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DOE OSTI2023

Technical Evaluation of Accelerated Basin De-Inventory Material Addition to Sludge Batch 11

Savannah River Nuclear Solutions has a need to discard spent nuclear fuel (SNF), currently stored in L Basin, to the Defense Waste Processing Facility (DWPF) for vitrification. The Department of Energy (DOE) has approved the Accelerated Basin De-inventory (ABD) Program for discarding SNF via transfers from H-Canyon to the Savannah River Site (SRS) Liquid Waste (LW) system. The first ABD discards will occur during the preparation of Sludge Batch (SB) 11. An initial impact evaluation of the LW flowsheet was performed by the Savannah River National Laboratory (SRNL) prior to the approval of the ABD Program. This evaluation addressed the LW downstream facilities based on the current H-Canyon flowsheet sequence for the average ABD discard. The flowsheet evaluation only included aluminum-clad SNF, specifically Materials Test Reactor (MTR) fuel and High Flux Isotope Reactor (HFIR) fuel similar to the planned SB11 discard. Following this evaluation, the flowsheet has been slightly altered to address (i) new nuclear criticality safety controls for DWPF that credit a higher amount of gadolinium as a neutron poison for all of the enriched uranium contained in a SB and (ii) potential additions of the H-Canyon neutralized fuel stream prior to the Low Temperature Aluminum Dissolution (LTAD) process in Tank 51. The early introduction of ABD material into the SB assembly process is being investigated to provide flexibility regarding transfer opportunities for H-Canyon to Tank 51 for SB11 and future sludge batches.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2025

Modeling Continuous Online Refueling with SCALE 6.3.1 and Serpent-2 in the EIRENE Novel Molten Salt Reactor Design

The Molten Salt Reactor (MSR) is a Generation IV advanced fission reactor design in which the coolant, and in some cases the fuel itself, is in the form of liquid molten alkali-halide salts with a fluoride or chloride ionic base. In liquid-fueled MSRs, reactor refueling may be performed online, where fresh fuel salt is added to the core during operation without the need for shutdown periods. Refueling for these reactor designs is typically modeled using either a batch or continuous refueling approach, both of which can be simulated with the SCALE 6.3.1 and Serpent-2 code systems. However, the specific manner in which they are implemented can vary depending upon the desired rate of refueling, whether the refueling rate is constant or variable, and consideration of salt drainage for systems where the in-core salt volume is kept constant. In a novel MSR fuel cycle concept termed the “Sourdough” fuel cycle, fuel salt is allowed to “grow” within the core, with excess salt either being transferred to an external holding tank to maintain a constant core volume or diverted to an upper plenum within the core to allow for volume growth. In this work, continuous refueling was modeled in a thermal-spectrum, LEU-fueled, small MSR design operating with the Sourdough fuel cycle using the SCALE 6.3.1 and Serpent-2 codes. Two different continuous refueling approaches were simulated, with the performance of each being compared to determine which is most suitable for use with the Sourdough fuel cycle concept.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

FY25 Task 5: Small-Scale Mixing

The U.S. Department of Energy (DOE) Hanford Site has 177 underground storage tanks that contain a complex and diverse mix of chemical and radioactive wastes from past nuclear fuel reprocessing and waste management operations. The strategy of the DOE Hanford Field Office is to retrieve this waste, ~20 vol% of which is in the form of insoluble undissolved solids (UDS) or sludge, and treat it via immobilization at the Hanford Waste Treatment and Immobilization Plant (WTP). The diverse properties and characteristics of Hanford tank waste lead to major challenges related to its transport from the underground tanks to the WTP. These challenges, however, can be addressed by investigating the behavior of tank waste samples and simulant materials and evaluating their behavior against the capabilities of mixing and transport system designs that may be incorporated to retrieve and treat the waste.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2021

Study of Hydrogen Fuel Cell Technology for Freight Rail Propulsion and Review of Relevant Industry Standards.

