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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 OSTI2021

Validating Thermal Compensated Deposition using Computed Aided Manufacturing Software

DP Technology Corporation’s flagship product, ESPRIT, is a highly adaptable computer-aided manufacturing system that’s used across industries and continents to create nearly anything. ESPRIT is used to generate toolpath trajectories for traditional subtractive and additive manufacturing (AM) cycles. DP Technology and Oak Ridge National Laboratory have partnered together to improve the generated additive toolpath by means of API simulation. The potential impact of this research is the enhancement of toolpath planning for additive and hybrid manufacturing. Being able to simulate and compensate for various effects such as overheating, and distortion are critical components for the industrial adoption of hybrid manufacturing processes. Industrial applications include the mold & die, automotive, and aerospace industries.

42 ENGINEERING↗
DOE OSTI2023

Techno-economic evaluation of industrial heat pump applications in US pulp and paper, textile, and automotive industries

Industrial process heat decarbonization through electrification could contribute significantly to climate change mitigation efforts. In the US industry, thermal processes accounted for more than two-thirds of the total final energy demand in 2021. Cross-cutting electrification technologies like industrial heat pumps are suitable for the process heat supply to several industrial unit operations in a sustainable way while also improving overall energy efficiency. This study employs a bottom-up approach to investigate the techno-enviro-economic potentials of deploying high-temperature and steam-generating heat pumps in US textile, pulp and paper, and automotive sectors in different timeframes. The results show that the annual technical potential energy and CO 2 savings by electrifying heat supply are 310 PJ (or 36% of the projected energy demand) and 28 MtCO 2 (or 71% of the projected CO 2 emissions) in 2050 respectively, however, these incur additional costs in each sector (ranging between 5 and 18 $\$$/GJ). The required heating capacity of industrial heat pumps is estimated at 15 GW, which translates roughly into a market of over 6000 heat pump units and an investment volume of $\$$7 billion in the studied processes. Although there may be individual cost-effective opportunities for electrifying heat supply in specific industrial sites, the overall costs are estimated to be high in the three industrial sectors due to the large disparity between electricity and natural gas prices and low heat source temperatures. To overcome the identified techno-economic barriers, comprehensive action plans for different stakeholders are also given. This study provides novel insights that should inform policymakers’ and executives’ decisions about the electrification of the current and future US industrial heat supply in relevant industrial sectors.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2020

Towards the scale-up production of cellulose nanocomposites using melt processing: A critical review on structure-processing-property relationships

Cellulose nanomaterials (CNMs) naturally exist in plant biomass. The success of extraction of CNMs opened up a new era of using plant biomass for innovative industrial applications. Because CNMs are abundant, renewable, biodegradable, transparent, light weight and low in cost, they are ideal materials for large volume applications such as packaging, automotive, building and infrastructure. In many potential application areas, CNM-enable products appear in a composite form, mostly polymer composites. Additionally, the industrial-scale manufacturing of CNM/thermoplastic composites remains as a set of unsolved problems for academia and industry. A prime challenge in applications is the nanoscale dispersion of CNMs in thermoplastic matrices during melt processing. Both bench-scale and pilot-scale studies have been conducted to solve the dispersion issue of CNMs. In this article, research related to the dispersion of CNMs in thermoplastic matrices during melt processing were critically reviewed. All research papers were classified into three groups: chemically-aided dispersion, physically-aided dispersion and mechanically-aided dispersion. Numerous factors affect the CNM dispersion and the mechanical performance of its nanocomposites. There are material-related factors, including CNM types and forms, polymer matrices, surface modification, coupling agents, etc. Furthermore, extrusion processing parameters also play a significant role, covering screw rotation speed, extrusion barrel temperature settings and screw design. In addition, the material-related factors interact with the processing-related factors. Understanding all factors and their interactions are important for moving CNM nanocomposites research a step further towards industrial-relevant production, which is the final ambitious goal of this manuscript.

