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DOE OSTI2014

Modular Thermal Hub For Building Cooling, Heating and Water Heating

A thermally activated hub for modular, scalable, distributed cooling and heating in buildings, which uses working fluids with zero Global Warming Potential (GWP), and can run on thermal energy from combustion, low-grade waste heat, or solar energy, was developed and demonstrated in this project. The concept capitalizes on several-fold enhancements in coupled heat and mass transfer possible in microscale passages to remove the primary hurdle that has hindered the implementation of thermally activated heat pumps for more than a century. Cooling capacities of hundreds of watts to tens of kilowatts are possible simply through scaling-up of component geometry. In this project, the proof-of-concept 300 W capacity unit was successfully scaled up to 3.5 kW cooling capacity, and packaged into a compact system. These systems can be utilized for a variety of cooling, heating, and air-conditioning applications in residential and commercial buildings. Additional current and potential market opportunities include CCHP applications (military and private sector mobile power generation, and small residential and light commercial stationary power systems (engine, microturbine and fuel cell driven)), solar cooling applications, distributed process waste heat recovery applications, and long-haul transport refrigeration.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

Characterizing the negative triangularity reactor core operating space with integrated modeling

Negative triangularity (NT) has received renewed interest as a fusion reactor regime due to its beneficial power-handling properties, including low scrape-off layer power and a larger divertor wetted area that facilitates simple divertor integration. NT experiments have also demonstrated core performance on par with positive triangularity (PT) high confinement mode (H-mode) without edge-localized modes (ELMs), encouraging further study of an NT reactor core. In this work, we use integrated modeling to scope the operating space around two NT reactor strategies. The first is the high-field, compact fusion pilot plant concept Modular, Adjustable, NT ARC (MANTA) and the second is a low field, high aspect ratio concept based on work by Medvedev et al. By integrating equilibrium, core transport, and edge ballooning instability models, we establish a range of operating points with less than 50 MW scrape-off layer power and fusion power comparable to PT H-mode reactor concepts. Heating and seeded impurities are leveraged to accomplish the same fusion performance and scrape-off layer exhaust power for various pressure edge boundary conditions. Scans over these pressure edge conditions accommodate any current uncertainty of the properties of the NT edge and show that the performance of an NT reactor will be extremely dependent on the edge pressure. The high-field case is found to enable lower scrape-off layer power because it is capable of reaching high fusion powers at a relatively compact size, which allows increased separatrix density without exceeding the Greenwald density limit. Adjustments in NT shaping exhibit small changes in fusion power, with an increase in fusion power density seen at weaker NT. Infinite-n ballooning instability models indicate that an NT reactor core can reach fusion powers comparable to leading PT H-mode reactor concepts while remaining ballooning-stable. Seeded krypton is leveraged to further lower scrape-off layer power since NT does not have a requirement to remain in H-mode while still maintaining high confinement. We contextualize the NT reactor operating space by comparing to popular PT H-mode reactor concepts, and find that NT exhibits competitive ELM-free performance with these concepts for a variety of edge conditions while maintaining relatively low scrape-off layer power.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2015

Final Report of the HyPER Harvester Project

The HyPER Harvester Project resulted in the first fullscale design, fabrication and testing of two verticalaxis harvester prototypes at the Elephant Butte Irrigation District Drop 8 Station in Southern New Mexico. The design, followed by fabrication, and deployment clearly demonstrated the feasibility to manufacture and deploy harvester prototypes at low cost. While several issues common to irrigation canal systems have to be overcome, the electromechanical performance of the integrated turbinegenerator system demonstrated proofofconcept. Proofofconcept includes 1) feasibility for using additive manufacturing techniques to fabricate Carboncomposite turbinegenerator components at low cost, 2) ease of transportation and deployment, and 3) the harvester performance. The benefits of modularity were demonstrated in terms of rapid deployment at the Drop 8 Station. Scalability and adaptability were proven in terms of the customfitting characteristics that enabled rapid deployment. While keeping the same shape and form, the harvester can be easily adapted to any drop environment. Selfsupporting ability makes the harvester design minimally intrusive on existing structures. There are two technical challenges ahead that have to be addressed. Irregular flow patterns in canal flow induce vertical oscillations due to pressure change across the impeller. Despite the nosecone in conventional Kaplan turbine design that ordinarily dampens oscillations, an effective coupling design is required to eliminate the hydrodynamic effect on the generating system. In arid areas where tumbleweed is present, a robust design to prevent trash entering the drop is required. The compact shape and form have an aesthetic appearance and appear to illustrate an environmentally friendly attribute. The systemsengineered design enables rapid manufacturing and assembly of desired size units that can be deployed at sites along U.S. waterways as small hydropower plants. There is worldwide potential for this technology to provide sustainable hydropower to communities isolated from grid supply.

