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DOE OSTI2022

Multiscale Experiments and Multiphysics Simulation of Multiphase Flow for Transportable Small Modular Reactors

A new type of safe, small, transportable nuclear reactor would address the intense and ever-growing global demand for energy produced via a resilient, carbon-free energy source. In this regard, transportable small modular reactors (SMRs) are being designed and developed for electricity generation within small/micro-grid/off-grid isolated systems, as well as for heat generation in industrial/residential applications. These reactors feature the capability to be fully factory fabricated and then directly transported to utilities’ sites as “plug-and-play” systems. Research and development (R&D) programs are underway at Idaho National Laboratory (INL) to successfully design, develop, and demonstrate such safe-by-design mobile reactor technologies, in collaboration with partner organizations. Multiscale experimental facilities and multiphysics simulation tools are required for reactor design verification and validation (V&V), and licensing. These advanced reactors are intended to feature passive safety systems such as passive containment cooling systems (PCCS), which consist of multiphase flows and multispecies distributions. This seminar talk will focus on designing and analyzing transportable SMR PCCS by using multiscale experiments and multiphysics computational fluid dynamics (CFD) simulations to support reactor licensing and safety. The corresponding research challenges are addressed via supportive verification and validation results generated by the models and simulation tools in combination with selective parametric and uncertainty analysis. This solution approach could blaze the trail for commercial adoption of such technologies. The facilities, simulation capabilities, and research opportunities available at INL in regard to such reactors and the integrated energy systems with which they go hand in hand are also discussed briefly, and may spark interest in deeper research as well as new collaborative projects.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2023

Togiak Heat Recovery Project

Togiak is one of hundreds of Alaskan Native, roadless communities only accessible by boat or plane. This project constructed a heat recovery (HR) system which pipes what was previously wasted heat generated at the power plant to four nearby community buildings. The power plant houses diesel fired generators which provide electricity to the community. This project designed and constructed the system that recovers a portion of the heat produced by the generators and pipes it to the end-user buildings. The heat recovery system integrates with each building’s internal heating system. The objective is to significantly reduce the heating costs in these four community facilities. By reducing the energy use and cost in these community facilities, the local economy is strengthened by keeping the funds inside the community that were formerly used to purchase imported fuel, thereby multiplying the impact of the energy cost reduction. Energy independence is enhanced and energy resilience is increased by reducing dependence on long fuel supply chains which are easily interrupted by unpredictable natural and man-made disasters such as earthquakes, climate change, road rail and sea accidents, etc.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2023

Urban land patterns can moderate population exposures to climate extremes over the 21st century

Abstract Climate change and global urbanization have often been anticipated to increase future population exposure (frequency and intensity) to extreme weather over the coming decades. Here we examine how changes in urban land extent, population, and climate will respectively and collectively affect spatial patterns of future population exposures to climate extremes (including hot days, cold days, heavy rainfalls, and severe thunderstorm environments) across the continental U.S. at the end of the 21st century. Different from common impressions, we find that urban land patterns can sometimes reduce rather than increase population exposures to climate extremes, even heat extremes, and that spatial patterns instead of total quantities of urban land are more influential to population exposures. Our findings lead to preliminary suggestions for embedding long-term climate resilience in urban and regional land-use system designs, and strongly motivate searches for optimal spatial urban land patterns that can robustly moderate population exposures to climate extremes throughout the 21st century.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2024

Cosimulating Integrated Energy Systems With Heterogeneous Digital Twins: Matching a Connected World

Energy system integration promises in-creased resiliency and the unlocking of synergies, while also contributing to our goal of decarbonization. It is enabled by both old and new technologies, glued together with data and digital services. Hydrolyzers, heat pumps, distributed renewable generation, smart buildings, and the digital grid edge are all currently the subject of integration with the power system and the energy sector at large. To plan and operate such a multidisciplinary and multisectoral system properly, insight, tools, and expertise are all needed. Further, this is exactly where the state of the art fails to deliver: tools for integrated energy systems (IESs) are still in their infancy, and many times, even academia treats these sectors separately, producing experts in each of them but not across.

