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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.

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At least 271 records · Page 15
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Sustainable and Energy-Efficient Production of Rare-Earth Metals via Chloride-Based Molten Salt Electrolysis

Neodymium metal is a critical component of rare earth magnets, essential for electric vehicles and the green energy transition, but its production has severe environmental impacts across its mining, separation, purification, and metal electrowinning steps. Specifically, conventional neodymium electrowinning in oxyfluoride molten salts using a consumable graphite anode generates greenhouse gases, e.g., carbon dioxide and perfluorocarbon (PFC). We propose an alternative chloride-based molten salt electrolysis process utilizing a novel dimensionally stable anode (DSA). Our process lowers the specific electrical energy consumption compared to the state of the art, while producing reusable chlorine gas and eliminating direct CO 2 and PFC emissions. Chloride-based molten salt electrolysis of NdCl 3 (1.65 M) added to a LiCl–KCl eutectic (45:55 wt %), while using a RuO 2 -coated DSA enables high Coulombic efficiency (>80%), low specific energy consumption (2.3 kWh/kg-Nd), and excellent electrowon Nd product purity (>97 wt %). Life cycle analysis, excluding the common input feedstock (Nd 2 O 3 ), shows that the global warming potential for the proposed chloride-based electrolysis approach is 5 kg CO 2 equivalent, compared to 9–16 kg CO 2 equivalent for the conventional process, representing a 44–69% reduction in CO 2 emissions.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Coupled neutronics and species transport simulation of the Molten Salt Reactor Experiment

This paper presents the development of coupling between the molten salt reactor species transport code Mole and the reactor physics code Griffin. Here, in this study, tracking of delayed neutron precursors was investigated in the Molten-Salt Reactor Experiment (MSRE), accounting for changes in fuel flow velocity as a function of position in the primary loop. The neutron transport calculations in Griffin were performed using 11 energy groups, and the species advection calculations in Mole used 6 delayed neutron precursor groups to predict spatial distribution of the neutron flux and neutron precursors in the MSRE. Mole–Griffin was used to calculate $k$ eff and $β$ eff in the reactor as a function of different volumetric flow rates.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2025

Initial steady-state core simulation capability or thermal and pool-type molten salt reactors, coupling reactor physics, thermal-hydraulics, and evolving chemistry

This report presents the development and validation of an initial steady-state multiphysics capability for molten salt reactors (MSRs) under the Nuclear Energy Advanced Modeling and Simulation (NEAMS) program in Fiscal Year 2025. The framework integrates neutronics, thermal-hydraulics, species transport, and thermochemistry to capture the coupled dynamics of liquid-fueled systems. Implementation and testing were performed on two representative designs: the Molten Salt Reactor Experiment (MSRE), a thermal-spectrum, channeled-flow reactor, and the Lotus Molten Salt Reactor (L-MSR), a fast-spectrum, pool-type reactor. The modeling suite employs Griffin for reactor physics and depletion, Pronghorn and SAM for thermal-hydraulics, Thermochimica for chemistry, and Saline for thermophysical properties, with benchmarking and validation carried out against historical MSRE data, experimental flow-loop measurements, and reference depletion calculations from Monte Carlo codes. The framework demonstrated the ability to reproduce key reactor behaviors including temperature feedback, reactivity losses, delayed neutron precursor transport, xenon poisoning, and redox potential evolution. The results confirm the feasibility and accuracy of the coupled models in predicting steady-state and selected transient MSR behaviors. This latter ones are used in this report as a proxy indicating that the steady-state models from which the transient starts are accurate. For MSRE, validation showed good agreement with pump start-up and natural circulation tests, while for the L-MSR, benchmarking confirmed hydraulic calibration and consistency of neutronics–thermal coupling. The tools also provided new insights into species transport, noble metal deposition, and salt solidification dynamics. On the Xenon transport front, the code is validated against the steady state Xenon poisoining measurement and showed good agreement with the experimental value. Identified areas for future work include advanced void transport modeling, three-dimensional simulations, improved alloy corrosion models, and tighter integration with high-fidelity Monte Carlo codes. These developments provide a foundation for high-fidelity MSR simulations that can support reactor design optimization, safety assessments, and long-term operational strategies.