13 HYDRO ENERGY↗

DOE OSTI2013

Cleanup and Dismantling of Highly Contaminated Ventilation Systems Using Robotic Tools - 13162

The UP1 plant reprocessed nearly 20,000 tons of used natural uranium gas cooled reactor fuel coming from the first generation of civil nuclear reactors in France. Following operating incidents in the eighties, the ventilation system of the continuous dissolution line facility was shut down and replaced. Two types of remote controlled tool carriers were developed to perform the decontamination and dismantling operations of the highly contaminated ventilation duct network. The first one, a dedicated small robot, was designed from scratch to retrieve a thick powder deposit within a duct. The robot, managed and confined by two dedicated glove boxes, was equipped for intervention inside the ventilation duct and used for carrying various cleanup and inspection tools. The second type, consisting of robotic tools developed on the base of an industrial platform, was used for the clean-up and dismantling of the ventilation duct system. Depending on the type of work to be performed, on the shape constraints of the rooms and any equipment to be dismantled, different kinds of robotic tools were developed and installed on a Brokk 40 carrier. After more than ten years of ventilation duct D and D operations at the UP1 plant, a lot of experience was acquired about remote operations. The three main important lessons learned in terms of remote controlled operation are: characterizing the initial conditions as much as reasonably possible, performing non-radioactive full scale testing and making it as simple and modular as possible. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2016

Modular Homogeneous Chromophore–Catalyst Assemblies

Photosynthetic reaction center (RC) proteins convert incident solar energy to chemical energy through a network of molecular cofactors which have been evolutionarily tuned to couple efficient light-harvesting, directional electron transfer, and long-lived charge separation with secondary reaction sequences. These molecular cofactors are embedded within a complex protein environment which precisely positions each cofactor in optimal geometries along efficient electron transfer pathways with localized protein environments facilitating sequential and accumulative charge transfer. By contrast, it is difficult to approach a similar level of structural complexity in synthetic architectures for solar energy conversion. However, by using appropriate self-assembly strategies, we anticipate that molecular modules, which are independently synthesized and optimized for either light-harvesting or redox catalysis, can be organized into spatial arrangements that functionally mimic natural photosynthesis. In this Account, we describe a modular approach to new structural designs for artificial photosynthesis which is largely inspired by photosynthetic RC proteins. We focus on recent work from our lab which uses molecular modules for light-harvesting or proton reduction catalysis in different coordination geometries and different platforms, spanning from discrete supramolecular assemblies to molecule–nanoparticle hybrids to protein-based biohybrids. Molecular modules are particularly amenable to high-resolution characterization of the ground and excited state of each module using a variety of physical techniques; such spectroscopic interrogation helps our understanding of primary artificial photosynthetic mechanisms. In particular, we discuss the use of transient optical spectroscopy, EPR, and X-ray scattering techniques to elucidate dynamic structural behavior and light-induced kinetics and the impact on photocatalytic mechanism. Two different coordination geometries of supramolecular photocatalyst based on the [Ru(bpy)3]2+ (bpy = 2,2'-bipyridine) light-harvesting module with cobaloxime-based catalyst module are compared, with progress in stabilizing photoinduced charge separation identified. These same modules embedded in the small electron transfer protein ferredoxin exhibit much longer charge-separation, enabled by stepwise electron transfer through the native [2Fe-2S] cofactor. We anticipate that the use of interchangeable, molecular modules which can interact in different coordination geometries or within entirely different structural platforms will provide important fundamental insights into the effect of environment on parameters such as electron transfer and charge separation, and ultimately drive more efficient designs for artificial photosynthesis.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2024

Analysis of AP1000 Small-Break Loss-of-Coolant Accident Using Reactor Transient Simulator