24 POWER TRANSMISSION AND DISTRIBUTION↗

NASA NTRS1980

Installing fiber insulation

A method for installing fragile, high temperature insulation batting in an elongated cavity or in a resilient wire sleeve to form a resilient seal. The batting is preformed to rough dimensions and wrapped in a plastic film, the film being of a material which is fugitive at a high temperature. The film is heat sealed and trimmed to form a snugly fit skin which overlaps at least at one end to permit attachment of a pull cord. The film absorbs the tensile force of pulling the film enclosed batting through the cavity or wire mesh sleeve and is subsequently driven off by high temperature baking, leaving only the insulation in the cavity or wire mesh sleeve.

Wang, D. S.↗

NASA NTRS2000

Rudder/Fin Seal Investigations for the X-38 Re-Entry Vehicle

NASA is currently developing the X-38 vehicle that will be used to demonstrate the technologies required for a crew return vehicle (CRV) for the International Space Station. The X-38 control surfaces require high temperature seals to limit hot gas ingestion and transfer of heat to underlying low-temperature structures to prevent over-temperature of these structures and possible loss of the vehicle. This paper presents results for thermal analyses and flow and compression tests conducted on as-received and thermally exposed seals for the rudder/fin location of the X-38. A thermal analysis of the rudder/fin dual seal assembly based on representative heating rates on the windward surface of the rudder/fin area predicted a peak seal temperature of 1900 F. The temperature-exposed seals were heated in a compressed state at 1900 F corresponding to the predicted peak temperature. Room temperature compression tests were performed to determine load versus linear compression, preload, contact area, stiffness, and resiliency characteristics for the as-received and temperature-exposed seals. Temperature exposure resulted in permanent set and loss of resiliency in these seals. Unit loads and contact pressures for the seals were below the 5 lb/in. and 10 psi limits set to limit the loads on the Shuttle thermal tiles that the seals seal against in the rudder/fin location. Measured seal flow rates for a double seal were about 4.5 times higher than the preliminary seal flow goal. The seal designs examined in this study are expected to be able to endure the high temperatures that they will be exposed to for a single-use life. Tests performed herein combined with future analyses, arc jet tests, and scrubbing tests will be used to select the final seal design for this application.

Dunlap, Patrick H., Jr.↗

NASA NTRS2000

Rudder/Fin Seal Investigations for the X-38 Re-Entry Vehicle

NASA is currently developing the X-38 vehicle that will be used to demonstrate the technologies required for a crew return vehicle (CRV) for the International Space Station. The X-38 control surfaces require high temperature seals to limit hot gas ingestion and transfer of heat to underlying low-temperature structures to prevent over-temperature of these structures and possible loss of the vehicle. This paper presents results for thermal analyses and flow and compression tests conducted on as-received and thermally exposed seals for the rudder/fin location of the X-38. A thermal analysis of the rudder/fin dual seal assembly based on representative heating rates on the windward surface of the rudder/fin area predicted a peak seal temperature of 1900 F. The temperature-exposed seals were heated in a compressed state at 1900 F corresponding to the predicted peak temperature. Room temperature compression tests were performed to determine load versus linear compression, preload, contact area, stiffness, and resiliency characteristics for the as-received and temperature-exposed seals. Temperature exposure resulted in permanent set and loss of resiliency in these seals. Unit loads and contact pressures for the seals were below the five pounds/inch and ten psi limits set to limit the loads on the Shuttle thermal tiles that the seals seal against in the rudder/fin location. Measured seal flow rates for a double seal were about 4.5 times higher than the preliminary seal flow goal. The seal designs examined in this study are expected to be able to endure the high temperatures that they will be exposed to for a single-use life. Tests performed herein combined with future analyses, arc jet tests, and scrubbing tests will be used to select the final seal design for this application.

