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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 685 records · Page 38
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Developing Efficient Perovskite/Silicon Tandem Devices

This project aims at developing highly efficient perovskite/silicon tandem solar cells by developing efficient perovskite top cells, silicon bottom cells, and monolithically integrating the subcells for highly efficient tandem solar cells. The project focused on increasing the efficiency of perovskite solar cells to 20% and understanding related materials science and device physics, as well as developing a compatible bottom high-efficiency c-Si solar cell. The perovskite cells with a wide bandgap of 1.61 eV and 1.84 eV are fabricated by a low-cost, low-temperature, scalable solution process on lower bandgap silicon bottom cells. The bandgaps of perovskite top cells have been tuned between 1.61 eV and 1.84 eV by composition engineering mainly through controlling the halide mixing ratio in perovskite materials. The efficiencies of the wide bandgap perovskite solar cells have been improved to an excellent efficiency of 21.0% for perovskites with a bandgap of 1.63 eV with increased grain size, reduced energy disorder at cathode contact, and defect passivation. We invented a solvent annealing approach with solvent vapor during thermal annealing to enlarge grain size of perovskite film which reduces the charge trap density and improves the device efficiency. Moreover, we discovered that the non-wetting surface could further increase the grain size for perovskite films, because non-wetting surface could prevent the formation of too dense nuclei from heterogeneous nucleation process. We proposed to reduce the energy disorder of organic charge extraction layer to reduce the power loss in perovskite cells. We pioneered defect passivation concept and techniques to suppress the charge non-radiative recombination in perovskite solar cells to boost the efficiency. For the silicon bottom cell development, different from the conventional silicon cell work under full illumination, the light available for the silicon bottom cell in tandem structure is mainly NIR region. We developed a NIR enhanced silicon cell with efficiency of 21.2% by applying a double-layer antireflection coating at the front side and a MgF2 back reflector layer at the rear side. For the perovskite/silicon tandem device, we achieved a highest reported power conversion efficiency of 25.4% in 2018, and further increased the efficiency up to 26.0% in 2019. The research on tandem solar cells focused on reducing reflection loss to <5% at spectrum of 300-1100 nm by antireflection layer, tuning the bandgap of perovskite film for matched current density between sub-cells, and utilizing a ITO layer between perovskite top cell and silicon bottom cell as interconnect layer without Voc loss. Finally, we developed a blading technique to fabricate perovskite films which produces perovskite solar cells with comparable or even superior efficiency to those made by non-scalable spin coating method. This paves the way for scaling up perovskite/silicon tandem solar cells using solution approach.

14 SOLAR ENERGY↗
DOE OSTI2020

Developing inductively driven diagnostic X-ray sources to enable transformative radiography and diffraction capabilities on Z

Penetrating X-rays are one of the most effective tools for diagnosing high energy density experiments, whether through radiographic imaging or X-ray diffraction. To expand the X-ray diagnostic capabilities at the 26-MA Z Pulsed Power Facility, we have developed a new diagnostic X-ray source called the inductively driven X-pinch (IDXP). This X-ray source is powered by a miniature transmission line that is inductively coupled to fringe magnetic fields in the final power feed. The transmission line redirects a small amount of Zs magnetic energy into a secondary cavity where 150+ kA of current is delivered to a hybrid X-pinch. In this report, we describe the multi-stage development of the IDXP concept through experiments both on Z and in a surrogate setup on the 1 MA Mykonos facility. Initial short-circuit experiments to verify power ow on Z are followed by short-circuit and X-ray source development experiments on Mykonos. The creation of a radiography-quality X-pinch hot spot is verified through a combination of X-ray diode traces, laser shadowgraphy, and source radiography. The success of the IDXP experiments on Mykonos has resulted in the design and fabrication of an IDXP for an upcoming Z experiment that will be the first-ever X-pinch fielded on Z. We have also pursued the development of two additional technologies. First, the extended convolute post (XCP) has been developed as an alternate method for powering diagnostic X-pinches on Z. This concept, which directly couples the current owing in one of the twelve Z convolute posts to an X-pinch, greatly increases the amount of available current relative to an IDXP (900 kA versus 150 kA). Initial short-circuit XCP experiments have demonstrated the efficacy of power ow in this geometry. The second technology pursued here is the inductively driven transmission line (IDTL) current monitor. These low-current IDTLs seek to measure the current in the final power feed with high fidelity. After three generations of development, IDTL current monitors frequently return cleaner current measurements than the standard B-dot sensors that are fielded on Z. This is especially true on high-inductance experiments where the harshest conditions are created in the nal power feed.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2021

Development of Algal Biomass Yield Improvements in an Integrated Process (Final Report)

