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At least 397 records · Page 22

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DOE OSTI2022

FAST-1.1: Integral Assessment

An integral assessment has been performed to quantify the predictive capabilities of FAST, a thermal-mechanical nuclear fuel performance code designed to analyze fuel behavior from beginning of life to burnup levels allowed by the U.S. Nuclear Regulatory Commission (NRC). FAST code calculations are shown to compare satisfactorily to a preselected set of experimental data with both steady-state and anticipated operating occurrence (AOO) conditions and design basis accident (DBA) transient operating conditions. This document describes the assessment of FAST-1.1, the latest version of FAST, released April 2022. Abstract

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2023

FAST-1.2: Integral Assessment

An integral assessment has been performed to quantify the predictive capabilities of FAST, a thermal-mechanical nuclear fuel performance code designed to analyze fuel behavior from beginning of life to burnup levels allowed by the U.S. Nuclear Regulatory Commission (NRC). FAST code calculations are shown to compare satisfactorily to a preselected set of experimental data with both steady-state and anticipated operating occurrence (AOO) conditions and design basis accident (DBA) transient operating conditions. This document describes the assessment of FAST-1.2, the latest version of FAST, released March 2023.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2022

Design and Implementation of Automated Characterization of T-type based Power Module for PV Inverter Reliability Assessment

Reliability of power electronics holds the key for future power and energy systems since it is essential for system integration with renewables and energy storage systems. Variation of power module characteristics over the converter’s operational lifetime is a critical indicator to assess its reliability. Device characterization consists of different steps to collect, process, and visualize results, which is usually time-consuming, especially for power modules based on a non-phase-leg configuration, such as T-type circuits, widely applied for PV inverters. To reduce the time, ensure repeatability, and guarantee consistency, an automated test bench can be helpful. This paper focuses on a T-type-based power module and proposes a unique characterization platform and corresponding automation procedure and implementation. Considering the major characterization difference between T-type power modules over the conventional phase-leg power module, first, the special consideration for static characterization is highlighted. Second, the unique dynamic characterization design associated with the T-type power module is described. Finally, the automation of the power module characterization and the test platform is presented along with results and special considerations.

Siraj, Ahmed↗

DOE OSTI2023

Understanding the Uncertainty in the Technical Performance Level Assessment for Wave Energy

In recent years, the design and development of wave energy converters (WECs) has been explored with intense interest, with highly varying design concepts emerging globally across both research enterprises and industry. The design space for WECs is vast - many concepts ranging in functionality, control systems, power development systems, materials, and scale have been ideated and prototyped, but WEC technology has yet to converge. One critical element of the technology trajectory that governs the speed of adoption is the performance of a WEC concept. In analogous but more-established industries (such as aerospace, and environmentally sustainable electronics design), performance assessment is a quantitative method, based on historical data, that is used as an iterative tool to improve the design of these systems early on in the design process. Though more nascent than these approaches, in wave energy R&D, WEC performance has been assessed using the Technology Performance Level (TPL) assessment, which provides designers with a quantitative score, situating a grid-scale WEC concept on a scale from 1-9 (1 being the lowest performance, and 9 being the highest, trending with the oft-used Technology Readiness Level, or TRL). The TPL assessment is designed to be used during design iteration, when a WEC concept is fully ideated, to enable designers to consider potential means of improving the downstream performance of the concept. One concern that may be slowing the adoption of TPL among WEC developers is the inherent uncertainty in the assessment, and how uncertainty in the individual questions asked as part of the assessment may contribute to perceived inaccuracies in the final score. In this work, we explore the uncertainty present in the assessment and quantify this uncertainty using both traditional mathematical operations and a Monte Carlo simulation. Results imply areas of improvement of the TPL assessment, where reducing uncertainty will be most helpful to end users, enabling both TPL practitioners and users to understand with more accuracy those design elements that can be improved to impact device performance most substantively.

techno-economic analysis↗

DOE OSTI2025

A quantitative risk assessment framework for fault reactivation in underground hydrogen storage: Coupled simulation and deep learning approach