Dunlap, Patrick H., Jr.↗

DOE OSTI2025

The Interplay Between Climate and Urban Expansion on Building Energy Demand in Morocco

Understanding building energy demand is critical for addressing climate uncertainty challenges and ensuring sustainable urban growth. This study develops a building energy demand (BED) model to explore how climate variation and urban expansion affect residential and commercial space heating and cooling demands in Morocco for three scenarios, namely, 2005, 2018, and 2018 + 1.5 °C. The results show that coastal cities have lower heating and cooling needs due to the oceanic influence, while interior cities require significantly higher heating demand per-unit-floorspace. Between 2005 and 2018, urban growth increased total heating and cooling demand by 218.8 GWh, particularly in northern and coastal regions, despite per-unit-floorspace reductions in milder climates and improved building efficiency in 2018. Residential heating remains the dominant energy use, though commercial demand is significant in urban centers. Under the 2018 + 1.5 °C hypothetical scenario, heating demand across Morocco declines by 335.8 GWh compared to 2018, with urban areas amplifying this trend. Meanwhile, cooling demand increases slightly by 44.4 GWh, with major cities experiencing relative increases of up to 50%. These findings highlight a trade-off where reduced winter heating needs are partly offset by increased summer cooling demands in densely urbanized areas. In conclusion, the study identifies key urban hotspots for targeted interventions, emphasizing the need for energy-efficient building designs, climate-adaptive urban planning, and resilient energy management strategies to sustainably address shifting seasonal energy patterns.

Morocco↗

DOE OSTI2023

Climate change-related warming reduces thermal sensitivity and modifies metabolic activity of coastal benthic bacterial communities

Besides long-term average temperature increases, climate change is projected to result in a higher frequency of marine heatwaves. Coastal zones are some of the most productive and vulnerable ecosystems, with many stretches already under anthropogenic pressure. Microorganisms in coastal areas are central to marine energy and nutrient cycling and therefore, it is important to understand how climate change will alter these ecosystems. Using a long-term heated bay (warmed for 50 years) in comparison with an unaffected adjacent control bay and an experimental short-term thermal (9 days at 6–35 °C) incubation experiment, this study provides new insights into how coastal benthic water and surface sediment bacterial communities respond to temperature change. Benthic bacterial communities in the two bays reacted differently to temperature increases with productivity in the heated bay having a broader thermal tolerance compared with that in the control bay. Furthermore, the transcriptional analysis showed that the heated bay benthic bacteria had higher transcript numbers related to energy metabolism and stress compared to the control bay, while short-term elevated temperatures in the control bay incubation experiment induced a transcript response resembling that observed in the heated bay field conditions. In contrast, a reciprocal response was not observed for the heated bay community RNA transcripts exposed to lower temperatures indicating a potential tipping point in community response may have been reached. In summary, long-term warming modulates the performance, productivity, and resilience of bacterial communities in response to warming.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2021

Scalable and Resilient Etched Metallic Micro- and Nanostructured Surfaces for Enhanced Flow Boiling

Flow boiling and evaporation in tubes and channels occur in a wide variety of energy systems, such as refrigeration, air conditioning, power generation, electronics cooling, distillation, and purification. In this work, we demonstrate remarkably increased heat transfer coefficients of 270% during refrigerant flow boiling in scalable microstructured (~40 µm), industrial-scale (~1 m long) aluminum (Al) tubes, when compared to smooth unstructured Al tubes. To achieve scalable nanomanufacturing, we create highly conformal and durable structured surfaces by relying on hydrochloric acid Al etching. Flow boiling tests were conducted in 6.35 mm diameter Al tubes using R134a refrigerant as the working fluid. To benchmark our approach and to elucidate the effect of the structure length scale, we also fabricated ultrascalable boehmite (AlO(OH)) nanostructured (~300 nm) Al tubes, showing that etched microscale features are necessary and key to enhancement. Durability tests conducted using a 28 day long continual flow boiling experiment demonstrated negligible degradation of the etched surfaces. The scalable and cost-effective techniques used to create these durable, etched-Al microstructures may significantly reduce manufacturing cost when contrasted with current enhancement approaches such as extrusion, drawing, and welding.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Demonstrating Advanced Nuclear Energy Solutions for Net Zero

