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DOE OSTI2023

Ampaire ARPA-e Electric Flight Testbed

A hybrid-electric aircraft flying testbed was developed in this program with the intent to serve as a dedicated, enduring testbed to test and evaluate ARPA-e CIRCUITS Program and other electrified aviation technologies in relevant flight environments. This testbed enabled rapid development cycles of novel and innovative technologies in the electrified aviation space, maturing them from a research lab environment to flying in an aircraft. By providing research groups with the means to test their transformative technologies in a real-world, aircraft environment, the path to validating the safety and reliability of their technologies for future commercial opportunities was greatly accelerated. Three core technologies were integrated and tested: an inverter/motor drive built by the University of Arkansas, a solid-state circuit breaker (iBreaker) built by the Illinois Institute of Technology, and a Flying Capacitor Multi-level (FCML) DC/DC converter built by the University of California, Berkeley. In each of these cases, the requirements established for safety of flight resulted in a holistic approach to the designs, evoking a deeper understanding of the potential failure modes and mitigations necessary to build a robust and flightworthy system. Further, the integration into a hybrid-electric aircraft de-risked the potential electrical and mechanical issues that cannot easily be experienced or replicated in a lab environment. The experiments were also required to undergo representative temperature, shock, and vibration testing as the FAA prescribes for this category of aircraft, facilitating familiarity with the relevant design and test guidelines necessary to commercialize the technologies. This testbed unlocks the massive potential of core power electronics technologies necessary for a safe, robust, and efficient electric aviation future. With quick iterative design, test, and flight cycles, these core technologies are on a quicker path to technology readiness level maturity and commercialization, enabling a more sustainable future for the aviation industry.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2023

Partial Least Squares, Experimental Design, and Near-Infrared Spectrophotometry for the Remote Quantification of Nitric Acid Concentration and Temperature

Near-infrared spectrophotometry and partial least squares regression (PLSR) were evaluated to create a pleasantly simple yet effective approach for measuring HNO3 concentration with varying temperature levels. A training set, which covered HNO3 concentrations (0.1–8 M) and temperature (10–40 °C), was selected using a D-optimal design to minimize the number of samples required in the calibration set for PLSR analysis. The top D-optimal-selected PLSR models had root mean squared error of prediction values of 1.4% for HNO 3 and 4.0% for temperature. The PLSR models built from spectra collected on static samples were validated against flow tests including HNO 3 concentration and temperature gradients to test abnormal conditions (e.g., bubbles) and the model performance between sample points in the factor space. Based on cross-validation and prediction modeling statistics, the designed near-infrared absorption approach can provide remote, quantitative analysis of HNO 3 concentration and temperature for production-oriented applications in facilities where laser safety challenges would inhibit the implementation of other optical techniques (e.g., Raman spectroscopy) and in which space, time, and/or resources are constrained. The experimental design approach effectively minimized the number of samples in the training set and maintained or improved PLSR model performance, which makes the described chemometric approach more amenable to nuclear field applications.

07 ISOTOPE AND RADIATION SOURCES↗

DOE OSTI2023

Chapter 6: Abuse Response of Batteries Subjected to Mechanical Impact

Electrochemical and thermal models to simulate nominal performance and abuse response of lithium-ion cells and batteries have been reported widely in the literature. Studies on mechanical failure of cell components and how such events interact with the electrochemical and thermal response are relatively less common. This chapter outlines a framework developed under the Computer Aided Engineering for Batteries program to couple failure modes resulting from external mechanical loading to the onset and propagation of electrochemical and thermal events that follow. Starting with a scalable approach to implement failure criteria based on thermal, mechanical, and electrochemical thresholds, we highlight the practical importance of these models using case studies at the cell and module level. The chapter also highlights a few gaps in our understanding of the comprehensive response of batteries subjected to mechanical crash events, the stochastic nature of some of these failure events, and our approach to build safety maps that help improve robustness of battery design by capturing the sensitivity of some key design parameters to heat generation rates under different mitigation strategies.

