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At least 307 records · Page 17

FEM Analysis of Hybrid LTS/HTS Cos-Theta Dipole Magnet

After the recent results on Bi-2212 superconductive magnets realized and tested in canted cosine-theta and solenoid designs, respectively, at Lawrence Berkeley National Laboratory (LBNL) and NHMFL, the first Bi-2212 stress-managed cosine-theta insert magnet is in the assembly phase at Fermilab. This insert will be part of the first hybrid cosine-theta magnet made of Nb3Sn outer layers within the US-MDP effort to reach 20 T bore field. This paper reports the analytical analysis of the cosine-theta Nb3Sn/Bi-2212 hybrid magnet. As an introduction, it shows the validation of the finalized HTS coils' design optimized using the ROXIE code. Subsequently, it reports the parameters, logic, and implementation method of the 2D electromagnetic and mechanical FEM analysis of the LTS/HTS hybrid magnet. Results from the ANSYS detailed model made with sub-modeling geometry are compared with the homogeneous model implemented in the past. Moreover, a Python code was implemented to simulate the current degradation due to stresses in the detail-modeled conductor areas. The current degradation is introduced in the simulation dynamics for both conductors as an iteration process during the energization load step only after applying pre-stress and thermal loads. The numerical and graphic results of the 2D cosine-theta LTS/HTS magnet cross-section will be described and analyzed.

D'Agliano, A.↗

Test and Validate Distributed Coaxial Cable Sensors for in situ Condition Monitoring of Coal-Fired Boiler Tubes

This project aims to test, validate, and advance the technology readiness level (from TRL5 to TRL7) of a novel low-cost distributed stainless-steel/ceramic coaxial cable sensing (SSC-CCS) technology for in situ monitoring of the boiler tube temperature in existing coal-fired power plants. The novel SSC-CCS sensing technology and associated condition-based monitoring (CBM) software to be demonstrated in this project will lead to an improved understanding of the boiler tube failure mechanisms and a prognostic system to improve the overall performance, reliability, and flexibility of the nation’s coal-fired power plant fleet. A boiler tube monitoring system with distributed coaxial cable temperature sensors and a sensor acquisition system was constructed. The high-temperature coaxial cable sensor with a length of 1.3m was made by using a quartz tube (1mm inner diameter (ID) and 6mm outer diameter (OD)) to concentrically separate a 304 stainless-steel (SS) rod (1mm OD) and SS tube (7.94mm OD and 6.16mm ID). The sensor acquisition system includes a vector network analyzer (VNA), a radio frequency (RF) power amplifier, multiple switches and a USB hub. The distributed stainless-steel quartz coaxial cable sensor (SSQ-CCS) had a linear response to temperature with a resolution uncertainty of σ = 0.77℃. To withstand the harsh conditions of 3,300 steam pressures and 800℃ high temperatures, the sensor was shielded by a protective tube made of the same material as the boiler tube. The protection tube had an OD of 1.5 inches and a thickness of 0.25 inches. In the laboratory tests, the sensor showed good sensitivity and fast response. The drift was bounded between +0.33% and -0.67% during a test at 600℃ for 350 hours, indicating good stability of the sensor. A field test was conducted where four sensors were welded on four superheat tubes (SH-Ts) at a coal-fired power station over 400 days. Conventional thermocouples were welded to the superheater tubes alongside the coaxial cable sensors for the purpose of comparison. Two sensors were capable of distributed sensing, with three multiplexed sensing sections. The other two sensors were single section. During the 400-day test period, the power plant experienced startups and shutdowns. At the steady state operations, the temperature of the boiler tube is about 600℃ (1112°F). The sensors recorded the entire coal-firing processes (start-up, steady state, and shut-down) and the glitch event. A GSM modem and a Watchdog were added to the system to ensure reliable data recording. The GSM modem sent daily messages to plant managers and Clemson team to inform the status of the sensor system. If the system was not normally working, the Watchdog would reboot the system automatically. The new coaxial cable based distributed sensing technology has been proven to be successful in both laboratory and field tests. A comprehensive four-stage multi-physics computational framework has been developed to assist the design, optimization, installation, and operation of SSQ-CCS. With the consideration of various operation conditions, we predict the distributions of flue gas temperatures within coal-fired boilers, the temperature correlation between the boiler tube and SSQ-CCS, and the safety of SSQ-CCS. A conditional-based monitoring system is implemented as well. The computational framework developed in this work can guide the future operation of coal-fired plants and other power plants for the safety prediction of boiler operations.