Alternatives to conventional diesel electric propulsion are currently of interest to rail operators. In the U.S., smaller railroads have implemented natural gas and other railroads are exploring hydrogen technology as a cleaner alternative to diesel. Diesel, battery, hydrogen fuel cell, or track electrification all have trade-offs for operations, economics, safety, and public acceptability. A framework to compare different technologies for specific applications is useful to optimize the desired results. Standards from the Association of American Railroads (AAR) and other industry best practices were reviewed for applicability with hydrogen fuel cell technology. Some technical gaps relate to the physical properties of hydrogen, such as embrittlement of metals, invisible flames, and low liquid temperatures. A reassessment of material selection, leak/flame detection, and thermal insulation methods is required. Hydrogen is less dense and diffuses more easily than natural gas, and liquid hydrogen is colder than liquefied natural gas. Different densities between natural gas and hydrogen require modifications to tank designs and flow rates. Leaked hydrogen will rise rather than pool on the ground like diesel, requiring a modification to the location of hydrogen tanks on rolling stock. Finally, the vibration and shock experienced in the rail environment is higher than light-duty vehicles and stationary applications for which current fuel cell technology has been developed, requiring a modification in tank design requirements and testing.

08 HYDROGEN↗

DOE OSTI2023

Critical Experiments Targeting the Epithermal/Intermediate Cross Sections of Tantalum

Sandia National Laboratories (SNL) and Oak Ridge National Laboratory (ORNL) have collaborated to develop a capability to test the epithermal/intermediate cross sections of materials at the SNL critical experiments facility using the Seven Percent Critical Experiment (7uPCX) fuel. The Sandia Critical Experiments Program provides a specialized facility for performing water moderated and reflected critical experiments with UO 2 fuel rod arrays. The facility offers the ability to modify the core configuration and reactor tank to evaluate various reactor cores for pitch, moderator characteristics, and other criteria. A history of safe operations and flexibility in reactor core configuration has resulted in the completion of nine sets of critical benchmark experiments that have been documented in the International Criticality Safety Benchmark Evaluation Project (ICSBEP) Handbook. The experiment described here is expected to be evaluated for inclusion in the 2024 edition of the ICSBEP Handbook.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2023

Experimental Comparison of Hydrogen Refueling with Directly Pressurized vs. Cascade Method

This paper presents a comparative analysis of two hydrogen station configurations during the refueling process: the conventional “directly pressurized refueling process” and the innovative “cascade refueling process.” The objective of the cascade process is to refuel vehicles without the need for booster compressors. The experiments were conducted at the Hydrogen Research and Fueling Facility located at California State University, Los Angeles. In the cascade refueling process, the facility buffer tanks were utilized as high-pressure storage, enabling the refueling operation. Three different scenarios were tested: one involving the cascade refueling process and two involving compressor-driven refueling processes. On average, each refueling event delivered 1.6 kg of hydrogen. Although the cascade refueling process using the high-pressure buffer tanks did not achieve the pressure target, it resulted in a notable improvement in the nozzle outlet temperature trend, reducing it by approximately 8 °C. Moreover, the overall hydrogen chiller load for the two directly pressurized refuelings was 66 Wh/kg and 62 Wh/kg, respectively, whereas the cascading process only required 55 Wh/kg. This represents a 20% and 12% reduction in energy consumption compared to the scenarios involving booster compressors during fueling. The observed refueling range of 150–350 bar showed that the cascade process consistently required 12–20% less energy for hydrogen chilling. Additionally, the nozzle outlet temperature demonstrated an approximate 8 °C improvement within this pressure range. These findings indicate that further improvements can be expected in the high-pressure region, specifically above 350 bar. This research suggests the potential for significant improvements in the high-pressure range, emphasizing the viability of the cascade refueling process as a promising alternative to the direct compression approach.

08 HYDROGEN↗

DOE OSTI2025

Exploring the Potential of Solid-state H2 Storage for Fuel Cell Vessels

This is a ~ 7 minute oral poster talk which is meant to briefly tell the audience about the subject of a poster, and then direct them to the poster itself. It describes a new project to investigate if storing hydrogen in a metal hydride enables a "shape optimized" hull conforming hydrogen tank that can be placed in the hull of a ship, increasing the amount of hydrogen that can be stored on emerging H2 Fuel Cell vessels. it is for the 2025 Hydrogen Metal Systems Gordon Research Conference.