abuse simulations↗

DOE OSTI2020

HAZARD ANALYSIS OF DIGITAL ENGINEERED SAFETY FEATURES ACTUATION SYSTEM IN ADVANCED NUCLEAR POWER PLANTS USING A REDUNDANCY-GUIDED APPROACH

Replacing the existing aging analog instrumentation and control (I&C) systems with modern safety control and protection digital technology offers one of the foremost means of performance improvements and cost reductions for the existing nuclear power plants (NPPs). However, the qualification of digital I&C systems remains a challenge, especially considering the issue of software common-cause failures (CCFs), which are difficult to address. With the application and upgrades of advanced digital I&C systems, software CCFs have become a potential threat to plant safety because most redundant designs use similar digital platforms or software in the operating and application systems. With complex designs of multilayer redundancy to meet the single-failure criterion, digital I&C safety systems (e.g., engineered safety-features actuation system [ESFAS]) are of a particular concern in the U.S. Nuclear Regulatory Commission (NRC) licensing procedures. This paper applies a modularized approach to conduct redundancy-guided systems-theoretic hazard analysis for an advanced digital ESFAS with multilevel redundancy designs. Systematic methods and risk-informed tools are incorporated to address both hardware and software CCFs, which provide guidance to eliminate the triggers of potential single points of failure in the design of digital safety systems in advanced plant designs.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2022

Activation of lead coolant in Westinghouse lead fast reactor

The Westinghouse Lead-cooled Fast Reactor (LFR) is a medium-sized, passively safe, scalable reactor being developed by Westinghouse in collaboration with domestic and international organizations with the primary goals of reducing front-end capital cost and generating flexible and cost-competitive electricity while satisfying the highest standards in terms of safety and sustainability. An important aspect of new plant design is an assessment of activation level of its components so that an appropriate nuclear waste management plan can be established. As lead coolant is a distinguishing design feature of the LFR, its activation due to irradiation and the implications on establishing an appropriate waste disposal approach are important for engagement of project stakeholders, customers and nuclear safety regulators. This paper provides a brief description of the Westinghouse LFR design, a background on lead activation phenomenology, and then describes the methodology used for lead activation analysis performed with the computer code Serpent 2. It was determined that impurities naturally occurring in lead have the biggest contribution to lead activation. Corrosion and erosion products from the components immersed in lead can also be important contributors to lead activity and their impact can be limited by appropriate selection of materials and operating conditions. Polonium isotopes, resulting from bismuth generated from lead irradiation and its impurities, bring a notable contribution to the inhalation and ingestion doses during the plant operation and in the first years after the plant shutdown. However, it is not by far as important as for lead-bismuth coolant.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2025

Crossing the Finish Line: Integration of Data-Driven Process Control for Maximization of Energy and Resource Efficiency in Advanced Water Resource Recovery Facilities

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2026

Development of a Digital Twin for Hydrogen Dispersion and Safety Assessment in an Electrolyzer-Based Hydrogen Production Facility: Preprint

Digital twin models are virtual representations of physical systems that use real-time data to simulate and optimize performance. This study presents the development and initial implementation of a digital twin (DT) for the electrolyzer-based hydrogen production facility at the National Renewable Energy Laboratory (NREL)'s Advanced Research on Integrated Energy Systems (ARIES), focused on enhancing safety and optimizing sensor placement through physics-based simulations and metadata integration. The DT incorporates detailed facility-specific information, including component layout, leak locations, and controlled release parameters, to model hydrogen dispersion under varying environmental conditions. Using steady-state computational fluid dynamics (CFD) simulations informed by real meteorological data, such as wind speed, direction, and vertical wind profiles, the DT enables visualization of hydrogen plume behavior and spatial concentration distributions. Comparative analysis between high and low wind speed scenarios illustrates the significant influence of wind dynamics on plume shape and extent, with horizontal momentum dominating dispersion at higher speeds, while buoyancy effects become more prominent under low wind conditions. These simulations generate a rich dataset embedded within the DT, allowing users to assess potential leak outcomes and identify optimal sensor locations based on concentration thresholds. The model supports scenario-based analysis to guide safety strategies and equipment deployment for open-area hydrogen infrastructure. The digital twin thus serves as a dynamic platform for virtual prototyping, providing predictive insight into hydrogen behavior and enhancing risk-informed decision-making. This initial phase establishes a validated foundation for future integration of transient, uncontrolled leak scenarios and real-time sensor feedback, positioning the DT as a critical tool for safety design, operational planning, and adaptive monitoring in hydrogen systems. Overall, the approach demonstrates the value of combining environmental data with digital simulations to inform safer and more efficient deployment of hydrogen technologies.