The Westinghouse Electric Company’s Advanced Passive Reactor (AP1000) is characterized by the incorporation of passive safety systems (PSSs) designed to ensure core cooling during transient events. The assessment of PSSs requires evaluation of their performance through a combination of experiments and simulations employing various thermal-hydraulic codes. In addition, detailed evaluation of PSSs for a specific reactor system transient analysis such as loss-of-coolant-accident analysis supports understanding representative integral effects test facility development and the further evolution model development and assessment process. Developing a reactor system code is a complex and time-consuming process that requires significant engineering expertise and effort. It can take several months to even years to complete in the early stages of reactor system design and analysis. However, this process can be expedited through the use of transient simulator models for similar reactor systems, which can be used for lesson learning and training purposes. This study uses the Personal Computer Transient Analyzer (PCTRAN) code. The main advantage of PCTRAN is its ease of use and ability to run faster than real time. This study presents the results obtained for a small-break loss-of-coolant accident (SBLOCA) for two breaks using the full version (licensed) of PCTRAN. The purpose of this investigation is to evaluate the overall system behavior during the postulated SBLOCA event as well as assess the capability of the PCTRAN code to reproduce the system response during transient events. The obtained results were compared with the Westinghouse NOTRUMP system code. The PCTRAN code proved to be reliable in predicting the qualitative behavior of the system in both transient cases. As for the system response, it was found that it is contingent on the activation time of the PSSs. The differences in reactor coolant system pressure between the two codes were attributed to the critical flow model and simplification of mass and energy balance. Despite PCTRAN’s limitations, it can still provide a reasonable prediction of various reactor parameters such as pressure, mass flow rate, and void fraction during a SBLOCA scenario. It is worth noting that PCTRAN currently employs a bulk approach similar to that of the Modular Accident Analysis Program (MAAP) and MELCOR codes. However, the upcoming version of PCTRAN will include an artificial intelligence–based detection and accident prevention system, as well as different models for different reactor components. Consequently, PCTRAN has the potential to be upgraded to match the system thermal-hydraulic codes of the U.S. Nuclear Regulatory Commission and become more widely used in cybersecurity to safeguard nuclear power plants from cyberattacks.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2022

Modular Plasma Microreactor for Intensified Hydrogen Peroxide Production

Sustainable and decentralized manufacturing of hydrogen peroxide (H 2 O 2 ) has been extensively sought to replace the energy- and waste-intensive anthraquinone process. We introduce a helical biphasic microreactor in a coaxial dielectric barrier discharge (DBD) configuration as a modular, adaptable, and scalable intensified unit for H 2 O 2 production. Geometric and operating parameters such as electrode length, applied voltage, and gas and liquid flow rates can be tuned to regulate the residence time, delivered power, and gas–liquid interfacial area. In turn, these affect the key output parameters, i.e., H 2 O 2 concentration, production rate, and energy yield. We found a direct correlation between the H 2 O 2 production rate and the product of the interfacial area and residence time in the plasma region. We investigated the H 2 O 2 formation pathways using DMSO as an ·OH radical scavenger and found that H 2 O 2 forms by the dissolution of gaseous H 2 O 2 at low interfacial areas and is enhanced probably due to the interfacial recombination of ·OH radicals at a large gas–liquid interfacial area. The reactor temperature can also be externally controlled to intensify the production rate and energy yield of H 2 O 2 . Concentrations of up to 33 mM can be attained with a small footprint reactor that features a maximum energy yield of 4 g kWh –1 . Here, the plasma microreactor could epitomize a powerful process intensification tool for sustainable and distributed chemical manufacturing.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2019

A Customizable Approach for the Enzymatic Production and Purification of Diterpenoid Natural Products

