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Sandia Wind Energy Program - FY23 Accomplishments

This report summarizes Fiscal Year 2023 accomplishments from Sandia National Laboratories Wind Energy Program. The portfolio consists of funding provided by the DOE EERE Wind Energy Technologies Office (WETO), Advanced Research Projects Agency-Energy (ARPA-E), Advanced Manufacturing Office (AMO), the Sandia Laboratory Directed Research and Development (LDRD) program, and private industry. These accomplishments were made possible through capabilities investments by WETO, internal Sandia investment, and partnerships between Sandia and other national laboratories, universities, and research institutions around the world. Sandia’s Wind Energy Program is primarily built around core capabilities as expressed in the strategic plan thrust areas, with 29 staff members in the Wind Energy Design and Experimentation department and the Wind Energy Computational Sciences department leading and supporting R&D at the time of this report. Staff from other departments at Sandia support the program by leveraging Sandia’s unique capabilities in other disciplines.

17 WIND ENERGY↗

Strategic Petroleum Reserve Enhanced Monitoring Compendium (FY23)

The Strategic Petroleum Reserve (SPR) is the world’s largest supply of emergency crude oil. The reserve consists of four sites in Louisiana and Texas. Each site stores crude in deep, underground salt caverns. It is the mission of the SPR’s Enhanced Monitoring Program to examine available sensing data to inform our understanding of each site. This report discusses the monitoring data, processes, and results for each of the four sites for fiscal year 2023.

02 PETROLEUM↗

Data Architecture and Analytics Requirements for Artificial Intelligence and Machine Learning Applications to Achieve Condition-Based Maintenance

This report identified some of the important requirements that needs to be taken into consideration as part of the data evolution for the CBM application of a CWS in a NPP. In the data evolution process, the information is converted into insight leading into actions using advancements in AI/ML technologies. A notion of RESET AI: design, development, deployment, and operation principals are introduced to lifecycle of AI technologies. Towards the end of the report, we discussed how this CBM can be realized in a SDE. As path forward, this report lays the foundation for developing a more detailed industry guidance supporting data evolution for other plant applications like operations and plant support. These would be developed as part of ongoing research in the fiscal year 2023.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Development of a CRAB-MELCOR Framework for Utilization in Support of Estimating a Realistic Mechanistic Source Term for Microreactors

Research and development activities are being performed to link important advanced non-light-water microreactor technology research and development activities sponsored by the U.S. Department of Energy’s Office of Nuclear Energy with regulatory requirements and critical licensing needs likely to impact the deployment of a domestic commercial microreactor fleet. This report presents the progress of ongoing work to perform a gap analysis of the coupling of the Nuclear Regulatory Commission’s Comprehensive Reactor Analysis Bundle code suite and MELCOR code. This key Fiscal Year 2023 research reflects microreactor regulatory needs and challenges noted by industry, Department of Energy, and Nuclear Regulatory Commission stakeholders.

99 GENERAL AND MISCELLANEOUS↗

Software Quality Assurance, Software Requirements and Gap Analysis for the MOOSE-Based Open-Source Multiphysics Code Cardinal

Cardinal continuous development and improvement efforts have led to the software being considered as a high-fidelity design and licensing tool for key areas of nuclear reactor relevant physics, including neutron transport, fluid flow, heat transfer, and mechanical processes. The fast development and expansion of the software from a pure R&D framework towards its application in the nuclear industry and regulation require a focus on maintaining and enhancing Cardinal’s software quality through strict adherence to a Software Quality Assurance (SQA) framework. To facilitate compliance with SQA standards, the Cardinal SQA Program has been initiated during Fiscal Year 2023 (FY23).

97 MATHEMATICS AND COMPUTING↗

Impact of Radiolysis on Iodine Speciation in a Variety of Matrices

This report details the work conducted in fiscal year 2023 with the aim of providing a better understanding of the speciation of iodine in support of domestic 99 Mo production Shine who uses a sulfate matrix in their process. Laboratory experiments to study the behavior of iodine speciation were conducted using spectroscopic methods including UV-vis and Raman as well as electrochemical studies. Radiolysis occurring in solution presents a unique challenge that is largely unaddressed with thermodynamic modeling, therefore a kinetic model was developed to address these issues. The focus of the studies conducted this year used surrogate radiolytic conditions induced by hydrogen peroxide for comparison to radiolytic conditions from direct gamma irradiation and neat acid solutions. For each case a model incorporating the kinetics was used to predict iodine speciation in the defined conditions where the output was directly compared to the experimental conditions. Further modeling was conducted incorporating the process conditions that are specific to Shine with incorporation of radiolysis and gas sparging.

