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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2017

Dual-Particle Imaging System with Neutron Spectroscopy for Safeguard Applications

A dual-particle imager (DPI) has been designed that is capable of detecting gamma-ray and neutron signatures from shielded SNM. The system combines liquid organic and NaI(Tl) scintillators to form a combined Compton and neutron scatter camera. Effective image reconstruction of detected particles is a crucial component for maximizing the performance of the system; however, a key deficiency exists in the widely used iterative list-mode maximum-likelihood estimation-maximization (MLEM) image reconstruction technique. For MLEM a stopping condition is required to achieve a good quality solution but these conditions fail to achieve maximum image quality. Stochastic origin ensembles (SOE) imaging is a good candidate to address this problem as it uses Markov chain Monte Carlo to reach a stochastic steady-state solution. The application of SOE to the DPI is presented in this work.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2018

Fractionation and catalytic upgrading of bio-oil

The goal was to develop a biomass conversion process that optimizes fractionation and conversion to maximize Carbon efficiency and Hydrogen consumption to obtain drop-in fuels. Selective fractionation of raw biomass was obtained via multi-stage thermal fractionation to produce different streams that are enriched in a particular chemical family (acids, furanics or phenolics). These streams were later catalytically upgraded in both liquid and vapor phase to perform C-C bond formation and hydrodeoxygenation. Among various upgrading strategies investigated we have identified an effective path in which cyclopentanone is a crucial intermediate that can be derived from furfural and other furanics obtained in high concentrations from this thermal staged process. Cyclopentanone is a very versatile molecule, which can couple with itself to product high quality jet-fuel, or couple with phenolic or furanics to create long chain molecules. These (mono-oxygenated) compounds in the correct molecular weight fuel range can be hydrotreated to direct drop-in fuels. Interestingly, we have found that the conversion of furfural to cyclopentanone is not affected by the presence of acetic acid, and, more interestingly, it is enhanced by the presence of water. These are very significant findings, since water and acetic acid are always present in all streams from the primary conversion stage. These results have allowed to complete detailed life-cycle assessment and techno-economic analysis that have been back-fed to the experimentalists to refine the catalyst selection and process operations with the objective of maximizing C efficiency at minimum H utilization. These combined investigations have opened the possibility of an economically and technologically effective process that could result in commercial fuels produced from renewable sources at a cost that might be competitive with fossil fuels.

09 BIOMASS FUELS↗
DOE OSTI2018

Final Scientific/Technical Report: Integrating Advanced Software and Statistical Methods for Spectroscopic Dark Energy Surveys

“Dark energy” is a phenomenon of unknown origin that pervades the vacuum of space and is causing the present-day expansion of the universe to accelerate. Understanding the nature of dark energy is one of the most fundamental challenges to modern physics, having the potential to revolutionize our theories of both gravity and elementary particle physics. The effects of dark energy are currently only accessible to astronomical survey experiments that probe large volumes of the cosmos. One of the most powerful forms of experiment for studying dark energy is the cosmological “redshift survey,” which maps the large-scale structure of the universe as traced by the positions of galaxies, quasars, and intergalactic hydrogen clouds. The signature of dark energy and other cosmological parameters is imprinted on this large-scale structure as it evolves over cosmic time. This project focused on maximizing the accurate extraction of information from redshift surveys by improving the algorithms and statistics applied across the chain of inference from raw pixels to high-level cosmological parameter estimation. At the low level, this project developed new techniques for calibrating and analyzing high-background, low signal-to-noise data from astronomical survey spectrographs to provide reliable three-dimensional maps of galaxies and quasars throughout the universe. At the high level, this project developed new statistical frameworks for understanding the completeness of redshift surveys and the underlying demographics of the galaxies that they observe, thereby allowing for a more accurate connection between survey results and theoretical models. This work contributes to maximizing the scientific reach of existing and planned surveys, and opens new potential feasibility for more ambitious surveys in the future.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2018

