conducted November 2016 – May 2020 are summarized as follows. Several key steps have been accomplished toward validating the Broom Creek Formation as a CO2 injection and storage target at the RTE CCS site, including verification of the presence and structure of sandstone layers that may comprise the potential CO2 storage reservoir and the several thousand feet of overlying confining zone. Work included site characterization using existing data, interpretation of seismic data within the study area, and geologic modeling simulation of CO2 injection. Interpreted results estimate 3000 feet of confining zone between the Broom Creek Formation (storage target) and the lowermost underground source of drinking water (e.g., the Fox Hills Formation). The thickness of the Broom Creek injection target varies 230–420 ft within the survey area. Results were used to inform the location of a stratigraphic test well and associated characterization test program. No impediments were identified within the targeted CO2 storage complex that would prevent the project from moving forward. A stratigraphic test well is the next step to validate these results and to acquire remaining data necessary to develop a North Dakota CO2 SFP application. The EERC generated full carbon life cycle estimates for CCS integration with the RTE ethanol facility. Results indicated that an average 40% reduction in CO2 emissions is possible through CCS implementation. Approximately half of the carbon in the overall life cycle for a dry mill ethanol plant is generated through the fermentation process and emitted to the atmosphere; this is the CO2 stream targeted for CCS. The remaining carbon is attributed to corn feedstock farming (diesel, fertilizer), energy for fuel processing (natural gas, electricity), and transportation (diesel) of the fuel product. Life cycle carbon estimates are also affected by the anticipated energy consumption of a potential capture facility, which depend on the type of CO2 product generated. For example, a 30%–40% net CO2 emission reduction is estimated if a liquefied CO2 facility were incorporated compared to a 40%–50% net CO2 reduction if a supercritical “injection-grade” CO2 product is generated; i.e., more energy is required to further refine the CO2 stream, affecting the full carbon life cycle estimates. A CCS FIP was developed and initiated at the RTE CCS site, resulting in the development of several guidance documents: a CO2 Capture Process Design Package, a North Dakota CO2 geologic Storage Permits Template, and a Public Outreach Package for CCS in North Dakota. General FIP components include CO2 capture system, pipeline and well designs; monitoring, verification, and accounting (MVA) plans; geologic characterization and testing programs; and permitting and outreach plans. Vendor bids were also acquired for the CO2 liquefaction facility. Near-surface characterization (groundwater and soil gas sampling) and geologic characterization (seismic survey) were initiated to inform development of a UIC Class VI-compliant MVA plan compliant with a North Dakota CO2 SFP. Designs (well and geologic testing) were completed for a stratigraphic test well compliant with a North Dakota CO2 SFP. In addition, the outreach plan was executed, including community open houses, meetings with city/county/state officials, and development of public materials. Although other entities continued to mature incentive programs in 2019–2020, California and the Internal Revenue Service (IRS) currently provide the most advanced economic opportunities for CCS integrated with fuel production. The California Low-Carbon Fuel Standard (LCFS) adopted a CCS Protocol in January 2019, allowing submittal of a design-based pathway (DBP) application for an approved temporary (not certified) carbon intensity value for a fully engineered facility. An ethanol–CCS DBP application to the California LCFS Program (officially approved February 28, 2020) was developed to show that the RTE CCS effort meets LCFS requirements. The approved DBP provides confidence to advance the project and supports potential investments. Other entities continue to mature incentive programs. The IRS issued guidance in February 2020 that addresses the definition of beginning of construction and revenue procedure on partnerships for the Enhancement of Carbon Dioxide Sequestration Credit (a.k.a. Section 45Q) CCS tax credit program; the IRS anticipates issuing further guidance on issues such as secure geologic storage, utilization qualifications, and recapture of claimed credits. Maturing incentive programs coupled with workable permitting regulations provide confidence to advance CCS projects in North Dakota and support financial investment to proceed with designing, constructing, and implementing CCS projects at small-scale fuel production facilities. The largest hurdles for CCS implementation at small-scale industrial systems are often business/economic-related (i.e., not technical). Market uncertainty already exists for agriculture-based alternative fuels such as corn ethanol, for which production has increased by ~33%, and prices have correspondingly lowered since 2015. Passing the Section 45Q tax credit program improves economic feasibility for CCS but may require external investors for a small business to achieve maximum benefits. Public–private partnerships with NDIC and DOE have resulted in foundational technical and regulatory knowledge, growing stakeholder confidence, and a pathway to implementation that enables similar industrial CCS projects in the region to advance. This subtask was funded through the EERC–DOE Joint Program on Research and Development for Fossil Energy-Related Resources Cooperative Agreement No. DE-FE0024233. Nonfederal funding was provided by NDIC and RTE. The authors would also like to thank CMG, ESRI, IHS, Neuralog, and Schlumberger for allowing the use of their software packages in support of this work.