07 ISOTOPE AND RADIATION SOURCES↗

Identify and Assess Technical Challenges in Safeguards Measurements of Spent Advanced Reactor Fuels

Advanced reactor (AR) designs use various nuclear fuel types that can be significantly different than conventional light-water reactor (LWR) fuels, including differences in sizes, compositions, and chemical forms (e.g., oxide, carbide, metal). Nearly all the proposed AR fuels use high-assay low-enriched uranium (HALEU), which will have higher enrichments (5–20 wt% 235 U) than LWR fuels (currently limited to <5 wt% 235 U). In advance of the wide use of these new fuel types around the world, international safeguards organizations such as the International Atomic Energy Agency (IAEA]) are working with some of the AR vendors to formulate safeguards approaches for these AR fuel cycles. As part of the overall safeguards approach, it is important to identify the potential technical challenges in performing safeguards verification measurements of these AR fuels (both fresh and spent fuels) in advance of the widespread adoption of these new fuel types, because new safeguards technologies can take several years to develop, test, and approve for use. This report documents work performed in fiscal year 2024 based on modeling and simulation to assess the performance of the existing safeguards measurement technologies for irradiated or spent AR fuel elements or items. This work is a continuation of the work performed in fiscal year 2023 that focused on fresh AR fuels. Spent AR fuels have a distinct difference from their LWR counterparts: unlike the spent LWR fuels typically stored in a water-filled pool, some spent AR fuels—such as tristructural-isotropic (TRISO)-based fuels—will most likely be stored in air-filled hot cells. Because most safeguards measurements on spent fuel performed to date have been conducted under water, the air-filled hot cell environment could present unique challenges to safeguards measurements. Fork detector (FDET) and Cerenkov viewing device (CVD) systems have been the two primary instruments used by the IAEA for several decades to measure spent LWR fuel assemblies stored in pools for safeguards verification purposes. Because the lower refractive index of air causes Cerenkov light to be of lower intensity in air than in water, existing CVDs are likely unable to perform safeguards verification measurements for spent fuel stored in an air-filled hot cell, as is the case for the TRISO-based spent fuel elements (e.g., pebbles, graphite fuel blocks). Unlike FDET measurements, CVD measurements do not require fuel be moved, so they are a simpler and faster to take than FDET measurements. The inability to perform CVD measurements on the TRISO-based AR fuel types presents a major technical challenge in the effort to use existing technology to perform safeguards measurements on spent AR fuels. This study was mainly conducted through the modeling and simulation of an FDET or an FDET-like system on five spent AR fuel types, including one metallic fuel type and four TRISO-based fuel types in both pebble and graphite block forms in their respective storage configurations and environments. Because the various AR fuel types have significantly different dimensions, FDET systems must be adapted to accommodate them. Partial defect tests were also simulated in this study to assess the FDET’s ability to detect potential fuel diversions. The FDET measures the fuel’s total passive neutron and gamma emissions. The simulated FDET results from spent AR fuel items are compared against results from a typical spent pressurized water reactor (PWR) assembly. High-purity germanium (HPGe) gamma detector measurements were also simulated for the spent AR fuel types and the PWR assembly because the signature photopeaks have been used in LWR safeguards verifications, although HPGe is usually not used to detect diversions because of the fuel’s self-attenuation effects on those photopeaks. The results indicate that these detectors have significant challenges in performing safeguards measurements of the spent AR fuel items, including incompatibilities between AR fuel items and existing FDETs, lower neutron count rates, lower sensitivities to fuel diversions in certain AR fuel items, and significantly higher interference from a neighboring fuel item when the measurement is performed in air. These results suggest that an alternative technology or significant and timely technology development is needed to perform adequate safeguards measurements of some of these AR fuel items.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Real-Time Xenon Sensor Analysis Report

