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At least 685 records · Page 38

Binderjet Additive Manufacturing for Complex Heat Exchanger Geometries

Concentrated Solar Power (CSP) systems play a role in the worlds development of renewable energy. Mirrors are used to concentrate sunlight that is converted into electricity or other forms of useful energy. CSP impact depends significantly on its overall economics. The U.S. Department of Energy’s (DOE’s) Solar Energy Technology Office (SETO) cost goals for 2030include $0.05/kWh levelized cost of electricity (LCOE) for a baseload plant [1]. The power cycle cost goal is $900/kWe [1]. The envisioned recompression supercritical carbondioxide (sCO2) power cycle includes four heat exchangers, which together are at least ¾ of the total power cycle cost. Meeting the cost target requires reducing the heat exchanger cost. The 260 bar and 588 °C heat exchanger requirements are challenging. Shell and tube heat exchangers can meet the requirements, but the size and cost are prohibitive. State-of-the-art diffusion bonded printed circuit heat exchanger designs are 3 m3 or larger and expensive to manufacture. Additive manufacturing enables novel heat exchanger geometries that can reduce heat exchanger size and mass [2]. Binderjet technology is an additive manufacturing modality. It selectively deposits binder material onto the powder bed to form a solid part one layer at a time. Once applied, the binder is cured, the remaining powder removed, and the part heat treated in steps to remove the binder, sinter the metal powder, and densify the part. The Binderjet printing process is more than 10x faster than the best-known metal additive modality, direct metal laser melting (DMLM), thus enabling 10x the part through-put rate [3]. The high throughput rate results in a low-cost manufacturing process capable of creating complex heat exchanger geometries. This paper introduces a complex heat exchanger geometry and methods of Binderjet processing to fabricate the geometry.

Barua, Ananda↗

Performance of Compact Pulsed Thermal Imaging System for In-Service Applications. Pulsed thermal tomography nondestructive examination of additively manufactured reactor materials and components

Additive manufacturing (AM) is an emerging method for cost-efficient fabrication of complex topology nuclear reactor parts from high-strength corrosion resistance alloys, such as stainless steel and Inconel. AM of metallic structures for nuclear energy applications is currently based on laser powder bed fusion (LPBF) process, which has the capability of melting metallic powder and net shaping the structures with relatively high precision. Some of the challenges with using LPBF method for nuclear manufacturing include the possibility of introducing pores into metallic structures. Integrity of AM structures needs to be evaluated nondestructively because material flaws could lead to premature failures due to creep in high temperature nuclear reactor environment. Currently, there exist limited capabilities to evaluate actual AM structures nondestructively. Pulsed Thermography (PT) imaging provides a capability for non-destructive evaluation (NDE) of sub-surface defects in arbitrary size structures. The PT method is based on recording material surface temperature transients with infrared (IR) camera following thermal pulse delivered on material surface with flash light. The PT method has advantages for NDE of actual AM structures because the method involves one-sided non-contact measurements and fast processing of large sample areas captured in one image. The data cube of PT measurements consists of surface temperature taken at sequential time intervals T(x,y,t). Material defects can be detected either by analyzing the thermograms T(x,y,t) data cube, or by using thermal tomography (TT) algorithm to obtain 3D spatial reconstruction of thermal effusivity e(x,y,z). To reduce the cost and enable in-service NDE in spatially constrained environment, it is highly desirable to develop PT with compact and inexpensive IR camera. Following initial qualification of an AM component for deployment in a nuclear reactor, a compact PT system can also be used for in-service nondestructive evaluation (NDE) applications. However, data cube obtained with PT based on compact IR camera suffers from strong thermal noises and loss of features due to relatively low sampling rate. In this report we describe two unsupervised machine learning (ML) algorithms for enhancement of PT images obtained with compact IR camera. In one approach, we introduce Sparse Coding Discrete Cosine Transform (SC/DCT) algorithm to remove additive white Gaussian noise (AWGN) from spatial thermal effusivity reconstructions. In another approach we introduce a Spatial Temporal Denoised Thermal Source Separation (STDTSS) ML algorithm to process thermograms. The STDTSS algorithm consists of spatial and temporal denoising using Gaussian and Savitzky–Golay filtering, followed by the matrix decomposition using Principal Component Analysis (PCA), and Independent Component Analysis (ICA) to automatically detect flaws. In the work described in this report, we constructed a compact PT system using a relatively small and low-cost FLIR A65 camera, consisting on uncooled microbolometer detector. Performance of SC/DCT algorithm was demonstrated on enhancing TT images of Inconel 718 AM plate. Performance of the STDTSS methods was investigated using thermography data obtained from imaging stainless steel 316L specimens produced with LPBF method with imprinted calibrated porosity defects.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Measuring thermal profiles in high explosives using neural networks