Klebanoff, Leonard E. [Sandia National Laboratorie↗

DOE OSTI2024

Zirconium Sludge Criticality Calculations in Large Process Tanks

The Savannah River Site’s H-Canyon facility has been tasked with accelerating the disposition of used research reactor fuels. • Future missions will involve dissolution of “Non-Aluminum” clad fuels – not easily dissolved – Nitric acid is not capable of dissolving stainless steel, Zirconium, and Hastelloy, clad fuels by itself • The electrolytic dissolver has been (re) selected as a disposition path for these fuels. 2

Devine, Nathan P.↗

DOE OSTI2021

High-performance ammonia oxidation catalysts for anion-exchange membrane direct ammonia fuel cells

Low-temperature direct ammonia fuel cells (DAFCs) use carbon-neutral ammonia as a fuel, which has attracted increasing attention recently due to ammonia's low source-to-tank energy cost, easy transport and storage, and wide availability. However, current DAFC technologies are greatly limited by the kinetically sluggish ammonia oxidation reaction (AOR) at the anode. Herein, we report an AOR catalyst, in which ternary PtIrZn nanoparticles with an average size of 2.3 ± 0.2 nm were highly dispersed on a binary composite support comprising cerium oxide (CeO 2 ) and zeolitic imidazolate framework-8 (ZIF-8)-derived carbon (PtIrZn/CeO 2 -ZIF-8) through a sonochemical-assisted synthesis method. Additionally, the PtIrZn alloy, with the aid of abundant OH ad provided by CeO 2 and uniform particle dispersibility contributed by porous ZIF-8 carbon (surface area: ~600 m 2 g -1 ), has shown highly efficient catalytic activity for the AOR in alkaline media, superior to that of commercial PtIr/C. The rotating disk electrode (RDE) results indicate a lower onset potential (0.35 vs. 0.43 V), relative to the reversible hydrogen electrode at room temperature, and a decreased activation energy (~36.7 vs. 50.8 kJ mol -1 ) relative to the PtIr/C catalyst. Notably, the PtIrZn/CeO 2 -ZIF-8 catalyst was assembled with a high-performance hydroxide anion-exchange membrane to fabricate an alkaline DAFC, reaching a peak power density of 91 mW cm -2 . Unlike in aqueous electrolytes, supports play a critical role in improving uniform ionomer distribution and mass transport in the anode. PtIrZn nanoparticles on silicon dioxide (SiO 2 ) integrated with carboxyl-functionalized carbon nanotubes (CNT–COOH) were further studied as the anode in a DAFC. A significantly enhanced peak power density of 314 mW cm -2 was achieved. Density functional theory calculations elucidated that Zn atoms in the PtIr alloy can reduce the theoretical limiting potential of *NH 2 dehydrogenation to *NH by ~0.1 V, which can be attributed to a Zn-modulated upshift of the Pt–Ir d-band that facilitates the N–H bond breakage.

25 ENERGY STORAGE↗

DOE OSTI2025

Methane Mitigator – Development of a Scalable Vent Mitigation Strategy to Simultaneously Reduce Methane Emissions and Fuel Consumption from the Compression Industry (Final Technical Report)

Researchers at West Virginia University completed a multi-year project under DE-FE0031865 entitled “Methane Mitigator – Development of a Scalable Vent Mitigation Strategy to Simultaneously Reduce Methane Emissions and Fuel Consumption from the Compression Industry”. An assessment of natural gas production site emission sources was completed to quantify the potential for emissions reductions and reductions in fuel consumption. The main sources of fugitive methane emissions at gas productions sites include condensate tanks, produced water tanks, gas compressor packing vents, pneumatic controller vents, and natural gas engine crankcase vents.

