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NASA NTRS2012

Development and Analysis of Cold Trap for Use in Fission Surface Power-Primary Test Circuit

The design and analysis of a cold trap proposed for use in the purification of circulated eutectic sodium potassium (NaK-78) loops is presented. The cold trap is designed to be incorporated into the Fission Surface Power-Primary Test Circuit (FSP-PTC), which incorporates a pumped NaK loop to simulate in-space nuclear reactor-based technology using non-nuclear test methodology as developed by the Early Flight Fission-Test Facility. The FSP-PTC provides a test circuit for the development of fission surface power technology. This system operates at temperatures that would be similar to those found in a reactor (500-800 K). By dropping the operating temperature of a specified percentage of NaK flow through a bypass containing a forced circulation cold trap, the NaK purity level can be increased by precipitating oxides from the NaK and capturing them within the cold trap. This would prevent recirculation of these oxides back through the system, which may help prevent corrosion.

Wolfe, T. M.↗

NASA NTRS2005

Method for Determination of Less Than 5 ppm Oxygen in Sodium Samples

Alkali metals used in pumped loops or heat pipes must be sufficiently free of nonmetallic impurities to ensure long heat rejection system life. Life issues are well established for alkali metal systems. Impurities can form ternary compounds between the container and working fluid, leading to corrosion. This Technical Memorandum discusses the consequences of impurities and candidate measurement techniques to determine whether impurities have been reduced to suf.ciently low levels within a single-phase liquid metal loop or a closed two-phase heat transfer system, such as a heat pipe. These techniques include the vanadium wire equilibration, neutron activation analysis, plug traps, distillation, and chemical analysis. Conceptual procedures for performing vanadium wire equilibration purity measurements on sodium contained in a heat pipe are discussed in detail.

Reid, R. S.↗

NASA NTRS2011

Fission Surface Power Technology Development Update

Power is a critical consideration in planning exploration of the surfaces of the Moon, Mars, and places beyond. Nuclear power is an important option, especially for locations in the solar system where sunlight is limited or environmental conditions are challenging (e.g., extreme cold, dust storms). NASA and the Department of Energy are maintaining the option for fission surface power for the Moon and Mars by developing and demonstrating technology for a fission surface power system. The Fission Surface Power Systems project has focused on subscale component and subsystem demonstrations to address the feasibility of a low-risk, low-cost approach to space nuclear power for surface missions. Laboratory demonstrations of the liquid metal pump, reactor control drum drive, power conversion, heat rejection, and power management and distribution technologies have validated that the fundamental characteristics and performance of these components and subsystems are consistent with a Fission Surface Power preliminary reference concept. In addition, subscale versions of a non-nuclear reactor simulator, using electric resistance heating in place of the reactor fuel, have been built and operated with liquid metal sodium-potassium and helium/xenon gas heat transfer loops, demonstrating the viability of establishing system-level performance and characteristics of fission surface power technologies without requiring a nuclear reactor. While some component and subsystem testing will continue through 2011 and beyond, the results to date provide sufficient confidence to proceed with system level technology readiness demonstration. To demonstrate the system level readiness of fission surface power in an operationally relevant environment (the primary goal of the Fission Surface Power Systems project), a full scale, 1/4 power Technology Demonstration Unit (TDU) is under development. The TDU will consist of a non-nuclear reactor simulator, a sodium-potassium heat transfer loop, a power conversion unit with electrical controls, and a heat rejection system with a multi-panel radiator assembly. Testing is planned at the Glenn Research Center Vacuum Facility 6 starting in 2012, with vacuum and liquid-nitrogen cold walls to provide simulation of operationally relevant environments. A nominal two-year test campaign is planned including a Phase 1 reactor simulator and power conversion test followed by a Phase 2 integrated system test with radiator panel heat rejection. The testing is expected to demonstrate the readiness and availability of fission surface power as a viable power system option for NASA's exploration needs. In addition to surface power, technology development work within this project is also directly applicable to in-space fission power and propulsion systems.