We present a new method for calculating the temperature profile of high explosive (HE) material using a Convolutional Neural Network (CNN). To train/test the CNN, we have developed a hybrid experiment/simulation method for collecting acoustic and temperature data. We experimentally heat cylindrical containers of HE material until detonation/deflagration, where we continuously measure the acoustic bursts through the HE using multiple acoustic transducers lined around the exterior container circumference. However, measuring the temperature profile in the HE in an experiment would require inserting a large number of thermal probes, which would disrupt the heating process. Thus, we use two thermal probes, one at the HE center and one at the wall. We then use numerical simulation of the heating process to calculate the temperature distribution and correct the simulated temperatures based on the experimental center and wall temperatures. We calculate temperature errors on the order of 15 °C, which is ∼12% of the range of temperatures in the experiment. We also investigate how the algorithm’s accuracy is affected by the number of acoustic receivers used to collect each measurement and the resolution of the temperature prediction. This work provides a means of assessing the safety status of HE material, which cannot be achieved using existing temperature measurement methods. In addition, it has implications for a range of other applications where internal temperature profile measurements would provide critical information. These applications include detecting chemical reactions, observing thermodynamic processes such as combustion, monitoring metal or plastic casting, determining the energy density in thermal storage capsules, and identifying abnormal battery operations.

97 MATHEMATICS AND COMPUTING↗

Low-temperature failure mechanism of [001] niobium micropillars under uniaxial tension

The plasticity of body-centered cubic (bcc) metals is dependent of temperature as well as sample dimension at the micrometer scale, but the effects of cryogenic temperature on the plasticity and the related failure process in micron-sized bcc metals have not been studied under uniaxial tension. In this work, we utilized in situ cryogenic micro-tensile tests, transmission electron microscopy, and dislocation dynamic simulations to examine the plasticity and failure processes of [001]-oriented bcc niobium micropillars. Our study reveals that a strong suppression of cross-slip at low temperatures prevents dislocation multiplication and leads to a dislocation starvation state, at which no mobile dislocation exists due to the rapid annihilation of dislocations at free surfaces. New dislocations are then nucleated until stress concentration at a slip step creates a micro-crack, the propagation of which leads to catastrophic failure. As a result, this unique failure process results from the combined effects of sample dimension and temperature.

36 MATERIALS SCIENCE↗

Traveling Molten Zone Refining Process Development for Innovative Fuel Cycle Solutions

Considering the phase diagrams of metallic spent fuel constituents, the melting and solidifying of spent metallic fuel causes three immiscible layers (actinide-rich, lanthanide-rich, and Group II-rich) and the condensate phase (Group I) to form. We believe this anticipated immiscibility offers an untapped opportunity for innovative fuel cycle solutions. Through the proposed project, we anticipate confirming the expected phase behavior and develop a thermal treatment process to rapidly extract actinides from spent metallic fuels. The prime apparatus for both purposes is a traveling molten zone system with induction heating. We envision that one rapid pass of the molten zone from the bottom to the top of the metallic rod incorporating species of spent metallic fuels should produce the expected immiscible layer formation and provide species partitioning data effectively and cleanly. It will also demonstrate an actinide extraction process by concentrating the impurities at the top segment of the rod and leaving the actinide species behind as the bulk rod. The successful execution of the project will demonstrate proof of concept for a transformative process path for used metal fuels in terms of economics and safeguards.