03 NATURAL GAS↗

DOE OSTI2026

Next Generation Multi-Use Heavy-Duty High-Flow Direct-Fill Hydrogen Refueling Station with Standardized Design (CRADA Final Report)

The Contractor will build a liquid hydrogen (LH2) fueling station model that is capable of simulating the amount of hydrogen transferred from the liquid storage tank to the vehicle, depending on the station’s design and control scheme. This modeling work will allow the Parties to seek the design and control scheme of an LH2 station that can fill a targeted number of vehicles while meeting a time-average flow rate of 10 kg/min for each fill. While evaluating a high dispensing performance station design and control scheme, the Contractor will analyze the design and control scheme are economically viable.

08 HYDROGEN↗

DOE OSTI2024

Evaluation of the Potential for Precipitation of Solids during Storage of Non-Aluminum SNF Solutions

Non-aluminum clad spent nuclear fuels (NASNF) stored in the L-Area basin will be dissolved in H-Canyon using the 6.3D electrolytic dissolver. The solutions will be stored in either the hot or warm canyon until the preparation of a sludge batch for the Defense Waste Processing Facility. Spent nuclear fuel solutions could be stored for 1-2 years before transfer to the H-Area Tank Farm depending on the interval between sludge batches. The solution level in the storage tanks will be maintained; therefore, precipitation of solids due to evaporation is not an issue. However, the precipitation of solids from completely dissolved SNF due to solution instabilities has been observed during intermediate storage of solutions generating hydrated oxides.The presence of fissile material in these solids is generally associated with zirconium molybdate, which is known to act as a host lattice for Pu and can carry the actinides upon precipitation. The formation of zirconium molybdate solids which carry fissile material is a potential concern for the storage of NASNF solutions. To address this concern, the Savannah River National Laboratory performed a literature review to identify knowledge gaps which may require experimental work to determine if the formation of solids is a concern during storage of these solutions. Based on the literature review, the precipitation of zirconium molybdate solids from the Campaign 1 NASNF solutions during intermediatestorage is expected. This conclusion is supported by the identification of zirconium molybdate solids found on the H-Canyon 6.1D Dissolver MK-12 insert spacer. The formation of the zirconium molybdate solids is attributed to hydrolysis and radiolytic processes in the nitric acid solution. As the molybdate solids form, U and Pu can substitute for Zr in the crystal lattice resulting in co-precipitation. Generally, the Pu substitutes directly into the crystal lattice during precipitation while the U associated with the molybdate solids more likely absorbs from the solution. The U in the NASNF solutions is present as uranyl nitrate, a 2+ cation which will not substitute as easily into the molybdate crystal lattice for the Zr 4+ ion.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2025

2016 US Petroleum fuels Life Cycle Baseline Data Package

This data package accompanies the report "2016 U.S. Petroleum Fuels Life Cycle Baseline." It contains the openLCA life cycle model that generated the results and an Excel spreadsheet that contains well-to-tank life cycle inventory for all products.

Life Cycle Analysis Options - Fuels↗

DOE OSTI2020

Long-Term Corrosion Studies Of Pine Derived Bio-Oil And Blends With Heavy Fuel Oil

Biomass derived liquid fuels offer a means to reduce greenhouse gas emissions compared to those produced by combustion of petroleum derived liquid fuels. However, the corrosivity of bio-oils toward the less expensive structural materials creates a material selection problem for designers of storage tanks and combustion systems. Samples of candidate structural materials are being exposed for thousands of hours in multiple fast pyrolysis bio-oils and conditions to evaluate the corrosion resistance of these materials. One method to mitigate the corrosivity of bio-oils and speed their adoption, while also decreasing the pollution issues associated with low quality petroleum derived fuels, is to utilize blends of bio-oil and heavy fuel oil in engines currently solely burning a petroleum-based fuel. In addition to the corrosion studies conducted in 100% bio-oil, studies were also conducted with blends of the fast pyrolysis bio-oil produced from pine tree components with a heavy fuel oil that is used in ocean-going ships. This bio-oil had a very high carboxylic acid content which made it very corrosive to carbon and 2¼ Cr-1 Mo steel and even 409 stainless steel. The heavy fuel oil was not corrosive to carbon steel, but its sulfur content makes it a significant pollution producer and particularly undesirable for use near coastlines. Corrosion tests were conducted with the individual components and with various blends of the two liquid fuels. Studies showed a significantly lower corrosivity of the blends than would be projected assuming linear mixing behavior. Adoption of such blends holds the potential to reduce production of sulfur-containing exhaust gases as well as carbon dioxide from non-renewable fuels.