Palac, Donald T.↗

NASA NTRS1997

STS 87: Meal - Suit Up - Depart O&C - Launch Columbia On Orbit - Landing - Crew Egress

The STS-87 Space Shuttle Columbia mission begins with the introduction of the seven crew members. The seven crew members include: Commander Kevin R. Kregel, pilot Steven W. Lindsey, mission specialists: Winston E. Scott, Kalpana Chawla and Takao Doi and payload specialist Leonid K. Kadenyuk. The United States Microgravity Payload (USMP-4), Orbital Acceleration Research Experiment (OARE), the EVA Demonstration Flight Test 5 (EDFT-05), Shuttle Ozone Limb Sending Experiment (SOLSE), Loop Heat Pump (LHP), and Sodium Sulfur Battery Experiment (NaSBE) were all shown during this video presentation. The launch of the STS-87 from different Kennedy Space Flight Center (KSFC) areas and Pre-flight training at the Johnson Space Center is presented. The retrieve and recovery spot satellite are also shown. Also, the landing of the Space Shuttle Columbia is presented from different areas at Kennedy Space Flight Center.

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NASA NTRS2005

Heat Rejection Concepts for Brayton Power Conversion Systems

This paper describes potential heat rejection design concepts for closed Brayton cycle (CBC) power conversion systems. Brayton conversion systems are currently under study by NASA for Nuclear Electric Propulsion (NEP) applications. The Heat Rejection Subsystem (HRS) must dissipate waste heat generated by the power conversion system due to inefficiencies in the thermal-to-electric conversion process. Space Brayton conversion system designs tend to optimize at efficiencies of about 20 to 25 percent with radiator temperatures in the 400 to 600 K range. A notional HRS was developed for a 100 kWe-class Brayton power system that uses a pumped sodium-potassium (NaK) heat transport loop coupled to a water heat pipe radiator. The radiator panels employ a sandwich construction consisting of regularly-spaced circular heat pipes contained within two composite facesheets. Heat transfer from the NaK fluid to the heat pipes is accomplished by inserting the evaporator sections into the NaK duct channel. The paper evaluates various design parameters including heat pipe diameter, heat pipe spacing, and facesheet thickness. Parameters were varied to compare design options on the basis of NaK pump pressure rise and required power, heat pipe unit power and radial flux, radiator panel areal mass, and overall HRS mass.

Siamidis, John↗

NASA NTRS2005

Design and Off-design Performance of 100 Kwe-class Brayton Power Conversion Systems

The NASA Glenn Research Center in-house computer model Closed Cycle Engine Program (CCEP) was used to explore the design trade space and off-design performance characteristics of 100 kWe-class recuperated Closed Brayton Cycle (CBC) power conversion systems. Input variables for a potential design point included the number of operating units (1, 2, 4), cycle peak pressure (0.5, 1, 2 MPa), and turbo-alternator shaft speed (30, 45, 60 kRPM). The design point analysis assumed a fixed turbine inlet temperature (1150 K), compressor inlet temperature (400 K), working-fluid molecular weight (40 g/mol), compressor pressure ratio (2.0), recuperator effectiveness (0.95), and a Sodium-Potassium (NaK) pumped-loop radiator. The design point options were compared on the basis of thermal input power, radiator area, and mass. For a nominal design point with defined Brayton components and radiator area, off-design cases were examined by reducing turbine inlet temperature (as low as 900 K), reducing shaft speed (as low as 50% of nominal), and circulating a percentage (up to 20%) of the compressor exit flow back to the gas cooler. The off-design examination sought approaches to reduce thermal input power without freezing the radiator.

