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DOE OSTI2020

FAST-1.0 Software Release Document

The purpose of this document is to detail the release of FAST-1.0 and the documents that accompany the development and testing of FAST-1.0. Design requirements were for FAST-1.0 developed in the NRC Statement of Work (SOW) for NRC Agreement Number NRC-HQ-25-14-D-001 and are transcribed to this document as part of the Software Quality Assurance Plan for the FAST Code System, PNNL-28767. FAST 1.0 represents the merger of the FRAPCON and FRAPTRAN codes and as such FAST-1.0 performs steady state and transient fuel performance calculations described below. FAST-1.0 calculates the steady state response of light-water reactor fuel rods during long-term burnup. The code calculates temperature, pressure, and deformation of a fuel rod as functions of time-dependent fuel rod power and coolant boundary conditions. The phenomena modeled by the code include: 1) heat conduction through fuel and cladding to the coolant; 2) cladding elastic and plastic deformation; 3) fuel-cladding mechanical interaction; 4) fission gas release from the fuel and rod internal pressure; and 5) cladding oxidation. FAST is used to perform independent calculations for regulatory evaluations of fuel performance under normal operation and anticipated operational occurrences (AOOs).

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Application of BISON to UO 2 MiniFuel fission gas release analysis

There has been a recent push to accelerate fuel qualification by developing revolutionary capabilities to reduce irradiation periods, and thereby, reduce the time required to qualify a new fuel system. One such capability is the MiniFuel irradiation capsule designed to miniaturize fuel samples and irradiate “mini” fuel samples under isothermal temperature conditions. MiniFuel allows steady-state irradiations to decouple the traditionally coupled fission rate (i.e., power) and temperature parameters to understand and generate microstructures observed in fuel operated in a commercial reactor. Furthermore, this process offers the possibility to gather in situ data as well as postirradiation or transient data such as thermal conductivity, specific heat, fission gas diffusion and release, etc. However, accelerating fuel qualification is not solely reliant on generating large amounts of data but also on developing an informed test matrix designed to rapidly generate impactful data. Additionally, this process is reliant on fuel performance codes, such as BISON, to evaluate MiniFuel irradiations using existing material models. This process pinpoints model/data gaps, identifies desired irradiation conditions, and subsequently supports model validation and development. This work describes the use of BISON to perform a number of sensitivity studies designed to understand conditions that lead to fission gas release (FGR) under steady-state isothermal irradiation conditions and temperature transient conditions. The model is applied to a UO 2 MiniFuel example and shows an overall good qualitative agreement with experimental FGR annealing tests under different temperature conditions. It also accounts well for microstructural effects on FGR. When quantitatively compared with FGR data from previously irradiated 103 MWd/kgU UO 2 discs under thermal annealing, the model shows a less satisfactory agreement with the experimental data. Finally, a UO 2 MiniFuel test matrix is proposed to help to extend the model's operational range and validate the new FGR model capabilities to higher burnups and transient conditions.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Draft Summary Report on Irradiated Fuel Handling and Management for LOTUS