42 ENGINEERING↗
DOE OSTI2024

Assessments of advanced reactor heat supply to high temperature industrial unit operations: Heat Engines and Heat Pumps

In this report, the feasibility of employing Advanced Nuclear Reactors to supply the necessary high-quality heat to Industrial Processes is investigated. As a first step, the most relevant industrial applications that could benefit from this coupling were identified. Four industries including petroleum refining (distillation, catalyst regeneration, hydro-steam cracking), chemical polymers, steel manufacturing (metals annealing/soaking) and cement manufacturing (calcination of limestone and dolomite industries) were considered. An overview of the heat duties, i.e., the temperatures and thermal powers required by representative plants of the different processes, was provided. Secondly, the thermodynamic conditions of the steam produced by representative designs of Advanced Reactor concepts (Liquid Metal Fast Breeder Reactors, Molten Salt Reactors, and High Temperature Gas-cooled Reactors) were summarized. The comparison between the requirements of the industrial processes and the capabilities of the candidate nuclear power plants showed that only a few processes could benefit from the coupling. Although Advanced Reactors operate at higher temperatures than Light Water Reactors, the thermodynamic conditions of the generated steam flow rates are generally not suitable for the selected applications. At the same time, data indicate that most of the processes can be suitably supplied if the temperature of steam is elevated to 900 °C. One possible solution to boost the quality of the steam from the nuclear island involves the use of a heat pump. Based on a technology similar to that found in refrigerators and air conditioners, heat pumps extract heat from a source, elevate its temperature and transfer it to where it is needed. A simple numerical example illustrating the viability of this method is described. Specifically, the energy conversion cycle of a conventional Pressurized Water Reactor was extended to incorporate a compressor to raise the heating value of the steam produced by the reactor. Two reference configurations, i.e., one where the industrial process coupled to the nuclear power plant exhausts saturated liquid and the other where it exhausts saturated steam, were considered. The thermal efficiencies achievable by increasing the heating value of the reactor steam in this way are significantly greater than by direct electric heating.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Hermetically sealed porous-wall hollow microspheres enabled by monolithic glass coatings: Potential for thermal insulation applications

Thermal insulation materials are crucial to improve the energy performance of buildings and industrial applications. We report an approach to create hermetically vacuum-sealed silica-based hollow microspheres that can lower the thermal conductivity of closed-cell insulation materials. The wall structure of these hollow microspheres includes a reticulated network of pores or channels that extend through the thickness of the wall. When a thin layer of glass material is applied to the wall exterior, followed by a vacuum-assisted thermal treatment process, the coated microsphere surfaces display a highly dense conformal coverage and near-complete elimination of surface porosity. The sealing efficiency of these microspheres is verified by trapping argon within their cavities as well as through evacuating their hollow cores. Notably, incorporating the evacuated microspheres into a polymer matrix resulted in ~27% enhancement in its thermal insulation performance and no notable loss of performance was observed following three months of exposure to ambient conditions. Thus, we believe that the present study offers a commercially viable strategy that opens the door to applications of such inorganic hollow particles in areas ranging from vacuum-based thermal insulation systems to catalysis, separation technologies, and medical fields.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Metabolic engineering of non-pathogenic microorganisms for 2,3-butanediol production

2,3-Butanediol (2,3-BDO) is a promising commodity chemical with various industrial applications. While petroleum-based chemical processes currently dominate the industrial production of 2,3-BDO, fermentation-based production of 2,3-BDO pro- vides an attractive alternative to chemical-based processes with regards to economic and environmental sustainability. The achievement of high 2,3-BDO titer, yield, and productivity in microbial fermentation is a prerequisite for the production of 2,3-BDO at large scales. Also, enantiopure production of 2,3-BDO production is desirable because 2,3-BDO stereoisomers have unique physicochemical properties. Pursuant to these goals, many metabolic engineering strategies to improve 2,3-BDO pro- duction from inexpensive sugars by Klebsiella oxytoca, Bacillus species, and Saccharomyces cerevisiae have been developed. Furthermore, this review summarizes the recent advances in metabolic engineering of non-pathogenic microorganisms to enable efficient and enantiopure production of 2,3-BDO.