Johnson, Paul K.↗

NASA NTRS2005

Design and Off-Design Performance of 100 kWe-Class Brayton Power Conversion Systems

The NASA Glenn Research Center in-house computer model Closed Cycle Engine Program (CCEP) was used to explore the design trade space and off-design performance characteristics of 100 kWe-class recuperated Closed Brayton Cycle (CBC) power conversion systems. Input variables for a potential design point included the number of operating units (1, 2, 4), cycle peak pressure (0.5, 1, 2 MPa), and turbo-alternator shaft speed (30, 45, 60 kRPM). The design point analysis assumed a fixed turbine inlet temperature (1150 K), compressor inlet temperature (400 K), helium-xenon working-fluid molecular weight (40 g/mol), compressor pressure ratio (2.0), recuperator effectiveness (0.95), and a Sodium-Potassium (NaK) pumped-loop radiator. The design point options were compared on the basis of thermal input power, radiator area, and mass. For a nominal design point with defined Brayton components and radiator area, off-design cases were examined by reducing turbine inlet temperature (as low as 900 K), reducing shaft speed (as low as 50 percent of nominal), and circulating a percentage (up to 20 percent) of the compressor exit flow back to the gas cooler. The off-design examination sought approaches to reduce thermal input power without freezing the radiator.

Johnson, Paul K.↗

DOE OSTI2025

Refining NEAMS MARVEL Reactor Model Accuracy

This report outlines the progress of Idaho National Laboratory (INL) in improving the fidelity of the multiphysics model of the Microreactor Applications Research Validation and Evaluation (MARVEL) reactor developed in FY24. The multiphysics model firstly developed in FY24 leverages three single-physics models coupled via the MOOSE’s MultiApps and Transfer systems. The first single-physics model, that functions as the driver application, leverages Griffin to model the neutron transport in the core through the discontinuous finite element (DFEM) discrete ordinates solver (SN). The second single-physics model uses BISON to compute the solid temperature in the reactor. Finally, the System Analysis Module (SAM) was used to model the flow of the sodium-potassium eutectic in the primary loop. In this report we detail the following improvement and enhancements: • An updated mesh leveraging the latest feature in the reactor module (see Section 3.1.).

42 - ENGINEERING↗

NASA NTRS2011

Test Results From a Pair of 1-kWe Dual-Opposed Free-Piston Stirling Power Convertors Integrated With a Pumped NaK Loop

As a step towards development of Stirling power conversion for potential use in Fission Surface Power (FSP) systems, a pair of commercially available 1-kW-class free-piston Stirling convertors were modified to operate with a NaK (sodium (Na) and potassium (K)) liquid metal pumped loop for thermal energy input. This was the first-ever attempt at powering a free-piston Stirling engine with a pumped liquid metal heat source and is a major FSP project milestone towards demonstrating technical feasibility. The convertors were successfully tested at the Marshall Space Flight Center (MSFC) from June 6 through July 14, 2009. The convertors were operated for a total test time of 66 hr and 16 min. The tests included (a) performance mapping the convertors over various hot- and cold-end temperatures, piston amplitudes, and NaK flow rates and (b) transient test conditions to simulate various startup (i.e., low-, medium-, and high-temperature startups) and fault scenarios (i.e., loss of heat source, loss of NaK pump, convertor stall, etc.). This report documents the results of this testing

Geng, Steven M.↗

DOE OSTI2025

Thermal Hydraulic Experimental Test Article: Second Year of Testing with Secondary Sodium System (Fiscal Year 2025 Final Report)

The Thermal Hydraulic Experimental Test Article (THETA) is currently installed in the Mechanisms Engineering Test Loop (METL) 28” test vessel #4. Both the primary and secondary sodium systems remain online to facilitate continued testing. This fiscal year, work was performed using a COMSOL Multiphysics magnetohydrodynamic model to characterize flow more accurately in the secondary electromagnetic flowmeters. Experimental campaigns were then performed to study the thermal hydraulic differences between sodium and water as a surrogate fluid in the THETA geometry as well as a study to better characterize and understand temperature oscillations that exist at the outlet of the core to the hot pool. A peer-reviewed article was published in the ASME Journal of Nuclear Engineering and Radiation Science detailing the THETA facility and providing an overview of a test that was performed with the primary and secondary system online [1]. Work continues to develop a database to house experimental THETA data to better facilitate collaboration with industry and laboratory partners for their use of the data for code benchmarking/validation. THETA remains fully operational and is positioned for continued testing in fiscal year 2026.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2025