Background/Objectives. The aggressive goals being set by nation states, communities, and private industry for decarbonization of grid electricity, industrial heat sources, and transportation around the world are imperative to mitigating the devastating effects that we are seeing from climate change. Although many of these goals focus on accomplishments by 2035 or 2050, the decisions that we make today won’t just impact the landscape of energy systems for the next 20 or 30 years—they will shape the world’s environment for centuries to come. That means that we can’t just focus on technologies that will get us to 2050, but technologies that will withstand our energy demands over that long-ranging future. Success will require us to utilize all of the clean energy resources that we have available to meet demands for electricity, heat, and steam, and we will need energy carriers such as hydrogen that do not emit additional greenhouse gases at the point of use. Nuclear energy, ranging from technologies in service today to advanced, higher temperature and modular systems that will be in service this decade, will provide a robust complement to renewable energy resources that operate variably. Researchers across the U.S. Department of Energy laboratory complex are working to advance multiple aspects of these clean energy solutions, with many focusing on integrated energy system solutions that leverage all available clean energy assets to meet wide-ranging energy demands. Approach/Activities. Nuclear energy is a proven, zero-emission option during operation that can provide consistent, dispatchable power to meet electricity demands while also providing high-quality heat that can meet energy demands beyond the electricity sector. Energy system design should seek to maximize these assets. As a dispatchable energy source with a small land utilization footprint, nuclear energy can be collocated with renewable resources, and the smaller systems that will be deployed this decade (ranging from a few megawatts to hundreds of megawatts) can be installed right where that energy is needed. Integrated nuclear and renewable systems will enhance power grid reliability and resilience, and they will help stabilize the grid through their increasingly flexible operation. Licensing, installation, and broad adoption of these advanced nuclear energy systems are expected to progress significantly in the 2020s, but this may be longer than desired by some stakeholders wishing to implement impactful clean energy decisions today. However, one must recall that nuclear energy systems will operate for 80 or more years, as is being demonstrated by current fleet nuclear systems. The nuclear community is extremely thorough in reviewing these systems with regard to safety and security; these efforts ensure that the deployed systems will continue to provide reliable, resilient energy over that operational lifetime. That investment of time up front will ensure that we can support energy demands over the centuries to come. While advanced nuclear technologies move through this process, communities and private industry may choose to install renewable generation systems that can later be coupled to the complementary nuclear systems as they become available—thus moving closer to the net zero goals in the near term. Choosing technologies and deployment configurations that allow small modular nuclear powerhouses to be added to these “energy parks” as they become available will ensure that advanced technologies can be readily adopted to support growing demands for clean energy. Results/Lessons Learned. The primary focus of integrated energy systems (IES) research is to assess the technical and economic potential of novel multi-input, multioutput solutions that are expected to enhance energy system flexibility, reliability, and resilience as we pursue a clean energy transition. Various energy applications and product streams beyond electricity are being evaluated, ranging from generation of potable water to production of hydrogen, fertilizers, synthetic fuels, and various chemicals. In early FY23 Idaho National Laboratory (INL) will commission thermal energy generation systems that emulate nuclear fission energy input using electric heating and will allow for integrated system testing with thermal energy storage, hydrogen production via high temperature electrolysis (HTE), and power systems hardware to demonstrate operation of a clean energy park within a microgrid or larger grid infrastructure, supporting up to 450 kW of heat input via electric heating and demonstrating operation of HTE systems at the multi-hundred kW scale. This presentation will highlight the wide array of RD&D being conducted at INL and partner laboratories to develop and deploy nuclear and renewable-based IES that will be key to achieving our net zero goals, including both computational and experimental demonstrations. By working with key collaborators in industry, analytical st