This project built on the success of Global Algae Innovations Algae Biomass Yield Phase 1 project to accelerate the commercialization of algal biofuels through development of an integrated, economical, photosynthetic, open raceway system to produce algal oil. Two parallel pathways to a biofuel were investigated. In the algal crude oil pathway, highlighted in blue, the dewatered algal biomass slurry is used as a feed to hydrothermal liquefaction to produce an algae crude oil and recycle aqueous stream. In the algal lipid oil pathway, highlighted in green, the algal biomass slurry is dried, and the oil is extracted to produce an algal lipid oil biofuel intermediate and a high protein algae meal co-product. Upgrading to drop-in fuels has been demonstrated for the biofuel intermediates in both pathways. Since the algal lipid oil pathway requires lipid accumulation, the productivity is generally lower than the algal crude oil pathway, but the required productivity for economical algal biofuel production is also lower because the coproduct value is greater. The outdoor cultivation was performed at the Kauai Algae Farm. The project team has expertise across the full breadth strain development, advanced algal cultivation, open raceway contamination control, CO 2 supply, harvesting, dewatering, extraction, hydrothermal liquefaction, technoeconomic analysis and life cycle analysis: Hildebrand laboratory at Scripps Institution of Oceanography – diatom strain development. Mayfield laboratory at UCSD - green algae strain development. TSD Management Associates- CO 2 supply, algal harvesting and dewatering, and algal drying and extraction. Qualitas - large-scale test site for algal harvesting technology. Texas A&M University - algal drying and extraction technology. Pacific Northwest National Laboratory - hydrothermal liquefaction technology. GE Water and Power - membrane technology. National Renewable Energy Laboratory - algal techno-economic analysis. Phase 1 of the project resulted in tremendous productivity and pre-processing improvements in an integrated, large-scale, low-cost cultivation and pre-processing process that moved algal technology closer to economic viability for biofuels than ever before. Phase 2 accomplishments further facilitate development of a commercial algal biofuel industry by adding: several top performing strains and strain development tools including breeding; open-pond cultivation innovations that achieved a 30% improvement in overall productivity, an 83% reduction in cost, and a 95% reduction in energy use relative to conventional technology; further improvements in harvesting that led to the Zobi harvester ® as a universal, economical, low energy, commercially available microalgae harvesting solution; breakthroughs in drying and extraction including a new low energy drying process and several new low energy extraction unit operations that together with the Zobi harvester ® achieve a 90% reduction in cost and 97% reduction in energy use relative to conventional technology. These improvements are sufficient to enable economical production of algae biofuel and protein meal co-product if the process were scaled up to a commercial-scale 5,000-acre algae farm.

09 BIOMASS FUELS↗
DOE OSTI2021

SAM Co-Development to Support Fluoride-salt-cooled High-temperature Reactor Design and Licensing (CRADA 2018-18177 Final Report)

This project aims to raise the SAM code's technical and commercial maturity level to enable the Kairos Power ("Kairos") to use SAM to support its KP-FHR design analysis and licensing application. Argonne National Laboratory ("Argonne") has actively developed and maintained SAM, a modern system-level analysis tool for advanced nonlight water reactors safety analysis. Kairos is currently actively pursuing development of an FHR design and associated technology, and consequently requires a pedigreed safety analysis tool. The purpose of this project is to increase the maturity of the SAM code for the modeling and simulation of the KP-FHR design, thus enabling its use in safety analyses that support licensing application. Argonne will primarily be responsible for software design, development, and testing; while Kairos will be responsible for software requirements, assessment of software capabilities, needs, gaps, and priorities, and development of proprietary models. The research and development activities for the joint SAM development project include: a series of identification and prioritization studies on design characteristics, event sequences, relevant phenomena, and software capabilities; SAM capability enhancements for specific KP-FHR systems and components; performing code verification and validations; integrating uncertainty quantification (UQ), model calibration, and sensitivity analysis (SA) techniques in safety analyses; and raising the software quality rigor level for commercial-grade applications.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Development and Application of a Data-Driven Methodology for Validation of Risk-Informed Safety Margin Characterization Models

The document is the Final Technical Progress Report for the Nuclear Energy University Program’s Integrated Research Project (IRP) on “Development and Application of a Data-Driven Methodology for Validation of Risk-Informed Safety Margin Characterization Models” that supports the LWR Sustainability Program’s RISMC R&D Pathway. The project goal is to develop and demonstrate a data-driven methodology for validation of advanced computer models used in nuclear power plant safety analysis. Specifically, the advanced computer models are those in the toolkit developed to support risk-informed safety margin characterization (RISMC), an integrated deterministic/probabilistic safety analysis methodology developed in the Department of Energy’s Light Water Reactor Sustainability (LWR-S) program. The report reflects the progress made towards the project’s stated goal by contributions by researchers and graduate students from universities, with support from researchers from national laboratories and industry companies. The project organization, effort coordination and technical implementation are summarized, followed by discussion of main findings, issues, and path forward. Selected chapters provide a more detailed description of tasks, approaches and respective findings and recommendations. Noteworthy are contributions that serve as guidelines for methodology development. It is also noted that this report is complemented by other milestone reports (as stand-alone deliverables) that provide detailed discussion of the technical developments. The project results have been documented in a number (12) dissertations and these, 50+ peer-reviewed publications in technical journals and conference proceedings.