Thermal Conductivity of Metallic Uranium

This project has developed a modeling and simulation approaches to predict the thermal conductivity of metallic fuels and their alloys. We focus on two methods. The first method has been developed by the team at the University of Wisconsin Madison. They developed a practical and general modeling approach for thermal conductivity of metals and metal alloys that integrates ab-initio and semi-empirical physics-based models to maximize the strengths of both techniques. The second method has been developed by the team at Virginia Tech. This approach consists of a determining the thermal conductivity using only ab-initio methods without any fitting parameters. Both methods were complementary. The models incorporated both phonon and electron contributions. Good agreement with experimental data over a wide temperature range were found. The models also provided insight into the different physical factors that govern the thermal conductivity under different temperatures. The models were general enough to incorporate more complex effects like additional alloying species, defects, transmutation products and noble gas bubbles to predict the behavior of complex metallic alloys like U-alloy fuel systems under burnup. 3 Introduction Thermal conductivity is an important thermal physical property affecting the performance and efficiency of metallic fuels. Some experimental measurement of thermal conductivity and its correlation with composition and temperature from empirical fitting are available for U, Zr and their alloys with Pu and other minor actinides. However, as reviewed in by Kim, Cho and Sohn, due to the difficulty in doing experiments on actinide materials, thermal conductivities of metallic fuels have only been measured at limited alloy compositions and temperatures, some of them even being negative and unphysical. Furthermore, the correlations developed so far are empirical in nature and may not be accurate when used for prediction at conditions far from those used in the original fitting. Moreover, as fuels burn up in the reactor and fission products are built up, thermal conductivity is also significantly changed. Unfortunately, fundamental understanding of the effect of fission products is also currently lacking. In this project, we probe thermal conductivity of metallic fuels with ab initio calculations, a theoretical tool with the potential to yield better accuracy and predictive power than empirical fitting. This work will both complement experimental data by determining thermal conductivity in wider composition and temperature ranges than is available experimentally, and also develop mechanistic understanding to guide better design of metallic fuels in the future. So far, we focused on α-U perfect crystal, the ground-state phase of U metal. We focus on two methods. The first method has been developed by the team at the University of Wisconsin Madison. They developed a practical and general modeling approach for thermal conductivity of metals and metal alloys that integrates ab-initio and semi-empirical physics-based models to maximize the strengths of both techniques. The second method has been developed by the team at Virginia Tech. This approach consists of a determining the thermal conductivity using only ab-initio methods without any fitting parameters. Both methods were complementary and very helpful to understand the physics behind the thermal conductivity in metallic uranium and other materials with similar characteristics. In Section I, the combined model developed at UWM is explained. In Section II, the ab-initio method developed at VT is described along with the uranium pseudo-potential and its validation. Section III is devoted to the work done by Jianguo Yu at INL. Finally, we will present the performance of the project in terms of milestones, publications, and presentations.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2018

Final Report: Advanced Detector Technologies for Precision Measurement of Inflation, Dark Energy, and Neutrino Masses with the Cosmic Microwave Background

Precision measurements of the Cosmic Microwave Background (CMB) provide unparalleled op- portunities to probe the conditions in the early universe and thereby explore particle physics and gravity at the highest energies yet; measure the number of neutrino species and the sum of the neutrino masses with sensitivity beyond what is achievable with planned terrestrial experiments; improve our knowledge of dark energy; and search for other forms of new physics. The P-5 panel recognized the importance and potential of future CMB observations and recommended the DOE fund a stage four CMB experiment (CMB-S4) under all budget scenarios with construction commencing near the end of this decade. The objective of this proposal is to develop and demonstrate new technologies in time to maximize the science return of CMB-S4. The proposed technologies include: (i) broad band metamaterial antireflection coatings on relevant lenses with negligible absorptive and reflective losses; (ii) filters that reduce out of band optical loading with near perfect in band transmission; (iii) broad-band continuously spinning metamaterial half wave plates that boost the sensitivity to inflationary gravitational waves on large angular scales and mitigate systematics with minimal penalty to the instantaneous sensitivity; and (iv) broad band detectors that will enable excellent foreground discrimination while simultaneously maximizing the sensitivity to the signals from inflation and neutrinos. Together these technologies can realize significant improvements in instrumental sensitivity and control of systematic effects. This improvement in raw sensitivity could be used to reduce costs without sacrificing science by deploying a smaller number of more sensitive detectors, or to improve the sensitivity of CMB-S4 to physics parameters including reducing the error bar on r by the inverse of the mapping speed improvement. Beyond raw sensitivity these technologies address key systematics including polarization mixing and galactic foregrounds and enable CMB-S4 to test the shape of the polarization power spectrum out to larger angular scales further boosting measurements of inflation. In this report we detail the progress that has been made in these technical areas. This includes: (i) a demonstration of 4:1 bandwidth AR coating technology and a detailed understanding of the production challenges, (ii) prototype filters that incorporate absorptive and reflective components into silicon, (iii) a prototype broad band HWP fabricated from metamaterial silicon, and (iv) detector designs spanning 20-350 GHz with an understanding of the difficulties associated with bandwidths greater than one octave.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2018