Keiser, Jim↗

DOE OSTI2020

Long-Term Corrosion Studies of Pine Derived Bio-Oil and Blends with Heavy Fuel Oil

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2025

DOESC Remote Canister Closure System UT Inspection Couplant Solutions

The DOE Standard Canister (DOESC) Remote Canister Closure System is a remotely operated welding and inspection mechanism designed for the packaging of DOE-managed spent nuclear fuel into canisters. The ultrasonic testing (UT) inspection, included in the system, requires the use of water tanks that are opened to act as a couplant between the canister and the sensors. With the couplant, the UT inspection can guarantee accurate results determining imperfections in the weld.

12 - MGMT OF RADIOACTIVE AND NON-RADIOACTIVE WASTE↗

DOE OSTI2023

Assessment of tank designs for hydrogen storage on heavy duty vehicles using metal hydrides

The objective of this project was to evaluate material-based hydrogen storage solutions as a replacement for high-pressure hydrogen gas or liquid hydrogen on Class 7 or 8 tractor fuel cell electric vehicles. The project focused on low-density main-group hydrides, a well-known class of materials for hydrogen storage. Prior research has considered metal amides as storage materials for light-duty vehicles but not for heavy-duty applications. The project established the basis for further development of storage systems of this type for heavy duty vehicles (HDV). Systems analysis of an HDV storage system comprised of a tank and associated balance of plant (piping, coolant tubes, burner) was performed to determine the usable hydrogen capacity. A composite storage material comprised of a metal hydride mixed with a high thermal-conductivity carbon is predicted to have a usable hydrogen volumetric capacity comparable to or exceeding that of 700 bar pressurized hydrogen gas. The gravimetric capacity of this material is also predicted to be competitive with pressurized gas, particularly if costly carbon fiber composite Type III or Type IV tanks are excluded. The storage system design parameters and material properties served as inputs to a second model that simulates fuel cell operation in conjunction with the storage system during an HDV drive cycle. The results show that sufficient hydrogen pressure can be produced to operate a Class 8 HDV, yielding a range of ~480 miles. These results are particularly relevant for high-impact regions, such as the South Coast Air Quality Management District, for which an economical vehicular hydrogen storage system with minimal impact on cargo capacity could accelerate adoption of heavy-duty fuel cell electric vehicles. An additional benefit is that knowledge generated by this project can assist in development of material-based storage for stationary applications such as microgrids and backup power for data centers.

08 HYDROGEN↗

DOE OSTI2024

The Utility of Waste Tank Historical Reviews in Bulk Waste Removal Operations at the Savannah River Site – 25271

SRMC is actively working to remove, treat, and dispose radioactive waste generated by the separation facilities at SRS since their initial operations in the 1950s. The separation facilities at SRS have produced nuclear materials for a variety of purposes, particularly national defense, and continue to support the disposition of spent fuel through the Accelerated Basin Deinventory program. In almost 70 years of operation, nearly 625,000 m3 (165 million gallons) of radioactive waste have been generated and transferred to the tank farm facilities at SRS [1]. As a result of volume reduction (e.g., evaporation) and waste solidification (e.g., vitrification), approximately 127,000 m3 (33.5 million gallons) of material remain as of June 30, 2024 [2]. This liquid waste has since been stored in 51 large underground waste tanks present on the site. These waste tanks may contain up to 4,921 m3 (1.3 million gallons) of radioactive waste each in the form of saltcake or sludge. SRMC’s contract is to treat and dispose of this waste, clean the tanks, and operationally close them. To date, 8 of the 51 waste tanks have been operationally closed. Waste retrieval and tank closure activities are ongoing in an additional 17 tanks through either operations in the field or in design [3].

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