2,3-BDO stereoisomers↗
DOE OSTI2022

Analysis of the laser welding keyhole using inline coherent imaging

Laser beam welding is a widely used fusion welding process in many industrial applications such as automotive, aerospace, energy, defense, and medical products. Industry has a fundamental need to model the laser welding process to minimize experimental testing and improve confidence in production welds. However, computational models attempting to predict weld formation are limited by an incomplete understanding of the beam-material interactions. As a consequence, these models do not accurately predict the mechanisms associated with laser weld formation. To improve the current state of prediction capabilities, it is vital to better detect/measure the physical aspects of the weld pool during high energy density welding. In this work, a novel real-time laser weld monitoring device using inline coherent imaging (ICI) was used to provide a fundamental understanding of laser weld formation via vaporization. The objective of this work was to investigate and quantify the relationship relating laser weld parameters and the vapor capillary (keyhole) through a state-of-the-art measurement technique. Bead-on-plate laser beam welds were produced with partial penetration on 304L stainless steel, 2205 duplex stainless steel, and Ti-6Al-4V. Keyhole monitoring was performed using a commercially available ICI system to collect keyhole penetration data in real time. These measurements were reconstructed to generate the vapor capillary shape at different welding parameters. Process parameters significantly influenced the keyhole shape and the keyhole root position relative to the process beam. Finally, the keyhole geometry showed distinct differences between the stainless steel alloys and Ti-6Al-4V.

2205↗
DOE OSTI2020

Production of Cf-252 and other transplutonium isotopes at Oak Ridge National Laboratory

In 1957 Glenn T. Seaborg conceived and advocated for the construction of the High Flux Isotope Reactor (HFIR) and the Transuranium Processing Plant (since then renamed the Radiochemical Engineering Development Center, or REDC) at Oak Ridge National Laboratory. There, heavily shielded hot cells, glove boxes, and laboratories allow recovery of transuranium elements produced in substantial quantities. Seaborg’s vision of HFIR and REDC producing milligram quantities of berkelium, californium, and einsteinium has been fulfilled beginning in 1966 through May 2019 with 78 production campaigns yielding a cumulative totals of 1.2 g of 249 Bk, 10.2 g of 252 Cf, 39 mg of 253 Es, and 15 pg of 257 Fm. Notably, 252 Cf is a neutron source used in many industrial applications including oil exploration; process control systems for the cement industry, coal analysis, and power production; sources to start nuclear reactors and perform nondestructive materials analyses; homeland security and national defense detection devices; and medical research. Isotopes made available through transplutonium production at HFIR/REDC have enabled scientists to study the nuclear properties and reactions, chemical properties, optical properties, and solid-state properties of transplutonium elements. Long-lived isotopes have served as targets in heavy ion accelerators to produce heavier elements leading to the discovery of 104 Rf, 105 Db, 106 Sg, 113 Nh, 114 Fl, 115 Mc, 116 Lv, 117 Ts, and 118 Og. This paper reviews the evolution of the processing flowsheets to produce, separate, and purify transplutonium isotopes, which have evolved over 50 years of operation at HFIR and REDC, and summarizes directions of future work to improve the efficiency of the production operations.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
DOE OSTI2021

Advancements Toward ASME Nuclear Code Case for Compact Heat Exchangers

Our research team proposes to advance the state of the ASME section III code (nuclear service) for Compact Heat Exchangers (CHX). This work will improve the technical state of CHXs and lay the foundation necessary for these heat exchangers to be certified for use in nuclear service. During the course of this work, we will advance the understanding of the performance, integrity, and lifetime of the CHXs for use in any industrial application, making their use more attractive and accessible to the industry. We will do this by developing qualification and inspection procedures that utilize Non-destructive evaluation (NDE) and advanced in-service inspection techniques, with insight from the industrial utility leader EPRI. We have enlisted colleagues at MPR Associates (MPR), an elite nuclear code consulting firm, who are experts on the ASME section III code and who, with input from members of the ASME section III committee, will direct the testing and help develop a series of documents that define the rules and regulations for use of the CHX. Colleagues at North Carolina State University (NCSU) and Oregon State University (OSU) will conduct extensive tensile, creep, and fatigue experiments on diffusion bonded samples (manufactured by US-based Vacuum Process engineering) along with modeling using the elastic perfectly plastic assumptions and comprehensive full inelastic finite element analysis (FEA). This work will allow analysis by design and confidence in the strength of different internal structures. To ensure industry acceptance and long term confidence, team members at the University of Wisconsin–Madison (UW), University of Michigan (UM), Georgia Tech (GT), and the University of Idaho (UI) will extensively test prototypic heat exchangers manufactured by US-based manufactures CompRex and Vacuum Process Engineering (VPE), a leader in the development of advanced CHX. This testing will include the use of various working fluids (salt, sodium, helium, and sCO2) to evaluate operational issues as well as structural integrity under the most severe conditions. Post-test analysis of the tested CHXs coupled with pre/in-service/post NDE (ultrasonic and radiography) led by the Electric Power Research Institute (EPRI) will be incorporated into the development of the rules and regulations for their use in nuclear service.