The National Reactor Innovation Center (NRIC) has conceptualized the design of the Laboratory for Operation and Testing in the United States (LOTUS) test bed to provide the United States Department of Energy (DOE) with the infrastructure necessary to make advanced reactor designs available for commercial developers. LOTUS will provide a test bed to developers with the capabilities of supporting a wide range of experiment design possibilities. Upon completion of the developers’ operations and experiments within the test bed, the irradiated fuel, reactor components, and other experiment materials must be removed. Idaho National Laboratory (INL) possesses significant capabilities for radioactive material handling such as casks, carts, and forklifts. However, given the unique environment presented by the NRIC-LOTUS test bed, located inside the Zero Power Physics Reactor (ZPPR) Perimeter Intrusion Detection and Assessment System (PIDAS) area at the Materials and Fuels Complex (MFC) and the complexity of novel removal activities of recently operated reactor experiments through the new proposed access tunnel. The efficacy was not apparent for existing equipment to provide all the needed capability. To bridge the potential gaps in cask designs, storage, and transportation, NRIC requested the development of trade studies for the transfer, handling, and storage requirements of irradiated fuel salts and other radioactive materials. NRIC directed Boston Government Services, LLC (BGS) to perform the trade studies and develop a report analyzing alternatives. In addition to the BGS reports, the Idaho National Lab’s (INL), provided by the first potential user’s Advanced Reactor Development (ARD) team, prepared a feasibility study for the storage of specific irradiated fuel within the existing ZPPR vault.This summary report is intended to present the trade studies, options, and alternatives that were investigated. The maturity level of LOTUS, the reactor, fuel salt containers, gloveboxes, and reactor testing campaign and concept of operations were not at a level sufficient to base critical decisions on. This report is not intended to present a final recommendation. The final recommendations for fuel storage location, transport, handling equipment, and operations will be made in FY 2024 and will be based on known materials, test campaign requirements, funding, and final analysis of the fuel and equipment to be used.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2024

Improvement of Coal Power Plant Dry Cooling Technology through Application of Cold Thermal Energy Storage

The U.S. power infrastructure is currently heavily reliant on water cooling. The power plants in the U.S. account for approximately 40% of freshwater withdrawals, with 90% of it used in condenser cooling. The most used cooling technology in coal-fired power plants is a once-through condenser; however, this cooling method requires high water withdrawal rates and results in thermal pollution of the water source. Wet WCTs offer an alternative to once-through condensers due to much lower water withdrawals. However, these systems suffer from water consumption through evaporation making them undesirable options in areas subject to droughts and in arid areas. The direct dry cooled condensers (ACCs) and dry cooling towers (DCT) account for 1.8%, hybrid cooling (ACC + WCT) accounts for 0.5%, while other cooling technologies represent the rest (0.7%). The ACC/DCTs represent an attractive alternative for power plants; however, this technology has not been widely adopted in the US (less than 2% of power plants) due to its negative impact on plant performance. As a rule of thumb, dry cooling results in performance penalty equivalent to approximately 2%-point efficiency loss compared to wet cooling, although the actual magnitude varies with ambient dry bulb temperature, DBT which may vary considerably during the day. As DBT increases, the plant power output decreases, reaching a minimum at the hottest period of the day, which usually coincides with the highest electricity demand for air condition load. Therefore, performance of power plants using DCT/ACC cooling technology is the lowest during the summer mid-day when ambient temperature is the highest. For example, the decrease of the inlet air temperature to the DCT/ACC by 2 Deg C could generate up to 5% additional power at peak demand. It is, therefore, important to improve dry cooling technology to maintain the viability of coal-fired power plants in a carbon constrained future. The method for reducing the cooling air temperature and keeping it constant would mitigate this problem significantly. Objectives of this project were to develop, design, evaluate, and demonstrate a cost-effective system for improving performance of a DCT or ACC for thermal (coal-fired) power plant applications using a low-cost heat storage materials, such as pervious concrete (PC) and phase change material (PCM). Thus, the study focused on development of the system(s) that could be used to alleviate the difficulties in operating DCT/ACC during the summer months by storing cold energy during the nighttime in inexpensive materials PC and PCM and using it during the hottest period(s) of the day. Since very large quantities of cold energy need to be stored to make an impact on performance of a large power plant, it is essential that the storage materials and associated cold energy storage design(s) are inexpensive and the system is simple to build, maintain and operate. To achieve the project objectives, a comprehensive approach, including material development and characterization, component and system modeling, and laboratory- and prototype-scale experiments, was employed including modeling of the system components and of the entire system, development (engineering) of the materials for the heat storage modules of the Cold Thermal Energy Storage System (CTESS) and determination of their properties, design, manufacturing and setup of the laboratory- and prototype-scale test facility and testing, design, manufacturing and setup of the prototype-scale test facility. A modular design of CTESS was employed, where representative modules were designed as the integrated direct contact heat exchanger and thermal energy storage (TES) system. CTESS modules were manufactured and tested. Two prototype-scale designs of the CTESS modules were developed and tested. The use of CTESS increases plant generation increases since it lowers air temperature entering ACC/DCT and keeps it constant during the hottest time of the day. For a PCM-based CTESS, the ambient air temperature is lowered close to the PCM phase change temperature. The duration of the cooling effect depends on the latent heat and mass of PCM in the CTESS. For this project, commercial grade CaCl2 hexahydrate (CaCl2·6H2O or CC6) PCM with phase change temperature of 25 Deg. C was used due to its low cost. For practical reasons, the CTESS was designed to maintain the cooling effect for four hours. The low phase change temperature associated with the commercial grade PCM used in CTESS results in considerably higher improvement in net generation compared to the laboratory (pure) grade. The resistance to heat transfer results in lower net generation compared to the ideal case where resistance to heat transfer is zero. The results demonstrate that CTESS is effective in improving the performance of a dry cooling system. However, its effectiveness depends on the relationship between the ambient air conditions and PCM phase change temperature. As is the case with the heat rejection system, for the best performance, the PCM used in CTESS would need to be matched to the ambient air conditions. The results obtained in this report for selected geographical locations are valid for CC6 and demonstrate that the level of performance to be achieved by the technology will be location-dependent, as is the case with the air cooled condensers. The methodology for engineering of PC-PCM-based heat storage medium is applicable to other PCMs that may need to be used for other ambient air conditions and geographical locations.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2022

