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DOE OSTI2023

Simulation of Reverse Osmosis Membrane Compaction Using Material Point Method

Reverse Osmosis (RO) is a promising technology to address the impending water-crisis in the upcoming decades. RO at high salinities and high pressures is challenging due to membrane compaction that changes its porosity and permeability. In this study, we present a simulation methodology for membrane structural mechanics to understand pore size distribution and permeability variations under high pressure. We use the material point method (MPM), that solves the solid mechanics equations in a Lagrangian framework. MPM provides many features that make it well-suited for simulating mesoporous membranes. The Lagrangian framework allows for large deformations, easy integration of constitutive models and direct import of complex geometries as particles. The spatial discretization in our MPM solver is achieved using linear or cubic-spline shape functions while the time integration is carried out using the explicit Euler method. A series of images containing detailed pore structures obtained from X-ray tomography is first converted to a collection of material points. Compressive loads are applied to the top layer of the membrane to simulate the application of pressure. The membrane deformation and pore size distribution before and after load application are reported and compared with the experimental measurements. The presentation discusses the numerical methods used, the performance of the solver on high-performance computing machines, and the results of membrane compact in detail.

compaction↗

DOE OSTI2021

The advanced tokamak path to a compact net electric fusion pilot plant

Abstract Physics-based simulations project a compact net electric fusion pilot plant with a nuclear testing mission is possible at modest scale based on the advanced tokamak concept, and identify key parameters for its optimization. These utilize a new integrated 1.5D core-edge approach for whole device modeling to predict performance by self-consistently applying transport, pedestal and current drive models to converge fully non-inductive stationary solutions, predicting profiles and energy confinement for a given density. This physics-based approach leads to new insights and understanding of reactor optimization. In particular, the levering role of high plasma density is identified, which raises fusion performance and self-driven ‘bootstrap currents’, to reduce current drive demands and enable high pressure with net electricity at a compact scale. Solutions at 6–7 T, ∼4 m radius and 200 MW net electricity are identified with margins and trade-offs possible between parameters. Current drive comes from neutral beam and ultra-high harmonic (helicon) fast wave, though other advanced approaches are not ruled out. The resulting low recirculating power in a double null configuration leads to a divertor heat flux challenge that is comparable to ITER, though reactor solutions may require more dissipation. Strong H-mode access (x2 margin over L–H transition scalings) and ITER-like heat fluxes are maintained with ∼20%–60% core radiation, though effects on confinement need further analysis. Neutron wall loadings appear tolerable. The approach would benefit from high temperature superconductors, as higher fields would increase performance margins while potential for demountability may facilitate nuclear testing. However, solutions are possible with conventional superconductors. An advanced load sharing and reactive bucking approach in the device centerpost region provides improved mechanical stress handling. The prospect of an affordable test device which could close the loop on net-electric production and conduct essential nuclear materials and breeding research is compelling, motivating research to validate the techniques and models employed here.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2024

Design and testing of ultrasound probe adapters for a robotic imaging platform

Medical imaging-based triage is a critical tool for emergency medicine in both civilian and military settings. Ultrasound imaging can be used to rapidly identify free fluid in abdominal and thoracic cavities which could necessitate immediate surgical intervention. However, proper ultrasound image capture requires a skilled ultrasonography technician who is likely unavailable at the point of injury where resources are limited. Instead, robotics and computer vision technology can simplify image acquisition. As a first step towards this larger goal, here, we focus on the development of prototypes for ultrasound probe securement using a robotics platform. The ability of four probe adapter technologies to precisely capture images at anatomical locations, repeatedly, and with different ultrasound transducer types were evaluated across more than five scoring criteria. Testing demonstrated two of the adapters outperformed the traditional robot gripper and manual image capture, with a compact, rotating design compatible with wireless imaging technology being most suitable for use at the point of injury. Next steps will integrate the robotic platform with computer vision and deep learning image interpretation models to automate image capture and diagnosis. This will lower the skill threshold needed for medical imaging-based triage, enabling this procedure to be available at or near the point of injury.