36 MATERIALS SCIENCE↗

Nickel Sulfide-Nanowire-Filled Carbon Nanotubes as an Efficient Overall Water Splitting Electrocatalyst

Pursuing stable, efficient, and cost-effective nanostructured bifunctional electrocatalysts is crucial for advancing the electrochemical water splitting process and enabling clean hydrogen energy production. In recent years, considerable efforts have focused on developing highly efficient and durable commercial electrocatalysts for the oxygen evolution reaction (OER) and overall water splitting (OWS). This research introduces an OWS electrocatalyst-nickel sulfide-filled carbon nanotubes grown on a carbon cloth substrate (Ni 3 S 2 @CNTs/CC), synthesized via a one-step in-situ process. The synergistic integration of metal sulfide (Ni 3 S 2 ) and carbon nanotubes provides abundant active sites for catalytic reactions, ensuring a robust composite nanostructure with enhanced durability. Furthermore, the electrocatalytic performance for OER and OWS has been significantly improved by a simple acid treatment to the electrocatalysts, which introduces physical and chemical defects, particularly oxygen functional groups (the acid-treated sample is termed as Ni 3 S 2 @CNTs/CC-AT). As OER electrocatalysts, Ni 3 S 2 @CNTs/CC and Ni 3 S 2 @CNTs/CC-AT present overpotentials of 304 and 200 mV, respectively, for achieving a current density of 10 mA/cm 2 in the OER process. Furthermore, for complete water splitting in 1.0 M KOH electrolyte, Ni 3 S 2 @CNTs/CC and Ni 3 S 2 @CNTs/CC-AT exhibit potentials of 1.63 and 1.44 V, respectively, to achieve a current density of 10 mA/cm 2 when employed as both anode and cathode. Moreover, Ni 3 S 2 @CNTs/CC and Ni 3 S 2 @CNTs/CC-AT demonstrate durable nature for 22 and 20 h durability in the OER and OWS processes, respectively, offering a promising alternative to ruthenium- and iridium-based electrocatalysts for electrochemical hydrogen production through water splitting. In conclusion, the in-situ synthesis method and acid treatment strategy described in this research are promising approaches to fabricating high-performance encapsulated carbon-nanotube-based electrocatalysts.

36 MATERIALS SCIENCE↗

Material and Design Optimization of Printed Melt Wire Arrays

Recent work conducted by the Advanced Sensors and Instrumentation (ASI) program at Idaho National Laboratory resulted in the establishment of in-house capabilities for fabricating and testing new advanced manufactured sensors for measuring irradiation temperatures inside a nuclear test reactor. Though current methods of real-time temperature monitoring (e.g., thermocouples) can still be used, the complexity of the feedthroughs and attachments needed for collecting real time measurements greatly increases the experiment-related costs. On the other hand, passive monitoring techniques can be used for collecting post irradiation temperature measurements by inferring reactor temperatures, based on the melting points of well-characterized materials (i.e., standard melt wires). However, challenges have arisen due to the limited space available for including instrumentation in experiments. To resolve this issue, the ASI program expanded its temperature detection capabilities to include advance manufactured melt wires for post-irradiation temperature measurements. These melt wires can determine reactor temperatures while also accommodating space limitations in irradiation experiments. To improve performance reliability and enhance melt wire readability following irradiation, FY-22 efforts have focused on optimizing the materials used in the encapsulation and printed melt wire array. This report details the design and fabrication tasks, along with the subsequent x ray computed tomography (XCT) evaluation process. The melt wire array consisted of indium with a melting point of 157°C, indium/silver (96/4 at%) with a melting point of 219°C, and tin with a melting point of 230°C. The encapsulation disc was made of vanadium due to its low activation properties and radiation resistance when deployed in nuclear reactors. Additionally, the melt wire design consisted of a ceramic sublayer (alumina disc) to further enhance the XCT post melting images of the printed melt wires. However, when sealing the vanadium container, all three melt wires melted, reflecting the temperature limitations that must be considered when employing metal containers in the sealing process.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Tailoring Carbide Dispersed Steels: A Path to Increased Strength and Hydrogen Tolerance