08 HYDROGEN↗

DOE OSTI2021

America Resilient Climate Conference

On April 14, 2021, scientists, policymakers, and other interested parties from research institutes, academia, and other organizations gathered together virtually at the America Resilient Climate Conference to discuss one of the most pressing challenges of the 21st century: building resilience to climate change. Climate change affects the security and health of all Americans. Coastal areas are enduring more frequent and severe flooding due to sea level rise and storm surge; western states and Alaska have experienced increasingly devastating wildfires, driven in part by hotter, drier, and longer fire seasons; and communities across the nation have suffered through extreme precipitation events and heat waves. Even if emissions are reduced aggressively in the near future, the world—and the United States—will continue to feel the impacts of climate change for decades to come, due to the continued accumulation of greenhouse gasses in the atmosphere. Consequently, it is essential to act now to protect natural and human assets from the gradual—as well as extreme—impacts of a changing climate. To build resilient communities, leaders and community members need science-based information about the potential impacts climate change will have decades into the future and for specific regions. Therefore, it is essential to develop high-resolution climate models that can project both various climate impacts and the interactions between earth system variables and humans down to regional and local scales. Collecting and curating data for such models and their computational requirements poses large challenges. In the future, artificial intelligence will be needed to increase their accuracy and reduce associated uncertainties. The investments in Earth system science and artificial intelligence made by the U.S. Department of Energy and other federal entities will be essential in addressing these challenges.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2023

Data Center Facility Monitoring with Physics Aware Approach

U.S. Department of Energy's National Renewable Energy Laboratory (NREL) hosts one of the world's most energy-efficient HPC data centers; this system uses component-level warm-water liquid cooling to efficiently remove heat from the data center and capture it for reuse in the building or rejection to the atmosphere. Given the complexity of this system, building data-driven tools for holistically monitoring and operating the entire data center is a priority for ensuring maximal efficiency and resiliency. In this advanced smart facility, over one million metrics are recorded per minute using state-of-the-art streaming data architecture and software to capture and process the state of the system in real time. Here we detail two efforts to effectively analyze, visualize, and interpret this large volume streaming data. We have developed a novel, flexible system for identifying and visualizing individual metric anomalies and component performance across the data center through automatic metadata extraction and physically-motivated visualization for quick interpretation. Additionally, to directly connect system maintenance to data stream processing we explore a physics informed multi-metric drift and anomaly detection application to detect scale-build up in heat exchangers.

anomaly detection↗

DOE OSTI2024

U.S. DOE Midwest Combined Heat and Power Technical Assistance Partnership (Midwest CHP TAP) (Final Technical Report)

The University of Illinois Chicago (UIC) was awarded the U.S. DOE Midwest Combined Heat and Power Technical Assistance Partnership (Midwest CHP TAP) program to provided technical and policy expertise to support local opportunities to promote CHP, waste heat to power, district energy, and microgrids in the Midwest and Central regions of the U.S. that included the states of Illinois, Indiana, Iowa, Kansas, Michigan, Minnesota, Missouri, Nebraska, Ohio, and Wisconsin. During this contract period, UIC, through the Midwest CHP TAP activities, provided significant regional support to the U.S. strategic goals of: 1) Stimulating America’s Energy Revolution and Promoting Energy Independence; 2) Promoting Jobs and Manufacturing Competitiveness; 3) Supporting a Positive Trade Balance; 4) Enhancing Energy System Resiliency and Energy Security; and 5) Improving the Nation’s Infrastructure. UIC met the annual go/no-go metrics each year and either met and/or exceeded the milestones each year.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2025

Implementation and Demonstration of the Digital Twin Certification System Remote Operations Framework