Final Report: Scale-up of Algal Biofuel Production Using Waste Nutrients

Renewable fuels can be more environmentally friendly than conventional fuels and can be produced locally, supporting energy independence. Liquid renewable fuels are of special interest due to their high energy density. Algae are a promising prospective feedstock for low carbon intensity liquid biofuels, due to their high productivity and potential for high lipid or carbohydrate content. Their ability to grow on wastewater and waste nutrients and on non-arable land are cost and sustainability advantages. The organic matter content of wastewater promotes mixotrophic and/or heterotrophic growth of both algae and bacteria, boosting biomass productivity further. However, economic and technologic challenges persist that prevent the scale-up of algal biofuels to commercial relevance. These challenges include algal harvesting, drying, dewatering, and the conversion of algal biomass to usable fuels (Hannon et al 2010, Dunlap and Shaw 2009, Pienkos et al. 2009). The US Department of Energy (DOE) Bioenergy Technologies Office (BETO) supports research to overcome these challenges and outlines the research and development goals for algal biofuels in their Multi-Year Program Plan (MYPP). The long-term goals of the MYPP for algal biofuels research are briefly as follows: develop the domestic ability to produce algal biofuels at a scale of 5 billion gallons per year (BGY) by 2030 and demonstrate technologies that produce biofuel intermediates from algae at a cost of $3/gallon of gasoline equivalent (GGE) by 2022 (BETO MYPP 2016). This research reported herein was funded to investigate methods of meeting an intermediate milestone of 2,500 gallons of biofuel intermediate per acre per year for a non-integrated process by improving algal productivity, harvesting efficiency, and conversion to biofuel intermediates. Use of wastewater and wastewater nutrients was a key distinguishing characteristic of this project. In pursuit of 2,500 gallons of biofuel intermediate (BFI) per acre per year, California Polytechnic State University, San Luis Obispo (Cal Poly) sought to develop the capability to produce biofuel intermediates from microalgae grown on municipal wastewater at a 20-acre algae-based wastewater treatment facility in Delhi, California (37.43° N), which includes 7 acres of raceway ponds. Coupling algal biofuel production with wastewater treatment capitalizes on the abundant waste nutrients and carbon present in wastewater and reduces use of clean water in algal biorefinery systems. In this research, the performance of the full-scale wastewater treatment plant was characterized by measuring productivity, wastewater treatment performance, hydraulic characteristics, and energy consumption. Nine 1,000-L pilot raceways with CO2 addition were used in experiments to maximize productivity. Low-cost, energy-efficient algae bioflocculation and settling were monitored. Population genetics were monitored in an attempt to correlate taxa with superior productivity and/or settling. Algae-bacterial biomass was converted to biofuel intermediates via bench-scale hydrothermal liquefaction (HTL), and the resulting fuel quality was characterized. To develop rapid strain screening capabilities, a climate simulating photobioreactor (“LEAPS”) was developed and validated against outdoor raceways. A techno-economic analysis (TEA) and a lifecycle assessment (LCA) were performed to model process economics and sustainability. The major outcomes of this research included demonstration of 33 g/m2-day annual average algal-bacterial productivity in pilot raceways, and a biofuel intermediate yield of 0.35 g intermediate/g algae biomass via HTL, for a yield of 4,100 gallons BFI per acre per year, assuming a 90% harvest efficiency and ignoring other minor losses. This exceeded the project goal of 2,500 gallons of BFI per acre per year and nearly met the 2030 program goal, highlighting the promise of integrating wastewater treatment and biofuels production. The biocrude BFI produced by the process is refined to diesel and naphtha fuels. These fuels are normalized to the energy content of gasoline (gallons gasoline equivalent, GGE, for comparison to other fuels). Results from the TEA of the this complete “well-to-wheel” process demonstrated that, at a 400-ha scale, a minimum fuel selling price (MFSP) of $12.55/GGE, which could be decreased 57% to $7.14/GGE when including revenue from coupling the biofuel production with the co-products of wastewater treatment services and low carbon fuel credits from California and Federal programs. Due mainly to the high capital costs of thickener centrifuges and hydrothermal processing equipment, the fuel cost is sensitive to scale, with significantly lower costs expected for larger farms. In this research project, significant advances were made in improving raceway algal productivity and fuel production from algae biomass, while also improving process economics. These outcomes brought the algal biofuel technology closer to being a sustainable and marketable process. The remainder of this executive summary is organized into the following six primary project tasks: (1) to optimize biomass productivity for a selected strain at Delhi, (2) to maximize algal productivity and harvesting efficiency in Delhi pilot ponds, (3) a full-scale raceway hydraulic characterization, (4) biomass processing to biofuel intermediates, and (5) scale-up engineering analysis, modeling, and planning.