Demo-scale testing of a hybrid membrane-sorbent system for post-combustion CO2 capture

TDA Research is developing a novel hybrid membrane-sorbent system for the post-combustion capture of carbon dioxide (CO 2 ) from supercritical pulverized coal (PC) power generation facilities or large point industrial emitters. Here, the novel design incorporates a 1st-stage continuous membrane separator developed by Membrane Technology and Research, Inc. (MTR) with a dual-bed radial-flow sorbent contactor (designed and developed at TDA). Testing of a pilot unit at 1 MWe scale has been conducted at the site for emerging technologies at the Technology Centre Mongstad (TCM) in Mongstad, Norway using residue fluid catalytic cracker (RFCC) flue gas from Equinor’s Mongstad refinery.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2022

High-Temperature Linear Receiver Enabled by Multicomponent Aerogels

Concentrating solar thermal (CST) technology has significant potential mainly due to its dispatchability and low cost of storage. However, to compete with other sources, including utility-scale solar PV, its final cost (cents/kWh) still needs to be lowered. Cost reduction can be achieved by improving the system level efficiency of the CST plants through the deployment of advanced power cycles, which operate at high temperatures of ~700°C. However, optical, and thermal losses pose a major challenge to the efficiency of such CST systems. The overall aim of this project is to investigate and de-risk a linear solar receiver concept called an Aerogel Insulated Receiver (AIR) that generates high temperatures (up to 700°C) at a low solar concentration ratio (<100) and with a high collection efficiency (optical × receiver). Our prior work has demonstrated the thermal stability1 and optical and heat-insulating properties2,3 of transparent aerogel insulation at a one-inch scale. The focus of this work is on (1) co-optimization of the geometry of the aerogel tile and receiver enclosure to fit a standard parabolic collector (PTC), (2) scale-up of aerogels into 4-inch tiles while preserving key properties, (3) experimental measurement of receiver heat loss (W/m) in a >70-cm test stand and validation of anticipated receiver performance at high temperatures. Regarding (1), appropriate optical and thermal models for a parabolic trough receiver (PTR) are developed and validated. The geometry of the aerogels and the receiver enclosure are co-optimized to maximize the collection efficiency. The model predicts a 54% collection efficiency at 700°C for an AIR design based on flat aerogels. By combining the collection efficiency with the power block efficiency of supercritical CO 2 cycles, we predict >10% improvements in peak plant efficiency relative to existing line-focusing CST systems. The application of curved plasmonic aerogels is predicted to further increase the collection efficiency to 64%. Regarding (2), we demonstrate the successful development of 6-inch-long refractory aerogel tiles with optical, thermal, and stability characteristics consistent with our prior work. This scale-up requires a transition to a larger ALD station and modifying the ALD process variables such as exposure time and the number of precursor doses. Regarding (3), we design and develop an AIR test stand measuring 3 feet in length. Heat loss performance analysis is carried out using the test stand. The results indicate that aerogel insulation can significantly reduce receiver thermal losses at the high operating temperatures required for next-generation PTRs. The experimental results agree with the heat loss performance predicted by our receiver model. Lastly, we conducted preliminary failure mode and effects (FMEA) and techno-economic (TEA) analyses to identify failure mitigation strategies and commercial opportunities, respectively. Overall, this project identifies key opportunities and challenges in deploying aerogel insulating receivers in next-generation line-focusing CST technologies.