01 COAL, LIGNITE, AND PEAT↗

DECOVALEX-2023: Task A Final Report

Task A, also known as HGFrac, examines the fracturing processes that may occur in the Callovo-Oxfordian claystone (COx) in the context of the high-level (HLW) and intermediate-level long-lived (ILW-LL) radioactive waste repository in France. Understanding these processes and improving numerical models to reproduce them will aid in the design, optimization, and safety of the repository. Heat and gas fracturing are studied in two independent subtasks following a stepwise approach: laboratory tests/benchmark exercises, in-situ experiment, and finally, an application case. The in-situ heater experiment aimed to thermally induce a hydraulic fracture; temperature and pore pressure were monitored to detect any evidence of fracturing. The in-situ gas injection experiment aimed to study the effect of the stress orientation and gas injection kinetics on the gas fracturing process. The occurrence of fracturing was monitored by gas pressure measured in the injection interval. In both experiments, the excavation-induced fracture network around the heater/injection boreholes played an important role in the reduction of the compressive stress state, leading to both a tensile and shear failure response of the COx. During the first two years of the project, the research teams working on each task developed and/or proposed numerical approaches for reproducing the occurrence of fracturing in the in-situ experiments. The failure criteria were defined by reproducing the measurements from laboratory extension tests for the heat fracturing subtask. In the gas fracturing subtask, their approaches were used for simulating several benchmark exercises, and an inter-comparison between models was carried out. In both tasks, the developed approaches were compared with a simplified approach considering poro-elasticity for the mechanical behaviour of the COx. Most of the developed approaches are based on a continuous medium that takes into account variations in hydraulic properties due to mechanical degradation, such as plastic deformation or damage. Other approaches implicitly modelled weak planes or embedded discontinuities to reproduce fracture propagation. The potential for fracture initiation was also studied through of a discrete approach. In the second half of the project, the research teams mainly focused on interpretative modelling of two in-situ experiments and a blind prediction exercise to test their respective approaches. The models developed by the research teams were also applied at the repository scale to evaluate fracture initiation in a case study under vi unfavourable conditions, particularly in terms of spacing between High-Level Waste cells. The results showed that the poro-elasticity approach could be an efficient tool for understanding the main processes occurring in the COx. One example is the explicit representation of the excavation-induced fracture network around the boreholes, which yielded acceptable results compared to the measurement data. However, advanced approaches were needed to evaluate the potential increase of the excavation-induced fracture network extend and better understand fracture initiation. The stress analyses carried out by the teams revealed that hydraulic boundary conditions had a strong impact on fracture initiation in the heater experiment. Furthermore, in most cases, the results required higher pore pressure increments to reach fracturing than those measured in the experiment. This implies that the measurements may have been biased by the packer’s capacity to fully isolate the piezometric chambers, leading to lower pressures. On the contrary, there was no agreement on the fracturing mode, as some reported either shear or tensile fracturing, while others reported a combination of the two modes. In the case of gas fracturing, the research teams were limited to the comparison of a single point, which complicated their task. Nonetheless, the numerical results were able to reproduce the measurements and capture processes such as longitudinal gas flow through the excavation-induced fracture network, as suggested by some evidence in the observation piezometric chambers. The numerical models also agreed with the measurements in the sense of higher probability of developing along the injection borehole than radially towards the sound rock. The approaches developed by the research teams showed that they are capable of analysing and reproducing fracture initiation in the COx. However, areas of future work should focus on the fracture propagation and fracture aperture, which were out of the scope of this task. To this end, additional data must be gathered for the parameter characterisation and validation of the numerical models. Nonetheless, various approaches showed promising results as they were able to reproduce fracture development under certain conditions.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Printed Metal Molds for Mainstream Automotive Production

The main focus of this work was to evaluate additive manufacturing of metal molds, with significantly reduced cost and/or procurement lead time, for production of large composite components for mainstream (> 100k units/yr) automobiles. A two-component large tool with conformal heating channels was designed, optimized, printed, machined, and tested in production. The resulting analysis indicates that large scale AM is suitable for manufacturing complex geometry large scale metal molds.

