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DOE OSTI2025

Primary material supply configurations and domestic recycling for cost-effective battery material production in the US

Battery cathode active material costs hinge on regionally concentrated, price-volatile metal supply. Here. we construct a regional facility-level cost model based on over 80 global lithium, cobalt, and nickel mines, refineries, and battery-grade material plants. Our model yields aggregated lithium, nickel, manganese, and cobalt production material costs from 392 region-based supply configurations for five different cathode active materials. Focusing on the United States, all-domestic supply is 9–34% costlier than global average, increasing by cobalt content, while these shortfalls can be overcome by selective low-cost material imports. Furthermore, we analyze costs of two U.S.-based recycling facilities from primary data and techno-economic modelling and compare resulting cathode active material-level costs to primary supply. Although it is still significantly higher on cathode active material cost-level, rising end-of-life flows and lowered black-mass prices will, however, make secondary supply cost-competitive to domestic and foreign primary supply cost floors. Facility-level benchmarks reveal targeted import, scaling, and production cost optimization as levers for a resilient, cost-effective U.S. battery-material supply chain.

Energy↗

DOE OSTI2025

Structural Design and Modeling of MARVEL Primary Coolant System Using the ASME Section III, Division 5, Code

This paper presents the structural design and supporting analysis for the Microreactor Applications Research Validation and Evaluation (MARVEL) primary coolant system (PCS) using the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code Section III, Division 5, rules. MARVEL is a liquid metal–cooled microreactor intended to provide experimental capabilities for the rapid testing and development of microreactor technologies. The PCS utilizes high-temperature sodium-potassium liquid metal as the primary coolant and operates at a design temperature of 570°C, necessitating the consideration of creep-related failure mechanisms. The base metal for the PCS is 316H stainless steel, and the weldments are made with a 16-8-2 filler. The design approach incorporates the current base code rules along with ASME code cases N-924, N-861, and N-862 to address primary load, ratcheting, and creep-fatigue evaluations, respectively. The reactor’s operation involves complex thermal and mechanical interactions due to natural convective flow and differential thermal expansion between components. In conclusion, this paper discusses the structural engineering challenges encountered, such as managing thermal stresses in the distribution plenum and guard vessel, and outlines the strategies implemented to meet the code requirements, including design modifications and operational constraints.

21 - SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLAN↗

DOE OSTI2025

On the Role of Airborne Ice Nucleating Particles in Primary and Secondary Ice Formation Processes in Convective Midlatitude Clouds

Abstract Formation of ice in mixed-phase clouds may proceed via primary nucleation and secondary ice production (SIP). Primary nucleation involves the presence of ice nucleating particles (INPs), while SIP follows primary nucleation, resulting in ice crystal number concentrations N ice exceeding the number of INPs. The ice formation pathways in young congestus clouds are not well understood nor are the environmental conditions favorable for the onset of SIP. Coincident airborne measurements of INPs and N ice collected during the Secondary Production of Ice in Cumulus Experiment (SPICULE) campaign over the U.S. central Great Plains are reported for young congestus clouds. Number concentrations of INPs and N ice at temperatures between −10° and −20°C were used to categorize whether SIP was active in each analyzed cloud pass. Observational data suggested that fragmentation of freezing droplets (FFDs) was occurring and the most likely SIP mechanism for ice enhancement during the early stages of the sampled clouds, where higher cloud-base temperatures and stronger updrafts produced conditions favorable for the onset of FFD. Simple model simulations of a congestus cloud were used to compare predictions of N ice from newly implemented SIP mechanisms (including FFD) alongside those from the existing Hallett–Mossop (HM) mechanism. Although predicted N ice , when all SIP mechanisms were active, was in good agreement with observations, the dominant SIP mechanism in the model was predicted to be HM. The rate of heterogeneous freezing in raindrops was likely inhibiting realistic FFD rates in the simulated cloud. These discrepancies between the observations and simulations underscore the need for extended laboratory studies to formulate improved model representations of SIP in convective clouds.