Diterpenoids form a diverse class of small molecule natural products that are widely distributed across the kingdoms of life and have critical biological functions in developmental processes, interorganismal interactions, and environmental adaptation. Due to these various bioactivities, many diterpenoids are also of economic importance as pharmaceuticals, food additives, biofuels, and other bioproducts. Advanced genomics and biochemical approaches have enabled a rapid increase in the knowledge of diterpenoid-metabolic genes, enzymes, and pathways. However, the structural complexity of diterpenoids and the narrow taxonomic distribution of individual compounds in often only a single species remain constraining factors for their efficient production. Availability of a broader range of metabolic enzymes now provide resources for producing diterpenoids in sufficient titers and purity to facilitate a deeper investigation of this important metabolite group. Drawing on established tools for microbial and plant-based enzyme co-expression, we present an easily operated and customizable protocol for the enzymatic production of diterpenoids in either Escherichia coli or Nicotiana benthamiana, and the purification of desired products via silica chromatography and semi-preparative HPLC. Using the group of maize (Zea mays) dolabralexin diterpenoids as an example, we highlight how modular combinations of diterpene synthase (diTPS) and cytochrome P450 monooxygenase (P450) enzymes can be used to generate different diterpenoid scaffolds. Purified compounds can be used in various downstream applications, such as metabolite structural analyses, enzyme structure-function studies, and in vitro and in planta bioactivity experiments.

09 BIOMASS FUELS↗

DOE OSTI2025

Challenges and Gaps in the Development of Pulsed Power for Fusion Applications: A Preroadmapping Perspective From Industry, Academia, and National Laboratory Experts

Fusion energy meets the twenty-first century World Grand Challenge of sustainable, ubiquitous, and safer energy sources. However, harnessing the promise of fusion energy has proven elusive. The competing approaches to fusion power plant design include inertial confinement fusion, National Ignition Facility (ICF-NIF, Z machine, etc.,) magnetic confinement fusion (MCF-Tokamak, stellarators, etc.), and other approaches that show promise in small- (flow stabilized Z pinches) or large-scale applications. These approaches are being accelerated with private and public funding and seek to demonstrate the feasibility of different approaches to fusion-based power plants. Yet, how can the necessary pulsed power technologies for these disruptive technology bases be accelerated with no clear “Dominant Design?” Roadmapping holds the promise to identify and develop common critical pulsed power components for laboratory, prototype, and commercial fusion, and can accelerate the commercialization of fusion reactor designs. A preroadmapping Workshop on Pulsed Power for Fusion was held at the IEEE International Pulsed Power Conference in San Antonio, TX, USA, in June 2023. The workshop had 177 attendees. Here, the common elements for many of the ICF technologies vying for dominant design were identified. The advancement of these technologies through roadmapping will enhance commercial expectations that require their rapid and innovative development in the next five years, as well as the next five to ten years. The key technologies identified that underpin and limit the advancement of fusion power include pulsed power technologies such as energy storage, high-voltage switching, additive manufacturing, and modular pulsed power circuit topologies. In conclusion, they are the focus of our effort in the following roadmap scenario, which will delineate potential paths to technology development.

Curry, Randy D. [I-Pulse Group, Albuquerque, NM (U↗

DOE OSTI2019

Simulation of thermal hydraulic performance of multiple parallel micropin arrays for concentrating solar thermal applications with supercritical carbon dioxide

Concentrated solar power (CSP) plants have the potential to provide 24 h, renewable electricity. Current CSP systems have high capital and operational costs which makes the levelized cost of electricity uncompetitive with conventional techniques. Recent experimental research has shown the potential of small unit cells (up to 2 × 2 cm) containing micropin arrays (D H < 1 mm) to operate efficiently at high incident flux (>140 W cm -2 ) using supercritical carbon dioxide as the working fluid. Applying this technology to CSP systems would result in a smaller central receiver, which would reduce thermal losses, increase receiver efficiency and reduce the capital cost of the receiver component. This study investigates and addresses the practical thermal and hydraulic issues in numbering up these small unit cells into numerous parallel cells within an integrated module design. A thermal hydraulic network model is developed to quantify the distribution and the overall receiver efficiency of an integrated module. This model is used to specify maximum allowable unit cell size and header dimensions to maintain acceptable thermal performance and pressure loss. Once a module design was finalized, parametric studies were performed to study the effects of varying incident flux on flow distribution and thermal performance of the module. Finally, the results show that an integrated module design can be achieved with less than 5% flow maldistribution and a pressure drop acceptable to the remainder of the system.