09 BIOMASS FUELS↗
DOE OSTI2018

Tailoring Electron-Photon Interaction in Active 3D Photonic-Crystal Architectures

A photonic-crystal is an artificially engineered periodic structure. It is often referred to as an “optical semiconductor” due to its unparallel capability to mold the flow-of-light on-chip, not only in plane (the x-y plane) but also along the third direction. Examples of the unique 3D control-of-light include diffraction less light-guiding, slow light, super prism, negative refraction and high-Q cavity. A new research frontier exists in which the concept of complete control-of-light is utilized to facilitate and maximize electron-photon interaction. The close proximity and strong interaction between a photonic-crystal and an electronic medium can lead to new optoelectronic properties not easily attainable by other means. In this program, we will study this new class of active photonic-crystal and to achieve improved device performances and basic discoveries. Under this program, the PI has made significant progress in the following areas: (i) We have maximized light trapping and absorption by a 3D simple-cubic photonic-crystal; By advancing the concept of simple-cubic symmetry design, we have successfully designed a super thin-film architecture for high efficiency, crystalline silicon solar cells; Most recently, we have provided a theoretical roadmap for thin-film silicon solar cells with 30% power conversion efficiency. (ii) In the modification of thermal radiation area, we have observed quasi- optical coherence in thermal radiation from a 3D metallic photonic-crystal; Furthermore, we have made a direct confirmation of super-Planckian radiation a tungsten photonic-crystal; (iii) We have made simultaneous observation of a large light diffraction-efficiency, 82%, and efficiency enhancement by a volume hologram material (PQ-PMMA) for solar concentration application. (iv) we have also successfully fabricated a 3D metal-oxide photonic crystal. We demonstrated that this TiO 2 photonic crystal can achieve an effectively infinite optical path-length created using a simple-cubic photonic crystal for extreme light trapping.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Approaches for Integrating Renewable Energy Technologies in Oil and Gas Operations

Petroleum (including both oil and gas) heats our homes, drives our transportation system, generates electricity and makes modern life possible. Continued demand from developed countries along with growth from developing economies implies demand for oil and gas will likely continue to be robust. Considering the desire to maximize production efficiency and economic returns, there is increased attention to the fact that nearly 10% of oil is consumed in the process of oil production, transportation and refining (Halabi, et al., 2015), and that a quarter of a barrel of oil is used to produce a barrel of heavy oil (Wesoff, 2015). As oil and gas development shifts to secondary and other non-conventional sources, meeting future demand is anticipated to require substantial amounts of energy to produce, transport and refine petroleum. Increasing efficiency of operations and incorporating energy sources that maximize product revenue while simultaneously addressing local environmental concerns as well as reducing overall greenhouse gas emissions has prompted a growing interest in integrating renewable energy technologies in oil and gas operations. Furthermore, due to dramatic declines in the cost of energy generation from renewable sources, integrating renewable energy technology can in many cases reduce operations costs as well. This report provides an overview of where renewable energy technologies can economically be integrated into oil and gas operations.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2019

Neutronic Design and Analysis of the Holos-Quad Concept

HolosGen, LLC is proposing a highly innovative micro-reactor concept targeting both civilian and military applications. It consists of an advanced helium-cooled gas reactor using a turbojet-type turbine and compressor to achieve a highly condensed reactor that fits into a commercial ISO container. The Holos-Quad concept being considered for civilian applications will generate 22MWt, using four Subcritical Power Modules (SPMs) that fit into one 40-foot ISO container. It is a high-temperature gas-cooled reactor concept using TRISO fuel distributed in graphite hexagonal blocks, cooled with helium gas at 7MPa and a high outlet temperature. In FY2019, HolosGen, LLC received an ARPA-E MEITNER grant to team up with the Argonne National Laboratory (ANL) design team to demonstrate the feasibility of the Holos-Quad concept in terms of neutronics. In particular, the evaluation study of the Holos design features and alternative options for reactivity control was considered. Through these tasks, the ANL design team has been working on demonstrating the feasibility of the Holos-Quad concept in terms of neutronics to help advance the core design of the Holos-Quad. A rigorous design approach was employed for the Holos-Quad in order to ensure that the input space is fully investigated, and that the best solutions are considered. The first step of this approach consisted of properly defining the Holos-Quad design problem by identifying the competitive design objectives: its economic performance is maximized with longer lifetime and its transportability to remote locations is maximized with reduced weight. The design problem also required to identify the operational constraints (in terms of thermal hydraulics, reactivity feedback and shutdown margins) and the input parameters that could be varied. In the second step, a sensitivity analysis was performed to enable preliminary investigation of the input space to identify the correlations among input and output variables. It allowed, for instance, to find input parameters that have relatively poor impact on the core performance and that could be removed from the optimization problem to accelerate its convergence. This sensitivity analysis showed that the design problem defined is highly constrained since only 117 solutions out of 1,000 simulated cores met all the design constraints. The design optimization was performed in the third step employing a genetic algorithm to effectively explore this highly constrained input space and find global optimal solutions. More than 2,500 cores were fully evaluated to converge to a Pareto Frontier of optimum solutions providing best compromise between the life-time target and the total core weight, as shown in Figure 1. The main benefit of this approach was to reduce the human effort and to be able to automatically re-run the optimization problem when changing the design problem. The multi-objective optimization identified various core solutions that would be optimum solutions for different types of applications.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2019