08 HYDROGEN↗

DOE OSTI2025

Development of a Digital Twin for Hydrogen Dispersion and Safety Assessment in an Electrolyzer Based Hydrogen Production Facility

Digital twin models are virtual representations of physical systems that use real-time data to simulate and optimize performance. This study presents the development and initial implementation of a digital twin (DT) for the electrolyzer-based hydrogen production facility at NREL's Advanced Research on Integrated Energy Systems (ARIES), focused on enhancing safety and optimizing sensor placement through physics-based simulations and metadata integration. The DT incorporates detailed facility-specific information, including component layout, leak locations, and controlled release parameters, to model hydrogen dispersion under varying environmental conditions. Using steady-state computational fluid dynamics (CFD) simulations informed by real meteorological data, such as wind speed, direction, and vertical wind profiles, the DT enables visualization of hydrogen plume behavior and spatial concentration distributions. Comparative analysis between high and low wind speed scenarios illustrates the significant influence of wind dynamics on plume shape and extent, with horizontal momentum dominating dispersion at higher speeds, while buoyancy effects become more prominent under low wind conditions. These simulations generate a rich dataset embedded within the DT, allowing users to assess potential leak outcomes and identify optimal sensor locations based on concentration thresholds. The model supports scenario-based analysis to guide safety strategies and equipment deployment for open-area hydrogen infrastructure. The digital twin thus serves as a dynamic platform for virtual prototyping, providing predictive insight into hydrogen behavior and enhancing risk-informed decision-making. This initial phase establishes a validated foundation for future integration of transient, uncontrolled leak scenarios and real-time sensor feedback, positioning the DT as a critical tool for safety design, operational planning, and adaptive monitoring in hydrogen systems. Overall, the approach demonstrates the value of combining environmental data with digital simulations to inform safer and more efficient deployment of hydrogen technologies.

08 HYDROGEN↗

DOE OSTI2022

Crossing the Finish Line: Integration of Data-Driven Process Control for Maximization of Energy and Resource Efficiency in Advanced Water Resource Recovery Facilities

Improvements in process monitoring and control at water resource recovery facilities (WRRFs) could result in reductions in electricity consumption, chemical inputs, and greenhouse gas emissions, as well as improved energy recovery. Many current WRRF data collection, monitoring, and control approaches use 20th century process monitoring and control systems, which require large design safety factors to ensure reliability in the absence of more advanced, precise controls. Implementation of more modern data-driven control tools could lead to more efficient operations that provide intrinsic reliability with better overall process performance at full-scale. This presentation provides an overview of a recently initiated project "Crossing the Finish Line: Integration of Data-Driven Process Control for Maximization of Energy and Resource Efficiency in Advanced Water Resource Recovery Facilities" which will (1) develop and demonstrate data-driven process controls at full-scale facilities for five promising WRRF Applications (i.e., process technologies) that provide whole-plant approaches and offer substantial energy and resource recovery benefits, and (2) create a toolbox of new process control approaches and an implementation guide including five examples for application at utilities. The presentation also provides a detailed overview of the research approach and progress being made on one of the five Applications, namely Application 2: Biological Nutrient Removal (BNR): ammonium-based aeration control (ABAC) / ammonia vs. NOx (AvN) + partial denitration with anammox (PdNA), which is being implemented at Hampton Roads Sanitation District. This project is a collaboration of work being conducted by DC Water, Hampton Roads Sanitation District, Metro Water Recovery, University of Michigan, Northwestern University, US Military Academy - West Point, Black & Veatch, and Oak Ridge National Laboratory. Research partner: U.S. Department of Energy.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2025