14 SOLAR ENERGY↗

DOE OSTI2023

Coal-based Bricks & Blocks (CBBs): Process Development to Prototype Fabrication Coupled with Techno-Economic Analysis and Market Survey

The decline of coal use for energy production provides an abundance of local feedstock for new innovative uses and value-added products. Expanding the U.S. coal-value chain to manufacture high-value carbon products can strengthen the nation’s energy and mineral security, enhance the U.S. national defense security, increase the United States’ economic prosperity, while achieving U.S. environmental objectives. The primary project goal is a relatively light-weight composite product with superior (or comparable) compressive strength. Both virgin and, where available, post-consumer recycled thermoplastic versions are tested for each thermoplastic species. A useful attribute of thermoplastics as binders is that they can be heated to their melting point, cooled, and reheated again without significant degradation. A key advantage of thermoset CBBs is that they require only mixing and molding. CBB advantages include low cost, availability, binding ability and processability. Coal-based bricks and blocks (CBBs) weigh about 50% less than clay bricks and can be manufactured with an interlocking design to promote ease of use for the novice builder. CBB formulation is evaluated according to a design-of-experiments (DoE) approach. DoE variables are a) relative weight fractions of binder, b) relative proportions of large versus small (milled) anthracite size fractions, and c) additive percentage. Fabrication methods include hot-press molding and extrusion, the later being the most commercially viable. CBBs are tested for compressive strength, modulus of rupture (by flexure test) and water absorption per ASTM C67, with density determined by the Archimedes drainage method. Fractured interfaces are examined by SEM (Scanning Electron Microscopy) to resolve fracture dynamics and interior microstructure uniformity. Differential scanning calorimetry (DSC) is used to compare plastic transition temperatures i.e., glass and melting temperatures to contrast virgin with post-consumer recycled thermoplastics and optimize their usage. These results are used in the DoE analysis to identify the binder and relative weight percentages for optimum strength, density, and porosity. Overall, CBBs possess strength comparable to clay-based bricks but are non-permeable and hydrophobic, and hence resistant to degradation by freeze-fracturing, corrosion, and efflorescence. The strongest composites have been made with the following thermoplastic binders (in order of strength): thermoset, high-density polyethylene crosslink resin, high-density polyethylene, nylon 6/6, and polypropylene. Results from a techno-economic analysis TEA show economy of scale for CBBs by modularization and reveal the binder as the cost driver for material costs. Ideally, the incorporation of post-consumer recycled thermoplastic will decrease material acquisition costs and increase product sustainability. Notably, CBBs do not require the high temperature calcination needed to produce cement, nor do they require firing in the 1600-2400 °F range for three days using natural gas, as do clay brick equivalents. Instead, CBBs are heated to a modest <600 °F according to the melt flow index of the thermoplastic binder. Existing anthracite mines can be expanded to produce CBBs to reduce aggregate transportation costs and emissions that exist for clay bricks. TEA reflects this reduced energy cost while a comparative CO2 emission analysis quantifies the reduced environmental footprint. The market survey identifies several commercialization opportunities, dependent upon the brick classification.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2016

Engineering a trifunctional proline utilization A chimaera by fusing a DNA-binding domain to a bifunctional PutA

Proline utilization A (PutA) is a bifunctional flavoenzyme with proline dehydrogenase (PRODH) and Δ1-pyrroline-5-carboxylate (P5C) dehydrogenase (P5CDH) domains that catalyses the two-step oxidation of proline to glutamate. Trifunctional PutAs also have an N-terminal ribbon–helix–helix (RHH) DNA-binding domain and moonlight as autogenous transcriptional repressors of the put regulon. A unique property of trifunctional PutA is the ability to switch functions from DNA-bound repressor to membrane-associated enzyme in response to cellular nutritional needs and proline availability. In the present study, we attempt to construct a trifunctional PutA by fusing the RHH domain of Escherichia coli PutA (EcRHH) to the bifunctional Rhodobacter capsulatus PutA (RcPutA) in order to explore the modular design of functional switching in trifunctional PutAs. The EcRHH–RcPutA chimaera retains the catalytic properties of RcPutA while acquiring the oligomeric state, quaternary structure and DNA-binding properties of EcPutA. Furthermore, the EcRHH–RcPutA chimaera exhibits proline-induced lipid association, which is a fundamental characteristic of functional switching. Unexpectedly, RcPutA lipid binding is also activated by proline, which shows for the first time that bifunctional PutAs exhibit a limited form of functional switching. Altogether, these results suggest that the C-terminal domain (CTD), which is conserved by trifunctional PutAs and certain bifunctional PutAs, is essential for functional switching in trifunctional PutAs.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2019