The use of transition metal carbides is reported for use as a hydrogen trapping mechanism for ferritic and austenitic steel materials. The program combined computational modeling and simulations to guide experiments towards candidate metal carbide traps, both for interfacial and interior trapping. It was found that interfacial trapping is less effective than interior trapping, with the group IVB transition metal carbides being the most effect internal traps with a loss of carbon. The sub-stoichiometric rocksalt structure accommodate the hydrogen atoms in its octahedral interstices. Using percolation theory, carbon loss of approximately 25% or more was sufficient to ensure an interconnected network of vacancies for such trapping from the surface to the internal sites within the carbide. Using this as a guide, the program developed a means to provide a uniform dispersion of ZrC nanoparticles with either Fe or 304L micron-scale powders which was then consolidated by direct current sintering. Electrolytic hydrogen diffusivity studies confirmed the reduction of hydrogen diffusion in the matrix with increasing ZrC content, which was a linear response over the sample range studied (0.01 to 1.0 wt.%). The consolidated material was micro-tensile tested in either a non-hydrogen or hydrogen charge condition and compared to a control with no carbides. Additions up to 0.05 wt.% ZrC increased the yield strength with no loss in ductility in either the non-hydrogen or hydrogen tested condition. ZrC concentrations above this amount further increased the yield strength at the expense of ductility. While these samples had a lower absolute ductility value prior to failure, the relative change in ductility between the non-hydrogen and hydrogen charge states was less for the carbides than that of the control. Metal-rich ZrC nanoparticles were fabricated through a conformal coating process yielding ZrC0.66 particles that were then incorporated into a metal matrix. Notch fatigue testing in a hydrogen environment was conducted where the number of cycles to failure was found to be less in the control than that of the carbide addition. However, the spread in experimental data and the number of samples tested limits a conclusive outcome based on defects noticed in the gauge section of all the powder processed samples. The collective outcomes of this report provide further insight into the mechanisms by which carbides act as hydrogen traps; a means to process such carbides through powder metallurgy; and their associated mechanical performance in either a non-hydrogen or hydrogen-charged condition.

08 HYDROGEN↗

Carbonation of metal silicates for long-term CO2 sequestration

In a preferred embodiment, the invention relates to a process of sequestering carbon dioxide. The process comprises the steps of: (a) reacting a metal silicate with a caustic alkali-metal hydroxide to produce a hydroxide of the metal formerly contained in the silicate; (b) reacting carbon dioxide with at least one of a caustic alkali-metal hydroxide and an alkali-metal silicate to produce at least one of an alkali-metal carbonate and an alkali-metal bicarbonate; and (c) reacting the metal hydroxide product of step (a) with at least one of the alkali-metal carbonate and the alkali-metal bicarbonate produced in step (b) to produce a carbonate of the metal formerly contained in the metal silicate of step (a).

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Long-Range Metal–Sorbent Interactions Determine CO 2 Capture and Conversion in Dual-Function Materials

Carbon capture and utilization involve multiple energy- and cost-intensive steps. Dual-function materials (DFMs) can reduce these demands by coupling CO 2 adsorption and conversion into a single material with two functionalities: a sorbent phase and a metal for catalytic CO 2 conversion. The role of metal catalysts in the conversion process seems salient from previous work, but the underlying mechanisms remain elusive and deserve deeper investigation to achieve maximum utilization of the two phases. Here, for this work, preformed colloidal Ru nanoparticles were deposited onto a “NaOx”/Al 2 O 3 sorbent to prepare prototypical DFMs with controlled phases for CO 2 capture and hydrogenation to CH 4 . Ru addition was found to double the high-temperature CO 2 adsorption capacity by activating the “NaOx”/Al 2 O 3 sorbent phase during a reductive pretreatment step. Most importantly, low Ru loadings were sufficient to ensure maximum CO 2 adsorption and conversion. This was attributed to the key role of the metal–sorbent interactions, wherein Ru was required to hydrogenate strongly bound CO 2 on the “NaO x ”/Al 2 O 3 sorbent to CH 4 via the H 2 activated on Ru. This interaction facilitated rate-determining carbonate migration and subsequent hydrogenation at the metal–sorbent interface. Overall, Ru controlled the CO 2 hydrogenation reaction rate, while the “NaO x ”/Al 2 O 3 sorbent dictated the CO 2 uptake capacity. By controlling metal–sorbent interactions at the molecular level, we demonstrate the critical role of the two phases and their synergy, facilitating the design of DFMs with maximum CO 2 capture and conversion efficiency.

