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DOE OSTI2024

Models implemented in the methodological approach to design the initial STEP first wall contour

The official Spherical Tokamak for Energy Production mission aims to demonstrate the ability to generate net electricity from fusion with the STEP Prototype Power plant. One of the key technological and engineering challenges in fusion power plants is managing the loads on the first wall within acceptable limits. Therefore, the conceptual design development of the STEP Prototype Power plant needs to be based on load estimates derived using legitimate plasma physics assumptions through dynamic and flexible tools. The current design foresees the STEP main chamber first wall to withstand steady-state heat loads of up to ~1 MW/m 2 , excluding critical regions expected to receive higher heat loads such as the baffle regions approaching the divertors. These critical areas will require ad hoc assessments and will be designed with the presence of limiters. This article focuses on the models and methodology adopted for designing the 2-D poloidal contour of the STEP first wall, based on the anticipated charged particle and radiation heat loads during normal operation. Firstly, the models adopted for calculating the charged particle and radiation heat loads are introduced. The first model is validated through benchmarking against the particle tracing code SMARDDA, while the second model is verified by comparing it with data from the MAST-U experiment. Secondly, the model used to design the 2-D first wall contour according to the heat loads is explained. We acknowledge that this preliminary design stage assumes certain simplifications, notably an axisymmetric geometry, for computational efficiency and clarity in presentation. It is understood that subsequent design phases will address the complexities of real-world engineering, including non-axisymmetric effects, transient plasma scenarios, and the impact of disruptions on the first wall design. Finally, an automatic procedure based on these models is presented for defining the 2-D poloidal contour of the STEP first wall to minimize heat loads, taking into account the need to radiate most of the alpha-particle and auxiliary heating power. Here, by providing an overview of the models, methodology, and an automatic procedure, this paper contributes to the design process of the STEP first wall, addressing the engineering challenges associated with fusion power plant development.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2023

Preliminary Design of Critical Experiments Involving Commercially Available B 4 C Neutron Absorber Plates with Low-Enriched UO 2 Fuel

The International Criticality Safety Benchmark Evaluation Project (ICSBEP) is an initiative to provide high-quality benchmark data in a standardized format for criticality safety analysts to use to validate calculational tools and nuclear data. In the last released 2022 version, the ICSBEP handbook contains over 5,000 critical experiment descriptions, results, and associated models. This paper describes the critical configurations proposed and calculations performed as part of the conceptual design phase of Integral Experiment Request (IER) 554 (IER-554). The goal of IER-554 is to add to the benchmark experiments available to the criticality safety community by designing critical experiments that can analyze how adding commercially available Boralcan plates to an assembly of low-enriched UO2 fuel rods affects the effective neutron multiplication factor (k eff ). Boralcan, a neutron absorber product developed by Rio Tinto, is made of B4C in an Al 1100 matrix and is commonly used for criticality suppression in fuel storage pools. In the current version of the ICSBEP handbook, only a few dated critical experiments involve B4C materials, and none involve Boralcan in a thin plate shape. The experiments designed as part of IER-554 are intended to be performed at the Sandia Pulsed Reactor Facility/Critical Experiments (SPRF/CX) apparatus at Sandia National Laboratories. SPRF/CX is a well-characterized assembly considered trustworthy by the benchmarking community because of the numerous high-quality evaluations with very low experimental uncertainties included in the ICSBEP handbook. Figure 1 illustrates the assembly for a particular configuration from LCT-078, one of the published benchmarks in the ICSBEP handbook. The experiments will be moderated and reflected by light water at ambient atmospheric pressure. Before the plates are inserted in the critical assembly, they will be characterized with x-ray computed tomography (XCT) to identify the sizes and distribution of the B 4 C powder particles inside the plates. The preliminary design calculations were performed with SCALE 6.3.0 using the KENO V.a sequence for the criticality calculations, the CE-TSUNAMI-3D sequence for the sensitivity and uncertainty studies, and the ENDF/B-VII.1 Continuous Energy cross section library. All the calculation results presented have 10 pcm statistical uncertainties. A set of critical experiments with Boralcan plates could increase the confidence of the criticality safety community in its modeling methods when using this type of neutron absorber material. Experiments would also help validate k eff calculations, and the industry could use these validations to change the B loading credit limits from the US Nuclear Regulatory Commission standard review plan for dry cask storage of spent nuclear fuel. This paper summarizes only part of the analysis documented in the preliminary design report.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