Polyelectrolyte character of rigid rod peptide bundlemer chains constructed via hierarchical self-assembly

Short α-helical peptides were computationally designed to self-assemble into robust coiled coils that are antiparallel, homotetrameric bundles. These peptide bundle units, or ‘bundlemers’, have been utilized as anisotropic building blocks to construct bundlemer-based polymers via a hierarchical, hybrid physical-covalent assembly pathway. The bundlemer chains were constructed using short linker connections via ‘click’ chemistry reactions between the N-termini of bundlemer constituent peptides. The resulting bundlemer chains appear as extremely rigid, cylindrical rods in transmission electron microscopy (TEM) images. Small angle neutron scattering (SANS) shows that these bundlemer chains exist as individual rods in solution with a cross-section that is equal to that of a single coiled coil bundlemer building block of ≈20 Å. SANS further confirms that the interparticle solution structure of the rigid rod bundlemer chains is heterogeneous and responsive to solution conditions, such as ionic-strength and pH. Due to their peptidic constitution, the bundlemer assemblies behave like polyelectrolytes that carry an average charge density of approximately 3 charges per bundlemer as determined from SANS structure factor data fitting, which describes the repulsion between charged rods in solution. This repulsion manifests as a correlation hole in the scattering profile that is suppressed by dilution or addition of salt. Presence of rod cluster aggregates with a mass fractal dimension of ≈2.5 is also confirmed across all samples. The formation of such dense, fractal-like cluster aggregates in a solution of net repulsive rods is a unique example of the subtle balance between short-range attraction and long-rage repulsion interactions in proteins and other biomaterials. With computational control of constituent peptide sequences, it is further possible to deconvolute the underlying sequence driven structure–property relationships in the modular bundlemer chains.

36 MATERIALS SCIENCE↗

DOE OSTI2015

High Temperature Fluoride Salt Test Loop

Effective high-temperature thermal energy exchange and delivery at temperatures over 600°C has the potential of significant impact by reducing both the capital and operating cost of energy conversion and transport systems. It is one of the key technologies necessary for efficient hydrogen production and could potentially enhance efficiencies of high-temperature solar systems. Today, there are no standard commercially available high-performance heat transfer fluids above 600°C. High pressures associated with water and gaseous coolants (such as helium) at elevated temperatures impose limiting design conditions for the materials in most energy systems. Liquid salts offer high-temperature capabilities at low vapor pressures, good heat transport properties, and reasonable costs and are therefore leading candidate fluids for next-generation energy production. Liquid-fluoride-salt-cooled, graphite-moderated reactors, referred to as Fluoride Salt Reactors (FHRs), are specifically designed to exploit the excellent heat transfer properties of liquid fluoride salts while maximizing their thermal efficiency and minimizing cost. The FHR s outstanding heat transfer properties, combined with its fully passive safety, make this reactor the most technologically desirable nuclear power reactor class for next-generation energy production. Multiple FHR designs are presently being considered. These range from the Pebble Bed Advanced High Temperature Reactor (PB-AHTR) [1] design originally developed by UC-Berkeley to the Small Advanced High-Temperature Reactor (SmAHTR) and the large scale FHR both being developed at ORNL [2]. The value of high-temperature, molten-salt-cooled reactors is also recognized internationally, and Czechoslovakia, France, India, and China all have salt-cooled reactor development under way. The liquid salt experiment presently being developed uses the PB-AHTR as its focus. One core design of the PB-AHTR features multiple 20 cm diameter, 3.2 m long fuel channels with 3 cm diameter graphite-based fuel pebbles slowly circulating up through the core. Molten salt coolant (FLiBe) at 700°C flows concurrently (at significantly higher velocity) with the pebbles and is used to remove heat generated in the reactor core (approximately 1280 W/pebble), and supply it to a power conversion system. Refueling equipment continuously sorts spent fuel pebbles and replaces spent or damaged pebbles with fresh fuel. By combining greater or fewer numbers of pebble channel assemblies, multiple reactor designs with varying power levels can be offered. The PB-AHTR design is discussed in detail in Reference [1] and is shown schematically in Fig. 1. Fig. 1. PB-AHTR concept (drawing taken from Peterson et al., Design and Development of the Modular PB-AHTR Proceedings of ICApp 08). Pebble behavior within the core is a key issue in proving the viability of this concept. This includes understanding the behavior of the pebbles thermally, hydraulically, and mechanically (quantifying pebble wear characteristics, flow channel wear, etc). The experiment being developed is an initial step in characterizing the pebble behavior under realistic PB-AHTR operating conditions. It focuses on thermal and hydraulic behavior of a static pebble bed using a convective salt loop to provide prototypic fluid conditions to the bed, and a unique inductive heating technique to provide prototypic heating in the pebbles. The facility design is sufficiently versatile to allow a variety of other experimentation to be performed in the future. The facility can accommodate testing of scaled reactor components or sub-components such as flow diodes, salt-to-salt heat exchangers, and improved pump designs as well as testing of refueling equipment, high temperature instrumentation, and other reactor core designs.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2023