42 ENGINEERING↗
DOE OSTI2021

Development and Field Testing Novel Natural Gas Surface Process Equipment for Replacement of Water as Primary Hydraulic Fracturing Fluid (Final Report)

Southwest Research Institute® (SwRI ® ), Schlumberger Technology Corporation (SLB), and Chevron Corporation ® (Chevron) developed a novel, optimized, and lightweight process for natural gas (NG) to replace water as a low-cost fracturing medium with a low environmental impact. Hydraulic fracturing is used to increase oil and NG production by injecting high-pressure fluid, primarily water, into a rock formation, which fractures the rock and releases trapped oil and NG. This method was developed to increase yield and make feasible production areas that would not otherwise be viable for large-scale oil and NG extraction using traditional drilling technologies. Since the fracturing fluid is composed of approximately 90% water, one of the principal drawbacks to hydraulic fracturing is its excessive water use and associated large environmental footprint. According to recent data collected at fracture sites within the United States, fracturing applications in North America can consume as much as 9 million gallons of water per well. During the fracturing process, some of the fracturing fluid is permanently lost and the portion that is recovered is contaminated by both fracturing chemicals and dissolved solids from the formation. The recovered water or flow-back represents a significant environmental challenge, as it must be treated before it can be reintroduced into the natural water system. Although there is some recycling for future fracturing, the majority of the flow-back water is hauled from the well site to a treatment facility or to an injection well for permanent underground disposal. To mitigate these issues, an optimized, lightweight and modular surface process using NG to replace a majority of the water was developed as a cost-effective and environmentally clean fracturing fluid. Using NG will result in significantly less consumption since the gas that is injected as a fracturing fluid will be mixed with the formation gas and extracted as if it were from the formation itself. This process will minimize the collection, waste, and treatment of large amounts of water and will reduce the environmental impact of transporting and storing the fracturing fluid. There are two major steps involved in utilizing NG as the primary fracturing medium: (1) increasing the supply pressure of NG to wellhead pressures suitable for fracturing and (2) mixing the required chemicals and proppant needed for the fracturing process at these elevated pressures. The second step (NG-proppant mixing at elevated pressures) still requires demonstration; but very similar processes have been demonstrated in the field with other gases such as nitrogen (N 2 ) and carbon dioxide (CO 2 ). However, the first step (a compact, on-site unit for generating high-pressure NG at costs feasible for fracturing) has not been developed and is currently not commercially available. Due to the inherent compressibility of NG, more energy is required to compress the gas than what is required to pump water (or other incompressible liquids) to the very high pressure required for downhole injection. This project aimed to develop a novel, hybrid method to overcome this challenge. The project accomplishments and findings are discussed in this report. Ultimately, the research and development efforts described herein demonstrate that fracturing with NG foam is a feasible alternative to using water.

02 PETROLEUM↗
DOE OSTI2020

Mercury Remediation Technology Development for Lower East Fork Poplar Creek (FY2020 Update)

Mercury (Hg) remediation is a high priority for the US Department of Energy (DOE) Oak Ridge Office of Environmental Management. Mercury contamination in the environment can be found at all three DOE facilities in Oak Ridge, but probably the greatest environmental risk concern relative to Hg on the Oak Ridge Reservation is associated with historical Hg losses at and near the Y-12 National Security Complex (Y-12). Water and fish from East Fork Poplar Creek (EFPC) downstream of Y-12 exceed regulatory thresholds. Because of the complexities of Hg transport and fate in the aquatic environment, conventional remedial options for EFPC are highly uncertain. DOE is using a phased adaptive management approach to Hg remediation at Y-12 with a focus in the next few years on construction of the Mercury Treatment Facility (MTF) to treat the most contaminated Y-12 outfall entering EFPC (DOE 2017a; DOE 2017b). Once operational, the MTF will provide additional protection against inadvertent releases of Hg into the stream from decontamination and decommissioning of Y-12 Hg-use buildings. Although the MTF is anticipated to substantially decrease Hg water concentrations and flux in the upper part of EFPC, research and technology development are needed to develop appropriate and long-term remedial solutions for the downstream environment. Since late 2014, the Oak Ridge Office of Environmental Management and URS | CH2M Oak Ridge LLC/Restoration Services, Inc. have supported DOE’s Oak Ridge National Laboratory (ORNL) Environmental Sciences Division staff in conducting field and laboratory studies to develop Hg remedial technology solutions for lower EFPC (LEFPC). A technology development strategy for LEFPC was developed in 2014 that was consistent with the adaptive management paradigm and DOE’s technology readiness level (TRL) guidelines (Peterson et al. 2015). Initially, a thorough review of the literature was conducted and site-specific information was collected to develop a broad number of potential technologies that might be applied in LEFPC. An adaptive management approach was then used to focus on technologies that might have the most promise and potential remediation benefit. Field and laboratory studies conducted from 2014 to 2020 have identified the major drivers of Hg flux and bioaccumulation in EFPC and narrowed the list of high-merit technologies that might be of use in remediating the downstream environment.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