Upgrading Fermilab s Accelerator Control System with ACORN

The Fermilab Accelerator Complex is the largest national user facility in the Office of High Energy Physics (DOE/HEP) program and the only national user facility operating at Fermilab. Fermilab serves as the host to the Long Baseline Neutrino Facility/Deep Underground Neutrino Experiment (LBNF/DUNE), the laboratory’s flagship project for neutrino science that is under construction. LBNF/DUNE will be powered by megawatt beams from an upgraded accelerator, the Proton Improvement Plan II (PIP-II) that will replace the laboratory’s aging linear accelerator with a new one based on superconducting radio-frequency cavities. The Accelerator Controls Operations Research Network (ACORN) Project will support LBNF/DUNE and PIP-II by modernizing the accelerator control system. The project is at the conceptual design phase and looking to achieve Critical Decision 1 (CD-1) later this year. The scope and structure of the project will be presented, along with an overview of how that has changed in the past year. Current design and technology choices will be shared. Specific challenges facing the project will be addressed, along with current thinking on solutions.

Roehrig, Christian [Fermilab]↗

DOE OSTI2022

Mild hybridisation of turboprop engine with high-power-density integrated electric drives

Here this paper shares with the aerospace community a case study of turboprop mild hybridisation using a recently developed integrated drive system in the University of Nottingham, UK, within the ACHIEVE project under EU H2020 CleanSky 2 program (project No. 737814). The developed drive system enables green taxiing of a turboprop aircraft while on the ground with its engine off, and as an electrical generator when the turboprop is in the air. The entire system is designed to be able to integrate within the power auxiliary gear box (PAGB) of a turboprop aircraft. Some of the key features of the developed system include a high-speed permanent magnet machine (up to 14,200rpm) with dual three-phase design, SiC-based high power density (11.8kW/L for the power converter, 35.3kW/L and 7.2kW/kg for the machine active parts), integrated cooling design for high-temperature operation (>130°C ambient temperature), fault tolerance consideration with dual channel operation capabilities and sensorless control for entire operational conditions. This paper is giving an overview of the design process of the electrical machine, power converters, and its cooling of the entire drive. Numerical analysis (FEM and CFD) and some experimental results are presented to demonstrate the effectiveness and the desired performance of the developed integrated drive system.

42 ENGINEERING↗

DOE OSTI2025

Building a Collaborative Relationship between Contractor and Oversight at SRPPF

The success of Department of Energy (DOE) projects is dependent on a functional, healthy, and collaborative relationship between the contractor and the federal oversight. A healthy relationship marked by a collaborative mindset between these two groups, can facilitate better operational safety, operational efficiency, and regulatory compliance. This paper will explore aspects of such a relationship, the roles and responsibilities of the contractor and federal oversight, the present and historical relationships in the DOE complex, and best practices considered by the contractor and federal oversight used at the Savannah River Plutonium Processing Facility (SRPPF) at the Savannah River Site (SRS). Due to the current design phase of the SRPPF, the contractor and federal oversight have a unique opportunity to begin establishing a strong relationship early in the project’s life. As a result of this dynamic, the two groups have already demonstrated their ability to successfully respond to ongoing design issues. In general, a strong criticality safety program is beginning to mature for the SRPPF alongside a developing criticality safety federal oversight group. This paper will discuss the various factors that have brought about this collaborative relationship. Lastly, a case study will be incorporated into this paper demonstrating the ability of the SRPPF contractor and federal oversight to overcome challenges relating to the SRPPF project. This case study may guide groups around the DOE Complex to create better, more functional relationships between the two parties. The case study will provide a detailed description of the issue and parties involved, highlight the factors that allowed the group to overcome the challenge via effective collaboration, and the outcome of the event. Increasing collaboration may benefit the complex, as a whole, in order to meet the mission demands of the DOE.

collaboration↗

DOE OSTI2022

Designing Glass and Crystalline Phases of Metal–Bis(acetamide) Networks to Promote High Optical Contrast

Owing to their high tunability and predictable structures, metal–organic materials offer a powerful platform to study glass formation and crystallization processes and to design glasses with unique properties. In this work, we report a novel series of glass-forming metal–ethylenebis(acetamide) networks that undergo reversible glass and crystallization transitions below 200 °C. The glass-transition temperatures, crystallization kinetics, and glass stability of these materials are readily tunable, either by synthetic modification or by liquid-phase blending, to form binary glasses. Pair distribution function (PDF) analysis reveals extended structural correlations in both single and binary metal–bis(acetamide) glasses and highlights the important role of metal–metal correlations during structural evolution across glass–crystal transitions. Notably, the glass and crystalline phases of a Co–ethylenebis(acetamide) binary network feature a large reflectivity contrast ratio of 4.8 that results from changes in the local coordination environment around Co centers. These results provide new insights into glass–crystal transitions in metal–organic materials and have exciting implications for optical switching, rewritable data storage, and functional glass ceramics.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2024