47 OTHER INSTRUMENTATION↗

DOE OSTI2020

Millimeter wave traveling wave tubes for the 21st Century

Traveling wave tubes are rapidly evolving to provide unprecedented power level in comparison to solid state devices in the millimeter waves region of the spectrum (80–300 GHz) thus enabling a wide range of applications. Wireless communications, imaging, plasma diagnostics, healthcare and many others will gain substantial features if high power at millimeter waves would be available from compact sources. The development of fabrication technologies is proving crucial for introducing new topologies and structures for millimeter wave vacuum electronic devices, compatible with the dimensions dictated by the short wavelength that poses substantial manufacturing challenges due to tight tolerances. This review paper will provide an overview of the principles, evolution and state of the art of one of the most widely utilized vacuum electronic device, the traveling wave tube (TWT). The wide band, high gain features of TWTs make those devices the most promising solutions for high power at millimeter waves and THz frequencies.

42 ENGINEERING↗

DOE OSTI2021

High Power Superconducting Electron Linear Accelerators For Industrial Application

Fermilab is executing a technology development program to develop a compact yet powerful electron accelerator. We are leveraging R&D breakthroughs in SRF cavities, cost-effective radio-frequency sources, modern cryo-coolers, and high average current electron guns. We show that a single accelerator module can deliver average beam power as high as 1 MW through detailed thermal, RF, and particle simulations.

Thangaraj, Jayakar Tobin↗

DOE OSTI2020

On-chip integrated laser-driven particle accelerator

Particle accelerators represent an indispensable tool in science and industry. However, the size and cost of conventional radio-frequency accelerators limit the utility and reach of this technology. Dielectric laser accelerators (DLAs) provide a compact and cost-effective solution to this problem by driving accelerator nanostructures with visible or near-infrared pulsed lasers, resulting in a 10 4 reduction of scale. Current implementations of DLAs rely on free-space lasers directly incident on the accelerating structures, limiting the scalability and integrability of this technology. In this article, we present an experimental demonstration of a waveguide-integrated DLA that was designed using a photonic inverse-design approach. By comparing the measured electron energy spectra with particle-tracking simulations, we infer a maximum energy gain of 0.915 kilo–electron volts over 30 micrometers, corresponding to an acceleration gradient of 30.5 mega–electron volts per meter. On-chip acceleration provides the possibility for a completely integrated mega–electron volt-scale DLA.

43 PARTICLE ACCELERATORS↗

DOE OSTI2022

Versatile Heat Transfer Module

Development of micro-reactors that can be easily transported to remote areas for civilian or military applications is an immediate focus of U.S. nuclear industry and therefore is being pursued by multiple reactor vendors (e.g. HolosGen LLC, Westinghouse, Ultra Safe Nuclear Corporation, URENCO, etc.) and actively supported by DOE-NE, DOE-ARPA-E and by the Department Of Defense (DoD). Very-high-temperature gas-cooled (VHTR) and heat pipe cooled reactor technologies are regarded as promising concepts for microreactors applications since they enable compact power conversion systems and display beneficial inherent safety features. Development of microreactors with enhanced performance must be supported by innovations in nuclear technologies. Several technologies being developed by the microreactor industry are being revisited with material technologies developed at the Argonne National Laboratory (ANL). Innovative high-temperature compatible solutions are developed to enable advanced thermal-spectrum microreactor designs featuring improved neutronics performance at high-temperature operating conditions to enable high thermal efficiency and economic competitiveness. This report focuses on the Versatile Heat Transfer Module (VHTM) technology that is developed at ANL for heat-transfer in thermal-spectrum microreactors. This technology is built on a liquid alkali metal heat pipe concept while leveraging advanced nuclear material technologies for high-temperature applications at reduced neutronic penalty with potential improvement in inherent safety behavior. The VHTM can be applied to design high-temperature thermal-spectrum microreactor systems with reduced size, weight, uranium enrichment, or increased lifetime. The INFINIT technology deriving from the VHTM enables design of a highly compact long-life microreactor concept for fission surface power (FSP). Demonstration of multiphysics modeling capability was also completed to showcase the added inherent safety benefits obtained with this concept. The VHTM technology remain at an early development stage with low Technology Readiness Level and Manufacturing Readiness Level. The current demonstration of these technologies has focused on manufacturing capability, on performance of the hydrogen diffusion barrier under thermal cycling, while radiation tolerance demonstration is planned. The next step of the demonstration plan will be the assembly of miniature VHTM for high-temperature testing, which can be used as a prototype for future pilot scale demonstration. Such research is critical to pursue development of these technologies that have the clear potential to significantly improve the performance of currently investigated micro-reactors systems.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2025