Radiotracer release experiments were performed at the Nevada National Security Site in October 2022. The overall experiment was called the RElease ACTivity (REACT) experiment. Twenty-two real-time xenon sensors were deployed for each of four releases. Initial, quick-look analysis results were reported in December 2022. This report reviews the more comprehensive offline analysis effort that was conducted during the remainder of fiscal year 2023 by the Dynamic Networks venture. Improved energy stabilization routines were implemented along with an improved background subtraction routine compared to the original quicklook calculations. The relative detection efficiencies of all real-time sensors were examined. Finally, simulated detector response functions were coupled to two different meteorological models using the measured conditions for the final release (REACT-04) to compare simulated detections with measurements. While there is some agreement between the models and measured data on the detection locations and timing, there is less agreement on the magnitude of those detections. Future sensor and meteorological modeling work will be needed to improve the agreement and to examine the additional releases (REACT-01 through REACT-03).

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Flexible Plant Operation and Generation Technical Program Plan for FY2023

This report presents the Technical Program Plan for Fiscal Years 2023-2027 (FY2023 to FY2027) for the U.S. Department of Energy (DOE) Light Water Reactor Sustainability Program—Flexible Plant Operation and Generation Research Pathway. The objective of this pathway is to carry out the research needed to help nuclear power plants diversify revenue generation for the life of these plants. The purpose of these research and development activities is two fold: (1) to reduce the technical and economic risks of implementing FPOG applications and (2) to provide guidance on relevant safety and environmental operating license reviews, amendments, and renewals. This pathway provides a clear understanding of the benefits of nuclear energy beyond electricity markets. A detailed description of the research and development activities that have been completed and that are planned for FY2023—FY2027 are presented in this report. These activities include completing the development of analysis tools to perform technical and economic assessments of realistic market opportunities for producing secondary energy products near nuclear power plants. They also include developing and demonstrating engineering systems and control concepts to dispatch thermal and electrical power to an industrial user. Additionally, this plan includes developing guidance for addressing potential regulatory and licensing requirements. In addition, the formation, purpose, and activities of a group referred to as the Hydrogen Regulatory Research and Review Group is discussed. An overview is also provided on the potential benefits of the Infrastructure Investment and Jobs Act (IIJA) Bill that will support the commencement of Regional Clean Hydrogen Hubs, and the Inflation Reduction Act (IRA) that provides compelling production tax credits for nuclear electricity and clean hydrogen using nuclear energy.

08 HYDROGEN↗

FY23 status report on the development of new ASME Section III, Division 5 Class B rules

This report summarizes the work done in Fiscal Year 2023 on the development of the new American Society of Mechanical Engineers Boiler and Pressure Vessel Code, Section III, Division 5, Class B rules to address the gaps identified for high temperature reactor designs. The summary of the design-by-analysis strain limit evaluation and creep-fatigue damage assessment is presented. The proposed design-by-analysis creep-fatigue damage calculation approach uses a new elastic follow-up-based Isochronous Stress Strain Curve stress relaxation procedure. This approach captures the elastic follow-up generated due to interactions of components with adjacent components, supports, and other connections in the power plant. A set of sample problems are selected to validate the proposed design-by-analysis rules for creep-fatigue damage assessment. The proposed Class B rules are evaluated against the Class A elastic design rules, and the experimental data obtained from a family of Simplified Model Test based key-feature test results. The proposed Class B creep-fatigue damage assessment methodology yields conservative design cycles estimates compared to the experimental results.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Multiscale modeling for high burnup structure formation and associated pulverization

This report summarizes the lower length scale modeling work performed in the fiscal year 2023 under the Nuclear Energy Advanced Modeling and Simulation (NEAMS) program to capture the microstrutural evolution and associated pulverization criteria in the high burnup regions. This year, the resolution mechanisms within the cluster dynamics code has been updated and it influence on the bubble growth in HBS regions at the mesoscale is studied. To improve the accuracy of phase-field models of fission gas bubble growth, a new Helmholtz free energy for high-density Xe gas is derived from a virial equation of state. Two previously used strategies for representing net vacancy production in phase-field models of fission gas bubble growth are compared with each other and with analytical models of bubble growth. The vacancy source only model is found to be more convenient to parameterize realistically compared with the vacancy source+sink model. Furthermore, the phase-field-fracture simulation have been performed using MD- informed failure stress values and realistic HBS structure obtained from the phase-field simulations. We also present the uncertainty bands on prediction of the critical stress to account for the effect of the lower length scale variabilities on the failure criteria at the mesoscale. It is observed that pulverization may occur in partially restructured regions with restructuring fraction as low as 17%. In light of this, an update to the BISON’s pulverization criteria is recommended.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