Testing in Support of the Development of EPP Plus SMT Design Method at ORNL (FY2021)

Experiments in support of the development of the integrated Elastic–Perfectly Plastic (EPP) plus Simplified Model Test (SMT) design methodology, referred to as the EPP+SMT method, continued in FY21. This report focuses on the methodology for developing the EPP+SMT creep-fatigue (CF) design curves at low strain ranges. The creep damage-based method and dissipated work-based method were used to evaluate the available CF data at the low strain range region. A set of failure criteria were determined, and a simple extrapolation method was developed to predict the CF life cycles at low strain ranges that are not accessible by experiments due to the extraordinarily long failure times at the low strain region (thousands to hundreds of thousands of years) and the inability of the test machine to control these small strain ranges due to the signal to noise issues. An experimental method with the concept of block-strain range CF testing was proposed to generate the information needed to extrapolate the CF design curves to low strain ranges. Based on this new testing approach, a preliminary EPP+SMT CF design curve was developed for Alloy 617 at 950°C with tension hold time of 100 s. The analysis in this report shows the potential of generating a set of EPP+SMT CF design curves with different hold times within a reasonable amount of time and testing effort. Based on such a progress, a hold time extrapolation procedure for low strain ranges will be developed in FY22 and critical testing will be carried out to complete the development of the EPP+SMT CF design curves for Alloy 617.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Developing Generic Prior Distributions for Common Cause Failure Alpha Factors and Causal Alpha Factors

This report is a revision of the original report, INL/LTD-17-43723. Distribution of the original report was to the Nuclear Regulatory Commission (NRC) only, and the report was not made available to the public. The original report was revised as this report for public distribution. This report presents the latest update of generic prior distributions for common cause failure (CCF) alpha factors, as well as the development of new generic prior distributions for CCF causal alpha factors. The history of CCF treatment and parameter estimations is reviewed. The existing process for developing generic prior distributions is reviewed and used to develop new priors for CCF alpha factors and causal alpha factors. For causal alpha factors, different priors are developed for the five different CCF cause groups: Component (GC), Design (GD), Environment (GE), Human (GH), and Other (GO). These generic prior distributions could be used in the Standardized Plant Analysis Risk (SPAR) models for CCF parameter estimation. The issues and preliminary thoughts regarding prior distribution development are documented. Potential future work is then proposed for improving the process of developing priors.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2021

Development of Additively Manufactured Complex Tools for Autoclave Cure Composites

