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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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DOE OSTI2022

Multiphysics Analyses of the Bottom Components of the 3D Printed Transformational Challenge Reactor

This research presents multi-physics analyses on the bottom components of the Transformational Challenge Reactor (TCR) facility. These components include the bottom axial reflector and the steel exit cone. The bottom axial reflector is made of pure silicon carbide elements hosting helium cooling channels These elements are 3D printed and therefore can host any arbitrary shape of the helium cooling channels. The design of the bottom reflector considers the neutronics and thermo-fluid dynamics performances as well as the manufacturing process optimization. More precisely, the best design of the bottom reflector reduces neutron leakage by avoiding straight cylindrical helium channels that facilitate neutron leakage, minimizes the helium flow pressure drop, and reduces the number of 3D printed silicon carbide pieces. The exit cone steel structure collects the hot helium from the bottom fuel assemblies and channels the cold helium to the top of the fuel assemblies. The steel simultaneous contact with hot and cold helium flows sets a large thermal gradient. Different designs of the exit cone are proposed to reduce the steel equivalent stress from the helium thermal load. The multi-physics analyses have been performed using Ansys Fluent, Ansys Mechanical, STAR-CCM+, and Serpent computer programs.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2019

Measuring the Lower Critical Field of Superconductors Using Nitrogen-Vacancy Centers in Diamond Optical Magnetometry

The lower critical magnetic eld, H c1 , of superconductors is measured by using ensembles of NV-centers-in-diamond optical magnetometry. The technique is minimally invasive, and has sub- gauss eld sensitivity and submicrometer spatial resolution, which allow for accurate detection of the vector eld at which the vortices start penetrating the sample from the corners. Aided by the revised calculations of the effective demagnetization factors of actual cuboid - shaped samples, H c1 and the London penetration depth, λ, derived from H c1 can be obtained. We apply this method to three well-studied superconductors: optimally doped Ba(Fe 1-x Co x ) 2 As 2 , stoichiometric CaKFe 4 As 4 , and high-Tc cuprate YBa 2 Cu 3 O 7-δ . Our results are well compared with the values of λ obtained using other techniques, thus adding another non-destructive and sensitive method to measure these important parameters of superconductors.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2022

Inverse Calculation of Burden Distribution Matrix Using B-spline Model Based PDF control in Blast Furnace Burden Charging Process

The inverse calculation of burden distribution matrix (BDM) is one of the most important challenges in the blast furnace operation in iron-making processes. In general, blast furnace consumes 65% of the total energy for the whole steel-making. Focusing on this practical challenge, this article proposes a new burden distribution spatial model in calculating burden charging process, and develops a B-spline approximation-based probability density function (PDF) control algorithm to assign the expected thickness distribution of burden layer and, thus, develops a new method for the required inverse calculation of BDM. First, a novel method for the thickness distribution of burden layer is given using B-spline model to produce an expected distribution shape subjected to a desired tracking within a specific spatial constraint. Then, according to the coexistence of continuous and bounded discrete variables in BDM, a novel hybrid optimization control method by combining integer programming and PDF tracking is further established for the effective inverse calculation of BDM. Finally, the proposed PDF-based iterative inverse calculation of BDM using B-spline models are tested using various data from industrial examples. Furthermore, the simulation results show that the proposed method is well suited to solve the BDM inverse calculation problem in practice.

