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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 307 records · Page 17
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Design and Operability of a Pressurized Oxy Combustion System

Fossil fuel powers more than two-thirds of the world’s electricity, a significant share of which is derived from coal power plants. Despite coal being an abundant and energy-rich fuel, the major halt to its progress is greenhouse gas emissions. Pressurized oxy-combustion cycles can achieve theoretically high thermal efficiencies along with a 90% carbon capture rate. Additionally, the high energy density allows smaller turbomachinery and save capital cost. Thus, the primary objective of this dissertation is to present the design and operability of a pressurized oxy-combustor system. The initial part of the dissertation investigates different thermodynamic cycles and presents a model that can be adapted for existing power plants. The thermodynamic model will be used in the later part to design the proposed combustor. The two cycles analyzed are ENEL and TIPS. This study focuses on qualitative analyses of the cycles using a commercially available software called Aspen Plus®. A detailed benchmark study has been performed to validate the modeling process. ENEL and TIPS cycles are designed in the software, adopting the same principles. Recirculation ratio and pressures are varied to find the efficiency range of the cycles. Power calculations are done to find overall and net efficiency for a fixed recirculation ratio. The efficiencies of the cycles are compared to select an optimum cycle. A recirculation ratio of 50% is selected for implementation. The comparison shows that ENEL is marginally efficient over TIPS, at the cost of a pressure difference of about 70bars. Technology Readiness Level analysis is performed to present the availability of the specialized equipment for the cycles. From the TRL analysis, it is seen that the cost and availability of high viii pressure equipment surmount the edge of TIPS over ENEL. Thus, ENEL is chosen as the better cycle for investigating a scaled experiment considering efficiency and viability. The later part of the dissertation focuses on developing the combustor's design for a pressurized oxy-combustion cycle. The proposed combustor is a powerhead-mounted design aimed to produce 1MW of thermal outputThe different aspects of the design of a down-fired pressurized swirl combustor are presented in this dissertation.

Chowdhury, Mehrin↗
DOE OSTI2023

Techno-Economic Analysis of Solid Oxide Fuel Cell-Gas Turbine Hybrid Systems for Stationary Power Applications Using Renewable Hydrogen

Solid oxide fuel cell (SOFC)–gas turbine (GT) hybrid systems can produce power at high electrical efficiencies while emitting virtually zero criteria pollutants (e.g., ozone, carbon monoxide, oxides of nitrogen and sulfur, and particulate matters). This study presents new insights into renewable hydrogen (RH 2 )-powered SOFC–GT hybrid systems with respect to their system configuration and techno-economic analysis motivated by the need for clean on-demand power. First, three system configurations are thermodynamically assessed: (I) a reference case with no SOFC off-gas recirculation, (II) a case with cathode off-gas recirculation, and (III) a case with anode off-gas recirculation. While these configurations have been studied in isolation, here we provide a detailed performance comparison. Moreover, a techno-economic analysis is conducted to study the economic competitiveness of RH 2 -fueled hybrid systems and the economies of scale by offering a comparison to natural gas (NG)-fueled systems. Results show that the case with anode off-gas recirculation, with 68.50%-lower heating value (LHV) at a 10 MW scale, has the highest efficiency among the studied scenarios. When moving from 10 MW to 50 MW, the efficiency increases to 70.22%-LHV. These high efficiency values make SOFC–GT hybrid systems highly attractive in the context of a circular economy as they outcompete most other power generation technologies. The cost-of-electricity (COE) is reduced by about 10% when moving from 10 MW to 50 MW, from USD 1976/kW to USD 1668/kW, respectively. Renewable H 2 is expected to be economically competitive with NG by 2030, when the U.S. Department of Energy’s target of USD 1/kg RH 2 is reached.