SMR Accelerated Development Needs with Adequate Safety

The development of advanced Small Modular Reactors (SMRs) is ongoing. A customer-focused development approach requires accelerated design and analysis of the reactor system while minimizing engineering, regulatory, and economic challenges. SMRs, although not a new concept, are being considered for rapid deployment with optimized economic scalability, and several designs are currently seeking approval. Understanding the research and development needs, with adequate safety support, accelerates reactor development.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2023

Genome-scale metabolic reconstruction of 7,302 human microorganisms for personalized medicine

The human microbiome influences the efficacy and safety of a wide variety of commonly prescribed drugs. Designing precision medicine approaches that incorporate microbial metabolism would require strain- and molecule-resolved, scalable computational modeling. Here, we extend our previous resource of genome-scale metabolic reconstructions of human gut microorganisms with a greatly expanded version. AGORA2 (assembly of gut organisms through reconstruction and analysis, version 2) accounts for 7,302 strains, includes strain-resolved drug degradation and biotransformation capabilities for 98 drugs, and was extensively curated based on comparative genomics and literature searches. The microbial reconstructions performed very well against three independently assembled experimental datasets with an accuracy of 0.72 to 0.84, surpassing other reconstruction resources and predicted known microbial drug transformations with an accuracy of 0.81. We demonstrate that AGORA2 enables personalized, strain-resolved modeling by predicting the drug conversion potential of the gut microbiomes from 616 patients with colorectal cancer and controls, which greatly varied between individuals and correlated with age, sex, body mass index and disease stages. AGORA2 serves as a knowledge base for the human microbiome and paves the way to personalized, predictive analysis of host–microbiome metabolic interactions.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2021

Challenges and needs for system-level electrochemical lithium-ion battery management and diagnostics

The desire for energy-dense and fast-charged battery technology in consumer-electronics, electric-vehicle, grid, and aviation applications is pushing the envelope on materials to cells and pack designs to use and operating conditions. However, some approaches could inherently decrease safety of the battery—thus requiring the development of advanced management and diagnostics. Safety of lithium-ion batteries (LiBs), particularly in multicell configurations, is highly variable and could evolve with use. Existing works primarily focus on cell life and safety diagnostics without considering module and pack-level uncertainties and sometimes imply that cell-level electrochemical diagnostics would work in modules or packs, a naive oversimplification. Using example case studies, we highlight the potential and challenges associated with extending single-cell diagnostics to multiple cells, note the challenge involved, and motivate the research and development and support communities to devote efforts to fill the gap by developing diagnostics at these levels for current- and future-generation LiBs.

25 ENERGY STORAGE↗

DOE OSTI2021

Regulatory Treatment of Low Frequency External Events under a Risk-Informed Performance-Based Licensing Pathway

Significant efforts are underway to develop and implement a risk-informed performance-based licensing framework for advanced reactors built on the establishment of an affirmative safety case. Such approaches offer the benefits of increased flexibility regarding key design and licensing decisions based on a detailed assessment and understanding of plant risk. These methods include the comprehensive analysis of scenarios that have historically been addressed through conservative and deterministic licensing analysis approaches, such as the evaluation of event sequences at frequencies of occurrence beyond the design basis. While the detailed analysis of low frequency events provides insights that can help justify alternative treatments to past conservatism, the findings are dependent on the quality and confidence associated with the analyses. The assessment of external hazards presents a unique challenge, as their potential frequency of occurrence, especially of large magnitude events, is inherently uncertain given the long return periods in question. The current project seeks to further explore the regulatory treatment of low frequency external events as part of a risk-informed performance-based framework. The goals are to identify the benefits and challenges of such approaches for advanced reactor vendors and to aid in the development of consistent and appropriate methodologies. As part of this effort, the current report summarizes initial project findings, with a focus on the evaluation of the seismic hazard. This includes an exploration of the implementation of a risk-informed performance-based approach through an example analysis. Based on the identified challenges associated with the probabilistic treatment of low frequency event sequences, additional performance-based methods were explored as complementary tools for demonstrating regulatory compliance. The report highlights key challenges and opportunities associated with the methods and outlines recommendations and future activities to assist with their implementation.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2024