42 - ENGINEERING↗
DOE OSTI2021

FY21 Status Report on the Molten Salt Thermal Properties Database (MSTDB) Development

This report describes the thermodynamic assessments for the ZrF 4 -BeF 2 , AlCl 3 -NaCl, AlCl3-KCl and the PuCl 3 -CsCl pseudo-binary subsystems. Calculation results are compared to the inputs used to optimize the adjustable model parameters. The data came from experimental studies reported in the open literature, from the MSR research community, and/or computational results generated within the NEAMS program and from collaborators. The models from the thermodynamic assessment of these salt systems are integrated into the MSTDB-TC (Molten Salt Thermal Properties Database-Thermochemical). A brief description of the companion MSTDB-TP (Molten Salt Thermal Properties Database-Thermophysical) is given along with an overview of the approach for predicting both thermodynamic and thermophysical property behavior of multicomponent systems.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Publicly Available Molten Salt Data/Benchmarks

This presentation summarizes data for three molten salt reactors that has been made publicly available by Copenhagen Atomics. This information will be shared with the participants of the OECD/NEA International Reactor Physics Experiment Evaluation (IRPhE) Technical Review Group.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2025

In Situ Spectroscopic Monitoring of MSR Molten Salt and Off-Gas Systems

A significant challenge that must be overcome before commercialization of molten salt reactors is tracking special nuclear material (SNM) through the reactor and subsystems such as fuel chemical processing and off-gas systems. In recent years, several approaches have been explored to track SNM, fission products, and corrosion products in these different subsystems. One such approach is to employ laser and optical spectroscopy to measure the atomic and molecular signals of MSR salts. The advantages of these approaches are that they typically are non-intrusive and offer the capability of process monitoring while still providing low uncertainties. At the Idaho National Laboratory, spectroscopy approaches such as laser-induced breakdown spectroscopy (LIBS) and ultraviolet-visible (UV-Vis) spectroscopy have been utilized to investigate molten salts in an aerosol (LiCl, KCl, RbCl2, NdCl3, and PrCl3) and vapor phases (MgCl5, NdCl5, and ZrCl4) with success. Testing to date has yielded qualitative information on all the above species and quantitative data and analytical figures of merit for species in the vapor phases. These findings, including results from ongoing testing, as well as the experimental conditions and potential applications will be presented.

98 - NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL↗
DOE OSTI2026

Salt mass determination by 22 Na-based radioactive tracer dilution of a highly radioactive molten salt system for pyroprocessing spent oxide nuclear fuels

To demonstrate the feasibility of the 22 Na-based radioactive tracer dilution (RTD) for determining the total salt mass in a 60-kg oxide reduction (OR) system at Idaho National Laboratory (INL) for pyroprocessing spent oxide nuclear fuels, a LiCl- 22 NaCl tracer salt was prepared and spiked to the OR vessel, and salt samples were analyzed by gamma spectroscopy. Due to the high radioactivity (around 10 mCi/g) of the OR salt, mainly from 137 Cs, traditional gamma spectroscopy methods, which typically involve diluted salt samples, was not effective for analyzing the RTD samples. Since the 22 Na tracer radioactivity was very low, undiluted samples were necessary to detect the small amount of 22 Na tracer. Here, despite the high gamma radioactivity of the OR salt, increasing the detector-sample distance from 20 cm to 40 cm during gamma spectroscopy allowed the detection of radioactivity as low as 0.12 µCi/g 22 Na. The preparation of the 22 NaCl-LiCl tracer salt suitable for spiking into the OR salt was successful, and the mass determined by RTD was consistent with that estimated by salt level measurement. Therefore, the 22 Na-based RTD technique for total mass determination of the 60-kg molten salt system for OR is feasible, though more development work, particularly in the improving the uncertainty, is needed .

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Dynamic Modeling of a Fast Spectrum Molten Salt Reactor Integrated Energy System

Liquid-fueled molten salt fast reactors and nuclear-powered integrated energy systems (IESs) have the potential to play a pivotal role in the green energy transition. However, these systems have little to no operating experience. There is therefore increased interest and value in modeling and simulating these systems. The IES dynamic model developed in this work utilizes a lumped-parameter control volume methodology to investigate the behavior of the IES in a variety of accident scenarios. The results provide initial evidence for the potential inherent safety of the advanced reactor because of temperature-dependent reactivity feedback and the efficiency of hydrogen and electricity production at the high temperatures provided by the advanced reactor.