Microreactors are one promising advanced-reactor concept being pursued by the nuclear industry. They are distinguished by a relatively low power output of 20 MWth or less. These microreactors are intended for deployment in applications where conventional small-capacity power solutions, such as diesel generators, are either economically unfeasible or logistically challenging. Such applications include providing electric power and/or heat for remote communities, mining sites, defense installations, and humanitarian and disaster-relief missions. An important feature for the successful deployment of microreactors is their capability to be operated remotely. This capability can significantly reduce staffing costs by eliminating the need for licensed operators to be physically present at each reactor site. Instead, operators can be centralized in a single remote operations center placed in an economically advantageous location, thereby optimizing resources by consolidating expertise and enhancing operational efficiency. However, the implementation of a remote operation system for nuclear reactors raises new concerns regarding the security, reliability, and resilience of such a system. One way in which remote operations can be supported in a manner that maintains system security, reliability, and resilience is through the use of digital twins in a novel framework designed to verify and validate sensor data and commands communicated between the remote operations center and reactor. This framework, known as the Digital Twin Certification System (DTCS), has previously been proposed as an operations architecture that can bring security and resiliency levels of remote nuclear-reactor operations to a level acceptable for commercial deployment. This paper moves the proposed DTCS architecture from concept to reality by presenting the implementation and testing of the system. The rationale and implementation of the DTCS using tools such as DeepLynx and Apache Airflow, is covered in-depth. This is followed by a demonstration of the DTCS by applying the implemented system architecture to the Single Primary Heat Extraction and Removal Emulator, a small-scale non-nuclear test bed that emulates thermal behavior of a microreactor. The demonstration includes both normal and abnormal operating scenarios to highlight how the DTCS can increase the security, reliability, and resilience of a remote operations system.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2025

Implementation and Demonstration of the Digital Twin Certification System Remote Operations Framework

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2022

Climate Vulnerability Assessment and Resilience Planning for Idaho National Laboratory

Idaho National Laboratory’s (INL’s) mission is to discover, demonstrate, and secure innovative nuclear energy solutions, other clean energy options, and critical infrastructure. This INL’s Climate Vulnerability Assessment and Resilience Plan (VARP) was developed to enable and sustain that mission while ensuring the viability of operations considering expected climate change impacts. The VARP was developed according to the narrative requirements from the “Vulnerability Assessment and Resilience Planning Guidance, Version 1.2” document issued in February 2022. A prescribed process was used to identify mission-critical systems and components, determine historical and expected climate impacts, and develop resilient solutions. Experts from across INL, including operations staff, researchers, and climate scientists supplied input to the process. Analyses of climate modeling sources revealed that under scenarios of higher and lower greenhouse gas emissions (Representative Concentration Pathway (RCP) 4.5 and RCP 8.5), INL anticipates an increase in climate hazards, including drought, heat waves, wildfire, and precipitation. Increased frequency and duration of climatic hazards forecasts high impacts on certain mission-critical asset and infrastructure types. Utilizing the VARP Risk Assessment Tool, projected high climate hazard impacts across multiple asset and infrastructure types at the INL include energy generation and distribution systems, Site buildings, specialized or mission-critical equipment, and transportation and fleet infrastructure. Some of these mission-critical asset and infrastructure types maintain high adaptive capacity to climatic changes; however, others may need additional adaptive capacity to withstand increased frequency and duration of climate hazards. INL identified close to 300 resilient solutions that were consolidated into 11 solution categories to be tracked in the Department of Energy Sustainability Dashboard. The identified solutions are a starting point for future project development and analysis. These data are intended to inform decision makers on climate issues and potential solutions across INL and associated communities. The VARP is not intended to be a budget tool or project decision document on its own, but rather one of many tools used by decision makers to establish resilient priorities. This initial document provides the framework and foundation to resilient solutions. In the coming years, each solution needs to be fully developed, costed, and prioritized based on mission-critical risk and funding priorities.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2024

Toward improved thermal exposure classes for structural firefighters

In the early 1970s, there was an initial effort to quantify the conditions under which firefighters are expected to perform. Harvey Utech led this endeavor by defining three levels of thermal exposure—routine, ordinary, and emergency—which were characterized by combining a range of air temperatures and radiative heat fluxes. In the last half-century, there has been a concerted scientific effort to further understand the conditions to which firefighters are exposed during structural firefighting. Research has been conducted on the resiliency of turnout gear and facepiece lenses, the thermal conditions observed during a structure fire, and the impact of firefighter tactics such as ventilation and suppression. The authors synthesize the results from these research areas to update the original thermal classifications to six categories of exposure—routine, Ordinary I, Ordinary II, Emergency I, Emergency II, and Emergency III—which are more representative of the operating environment and protective equipment thresholds that firefighters should be aware of during firefighting operations and tactical decision-making.

Weinschenk, Craig↗