14 SOLAR ENERGY↗
DOE OSTI2021

Technology Development for Modular, Low-Cost, High-Temperature Recuperators for Supercritical CO 2 Power Cycles (Final Report)

The program’s focus was to evaluate, advance, and demonstrate recuperator design concepts, materials, and fabrication methods that facilitate the commercial availability of compact and low-cost recuperators. Emphasis was placed on recompression closed Brayton cycles having a turbine inlet temperature exceeding 700°C and differential pressures on the order of 200 bar and were scalable to accommodate plant sizes from 10 to 1,000 MWe. The primary objectives of the first budget period, which included conceptual design, preliminary development, and prototype fabrication and testing, were accomplished. A new recuperator design concept, stacked-sheet heat exchanger (SSHX), was realized during the project. The design was taken from paper to hardware and successfully tested. The SSHX prototype recuperator met or exceeded program thermal, hydraulic and performance/cost metrics goals. The first budget period was extended to retire risk in scaling the recuperator from the kWt to MWt thermal capacity scale. The fabrication and design requirements for the budget period one extension were met. Delays associated with the Covid-19 pandemic prevented the fabrication and testing of the industrial scale prototype.

14 SOLAR ENERGY↗
DOE OSTI2020

SCALE Code System

The SCALE Code System is a widely used modeling and simulation suite for nuclear safety analysis and design that is developed, maintained, tested, and managed by the Reactor and Nuclear Systems Division (RNSD) of Oak Ridge National Laboratory (ORNL). SCALE provides a comprehensive, verified and validated, user-friendly tool set for criticality safety, reactor and lattice physics, radiation shielding, spent fuel and radioactive source term characterization, and sensitivity and uncertainty analysis. Since 1980, regulators, licensees, and research institutions around the world have used SCALE for safety analysis and design. SCALE provides an integrated framework with dozens of computational modules, including three deterministic and three Monte Carlo radiation transport solvers that are selected based on the desired solution strategy. SCALE includes current nuclear data libraries and problem-dependent processing tools for continuous-energy (CE) and multigroup (MG) neutronics and coupled neutron-gamma calculations, as well as activation, depletion, and decay calculations. SCALE includes unique capabilities for automated variance reduction for shielding calculations, as well as sensitivity and uncertainty analysis. SCALE’s graphical user interfaces assist with accurate system modeling, visualization of nuclear data, and convenient access to desired results.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

Accelerating Learning with Set-Based Concurrent Engineering

The traditional design approach for product development is to develop a design based on customer requirements and technical knowledge, build the product according to the detail requirements provided, and then test the product to validate that it works as intended. The team typically starts by identifying a single design approach and spends their time validating a single design during testing. Design teams often encounter issues in the course of development with performance, manufacturability, interfaces and more. To compensate for test failures, teams often build in time into the schedule for additional design loopbacks. Further, when the loopbacks lead to change, the late changes are costly and risky, causing the team to focuses on "fixing the bare minimum" to meet cost and schedule expectations.