Underground hydrogen storage (UHS) is emerging as a critical solution for large-scale energy storage. However, like all subsurface fluid injection activities, UHS poses the risk of injection-induced fault reactivation. Accurate risk assessment is essential to ensuring the safety and efficiency of UHS operations. This study presents the development of deep-learning surrogate models for fault reactivation prediction in UHS, trained on a comprehensive database of fully coupled fluid flow-geomechanics simulations. Our findings reveal that analytical models often yield unreliable estimates, with errors up to 54% in the allowable injection pressure, potentially leading to a 40% reduction in UHS operational capacity. The developed surrogate models were incorporated into a quantitative risk assessment (QRA) framework, enabling probabilistic evaluation of fault reactivation risk while accounting for uncertainties in the input variables. Site-specific features, such as horizontal stress gradients, fault’s dip and strike angles, and operational parameters like bottom-hole injection pressure and well-fault distance, were identified as the primary drivers of fault reactivation across various stress regimes. Whereas other hydraulic, geological, and poroelastic reservoir properties were found to have a secondary impact. Notably, we observed that the risk of fault reactivation for a critically oriented fault with a static friction coefficient greater than 0.55 remains below 10% in a normal faulting stress regime. However, the risk significantly increases as the stress regime transitions from normal to strike-slip and ultimately to reverse faulting conditions. These findings underscore the importance of rigorous site characterization and comprehensive QRA evaluations to optimize UHS performance and minimize geomechanical risks.

25 ENERGY STORAGE↗

DOE OSTI2026

FAST-1.2.2: Integral Assessment

This integral assessment quantifies the predictive capabilities of Fuel Analysis under Steady-state and Transients (FAST), a thermal-mechanical nuclear fuel performance code designed to analyze fuel behavior from beginning of life to burnup levels allowed by the U.S. Nuclear Regulatory Commission. FAST code calculations are shown to compare satisfactorily to a pre-selected set of experimental data with both steady-state and anticipated operating occurrence conditions and design basis accident transient operating conditions. This document describes the assessment of FAST-1.2.2, the latest version of FAST, released April 2026.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2021

Investigation of post-injection strategies for diesel engine Catalyst Heating Operation using a vapor-liquid-equilibrium-based spray model

Most multidimensional engine simulations spend much time solving for non-equilibrium spray dynamics (atomization, collision, vaporization). However, their accuracy is limited by significant grid dependency, and the need for extensive calibration. This is critical for modeling cold-start diesel fuel post injections, which occur at low temperatures and pressures, far from typical model validation ranges. At the same time, resolving micron-scale spray phenomena would render full Eulerian multiphase calculations prohibitive. In this study, an improved phase equilibrium based approach was implemented and assessed for simulating diesel catalyst heating operation strategies. A phase equilibrium solver based on the model by Yue and Reitz [1] was implemented: a fully multiphase CFD solver is employed with an engineering-size engine grid, and fuel injection is modeled using the standard Lagrangian parcels approach. Mass and energy from the liquid parcels are released to the Eulerian multiphase mixture according to an equilibrium-based liquid jet model. An improved phase equilibrium solver was developed to handle large real-gas mixtures such as those from accurate chemical kinetics mechanisms. The liquid-jet model was improved such that momentum transfer to the Eulerian solver better reproduces the physical spray jet structure. Validation of liquid/vapor penetration predictions showed that the model yields accurate results with very limited tuning and low sensitivity to the few calibration constants. In-cylinder simulations of diesel catalyst heating operation strategies showed that capturing spray structure is paramount when short, transient injection pulses and low temperatures are present. Furthermore, the EP model provides improved predictions of post-injection spray structure and ignitability, while conventional spray modeling does not capture the increase of liquid penetration during the expansion stroke. Finally, the only important EP model calibration constant, Cliq, does not affect momentum transfer, but it changes the local charge cooling distribution through the local energy transfer, which makes it candidate to additional research. The results confirm that non-equilibrium spray processes do not need to be resolved in engineering simulations of high-pressure diesel sprays.