42 ENGINEERING↗
DOE OSTI2019

Controllable 3D Manufacturing System

Next generation Small Modular Reactor (SMR) requires new and improved techniques, instrumentations and strategies to deal with the anticipated high radiation and high temperature environment (esp. in reactors). Component manufacturing technologies will be required that take full advantage of the new 3-D printing methods employed by additive manufacturing technologies. These manufacturing methods must be capable of producing components or sub components on a limited production basis and with nuclear quality. Based on our success in developing a variety of award-winning high energy and high power ultrafast fiber lasers and our pioneered work in fs laser 3D manufacturing (US patents, 9643361 and 9770760), PolarOnyx proposes to use tunable fiber lasers to develop smart AM & SM system to make nuclear quality components for SMR. In Phase I, we have achieved critical milestones and experimentally demonstrated the most critical functions of the proposed controllable laser AM: • Developed and investigated a series of NDI sensing technologies. Combination of IR thermal image and high resolution visible camera provides a powerful tool to characterize thermal distribution and defects. • Built an in-line laser induced breakdown spectroscopy (LIBS) to real time detect compositions of powder and parts, and melting temperature of the melting pool. It proves the LIBS is a very powerful tool to precisely guide the process. • Filed a patent (Application number 16378485) for integrating IR and visible images and LIBS for intelligent AM system. • Developed control algorithm and proved it works well for overhang experiment. • Achieved high density (>99%) and excellent mechanical properties. • Succeeded in developing a working and reliable calibration method to extract true temperature distribution during AM process. • Demonstrated spatial and temporal pulse shaping methods, and impact on microstructures. • Filed one utility patent • Laid out a solid path for phase II to work on controllable 3D manufacturing system development and optimization and to make components with nuclear quality. Our proprietary fs fiber laser based AM processing offers an ultimate solution for manufacturing high temperature components with high strength for nuclear systems. The 3D AM system in conjunction with the intelligent sensing and control is energy efficient and cost effective for the growing nuclear industries. Successful development of the proposed AM technology will provide a vital tool to solve existing and potential issues. This technology will be directly applied in the 3D printing area with combined market share of $10(s) of billions. The achievement in this research will have significant and wide social, scientific, and economic impacts by providing affordable low cost intelligent AM/SM systems, laser micromachining systems, improving energy efficiency, and reducing fabrication and operational cost. Having demonstrated the proof of concept in Phase I, we will prototype the controllable AM/SM system and investigate the efficiency and qualification of fabricating various nuclear quality components in Phase II.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2014

Guidelines for internal optics optimization of the ITER EC H and CD upper launcher

The importance of localized injection of Electron Cyclotron waves to control Magneto-HydroDynamic instability is well assessed in tokamak physics and the set of four Electron Cyclotron (EC) Upper Launchers (UL) in ITER is mainly designed for this purpose. Each of the 4 ULs uses quasi-optical mirrors (shaping and planes, fixed and steerable) to redirect and focus 8 beams (in two rows, with power close to 1 MW per beam coming from the EC transmission lines) in the plasma region where the instability appears. Small beam dimensions and maximum beam superposition guarantee the necessary localization of the driven current. To achieve the goal of MHD stabilization with minimum EC power to preserve the energy confinement in the outer half of the plasma cross section, optimization of the quasi-optical design is required and a guideline of a strategy is presented. As a result of this process and following the guidelines indicated, modifications of the design (new mirrors positions, rotation axes and/or focal properties) will be proposed for the next step of an iterative process, including the mandatory compatibility check with the mechanical constraints.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2020

Data-driven predictive probability density function control of fiber length stochastic distribution shaping in refining process

Pulp is the most important raw material in paper in paper industries, whose Fiber Length Stochastic Distribution (FLSD) shaping directly determines the energy consumption and paper quality of the subsequent papermaking processes. However, the mean and variance are insufficient to describe the output FLSD shaping, which display non-Gaussian distribution properties. Therefore, the traditional control, method based on the mean and variance of fiber length is difficult to control the FLSD shaping effectively. In this paper, a novel data-driven predictive probability density function (PDF) control method is proposed for output FLSD shaping in refining process. Primarily, in order to improve the approximation accuracy of the PDF employing RBF neural network, the parameters (center value and width) of each RBF basis functions are tuned via utilizing iterative learning control (ILC) law, and the corresponding estimations of weights law can be obtained. Secondly, considering that the conventional linear model of weights vector has drawbacks of low accuracy and weak generalization ability, random vector functional link networks (RVFLNs) based data driven nonlinear modelling method is employed to characterize the prediction model between the input variables and weights vector. Finally, in order to reduce the randomness of the output FLSD, a minimum entropy control method under mean constraint is employed to design the predictive PDF controller for the output FLSD shaping with the help of the established nonlinear stochastic distribution model. Both simulations and experiments are given to illustrate the effectiveness and practicability of the proposed method.