Ultrahigh pressure compaction-resistant thin film crosslinked composite reverse osmosis membranes

In this study, we present a class of thin-film crosslinked (TFX) composite reverse osmosis (RO) membranes that resist physical compaction at ultrahigh pressures (up to 200 bar). Since RO membranes experience compaction at virtually all pressure ranges, the ability to resist compaction has widespread implications for RO membrane technology. The process described herein involves crosslinking a phase inverted porous polyimide (PI) support membrane followed by interfacial polymerization of a polyamide layer, thereby forming a fully thermoset composite membrane structure. We explore a range of phase inversion membrane formation parameters such as PI concentration, solvent-cosolvent ratios, coagulation bath composition, and crosslinking methods in addition to interfacial polymerization reaction chemistry and conditions. Overall, TFX membranes exhibit significantly less compaction compared to hand-cast and commercial high-pressure RO membranes, experiencing less than 10% decline in water permeance and maintaining salt rejection over 99% for NaCl solutions up to 180,000 mg/L with 200 bar applied pressure.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2022

SPT-3G+: mapping the high-frequency cosmic microwave background using kinetic inductance detectors

We present the design and science goals of SPT-3G+, a new camera for the South Pole Telescope, which will consist of a dense array of 34100 kinetic inductance detectors measuring the cosmic microwave background (CMB) at 220, 285 and 345 GHz. The SPT-3G+ dataset will enable new constraints on the process of reionization, including measurements of the patchy kinematic Sunyaev-Zeldovich effect and improved constraints on the optical depth due to reionization. At the same time, it will serve as a pathfinder for the detection of Rayleigh scattering, which could allow future CMB surveys to constrain cosmological parameters better than from the primary CMB alone. In addition, the combined, multi-band SPT-3G and SPT-3G+ survey data, will have several synergies that enhance the original SPT-3G survey, including: extending the redshift-reach of SZ cluster surveys to z > 2; understanding the relationship between magnetic fields and star formation in our Galaxy; improved characterization of the impact of dust on inflationary B-mode searches; and characterizing astrophysical transients at the boundary between mm and sub-mm wavelengths. Finally, the modular design of the SPT-3G+ camera allows it to serve as an on-sky demonstrator for new detector technologies employing microwave readout, such as the on-chip spectrometers that we expect to deploy during the SPT-3G+ survey. In this paper, we describe the science goals of the project and the key technology developments that enable its powerful yet compact design.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2026

Confinement and String Breaking in the Compact Abelian Higgs Model

While real-time simulation of Quantum Chromodynamics remains technologically out of reach, simplified models for studying elements of QCD phenomenology abound. This work presents a simple model, a spin-1 truncation of the Compact Abelian Higgs Model simulated on qutrit sites, in which confinement and string breaking is accessible to current simulation methods. In the low-energy regime of 1+1D scalar electrodynamics, the heavy modes are integrated out, producing a spin chain effective Hamiltonian in which Gauss' law is implicitly satisfied. We study the spectrum of string-like excitations using DMRG methods on the order of 100 sites. We demonstrate that an added, local chemical potential, playing a role analogous to external charges, permits parameter-dependent measurements of physical features of interest like the string tension and effective meson mass. Varying the chemical potential also permits a characterization of string stability not assessed in prior studies of confining lattice models.