MCFR↗
DOE OSTI2025

Government sector activities to reduce thermal-spectrum molten salt breeder reactor investment risk

Thermal-Spectrum Molten Salt Breeder Reactors (TS-MSBRs) have long been recognized as having high potential for clean, safe, large-scale, cost-effective energy production for the foreseeable future. U.S. government support for TS-MSBR development was stopped half a century ago in the belief that they were too technically difficult. Technology progression over the past several decades as well as the pressing need for clean power on-demand provides incentives to reconsider the development program cancellation. Limited, early-stage, government sector activities have the potential to sufficiently reduce investor risk to trigger the private sector investment necessary to commercialize the reactor class. In conclusion, these activities are summarized in this article.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2025

Towards the development of resonantly enhanced laser-based diagnostics for molten salt reactor safeguards

The adoption of Generation IV molten salt reactors (MSRs) depends on the ability to implement compatible monitoring instrumentation to ensure adherence to nuclear safeguards. This task is nontrivial due to the high temperature, reactive, and chemically complex fuel and coolant components contained within these systems. Optical spectroscopy techniques such as laser-induced fluorescence (LIF) and laser-induced breakdown spectroscopy (LIBS) are candidates for monitoring instrumentation. They offer many advantages for continuous monitoring, including the ability to operate at a standoff and compatibility with liquid-phase analytes. We discuss the use of LIF for the detection of Nd, a common fission fragment, within a liquid matrix. Results show that for NdCl3 dissolved in water, the Nd I 492.45 nm resonant transition is detectable without the need to induce a plasma and that the fluorescence emission can be separated in the time domain from the laser scatter signal. Additionally, we present a setup and preliminary results for measurements of solid Nd and U using resonant LIBS. The results demonstrate element-selective measurement capabilities and provide the foundational data necessary to continue the development of laser-based MSR diagnostics. This work also helps address gaps in the literature regarding energy level assignments of Nd.

98 - NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL↗
DOE OSTI2022

Transient convective delayed neutron precursor of {sup 235}U for the molten salt reactor experiment

This work investigates the delayed neutron precursors from the fission of {sup 235}U in molten salt reactors. The six delayed neutron groups predict the spatial distribution of the advective transport for radioactive mass transfer in the molten-salt reactor experiment (MSRE). The Mole code, using the framework of the Multiphysics Object-Oriented Simulation Environment (MOOSE), was used to compute the delayed neutron concentration of the whole system. This approach can be used for analysis of reactivity in circulating conditions. The effect of delayed neutron concentrations on the static or dynamic behavior of the system in MSRE was analyzed. Using this approach, the pattern and validation of delayed neutron for a range of parameters of interest are reported and discussed herein. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2025

Round Robin Measurements of Molten Salt Properties for LiF-NaF-KF (FLiNaK) and NaCl-KCl Mixtures

The development, operation, and regulation of nuclear reactors that utilize molten salts as fuel or as heat transfer media require knowledge of the thermal properties of the salt systems and quantification of the corresponding uncertainties. Knowledge of molten salt properties is also necessary for applications in material synthesis, processing, separations, solar thermal power generation, and energy storage. A round robin was conducted with national laboratory and university participants from twenty-one laboratories in five countries to compare property measurements, to better understand uncertainties, and to identify possible best practices. Two salt mixtures, each from a common batch, were distributed to participants for evaluation: equimolar NaCl-KCl and 45.0LiF-13.7NaF-41.3KF mol % (FLiNaK). Measurements were performed to determine the major constituent composition, oxygen content, density, thermal expansivity, melting point, and thermal conductivity. Error analysis was performed on each measurement for uncertainty quantification for each type of property that was explored. Finally, the resulting discussion of the methodologies used in this work is meant to lay the groundwork for the development of standard methods and reference materials for future high-temperature property measurements on halide melts.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

High Toughness Cermets for Molten Salt Pumps

Concentrated Solar Power plants using nitrate salts used cantilevered pump designs to avoid use of bearings in the 565°C salt; however, this necessitated the use of a sump that added additional cost, complexity, and thermal losses. Sump systems had their own complications, including risk of flooding the sump due to control issues either with level indicators or failures in the control valve responsible for filling the sump. Long-shafted pumps were developed and tested, and they outline the need to develop journal sleeves and bearings for new salt systems. Based on reports, pumps will need to be a vertical single- or multi-stage type, mounted to the roof of the molten salt tanks. Design and service for molten salt pumps above 550°C is relatively limited, and at temperatures up to 750°C there is no available design or service experience. Long-shaft pumps that extend to the bottom of the thermal energy storage tank will require bearing materials that are suitable to the given salt chemistry. Lubricity of proposed salts is unclear and need to be determined, especially for cold-tank pumps that require multi-stages for lifting the salt to the top of the tower. Materials, design, and maintenance are all major unknowns.