25 ENERGY STORAGE↗
DOE OSTI2022

Upgrade of Gamma Spectrometry Systems for ORNL TRISO Fuel PIE

Gamma spectrometry is a key element in much of the post-irradiation examination (PIE) work performed under the Advanced Gas Reactor Fuel Development and Qualification (AGR) Program (Demkowicz et al. 2015; Stempien et al. 2021). Gamma spectrometers are integrated into three major capabilities used at the Oak Ridge National Laboratory (ORNL) Irradiated Fuels Examination Laboratory (IFEL) for PIE of tristructural-isotropic (TRISO) coated particles and fuel compacts: the Core Conduction Cooldown Test Facility (CCCTF), the Vertical Counting System (VCS), and the Irradiated Microsphere Gamma Analyzer (IMGA). The CCCTF includes liquid-nitrogen-cooled traps to extract 85 Kr out of the He sweep gas that passes through the furnace in which the fuel compacts are heated during safety testing. Analysis of the 85 Kr activity in the traps is the primary indicator for TRISO failure during safety testing. The VCS is a system used to accurately measure gamma emission from components placed in a lead-shielded chamber. It is used to count the CCCTF deposition cups after removal from furnace. Each cup resides in the CCCTF furnace for typically 12–24 h and is periodically replaced with a fresh cup throughout the safety test. Metallic fission products collect on the water-cooled cups and several gamma-emitting isotopes ( 110 mAg, 134 Cs, 137 Cs, 154 Eu, and 155 Eu) are often measured and provide indication of the retention performance of the TRISO coatings. The VCS is also used to measure the presence of these isotopes on the CCCTF tantalum liner and sweep gas inlet tube for the determination of cup collection efficiency, as well as support other gamma spectrometry needs related to calibration of the 85 Kr fission gas traps and various other special PIE tasks. The IMGA uses gamma spectrometry to measure the inventory of gamma-emitting isotopes in individual TRISO particles. An automated particle handling system within the IMGA hot cell removes each particle from a source vial and positions it in front of a gamma detector, and output from the gamma spectrometer is used by the IMGA software to determine a destination vial such that particles are sorted according to their inventory and retention characteristics. At the conclusion of the AGR-1 and AGR-2 PIE campaigns, the gamma spectrometer systems used at ORNL to support that PIE had reached the end of its life cycle due to gradual obsolescence of the hardware and software. Upgrade of the Canberra Genie 2000 software used by these systems to a Windows 10 version was not a viable option, because the newest Windows 10 version offered by Mirion (the new owner of the Canberra technology) did not include the dynamic-link libraries (DLLs) needed for integration with the custom PIE software used with the CCCTF and IMGA, and Mirion had no current plans for development and release of Windows 10 versions of these DLLs with the Model S560 Genie 2000 Programming Library. Ultimately a switch was made to ORTEC gamma spectrometry systems, which appeared to be a more sustainable solution due to more proactive vendor support. The ORTEC conversion involved replacing the aging detector preamplifier and multichannel analyzer (MCA) hardware, upgrading the obsolete Windows 7 computers to Windows 10 compatible models, adopting ORTEC GammaVision software, and extensive modification of the ORNL-developed Visual Basic .NET (VB.NET) programs that provide the CCCTF and IMGA user interfaces.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2022

Dynamic System Scaling Application to Accelerated Nuclear Fuel Testing

The development of nuclear fuel and materials requires a continuous effort to investigate the acute and prolonged effects of irradiation, thermal-material stress, chemical change, or other conceivable damage mechanics acquired during normal operation or accident scenarios throughout its lifetime. As in-core fuel property measurement techniques advance to support in the real-time, non-invasive, and enhanced accuracy realm, it is the future of fuel development to pursue to higher degrees of control, predictability of integral test behavior via separate effects test (SET), and shorter test time intervals. The fuel development life cycle from initial concept to commercial licensing is approximated to be 20 years and current literature suggests by optimizing fuel performance codes with SETs, the process could possibly be compressed to 5 to 10 years. Recently, a research group in the Idaho National Laboratory (INL) is testing reduced scale fuel rods and increased power density to accelerate evolution of fuel phenomena in metallic fuels. In support of nuclear fuel rod development, compressing fuel test process, and accelerating fuel phenomena, it was the purpose of this study to investigate nuclear fuel performance phenomena via literature review and effectively scale the initial conditions, boundary conditions, and geometric properties to describe the time-dependent response including to fuel burnup, thermal and mechanical stress, transmutations and inter-diffusion, and other relevant observed phenomena. The study was based on BISON simulations of historic EBR-II metallic fuel experiments and Dynamical System Scaling (DSS) method are utilized to assess effects of scaling activity including fuel phenomena acceleration and calculations of time-dependent distortions. The research successfully scaled metallic fuel phenomena, accelerated fuel testing, and assessed the distortions for each scaled case derived.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Preignition mitigation strategy for gaseous fuel engine