A Functional Reference Architecture and Assessment Thereof for the National Ignition Facility Industrial Controls Systems

The Industrial Control System (ICS) at the National Ignition Facility (NIF) has an effective, well-established architecture based off a conventional cyclical software paradigm focused on maintainability and the identification of issues. This architecture exhibits scalability in ensuring expansions of the system conform to the existing architecture, modularity enough to allow relatively easy integrations of such expansions and works as a successful tool to introduce control system engineers new to the NIF ICS to the structure of the system at each layer. This architecture, like most software architectures, is object-oriented, lending itself to ease of understanding by control systems engineers and software engineers familiar with an object-oriented perspective. There are occasions, however, where engineers of other disciplines require insight into the functionality and structure of the ICS for the purposes of understanding fundamentally how their own system is or will be governed by the ICS, without the need for the details of operation of the ICS or the object-oriented view. For this reason, a functional architecture of the ICS could be a potent tool for communicating this insight. Even more powerful, a generalization of this proposed functional ICS architecture in the form of a National Ignition Facility and Photon Science (NIF & PS) Industrial Controls Reference Architecture could communicate this insight not just to systems governed by the ICS in the NIF proper, but across entirety of the NIF & PS Principal Associate Directorate (PAD), anywhere an instance of the ICS architecture is present, such as the approximately 40 “small labs” distributed across the directorate. Such a tool will provide an alternative means of understanding the implementation of these control systems, conducive to a larger variety of engineering and scientific disciplines.

42 ENGINEERING↗

DOE OSTI2023

Large Format Composite Additive Manufacturing for Low-Head Hydropower

Hydropower with a small elevation change from inlet to outlet, known as “low-head” hydropower, is a relatively untapped resource for reliable green power generation. One major barrier to entry is the cost of the components needed to generate the power. Each installation site is unique, with various head levels, flow rates, and other unique site characteristics that drive up the cost of development and installation. As a result, custom-made components are necessary because the sites are intrinsically inefficient. However, customized parts are generally more expensive to manufacture than ready-made parts. Often times, the cost of custom-made components is so high that the low-head hydropower installation becomes non-viable. Additive manufacturing offers the ability to make custom components, ideal for one-off applications, at low costs that are well suited for the needs of low-head hydropower. Indirect additive manufacturing, such as making tools or dies rather than end use components, can also be used to make low-cost composite tooling as needed for these custom applications. This paper explores the use of additive manufacturing, both directly and indirectly, to produce the components of a turbine system for a low-head hydropower site. The parts were designed to form a unique modular system, which saves time for future designs and iterations. The system has operated for more than three years without failure at a test site in Wisconsin, USA. This work serves as a basis for future application of AM to low-head systems, in which the modular components can be customized for each unique hydropower installation.