Probability debsity function, Fiber length distrib↗
DOE OSTI2025

Development of a Digital Twin for Hydrogen Dispersion and Safety Assessment in an Electrolyzer Based Hydrogen Production Facility

Digital twin models are virtual representations of physical systems that use real-time data to simulate and optimize performance. This study presents the development and initial implementation of a digital twin (DT) for the electrolyzer-based hydrogen production facility at NREL's Advanced Research on Integrated Energy Systems (ARIES), focused on enhancing safety and optimizing sensor placement through physics-based simulations and metadata integration. The DT incorporates detailed facility-specific information, including component layout, leak locations, and controlled release parameters, to model hydrogen dispersion under varying environmental conditions. Using steady-state computational fluid dynamics (CFD) simulations informed by real meteorological data, such as wind speed, direction, and vertical wind profiles, the DT enables visualization of hydrogen plume behavior and spatial concentration distributions. Comparative analysis between high and low wind speed scenarios illustrates the significant influence of wind dynamics on plume shape and extent, with horizontal momentum dominating dispersion at higher speeds, while buoyancy effects become more prominent under low wind conditions. These simulations generate a rich dataset embedded within the DT, allowing users to assess potential leak outcomes and identify optimal sensor locations based on concentration thresholds. The model supports scenario-based analysis to guide safety strategies and equipment deployment for open-area hydrogen infrastructure. The digital twin thus serves as a dynamic platform for virtual prototyping, providing predictive insight into hydrogen behavior and enhancing risk-informed decision-making. This initial phase establishes a validated foundation for future integration of transient, uncontrolled leak scenarios and real-time sensor feedback, positioning the DT as a critical tool for safety design, operational planning, and adaptive monitoring in hydrogen systems. Overall, the approach demonstrates the value of combining environmental data with digital simulations to inform safer and more efficient deployment of hydrogen technologies.

08 HYDROGEN↗
DOE OSTI2026

Development of a Digital Twin for Hydrogen Dispersion and Safety Assessment in an Electrolyzer-Based Hydrogen Production Facility: Preprint

Digital twin models are virtual representations of physical systems that use real-time data to simulate and optimize performance. This study presents the development and initial implementation of a digital twin (DT) for the electrolyzer-based hydrogen production facility at the National Renewable Energy Laboratory (NREL)'s Advanced Research on Integrated Energy Systems (ARIES), focused on enhancing safety and optimizing sensor placement through physics-based simulations and metadata integration. The DT incorporates detailed facility-specific information, including component layout, leak locations, and controlled release parameters, to model hydrogen dispersion under varying environmental conditions. Using steady-state computational fluid dynamics (CFD) simulations informed by real meteorological data, such as wind speed, direction, and vertical wind profiles, the DT enables visualization of hydrogen plume behavior and spatial concentration distributions. Comparative analysis between high and low wind speed scenarios illustrates the significant influence of wind dynamics on plume shape and extent, with horizontal momentum dominating dispersion at higher speeds, while buoyancy effects become more prominent under low wind conditions. These simulations generate a rich dataset embedded within the DT, allowing users to assess potential leak outcomes and identify optimal sensor locations based on concentration thresholds. The model supports scenario-based analysis to guide safety strategies and equipment deployment for open-area hydrogen infrastructure. The digital twin thus serves as a dynamic platform for virtual prototyping, providing predictive insight into hydrogen behavior and enhancing risk-informed decision-making. This initial phase establishes a validated foundation for future integration of transient, uncontrolled leak scenarios and real-time sensor feedback, positioning the DT as a critical tool for safety design, operational planning, and adaptive monitoring in hydrogen systems. Overall, the approach demonstrates the value of combining environmental data with digital simulations to inform safer and more efficient deployment of hydrogen technologies.