Operating a gaseous fuel engine system includes detecting preignition in one or more of a plurality of cylinders based on a monitored cylinder pressure during combustion of a gaseous fuel such as a gaseous hydrogen fuel. Operating a gaseous fuel engine system also includes reducing a fuel injection amount for the one or more of the plurality of cylinders to a derated fuel injection amount that is based on a timing of the detected preignition. Fuel injection amount may be reduced to a greater relative extent if detected preignition is early, and to a lesser relative extent if detected preignition is later, in an engine cycle. Related apparatus and control logic is also disclosed.

Graziano, Jr., Michael T.↗
DOE OSTI2025

High Flux Isotope Reactor Low-Enriched Uranium High Density Silicide Fuel Preliminary Design Update: System Transient Analysis

As a part of conversion efforts from highly enriched uranium (HEU) to low-enriched uranium (LEU) fuel under direction of the National Nuclear Security Administration of the U.S. Department of Energy, multiple proposed designs of the High Flux Isotope Reactor (HFIR) have been created and assessed regarding reactor physics performance metrics, including designs utilizing uranium silicide dispersion fuel (U3Si2-Al). This report updates the previous analyses that evaluated the nuclear safety performance of LEU fuel designs with respect to selected accident events from the HFIR Safety Analysis Report (SAR). Both the Low Density (LD) and High Density (HD) Optimized designs’ reactivity initiated accident fuel performance improved relative to the HEU fuel, attributed to greater 238 U negative Doppler feedback. However, the thermal margins for primary coolant system accidents were reduced with some acceptance criteria unable to be met. The need to resolve reduced thermal margin, open modeling items, and unresolved assumptions was identified.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

VTR Casting Furnace Conceptual Design

This TEV describes the development of a conceptual design for a fuel casting system to be used in the development and demonstration of fuel designs for the new Versatile Test Reactor (VTR). This system will be installed in the Fuel Manufacturing Facility (FMF). The system will be in a shielded glovebox and will be used to melt fuel materials and injection cast these materials into fuel slugs, which will further be used to fabricate fuel elements for the VTR. This TEV covers only the injection casting system itself. Operations such as removing the castings from the injection molds, trimming of the castings, and installation of the castings into fuel element cladding are beyond the scope of the TEV. The conceptual design herein is principally concerned with the mechanical portion of the casting system and does not include details of the control or power supply systems.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

DEVELOPMENT OF AN INTEGRATED SECURITY AND SAFETY MONITORING SYSTEM FOR SPENT NUCLEAR FUEL AND HIGH-LEVEL WASTE TRANSPORTATION

This paper provides an overview of the progress to date, and discussion of the path forward, related to designing, fabricating, and testing an integrated security and safety monitoring system (ISSMS) for railcars used to transport spent nuclear fuel (SNF) and high-level radioactive waste (HLW) in the United States. The system will comply with the US Department of Energy’s (DOE) Order 460.2B “Departmental Materials Transportation Management” and the Association of American Railroads’ (AAR) standard S-2043 “Performance Specification for Trains Used to Carry High-level Radioactive Material” [1] developed specifically for railcars used to transport high-level radioactive material (HLRM). DOE is in the process of developing and testing an ISSMS that will satisfy both DOE requirements and AAR standards. DOE has already developed railcar designs for transportation of HLRM. In 2024, DOE’s Atlas railcar project completed the design, fabrication and testing of three railcar types: transportation cask-carrying, buffer, and security escort, resulting in AAR conditional approval to operate on freight rail networks in North America. DOE decided to combine the required security and safety systems into one system, and this combined system is the subject of the current effort. DOE is developing and proposes to implement the ISSMS for these railcars as part of the build out of the railcar fleet. DOE began planning for development of the ISSMS in February 2020. The project is divided into seven phases starting with conceptual design and continuing through production design, as shown in Figure 1. An earlier version of the system was tested as part of the Atlas railcar consist demonstration test run in 2023. This paper describes the design features and system testing using the Atlas project railcars, and laboratory testing completed to date. The paper will also describe the activities planned to support the DOE project to ship the High Burn-Up Research Cask (HBRC) in 2027.