42 ENGINEERING↗

DOE OSTI2023

Populating the Hydrogen Component Reliability Database (HYCRED) with Incident Data from Hydrogen Dispensing

Safety, risk, and reliability issues are vital to ensure the continuous and profitable operation of hydrogen technologies. Quantitative risk assessment (QRA) has been used to enable the safe deployment of engineering systems, especially hydrogen fueling stations. However, QRA studies require reliability data which are essential to collect to make the studies as realistic and relevant as possible. These data are currently lacking and data from other industries, such as oil and gas, are used in hydrogen system QRAs. This may lead to inaccurate results since hydrogen fueling stations have differences in physical properties, system design, and operational parameters when compared to other fueling stations, thus necessitating new data sources are necessary to capture the effects of these differences. To address this gap, we developed a structure for a hydrogen component reliability database, (HyCReD) [1], which could be used to generate reliability data to be used in QRA studies. In this paper, we demonstrate populating the HyCReD database with information extracted from new narrative reports on hydrogen fueling station incidents, specifically focused on the dispensing processes. We analyze five new events and demonstrate the feasibility of populating the database and types of meaningful insights that can be obtained at this stage.

component reliability↗

DOE OSTI2024

Wind Turbine Maintenance Costs: Assessing the Potential of Gear Oil Improvements

Wind turbine operations & maintenance (O&M) costs constitute a sizable portion of total energy cost for wind power. There are many components in a utility-scale wind turbine that need to be lubricated with either oil or grease. This study uses gearbox oil as an example and assesses how lubricant technology improvements may impact wind turbine power production and levelized cost of energy. Using the modeling tools (i.e., WOMBAT, reV, and SAM) developed at National Renewable Energy Laboratory and lubrication oil technology scenarios defined based on inputs provided by ExxonMobil and industry stakeholders, we quantify the potential for increasing energy production and reducing maintenance costs across the current and future U.S. fleet of wind turbines as a result of improvements in lubrication technologies. The modeled improvements reduce the median levelized cost of energy by 1-2% across the U.S. fleet. Cumulative saving from gear oil technology improvements in 2050 for U.S. fleet is estimated to be approximately $6 billion. Extending the lubricant replacement interval has a larger impact on total cost and energy production than reducing lubricant cost.

costs↗

DOE OSTI2023

Standard Operating Procedure for Optimal Deployment of Meteorological Instrumentation Within the Solar Radiation Research Laboratory (BMS and RMS SOP)

The objective of the National Renewable Energy Laboratory's (NREL's) Solar Radiation Research Laboratory (SRRL) is to collect and use high-quality solar radiation data sets for research leading to the widespread adoption of solar technologies. To appropriately populate and track the diverse array of instruments at the NREL-SRRL, NREL has established a Standard Operating Procedure (SOP) for optimal instrument deployment within the SRRL for both the Baseline Measurement System (BMS) and the Research Measurement System (RMS). Using best practices methodologies, the NREL-SRRL maintains a varied and extensive array of solar monitoring equipment to test, evaluate, and characterize the solar sensors used by federal and international agencies as well as the solar industry to determine the solar resource. The SOP provides the industry with guidance for solar resource assessment and is used for procedures in the long-term continuous monitoring of legacy instruments alongside state-of-the-art instruments. Based on the SOP, instruments are annually evaluated for continued deployment. Instruments that do not meet the SOP criteria are decommissioned, and new instruments that meet the criteria are deployed. Streamlining and optimizing the use of this facility ensures that the lab continues to be a world-leading solar calibration and measurement facility.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2024

Standard Operating Procedure for Optimal Deployment of Meteorological Instrumentation Within the Solar Radiation Research Laboratory: 2024 Edition

14 SOLAR ENERGY↗

DOE OSTI2025

Standard Operating Procedure for Optimal Deployment of Meteorological Instrumentation Within the Solar Radiation Research Laboratory: 2025 Edition

14 SOLAR ENERGY↗

DOE OSTI2026

Daily operational impacts on battery degradation in heavy-duty electric drayage trucks