IACMI Project 4.9, Tooling for Composites with Washout Features Produced by Additive Manufacturing, assembled a team including the industry lead, Ability Composites, NREL and Colorado State University (CSU). Ability Composites had originally expressed interest in alternate methods of producing tooling for composite parts. In follow-up discussions, it became clear that one of the bigger tooling challenges revolved around small production volume composite parts that were tooled on washout material due to the complex geometry. To build an understanding of the potential, both from a technology and a cost perspective, for replacing conventional washout tooling with 3D printed thermoplastic tooling, a number of commercially available dissolvable FDM printing materials were evaluated, leading to tooling representative of commercial articles of interest to Ability Composites. Ultimately, Ability Composites was able to directly compare autoclave processed prepreg composite parts produced on conventional washout tooling to composite parts molded on 3D printed dissolvable tooling produced at CSU. Small, laboratory test specimens were developed to investigate the structural performance of the candidate materials under autoclave processing conditions, which were nominally 121 °C (250 °F) and 345 kPa (50 psi). In addition, several internal structural configurations (infills) were evaluated under autoclave conditions using model materials. The results of these tests indicated that two materials, Stratasys ST 130 and Infinite Materials Solutions Aquasys 180 (AQ 180), were the best candidates, given the specified autoclave processing conditions. ST-130 was slightly more robust than AQ-180; however, the AQ-180 was carried forward as it was dissolvable in water, not requiring the basic solution needed to dissolve ST-130. Based on the preliminary material and 3D printed structures evaluations, larger tools with a truncated square pyramid geometry were created to produce prepreg composite test articles for 3D printed dissolvable tool evaluation under standard autoclave fabrication conditions. Two tools were manufactured using ST-130 and one tool using traditional ceramic washout tooling media. The tools were evaluated for geometric fidelity and surface roughness changes before and after carbon fiber/epoxy prepreg composites were manufactured on the tooling. The autoclave processing did not impact the geometry significantly and was completed at 121 °C and 345 kPa, indicating satisfactory tool performance. The results from surface roughness testing of both the resulting composite and the associated tooling indicated that an adequate surface resulted without the need for a surface sealing step, as was required for the conventional washout tooling. Based on results of the truncated pyramid tests as a basis, ST-130, AQ-120 and AQ-180 materials were carried forward to the tool geometry of interest to Ability Composites. These hollow rectangular bent ducts, which were complex in nature and not extractable after cure, were used to understand the impacts of tool material and thickness. One ST-130 tool was produced as a partially solid part, with an enclosed 40% dense infill region to reduce weight and material use. This was the same approach evaluated in the truncated pyramid portion of the study. This tool was to be envelope vacuum bagged and directly compared to a monolithic tool of conventional washout material. The traditional monolithic ceramic tool was manufactured by Ability composites using CNC-based subtractive methods. An additional five dissolvable polymer tools, manufactured from ST-130, AQ-120, and AQ-180, using a hollow design were 3D printed and used to produce carbon fiber/epoxy composite evaluation articles. These hollow dissolvable tools were expected to be less influenced by the autoclave conditions as the wall was solid and vacuum bagging was inside and outside the tool. This alternative geometry was also evaluated as an option in techno-economic modeling. Print times were reduced from in excess of 3 days to under 30 hours, while surface quality and and tool integrity were substantially improved in the transition from the partially solid tool to the hollow tooling concept. Ability Composites produced autoclave-cured prepreg ducts on each of these tools. The autoclave conditions utilized were more severe than those of the initial trials, reaching temperatures of 160 °C and a pressure of 414 kPa. Under these conditions, the partially solid 3D printed tool with skin and 40% dense infill crushed significantly; however, the thicker ST-130 hollow tool showed good promise, deforming only slightly. The thinner hollow tool walls were unsuccessful as were the other materials. Overall, the hollow tool manufacturing process saved significant amounts of time and material in manufacturing as compared to the solid ducts and produced composite surface quality improvements compared to the traditional washout tooling. The TEM was developed to allow direct comparisons between conventional washout tool manufacturing processes and those developed at CSU. It also allowed for two separate 3D printed tool geometries to be analyzed and compared. In this case, the square bent duct tool geometry was determined to be representative of common washout tools. This geometry was compared with a scaled-up version of it to assess differences in the two manufacturing processes based on tool size. The model was developed to make use of user input in the form of geometry details, process steps, manufacturing parameters, bulk material costs, capital equipment costs, and general costs to calculate overall labor, material, capital equipment, and energy costs per manufactured tool for the conventional and additive manufacturing processes for the two representative geometries. It was also able to estimate step-by-step process times for the manufacturing process and geometries. Based on significant input from Ability Composites and CSU from their knowledge gained from hands-on manufacturing of the 3D printed bent duct tool geometry, costs and process times were calculated for the two manufacturing processes. Results showed that the additive manufacturing techniques developed at CSU can substantially reduce the costs of tool manufacturing by reducing labor times and material usage. This is because additive manufacturing is a relatively hands-off process and allows for the tool design to be optimized to reduce material usage. The disadvantage, however, is that process times for additive manufacturing are significantly longer. The three-dimensional (3D) printing process is slow if tight tolerances are required, but the analysis did show that print times could be reduced with the hollow tool geometry. Also, further advances in additive manufacturing could expedite the process. Costs and process times for the tool washout process were calculated separately. They showed that costs are relatively insignificant when compared to the overall tool manufacturing processes, but with increases in tool size, costs for the conventional manufacturing approach are larger than for additive manufacturing. Again, the washout process for conventional tools is very hands-on, whereas for additively manufactured tools the print medium is dissolved in an automated detergent bath at the sacrifice of process time. The analysis showed that optimizing the additively manufactured tools may also reduce washout times. Overall, Project 4.9 demonstrated that commercially available dissolvable 3D printing materials exist that can be used to produce dissolvable tooling capable of surviving prepreg composites fabrication under autoclave conditions of 121 °C (250 °F) and 345 kPa (50 psi). An alternative hollow dissolvable tool design was developed which was structurally superior to the initial concept and was cost and time effective versus conventional washout tooling. The 3D printed sacrificial tool required no added surface sealing steps prior to composite part layup and cure, offering a significant advantage over the porous conventional washout tooling.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Testing and Expertise for Marine Energy (TEAMER) Program Support - Numerical Modeling Assistance for iProTech's "PIP" WEC Device: Cooperative Research and Development Final Report, CRADA Number CRD-20-17303

Develop a time-domain, 3 degree of freedom numerical model of IProTech's PIP device, including power take-off (PTO), that can be used to develop control algorithms and establish a baseline technology performance level (TPL). This is important to IProTech because having a good numerical model allows IProTech to optimize design and control algorithms on an ongoing basis. A baseline TPL enables the PIP technology to be benchmarked against other wave energy converter (WEC) concepts, providing (i) justification (or not) for investment in wave tank model testing, (ii) identifying optimum design parameters and control algorithms for the test model, (iii) specifying test conditions and (iv) interpreting wave tank test results. An accredited WEC-Sim model of the PIP device is an essential tool for further development of the technology. 1) The development of numerical models of the PIP concept will enable iProTech to evaluate the potential performance of this concept, and to investigate how sensitive the device is to different variables within the system (e.g. hydraulic components, geometry dimensions, etc.) 2) The numerical models were developed with WEC-Sim and PTO-Sim -- the de-facto industry standard WEC numerical modeling tools. A detailed model of the system's hydraulic circuit was developed with PTO-Sim. However, WEC-Sim is based on linear hydrodynamics and has several limitations; validation against high fidelity models/physical scale models would help to build confidence in the results.