Schultze, Michael [ORNL] (ORCID:0000000283205671)↗
DOE OSTI2023

Thermal & Electrochemical Power Plant Design and Cost Estimation

Public textbook for "Thermal & Electrochemical Power Plant Design and Cost Estimation: Version#1" This public textbook is an extension of class notes from Carnegie Mellon University courses: Energy System Modeling (24-722) and Fuel Cell Systems (24-262), taught by Dr. Nicholas Siefert between 2010-2021. Textbook includes some references to class notes from Dr. Shawn Litster, Department of Mechanical Engineering, Carnegie Mellon University. Textbook covers the equilibrium and nonequilibrium thermodynamics of power systems as well as an overview of system and economic modeling of these systems. There is in-depth coverage of (a) entropy generation, (b) exergy and (c) the redox state of molecules in equilibrium with the natural environment. This textbook is integrated with other materials (such as lecture slides, solved homeworks, and solved exams) that will be posted to the PowerShare: Energy Systems Modeling group on EDX. Publication Number: DOE/NETL-2023/3913

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2024

Northwest Combined Heat and Power Technical Assistance Partnership: Final Scientific/Technical Report

During the years of 2018 through 2023, The Washington State University Energy Program (WSU EP) operated the Northwest Combined Heat and Power Technical Assistance Partnership under contract to the US Department of Energy’s Advanced Manufacturing Office (AMO), a part of DOE’s larger Office of Energy Efficiency and Renewable Energy. This contract provided direction and funding for providing technical outreach, information and technical/economic analysis services in support of expanding development of Combined Heat and Power (CHP) over a four state region in the Pacific Northwest. The states served included Alaska, Idaho, Oregon and Washington. During the duration of this contract, the WSU EP delivered performed specific assigned tasks and provided services of various generally prescribed types, with the overall goal of increasing adoption of CHP as an efficient heat and power supply in the region. Indications – though not formally evaluated to our knowledge – are that this goal was achieved. Over many years, the WSU team has provided support for CHP developments in these states under similar previous Department of Energy contracts, and many such projects have been built. While the early-phase outreach, education and techno-economic assessments that the NW CHP TAP provides rarely immediately result in project construction, there is no doubt that the WSU EP team has had substantial influence in the construction of a number of important CHP projects in the region. Examples of projects implemented directly under the current team’s guidance and services during this contract cycle include an 875 kilowatt biomass fueled CHP system installed at the University of Idaho, and 5 megawatt natural gas fueled CHP system at the University of Montana ( UM Breaks Ground on New Power Facility, Slashes Emissions 30% (umt.edu) ). Many other CHP systems recently installed are also either directly or at least partially the result of information and technical services provided by the team. Finally, though much more difficult to quantify and less glamorous, the team has helped countless organizations to understand CHP and determine whether and how CHP may be a fit for them, before they consider paying for engineering services. Whether the ultimate outcome has been to include CHP or not, the expert skills provided by the NW CHP TAP team have provided real value to these organizations considering this relatively complex technology. Over the duration of the contract our team provided 71 Initial Technical Assessments and 17 Advanced Technical Assessments; 53 End-User Engagements and 33 Stakeholder Engagements of various types; 42 Technical Profiles (Project Profiles, Program Profiles and Policy Profiles), and produced 14 technical articles for the Department of Energy. Unfortunately, these quantities provide no measure of the value that the team has provided. Only our clients can judge that, and we are confident that they are pleased with the benefits we have offered them.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2020

An Enhanced Safeguards Approach for Accelerator Driven Systems utilized to Close the Fuel Cycle