42 ENGINEERING↗
DOE OSTI2024

Schema Elements for Granta Annual Report: FY2024

Granta: Materials Intelligence (Granta: MI) is a commercial database software distributed by Ansys, Inc. that is utilized by the Nuclear Security Enterprise (NSE) to organize and store relevant materials data. Lack of standard and well-documented database schema is the primary obstacle to an NSE materials data management solution, so the objective of this project is to create and document such a schema. In FY21, an approach for designing, documenting, and managing a standard database schema was described based on the creation of schema elements (collections of attributes used to describe particular aspects of the data) to be used as building blocks for creating various database tables without duplication. In FY22, these methods were applied through a multi-site collaboration to create and document the schema elements necessary to build a thermogravimetric analysis (TGA) testing table. In FY23 the schema was expanded to include elements for a differential scanning calorimetry (DSC) table, along with schema for supporting metadata tables including Instruments, Projects, Documents, and Testing Series. In FY24 the following progress was made, again through multi-site collaboration: • The existing schema elements were modified to accommodate thermomechanical analysis (TMA) data, and a table, Test Data: TMA, was created for managing TMA data. • The elements necessary for the following additive manufacturing (AM) data tables (directed at data specific to selective laser sintering AM technology) were created: • AM Builds • AM Processes • AM Part Designs • Built AM Parts • AM Feedstock Materials • AM Feedstock Material Batches • The elements necessary for creating a Calibrated Material Models table were created, and the Calibrated Material Models table was created. In FY25 the existing schema will be deployed on the production enterprise Granta instance on the enterprise secure network. Schema elements will be appended, and new elements created as necessary, to allow the creation of tables specifically to support materials testing, AM process development, and design and analysis for modernization programs.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Characterization of modeling and experimental data inconsistencies from burst testing for high-burnup commercial fuel rod applications

Fuel fragmentation, relocation, and dispersal are some of the largest issues remaining in the nuclear industry before rod-average burnup can be increased beyond 62 GWd/tU. The issue is primarily related to the potential for fuel to be dispersed into the reactor primary system, which may increase public risk. One way to prevent dispersal is to avoid cladding burst. The objective of this work is to support the high burnup safety case by evaluating cladding burst under high-burnup, full-length fuel rods and to identify uncertainties that could improve model predictions. The results of this analysis will evaluate realistic, prototypic loss-of-coolant accident (LOCA) conditions; support future cladding burst test designs; and inform the development of mechanistic material models. Realistic high-burnup operating conditions were implemented in the BISON fuel performance code to simulate steady-state and LOCA transient fuel rod evolution to the point at which cladding burst occurred. Parametric studies are performed to assess code response to changes in rod internal pressures and heating rates. Results were compared with simulated LOCA experiments to identify inconsistencies between commercial fuel rod analysis and experimental validation. The representative full-length fuel rod LOCA simulation results did not agree with cladding burst tests. Cladding burst tests indicated burst occurring well below (100–150 °C) those calculated in the full-length fuel rod LOCA analysis. Further investigation indicated that the cladding burst tests do not appear to be representative for full-length fuel rods. The inconsistency investigated in this work showed that the differences between the BISON simulation and the experiment's cladding burst conditions arise from an incomplete characterization of the cladding surface temperature, detailed rodlet characterization, lack of cladding strain measurements, and uncertainty in the cladding creep and failure models.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Development of Conceptual Lead Cartridge Design to Perform Irradiation Experiments in VTR