36 MATERIALS SCIENCE↗

RAFT: Reconfigurable Array of High-Efficiency Ducted Turbines for Hydrokinetic Energy Harvesting

Diversifying the energy harvesting portfolio is crucial to achieving the ambitious goal of transitioning to clean energy by 2030. Marine hydrokinetic energy has garnered renewed interest due to its high harvesting potential in the U.S., and the resource's reliability and predictability—remaining relatively constant on a daily basis and available 24/7. However, there are currently few commercial devices capable of harnessing the energy from flowing water. This project aims to bridge that gap by designing and evaluating a novel hydrokinetic turbine concept that can efficiently harvest energy from both rivers and tidal streams. The RAFT (Reconfigurable Array of High-Efficiency Ducted Turbines) concept introduces a duct surrounding the turbine rotor and creates an array of small 5-kW units. The duct serves two primary purposes: (1) it enhances hydrodynamic efficiency by accelerating flow to the rotor, and (2) it functions as a structural component, facilitating the formation of modular arrays that lower costs. This project focuses on demonstrating this concept and validating these benefits through simulations and scaled prototype testing. The project team includes 8 faculty members and over 20 students from 3 universities, organized into three core areas: hydrodynamics, electrical systems, and structural analysis, with additional teams dedicated to system integration, environmental assessment and risk management, and tech-to-market strategy. The team successfully demonstrated the increased hydrodynamic efficiency of a ducted turbine compared to an unducted version using high-fidelity simulations and prototype tests. Moreover, design optimization efforts led to surpassing the SHARKS program's goal of 60% reduction of the levelized cost of energy with a significant margin.

13 HYDRO ENERGY↗

Application of Advanced Materials Processing to Enable Direct Production of Fast Reactor Fuel Alloys

Argonne National Laboratory (the Contractor), located in Lemont, IL, and Oklo, Inc. (the Participant), headquartered in Sunnyvale, CA, entered into a Cooperative Research and Development Agreement (CRADA) to integrate advanced electrorefining co-deposition and molten-salt monitoring technologies to produce a uranium-transuranic (U/TRU) alloy within a controlled composition range that can be used as fast reactor fuel for Oklo, Inc.’s advanced reactor technology. Argonne performed the integration of electrorefining and process monitoring technologies, determined operating parameters for producing U/TRU alloys, and developed optimized design and operating parameters for co-deposition of U/TRU alloys. Oklo, Inc. worked with Argonne and the Nuclear Regulatory Commission (NRC) to provide the necessary process documentation to begin implementing pyroprocessing technology in the fast reactor fuel production process. Outcomes of this project included a pilot-scale co-deposition cathode design and technical basis for the operation of the co-deposition electrorefiner to produce U/TRU alloys with controlled composition.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Hypercomplex Automatic Differentiation in the Eulerian Hydrocode PAGOSA

Enabling the computation of partial derivatives or sensitivities in production hydrocodes is beneficial for design, optimization, sensitivity analysis, and uncertainty quantification. Traditional finite difference approximations of these sensitivities are inefficient since convergence studies of the step size is required for each parameter of interest. For these reasons, HYPercomplex Automatic Differentiation (HYPAD) was implemented in the Eulerian hydrocode PAGOSA. HYPAD is analogous to forward-mode automatic differentiation except hypercomplex numbers (numbers with multiple imaginary parts) are used instead of dual numbers. Accurate partial derivatives can be computed of all state variables with respect to multiple input variables in a single run. The method was implemented using operator overloading to handle hypercomplex algebra. HYPAD was demonstrated and verified on Sod’s shock tube problem to compute derivatives of the state variables with respect to a material parameter, initial conditions, and geometry.