Further to our previous safeguards approach for Accelerator Driven Systems, which focused on estimates of fissile material production using relevant proton accelerator systems and corresponding safeguards needs for fuel storage, the subcritical reactor, and spent fuel storage material balances areas, this report is more expansive and considers utilization of ADS for either burning of transuranics or breeding of fissile materials. We find that the recycled fuels likely intended for ADS will be thermally and radioactively hot to such a degree that it is likely reprocessing and fuel fabrication will have to be co - located with the ADS reactor facility to avoid impractical hot fuel transportation issues. As such, we consider in detail the full ADS system to include material balance areas for spent fuel receiving, reprocessing, storage & cooling, fuel fabrication, subcritical reactor area, and waste storage & handling. Furthermore, aqueous - based separation methods like PUREX cannot tolerate the intense heat of the ADS fuels, so pyroprocessing will likely be required. With these considerations, we developed an Enhanced Safeguards Approach for ADS beyond the work done in our first report, and conclude that significant diagnostic development is needed , a nd provide safeguards recommendations. We have also included an appendix regarding some country programs, in particular the Chinese ADANES burner/breeder program a nd the Indian thorium - based breeder program.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Review of Experimental Data for Validating Computer Codes Used in Shielding Calculations for Spent Fuel Storage and Transportation Systems

This report presents a review of available radiochemical assay data and shielding benchmarks applicable to spent nuclear fuel (SNF) shielding calculations. The relevant information reviewed herein includes the Spent Fuel Composition (SFCOMPO) database, the Shielding Integral Benchmark Archive and Database (SINBAD), the International Handbook of Evaluated Criticality Safety Benchmark Experiments, and published measurements of external dose rates of casks loaded with SNF. The relevant experimental data identified in this report may be used to support verification and validation of computer codes used in SNF cask/transport shielding applications, as well as development of calculation uncertainties. It should be noted that a relatively small subset of the identified experimental data (e.g., criticality alarm experiments) is available in a standard format established by the international community participating in experimental isotopic and shielding data evaluations. An effort of the SFCOMPO Technical Review Group (TRG) is underway to publish first isotopic evaluations of individual assay data using a standard data evaluation format. The SINBAD TRG has recently initiated benchmark evaluations and modernization of the database. Therefore, more relevant information is expected in the future that will enable users to select quality experimental data in depletion code and shielding code validations for SNF applications.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Simultaneous Control of Unburned NH 3 and NO x Emissions From High Load Dual-Fuel Ammonia Operation on a High-Speed Diesel Engine Using a Cu-SCR System

Dual-fuel ammonia strategies are being investigated as a promising way to utilize NH 3 as an alternative fuel for internal combustion engines in the maritime sector. One of the remaining barriers to implementing dual-fuel NH 3 combustion strategies is understanding ways to minimize unburned NH 3 and nitrogen oxide (NO x ) emissions from these engines, both of which are elevated relative to a conventional diesel baseline. Selective catalytic reduction (SCR) systems are widely used for lean NO x emission controls for engines across transportation and stationary energy applications. SCR systems use a reducing agent, such as NH 3 , to react with NO x in the exhaust, converting it into nitrogen and water. Typically, NH 3 is injected into the exhaust as a urea solution. In dual-fuel NH 3 engines, where unburned NH 3 is present in the exhaust, an SCR system could be used to mitigate both NH 3 and NO x emissions. The presented work evaluates a commercial copper-zeolite SCR and ammonia slip catalyst system, designed for on-road diesel engine applications, for controlling unburned NH 3 and NO x emissions from a dual-fuel NH 3 combustion engine. The aftertreatment system was installed downstream of a single-cylinder four-stroke diesel engine that has been modified for dual-fuel ammonia use. Furthermore, the emissions were characterized by using a Fourier transform infrared spectrometer for both late- and early-injection diesel pilot strategies over three air–fuel equivalence ratios spanning from 1.6 to 1.0 at 1200 rpm and 12.6 bar IMEP g condition (with greater than 95% ammonia energy fraction). Initial findings indicate that the SCR achieves more than 99% NO x conversion with less than 50 ppm NH 3 slip at air–fuel equivalence ratios greater than 1.4 at the operating conditions investigated. However, these benefits are accompanied by additional N 2 O emissions that are formed over the Cu-SCR.