42 ENGINEERING↗
DOE OSTI2025

Reevaluation of Radiation-Protection Standards for Workers and the Public Based on Current Scientific Evidence

President Trump’s recent executive orders to “Usher in a Nuclear Renaissance,” coupled with the global pledge to triple nuclear energy capacity by 2050, underscore nuclear energy’s importance to national security and economic prosperity. This renewed interest has prompted efforts to spur nuclear-energy deployment, including assessing factors impeding it. One issue that has previously been identified as adding to the cost of nuclear energy is excessively conservative requirements, including those related to radiation protection. This technical review, therefore, examines current radiation-protection standards that were established decades ago when more limited data were available and nuclear-energy expansion was not a national priority. The review focuses on scientific evidence regarding the health effects of ionizing radiation at annual doses of 10,000 mrem or less. The review evaluates epidemiological studies, radiobiological research, and positions of relevant professional organizations to assess whether such doses result in discernable or observable increases in negative health outcomes. The review also surveys the literature related to economic and practical implications of current radiation-protection standards and practices. Based on this assessment, we propose maintaining an annual occupational whole-body dose limit of 5,000 mrem/yr and eliminating all “as low as reasonably achievable” requirements and limits below this threshold. This change could potentially reduce radiation-protection costs by millions of dollars annually for each reactor, as well as decrease the overall costs and correct misconceptions about the risks associated with all nuclear technologies. The evidence further supports future consideration of a 10,000 mrem/yr limit that would maintain appropriate safety margins while further reducing protection costs. Similarly, given the data and that the average annual radiation dose per person in the U.S. is 620 mrem, we believe the public dose limits of 100 mrem/yr are unnecessarily restrictive; increasing to 500 mrem/yr would maintain substantial safety margins—a factor of 10 below the occupational limit—while reducing regulatory burdens and associated bureaucracy. While we acknowledge ongoing scientific debate and encourage continued research on the health effects of ionizing radiation, our review indicates current frameworks are overly conservative. These overly stringent limits not only impose unnecessary economic burdens without corresponding health benefits but also divert safety focus and resources from more important considerations. Although this study was motivated by nuclear-power considerations, reforms to radiation-protection requirements have significant positive implications for other areas, such as nuclear medical applications, environmental remediation, nuclear-waste management and disposal, and industrial applications of nuclear technologies.

61 RADIATION PROTECTION AND DOSIMETRY↗
DOE OSTI2022

Resonant acoustic monitoring of damage in plug‐screw feeders

Abstract Plug‐screw feeders are critical in many industrial processes for compressing slurry materials via a rotating plug‐screw feeder. Over time, increasing plug‐screw feeder wear will eventually lead to catastrophic mechanical failure. Early detection of the wear state can prevent unplanned catastrophic failures resulting in operational shut‐downs, costly repairs, and most importantly the health and safety of workers. We present a theoretical basis for a noninvasive, in operando acoustic resonant technique to monitor the wear state of plug‐screw feeders. The technique is based on tracking the resonant acoustic modes of the plug‐screw feeder, which are sensitive to the plug‐screw feeder geometry, material, and operating conditions. We implemented a multivariate polynomial model to estimate the plug‐screw feeder wear state using multiple acoustic resonances by simulating the acoustic resonant modes for two categories of wear (tip and thread damage) that are common in plug‐screw feeders. Fitting multiple resonances to the polynomial model, we demonstrate accurate estimation of the total mass loss, as well as characterization of the type of damage (i.e., tip vs. thread). Current approaches for monitoring plug‐screw feeder wear rely on shutting down the operation and visually inspecting the plug‐screw feeder. The presented acoustic technique offers a noninvasive, in operando measurement approach that mitigates unplanned catastrophic failures. The acoustic resonance technique presented in the paper has a broad range of industrial applications including the Pharmaceutical, Mining, Integrated Biorefineries (IBR), and Additive Manufacturing industries, to name a few.