42 ENGINEERING↗
DOE OSTI2019

A Fixed-Flexible BESS Allocation Scheme for Transmission Networks Considering Uncertainties

Battery energy storage systems (BESSs) can play a key role in mitigating the intermittency and uncertainty associated with adding large amounts of renewable energy to the bulk power system (BPS). Two BESS technologies that have gained prominence in this regard are Lithium-ion (LI) BESS and Vanadium redox flow (VRF) BESS. Here, this paper proposes a fixed-flexible BESS allocation scheme that exploits the complementary characteristics of LI and VRF BESSs to attain optimal techno-economic benefits in a wind-integrated BPS. Studies carried out on relatively large transmission networks demonstrate that benefits such as reduction in system operation cost, wind spillage, voltage fluctuations, and discounted payback period, can be realized by using the proposed scheme.

42 ENGINEERING↗
DOE OSTI2014

Advanced Natural Gas Reciprocating Engine(s)

The objective of the Cummins ARES program, in partnership with the US Department of Energy (DOE), is to develop advanced natural gas engine technologies that increase engine system efficiency at lower emissions levels while attaining lower cost of ownership. The goals of the project are to demonstrate engine system achieving 50% Brake Thermal Efficiency (BTE) in three phases, 44%, 47% and 50% (starting baseline efficiency at 36% BTE) and 0.1 g/bhp-hr NOx system out emissions (starting baseline NOx emissions at 2 – 4 g/bhp-hr NOx). Primary path towards above goals include high Brake Mean Effective Pressure (BMEP), improved closed cycle efficiency, increased air handling efficiency and optimized engine subsystems. Cummins has successfully demonstrated each of the phases of this program. All targets have been achieved through application of a combined set of advanced base engine technologies and Waste Heat Recovery from Charge Air and Exhaust streams, optimized and validated on the demonstration engine and other large engines. The following architectures were selected for each Phase: Phase 1: Lean Burn Spark Ignited (SI) Key Technologies: High Efficiency Turbocharging, Higher Efficiency Combustion System. In production on the 60/91L engines. Over 500MW of ARES Phase 1 technology has been sold. Phase 2: Lean Burn Technology with Exhaust Waste Heat Recovery (WHR) System Key Technologies: Advanced Ignition System, Combustion Improvement, Integrated Waste Heat Recovery System. Base engine technologies intended for production within 2 to 3 years Phase 3: Lean Burn Technology with Exhaust and Charge Air Waste Heat Recovery System Key Technologies: Lower Friction, New Cylinder Head Designs, Improved Integrated Waste Heat Recovery System. Intended for production within 5 to 6 years Cummins is committed to the launch of next generation of large advanced NG engines based on ARES technology to be commercialized worldwide.

Pike, Edward↗
DOE OSTI2019

NEAMS Workbench Status and Capabilities

The mission of the US Department of Energy’s Nuclear Energy Advanced Modeling and Simulation (NEAMS) program is to develop, apply, deploy, and support state-of-the-art predictive modeling and simulation tools for the design and analysis of current and future nuclear energy systems. This is accomplished by using computing architectures that range from laptops to leadership-class facilities. The NEAMS Workbench is a new initiative that will facilitate the transition from conventional tools to high fidelity tools by providing a common user interface for model creation, review, execution, output review, and visualization for integrated codes. The Workbench can use common user input, including engineering-scale specifications that are expanded into application-specific input requirements through the use of customizable templates. The templating process can enable multifidelity analysis of a system from a common set of input data. Additionally, the common user input processor can provide an enhanced alternative application input that provides additional conveniences over the native input, especially for legacy codes. Expansion of the integrated codes and application templates available in the Workbench will broaden the NEAMS user community and will facilitate system analysis and design. Current and planned capabilities of the NEAMS Workbench are detailed here.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2012