Catalysts↗
DOE OSTI2022

Fuel injection module for segmented annular combustion system

The present disclosure is directed to a fuel injection module for a segmented annular combustion system. The fuel injection module includes a housing body, a fuel nozzle portion, and at least one fuel injection lance. The fuel nozzle portion is fluidly coupled to a fuel nozzle plenum within the housing body, and the at least one fuel injection lance is fluidly coupled to an injector fuel plenum within the housing body. In some cases, the fuel nozzle portion is a bundled tube fuel nozzle having one or more subsets of tubes. The fuel injection lances are positioned along a radial side of the housing body or circumferentially between two subsets of tubes. Liquid fuel cartridges extend through the fuel nozzle portion, the fuel injection lances, or both.

42 ENGINEERING↗
DOE OSTI2020

Initial development of an RIA envelope for dispersed nuclear fuel

A reactivity insertion accident (RIA) is a design basis accident in which reactivity is rapidly injected as a result of a control rod ejection or blade drop scenario. The resultant power increase can result in fuel rod failure and subsequent release of radioactive material into the reactor’s primary system. For light water reactors, failure under RIAs is typically a result of fuel melt, pellet-cladding interaction, or rod over-pressurization. Fuel melt occurs when the fuel system is unable to transport heat out of the fuel system. Pellet-cladding interaction occurs when an aggressive fuel pellet expansion pushes on an embrittled cladding beyond its strain limit. Rod over-pressurization occurs when a fuel rod exceeds the critical heat flux and departs from nucleate boiling, causing the rod internal pressure to rapidly increase, exceeding the systems pressure, and balloon until it bursts. To prevent failure, regulators have developed safety requirements that limit the injected enthalpy based on the state of the fuel system. However, dispersed fuel could enable the removal or relaxation of regulator-imposed safety criteria. Dispersed fuel embeds fuel particles in a highly conductive metal. Dispersed particles can have a particle radius of 1 µm to greater than 100 µm. Traditional fuel systems are plagued by poor thermal conductivity, especially at higher burnups, thus reducing the ability of the fuel system to respond to an RIA. However, dispersed fuel could improve the ability of the fuel system to transport injected energy away from the fissile material and into the coolant more efficiently. Furthermore, dispersing the fuel particles mitigates hard contact that typically occurs in the traditional zirconium-uranium dioxide fuel system, thus removing pellet-cladding mechanical interaction as a potential failure mechanism. This paper evaluates fuel particles dispersed in a metal matrix using the BISON fuel performance code to develop an initial failure threshold based on melt temperature of the fuel particle and/or cladding material as a function of fission density for beginning-of-life and end-of-life conditions. BISON results show that (1) reducing the size of the particles allows fission density to increase as a function of time, (2) particle-to-particle proximity must be considered to evaluate the limiting conditions, and (3) improving the fuel particle thermal conductivity improves thermal performance.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Testing- and Model- Based Optimization of Coal-fired Primary Heater Design for Indirect Supercritical CO 2 Power Cycles (Final Scientific and Technical Report)