Senseman, Blake [Iowa U.]↗

DOE OSTI2025

Compact X-band split electron linac for cabinet-size small-sample irradiators

Many small-scale industrial radiation facilities rely on hazardous radioisotope-based gamma ray irradiators, which are being gradually replaced by alternative technologies, such as particle accelerators. RadiaBeam has developed a compact, cabinet-size, 3 MeV electron-linac-based irradiator to match the penetration of Co-60 and provide high irradiation throughput. Here the linac utilizes X-band RF power to reduce size, employs an innovative split-linac approach to lower costs, and features a novel X-ray conversion target geometry that spreads the beam out across the target, providing a low dose uniformity ratio. In this paper, we discuss the accelerator design, fabrication, and test results.

43 PARTICLE ACCELERATORS↗

DOE OSTI2023

Defining a compact dry cooler design to reduce LCOE contribution in a CSP facility

Concentrating solar power (CSP), when coupled with a supercritical carbon dioxide (sCO 2 ) power cycle and sensible heat storage, presents a renewable and clean alternative for utility-scale power generation. However, in order to be competitive in the current and future markets, CSP facilities must limit their levelized cost of electricity (LCOE) by minimizing capital costs and reducing operating costs over the lifetime of the plant. Targeting this goal, this study investigates the LCOE impact of the power cycle pre-cooler. This study considers a compact dry cooler with micro-channel technology on the CO 2 side and formed fin geometry on the air side, using directly-coupled centrifugal fans and a transition duct to improve air distribution across the fins as well as protect the fins from contaminants which may cause blockage, soiling, fouling, and damage. In an effort to better understand the dry cooler impact on LCOE, a sensitivity study was conducted using various combinations of end-to-end approach temperatures, air-side pressure drop values, CO 2 -side pressure drop values, fan types, cooler turndown control schemes, cooler module sizes, and design-point ambient temperatures. Furthemore, off-design cycle performance data was calculated for each dry cooler design using NPSS simulation software; cycle performance data were then input to System Advisor Model (SAM) along with the associated capital costs for LCOE prediction of a 100 MW system over a 30 year plant lifetime. Results of this study show the LCOE is most sensitive to air-side performance, followed by heat transfer effectiveness and capital cost. It was found that a power cycle with a mid- to high-performance dry cooler will produce the most competitive power-production costs. Designing at the extreme ends for approach temperature (or effectiveness), design-point ambient temperature, and compactness (footprint) produce higher LCOE values; mid-range values for these parameters balance performance, operating costs, and associated capital cost to optimize LCOE.

14 SOLAR ENERGY↗

DOE OSTI2026

TCAD-Machine Learning Enabled TID Compact Model Development for Commercial SiC MOSFET

We propose a TCAD (Technology Computer Aided Design)-machine learning coupled approach that combines a TCAD tool (Charon), optimization/uncertainty quantification tool (Dakota), surrogate models, and Bayesian learning capabilities. The coupling approach is used for accurate modeling and calibration of total ionizing dose (TID) induced threshold voltage (V th ) shifts in Commercial-Off-The-Shelf (COTS) semiconductor devices and to develop physics-informed TID compact models. This versatile approach is applied to model the TID effect in an exemplar COTS 3.3 kV SiC power MOSFET (Metal-Oxide-Semiconductor Field-Effect Transistor). With the Charon-Dakota coupling, we can determine key device geometry and doping values based on device physics, which are difficult to obtain or not available for COTS devices but important for TCAD simulation; additionally, we can efficiently generate thousands of simulation results in a large parameter space, which makes it possible to develop data-driven surrogate models and perform Bayesian calibration. Utilizing the full tool-coupling approach, we achieve calibrated TCAD simulation models that accurately capture the average TID-induced V th shifts behavior with total doses and V th shifts saturation at high doses as observed in experimental data. More importantly, the calibrated TCAD simulations are obtained with determined TID model parameters (e.g., hole trap density and capture cross section) values that contain well quantified uncertainties. Furthermore, we can isolate and quantify the noises that are not captured by the TCAD models but exist in the measured data due to measurements and devices variabilities. Lastly, the calibrated surrogate models are used to develop physics-informed TID compact models. The method is generalizable to other devices and/or radiation conditions with few modifications and can provide well-determined uncertainties.