FY23 Laboratory Directed Research & Development Annual Report

At Savannah River National Laboratory (SRNL), we put science to work to protect the environment and address nuclear security challenges. Through our transformative science and technology efforts, SRNL provides solutions to the Department of Energy (DOE) Office of Environmental Management (EM) for the safe cleanup of environmental legacy resulting from nuclear weapons development and government-sponsored nuclear energy research. SRNL also supports DOE’s National Nuclear Security Administration (NNSA) as it maintains the nation’s nuclear stockpile and reduces the threat of nuclear proliferation around the world. Investments through SRNL’s Laboratory Directed Research and Development (LDRD) program drive exploratory research foundational to advancements in mission critical technologies for EM, NNSA and other offices of DOE. Our LDRD program also provides meaningful development opportunities for the people central to innovation. Seven Laboratory Director’s Postdoctoral Research Fellows were supported by LDRD during fiscal year 2023. These named postdoctoral fellows are driving SRNL’s scientific and technical core competencies forward through their dedication to research and advancement of technologies. The LDRD program supports established researchers to explore new concepts, while fueling opportunities for the next generation of scientists to join the SRNL workforce, contributing to the global scientific community through scientific publications. Enjoy reading this Annual Report which summarizes the innovative science and engineering contributions of SRNL staff supported by the LDRD Program. Dr. Vahid Majid

Majidi, Vahid↗

Development of Data Reporting Standards for High-Temperature Gas-cooled Reactor (HTGR) Nuclear Energy University Program (NEUP) Thermal-Fluid Experiments

Since 2009, the U.S. Department of Energy (DOE) Office of Nuclear Energy's Nuclear Energy University Program (NEUP) has been at the forefront of nuclear research, specifically concentrating on advancing high-temperature gas-cooled reactor (HTGR) technologies. By Fiscal Year 2023, NEUP has authorized 35 projects dedicated to HTGR research, each contributing significantly to the enhancement of our understanding of this technology. The outcomes of these diverse projects have been disseminated through final NEUP reports, peer-reviewed journal articles, and presentations at academic conferences, forming a comprehensive tapestry of knowledge. Despite the substantial value of these findings, their dissemination has been fragmented, posing challenges for accessibility to researchers and policymakers and leading to underutilization of DOE investments. Recognizing this critical gap and its potential consequences for the future of nuclear research, the Advanced Reactor Technologies (ART) Gas-Cooled Reactor (GCR) program conducted an extensive survey of completed and ongoing HTGR NEUP projects. This survey enabled the compilation of crucial data, resulting in the development of a specialized public-access database tailored for computational fluid dynamics and system code validation, specifically designed for HTGR applications. However, the data collection process revealed a significant challenge in central data organization due to individual researchers from different institutes employing varying logics and preferences for recording and documenting experimental data. Consequently, an urgent need has been identified to establish a standardized reporting format for HTGR experimental projects. Addressing this issue is essential for enhancing collaboration, maximizing the impact of DOE investments, and ensuring the seamless advancement of HTGR technologies in nuclear research.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Geothermal Heat Pump System Showcase: Short-Term Validation of Borehole Heat Exchanger Performance from Field Data to Numerical Modeling: Preprint

Since 2011, a geothermal heat pump (GHP) system has been operating to provide space heating and cooling for the Solar Radiation and Research Laboratory building at the National Laboratory of the Rockies (NLR) in Golden, Colorado. The system consists of 23 vertical boreholes, each extending to a depth of 300 ft (91 m), connected to 11 water-to-air heat pump units and four circulation pumps. Between fiscal years 2023 and 2025, additional power meters and temperature sensors were retrofitted to support detailed system performance assessment and model development. This study presents preliminary monitoring results and the development of an initial numerical model of the borehole heat exchanger field. The model incorporated site-specific geometry, ground thermal properties derived from thermal response tests, and ambient temperatures, and simulated system behavior over a representative operating day in September. Model predictions of outlet temperatures were compared against corresponding field measurements. Results showed that modeling initialized with a simplified linear subsurface temperature gradient presents systematic discrepancies in outlet temperature, whereas incorporating depth-resolved borehole temperature measurements for initialization yields substantially improved agreement with observations. The findings highlight the sensitivity of short-term predictive modeling to the representation of initial subsurface thermal conditions and underscore the value of high-resolution field measurements for model calibration and validation. These preliminary results inform ongoing efforts to extend the modeling framework to longer time horizons and to refine monitoring and modeling strategies that support the design guidance and operational optimization of GHP systems in research and commercial buildings.