36 MATERIALS SCIENCE↗
DOE OSTI2021

All-aerosol-jet-printed highly sensitive and selective polyaniline-based ammonia sensors: a route toward low-cost, low-power gas detection

In this work, we report the design and scalable fabrication of a low-cost and low-power polyaniline-based (PANI) ammonia (NH3) gas sensor on polyimide (PI) substrates using additive manufacturing techniques. The silver interdigitated electrode (IDE) arrays and conducting polymer films are printed onto PI using a direct-write technology of aerosol-jet printing. Morphological characteristics are examined by scanning electron microscopy and energy-dispersive X-ray analysis which reveal homogeneously printed PANI film on the IDE platform. The gas sensing performance is evaluated in the analytical early leak detection range of 5–1000 ppm NH3 in air as a function of both thermal (23 °C, 50 °C, 80 °C) and relative humidity (RH = 0%, 30%, 50%) exposures. The sensor exhibits sensitivity down to 5 ppm NH3 with a sub-ppm detection limit and good repeatability. We observe rapid NH3 detection at 0% RH with very extended times for equilibration and recovery. However, at both 30 and 50% RH, the room temperature response and recovery times are reduced to only about 1 min and 5 min, respectively. Experiments also reveal good sensitivity toward the analyte even at higher operating temperatures. Present results merit the practical application of aerosol-jet-printed, low-power sensors for industrial applications where low-level hazardous gas detection is essential.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Flow maldistribution in plate heat exchangers – Impact, analysis, and solutions

Plate heat exchangers are commonly used in various industrial applications, such as refrigeration, air conditioning, heat pumps, powerplants, and chemical industries. Plate heat exchangers are well known for their superior heat transfer performance, compactness, and low refrigerant charge. Despite offering several advantages, they suffer from flow maldistribution issues. The flow maldistribution can deteriorate both the heat transfer and pressure drop performance, ultimately resulting in a lower system efficiency where plate heat exchangers are deployed. The flow maldistribution issues become more pronounced when the heat exchanger size is relatively large and the number of plates is higher, limiting the deployment of plate heat exchangers in larger industrial systems. Consequently, analyzing and understanding the flow maldistribution behavior in plate heat exchangers and finding ways to mitigate flow maldistribution related issues become essential topics of interest. Further, this review aims to address the effect of flow maldistribution on plate heat exchanger characteristics. First, the experimental and numerical works on flow maldistribution under single-phase and two-phase conditions are detailed. Subsequently, the end-channel and end-plate effects are discussed. Then, the methods to mitigate flow maldistribution in plate heat exchangers are outlined. Finally, based on a thorough literature survey and industrial requirements, future research directions are recommended.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

The Development of Energy-Recovery Linacs

Energy-recovery linacs (ERLs) have been emphasised by the recent (2020) update of the European Strategy for Particle Physics as one of the most promising technologies for the accelerator base of future high-energy physics. The current paper has been written as a base document to support and specify details of the recently published European roadmap for the development of energy-recovery linacs. The paper summarises the previous achievements on ERLs and the status of the field and its basic technology items. The main possible future contributions and applications of ERLs to particle and nuclear physics as well as industrial developments are presented. The paper includes a vision for the further future, beyond 2030, as well as a comparative data base for the main existing and forthcoming ERL facilities. A series of continuous innovations, such as on intense electron sources or high-quality superconducting cavity technology, will massively contribute to the development of accelerator physics at large. Industrial applications are potentially revolutionary and may carry the development of ERLs much further, establishing another shining example of the impact of particle physics on society and its technical foundation with a special view on sustaining nature.