COTS↗

DOE OSTI2025

Small scale electron linear accelerators for industrial applications

Linear accelerators (linacs), producing electron or X-ray radiation in the MeV range, are critical tools for industrial irradiation, medical device sterilization, food pasteurization, non-destructive testing, security, medical, and many other applications. Many of these applications require compact and flexible radiation sources. In this paper, we present new technologies for small-scale electron linear accelerators and examples of their practical implementations. Furthermore, these developments include low energy accelerators with self-shielding options and form factors, ranging from cabinet-size to hand-portable generators; medium-energy accelerators for novel radiotherapy and security applications; and high-energy 10 MeV linacs capable of reaching 20–35 kW beam power for emerging industrial and phytosanitary applications

43 PARTICLE ACCELERATORS↗

DOE OSTI2024

Nb 3 Sn Superconducting Cavities by Bronze Routes for Accelerator Stewardship

This project explored the challenges of making Nb 3 Sn superconducting radio-frequency (SRF) cavities by bronze routes. The SRF research community has prioritized Nb 3 Sn for many reasons, including the possibility to operate linacs for stewardship applications in continuous-wave mode with compact cryogenic systems. Existing Nb 3 Sn approaches use a cavity body made of niobium and apply tin to the polished cavity interior, a starting point that contains the main costs of present niobium cavity technology. Further complexity is then added because a high vacuum and temperature >1100 °C must be used to prevent formation of undesirable Nb-Sn phases, de-gas interstitial contaminants, and maintain the high purity of the Nb body. The project sought a more cost-effective solution for the same performance opportunities by exploiting the Cu-Sn-Nb diffusion reactions used to make Nb 3 Sn superconducting wires for magnets, which can be carried out at ~700 °C and are compatible with much cheaper copper cavity bodies. The project also sought understanding of the materials science and factors that affect superconducting properties. The project has impacted SRF cavity technology by demonstrating feasibility of alternative routes that enable compact, high-power electron accelerators for energy, security, environment, medical, and commercial applications.

43 PARTICLE ACCELERATORS↗

DOE OSTI2020

High Effectiveness, Compact, High Pressure and Low-Cost Recuperator, Presented at The Fifth International Symposium – Super-Critical CO2 Power Cycles, San Antonio, Texas, March 28-31, 2016, by Dr. John Kelly, President, Altex Technologies Corporation

Closed Brayton super-critical CO2 power cycles are well suited to waste heat bottoming cycles, due to their increased efficiency and compactness, relative to Rankine steam bottoming cycles. Since waste heat applications would be retrofits, the power system compactness is important. To achieve high efficiency, these power cycles require high pressure recuperative type heat exchangers, of substantial heat duty. Current Printed Circuit Heat Exchangers (PCHE), originally developed for high pressure gas and oil applications, can be used as recuperators, but costs are higher than desired. Altex is developing a purpose-built high pressure and effectiveness recuperator to provide the reliability, compactness, performance and pressure capability of current recuperators, but at a reduced cost. The High Effectiveness Low Cost (HELC) recuperative heat exchanger design yields volume and weight metrics of .0024 m3/UA and 10.2 kg/UA, which are 4% and 77.3% below recuperator target metrics, respectively. A 50 kW test article was designed and fabricated. Performance tests on water and oil showed that the HELC design model could predict heat transfer, to within 10% of the measured value. This model was then used to project HELC performance, when operating on supercritical CO2. Besides performance tests, the test article was hydrostatically tested, for integrity at up to 4,000 psi pressure. At these conditions, some distortion of channels was encountered. To mitigate distortion, the inserts were redesigned and these results were used to project the cost of 500 kW and 5,083 kW HELC units. The cost metric for the 5,083 kW unit was determined to be $1,349/UA, which is 10% lower than the recuperator desired cost metric desired target of $1,500/UA. In addition, the 5,083 kW unit HELC cost of $61.09/kW is 33.6% lower than the $92/kW estimated cost for a PCHE. Hydrostatic pressure tests, at up to 4,000psi, showed that the unit did not leak. However, channels were distorted at this pressure differential. Design updates to minimize stress concentrations and distortion were prepared and analyzed, to show that distortion could be controlled, but to date tests have not been run to prove the design. Project results show the potential of the HELC approach, but more work is required to confirm this potential, at the larger scales of interest.