Regulatory Treatment of Low Frequency External Events under a Risk-Informed Performance-Based Licensing Pathway: Safety Criteria Evaluation

There has been recent progress in the development of risk-informed performance-based (RIPB) design and licensing approaches, which leverage the insights gained from detailed risk assessments and utilize performance-based metrics to permit flexibility and innovation. The RIPB approaches have included the probabilistic treatment of external hazards, including low frequency events that are beyond the design basis. A preceding study conducted in FY21 noted that there are certain challenges to the probabilistic treatment of low frequency external events, which are primarily the result of uncertainty in the hazard curve and the associated plant response to rare, severe events. The current work expands on the previous study by examining the regulatory safety criteria contained within draft 10 CFR Part 53 and associated draft RIPB seismic design guidance. The evaluation identified potential challenges in demonstrating satisfaction of the safety criteria for low frequency external events, with specific difficulties associated with demonstrating compliance with cumulative safety criteria metrics, such as the quantitative health objectives (QHOs). Non-LWRs are expected to utilize the direct calculation of offsite consequence, rather than use surrogates, for comparison to the QHOs, which can be particularly challenging as the previously identified uncertainties are compounded by uncertainties in the response of the neighboring population. The current work details this evaluation and key findings. The central recommendation from this effort is that it is necessary to develop an approach for demonstrating compliance with the safety criteria in draft Part 53 that addresses the key challenges while providing flexibility to applicants.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2025

CFD Simulations of Lower Plenum Mixing

Review of model development and validation performed in the Advanced Reactor Technologies (ART) program for thermal mixing at the outlet of High Temperature Gas Reactors (HTGRs). Understanding the mixing that occurs in the lower plenum in an HTGR is necessary to facilitate design improvements and to perform reactor safety analysis. Numerical models are one possible approach to gain a better understanding of mixing in the lower plenum. Given the complexity of the geometry and the intense mixing present, it is important to perform validation of numerical models. Three models have been developed during FY2025: a porous media with Pronghorn, a Reynolds Averaged Navier Stokes (RANS) with STAR-CCM+, and a Large Eddy Simulation (LES) with NekRS. The reference facility is a scaled-down version of the lower plenum of the High Temperature Gas-Cooled Reactor - Pebble-bed Module (HTR-PM) demonstration reactor. Preliminary results of the porous media and the RANS shows general good agreement against experimental benchmark data. Future work will leverage high-fidelity results obtained through LES to guide model selection and improvements to the lower-fidelity models, with particular attention to the Pronghorn porous media.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2022

MODULARITY-AT-SCALE FOR COST COMPETITIVE DEPLOYMENT OF NUCLEAR ENERGY

Modularity options have been limited for traditional nuclear energy deployment due to the conventional light water reactor (LWR) safety requirements, such as high pressure retaining heavy and robust containment structures. However, a relatively new regulatory approach called ‘Functional Containment’ has potential to allow less expensive and more flexible designs for non LWRs. Functional containment provides flexibility in design and deployment based on risk informed and performance-based criteria, so that reactors are not over-designed. Non-nuclear industry has successfully used modular design approaches in automotive, aerospace, chemical processing, building construction, and ship building. These industries have shown that modular construction reduces construction time by around 30% - 50% compared to the conventional stick built approach. The nuclear industry can use similar approaches to reduce construction time and costs, balanced with safety requirements, using the functional containment approach. This paper discussing the background of modularity in nuclear energy, examples of less learned, modularity approaches in non-nuclear industries and the potential of cost and schedule savings through the emerging regulatory design flexibilities potentially enabling combination of modular deployment at different scales.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2022