Modeling Sintering Processes of Nanoparticle Inks

The In-Pile Instrumentation program conducts research on advanced manufacturing of sensors for use within nuclear reactor experiments. The process for making these sensors involves the sintering of nanoparticles within solvent. The nanoparticles must be sintered in a way that minimizes pores and maximizes continuity. It has also been observed that the nanoparticle films may fall off the substrate, so maximizing adhesion is also important. To model the sintering process, the phase field method was employed for one and two nanoparticle - substrate systems and the contact angle was measured and compared to existing experimental and theoretical studies.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Wood-to-Fuel for California's Transportation Sector using Autothermal Pyrolysis (Progress Report)

We sent our updated draft Site License Agreement back to SPI on June 4 th , with redlines. Gary Blanc of SPI said he would circulate it internally to appropriate parties and get back to us. He did not return an accepted or redlined version to us before the end of the month of July, nor did he send us any questions/comments or updates, despite them being requested. He is currently traveling around visiting SPI’s various forestry locations and mills, so is difficult to reach. In working towards the commercialization strategy, during the month of July, further research was completed on understanding and evaluating the availability and potential availability of fire clearing forestry residue in California. In July, a meeting with Stephen Kaffka and Rob Williams who are both authors of the report “An Assessment of Biomass Resource in California, 2013” was attended. These individuals provided us with guidance and information about how to identify the availability and potential availability of forestry/wood resource biomass in California. Also, in the month of July, a meeting with Cal-Fire was attended in order to understand what Cal-Fire plans to do in terms of reducing the risk of wildfires and how much potential fire clearing forestry residue biomass this will produce for California. Additionally, the potential of a novel pathway of producing H2 from pyrolysis oil, maximizing the products’ value, as well as maximizing the carbon emission reduction potential by incorporating carbon capture onsite, was investigated. We continued with the process of subcontracting with Iowa State University and Frontline BioEnergy. We have our Contract Administrators working with their counterparts at each partner to get the details in place. Draft contracts with statements of work were provided to each partner, and updated schedules and budgets, broken down by task in the statements of work, have been requested from each.