Battery aging is a critical factor influencing the performance, longevity, and cost of ownership of battery electric trucks (BETs). This paper presents a comprehensive evaluation of battery aging for two Li-ion battery chemistries, Nickel-Manganese-Cobalt (NMC) and Lithium-Iron-Phosphate (LFP), accounting for both cycling and calendar aging. In contrast to traditional methods that rely on simplified linear degradation models based on manufacturer-provided data, this study employs semi-empirical aging models calibrated to experimentally collected data. The models are integrated into a detailed vehicle simulation environment, enabling a comprehensive assessment of battery degradation under realistic operating conditions. A case study focusing on heavy-duty electric drayage truck operations in the Port of Savannah, GA, is presented to illustrate the impact on battery pack lifespan of: seasonal variations, daily operational activities, charging strategies, and battery storage conditions. The results illuminate the significance of the battery pack’s state of charge during stationary periods, such as overnight storage or weekend parking, on battery degradation and its potential implications for long-term vehicle viability. Additionally, the study explores how different operational and environmental factors affect battery degradation, offering critical insights into best battery charging and storage practices. Our results demonstrate that LFP outperforms NMC in terms of years of useful life; however, by utilizing charging strategies that minimize the amount of time the battery spends resting at high levels of state-of-charge, the lifespan of the battery pack that uses NMC can nonetheless be increased by more than a factor of two.

25 ENERGY STORAGE↗

DOE OSTI2021

Concentric Ring Gas Atomization Die Design for Optimized Particle Production

In partnership with Linde plc (formerly Praxair, Inc.), Ames Laboratory will further develop and commercialize its concentric-ring high pressure gas atomization (CR-HPGA) gas-die technology with a goal to improve the precision of metal powder production in a desired size range and quality. The successful commercialization of this technology could reduce production cost of metal powders and improve reliability of this industrial process, increasing specialty alloy powder availability for new applications and adoption into additive manufacturing and multiple materials sectors. The project scope is to [1] utilize AMES compressible gas flow and melt break-up models to explore a wide swath of parameter space available for the CR-HPGA technology, identifying the most promising gas-die designs for fabrication, [2] verify and optimize the new gas-die design, fabricate it and select preferred operating parameters by gas-only flow imaging and aspiration pressure measurements, down-selecting gas compositions and atomization parameters for full scale testing, [3] perform pilot-scale atomization trials with Al and/or Cu alloys of a new CR-HPGA gas-die at selected parameters, [4] evaluate gas-die performance by comparing resulting powder size distribution and powder quality attributes with equivalent powders made by conventional close-coupled HPGA technology, and [5] assess (through Praxair partnership) reduction in operational costs of new CR-HPGA gas-die through the use of an inert gas recovery/recycling system. In partnership with Praxair, Inc., the team, led by Ames Laboratory senior metallurgist Iver Anderson, intend to demonstrate the performance of an optimized CR-HPGA gas-die design in a pilot scale atomizer and better understand the design and operational controls to increase overall benefits for precision metal powder production.

42 ENGINEERING↗

DOE OSTI2022

Identifying Opportunities and Recommendations for the Integration of Advanced Reactors for Industrial Heat and Electricity Users

Nuclear power in the United States has been used traditionally to provide baseload electric power to the grid. Advancements in nuclear power to create smaller and safer reactors have renewed interest in nuclear as a source of both heat and electricity for a variety of applications. There is great interest in coupling nuclear reactors with industrial applications because nuclear power is a low carbon energy source that can be utilized for process heating, hydrogen generation, on-site electricity demand, and more. Idaho National Laboratory is developing guidelines to identify and assist industrial heat and electricity decarbonization by integrating with nuclear power plants (NPPs) to provide clean, abundant, and dispatchable energy. Considerations include specific industrial hazards which impact NPP siting, heat transport requirements and associated technologies, and implementation feasibility based on site-specific demand profiles. To assess integration feasibility, facility process models are developed based on real data obtained from a survey of baseline requirements and process information from industrial facilities in the United States. An assessment of safety and siting requirements is also performed to determine how nuclear industrial pairings could meet licensing requirements for NPPs. In addition, site characterization of an industrial plant is essential to determining the feasibility and suitable integration methods for each industry. Characterization includes facility distance from the nearest population center, site size, rail or water transport availability, and proximity to undeveloped land. These characteristics are important to determine reactor- or industry-side design requirements for safe, efficient operation. The siting and technical data assessment will reveal opportunities for single-use nuclear integration and co-location opportunities for industries to share benefits from a single reactor. In addition to existing facilities, this “energy-park” style cooperation could include new construction like data centers which can cost-share energy investments or provide a stable demand-and-revenue stream to the investor. Deliverables will contain a library of documents and models to guide various industries toward understanding nuclear technologies based on their users’ needs. This paper is a summary of the current project status, and provides insights on suitable pairings for specific industries and reactor technologies