43 PARTICLE ACCELERATORS↗
DOE OSTI2020

Tracking Radioactive Isotopes in HVAC and Application for Hot Cell Analyses - 20155

In recent years, the surge in the number of isotope production facilities under design has increased the need to analyze isotope migration in facility Heating, Ventilation, and Air Conditioning (HVAC) during normal operations and accident scenarios. These facilities are used to produce isotopes for medical, security, and industrial applications and as such are subject to license and regulatory requirements 10CFR20, 10CFR30, 10CFR50, and 10CFR70. GOTHIC, a general-purpose thermal-hydraulics software package, includes the ability to model isotopic tracers, radioactive decay and isotope migration as well as HEPA and charcoal filters for isotope retention. A GOTHIC model was developed by Zachry Nuclear Engineering (ZNE) to examine the effect of negative room pressure, HEPA filtration, and HVAC fluctuations on radiation areas, hot cells and gloveboxes. Radioactive tracers were used to simulate the concentration of spills within contaminated areas, track the migration of isotopes of interest, and determine the isotopic retention and buildup on facility HEPA filters. A variety of isotopes with concern to dose (e.g., Kr-85, Sr-90, I-131, etc.), including their decay and progeny, are included in the analysis. Negative pressures are maintained in the regions of interest by a representative central HVAC system equipped with a volumetric fan that exhausts to the environment after a series of isolation valves and HEPA filters. GOTHIC is an industry trusted tool for providing engineering solutions for a variety of applications, including fission product tracking, aerosol and particulate transport and ventilation assessments. The software provides an integrated analysis environment that includes a graphical user interface (GUI) for constructing analysis models, a numerical solver that includes parallel processing capabilities and a post-processor for evaluating simulation results. It solves the conservation equations for mass, momentum and energy for multicomponent, multi-phase flow in lumped parameter and multi-dimensional geometries (1, 2, or full 3D), including the effects of turbulence, diffusion and buoyancy. It has been developed and maintained under a Quality Assurance program in compliance with the requirements of 10CFR50 Appendix B and applicable portions of ASME NQA-1 since 1995. GOTHIC has been used for assessing both forced and natural convection conditions for a wide range of applications, including: - Tracking concentration of hazardous gases and chemicals for habitability and safety assessments - Determining ventilation and filtration requirements and optimizing location and arrangement of these systems - Room heat-up, including diverse and Flexible coping strategies for Extended Loss of AC Power (FLEX/ELAP) - Equipment Qualification (EQ) A distinctive feature of GOTHIC is the ability to track many different fields/substances in a simulation, including user defined tracer elements, in the liquid, vapor and droplet fields as well as surfaces and filters. This capability allows GOTHIC to model fission product transport and release or the removal of particulates or harmful toxins from exhaust gases using a spray scrubber or other types of filtration systems. GOTHIC also includes models for engineered equipment, such as fans, filters, charcoal filters, dryers/demisters, dampers, etc. The aerosols and other filtered material are removed or accumulated in these components. The range of aerosol and radiological applications that GOTHIC has been used for includes: - Source Term: Primary Coolant (Equilibrium) Activity; Non-Water Coolant Source/Leakage. - Conditions for Iodine Re-evolution: Sump/Suppression Pool Conditions and pH; - RWST Conditions and pH. - Isotope Removal Mechanisms: Containment Sprayed and Unsprayed Region Mixing; Charcoal Filter Heating due to Iodine decay. - Radionuclide Transport and Decay: Post-LOCA Release in containment; Transport between connected Compartments and vent systems; Groundwater transport of radionuclides. - Non-Newtonian Fluid modeling for sludge, waste tanks, etc. ADAMS ML071581053 (titled 'Best Practice Guidelines for the use of CFD in Nuclear Reactor Safety Applications') poses guidelines for applying single phase CFD codes in nuclear reactor safety problems and GOTHIC is listed as a 'tool for 3D flows' and 'dispersal and deposition of radionuclides.' The Nuclear Quality Assurance (NQA) pedigree of GOTHIC is an important aspect for applications in the nuclear industry. The fundamental tracer models (convective transport, molecular and turbulent diffusion, removal mechanisms, etc.) have been verified using analytical solutions and validated against applicable separate effects tests. Also, GOTHIC has been benchmarked to many integrated effects tests, including Phebus FP (Fission Product). GOTHIC gives good agreement for the buildup and decay of fission products in Phebus Test 3. The model developed by ZNE demonstrates GOTHIC's applicability and acceptability for use in analyzing the migration and retention of radioactive isotopes and their progeny in normal operation and accident scenario analyses for isotope production facilities, hot cells, and gloveboxes. The tracer activities calculated by GOTHIC can then be used in downstream radiation transport and shielding codes like RADTRAD-NAI{sup C}, MCNP{sup R}, and MicroShield{sup R} to determine on-site and of-site doses. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2021