09 BIOMASS FUELS↗
DOE OSTI2020

Catalytic Bio-crude Production in a Novel, Short-Contact Time Reactor

RTI has developed a catalytic fast pyrolysis (CFP) process to produce biomass-based hydrocarbon replacement fuels. From a technology perspective, this advanced biofuels process produces liquid transportation fuels that can leverage capital expenditures in the existing petroleum distribution infrastructure. From a business perspective, this technology does not face potential market limitations caused by oxygenate blend limitations for light duty vehicle applications. A promising catalyst has been developed with excellent potential for deoxygenation to produce a hydrocarbon-rich biocrude that is more suitable for upgrading with traditional hydroprocessing technology. The role of the catalyst is to control the chemistry during biomass pyrolysis to produce a biocrude in a single step that has lower oxygen content and is more thermally stable than conventional biomass fast pyrolysis oil. Catalyst properties are optimized to minimize gas and coke production and improve catalytic deoxygenation and biocrude yields. Results from this project have demonstrated that biocrudes from catalytic fast pyrolysis contain <20 wt% oxygen, with the organic fraction as low as 12% oxygen. These oxygen numbers are > 50% lower compared to traditional fast pyrolysis oils. The biocrude produced from our CFP process can be upgraded to gasoline range hydrocarbons. A very conservative approach for upgrading included a preliminary stabilization step followed by a hydroprocessing step. The oxygen content in the upgraded product was decreased by 97% (to less than 3wt %) from the oxygen content of the biocrude sample. Additionally, the acid content was reduced by 99% from the acid content of the biocrude sample. In an optimized integrated process, the CFP step and the hydroprocessing (upgrading) step need to be carefully balanced to maximize the input biomass energy that is recovered in the finished biofuels. Hydrogen utilization and carbon recovery during both catalytic biomass pyrolysis and biocrude upgrading need to be optimized to maximize energy recovery in the finished biofuel. A nominal 1 ton per day (TPD) catalytic biomass pyrolysis system was designed based on the laboratory experimental data. The system was designed to achieve the short residence times (0.5–2 sec) and high heat transfer rates required for maximum liquid biocrude yields while optimizing process integration to maintain catalyst activity by continuous regeneration. The catalytic biomass pyrolysis reactor is a continuously circulating single-loop transport reactor design that is flexible enough to allow sensitivity studies around temperature, residence time, biomass feed rate, and catalyst-to-biomass ratio (i.e., catalyst circulation rate) for process optimization. For a nominal 100 lb/hr feed rate of dry biomass, the products include ~25 lb/hr char and coke, ~20 lb/hr permanent gases, and ~55 lb/hr condensable vapors. Pyrolysis temperatures are 350–600°C, and the system is operated close to ambient pressure. Production of the catalyst developed within the project was scaled up to provide enough material (200kg) for bench-scale testing. The 1TPD bench-scale unit was fabricated, installed and commissioned with this project. Biocrude samples from wood were produced in this unit with the CFP catalyst with material balance > 90%. The intermediate biocrude yields and chemical composition compare well with previous laboratory results and a hydroprocessing strategy for upgrading the resulting biocrude was developed. The experimental results obtained within this project were used to develop a process model for a 2000 TPD commercial facility. Detailed flow sheets were developed for all major unit operations in the process and provided a basis for an economic analysis to develop capital and operating costs. Estimates of the biofuel production costs were used to develop internal rates of return for the yields and compositions measured for the current state of technology at the end of this project and for the yields anticipated for an optimized (nth plant) scenario as additional process improvements are made.

09 BIOMASS FUELS↗
DOE OSTI2020

JEDEC Tray Flexures for High-Consequence Electronics

JEDEC matrix trays are an industry standard for the safe handling, transport, and storage of electronics. Manufacturing tolerances of the trays (typical for injection-molded components) forces the creation of an envelope around components rather than a secure interface to prevent the trays themselves from damaging the electronics during use. However, this allows relative motion between the components, another potential damage source. This paper covers the design of tray features (flexures) than enable intentional, tuned contact preload to prevent relative motion, maximizing component safety while keeping the JEDEC tray form-factor. The target preload is balanced between gravity and shipment forces that could be experience during adverse handling or transport to prevent loss of contact or slip and keeping the load itself low enough to prevent component damage. Typical features/dimensions for JECEC trays were employed to maximize utility and minimize tray fabrication difficulty. The design also increases usability and component safety by making the chips visible while still sandwiched between trays. The point design described here exemplifies a simple, easy-to-manufacture tray-matrix flexure that significantly improves the security of supported components

42 ENGINEERING↗
DOE OSTI2020

Supercritical Reforming of Wet Ethanol for High Efficiency Direct-injection Heavy-duty Compression-ignition Engines