AVESTAR Center for Operational Excellence of Electricity Generation Plants

To address industry challenges in attaining operational excellence for electricity generation plants, the U.S. Department of Energy’s (DOE) National Energy Technology Laboratory (NETL) has launched a world-class facility for Advanced Virtual Energy Simulation Training and Research (AVESTARTM). This presentation will highlight the AVESTARTM Center simulators, facilities, and comprehensive training, education, and research programs focused on the operation and control of high-efficiency, near-zero-emission electricity generation plants. The AVESTAR Center brings together state-of-the-art, real-time, high-fidelity dynamic simulators with full-scope operator training systems (OTSs) and 3D virtual immersive training systems (ITSs) into an integrated energy plant and control room environment. AVESTAR’s initial offering combines--for the first time--a “gasification with CO2 capture” process simulator with a “combined-cycle” power simulator together in a single OTS/ITS solution for an integrated gasification combined cycle (IGCC) power plant with carbon dioxide (CO2) capture. IGCC systems are an attractive technology option for power generation, especially when capturing and storing CO2 is necessary to satisfy emission targets. The AVESTAR training program offers a variety of courses that merge classroom learning, simulator-based OTS learning in a control-room operations environment, and immersive learning in the interactive 3D virtual plant environment or ITS. All of the courses introduce trainees to base-load plant operation, control, startups, and shutdowns. Advanced courses require participants to become familiar with coordinated control, fuel switching, power-demand load shedding, and load following, as well as to problem solve equipment and process malfunctions. Designed to ensure work force development, training is offered for control room and plant field operators, as well as engineers and managers. Such comprehensive simulator-based instruction allows for realistic training without compromising worker, equipment, and environmental safety. It also better prepares operators and engineers to manage the plant closer to economic constraints while minimizing or avoiding the impact of any potentially harmful, wasteful, or inefficient events. The AVESTAR Center is also used to augment graduate and undergraduate engineering education in the areas of process simulation, dynamics, control, and safety. Students and researchers gain hands-on simulator-based training experience and learn how the commercial-scale power plants respond dynamically to changes in manipulated inputs, such as coal feed flow rate and power demand. Students also analyze how the regulatory control system impacts power plant performance and stability. In addition, students practice start-up, shutdown, and malfunction scenarios. The 3D virtual ITSs are used for plant familiarization, walk-through, equipment animations, and safety scenarios. To further leverage the AVESTAR facilities and simulators, NETL and its university partners are pursuing an innovative and collaborative R&D program. In the area of process control, AVESTAR researchers are developing enhanced strategies for regulatory control and coordinated plant-wide control, including gasifier and gas turbine lead, as well as advanced process control using model predictive control (MPC) techniques. Other AVESTAR R&D focus areas include high-fidelity equipment modeling using partial differential equations, dynamic reduced order modeling, optimal sensor placement, 3D virtual plant simulation, and modern grid. NETL and its partners plan to continue building the AVESTAR portfolio of dynamic simulators, immersive training systems, and advanced research capabilities to satisfy industry’s growing need for training and experience with the operation and control of clean energy plants. Future dynamic simulators under development include natural gas combined cycle (NGCC) and supercritical pulverized coal (SCPC) plants with post-combustion CO2 capture. These dynamic simulators are targeted for use in establishing a Virtual Carbon Capture Center (VCCC), similar in concept to the DOE’s National Carbon Capture Center for slipstream testing. The VCCC will enable developers of CO2 capture technologies to integrate, test, and optimize the operation of their dynamic capture models within the context of baseline power plant dynamic models. The objective is to provide hands-on, simulator-based “learn-by-operating” test platforms to accelerate the scale-up and deployment of CO2 capture technologies. Future AVESTAR plans also include pursuing R&D on the dynamics, operation, and control of integrated electricity generation and storage systems for the modern grid era. Special emphasis will be given to combining load-following energy plants with renewable and distributed generating supplies and fast-ramping energy storage systems to provide near constant baseload power.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2012