15 GEOTHERMAL ENERGY↗

Sensor Development for Liquid Water Detection in Dry Storage Casks: FY 2023 Status

Modeling efforts were undertaken in fiscal year (FY) 2023 to evaluate the feasibility and capability for sensing of liquid water inside canister-based dry cask storage systems (DCSSs). The focus was on the development of full-scale finite element models (FEMs) of ultrasound propagation through DCSS canister components. For these initial investigations, simulation of the baseplate component was targeted, envisioning water collection at the bottom of a vertically oriented canister. The effects of internal canister components (i.e., fuel basket, fuel assemblies) on ultrasound propagation in the baseplate component were evaluated in these efforts. The environment inside a DCSS confinement is intended to be inert and free of water to prevent potential corrosion of used fuel cladding or other internal hardware. Spent fuel assemblies are dried, after storage in water pools, to make sure water has been removed from assembly cavities. However, there is some uncertainty about the amount of residual water potentially left behind in a DCSS after drying processes, because water can become trapped in cavities or other small crevices in the surfaces formed by the fuel cladding, fuel assemblies, and other internal hardware components. Considering the complex space- and time-dependent temperature profiles in DCSSs, water may be in a liquid or gas phase depending on its location in the cask and how long the cask has been in storage. Evacuating most water and oxidizing agents contained within a canister is recommended by NUREG-1536 (NRC 2010), which covers DCSSs. As summarized by Salazar et al. (2020), existing guidance typically relies on achievable vacuum pumping pressures sustained over a hold period as a signal of dryness and water removal. However, time series data about water removal from full-scale commercial drying procedures are lacking (Hanson and Alsaed 2019). A review of drying specifications from several vendors led to the conclusion that if the specifications are followed correctly, the residual moisture in DCSSs should present an insignificant risk of cladding degradation (Knoll and Gilbert 1987). A more recent analysis concluded that much larger quantities of residual water could remain in DCSSs, but the amount would still not be expected to lead to significant corrosion of fuel cladding or other internal components (Jung et al. 2013). Industry drying procedures are mostly prescriptive in nature, and operational issues arising during the process could result in incomplete drying. A summary of operational issues and potential negative effects of residual water is provided by Salazar et al. (2019). Experimental efforts are ongoing to validate the extent of water removal in a DCSS based on drying procedures used at nuclear power plants through well-designed investigations of drying process efficacy and water retention (Durbin et al. 2021; Pulido et al. 2022a, Pulido et al. 2022b). This has been approached by simulating limited portions of a DCSS internal volume and fuel assemblies. So far, these efforts have focused on the effects of potential water trapping in the dashpot region of control rod guide tubes but are expected to be expanded to include the effects of other internal hardware features and failed fuel rod cladding. A method for detection and measurement of liquid water (Meyer et al. 2022; Meyer et al. 2021), in tandem with the drying information gained through experimental investigations, provides comprehensive bases for understanding the internal conditions of DCSSs and provides technical information to support licensing decisions.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

GDSA Repository Systems Analysis Investigations in FY 2023

This report describes specific activities in the Fiscal Year (FY) 2023 associated with the Geologic Disposal Safety Assessment (GDSA) Repository Systems Analysis (RSA) work package funded by the Spent Fuel and Waste Science and Technology (SFWST) Campaign of the U.S. Department of Energy Office of Nuclear Energy (DOE-NE), Office of Spent Fuel and Waste Disposition (SFWD).

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

2023 Business Case Study: Hydrothermal Liquefaction of Algal Bloom Biomass

A business case study was developed for the fiscal year (FY) 2023 to explore the technical and economic feasibility of converting lake-harvested algal bloom biomass (ABB) into biofuel via hydrothermal liquefaction (HTL). The case study includes reporting on the experimental demonstration of converting the algal feedstock to HTL biocrude. Using the experimental data, a preliminary techno-economic assessment (TEA) of a commercial-scale facility was completed to determine the economic feasibility of the process.

09 BIOMASS FUELS↗