Patnaude, Ryan J. [Department of Atmospheric Scien↗

DOE OSTI2026

AmeriFlux FLUXNET-1F BR-Sa1 Santarem-Km67-Primary Forest

This is the AmeriFlux Management Project (AMP) created FLUXNET-1F version of the carbon flux data for the site BR-Sa1 Santarem-Km67-Primary Forest. This is the FLUXNET version of the carbon flux data for the site BR-Sa1 Santarem-Km67-Primary Forest produced by applying the standard ONEFlux (1F) software. Site Description - The LBA Tapajos KM67 Mature Forest site is a closed-canopy terra firme (upland) forest, located in the FLONA Tapajos, or National Forest, a 450,000 ha government conservation unit in the Brazilian Amazon. Bounded by the Tapajos River in the west and highway BR-163 to the east, the tower is located on a flat plateau (or planalto) that extends up to 40 km to the north, south, and east. The forest at the tower site is classified as primary or "old-growth"" predominantly by its uneven age distribution, emergent trees, numerous epiphytes and abundant large logs. In January 2006 and again in November 2023, falling trees hit the tower guy wires destroying the tower and halting measurements. In each case, the tower was restored and measurements resumed, first in August of 2008 (enabled by a Partnership for International Research and Education, or PIRE, grant from the U.S. National Science Foundation) and again in June 2024.

Restrepo-Coupe, Natalia [University of Arizona, Cu↗

DOE OSTI2024

Testing- and Model- Based Optimization of Coal-fired Primary Heater Design for Indirect Supercritical CO 2 Power Cycles (Final Scientific and Technical Report)

The overall objective of this project was to perform the R&D necessary to mitigate the risk associated with the design of a primary heat exchanger for a solid-fired combustion system coupled with an indirect-fired closed-loop Brayton Cycle utilizing supercritical CO 2 . The key technological hurdle was the coupling of a solid-fuel firing system with the primary heater, which poses a singular challenge, which is the management of burner performance and operational conditions in a way to manage heat exchanger tube metal temperatures and temperature ramp rates in the absence of fluid phase change on the inside of the tubes. We designed and built the first ever pseudo power system employing a simple recuperated supercritical CO 2 closed-loop Brayton Cycle coupled to a solid-fuel fired system. Advanced coupled CFD and process modeling were used to design the primary heat exchanger (PHX), which consisted of both radiative and convective sections, to limit tube metal temperatures resulting from the heat release profile of the solid fuel flame near the radiative tubes. The heat exchanger was designed to produce finished CO 2 temperatures of 600 °C a pressure of 20.7 MPa and CO 2 flow of 5.5 kg/s. The constructed PHX was capable of 1.2 MWth heat uptake. During design of the PHX, the modeling showed that most variables influencing flame shape (burner stoichiometric ratio and register velocities and swirl) were not suitable to manage heat flux to the metal surfaces. This is because they substantially increased adiabatic flame temperature through the influence of localized stoichiometric ratio. Excess air and firing rate were the two most powerful variables that could be used to control tube surface temperatures. The coupled system was operated for a total of 407 hours, with the longest continuous run of 248 hours. For 62% of the operational time, the unit was unmanned and in automatic control. The fuels used for the testing included natural gas, two Utah Bituminous coals, woody biomass, and bagasse. During the testing we were able to verify the 1.2 MWth heat uptake and we operated at a finished CO 2 temperature of 607 °C and a pressure of 20.3 MPa simultaneously. The real-time corrosion rate of the Super 304H tube CO 2 surface in the region of the radiative section of the PHX were measured, at an approximate temperature of 550 °C. The two key variables related to corrosion rate are the pressure and flow rate of the CO 2 . A technoeconomic analysis was performed at a scale of 120 MWE. The updated analysis showed that the efficiency of an sCO 2 power producing plant will be related to the pressure drop of the PHX.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2025

Primary and Low-Strain Creep Models for 9Cr Tempered Martensitic Steels Including the Effects of Irradiation Softening and High-Helium Re-Hardening