carbon capture↗

Radiation Effects on the Performance of Advanced Sulfur Monochloride Chlorination Processes

Advanced sulfur chloride-based chlorination technologies are being developed to enable efficient recycling of aluminum and zirconium-based materials used in the nuclear industry. However, the impacts of ionizing radiation on the performance of these sulfur chloride compounds are not well established, despite this being critical knowledge for assessing their feasibility and longevity under envisioned process conditions. Here, in the present article, we report on the effects of cobalt-60 gamma irradiation (≤ 5 MGy) on the aluminum alloy 6061 (AA6061-T6) chlorination yield in sulfur monochloride (S 2 Cl 2 ). Our findings indicate that, compared to nonirradiated solvent, radiation-induced changes in the chemical composition of S 2 Cl 2 —identified using Raman spectroscopy—afford an additional, dose-dependent exothermic process prior to the chlorination reaction’s typical thermodynamic behavior. We attribute this new process to reactions involving aluminum species (metal, oxide, or [oxy]hydroxides) and sulfur dichloride (SCl 2 ), an S 2 Cl 2 radiolysis product that accumulates with absorbed gamma dose, but is absent following an AA6061-T6 chlorination study. Despite the exothermicity of this new process, the overall yield of chlorination decreased with increasing preirradiation dose. Consequently, the chemical reactivity, specificity (aluminum metal vs aluminum passivation and corrosion layer constituents), and byproducts of SCl 2 must be more thoroughly evaluated to support the continued development of advanced S 2 Cl 2 chlorination technologies.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗

Production of Germanium and Gallium Concentrates for Industrial Processes

A conceptual design of a process to produce germanium and gallium metal from mixed rare earth concentrates (consisting of oxides or carbonates) (MREC) produced from lignite carbon-ore was developed. The design was based on past work associated with the recovery of Ge from carbon-ore ash, modeling of the behavior of Ge and Ga in pyrometallurgical processes, and laboratory testing of the potential recovery of Ge and Ga from MREC. A teaming plan was developed that encompasses the entire supply chain that consisted of the Ge and Ga-rich carbon-ore resource, MREC pilot scale concentrate producer, MREC processing facility to produce Ge/Ga concentrates, refining of Ge and Ga concentrates to produce high purity metals (99.999+ purity), and Ge/Ga end users. A research plan was developed to transition the Ge and Ga separation from MREC, concentrating, and refining technology from a conceptual design to commercial scale. A technical and economic assessment of the conceptual design indicated that MREC derived from the UND process can produce 90 to 99% pure Ge and Ga concentrates at >20% lower costs.

01 COAL, LIGNITE, AND PEAT↗

Enhanced Sustainability in Treatment of Contaminated Metals for Clearance and Recycling - 20290

Cyclife Sweden AB has, for more than 30 years, provided metal treatment services to the domestic and international nuclear industry with the aim of creating value through metal clearance and recycling. These operations are to a large extent based on the concept that the materials, after pre-treatment, including decontamination, will be melted for clearance. During the melting process, some nuclides separate from the metal while the remaining radioactivity becomes fully homogenized in the metal bath and the resulting ingots, along with the samples taken before casting At a time when activities to fight Climate Challenge are in focus, any savings in energy consumption, in addition to the positive environmental effect of recycling metals back to industry, is more than welcome. If the clearance of certain metallic items can be achieved safely, without using melting, it is the environmentally preferred option provided it carries a reasonable cost. It is even better if an object can go through a decontamination and clearance process prior to re-use inside or outside the nuclear sector. Cyclife Sweden is currently investing in a direct clearance process, to be operated in parallel with the melting process. This new process is expected to be fully operational in the late summer of 2020 and includes pre-treatment, decontamination and heavily shielded clearance measurement installations. The treatment will also allow clearance measurements of larger objects without the need for segmentation, along with allowing objects composed of different materials, like electric motors can be accepted for treatment. This paper gives an overview of the circular economy aspects in a nuclear back-end context, the Cyclife approach to further implement a circular economy approach in the processes, Material Acceptance Criteria for treatment, the facility set-up for the new process and how the melting route and the direct route can be combined in an efficient industrial scale process. To put the new capabilities into perspective, the two different treatment and clearance approaches, i.e. direct clearance and melting, are to be compared. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Prediction of stability constants of metal–ligand complexes by machine learning for the design of ligands with optimal metal ion selectivity