This paper seeks to introduce the latest design of the Extended Length Test Assembly–Cartridge Lead (ELTA-CL) with associated thermal-hydraulic (TH) assessment and related experiment activities to support the critical component development performed by the ELTA-CL team (Los Alamos National Laboratory, Westinghouse Electric Company, and the University of New Mexico). The goal of the ELTA-CL program is to develop and validate an experimental capability to perform irradiation experiments in the Versatile Test Reactor (VTR) addressing Lead Fast Reactor (LFR) technology gaps, in support of the commercial development of advanced lead-cooled fast reactor concepts. Through a design maturation process and parametric study, a conceptual design is proposed to meet the requirements for material and corrosion testing. Thermal-hydraulic characteristics for the conceptual design at desired operating conditions are assessed with systems-level (one-dimensional) and computational fluid dynamics (three-dimensional) simulations. Along with the conceptual design work, experimental activities for the development of critical components such as the pump and flowmeter are undertaken. From both the modeling study and the experimental results, the design requirements of the Phase 1 ELTA-CL (e.g., 500°C and 2 m/s) are achievable with the current conceptual design. Additional design improvements and safety assessments at both steady-state and transient conditions for the final ELTA-CL design will be pursued.

42 ENGINEERING↗
DOE OSTI2024

UHT-CAMANCHE: Ultra-High Temperature Ceramic Additively Manufactured Compact Heat Exchangers

The conceptual basis for this project is the convergence of advanced ultra-high temperature ceramic materials and additive manufacturing technologies to produce compact ceramic heat exchangers with complex internal flow path geometries. Task areas were broadly divided into materials and manufacturing development, heat exchanger design, component testing, and techno-economic analysis. Technical challenges included the design and commissioning of new test facilities, improving feature resolution and deposition rate of ceramic additive manufacturing techniques, establishing process-structure-property relationships in additively manufactured ultra-high temperature ceramics, and assessing high temperature materials compatibility in CO 2 environments. The primary candidate material evaluated in this work is a composite comprising zirconium diboride (ZrB2) with 30 vol. % silicon carbide (SiC) which was selected based on its desirable combination of high temperature mechanical properties, high thermal and electrical conductivities, and oxidation resistance. High solids loaded ZrB2-SiC pastes suitable for extrusion-based additive manufacturing were developed for the first time as part of this work. Materials compatibility studies indicate this material oxidizes in CO 2 to form a protective borosilicate scale which transforms to pure silica above 1000°C. Parts made by additive manufacturing displayed enlarged grain sizes produced by pressureless sintering as compared to hot-press sintering. Increases in microstructural coarseness have outsized effect on oxidation performance up to 1400°C due to incomplete oxidation of coarse large diameter SiC particles resulting in lower amounts of silica that apparently inhibit protective scale formation. Additive manufacturing as a forming technique did not appear to significantly affect thermal conductivity, hardness, or elastic modulus, though flexural strength was reduced by half or more as compared to traditionally hot-pressed materials. This effect was attributed to the presence of strength-limiting flaws (ca. 40 microns in size) originating from extrudate inhomogeneities that could potentially be eliminated with further process improvements. Attempts to attain economies of scale for production of multi-kilowatt scale heat exchangers by ceramic additive manufacturing proved difficult. Lack of automation and a modest extrusion rate while retaining fine feature resolution made the overall process labor intensive and limited experimental throughput. A number of full-scale components were taken through post-process heat treatments including drying, binder burnout, and sintering; however, none survived without significant flaws or cracks. Therefore, no operational data from a newly installed heat exchanger test loop were able to be obtained during the performance period. Continued research and development is recommended to improve economic feasibility of ceramic additive manufacturing by standardizing the use of advanced sensors, artificial intelligence, and automation tools to reduce associated labor costs and accelerate production rates. The materials and manufacturing techniques demonstrated in this work are likely to find applications in defense and energy applications.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2021

Dynamic Building Load Control to Facilitate High Penetration of Solar Photovoltaic Generation (Final Technical Report)