Design and Analysis of a Mutual Inductance Level Sensor for Liquid Metals

Here, this article describes the design and analysis of an electromagnetic level sensor for use in high-temperature liquid metal systems. The mutual inductance level sensor (MILS) described in this work was fabricated using two single-conductor mineral insulated cables wrapped in a bifilar fashion around a stainless steel tube core and was housed in an isolating thimble that preserved the pressure boundary of the test vessel. Two sensor variations were fabricated that differ only in active length, 1016 and 1778 mm. Experimental data were collected using the 1016-mm sensor (MILS-MKII-040) that demonstrated a sensitivity of 9.2 μ V/mm in a room temperature testing stand that used solid aluminum as a surrogate for liquid metal. Experimental data were collected using the 1778-mm sensor (MILS-MKII-070) that demonstrated a sensitivity of 6.9 μ V/mm in the high-temperature (300 ° C) liquid sodium environment at the mechanisms engineering test loop (METL) of Argonne National Laboratory. The sensor performance was found to be repeatable over the course of several months, with roughly ±1% deviation from nominal output. Finite element models were developed in COMSOL Multiphysics that fully describe each test setup, and the models were validated using experimental data. The validated COMSOL models were used to perform an array of analyses that examined the performance of the sensor in differing environments. Maximizing the coil diameter inside the isolating thimble was found to maximize the signal and sensitivity of the sensor. An optimal operating frequency was found near 1000 Hz using both experimental data and COMSOL. The influence of a metallic thimble surrounding the sensor and a metallic sensor core was quantified and found to be negligible at the optimal operating frequency. The sensitivity of the sensor was quantified when monitoring the level of additional liquid metals. These include lead, lead-bismuth eutectic (LBE), sodium-potassium alloy (NaK), and lithium (in addition to sodium). The sensitivities were quantified using liquid metal properties at 350 ° C and 650 ° C. The geometry of the test stand model, all material properties used in the model, and the results are presented in a manner that allows the reader can replicate the model and perform additional analyses.

COMSOL↗

NASA NTRS2011

Design of a Mechanical NaK Pump for Fission Space Power

Alkali liquid metal cooled fission reactor concepts are under development for spaceflight power requirements. One such concept utilizes a sodium-potassium eutectic (NaK) as the primary loop working fluid, which has specific pumping requirements. Traditionally, electromagnetic linear induction pumps have been used to provide the required flow and pressure head conditions for NaK systems but they can be limited in performance, efficiency, and number of available vendors. The objective of the project was to develop a mechanical NaK centrifugal pump that takes advantages of technology advances not available in previous liquid metal mechanical pump designs. This paper details the design, build, and performance test of a mechanical NaK pump developed at NASA Marshall Space Flight Center. The pump was designed to meet reactor cooling requirements using commercially available components modified for high temperature NaK service.

Mireles, Omar R.↗

NASA NTRS2010

Design of a Mechanical NaK Pump for Fission Space Power Systems

Alkali liquid metal cooled fission reactor concepts are under development for mid-range spaceflight power requirements. One such concept utilizes a sodium-potassium eutectic (NaK) as the primary loop working fluid. Traditionally, linear induction pumps have been used to provide the required flow and head conditions for liquid metal systems but can be limited in performance. This paper details the design, build, and check-out test of a mechanical NaK pump. The pump was designed to meet reactor cooling requirements using commercially available components modified for high temperature NaK service.