The overall objective of this project was to perform the R&D necessary to mitigate the risk associated with the design of a primary heat exchanger for a solid-fired combustion system coupled with an indirect-fired closed-loop Brayton Cycle utilizing supercritical CO 2 . The key technological hurdle was the coupling of a solid-fuel firing system with the primary heater, which poses a singular challenge, which is the management of burner performance and operational conditions in a way to manage heat exchanger tube metal temperatures and temperature ramp rates in the absence of fluid phase change on the inside of the tubes. We designed and built the first ever pseudo power system employing a simple recuperated supercritical CO 2 closed-loop Brayton Cycle coupled to a solid-fuel fired system. Advanced coupled CFD and process modeling were used to design the primary heat exchanger (PHX), which consisted of both radiative and convective sections, to limit tube metal temperatures resulting from the heat release profile of the solid fuel flame near the radiative tubes. The heat exchanger was designed to produce finished CO 2 temperatures of 600 °C a pressure of 20.7 MPa and CO 2 flow of 5.5 kg/s. The constructed PHX was capable of 1.2 MWth heat uptake. During design of the PHX, the modeling showed that most variables influencing flame shape (burner stoichiometric ratio and register velocities and swirl) were not suitable to manage heat flux to the metal surfaces. This is because they substantially increased adiabatic flame temperature through the influence of localized stoichiometric ratio. Excess air and firing rate were the two most powerful variables that could be used to control tube surface temperatures. The coupled system was operated for a total of 407 hours, with the longest continuous run of 248 hours. For 62% of the operational time, the unit was unmanned and in automatic control. The fuels used for the testing included natural gas, two Utah Bituminous coals, woody biomass, and bagasse. During the testing we were able to verify the 1.2 MWth heat uptake and we operated at a finished CO 2 temperature of 607 °C and a pressure of 20.3 MPa simultaneously. The real-time corrosion rate of the Super 304H tube CO 2 surface in the region of the radiative section of the PHX were measured, at an approximate temperature of 550 °C. The two key variables related to corrosion rate are the pressure and flow rate of the CO 2 . A technoeconomic analysis was performed at a scale of 120 MWE. The updated analysis showed that the efficiency of an sCO 2 power producing plant will be related to the pressure drop of the PHX.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2021

Metal-Supported Ceria Electrolyte-based SOFC Stack for Scalable, Low-Cost, High-Efficiency and Robust Stationary Power Systems (Final Report)

This is the end of project report for the DOE Project DE-FE-0027844 “Metal-Supported Ceria Electrolyte-based SOFC Stack for Scalable, Low-Cost, High-Efficiency and Robust Stationary Power Systems”. The objectives of the project were to develop several technologies required for the mass adoption of Solid Oxide Fuel Cell systems for medium to large power generation applications. The key achievements of this project were: 1) Development of fuel cells with complete internal fuel reforming capability. 2) Fuel cell power scale up with production of cells with larger active areas. 3) Assembly of an integrated 5 kW modular stack platform capable of installation into medium to large power systems. 4) Demonstration of a 10 kW Fuel Cell Power System utilizing the integrated 5 kW modular stack platform. 5) Cost modelling to show system cost of $1,500/kW are achievable at production volumes. 6) Development of cathode air poison getters for reduced degradation and extended fuel cell life. 7) Assessment of fuel poison on anode degradation, particularly poisons frequently produced from the process of gasification of coal. The Cummins led Voice of Customer (VOC) work identified several significant markets for natural gas powered fuel cell systems, where the end customer is interested in reducing energy consumption and emissions, or increasing reliability of electrical supply. Data centers and truck Auxiliary Power Units (APU) were highlighted as 2 key future markets for fuel cell systems.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2023

Post-irradiation examination of the Sirius-1 nuclear thermal propulsion fuel test

Nuclear Thermal Propulsion (NTP) systems hold promise in reducing transit times for exploration of the solar system by both crewed and uncrewed missions. NTP systems currently under investigation include a once-through high-temperature gas-cooled fission reactor to provide thermal energy to heat the coolant, which also serves as the propellant. The fuel system consists of angular UN fuel particles dispersed in a matrix of W/Re, creating a ceramic and metallic composite or cermet, which has been irradiated in Idaho National Laboratory's (INL) Transient Reactor Test Facility (TREAT). This enabled evaluation of these materials under representative nuclear heating rates (~95 K/s) and peak surface temperatures (~2527 K). Further, these surface conditions were indicative of achievement of the target peak internal temperature of approximately 2850 K. These tests named Sirius-1 (UN–W/Re), have been irradiated and this paper will present post-irradiation examination results. The Sirius-1 test produced minor, stable cracks in the fuel specimen and spalling of surface material. Volatilized uranium ‘soot’ was found deposited on the inner wall of the irradiation capsule indicating loss of some fissile material from the fuel specimen. Spalling from the surfaces was also noted upon visual inspection. Uranium diffusion from the fuel particles resulted in the formation of U/Re phases and the production of a laminar microstructure on the edge of the fuel system. Overall, the specimen was stable and remained within a coolable geometry upon conclusion of multiple thermal cycles to prototypical operating temperatures.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