97 MATHEMATICS AND COMPUTING↗

Develop an efficient and cost-effective novel anaerobic digestion system producing high purity of methane from diverse waste biomass

This project focuses on developing an advanced, intensified anaerobic digestion system aimed at transforming the treatment and conversion of organic wastes into valuable products, specifically renewable natural gas. The motivation for this research stems from the limitations of conventional anaerobic digestion technologies, which often face challenges such as long retention times, high operational costs, and incomplete organic material degradation. The new technology called Intensified Versatile Anaerobic Digestion (IVAD), is developed to address these challenges by incorporating innovative reactors and processes that enhance the overall efficiency and output of anaerobic digestion. The significance of this project lies in its potential to revolutionize waste management practices and waste biomass utilization. The IVAD system integrates a hyperthermophilic anaerobic acidification reactor, a hydrothermal treatment (HTT) unit, and both thermophilic and mesophilic methanogenic reactors. This combination enables a higher rate of organic breakdown and energy recovery, resulting in faster processing times, reduced reactor sizes, and lower operational costs compared to traditional systems. Key data include an increase in methane productivity to 1.18 m 3 /m 3 /day, a significant improvement compared to the baseline technology’s 0.64 m 3 /m 3 /day. Additionally, the IVAD system achieves a 45% reduction in levelized cost of energy (LCOE), down to $\$$10.04/MMBTU, and an energy return on investment (EROI) of 3.19, representing an 87% increase over baseline levels. Technical and economic analyses highlight that the IVAD system significantly reduces hydraulic retention time (HRT) and solid retention time (SRT). The HRT for the HTT reactor can be reduced from 1 hour to 0.5 hours, while decoupling SRT from HRT in the anaerobic acidification reactor (AAR) allows for further reductions. These design optimizations lead to smaller reactor volumes, cutting down equipment and construction costs. Despite these advancements, energy consumption remains comparable to conventional methods due to a novel heat recovery strategy, enhancing overall process productivity. The system also achieves in-situ CO 2 removal and ammonia stripping features, resulting in biogas with a methane purity level of 75%, and produces high-quality nitrogen fertilizer as an additional by-product. Public benefits of the IVAD system are substantial, contributing to sustainable waste management and renewable energy production. By providing a scalable solution that can be adopted by dairy farms and similar agricultural operations, the IVAD system helps reduce waste, produce renewable natural gas (RNG) suitable for transportation fuel, and generate fertilizer, supporting a circular economy. This project plays a role in achieving broader environmental objectives by mitigating greenhouse gas emissions and promoting energy independence. Additionally, it offers a pathway for farmers to lower operational costs while adopting practices that are both environmentally sustainable and economically advantageous.

03 NATURAL GAS↗

Broadband mm-Wave Substrate Integrated Waveguides [Poster]

At mm-wave frequencies, signals need to be supported by specialized, low-loss transmission lines such as waveguides. Substrate-integrated waveguides (SIWs) combine the good electrical properties of rectangular waveguides with the compactness of planar transmission lines. Additionally, SIWs can be fabricated using standard PCB manufacturing techniques and can be easily integrated with other mm-wave components. This study explores SIWs in the 50-75 GHz range, with designs optimized for simple fabrication.

42 ENGINEERING↗

Ultracoherent SRF Cavity-Based Multi-Qudit Platform with Error-Resilient Control

Superconducting radio-frequency (SRF) cavities offer a promising platform for quantum computing due to their long coherence times, yet integrating nonlinear elements like transmons for control often introduces additional loss. We report a multimode quantum system based on a 2-cell elliptical shaped SRF cavity, comprising two cavity modes weakly coupled to an ancillary transmon circuit, designed to preserve coherence while enabling efficient control of the cavity modes. We mitigate the detrimental effects of the transmon decoherence through careful design optimization that reduces transmon-cavity couplings and participation in the dielectric substrate and lossy interfaces, to achieve single-photon lifetimes of 20.6\,ms and 15.6\,ms for the two modes, and a pure dephasing time exceeding 40\,ms. This marks an order-of-magnitude improvement over prior 3D multimode memories. Leveraging sideband interactions and novel error-resilient protocols, including measurement-based correction and post-selection, we achieve high-fidelity control over quantum states. This enables the preparation of Fock states up to $N = 20$ with fidelities exceeding 95\%, the highest reported to date to the authors' knowledge, as well as two-mode entanglement with an estimated coherence-limited fidelities of 99.9\% after post-selection. These results establish our platform as a robust foundation for quantum information processing, allowing for future extensions to high-dimensional qudit encodings.