Primary and low-strain creep represents a very important integrity challenge to large, complex structures, like fusion reactors. Here, we develop a predictive empirical primary creep model for 9Cr tempered martensitic steels (TMS), relating the applied stress (σ) to strain (ε), time (t) and temperature (T). The most accurate model is based on the applied σ normalized by the steel’s T-dependent ultimate tensile stress (σo), σ/σo(T). The model, fit to 17 heats of 9Cr TMS, yielded a σ root mean square error (RMSE) of ≈±11 MPa. Notably, the model also provides robust predictions for all the other TMS, when calibrated only by the fusion candidate Eurofer97 database. The model was extended to explore two possible effects of neutron irradiation, which produces both displacements per atom (dpa) and helium (He in atomic parts per million, appm) damage. These effects, which have not been previously considered, include: (a) softening, as a function of dpa, at T > ≈400–450 °C, in low-He fission environments (<1 He/dpa); and (b) subsequent re-hardening in high-He (≥10 He/dpa) fusion first-wall environments. The irradiation effect models predict (a) accelerated primary creep due to irradiation softening; and (b) fully arrested creep due to high-He re-hardening.

Alam, Md Ershadul (ORCID:0000000345968026)↗

NASA NTRS1968

Telescope mount with azimuth-only primary

In large aperture telescope primary reflectors, the primary mirror is fixed with respect to the gravity vector to avoid varying gravity deflection problems. The primary reflector does not become distorted in various positions nor in changing positions.

Wells, W. H.↗

NASA NTRS1965

Primary feeds for the Goonhilly satellite-communication aerial

The 85-ft. diameter aerial at Goonhilly Downs, Cornwall uses a focal-plane paraboloidal reflector illuminated from a primary feed at the focus, Circularly polarized waves are transmitted and received. For optimum gain and uniformity of the aerial radiation patterns, circular symmetry of the primary feed radiation pattern is desirable. The primary feed has therefore been made circularly symmetric.

GROUND STATION↗

NASA NTRS1973

Internal performance of a wedge nozzle for a supersonic cruise aircraft with a multispoke primary for noise suppression

Nozzle performance was obtained with cold primary and secondary flows over a range of nozzle pressure ratio from 2 to 31 and corrected secondary-to primary-flow ratio from 0 to 11 percent. Several fixed shroud positions were tested to simulate a translating outer cylindrical shroud to provide data for both supersonic cruise and takeoff configurations. The addition of 14 spokes in the primary nozzle for noise suppression reduced the thrust efficiency 3 percent at supersonic cruise and 4.5 percent at takeoff.

Johns, A. L.↗

NASA NTRS1976

Apollo experience report guidance and control systems: Primary guidance, navigation, and control system development

The primary guidance, navigation, and control systems for both the lunar module and the command module are described. Development of the Apollo primary guidance systems is traced from adaptation of the Polaris Mark II system through evolution from Block I to Block II configurations; the discussion includes design concepts used, test and qualification programs performed, and major problems encountered. The major subsystems (inertial, computer, and optical) are covered. Separate sections on the inertial components (gyroscopes and accelerometers) are presented because these components represent a major contribution to the success of the primary guidance, navigation, and control system.

Holley, M. D.↗

NASA NTRS1976

Phenomenological model of nuclear primary air showers

The development of proton primary air showers is described in terms of a model based on a hadron core plus an electromagnetic cascade. The muon component is neglected. The model uses three parameters: a rate at which hadron core energy is converted into electromagnetic cascade energy and a two-parameter sea-level shower-age function. By assuming an interaction length for the primary nucleus, the model is extended to nuclear primaries. Both models are applied over the energy range from 10 to the 13th power to 10 to the 21st power eV. Both models describe the size and age structure (neglecting muons) from a depth of 342 to 2052 g/sq cm.

Tompkins, D. R., Jr.↗

NASA NTRS1978

Primary reflector for solar energy collection systems

A fixed, linear, ground-based primary reflector is disclosed which has an extended curved sawtooth-contoured surface covered with a metalized polymeric reflecting material. The device reflects solar energy to a movably supported collector that is kept at the concentrated line focus of the reflector primary. The primary reflector may be constructed by a process utilizing well-known freeway paving machinery.