The new LOGKPREDICT program integrates HostDesigner molecular design software with the machine learning (ML) program Chemprop. By supplying HostDesigner with predicted log K values, LOGKPREDICT enhances the computer-aided molecular design process by ranking ligands directly by metal–ligand binding strength. Harnessing reliable experimental data from a historic National Institute of Standards and Technology (NIST) database and data from the International Union of Pure and Applied Chemistry (IUPAC), we train message passing neural net algorithms. The multi-metal NIST-based ML model has a root mean square error (RMSE) of 0.629 ± 0.044 (R 2 of 0.960 ± 0.006), while two versions of lanthanide-only IUPAC-based ML models have, respectively, RMSE of 0.764 ± 0.073 (R 2 of 0.976 ± 0.005) and 0.757 ± 0.071 (R 2 of 0.959 ± 0.007). For relative log K predictions on an out-of-sample set of six ligands, demonstrating metal ion selectivity, the RMSE value reaches a commendably low 0.25. Here we showcase the use of LOGKPREDICT in identifying ligands with high selectivity for lanthanides in aqueous solutions, a finding supported by recent experimental evidence. We also predict new ligands yet to be verified experimentally. Therefore, our ML models implemented through LOGKPREDICT and interfaced with the ligand design software HostDesigner pave the way for designing new ligands with predetermined selectivity for competing metal ions in an aqueous solution.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

In situ probing the origin of interfacial instability of Na metal anode

The unstable and fragile solid electrolyte interphase (SEI) has restricted the application of Na metal anodes. Despite numerous research efforts being put into understanding its chemical composition and physical properties, direct observation of its formation remains a challenge due to the lack of temporal and spatial resolution. Here, through combined in situ probing techniques, we exhibit two pivotal stages associated with SEI instability during the often -neglected formation process. It is revealed that Na metal that is not uniformly passivated at the initial (passivating) stage will trigger unrestricted electrolyte decomposition and homogeneous components distribution during the subsequent (growing) stage. SEI with homogenously distributed components is found to have higher solubility than that with a layered structure evolved from a compact passivation layer. Furthermore, through demonstrating an SEI dissolution model that is closely related to its formation process and compositional distribution, this work sheds light on an uncharted territory of Na metal batteries.

25 ENERGY STORAGE↗

The γ -process nucleosynthesis in core-collapse supernovae

The γ-process nucleosynthesis in core-collapse supernovae is generally accepted as a feasible process for the synthesis of neutron-deficient isotopes beyond iron. However, crucial discrepancies between theory and observations still exist: the average yields of γ-process nucleosynthesis from massive stars are still insufficient to reproduce the solar distribution in galactic chemical evolution calculations, and the yields of the Mo and Ru isotopes are a factor of ten lower than the yields of the other γ-process nuclei. We investigate the γ-process in five sets of core-collapse supernova models published in the literature with initial masses of 15, 20, and 25 M ⊙ at solar metallicity. We compared the γ-process overproduction factors from the different models. To highlight the possible effect of nuclear physics input, we also considered 23 ratios of two isotopes close to each other in mass relative to their solar values. Further, we investigated the contribution of C–O shell mergers in the supernova progenitors as an additional site of the γ-process. Our analysis shows that a large scatter among the different models exists for both the γ-process integrated yields and the isotopic ratios. We find only ten ratios that agree with their solar values, all the others differ by at least a factor of three from the solar values in all the considered sets of models. The γ-process within C–O shell mergers mostly influences the isotopic ratios that involve intermediate and heavy proton-rich isotopes with A > 100. We conclude that there are large discrepancies both among the different data sets and between the model predictions and the solar abundance distribution. More calculations are needed; particularly updating the nuclear network, because the majority of the models considered in this work do not use the latest reaction rates for the γ-process nucleosynthesis. Moreover, the role of C–O shell mergers requires further investigation.

79 ASTRONOMY AND ASTROPHYSICS↗