Kim, T. [Northwestern U.]↗

Countrywide LED Lighting Retrofit for Safety, Visibility, and Energy Efficiency (Final Technical Report)

The project supported national clean energy goals by reducing electricity demand and improving energy efficiency in public infrastructure. Tasks defined in the Statement of Project Objectives included site assessments, retrofit planning, lighting design optimization, installation, monitoring, and reporting. All milestones and go/no-go decision points were successfully met.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Extension of SCALE/Sampler’s sensitivity index for the assessment of cross section, fission yield, and decay data uncertainties

Accurate prediction of nuclide compositions and neutron and gamma sources and spectra for fresh and spent nuclear fuel through computational modeling and simulations is the basis for safeguards instruments design, optimization, and calibration, and for validation of the measured responses. The accuracy of these simulations can be significantly impacted by uncertainties in input parameters to the applied computer code. Input parameters are, for example, dimensions, material compositions, and temperatures of the model. Additionally, important but sometimes neglected input parameters for simulations of nuclear systems are the nuclear data that include nuclear reaction cross sections, fission product yields, and decay data. It has been shown that uncertainties of calculated results are dominated by uncertainties of these nuclear data.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Characterizing the Impact of Heliostat Size, Focus Method, and Optical Error on Concentrating Solar Tower Systems

Concentrating Solar Power (CSP) tower systems use heliostat fields to direct solar energy to a central receiver. The efficiency of the heliostat field is crucial for achieving thermal generation targets and is also the largest cost component, making up 30-40% of total project costs. Developers face a tradeoff: reducing heliostat costs may decrease optical performance and increase land use, while improving performance could raise manufacturing costs (through higher precision). The optimal design depends on land, labor, and manufacturing costs. Additionally, inherent performance limitations exist - optical errors result in larger solar images as heliostats move farther from the receiver, increasing spillage and attenuation losses. Ultimately, there exists a point where receiver design power can no longer be achieved at design conditions for a given solar field area. This point depends on key heliostat field design parameters including field layout, heliostats size, focus method, and heliostat optical error. In this work, we explore and characterize the performance trade-offs between heliostat size, focus method, and optical error using Monte Carlo ray-tracing simulations using NREL's high performance computing resources. The goal of this fundamental investigation is to understand practical heliostat design performance impacts that can be used to produce more cost-effective heliostat fields while still achieving plant thermal generation targets.

14 SOLAR ENERGY↗

Ultracoherent superconducting cavity-based multiqudit platform with error-resilient control

Superconducting radio-frequency (SRF) cavities offer a promising platform for quantum computing due to their long coherence times, yet integrating nonlinear elements like transmons for control often introduces additional loss. We report a multimode quantum system based on a 2-cell elliptical-shaped SRF cavity, comprising two cavity modes weakly coupled to an ancillary transmon circuit, designed to preserve coherence while enabling efficient control of the cavity modes. We mitigate the detrimental effects of the transmon decoherence through careful design optimization that reduces transmon-cavity couplings and participation in the dielectric substrate and lossy interfaces, to achieve single-photon lifetimes of 20.6 ms and 15.6 ms for the two modes, and a pure dephasing time exceeding 40 ms. This marks an order-of-magnitude improvement over prior 3D multimode memories. Leveraging sideband interactions and novel error-resilient protocols, including measurement-based correction and post-selection, we achieve high-fidelity control over quantum states. This enables the preparation of Fock states up to N = 20 with fidelities exceeding 95%, the highest reported to date to the authors' knowledge, as well as two-mode entanglement with an estimated coherence-limited fidelities of 99.9% after post-selection. These results establish our platform as a robust foundation for quantum information processing, allowing for future extensions to high-dimensional qudit encodings.