16 TIDAL AND WAVE POWER↗
DOE OSTI2022

Salton Sea Geothermal Development: Nontechnical Barriers to Entry – Analysis and Perspectives

Geothermal energy offers an opportunity to generate baseload, renewable energy that can help support the transition to an energy economy with reduced impacts on climate change and replace older, more expensive, nonrenewable, and more resource-impacting energy-generation facilities. The United States has the largest known geothermal resource in the world, with over 31 GW of conventional geothermal potential. However, due to market conditions, an inability to properly quantify both electrical grid benefits and resource stability, and the difficulty of exploring and developing the geothermal resource, few new geothermal projects have come online over the past three decades. The Salton Sea, in Imperial County, California, provides a prime location and opportunity to develop new geothermal resources. The Salton Sea contains a robust, well-mapped, geothermal resource, with opportunities for concurrent development of lithium and other mineral resources. This report describes the history of geothermal development at the Salton Sea and compares geothermal to other renewable energy sources in the area. The report then uses a techno-economic analysis (TEA) model to analyze the relative benefits and costs of various challenges and opportunities and provides recommendations for streamlining geothermal development at the Salton Sea and elsewhere. The challenges and opportunities analyzed in the TEA model were informed by stakeholder interviews and literature reviews. Based upon the identified challenges and opportunities and the results of the TEA model, primary findings are that certain nontechnical barriers such as permitting costs play only a minor role in determining the viability of development of the geothermal resource at the Salton Sea. Other barriers such as permitting timelines, government/agency coordination, and the potential co-location of lithium extraction with a geothermal plant may result in much larger impacts on project viability.

15 GEOTHERMAL ENERGY↗
DOE OSTI2020

Development of Cable Aging Acceptance Criteria for Nuclear Facilities

The aging of nuclear power plant electrical cables has been the subject of substantial research and development (R&D) projects in the nuclear industry, national and international laboratories, universities, and vendor organizations for several years. More specifically, these R&D efforts were conducted to develop equipment and techniques for assessing age-related degradation of in-service cables in nuclear facilities including power plants, research reactors, waste facilities and fuel fabrication plants. In recent years, cable R&D efforts in the nuclear arena have also included work to develop new cables for the next generation of reactors. Over time, exposure to harsh environmental conditions such as elevated temperatures, radiation, and humidity in nuclear installations can result in age-related degradation and failure of cables. In the current fleet of nuclear reactors, there are thousands of miles of cabling installed in each plant and many of these cables are exposed to these harsh environmental conditions. For these cables, the jacket and insulation polymers harden and become brittle over time, making them more susceptible to crack formation and growth, moisture intrusion, and other mechanisms that can lead to cable failure. Moreover, the existing U.S. fleet of 98 nuclear reactors has an average operating age of 38 years. Many of these nuclear power plants have applied for and almost all have been granted regulatory approval for license renewals to operate for 60 years, 20 years beyond their original 40-year life. Further, subsequent license renewals (SLRs) are underway with a few commercial nuclear power sites already approved to operate up to 80 years. As these reactors pursue operating life extensions, utilities must find a way to address issues associated with age-related degradation of cables. Designers of small modular reactors are also in need of technologies to evaluate the performance of cables that will be installed in harsher environments (e.g. higher temperatures, radiation doses, dose rates, etc.) than those present in current-generation reactors. Today, a variety of cable condition monitoring (CM) techniques have been developed and successfully used in nuclear facilities. These techniques are used to identify age-related degradation and assess the condition of cables to determine if their performance characteristics have changed with age. However, objective criteria must be developed for these CM tests to help quantify cable condition and thereby develop repair and replacement schedules. With operating life extending to 80 years and more SLRs on the horizon, both nuclear facilities and regulators need an objective means to determine the aged condition of cables.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Survey of Relevant Data from the MSRP to Guide Development of MSR Chemistry Modeling Benchmarks

The Multiphysics Applications technical area of the Nuclear Energy Advanced Modeling and Simulation (NEAMS) program is tasked with assessing, demonstrating, and applying NEAMS tools in solving multiphysics problems of nuclear reactors, such as liquid-fueled molten salt reactors (MSRs), which are the focus of this report. MSRs are actively being pursued as a potential candidate for power and heat generation by the nuclear industry. However, the inherent multiphysics nature of liquid-fueled MSRs, stemming from the strong interrelationship of neutronics, thermal fluids, and chemistry phenomena, provides unique challenges in modeling and simulation (mod/sim). Therefore, it will be important to develop mod/sim tools with varying types of multiphysics coupling that depend on the problem. The current work is focused on the initiation and development of MSR chemistry modeling benchmarks useful for validating current and potential future NEAMS tools. Development of such benchmarks include the following actions: 1) Summarize available chemistry data from the Oak Ridge National Laboratory (ORNL) MSR Program (MSRP) including operation of the Molten Salt Reactor Experiment (MSRE) and design studies for the Molten Salt Breeder Reactor (MSBR) concept; 2) Recommend simulation problems in MSR chemistry mod/sim based on (1); 3) Assess the current state of NEAMS tools that may support (2); 4) Demonstrate and validate the capabilities of the NEAMS tools in (3) while providing iterative feedback on future code development activities. The objective of this report is to initiate this effort by completing actions (1) and (2), which are discussed in Section 2. An overview of the relevant available MSRE experimental data is provided with examples of how this data may be useful in chemistry mod/sim problems, with the caveat that most of this data is over 50 years old, therefore some problem details as well as uncertainty estimates are often not provided. In Section 3, the current state of NEAMS tools is assessed for potential use in these mod/sim problems, with considerations for future code development activities, supporting action (3). Future work supporting this project under NEAMS may include a deeper dive into the specific phenomena discussed here including tasks such as the compilation of additional available data, updates in code development activities, and ultimately the demonstration and validation of these tools, supporting action (4).