Interfacial Engineering for Highly Efficient-Conjugated Polymer-Based Bulk Heterojunction Photovoltaic Devices

The aim of our proposal is to apply interface engineering approach to improve charge extraction, guide active layer morphology, improve materials compatibility, and ultimately allow the fabrication of high efficiency tandem cells. Specifically, we aim at developing: i. Interfacial engineering using small molecule self-assembled monolayers; ii. Nanostructure engineering in OPVs using polymer brushes; iii. Development of efficient light harvesting and high mobility materials for OPVs; iv. Physical characterization of the nanostructured systems using electrostatic force microscopy, and conducting atomic force microscopy; v. All-solution processed organic-based tandem cells using interfacial engineering to optimize the recombination layer currents; vi. Theoretical modeling of charge transport in the active semiconducting layer. The material development effort is guided by advanced computer modeling and surface/ interface engineering tools to allow us to obtain better understanding of the effect of electrode modifications on OPV performance for the investigation of more elaborate device structures. The materials and devices developed within this program represent a major conceptual advancement using an integrated approach combining rational molecular design, material, interface, process, and device engineering to achieve solar cells with high efficiency, stability, and the potential to be used for large-area roll-to-roll printing. This may create significant impact in lowering manufacturing cost of polymer solar cells for promoting clean renewable energy use and preventing the side effects from using fossil fuels to impact environment.

14 SOLAR ENERGY↗
DOE OSTI2022

Improving Coal-Fired Plant Performance Through Integrated Predictive and Condition-Based Monitoring Tools

The project demonstrated the ability to improve boiler performance and reliability through the integrated use of condition-based monitoring (CBM) and predictions of the impacts of coal quality on boiler operations at a full-scale coal-fired power plant. The advanced tool developed actively monitors and manages coal quality and overall boiler conditions that maximizes availability and maintains generating capacity while reducing cost. The tool is used to forecast and alert plant operators and engineers about poor boiler conditions which may occur as a result of incoming coal and/or current power plant operating conditions. The Combustion System Performance Indices (CSPI) and CoalTracker (CT) programs predicts fireside performance of the plant including slagging, fouling, erosion, slag flow, strength development (sintering/densification), and slag layer thickness based on the composition of delivered coal. CT program is tailored for each plant and is used to track the coal from the point of delivery to the burner. The most successful application of the CSPI-CT has been at plants where the coal composition is determined through the use of a full stream elemental analyzers based on prompt gamma neutron analysis (PGNAA). The CSPI-CT program information is used by coal procurement, coal mining and plant operations personnel to select and blend coal properties for the best plant performance.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2022

Multi-Physics Coupled Seismic Safety Analysis of Molten-Salt Reactors

Pool-type Molten Salt Reactors (MSRs) are a promising advanced nuclear reactor concept relying on passive physical behavior to provide increased safety characteristics. The high heat capacity, high boiling point, unpressurized liquid salt contains the nuclear fuel and as it passes through the vessel achieves criticality and produces nuclear power. The salt then carries away the heat produced along with the delayed neutron precursors towards heat exchangers and primary pumps before entering the core. This forms a highly coupled multiphysics problem between neutronics and fluid flow, which makes modeling these reactors challenging. The safety/licensing case heavily relies on modeling and simulation to prove their safety, and significant effort has been expanded by the Nuclear Energy Advanced Modeling and Simulation (NEAMS) program to develop the appropriate simulation tools. Their safety/licensing will require a thorough analysis of their behavior during earthquake-based transients. Earthquakes are a transient condition commonly experienced in many regions, and are safely survived by dozens of reactors every year. Nonetheless, significant conservatisms were introduced with limited predictive modeling and simulation available. The first-of-a-kind capability developed by this research will allow for engineers to analyze ranges of design-basis and beyond-design basis accident scenarios to assess the integrity of the reactor vessel and surrounding system, possibly allowing for limiting the costly conservatisms in the design. This projects uses MASTODON, Griffin, and Pronghorn in the NEAMS ecosystem to model the coupled multiphysics problem posed by an earthquake in a molten salt reactor. It marches through a number of number of coupling schemes, from uncoupled simulations to tightly two-way coupled simulations. The appropriate level of coupling for these simulations will then be determined based on the accuracy in the quantities of interest (QoI) and computational effort involved in each scheme. The QoIs chosen for this paper include the mass flow rate across the heat exchanger (for Pronghorn simulations), power output of the reactor (for Griffin simulations), and the maximum Von Mises stress (for MASTODON simulations). This summary paper reports on the current progress of this project, with 2D tightly coupled multiphysics results.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2016