The purpose of the research was to investigate the potential of using a mature bio-fuel in heavy-duty compression ignition engines. By co-optimizing both the fuel characteristics and engine system the potential for a superior outcome was demonstrated. The use of wet bio-ethanol eliminates the majority of the energy intensive distilling and dehydrating fuel production processes, which moves the fuel towards carbon neutral and also lowers the fuel costs. The relatively high water content of the resulting fuel is leveraged in the proposed novel combustion system by incorporating an integrated high efficiency exhaust waste heat recovery system. This results in significantly higher thermal efficiency. In addition the combustion system features low criteria pollutant emissions and the potential to reduce the initial cost of the engine system hardware. Substantial societal benefits are demonstrated through the co-optimization of the fuel and engine system. A computational proof-of-concept study has been performed to demonstrate the potential benefits of a novel wet ethanol heavy-duty compression ignition combustion system featuring integrated exhaust waste heat recovery. A combined in-cylinder closed cycle 3D computational fluid dynamics (CFD) - 1D engine system simulation approach was used. The models were validated to baseline engine data using diesel fuel and then applied to the wet ethanol study. The original concept was to maximize exhaust waste heat recovery through supercritical reforming of the wet ethanol fuel. Phase I simulation results indicated that the optimal solution for maximum engine efficiency gains were realized through maximizing thermo-mechanical recuperation with negligible fuel reformation. The results show the potential to achieve impressive gains in brake thermal efficiency (BTE) over the base diesel engine. The potential to increase BTE up to 20.9% over the base diesel engine was demonstrated, with even larger gains possible through reduced in-cylinder heat transfer losses. The majority of the efficiency gains were realized through integrated high efficiency exhaust waste heat recovery. The concept also has the potential to achieve future ultra-low NO x emissions standards and negligible engine-out soot emissions. The mixing controlled combustion of high temperature wet ethanol features relatively low engine-out NO x emissions without the need for exhaust gas recirculation (EGR). The soot free combustion enabled by the relatively high oxygen content of ethanol also allows for the use of stoichiometric mixing controlled combustion, which is not practical with diesel fuel. When stoichiometric combustion is used a simple passive 3-way catalyst can be used for exhaust emissions after-treatment and near zero tailpipe emissions. The Phase I simulations results have defined the system layout and requirements in preparation for the Phase II experimental proof-of-concept study. The potential applications of the research include most current applications of diesel engines. The Phase I study focused on heavy-duty on-highway class 8 trucks. However, virtually any application that requires highly efficient clean power generation would benefit from the novel engine system proposed. The results indicate substantial fuel cost savings and reduced greenhouse gas emissions with similar or reduced initial system hardware costs compared to modern diesel engine systems.

09 BIOMASS FUELS↗
DOE OSTI2019

Report of the Workshop on Advanced Fusion with Machine Learning, April 30-May 2, 2019

The pursuit of fusion energy has led to extensive activities in both experimental and theoretical science. The central goal of all these activities has been to develop the knowledge necessary for the design of successful fusion power plants. Even today, following decades of research in many key areas including plasma physics and material science, much remains to be learned in order to achieve optimization of the tokamak or other paths to fusion energy. Data science methods from the fields of machine learning and artificial intelligence (ML/AI) offer opportunities for enabling or accelerating progress toward the realization of fusion energy by maximizing the amount and usefulness of information extracted from experimental and simulation output data. From April 30 to May 2 of 2019, a workshop on “Advancing Fusion with Machine Learning Research Needs” was held in Gaithersburg, MD, with joint support from the Fusion Energy Science (FES) and Advanced Scientific Computing Research (ASCR) Programs. The workshop brought together ~ 60 experts in fields spanning fusion science, data science, statistical inference and mathematics, machine learning, and artificial intelligence, along with DOE program managers and technical experts, with the goal of identifying Priority Research Opportunities (PROs) for the application of ML/AI methods to accelerating progress on solving fusion problems. During the workshop, seven key PROs were identified. The description of each PRO includes relevant fusion problems, potentially useful ML/AI approaches, known gaps currently preventing the use of such approaches, and research guidelines to maximize the effective application of ML/AI methods to the PRO. The report containing the full description of the workshop outcomes is available at https://science.osti.gov/-/media/fes/pdf/workshopreports/FES_ASCR_Machine_Learning_Report.pdf

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

NESHAPs CY19 Report: Radionuclide Air Emission Report for 2019

Lawrence Livermore National Security, LLC operates facilities at Lawrence Livermore National Laboratory (LLNL) in which radionuclides are handled and stored. These facilities are subject to the U.S. Environmental Protection Agency (EPA) National Emission Standards for Hazardous Air Pollutants (NESHAPs) in Code of Federal Regulations (CFR) Title 40, Part 61, Subpart H, which regulates radionuclide emissions to air from Department of Energy (DOE) facilities. Specifically, NESHAPs limits the emission of radionuclides to the ambient air to levels resulting in an annual effective dose equivalent of 10 mrem (100 μSv) to any member of the public. Using measured and calculated emissions, and building-specific and common parameters, LLNL personnel applied the EPA-approved computer code, CAP88-PC, Version 4.0.1.17, to calculate the dose to the maximally exposed individual member of the public for the Livermore Site and Site 300. In 2019, LLNL maintained its compliance with 40 CFR 61, Subpart H. All radioactive air emissions resulted in calculated doses far below the annual 10 mrem (100 μSv) sitewide standard. The annual doses to the site-wide maximally exposed individual member of the public at the Livermore Site and Site 300 from planned and unplanned operations in 2019 are: Livermore Site: 4.3 x 10⁻³ mrem (4.3 x 10⁻² μSv); Site 300: 9.5 x 10⁻⁸ mrem (9.5 x 10⁻⁷ μSv).