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2025

Roadmap for Assessing Fuel Reprocessing in Fluoride-Based Salts

This joint report assesses the pyroprocessing of used nuclear fuel from molten fluoride salts being conducted between Idaho National Laboratory and Argonne National Laboratory. The goal of this report is to identify the research and development gaps needed to reduce the technical risks of extending pyroprocessing technologies and unit operations to molten fluoride salts used in molten salt reactors (MSRs). Assessing and performing the tasks outlined in this report will help mitigate the technical risks and design appropriate flowsheets for reprocessing fuel and coolant salts. These suggested tasks will provide necessary data to implement the development of unit operations. Sections are highlighted to identify processes that need to be assessed and unit operations that may be used in fluoride-based chemistries. Research and development needs are listed and discussed including re-fluorination methods, electrowinning for separations, reference electrode development, materials compatibility, salt purification/re-fluorination, and waste disposition. This report will examine the technical challenges associated with pyroprocessing in molten fluoride-based salt and outline approaches to increase the technical readiness level of pyroprocessing in molten fluoride salts.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

Assessment of a Grade 91 Steel Forging and Seamless Pipe Section After 141,000-Hours of Operation in a Superheat Outlet Header

In this work, two unique heats of 9Cr creep strength enhanced ferritic (CSEF) steels extracted from a retired superheat outlet header after 141,000 hours of service were evaluated. These two CSEF steels were a forging manufactured to SA-182 F91 (F91) reducer and a seamless pipe produced to SA-335 P91 (P91) pipe. Their creep deformation and fracture behavior were assessed using a lever arm creep frame integrated with in-situ high-temperature digital image correlation (DIC) system. Critical metallurgical and microstructure factors, including composition, service damage, grain matrix degradation, precipitates, and inclusions were quantitatively characterized to link the performance of the two service aged F91 and P91 CSEF steels. The creep test results show the F91 and P91 steels exhibit a large variation in creep strength and creep ductility. The F91 steel fractured at 572 hours while P91 steel fractured at 1,901 hours when subjected to a test condition of 650 °C and 100 MPa. The nominal creep strains at fracture were 12.5% (F91) and 14.5% (P91), respectively. The high-resolution DIC strain measurements reveal the local creep strain in F91 was about 50% while the local creep strain in P91 was >80%. The characterization results show that the F91 steel possessed pre-existing creep damage from its time in service, a higher fraction of inclusions, and a faster matrix grain coarsening rate. These features contribute to the observed reduction in performance for the F91 steel. The context for these findings, and the importance of metallurgical risk in an integrated life management approach will be emphasized.

Wang, Yiyu↗

DOE OSTI2026

Permanent magnets for ELM suppression in tokamaks: feasibility and operational compatibility

Permanent magnets can provide static magnetic fields without power supplies or feed lines, offering a simpler alternative to conventional electromagnets in tokamaks. This work examines permanent magnet arrays (PMAs) for edge localized mode (ELM) control in double-null (DN) configurations, where traditional RMP coils exhibit limited effectiveness. Linear plasma response calculations using IPEC assess high-field-side (HFS) permanent magnet placement, benchmarking performance against DIII-D low-field-side (LFS) internal coils (I-coils) while evaluating engineering constraints. Modeling results demonstrate that HFS permanent magnet configurations generate HFS plasma response amplitudes more than 5 times larger than conventional I-coil systems. While other resonant response metrics show comparable or reduced response relative to I-coils, the combination of conventional RMP systems and permanent magnets is expected to provide enhanced performance. Operational impact assessments of persistent magnetic fields, including sideband field effects and startup/ramp-up compatibility, reveal acceptable performance within established operational boundaries. This analysis establishes PMAs as a technically viable approach for DN ELM control with reductions in system complexity, motivating further experimental validation on existing tokamak facilities.

3D magnetic perturbation↗