Miller, C. G.↗

NASA NTRS1979

Primary reflector for solar energy collection systems and method of making same

Solar energy is reflected to a movably supported collector that is kept at the concentrated line focus of the reflector primary by a fixed, linear, ground-based primary reflector having an extended curved sawtooth contoured surface covered with a metalized polymeric reflecting material. The primary reflector was constructed by a process utilizing well-known freeway paving machinery.

Miller, C. G.↗

NASA NTRS1978

The response of an RC line MWPC to primary cosmic rays

A simple 50 x 50 sq cm MWPC plane was arranged as an RC-line and flown on a balloon flight with the MSFC-UAH Cosmic Ray experiment. Positions of primary cosmic ray tracks in the RC-line were determined by the risetime method and compared with the expected position as indicated by a best line fitted through four planes of the conventional MWPC hodoscope. Mean errors were estimated for sea-level muons, and CNO group and iron group particles. It is believed that the delta-rays accompanying the primaries degraded the position resolution. Measured standard deviations allowing for uncertainty in the true track position are of the order of 1 cm or less in the primary charge region between 7 and 26.

Gregory, J. C.↗

NASA NTRS1978

Effects of secondary electrons from heavy primary cosmic rays in a MWPC hodoscope

A multi-wire proportional counter hodoscope, efficient for both primary track recovery and reading out all wires set by secondary electrons, was flown in a balloon flight experiment covering the range of cosmic ray charge from 4 to 28 and kinetic energy T greater than 0.5 GeV/nucleon. Data on the secondary electron effects in the hodoscope is presented for primary nuclei between C and Fe and kinetic energies between 0.6 and 7.0 GeV/nucleon. The total number of affected anodes in the hodoscope is seen to increase linearly with the cosmic ray change, with a slope that depends strongly on energy over this limited primary energy range.

Derrickson, J. H.↗

NASA NTRS1979

The performance of primary Cs beam clocks using quadrupole and hexapole deflection systems. Consequences for time keeping

Since 1978 the time-and-frequency standard CS1 of the Physikalisch-Technische Bundesanstalt (PTB) has operated continuously as a 'primary clock'. Its uncertainty (7.1 to the negative 15th power) is considerably smaller than that of the other existing primary standards. The CS1 is equipped with a combination of quadrupole and hexapole magnets and uses a longitudinal C-field. Consequences of utilizing primary clocks of this quality for the generation of the International Atomic Time Scale TAI are discussed.

Becker, G.↗

NASA NTRS1980

Primary cosmic ray positrons and galactic annihilation radiation

The observation (Leventhal et al, 1978) of positron annihilation radiation at 0.511 MeV from the direction of the Galactic Center is reexamined, suggesting the possibility of a primary positron component of the cosmic rays. The observed 0.511 MeV emission requires a positron production rate nearly two orders of magnitude greater than the production rate of secondary cosmic ray positrons from pion decay produced in cosmic ray interactions. Possible sources of positrons are reviewed with both supernovae and pulsars appearing to be the more likely candidates. If only about 1% of these positrons were accelerated along with the cosmic ray nucleons and electrons to energies not less than 100 MeV, it is believed that these primary positrons would be comparable in intensity to those secondary positrons resulting from pion decay. Some observational evidence for the existence of primary positrons in the cosmic rays is also discussed.

Lingenfelter, R. E.↗

NASA NTRS1981

Articulated primary mirror /APM/ for the Solar Optical Telescope /SOT/

Allowing the location of the primary vs secondary mirrors to be movable in space, the articulated primary mirror (APM) was designed as an inexpensive alternative, providing stable imagery, for the Solar Optical Telescope (SOT). Requirements of high resolution in the sub-arc-second region, and the ability to point the telescope through the Instrument Pointing System (IPS) were satisfied. Alignment sensors, contained within the subsystem, locate the points of coincidence of the foci of the primary and secondary optics (conic foci). These are utilized as inputs for subsystem actuators to correct via the digital controller algorithm.

Gowrinathan, S.↗