Rich-Text based PSA Model Transformation and Verification in RiskA

Nuclear Energy is one of the most possible alternative to fossil energy in large-scale. Nuclear safety is the lifeline of nuclear energy development, and has been an important part of national security, especially after the accident of Fukushima. On the basis of computer codes, reliability engineering and Probabilistic Risk Assessment (PSA) is effective methods to improve the safety of nuclear power plants. After many years of development, the methodologies, applications and relevant soft programs have been quite sufficient in the area of nuclear safety. However, it is still difficult for the current PSA technologies and software to meet the needs of dealing with the problems of quantitatively public risk assessment in the digital society. Especially, there are so many software that adopted different modeling and analyzing methods, which brings difficulties to the comparison, evaluation or verification for different software and models. By using its own academic advantages, the advanced nuclear energy research team, i.e., FDS Team has invested a few hundreds person-years of independent research and development of a reliability and probabilistic safety assessment software system RiskA. The system consists of three main functions: device reliability optimization management, probabilistic safety assessment and instantaneous risk monitoring, and the comprehensive public risk assessment in digital society. RiskA establishes an integrated risk evaluation system for the device reliability, nuclear power plant (NPP) risk monitoring and public risk assessment. Currently, RiskA has successfully been applied in more than 600 organizations and institutes from a variety of fields in 39 countries, involving nuclear, aerospace, defense and so on. For example, RiskA has been used in the safety analysis of International Thermonuclear Experimental Reactor (ITER), FDS series fusion reactor, and the Strategic Priority Research Program of Chinese Academy of Sciences 'the Future Advanced Nuclear Fission Energy - Accelerator Driven Sub-critical (ADS) transmutation system'. Also, RiskA has been used in public risk communication and risk assessment. Among them, Third Qinshan nuclear power plant Risk Monitor (TQRM), which is the China's first domestic nuclear safety analysis software used in the actual online operation, has been highly apprised by renowned experts in the field. Meanwhile, it has been identified as the first domestic nuclear power plant risk monitoring system with completely independent intellectual property rights, and has reached the international advanced level. (authors)

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2013

30-kW Maintenance-Free Stirling Engine for High-Performance Dish Concentrating Solar