Optimization of the Second Target Station cold source moderators using an automated workflow

The Second Target Station (STS) at the US Department of Energy’s Oak Ridge National Laboratory is designed to become the world’s highest peak-brightness spallation source of cold neutrons. Successful completion of the STS, which is currently in the preliminary design phase, will provide transformative new capabilities to examine novel materials for future technologies. At STS, neutrons will be generated by spallation reactions in a solid tungsten target. They will be moderated and thermalized in two cold (20 K) para-hydrogen moderators. Careful optimization of these moderators is essential to the project’s success. To find optimal moderator designs, an advanced optimization workflow integrates high-fidelity neutronics calculations using the Monte Carlo N-Particle (MCNP) transport code MCNP6.2 with state-of-the-art optimization algorithms in the Dakota optimization toolkit. For each design iteration, a parametrized solid CAD geometry is generated in Creo and automatically converted into an unstructured mesh geometry by Attila 4MC for the neutronics calculation with MCNP. Iterations repeat until optimal designs are found. Herein this paper presents the results of a sensitivity and optimization study for the cylindrical and tube moderators. Both moderators can be optimized for maximum peak brightness, maximum time-integrated brightness, or any combination between these extremes. Maximum peak brightness is achieved by using smaller optimal dimensions of the moderators, whereas maximum time-integrated brightness is achieved by using larger dimensions. A Pareto front details the designs that optimally balance both brightness metrics. The Pareto front can be found in only 40–110 iterations with 4–5 design parameters when using the efficient global and Pareto-set optimization algorithms in Dakota. Additionally, important engineering constraints can be taken into account, such as the coupling between the cylindrical moderator radius and aluminum vessel wall thicknesses required to ensure structural integrity of the vessels. This interaction has a significant impact on the resulting optimal designs. Our new, highly efficient, fully automated optimization workflow will be used to optimize additional STS components in the future and can be adopted for design and optimization studies at other experimental neutron and accelerator facilities.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2023

Final Design of the Material Plasma Exposure eXperiment

The Material Plasma Exposure eXperiment (MPEX) has completed its design phase. MPEX will be a unique facility to investigate plasma material interactions (PMIs) under fusion prototypic divertor conditions in steady state. This includes plasma exposure conditions expected in a fusion reactor divertor. Materials to be investigated will include solids, liquids, and neutron pre-irradiated materials. Electron and ion heating will allow for a large operational domain ranging from erosion-dominated PMI conditions to deposition-dominated PMI conditions. An overview of the final design for all MPEX systems is given. Here, in particular, it is shown how mission-driven project requirements have led to detailed design choices with innovative solutions. Examples are the water-cooled helicon window, the electron cyclotron heating launcher, the target holder and manipulator, and the autonomous decouplers.

Fusion reactor↗

DOE OSTI2025

Master Oscillator and Phase Reference Line Design for the PIP-II Linac

The phase averaging reference line system provides the RF phase reference, LO and clock signals to the LLRF and other accelerator sub-systems. The PIP-II linac has RF systems at three frequencies - 162.5 MHz, 325 MHz and 650 MHz. A temperature-stabilized, low-phase-noise oscillator is used as the master oscillator. Phase reference signals at 162.5 MHz, 325 MHz, and 650 MHz, along with LO signals at 182.5 MHz, 345 MHz, 670 MHz and LLRF clocks at 1320 MHz and 1300 MHz, are generated in temperature-controlled RF modules at each frequency section. A phase reference from each module travels to the next section, where it is doubled to produce required frequencies. The reference also travels alongside the accelerating cavities in the tunnel, allowing cavity probe and reference cables to temperature track and reduce measurement errors from temperature changes or phase drift.