Solar photovoltaic (PV) resources are the most common form of distributed generation in residential and commercial customer premises within electric distribution networks. A higher penetration of PV generation in distribution circuits will impose challenges on maintaining service voltages within the range of industry standards, power quality, and power flow. Buildings consume 74% of the electricity produced in the United States, and a significant portion of the building load is dispatchable, making them responsive to electrical grid needs. Oak Ridge National Laboratory—in collaboration with Southern Company; the University of Tennessee, Knoxville; and the Georgia Institute of Technology—is examining the PV integration issues in distribution-level electrical grids and developing integrated demand-side control and communication systems to enable responsive loads. The proposed responsive loads mechanism performs renewable generation following to increase the penetration of solar PV within each feeder. The specific objectives of this project are to (1) examine distribution-level PV integration scenarios to understand requirements, (2) undertake an end-to-end simulation-based design of a distributed control strategy of loads geographically near the PV generation asset to minimize the effect on the distribution feeder, (3) deploy and demonstrate the control technology developed in partnership with utilities, and (4) perform a scalability analysis at the utility scale. This 3-year integrated project aims to develop, demonstrate, and validate demand-side control technology to enable increased the penetration of renewables while mitigating challenges that arise due to their intermittency. Activities in Budget Period (BP) 1 focused on a literature review and the formal design of a control system for integrating local distribution with generation and loads. The team used modeling and simulation to evaluate the impact of varying buildings loads, variable PV generation, and power flow dynamics on the distribution circuit. The dynamic models developed in BP 1 were used in BP 2 to develop a model-based control design and a test bed. The test bed has enabled the simulation-based testing and comparison of different control designs and formulations applied to different configurations of the distribution grid, PVs, and building loads. The control approaches developed in BP 2 were implemented in BP 3 in the form of hardware deployed at the Central Baptist Church (CBC) in Knoxville, Tennessee, for testing and evaluation. The outcome of this project was the development and demonstration of open-source, low-cost, low-touch sensing and control retrofits to distributed PV generation and building loads that, in a coordinated fashion, provide the load-shaping response needed to integrate high levels of renewable penetration. This research addresses the target metrics by dynamically controlling a load with solar generation variability to minimize the extent of two-way power flow, enhance reliability, facilitate high PV penetration (>100% of peak load in a line segment), and generate scalable software and hardware solutions adaptable to any penetration levels. The research and development activities are focused and designed to be impactful within the relevant 2020 targets time frame.An accurate open-source integration simulation framework for end-to-end control design was developed and deployed at the CBC facility for testing and evaluation. This final report provides a detailed review of the technical results achieved during this 3-year integrated project. A novel spectral analysis of PV data is demonstrated to derive the requirements of the control design. A detailed simulation-based analysis of PV integration at increasing penetration levels is presented using 1 year of PV data to demonstrate the impact on the distribution circuits. Two different control strategies were developed and demonstrated via simulation to track variable PV generation with adaptive load dispatch. The report concludes with a summary of accomplishments and recommendations for a path forward.

14 SOLAR ENERGY↗
DOE OSTI2020

Optimization of target lifetime for production of 14 MeV neutrons

Two methods are examined for extending the life of tritium targets for production of 14 MeV neutrons by the 3 H( 2 H,n) 4 He nuclear reaction. With thick film targets the neutron production rate decreases with time due to isotope exchange of tritium in the film with implanted deuterium. Here, the target life is maximized by operating the target at elevated temperature where the implanted deuterium mixes by thermal diffusion throughout the entire thickness of the film. The number of neutrons obtained from a target is then proportional to the initial tritium content of the film. A novel thin-film target design was also developed and tested. With these thin-film targets, the incident deuterium is implanted through the tritide into the underlying substrate material. A thin permeation barrier layer between the tritide film and substrate, reduces the rate of tritium loss from the tritide film. Good thin-film target performance was achieved using W and Fe for the barrier and substrate materials respectively. Thin-film targets were fabricated and tested and shown to produce similar number of neutrons as thick-film targets while using only a small fraction of the amount of tritium.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2023

Rapid, Approximate Multi-Axis Vibration Testing [Thesis]