36 MATERIALS SCIENCE↗

DOE OSTI2015

DOE SBIR 2014 Topic 2.C – Phase I Final Report

Freshwater is a vital resource for human survival as well as a key component of a wide range of industrial and agricultural needs. However, only 0.65% of the world’s water resources are available as freshwater, and the demand on the world’s water reserves continues to increase, with the demand beginning to outpace the supply in many areas. A water-energy nexus is being reached that requires low –cost and –energy solutions for various degrees of treated water. In a 2012 survey, 88% of Americans were concerned about potential water shortages and approximately two-thirds of the world’s population will be suffering a water shortage over the next few years. Seawater and other saline water materials make up around 98% of the available water, representing an almost unlimited supply of water. The energy, cost and maintenance to remove salts and other unwanted compounds is a barrier to widespread implementation of salt-to-freshwater facilities. These facilities most commonly use reverse osmosis (RO) systems. Due to the high required pressures and moving parts these facilities consume much grid energy and require constant maintenance leading to high capital and operational costs. RO also generates highly concentrated brine that is costly to safely return to the ocean. Capacitive desalination (or capacitive deionization [CDI]) has no moving parts (aside from a low pressure pump and valves), operates at low pressure and does not generate brine that is hazardous to marine life. Not only can the capacitive charge/discharge be cycled almost indefinitely but the system uses low energy and capacitive discharge electrical current can be co-generated back to the system. However, CDI has not seen widespread use for large- or small- scale desalination because electrode efficiency limits the extraction rate below what is useful for most applications. Mainstream Engineering Corporation (MEC) has demonstrated an innovative new electrode structure for the high efficiency desalination of brackish water by capacitive deionization. Electrode manufacturing (nanomanufacturing) is a highly scalable and low-cost electrochemical self-assembly method using a templated process that Mainstream has pioneered and leveraged for several energy technologies over the last decade. The primary accomplishment for Phase I is the fabrication and demonstration of CDI electrode structures are: • Demonstrating the linear scalability of templated approach to the fabrication scaling the electrode structure. • Demonstrated the ability to tune the fabrication of the electrode structures to produce electrodes with a highly controllable aligned nanopore diameter and nanopore depth. • Demonstrated the efficient removal of a sodium chloride salt from brackish water with a 60 times improvement in mg-salt removed/g-carbon compared to a commercial system under the same conditions. • Demonstrated good reproducibility and stability of the electrode structure under realistic CDI operating conditions. • Demonstrated charge efficiency as high as 93% with an expected system level energy requirement of 0.7 to 1.5 kWh/m3 of water; significantly lower than the 2.9 to 3.7 kWh/m3 observed for RO systems Based on the performance characteristics of the electrodes, Mainstream was able to propose a modular and scalable capacitive deionization design that can be adapted to a wide range of conditions providing energy efficient desalination of brackish water.

36 MATERIALS SCIENCE↗

DOE OSTI2015

Deployment of large tank monosodium titanate strike to increase salt processing at the Savannah river site - 15115

The treatment of high level waste (HLW) salt solutions using the Actinide Removal Process (ARP) and Modular Caustic Side Solvent Extraction Unit (MCU) began at Savannah River Site (SRS) in 2008. Since that time, over 6 million gallons of liquid HLW have been treated and the resulting low level waste (LLW) effluent immobilized in cementitious grout at salt-stone. In addition to the continued stabilization of liquid HLW, operating experience from the ARP/MCU facilities has also been valuable in considering the design and construction of the Salt Waste Processing Facility (SWPF) which will utilize similar unit operations on a much larger scale. ARP removes actinides by contacting waste with monosodium titanate (MST) which is a solid adsorbent for soluble strontium and actinides. Once the sorption reaction is complete, the MST solids are separated from salt solution via ultrafiltration through a crossflow filter. The throughput of initial operations of ARP/MCU was limited by the flowrate through the extraction process. However, after the implementation of a new solvent flowsheet, filtration of MST will be the rate limiting step in salt processing. For the entirety of ARP/MCU operation, Savannah River Remediation (SRR) has sought to improve process efficiency and performance through optimization and modification of the original facility design. These efforts have resulted in a best-single-year throughput of 4.9 million liters of decontaminated salt solution. In keeping with these practices, SRR recently initiated a project to improve filtration throughput by relocating the MST strike from small batches immediately upstream of the filtration unit to the underground waste tank used to batch and store salt solution feed for ARP/MCU. This process change will allow the bulk of MST solids to decant in the waste tank prior to filtration which should improve both the nominal operational filter flux as well as the achieved utility of filter operation. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