Syed, A. [Fermilab]↗

DOE OSTI2021

Using Qualified On-Site Nuclear Power Plant Simulators in Human Factors Validations of Control Room Upgrades

Existing commercial nuclear power plants (NPPs) are valuable assets in the infrastructure portfolio of the United States (U.S.) because they safely and reliably generate about 1/5th of all the electricity used. The instrumentation and control (I&C) systems in commercial NPPs are the ‘eyes and ears' of the operator, allowing operators to maintain situation awareness, thereby allowing the plant to operate safely and efficiently for all phases of operation. Because the I&C systems in NPPs are still mostly based on analog technologies, which are reliable but not especially cost-effective, upgrading the existing I&C in com-mercial NPPs to new digital I&C is very important. Furthermore, simulators and simulation are critical human factors engineering tools for this I&C modernization work. NPP control room simulators are essential test beds to simulate normal, abnormal, and emergency operations that allow human factors researchers to safely and realistically evaluate early design phase prototypes of the upgraded digital I&C, and validate final as-built digital I&C systems that have been modernized deployed in NPPs. This paper describes research performed using qualified on-site NPP simulators to perform human factors validations of digital I&C control room upgrades.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2023

The research challenges in security and safeguards for nuclear fission batteries

This paper discusses the nuclear security and safeguards research challenges presented by the development and deployment of nuclear fission batteries. These are defined as easily transportable and deployable nuclear systems which are designed to operate either unattended or autonomously. We start by defining the current landscape of domestic and international safeguards and security and discuss how it can be affected by the introduction these new nuclear systems. We then specifically discuss the technology gaps and technologies to be developed to facilitate their practical deployment. We find that, as expected, we can leverage conclusions from existing security and safeguards studies for small modular rectors and develop bespoke target set analyses to inform security postures based on probabilistic risk assessment. We find also that specific fission battery security economic analysis tools are needed and security by design must be applied early. However, the most important finding is that these new systems will require a new comprehensive set of cyber tools covering transportation, installation, operation, maintenance security of the fission battery systems. Altogether, we find that the development of the necessary security and safeguards requirements at the design phase of such a technology will be of great benefit in the smooth deployment of this modern nuclear energy system.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2022

Extracting energy from ocean thermal and salinity gradients to power unmanned underwater vehicles: State of the art, current limitations, and future outlook

Thermal gradient energy-generation technologies for powering unmanned underwater vehicles (UUVs) or autonomous sensing systems in the ocean are mainly in the research development phase or commercially available at a limited scale, and salinity-gradient energy-generation technologies have not been adequately researched yet. The demand for self-powered UUVs suitable for long-term deployments has been growing, and further research related to small-scale ocean gradient energy systems is needed. In this study, we conducted a comprehensive review about harvesting energy from ocean thermal or salinity gradients for powering UUVs, focusing on gliders and profiling floats. Thermal gradient energy systems for UUVs based on phase change materials (PCM) cannot provide the energy required for powering autonomous sensing systems because of the systems' low energy conversion efficiency. Besides reducing energy consumption by developing more efficient electrical-mechanical systems, enhancing the thermal conductivity of the PCMs may help address this challenge by increasing the power generation rate of the UUVs. Several other emerging technologies, such as thermoelectric generators, shape memory alloys, and small-scale thermodynamic cycle systems, have shown potential for powering UUVs, but they are still only at the laboratory testing or conceptual design phase. The most advanced power generation technologies based on salinity gradients, reverse electrodialysis and pressure-retarded osmosis, are still not economically viable for large-scale deployment, mainly because of the high cost of the components required to operate in harsh saline environments. Our feasibility evaluation showed that existing salinity gradient power generation technologies are not directly feasible for powering UUVs in the open ocean.

16 TIDAL AND WAVE POWER↗

DOE OSTI2023

Automated Design-for-Reliability of a Power Electronics Module

The design of a power electronics module is a multiphysics problem and involves electrical, thermal, and reliability targets and constraints. Although the electrical and thermal design consider multiple aspects such as materials, geometry, and energy losses, reliability design is often limited to the selection of the attachment materials and electrical interconnect types. In this paper, we incorporate reliability metrics in the design phase by investigating the impact of package geometry on the thermomechanical behavior of the die-attachment material. To this end, we conducted thermal and power cycling simulations of a commercial six-pack power module with silicon carbide devices to compute junction temperature and strain energy density per cycle, respectively. We performed multiple simulations with different geometric dimensions and established a correlation between input features and output variables using subspace-based dimension reduction. The machine learning-based dimension reduction method serves as a surrogate model, which can be employed to identify the optimal module design from a thermal and reliability standpoint.

design-for-reliability↗

DOE OSTI2023

Engineering-In Cybersecurity

Cyber-Informed Engineering is a framework which allows engineers to build resiliency to the impacts of cyber attack into engineered systems starting in the early design phases. This article introduces the framework and provides a description of some of its principles and resources for learning more.