08 HYDROGEN↗
DOE OSTI2020

Laser-system model for enhanced operational performance and flexibility on OMEGA EP

The development of laser performance models having real-time prediction capability for the OMEGA EP laser system has been essential in meeting requests from its user community for increasingly complex pulse shapes that span a wide range of energies. The laser operations model PSOPS provides rapid and accurate predictions of OMEGA EP laser-system performance in both forward and backward directions, a user-friendly interface and rapid optimization capability between shots. We describe the model’s features and show how PSOPS has allowed real-time optimization of the laser-system configuration in order to satisfy the demands of rapidly evolving experimental campaign needs. We also discuss several enhancements to laser-system performance accuracy and flexibility enabled by PSOPS.

42 ENGINEERING↗
DOE OSTI2018

Structure and specificity of several triclocarban-binding single domain camelid antibody fragments

The variable VHH domains of camelid single chain antibodies have been useful in numerous biotechnology applications due to their simplicity, biophysical properties, and abilities to bind to their cognate antigens with high affinities and specificity. Their interactions with proteins have been well-studied, but considerably less work has been done to characterize their ability to bind haptens. Here, a high-resolution structural study of three nanobodies (T4, T9, and T10) which have been shown to bind triclocarban (TCC, 3-(4-chlorophenyl)-1-(3,4-dichlorophenyl)urea) with near-nanomolar affinity shows that binding occurs in a tunnel largely formed by CDR1 rather than a surface or lateral binding mode seen in other nanobody-hapten interactions. Additional significant interactions are formed with a non-hypervariable loop, sometimes dubbed “CDR4”. A comparison of apo and holo forms of T9 and T10 shows that the binding site undergoes little conformational change upon binding of TCC. Structures of three nanobody-TCC complexes demonstrated there was not a standard binding mode. T4 and T9 have a high degree of sequence identity and bind the hapten in a nearly identical manner, while the more divergent T10 binds TCC in a slightly displaced orientation with the urea moiety rotated approximately 180° along the long axis of the molecule. In addition to methotrexate, this is the second report of haptens binding in a tunnel formed by CDR1, suggesting that compounds with similar hydrophobicity and shape could be recognized by nanobodies in analogous fashion. Structure-guided mutations failed to improve binding affinity for T4 and T9 underscoring the high degree of natural optimization.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2016

Roadmap to Clinical Use of Gold Nanoparticles for Radiation Sensitization

The past decade has seen a dramatic increase in interest in the use of gold nanoparticles (GNPs) as radiation sensitizers for radiation therapy. This interest was initially driven by their strong absorption of ionizing radiation and the resulting ability to increase dose deposited within target volumes even at relatively low concentrations. These early observations are supported by extensive experimental validation, showing GNPs' efficacy at sensitizing tumors in both in vitro and in vivo systems to a range of types of ionizing radiation, including kilovoltage and megavoltage X rays as well as charged particles. Despite this experimental validation, there has been limited translation of GNP-mediated radiation sensitization to a clinical setting. One of the key challenges in this area is the wide range of experimental systems that have been investigated, spanning a range of particle sizes, shapes, and preparations. As a result, mechanisms of uptake and radiation sensitization have remained difficult to clearly identify. This has proven a significant impediment to the identification of optimal GNP formulations which strike a balance among their radiation sensitizing properties, their specificity to the tumors, their biocompatibility, and their imageability in vivo. This white paper reviews the current state of knowledge in each of the areas concerning the use of GNPs as radiosensitizers, and outlines the steps which will be required to advance GNP-enhanced radiation therapy from their current pre-clinical setting to clinical trials and eventual routine usage.