Lu, Yao [Fermilab] (ORCID:000000020413698X)↗

Sapphire Substrate Trenching to Advance Superconducting High-Coherence Quantum Devices

Achieving longer coherence times in superconducting qubits is essential for advancing quantum information processing and enabling scalable quantum computing. This work presents an innovative fabrication strategy focused on sapphire trenching of the substrate of superconducting high-coherence quantum devices, developed by the SQMS Nanofabrication Taskforce in collaboration with the materials characterization team. In this talk, we present a method to efficiently and consistently trench into the sapphire substrate, without compromising the surface roughness or profile of the etched sapphire. In the literature, trenching in the substrate has been shown to decrease losses, unwanted coupling and thermal stress. Sapphire’s strong covalent bonds make it harder to etch compared to silicon, yet it is more favorable for high-coherence quantum devices due to its lower dielectric losses. This innovative technique opens new possibilities for superconducting qubit fabrication: we fabricated high coherence qubit chips on sapphire substrates with trenching, to demonstrate that it will help pushing towards higher coherence times. By integrating this work with ongoing junction process optimization, design innovation, materials characterization and exploration, we outline a clear pathway toward transmon coherence times reaching millisecond scales and beyond.

Garattoni, S. [Fermilab]↗

Ultracoherent superconducting cavity-based multiqudit platform with error-resilient control

Superconducting radio-frequency (SRF) cavities offer a promising platform for quantum computing due to their long coherence times, yet integrating nonlinear elements like transmons for control often introduces additional loss. We report a multimode quantum system based on a 2-cell elliptical-shaped SRF cavity, comprising two cavity modes weakly coupled to an ancillary transmon circuit, designed to preserve coherence while enabling efficient control of the cavity modes. We mitigate the detrimental effects of the transmon decoherence through careful design optimization that reduces transmon-cavity couplings and participation in the dielectric substrate and lossy interfaces, to achieve single-photon lifetimes of 20.6 ms and 15.6 ms for the two modes, and a pure dephasing time exceeding 40 ms. This marks an order-of-magnitude improvement over prior 3D multimode memories. Leveraging sideband interactions and novel error-resilient protocols, including measurement-based correction and post-selection, we achieve high-fidelity control over quantum states. This enables the preparation of Fock states up to N = 20 with fidelities exceeding 95%, the highest reported to date to the authors' knowledge, as well as two-mode entanglement with an estimated coherence-limited fidelities of 99.9% after post-selection. These results establish our platform as a robust foundation for quantum information processing, allowing for future extensions to high-dimensional qudit encodings.

Lu, Yao [Fermilab] (ORCID:000000020413698X)↗

Sapphire Substrate Trenching to Advance Superconducting High-Coherence Quantum Devices

Achieving longer coherence times in superconducting qubits is essential for advancing quantum information processing and enabling scalable quantum computing. This work presents an innovative fabrication strategy focused on sapphire trenching of the substrate of superconducting high-coherence quantum devices, developed by the SQMS Nanofabrication Taskforce in collaboration with the materials characterization team. In this talk, we present a method to efficiently and consistently trench into the sapphire substrate, without compromising the surface roughness or profile of the etched sapphire. In the literature, trenching in the substrate has been shown to decrease losses, unwanted coupling and thermal stress. Sapphire’s strong covalent bonds make it harder to etch compared to silicon, yet it is more favorable for high-coherence quantum devices due to its lower dielectric losses. This innovative technique opens new possibilities for superconducting qubit fabrication: we fabricated high coherence qubit chips on sapphire substrates with trenching, to demonstrate that it will help pushing towards higher coherence times. By integrating this work with ongoing junction process optimization, design innovation, materials characterization and exploration, we outline a clear pathway toward transmon coherence times reaching millisecond scales and beyond.

Garattoni, S. [Fermilab]↗

Griffin Capability Improvements in Support of Ex-core Deep-Penetration Problems

Advanced reactor designs, especially portable reactors that are designed to be located closer to humans and operate autonomously, require the ability to accurately compute the ex-core neutron and gamma flux solutions in terms of shielding design optimization to reduce dose rates at the vessel boundary and detector signal prediction to drive the reactor control system. The Nuclear Energy Advanced Modeling and Simulation program has prioritized improvements to the Griffin discrete ordinates (SN) solver for deep-penetration problems in fiscal year 2025. Significant advancements have been made to the Griffin methodologies for solving ex-core deep-penetration problems for steady-state, fixed-source and transient calculations. This work presents the methodology improvements as well as a comprehensive demonstration with a Transient Test Reactor model and measurements.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