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

Manufacturing Demonstration Facility: Development and Evaluation of Hybrid Manufacturing Toolpaths

The integration of additive manufacturing (AM) capabilities on Computer Numerical Control (CNC) systems allows for the expansion of additive manufacturing to a wide range of part and tool repair operations. This multi-tasking integration, termed hybrid manufacturing, has been researched by others in the past, and Autodesk has been critical in developing process planning and toolpath algorithms for hybrid systems. Objectives and Tasks: Hybrid manufacturing systems enable both additive and subtractive capabilities in a single manufacturing workcell. These systems have the potential to impact a variety of industries, including the tool and die industry due to their repair, refurbishment, and complex geometry manufacturing capabilities. While there has been significant development of toolpath planning for both subtractive and additive processes independently, there has been little, if any, development of hybrid toolpath planning to integrate both processes during the manufacturing design and toolpath generation stage of a product’s lifecycle. Furthermore, additive toolpath planning has been limited to planar manufacturing, but this limitation could be overcome as hybrid CNC machines have multi-axis control. The objectives of this research include: - Development and demonstration of independent three-, four-, and five-axis toolpath generation algorithms for both additive and subtractive processes, and - Development, demonstration, and integration of three-, four-, and five-axis hybrid process planning and toolpath generation algorithms for hybrid additive and subtractive processes. The team will leverage the widely used Autodesk Fusion 360 product design and manufacturing (CAD/CAM) platform to achieve these objectives. Autodesk will provide the expertise in CAD tools, as well as access to their new CAD/CAM manufacturing tools (3-, 4-, and 5-axis milling, additive toolpath generation). ORNL will provide expertise in additive manufacturing toolpath generation, process planning, and manufacturing validation. By the end of the program, the team will have developed and validated multi-axis milling, additive manufacturing, and hybrid manufacturing on an industrial hybrid CNC system (Mazak 500-VC).

42 ENGINEERING↗
DOE OSTI2023

Research Plan and Preliminary Results in Developing the Fabrication Parameters for Alloy 709 in Different Product Forms―Grain Coarsening Temperature Evaluation

The Advanced Reactor Technologies (ART) Program has established a multi-year plan to develop Alloy 709 advanced stainless steel (A709), generate the data package and develop material-specific design parameters in qualifying it as a new structural material for Class A component design in the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code, Section III, Division 5, High Temperature Reactors. In collaboration with material vendors, the Advanced Materials Development activities under ART have successfully scaled the A709 plate form production from a laboratory heat of 500 pounds to commercial heats totaling 133,000 pounds of A709 plate fabricated from three heats. The goal of the overall A709 development program is to establish the necessary microstructural and mechanical properties relationship for A709 to ultimately develop fabrication parameters for other product forms such as bars, piping and forging using the available ART A709 materials. The objective of this A709 development work at ORNL in FY2023 is to experimentally determine grain coarsening behavior for the A709 heats and to experimentally generate the continuous cooling precipitation (CCP) diagram for A709 using the as-rolled commercial heat plate materials. Integral to this work is the characterization of the as-rolled materials and the determination of an effective solution annealing process. This report summarizes the work performed to identify the grain coarsening temperature for commercial heat 58776-3RB fabricated by G. O. Carlson and heat 529900-02 fabricated by Allegheny Technologies Incorporated (ATI) Flat Rolled Products.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Development of Genetic Algorithm Based Multi-Objective Plant Reload Optimization Platform