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2020

Optimization of Geometric Perturbations on a Rod Moving Through a High Explosive Target

After completing a study to ensure the simulation results were converged, several high resolution 3D Smoothed Particle Hydrodynamic (SPH) simulations of copper rods impacting a high explosive (LX14) target were performed. This was then formulated into an optimization problem: I wanted to find the optimum shape and location of a perturbation on the rod that would maximize its erosion after it left the target. The shape of the perturbation was modeled as a 2D Gaussian bump and parameterized by its location along the rod axis (z 0 ) and amplitude (A). The final mass of the coherent part of the rod as it leaves the target was used as a metric to represent the erosion of the rod, and the optimization was formulated to maximize this metric with respect to the aforementioned design variables. Due to the expensive nature of the high-fidelity 3D SPH simulations, a surrogate model needed to be chosen so that many function calls to the optimizer would be feasible. Thus, a strategic full factorial sampling plan was chosen to build a dataset, which consisted of 24 high-fidelity simulations. Two surrogate models, a third order polynomial regression model and a Gaussian Process Model, were analyzed using a 14%/86% test/train holdout technique. The root mean square and R2 score of the test set was used to determine the best model, and the third order polynomial regression model was chosen as the surrogate model. Finally, the Nelder-Mead Simplex and Basin-hopping optimization algorithms were implemented, and it was found that the two algorithms gave slightly different optimum values. Nelder-Mead gave an optimum point of [z* 0 ;A*] = [9:9;0:4] and Basin-Hopping gave an optimum value of x* = [z* 0 ;A*] = [9:2;0:1].

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗
DOE OSTI2020

Dissolution of Fluoride Salts in Hanford Tank Waste

The Direct Feed High-Level Waste (DFHLW) strategy seeks to bypass the Hanford Waste Treatment and Immobilization Plant Pretreatment Facility while retaining some processing functions to maximize waste feed loading and minimize high-level waste (HLW) waste volume. The DFHLW flowsheet needs leaching, washing, and solids concentration operations either in new or existing tanks. The effectiveness and efficiency of sludge washing has a substantial impact on DST space, mission duration, and the evaporation and low-activity waste (LAW) treatment operations required by these large wash-water additions. One target species requiring washing is fluoride. The HLW glass composition limits for fluorine drive operations to dissolve fluoride-bearing salts into the LAW fraction and thereby maximize waste loading in HLW glass. The fluoride in many high-level wastes at Hanford is predominantly in the form of fluoride-salt precipitates: villiaumite (NaF), kogarkoite (Na 3 FSO 4 ), and natrophosphate (Na 7 F(PO 4 ) 2 ·19H 2 O). Fluoride produces melter off-gas that creates corrosion risk in the off-gas system piping, while the sulfate and phosphate in the fluoride double salts kogarkoite and natrophosphate can be detrimental to glass waste loading. Fluoride salts are sparingly soluble, with solubilities ranging from approximately 40 to 130 kg per kL of pure water, and the dissolution kinetics of the three fluoride salts are not well known. Unexpected delays in a tank dissolution process could be encountered as a result of the lack of information about dissolution rates. In addition, if the double salts show transient non-stoichiometric dissolution of fluoride versus phosphate or sulfate, unexpectedly high concentrations of one of these other constituents could be produced. Washington River Protection Solutions authorized Pacific Northwest National Laboratory to collect the available data for fluoride salt dissolution rate, provide a scoping estimate of dissolution time if possible, and identify gaps in the understanding and predictive capability for estimating dissolution time. Open literature and Hanford reports were reviewed to document, understand, and (where possible) evaluate limitations on fluoride salt equilibria and dissolution kinetics, including both mass transport and surface reaction rate. Scoping estimates of dissolution time were made for mass-transfer-controlled dissolution of spherical particles of fluoride salts suspended in liquid. This is not the only potential governing mechanism; dissolution could be substantially slower if the surface reaction rate (the rate of release of ions from the surface) is the controlling mechanism. When the minimum amount of water for complete dissolution is used and the slip velocity between the liquid and suspended particles is less than or equal to the terminal settling velocity, the estimated mass-transfer rates allow 0.1 mm particles of fluoride salt to dissolve in minutes at 25 °C in water containing no other dissolved salts. Much larger solids, such as the 6-mm chunks that have been seen in heels, could take a few hours to more than a week to dissolve. The actual dissolution times will depend strongly on the actual slip velocity, the extent of particle suspension, constraint by surface reaction rates, the ratio of solvent to solid, and the presence of common ions that shift the solubility equilibria to restrict dissolution of fluoride salts.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