62 RADIOLOGY AND NUCLEAR MEDICINE↗
DOE OSTI2023

Finding middle ground: Flow regimes designed for salmon and energy value

In regulated rivers, shaping seasonal flows to recover species at risk depends on understanding when to expect conflicts with competing water users and when their interests are aligned. Multi-objective optimization can be used to reveal such conflicts and commonalities. When species are involved, multi-objective optimization is challenged by the need to simulate complex species responses to flow regimes. Previously, we addressed that challenge by developing a simplified salmon model (Quantus) that defines cohorts of salmon by the river section and time in which they were spawned. Salmon in these space-time cohorts are tracked from the time redds (nests) are constructed until the cohort exits the tributary en route to the ocean. In this study, we modeled seasonal patterns in energy value and developed a Pareto-optimal frontier of seasonal flow patterns to maximize in-river salmon survival and hydropower value. Candidate flow regimes were characterized by two pulse flows varying in magnitude, timing, and duration and constrained by a total annual flow near the historical median. Our analysis revealed times when economic and salmon objectives were aligned and times when they differed. Pulse flows that favored higher energy value were timed to meet demand during extreme temperatures. Both salmon and hydropower objectives produced optimal flow regimes with pulse flows in early summer, but only solutions favoring hydropower value included high flows in mid-winter. Solutions favoring higher age-0 salmon survival provided an extended pulse flow in late winter/early spring, which suggests that access to productive floodplain habitat allowed faster growth and earlier out-migration and reduced the need for higher temperature-moderating flows later in spring. Minimum flows were also higher among solutions favoring salmon over energy. The tools used to produce these results can help to design simplified seasonal flow regimes by revealing compromise solutions that satisfy both fish and energy producers and highlighting when potential conflicts are likely.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2014

Double injection, resonant-tunneling recombination, and current-voltage characteristics in double-graphene-layer structures

We evaluate the effect of the recombination associated with interlayer transitions in ungated and gated double-graphene-layer (GL) structures on the injection of electrons and holes. Using the proposed model, we derive analytical expressions for the spatial distributions of the electron and hole Fermi energies and the energy gap between the Dirac points in GLs as well as their dependences on the bias and gate voltages. The current-voltage characteristics are calculated as well. The model is based on hydrodynamic equations for the electron and hole transports in GLs under the self-consistent electric field. It is shown that in undoped double-GL structures with weak scattering of electrons and holes on disorder, the Fermi energies and the energy gap are virtually constant across the main portions of GLs, although their values strongly depend on the voltages and recombination parameters. In contrast, the electron and hole scattering on disorder lead to substantial nonuniformities. The resonant inter-GL tunneling enables N-shaped current-voltage characteristics provided that GLs are sufficiently short. The width of the current maxima is much larger than the broadening of the tunneling resonance. In the double-GL structures with relatively long GLs, the N-shaped characteristics transform into the Z-shaped characteristics. The obtained results are in line with the experimental observations [Britnell et al., Nat. Commun. 4, 1794–1799 (2013)] and might be useful for design and optimization of different devices based on double-GL structures, including field-effect transistors and terahertz lasers.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2015

Inversion-mode GaAs wave-shaped field-effect transistor on GaAs (100) substrate

Inversion-mode GaAs wave-shaped metal-oxide-semiconductor field-effect transistors (WaveFETs) are demonstrated using atomic-layer epitaxy of La{sub 2}O{sub 3} as gate dielectric on (111)A nano-facets formed on a GaAs (100) substrate. The wave-shaped nano-facets, which are desirable for the device on-state and off-state performance, are realized by lithographic patterning and anisotropic wet etching with optimized geometry. A well-behaved 1 μm gate length GaAs WaveFET shows a maximum drain current of 64 mA/mm, a subthreshold swing of 135 mV/dec, and an I{sub ON}/I{sub OFF} ratio of greater than 10{sup 7}.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2022

Simpler optimized stellarators using permanent magnets

Abstract A first-of-a-kind optimized stellarator for confining plasma has been designed and is being constructed with planar circular coils and permanent magnets composed of identical elements. The equilibrium is optimized to be quasi-axisymmetric for good particle confinement. The combination of permanent magnets and planar coils is significantly simpler to construct than fabricating three-dimensionally shaped coils, yet they are able to produce lower helical magnetic ripple than existing devices by two orders of magnitude in ϵ eff 3 / 2 , a characteristic neoclassical transport metric.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

Treatment of Problematic Reactive Metal Wastes Using GeoMelt ICV - WM2020 Conference Paper