The U.S. nuclear industry is facing a challenge in maintaining required levels of safety while ensuring economic competitiveness to stay in business. Safety remains a key parameter for all aspects of light-water reactor nuclear power plant operations. Safety can become more economical by using a risk-informed ecosystem, such as the one being developed in the Risk-Informed Systems Analysis Pathway under the U.S. Department of Energy Light Water Reactor Sustainability Program. The Light Water Reactor Sustainability Program promotes a wide range of research and development activities to maximize both the safety and economic efficiency of nuclear power plants through improved scientific understanding, especially given that many plants are now considering second license renewals. The Risk-Informed Systems Analysis Pathway has two main goals: Deploy methodologies and technologies that better represent safety margins and cost and safety factors; Develop advanced applications that enable cost-effective plant operations. The Plant Reload Optimization Platform development project aims to build a reactor core design tool that includes reactor safety and fuel performance analyses and uses artificial intelligence to support the optimization of core design solutions. This report summarizes genetic-algorithm-based multi-objective fuel reload optimization activities, specifically: Developing the non-dominated sorting genetic algorithm II optimizer in the Risk Analysis and Virtual ENviroment (RAVEN); Demonstrating and validating the developed non-dominated sorting genetic algorithm II optimizer using benchmark optimization problems.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Gas Stopper Developments for Improved Purity and Intensity of Low-Energy, Rare Isotope Ion Beams (Final Technical Report)

This final technical report summarizes the work of the Michigan State University (MSU) team supported by grant # DE-SC0021423 awarded by the Office of Nuclear Physics, Department of Energy. Objectives: The successful fulfillment of the FRIB science mission hinges on ensuring the availability of fast, stopped, and reaccelerated beams consisting of rare isotopes. This project's research and development focus was dedicated to supporting the advancement and creation of a cutting-edge linear gas stopper. The primary aim is to efficiently convert the high-intensity fast beams of rare isotopes provided by FRIB into high-quality, low-energy beams. These beams are essential for conducting stopped beam experiments or for subsequent reacceleration. The overarching goal is to advance technology, aiming to increase the beam rate capability of the linear gas stopper for medium-to-heavy-mass rare isotopes by more than tenfold compared to the currently most effective gas stopper in operation, and to improve the purity of the delivered beams. Project Description: The existing technology employed in gas stopping devices designed for low-energy, rare-isotope beams presents limitations in both the purity of extracted beams and the intensities of injected beams. These limitations are incompatible with the requirements of the recently commissioned rare isotope beam facility, FRIB. Our research and development efforts, aligned with the previously outlined objectives, focused on addressing the most critical aspects for enhancing beam-rate capability and purity. Specifically, advanced particle-in-cell simulations were developed and integrated into a simulation pipeline to explore the efficacy of multi-layer RF carpets on increasing ion transport efficiency with high incoming beam rates that generate space charge fields which can limit it. We also explored the possibility of using a collision-induced-dissociation (CID) gas cell to break up molecular contaminant ions that are generated during the stopping process. A prototype CID gas cell was constructed and tested with beams from an offline ion source, validating the concept with the successful demonstration of breaking of molecular ions. The outcome of this research enabled the formulation a conceptual design for a next-generation linear gas stopping device specifically tailored for FRIB. This device is envisioned to deliver rare-isotope-ion beams at a rate of 10 8 particles per second or higher, accompanied by advancements in purity. Methods employed: This project leverages advancements in technologies initially designed for the Advanced Cryogenic Gas Stopper (ACGS), the current state-of-the-art linear gas stopper, through the use of new simulations and beam purification via collision-induced-dissociation. The methods include: 1. Development of a prototype low-energy, low-pressure CID gas stopper. This prototype features a thin, approximately 20 nm, Si 3 N 4 entrance window designed for dissociating stable and rare-isotope molecular ions. The goal is to enhance beam purification and overall efficiency. 2. Creation of Particle-in-cell (PIC) simulations to assess the advantages of multi-layer RF carpets and multi-point extraction for ion transport efficiency. These simulations rely on the 3DCylPIC package, specifically designed for studying devices of this nature. The goal is to quantify and mitigate ion transport losses due to space charge generated in the stopping process of large numbers of ions. 3. Perform ion transport simulations across an RF carpet using an 8-phase travelling wave and evaluate its performance. Compared to the 4-phase RF carpets used in ACGS, the 8-phase carpets will double the wavelength of the generated traveling wave allowing for larger maximum RF amplitudes that could result in improved ion transport efficiency for high-intensity incoming beams when large space charge fields are present. Impact: Tackling the primary challenges associated with transforming high-energy projectile fragment beams into low-energy beams—specifically, addressing efficiency and purity—holds significant promise for advancing FRIB science. This advancement will particularly impact precision mass measurements, laser spectroscopy of short-lived nuclei, and studies in astrophysics and nuclear reactions using reaccelerated beams. These domains play a crucial role in addressing key questions outlined in the 2023 NSAC long-range plan, spanning nuclear structure, nuclear astrophysics, and fundamental symmetries. Additionally, they contribute to addressing 10 out of the 17 benchmarks identified by the NRC RISAC. The development of a next-generation gas stopping device capable of delivering low-energy, rare-isotope beams at a rate of 10 8 particles per second, or more, with high purity holds the potential to unlock experiments that would otherwise be unfeasible. Furthermore, it is expected to reduce the time required for experiments at FRIB, thereby maximizing scientific output. The research and development activities performed as part of this project bolstered essential competencies at FRIB in beam physics and ion source technologies, provided valuable training opportunities for junior scientists.

43 PARTICLE ACCELERATORS↗