Modularity-at-scale for advanced reactors presentation

Modularity options have been limited for traditional nuclear energy deployment due to the conventional light water reactor (LWR) safety requirements, such as high pressure retaining heavy and robust containment structures. However, a relatively new regulatory approach called ‘Functional Containment’ has potential to allow less expensive and more flexible designs for non-LWRs. Functional containment provides flexibility in design and deployment based on risk-informed and performance-based criteria, so that reactors are not over-designed. Non-nuclear industry has successfully used modular design approaches in automotive, aerospace, chemical processing, building construction, and ship building. These industries have shown that modular construction reduces construction time by around 30% - 50% compared to the conventional stick-built approach. The nuclear industry can use similar approaches to reduce construction time and costs, balanced with safety requirements, using the functional containment approach. This paper discussing the background of modularity in nuclear energy, examples of less learned, modularity approaches in non-nuclear industries and the potential of cost and schedule savings through the emerging regulatory design flexibilities potentially enabling combination of modular deployment at different scales.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2023

An Integrated Framework for Risk Assessment of Safety-related Digital Instrumentation and Control Systems in Nuclear Power Plants: Methodology Refinement and Exploration

This report documents activities performed by Idaho National Laboratory (INL) during Fiscal Year (FY) 2023 for the U.S. Department of Energy (DOE) Light Water Reactor Sustainability (LWRS) Program, Risk Informed Systems Analysis (RISA) Pathway, digital instrumentation and control (DI&C) risk assessment project. In FY 2019, the RISA Pathway initiated a project to develop a risk assessment strategy for delivering a technical basis to support effective, and secure DI&C technologies for digital upgrades/designs. A risk assessment-informed framework was proposed for this strategy, which aims to (1) provide a best-estimate, risk informed capability to quantitatively estimate the safety margin obtained from plant modernization, especially for safety-related DI&C systems, (2) support and supplement existing risk informed DI&C design guides by providing quantitative risk information and evidence, (3) offer a capability of design architecture evaluation of various DI&C systems, (4) assure the long-term safety and reliability of safety-related DI&C systems, and (5) reduce uncertainty in costs and support integration of DI&C systems in the plant. To achieve these technical goals, the LWRS-developed framework provides a means to address relevant technical issues by: (1) defining a risk informed analysis process for DI&C upgrade that integrates hazard analysis, reliability analysis, and consequence analysis, (2) applying risk informed tools to address common cause failures (CCFs) and quantify corresponding failure probabilities for DI&C technologies, particularly software CCFs, (3) evaluating the impact of digital failures at the component level, system level, and plant level, and (4) providing insights and suggestions on designs to manage the risks, thus to support the development and deployment of advanced DI&C technologies in nuclear power plants (NPPs). Adding diversity within a system or components is the primary means to eliminate and mitigate CCFs, but diversity also increases system complexity and may not address all sources of systematic failures. Optimization of diversity and redundancy applications for the safety-critical DI&C systems remains a challenge. To deal with the technical issues in addressing potential software CCFs in safety-related DI&C systems of NPPs and supporting relevant design optimization, the proposed framework provides: (a) A best-estimate, risk informed capability to address new technical digital issues quantitatively, focusing on software CCFs in safety-related DI&C systems of NPPs; (b) A common and a modularized platform for DI&C designers, software developers, cybersecurity analysts, and plant engineers to predict and prevent risk in the early design stage of DI&C systems; (c) Technical bases and risk informed insights to assist users address the risk informed alternatives for evaluation of CCFs in safety-related DI&C systems of NPPs; and (d) A risk informed tool that offers a capability of design architecture evaluation of various DI&C systems to support system design decisions in diversity and redundancy applications. The research and development efforts of this project in FY 2023 are focused on refining current methods on software CCF modeling and estimation and exploring additional innovative approaches to risk assessment of DI&C systems to enable a more comprehensive and complete assessment of various safety-related DI&C design architectures. The primary audience of this report are DI&C designers, engineers, and probabilistic risk assessment (PRA) practitioners. This includes stakeholders, such as the nuclear utilities and regulators who consider the deployment and upgrade of DI&C systems, DI&C software developers and reviewers, and cybersecurity specialists. It should be noted that all the analyses are performed for the demonstration of the methodology, not for the evaluation of an actual digital control system. Results are obtained based on limited design information and testing data.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