42 ENGINEERING↗

DOE OSTI2022

MPEX High Heat Flux Plasma Dump Design, Manufacture, and Articles Test

Here, the Material Plasma Exposure eXperiment (MPEX) device is a steady-state linear plasma device currently in the final design phase at the Oak Ridge National Laboratory. This device will reach ion fluences up to 10 31 m -2 and will be used to expose neutron-irradiated materials to divertor-relevant plasmas and to study the effects of plasma-material interactions. These studies will elucidate the complex effects of plasmas with divertor candidate materials capable of withstanding high heat flux and high fluences for next-generation fusion devices. Bidirectional plasma will be generated using a high-power (200 kW) helicon source. Plasma will be confined by superconducting magnets. The last plasma-facing component on the upstream side of the MPEX device is the dump, which has been designed to intercept plasma and energetic particles. The dump will have a total heat load of 9.2 kW. A copper alloy (Glidcop AL-15) was selected for use in the water-cooled flange design because of its high thermal conductivity, its retaining strength at elevated temperatures, and its ability to be used in the high-temperature braze joints used in this application. Titanium-zirconium-molybdenum (TZM) tiles are brazed to the Glidcop AL-15 flange using high-temperature braze alloy. External water-cooling channels are used on the dump flange to prevent water leakage inside the vacuum space. This article discusses the details of the high heat flux dump design, including the computational fluid dynamics (CFD) and structural analyses performed to validate the design to meet the operational requirements of the MPEX device.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2024

Enhanced beam-beam modeling to include longitudinal variation during weak-strong simulation

Beam-beam interactions pose substantial challenges in the design and operation of circular colliders, significantly affecting their performance. In particular, the weak-strong simulation approach is pivotal for investigating single-particle dynamics during the collider design phase. This paper evaluates the limitations of existing models in weak-strong simulations, noting that while they accurately account for energy changes due to slingshot effects, they fail to incorporate longitudinal coordinate changes ( z variation). To address this gap, we introduce two novel transformations that enhance Hirata’s original framework by including both z variation and slingshot effect-induced energy changes. Through rigorous mathematical analysis and extensive weak-strong simulation studies, we validate the efficacy of these enhancements in achieving a more precise simulation of beam-beam interactions. Our results reveal that although z variation constitutes a higher-order effect and does not substantially affect the emittance growth rate within the specific design parameters of the Electron-Ion Collider, the refined model offers improved accuracy, particularly in scenarios involving the interaction between beam-beam effects and other random diffusion processes, as well as in simulations incorporating realistic lattice models. Published by the American Physical Society 2024

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2023

Effects of finite sampling on fatigue damage estimation of wind turbine components: A statistical study

The variability of the wind turbine loads complicates fatigue assessment in the design phase, as performing simulations covering the entire lifetime is computationally expensive. The current work provides important information for assessing the uncertainty in fatigue damage estimation due to finite data. Here we study the sample size effect on mean, variance, and skewness of damage in each wind bin, identify the important wind bins, and study the uncertainty propagation from each wind bin to the lifetime damage using 3600 aeroelastic simulations and bootstrapping. To achieve less than 1% error in the damage estimation across all load channels in the current case study, at least 100 turbulence seeds are needed. Damage in different wind bins follows a lognormal distribution when using the conventional approach of six seeds. The provided insights and information allow the designer to achieve a specific level of accuracy for a given computational cost using strategic bin sampling.

17 WIND ENERGY↗

DOE OSTI2025

Advancing the STS Neutron Moderator Design with an Automated Optimization Workflow and Unstructured Mesh Modeling

With the Second Target Station approaching its final design phase, a detailed neutronics evaluation of its critical components is necessary. Optimizing the dimensions of the two cold-source moderators that are at the heart of this facility presents a multi-objective optimization problem for which an accurate geometric description is crucial. We have applied a fully automated optimization workflow in which a detailed unstructured mesh geometry is automatically generated with Attila4MC, starting from a parametrized CREO geometry followed by preprocessing with SpaceClaim. With this geometry, a MCNP run is performed to calculate the brightness metrics, which are subsequently provided to the optimization algorithm in DAKOTA that provides new parameters and drives the optimization loop until convergence. In this paper, we show the results of the analysis that are used for the final design of the cylindrical and tube moderator. The optimization simulations provide a refinement to and confirmation of the conclusions of the previous design iteration. Additional to the optimization, a sensitivity study is performed to study the effect of minor geometry changes, which is important for the final engineering design. In conclusion, with these studies, we demonstrate that the automated workflow and high-fidelity unstructured mesh modeling are efficient tools for a thorough design evaluation.

DAKOTA↗