Mireles, Omar R.↗

DOE OSTI2025

Biogenic carbon capture at pulp mills via sodium spiking and oxy-fuel calcination

Over 13 million metric tons of biogenic carbon dioxide (CO 2 ) are mineralized yearly in United States (US) pulp mill recovery boilers as molten sodium carbonate. The mineralized CO 2 is released downstream in the rotary lime kiln where it can be captured at a relatively low cost for permanent sequestration. The use of biocarbon and bioenergy at pulp mills enables the possibility for atmospheric carbon removal when biogenic CO2 is captured and sequestered. We demonstrate the feasibility of capturing biogenic CO 2 via sodium spiking coupled with oxy-fuel calcination in the rotary lime kiln at existing kraft pulp mills. Sodium (Na) spiking elevates the Na ion loading in the kraft chemical looping process by replacing chlorine-based bleaching with a highly alkaline bleaching sequence. Chemical pulping processes are modeled and simulated to understand the technical limits of implementing sodium spiking in existing pulp mills. Each 1 % of sodium added to the bleaching operations increases the rate of CO 2 mineralization by 4 %, and the maximum increase in sodium content in the kraft process is 9 %. Without sodium spiking, estimated CO 2 capture costs are $131 and $107/mt CO 2 for air and oxy-fuel combustion, respectively. With the implementation of sodium spiking, the cost of CO 2 captured decreases by 27 % and 31 %, showing costs of $96 and $74/mt CO 2 for air and oxy-fuel combustion, respectively. Oxy-fuel combustion reduces the costs of CO 2 capture compared to air combustion, but merged deployment with sodium spiking seems to be the most cost-effective pathway to integrate carbon capture.

60 APPLIED LIFE SCIENCES↗

NASA NTRS1971

Potassium Rankine cycle vapor chamber (heat pipe) radiator study

A structurally integrated vapor chamber fin (heat pipe) radiator is defined and evaluated as a potential candidate for rejecting waste heat from the potassium Rankine cycle powerplant. Several vapor chamber fin geometries, using stainless steel construction, are evaluated and an optimum is selected. A comparison is made with an operationally equivalent conduction fin radiator. Both radiators employ NaK-78 in the primary coolant loop. In addition, the Vapor Chamber Fin (VCF) radiator utilizes sodium in the vapor chambers. Preliminary designs are developed for the conduction fin and VCF concepts. Performance tests on a single vapor chamber were conducted to verify the VCF design. A comparison shows the conduction fin radiator easier to fabricate, but heavier in weight, particularly as meteoroid protection requirements become more stringent. While the analysis was performed assuming the potassium Rankine cycle powerplant, the results are equally applicable to any system radiating heat to space in the 900 to 1400 F temperature range.

Gerrels, E. E.↗

NASA NTRS1972

Vapor chamber fin radiator study for the potassium Rankine cycle.

Gerrels, E. E.↗

DOE OSTI2025

Loss of Flow Conditions in a Modern Pool-type SFR and In-Pile Experiment Design

The metallic fuel safety performance under unprotected design-basis transients is a key consideration for the deployment of advanced sodium fast reactors (SFRs). Reliable data are needed to validate advanced safety codes, reduce uncertainty in cladding failure thresholds, and strengthen confidence in licensing approaches. To address this need, this report develops blueprints for a conceptual sodium loss-of-flow (LOF) experiment in the Mk-IIIR loop at the Transient Reactor Test Facility (TREAT), providing the technical foundation for future integral testing.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS1971

SNAP-8 electrical generating system development program

The SNAP-8 program has developed the technology base for one class of multikilowatt dynamic space power systems. Electrical power is generated by a turbine-alternator in a mercury Rankine-cycle loop to which heat is transferred and removed by means of sodium-potassium eutectic alloy subsystems. Final system overall criteria include a five-year operating life, restartability, man rating, and deliverable power in the 90 kWe range. The basic technology was demonstrated by more than 400,000 hours of major component endurance testing and numerous startup and shutdown cycles. A test system, comprised of developed components, delivered up to 35 kWe for a period exceeding 12,000 hours. The SNAP-8 system baseline is considered to have achieved a level of technology suitable for final application development for long-term multikilowatt space missions.

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