The aerospace industry uses vibration shaker tables to perform component durability testing. In these tests a component, piece of equipment, or entire system is attached to a shaker table where it is subjected to dynamic excitation. The goal is to understand how the article under test will perform in its service environment without having to run it through its entire service life via field testing. In a vibration test, an aerospace system or component is qualified if it is shown to survive a test meant to replicate its lifetime service conditions. The test is designed based on recorded field data. To develop a test, a system is taken through all of its intended environments, e.g., transportation, launch, and reentry. Acceleration data measured from these environments is then brought back to the lab and imported into a shaker table controller. The controller then drives a vibration test intended to mimic the acceleration conditions experienced by the system or specific components of the system in the field. However, it is often difficult to match the measured field response in a lab test. This is largely due to the test’s boundary conditions and excitation methods. In a lab test, a shaker table is the excitation source. The two most common shaker table types, differentiated by their number of independent degrees of freedom, are single-axis and multi-axis shaker tables. Multi-axis shakers have the ability to reproduce service environments more realistically, as real accelerations inevitably produce multiple degrees of freedom of excitation simultaneously. Figure 1 depicts a generic multi-axis testing setup on a three-axis shaker table. Often multi-axis tests use six-degree-of-freedom (6DOF) shaker tables. Yet multi-axis shakers are not yet common in the aerospace industry due in part to their high cost and the difficulty for shaker controllers to handle the added complexity. Single-axis shaker tables are much more common. They are not as expensive to purchase and have a wide range of control software options.

42 ENGINEERING↗
DOE OSTI2023

A Power Takeoff Device for a Small Marine Hydrokinetic Turbine Deployed from an Unmanned Floating Platform

The design, development, and field-testing of a power takeoff (PTO) device equipped with a ball-type continuously-variable transmission (B-CVT) for a small marine hydrokinetic (MHK) turbine deployed from a floating unmanned autonomous mobile catamaran platform is described. The turbine is a partially-submerged multi-blade undershot waterwheel (USWW). The objective is to develop a PTO for the optimal conversion of the MHK energy harnessed by the turbine to electric power, which is stored in battery banks onboard the MHK platform. Modeling, simulation, and bench testing of the USWW and PTO show the feasibility of utilizing the B-CVT's variable gear ratio to decouple the USWW and generator speeds, maintaining the waterwheel within its optimal tip speed ratio (TSR) while varying the generator speed, thereby increasing the efficiency of the PTO. Results of bench and field testing in support of characterizing the power conversion capabilities of the PTO are described. The system being developed is in support of potential self-powered autonomous mobile recharge stations for unmanned aerial vehicles (U A V s) operating in coastal zones. Field tests of the complete MHK platform with 9 blades on the waterwheel and wheel sub mergences of 10 and 12 inches (full blade submergence) were performed. The overall proof-of-concept was successfully demonstrated, with the system satisfactorily capturing and converting water flow energy into electricity. The feasibility of utilizing the B-CVT as a means of increasing the PTO power capture capabilities and efficiency is analyzed.

Pimentel, Hugo↗
DOE OSTI2025

Geothermal well testing pressure prediction by using a hybrid transformer model system: FORGE well use case

Geothermal has huge potential to become an indispensable component in achieving the goal of sustainable energy economy, given its capability to provide consistent baseload power to the electric grid. Injection tests are crucial in geothermal energy system as they naturally help to evaluate reservoir properties, understand fluid flow and even enhance reservoir performance. In this research, we developed a hybrid model system that integrates machine learning (ML) regression, a physics-based mathematical model, and transformer deep learning. Trained and validated using FORGE injection test dataset, this system can forecast the pressure variations both upward and downward over time. The pressure prediction achieved prediction accuracy within 3-6% variance of true pressure values. The system can significantly save time and reduce costs by testing only a few cycles and then using model predictions for further analysis, instead of conducting additional real injection cycle tests. The developed model system also holds promise for designing injection test processes and maintaining well production in geothermal energy. Presented at the IMAGE ‘25 Conference led by Shell.

FORGE↗