This final report summarizes the final results of the 30-kW Maintenance-Free Stirling Engine for High-Performance Dish Concentrating Solar project performed by Infinia Corporation for the U.S. Department of Energy under contract DE-FC36-08GO18032 during the project period of March 1, 2008 – March 31, 2012. Over the course of the project, Infinia Corporation achieved substantial progress in the design, fabrication, assembly, testing and evaluation of a 30-kW multi-cylinder, free-piston Stirling engine (MCFPSE) prototype. In this effort, prior MCFPSE conceptual design approaches were adapted for the development of a 30-kW design, thereby producing a cohesive design package and detailed performance specifications. Numerical analysis using the Stirling Engine Analysis and Optimization Code (SAGE) was completed culminating in the selection of a fully balanced 6-cylinder configuration composed of two 3-cylinder engine modules. The model was refined throughout the program to include all wall conduction losses, piston and rod seal losses, appendix, shuttle and pumping losses, and piston radiation loss to closely represent the real system. Performance mapping of the engine was then completed using the detailed model. Based on knowledge and experience from its existing commercial products, and using the results from the extensive numerical modeling discussed above, Infinia successfully fabricated, assembled and tested two sets of 30-kW engine modules. One of these configurations was driven by an external power supply and operated as a cooler in order to verify the mechanical integrity of the system. In the engine configuration, induction heaters provided the energy to the heater head to operate the engine. Considerable effort was expended on correcting problems associated with contact and rubbing of internal components, identification and subsequent elimination of internal leaks, and undesirable amounts of piston bias. Many details concerning the fabrication and testing efforts are considered proprietary. As a result, those findings are not disclosed herein but rather can be found in proprietary reports supplied to the DOE on a periodic basis. The prototype did not fully demonstrate performance nor did it realize the projected cost targets. Furthermore, the basis of the mechanical and electrical architecture of the 30-kW multi-cylinder prototype design is now at least two generations old. Alternatively, Infinia’s 8-kW Bonneville generator, which was successfully demonstrated in April 2012, and is slated to enter commercial production in late 2013, offers immediate benefits of lower cost and significantly higher power density such that the generator will likely meet DOE’s Sunshot LCOE target goal of $\$$0.07-0.10/kWh by 2015 and $\$$0.05-0.07/kWh by 2020. Therefore, the design of a 30-kW Stirling engine as disclosed in the project will not be pursued further. However, Infinia remains keenly interested in developing higher power Stirling machines in the future based on the new Bonneville mechanical design.

14 SOLAR ENERGY↗
DOE OSTI2016

FutureGen 2.0 Oxy-combustion Large Scale Test – Final Report

The primary objectives of the FutureGen 2.0 CO 2 Oxy-Combustion Large Scale Test Project were to site, permit, design, construct, and commission, an oxy-combustion boiler, gas quality control system, air separation unit, and CO 2 compression and purification unit, together with the necessary supporting and interconnection utilities. The project was to demonstrate at commercial scale (168MWe gross) the capability to cleanly produce electricity through coal combustion at a retrofitted, existing coal-fired power plant; thereby, resulting in near-zeroemissions of all commonly regulated air emissions, as well as 90% CO 2 capture in steady-state operations. The project was to be fully integrated in terms of project management, capacity, capabilities, technical scope, cost, and schedule with the companion FutureGen 2.0 CO 2 Pipeline and Storage Project, a separate but complementary project whose objective was to safely transport, permanently store and monitor the CO 2 captured by the Oxy-combustion Power Plant Project. The FutureGen 2.0 Oxy-Combustion Large Scale Test Project successfully achieved all technical objectives inclusive of front-end-engineering and design, and advanced design required to accurately estimate and contract for the construction, commissioning, and start-up of a commercial-scale "ready to build" power plant using oxy-combustion technology, including full integration with the companion CO 2 Pipeline and Storage project. Ultimately the project did not proceed to construction due to insufficient time to complete necessary EPC contract negotiations and commercial financing prior to expiration of federal co-funding, which triggered a DOE decision to closeout its participation in the project. Through the work that was completed, valuable technical, commercial, and programmatic lessons were learned. This project has significantly advanced the development of near-zero emission technology and will be helpful to plotting the course of, and successfully executing future large demonstration projects. This Final Scientific and Technical Report describes the technology and engineering basis of the project, inclusive of process systems, performance, effluents and emissions, and controls. Further, the project cost estimate, schedule, and permitting requirements are presented, along with a project risk and opportunity assessment. Lessons-learned related to these elements are summarized in this report. Companion reports Oxy-combustion further document the accomplishments and learnings of the project, including: A.01 Project Management Report which describes what was done to coordinate the various participants, and to track their performance with regard to schedule and budget B.02 Lessons Learned - Technology Integration, Value Improvements, and Program Management, which describes the innovations and conclusions that we arrived upon during the development of the project, and makes recommendations for improvement of future projects of a similar nature . B.03 Project Economics, which details the capital and operation costs and their basis, and also illustrates the cost of power produced by the plant with certain sensitivities. B.04 Power Plant, Pipeline, and Injection Site Interfaces, which details the interfaces between the two FutureGen projects B.05 Contractual Mechanisms for Design, Construction, and Operation, which describes the major EPC, and Operations Contracts required to execute the project.

54 ENVIRONMENTAL SCIENCES↗