Decommissioning of sodium-cooled reactors and fast reactor technologies has generated a number of reactive metal waste configurations that are problematic to treat and typically lack cost effective treatment methods and disposition options. As a result, Veolia Nuclear Solutions, under contract with Idaho National Laboratory (owned by the U.S. Department of Energy and managed and operated by Battelle Energy Alliance, LLC) demonstrated its GeoMelt® In-Container Vitrification (ICV)™ technology to safely convert sodium metal to a non-reactive vitrified oxide form. The demonstration project, supported by glass formulation and crucible testing, consisted of a series of ICV™ melts that processed elemental sodium into stable non-reactive glass. INL is currently implementing GeoMelt® technology as a means to safely and reliably convert radioactive reactive metal residues that contaminate sodium cooled reactor components into waste forms that comply with existing disposition pathways. Reactive metal wastes require treatment in order to remove the Resource Conservation and Recovery Act (RCRA) reactivity and ignitability characteristics to comply with land disposal restrictions. GeoMelt®, which is an alternative to other potential treatment approaches, provides a robust approach that chemically converts the reactive metals to an inert oxide while also immobilizing radionuclides in a vitrified waste form with durability equal to or better than vitrified nuclear fuel reprocessing wastes (very robust and inert waste forms). Most other treatment approaches generate hydrogen gas which is problematic. In 2016, Veolia Nuclear Solutions first demonstrated the effectiveness of the GeoMelt® ICV™ process in deactivating reactive sodium metal. Crucible, bench-scale, and engineering-scale demonstrations were conducted on several surrogate waste configurations with various ratios of sodium metal and glass-formers. Each ratio and configuration demonstrated complete deactivation of the surrogate sodium metal. Follow-on work in 2017 demonstrated the deactivation of reactive sodium by GeoMelt® ICV™ at a higher waste loading relative to previously demonstrated work performed in 2016; the higher waste loading optimized glass chemistry while enhancing the economical full-scale treatment of reactive metals. Additionally, follow-on demonstration testing in 2018 and 2019 focused on more complex shapes and other reactive-metals (mocked up Experimental Breeder Reactor II [EBR-II] subassembly, sodium filled heat exchanger, and a can containing sodium potassium alloy) which were all performed at engineering-scale. Since 2018, a 10-metric ton full-scale GeoMelt unit (GeoMelt® Richland) was designed, installed, and commissioned at Perma-Fix Northwest in Richland, Washington for the treatment of reactive metal wastes. As of September 2019, over 900 55-gallon drums containing a total of around 3,500 lb of sodium with low levels of radioactivity have been treated at GeoMelt ® Richland, with resulting glass monoliths disposed at the Nevada National Security Site (NNSS). A full-scale radiological demonstration melt on an actual EBR-II subassembly has also been performed using the full-scale melter in 2019. The GeoMelt® technology is a proven radioactive waste treatment technology capable of immobilizing radioactive wastes, including bulk rubble such as drums and other steel vessels usually without pretreatment. Utilizing the GeoMelt® technology to treat reactive metals eliminates pretreatment steps resulting from having to separate the reactive metal from steel containers or jackets as GeoMelt® can easily operate at temperatures sufficient to melt the steel and expose the reactive metal for treatment. Eliminating handling steps of reactive metals is a significant safety advantage since reactive metals are pyrophoric. The results generated as a part of the 2018-2019 demonstration program are presented in the paper.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2023

An Initial Evaluation of the Elevated-Temperature Cyclic Properties of Optimized 316H Stainless Steel Fabricated by Powder Metallurgy Hot Isostatic Pressing

Powder metallurgy hot isostatic pressing (PM-HIP) is a mature advanced manufacturing technology, which can consolidate metallic powder under high temperature and pressure to generate near-net shape components. This process can lower production costs and reduce component lead times for nuclear reactor construction and can be readily deployed in the near term for microreactor components because of their smaller size. The purpose of this work is to continue the evaluation of elevated-temperature cyclic material properties for PM-HIP 316H stainless steel. Prior scoping results have shown that the commercially procured PM-HIP stainless-steel materials have reduced creep-fatigue performance compared to wrought 316 stainless steels. To better understand how PM-HIP processed material properties compare to traditional manufacturing methods, additional billets of PM-HIP 316H stainless steel were procured and tested. This testing is necessary to understand how elevated-temperature properties are influenced by the PM-HIP process and what data are needed for incorporating PM HIP 316H into the American Society of Mechanical Engineers Boiler Pressure Vessel Code, Section III, Division 5 for high temperature reactor construction. Specifically, an additional PM-HIP 316H stainless steel billet with lower oxygen and nitrogen concentrations was fabricated by the Nuclear Advanced Manufacturing Research Centre of the United Kingdom and tested to understand if elevated-temperature cyclic properties can be improved. The creep-fatigue resistance of the material from this new billet did not show appreciable improvement compared to prior testing.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