14 SOLAR ENERGY↗
DOE OSTI2024

Report on Initial Tribological Studies of Graphite in Dry Argon and Molten Salt Environment

This report documents completion of the Advanced Reactor Technologies (ART) Level 2 Milestone M2TG-24OR0501081: “Complete report on initial tribological studies within molten salt environment”, due January 31, 2024. This milestone is a carryover milestone from FY23 M2TG-23OR0501091. The report summarizes the initial studies on tribological characterization of the graphite–graphite sliding interface in a dry argon and molten FLiNaK salt environment. The experiments were conducted on a high-temperature multifunctional tribometer placed in a glovebox. This configuration enables probing the wear and friction properties at high temperatures in an inert environment. The worn surfaces were analyzed using high-resolution microscopy and white-light profilometry to determine the wear modes and wear rates. This report discusses the previous wear and friction studies on 316H stainless steel (SS) sliding against graphite in molten salt for different temperatures, sliding speeds, and salt amount. Moreover, key tribological parameters of pebble-on-pebble interaction in gas-cooled and molten salt reactors (MSRs) are analyzed and used to design an experimental test matrix for future studies. The outcomes of this project could provide key information about the tribological behavior of graphite pebbles in gas-cooled and MSRs, thereby contributing to safer operation.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Quantification of Lanthanides in a Molten Salt Reactor Surrogate Off-Gas Stream Using Laser-Induced Breakdown Spectroscopy

To enable the deployment of molten salt reactor technology, the development of off-gas treatment systems and advanced monitoring tools capable of operating with high temperatures and radiation fields while delivering near real-time information is necessary. Here, we aim to fulfill this requirement and proposes laser-induced breakdown spectroscopy (LIBS) for monitoring molten salt aerosol streams. A sheath gas measuring method was developed to protect optical elements from aerosol particles and to ensure a relatively constant aerosol stream for measurement. An aqueous system was studied to demonstrate the utility of LIBS for monitoring possible fission products in an aerosol stream: Gd, Nd, and Sm up to 2000 parts per million (ppm). A calibration model was built using partial least squares (PLS) regression with five, six, and nine latent variables for Gd, Nd, and Sm, respectively. This calibration model successfully estimated the concentrations of three test samples, which were validated with inductively charged plasma optical emission spectroscopy measurements at a 99.9% confidence interval. To enhance these models, a genetic algorithm was used to filter the spectra before entering the PLS model, thereby limiting the spectral features being regressed to those with greater correlations to concentration. This allowed for the number of latent variables used in the PLS models to be reduced to four, three, and three for Gd, Nd, and Sm, respectively. Finally, the genetic algorithm-filtered PLS models were used to predict the concentrations of the aerosol stream on a real-time dataset and resulted in a 73%, 18%, and 25% improvement in root mean squared error of prediction compared to the original PLS models developed.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Exponential Time Differencing Schemes for Fuel Depletion and Transport in Molten Salt Reactors: Theory and Implementation

A numerical framework for modeling depletion and mass transport in liquid-fueled molten salt reactions is presented based on exponential time differencing. The solution method involves using the finite volume method to transform the system of partial differential equations (PDEs) into a much larger system of ordinary differential equations. The key part of this method involves solving for the exponential of a matrix. We explore six different algorithms to compute the exponential in a series of progression problems that explore physical transport phenomena in molten salt reactors. This framework shows good results for solving linear parabolic PDEs with each of the six matrix exponential algorithms. For large problems, the series solvers such as Padé and Taylor have large run times, which can be mitigated by using the Krylov subspace.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Characterization of the molten salt FMgNaK through ab initio molecular dynamics and experimental density measurements

The selection of a salt species for use in a molten salt reactor MSR is a key part of any MSR design. However, many salts have sparse or no thermophysical property data sets, especially those with higher melting points. One such salt is the eutectic mixture of (NaF)0.345(KF)0.59(MgF 2 )0.065, or FMgNaK, and is explored here through ab initio molecular dynamics (AIMD) simulation (1023-1273K) as well as experimental measurement of the liquid density using the Archimedean method (973-1223K). Predicted densities from AIMD are similar to experimentally-measured densities, though with more noise, suggesting that the small scale necessitated by AIMD simulations may be problematic for simulating FMgNaK in particular. Here the coefficient of thermal expansion is predicted from simulation, and salt structure is characterized. Mg-F-Mg chaining is observed in the salt network, though the low concentration of Mg inhibits chaining on the scale that is observed in (LiF) 0.67 (BeF 2 ) 0.33 , or FLiBe.

36 MATERIALS SCIENCE↗