14 SOLAR ENERGY↗

DOE OSTI2021

A passively pumped vacuum package sustaining cold atoms for more than 200 days

Compact cold-atom sensors depend on vacuum technology. One of the major limitations to miniaturizing these sensors is the active pumps—typically ion pumps—that are required to sustain the low pressure needed for laser cooling. Although passively pumped chambers have been proposed as a solution to this problem, technical challenges have prevented successful operation at the levels needed for cold-atom experiments. The authors present the first demonstration of a vacuum package successfully independent of ion pumps for more than a week; their vacuum package is capable of sustaining a cloud of cold atoms in a magneto-optical trap (MOT) for greater than 200 days using only non-evaporable getters and a rubidium dispenser. Measurements of the MOT lifetime indicate that the package maintains a pressure of better than 2×10−7 Torr. This result will significantly enable the development of compact atomic sensors, including those sensitive to magnetic fields, where the absence of an ion pump will be advantageous.

Little, Bethany J. (ORCID:0000000332892798)↗

DOE OSTI2022

AI-Enabled Robots for Automated Nondestructive Evaluation and Repair of Power Plant Boilers. Final Report

Boiler failure could cause loss of life and safety issues, cost hundreds of thousands of dollars in equipment repairs, property damage and production losses, and drive up the cost of electric power. Boiler maintenance is challenging and risky for inspectors working on scaffolding in confined hazardous spaces inside of a boiler and sometimes the space is hard to access. The operation is also time-consuming due to the large area of vertical structures for inspection and the tremendous effort needed for scaffolding. Recently, the use of robotics (e.g., drones and crawlers) in power plants for maintenance is growing rapidly. However, the existing robotics solutions show two notable technological gaps: no live repair capability, and no Artificial Intelligence (AI) for smart autonomy. The objective of this project is to develop an integrated autonomous robotic platform that is equipped with compact non-destructive evaluation (NDE) sensors to perform live inspection, operates onboard repair devices to perform live repair, and uses AI for intelligent data fusion and predictive analysis for automated and smart spatiotemporal inspection, analysis and repair of the furnace walls in coal-fired boilers. The approach to achieve the objective includes developing NDE sensors with signal processing techniques, designing and evaluating repair devices for robots based on fusion and solid-state technologies, and an autonomous robotic platform that can attach to and navigate on boiler furnace walls using magnetic drive tracks. The robot is also powered by AI to automate data gathering (e.g., 3D mapping and damage localization) and predictive analysis. This project has advanced the state-of-the-art by providing technological breakthroughs including compact NDE and repair tools for robots, AI capabilities for smart autonomy, and a robotic platform for automated boiler maintenance. This project has great potential to result in significant benefits including limiting or eliminating the need to send operators to assess difficult-to-access or hazardous areas, enabling automated live inspection and repair, avoiding time consuming scaffolding (especially for partial maintenance during unplanned outage), collecting comprehensive and well-organized data smartly, and avoiding or limiting the need for onsite or remote piloting technicians. The impacts can be tremendous in terms of the time and cost savings, reducing the risk for human operators, and increasing boiler reliability, usability, and efficiency. In addition, by developing the new technologies on the autonomous inspection and repair robot, by involving multiple undergraduate and graduate students working together with the faculty members on this project, and by generating knowledge and building up collaborations with industrial partners, this effort will significantly update the education capabilities, support long-term fundamental research, and maintain the leadership of Colorado School of Mines and Michigan State University in energy fields.

20 FOSSIL-FUELED POWER PLANTS↗