Treatment of Problematic Reactive Metal Wastes Using the GeoMelt{sup R} In-Container Vitrification (ICV{sup TM}) Process - 20326

Decommissioning of sodium-cooled reactors and fast reactor technologies has generated a number of reactive metal waste configurations that are problematic to treat and typically lack cost effective treatment methods and disposition options. As a result, Veolia Nuclear Solutions, under contract with Idaho National Laboratory (owned by the U.S. Department of Energy and managed and operated by Battelle Energy Alliance, LLC) demonstrated its GeoMelt{sup R} In-Container Vitrification (ICV){sup TM} technology to safely convert sodium metal to a non-reactive vitrified oxide form. The demonstration project, supported by glass formulation and crucible testing, consisted of a series of ICV{sup TM} melts that processed elemental sodium into stable non-reactive glass. INL is currently implementing GeoMelt{sup R} technology as a means to safely and reliably convert radioactive reactive metal residues that contaminate sodium cooled reactor components into waste forms that comply with existing disposition pathways. Reactive metal wastes require treatment in order to remove the Resource Conservation and Recovery Act (RCRA) reactivity and ignitability characteristics to comply with land disposal restrictions. GeoMelt{sup R}, which is an alternative to other potential treatment approaches, provides a robust approach that chemically converts the reactive metals to an inert oxide while also immobilizing radionuclides in a vitrified waste form with durability equal to or better than vitrified nuclear fuel reprocessing wastes (very robust and inert waste forms). Most other treatment approaches generate hydrogen gas which is problematic. In 2016, Veolia Nuclear Solutions first demonstrated the effectiveness of the GeoMelt{sup R} ICV{sup TM} process in deactivating reactive sodium metal. Crucible, bench-scale, and engineering-scale demonstrations were conducted on several surrogate waste configurations with various ratios of sodium metal and glass formers. Each ratio and configuration demonstrated complete deactivation of the surrogate sodium metal. Follow-on work in 2017 demonstrated the deactivation of reactive sodium by GeoMelt{sup R} ICV{sup TM} at a higher waste loading relative to previously demonstrated work performed in 2016; the higher waste loading optimized glass chemistry while enhancing the economical full-scale treatment of reactive metals. Additionally, follow-on demonstration testing in 2018 and 2019 focused on more complex shapes and other reactive-metals (mocked up Experimental Breeder Reactor II [EBR-II] subassembly, sodium filled heat exchanger, and a can containing sodium potassium alloy) which were all performed at engineering scale. Veolia Nuclear Solutions designed, installed, and commissioned in September 2018, at Perma-Fix Northwest in Richland Washington, a 10-metric ton full-scale GeoMelt unit (GeoMelt{sup R} Richland) for the treatment of reactive metal wastes. As of September 2019, over 900 55-gallon drums containing a total of around 3,500 lb of sodium with low levels of radioactivity have been treated at GeoMelt{sup R} Richland, with resulting glass monoliths disposed at the Nevada National Security Site (NNSS). A full-scale radiological demonstration melt on an actual EBR-II subassembly has also been performed using the full-scale melter in 2019. The GeoMelt{sup R} technology is a proven radioactive waste treatment technology capable of immobilizing radioactive wastes, including bulk rubble such as drums and other steel vessels usually without pretreatment. Utilizing the GeoMelt{sup R} technology to treat reactive metals eliminates pretreatment steps resulting from having to separate the reactive metal from steel containers or jackets as GeoMelt{sup R} can easily operate at temperatures sufficient to melt the steel and expose the reactive metal for treatment. Eliminating handling steps of reactive metals is a significant safety advantage since reactive metals are pyrophoric. The results generated as a part of the 2018-2019 demonstration program are presented in the paper. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