Avoiding surface instability and slurry jamming in simultaneous multilayer coating of structured particulate films

Simultaneous multilayer coating techniques are widely known, but their industrial application remains limited to narrow market sectors. One barrier to adoption may be the mismatch between industries that are familiar with such processes but have no need, and industries that have need but are not familiar. Moreover, there are application-specific technical challenges to developing multilayer-coating processes. In this article, we describe our resolution of two specific issues in simultaneous multilayer coating of all aqueous highly loaded slurries for new and emerging energy applications. The first issue is particle jamming (associated with Shear-thickening) of the highly loaded slurries in the die internals, which we alleviated by adding small amounts of viscosity modifiers without reducing the solid loading. The second issue is a Marangoni-driven surface instability that resembles top layer de-wetting, which we solved by carefully selecting surfactants to tune the dynamic surface tensions of each slurry. Both issues were resolved early in a step-wise development, saving significant development cost which in our case was driven by expensive materials.

08 HYDROGEN↗
DOE OSTI2023

High-temperature thermal conductivity measurements of macro-porous graphite

Graphite is a unique material for high temperature applications and will likely become increasingly important as we attempt to electrify industrial applications. Here, we investigate the thermal properties of low-quality, macro-porous graphite to determine the tradeoff between quality and thermal performance. We use laser flash analysis (LFA) to measure the thermal diffusivity of graphite at high temperatures. Due to the large pores in the graphite samples preventing uniform laser flash heating, we first apply a thick coating to achieve the required flat, parallel surfaces for LFA measurements. We then develop a methodology to extract properties of the sample from the diffusivity measurements, based on finite element modeling of a variety of sample/coating interface profiles. Validating the methodology against a reference sample demonstrates a mean absolute percentage error of 8.5%, with potential improvement with better sample characterization. We show low-quality graphite has a thermal conductivity of ~10 W/m/K up to 1000 °C, which is an order of magnitude lower than high-quality graphite, but contributions from photon conductivity may result in higher conductivities at higher temperatures. Overall, we demonstrate an approach for measuring thermal properties of macro-porous materials at high temperatures, and apply the approach to measuring thermal conductivity of porous graphite, which will aid in the design of hightemperature systems for cost-competitive decarbonization.

Verma, Shomik↗
DOE OSTI2024

Leveraging Existing Assets for Long Duration Energy Storage

Increased renewables penetration to electrical grid is necessary to reduce overall emissions from the electrical power generation sector. Nonetheless, its integration creates challenges to grid operators who must match the power being generated by intermittent renewables and other traditional energy sources with the demand from consumers, while ensuring the reliability and power quality for the entire system. Energy storage has been proposed as an alternative to natural gas peaking plants and a form to deliver excess renewable energy generation at times of peak demand. For energy storage to provide benefits to end customers (energy consumers), it must be reliable, efficient, and cost effective. The Illinois Sustainable Technology Center (ISTC), one of the surveys that integrate the Prairie Research Institute (PRI), aims to develop a Center for Energy Storage at Existing Assets (CESEA) at UIUC with the participation of Waste Pressure Corp and Ecotek Engineering USA LLC. CESEA will focus on LDES systems that can integrate to existing infrastructure in a manner that reduces the initial capital expenditure and demonstrates the ability to repurpose fossil assets that would otherwise become stranded, to serve the energy transition. CESEA aims to leverage UIUC’s unique facilities to validate LDES systems performance at a relevant operating environment. UIUC’s facilities include a 85-MW combined heat and power (CHP) power plant, two (2) solar PV plants totaling over 18 MWdc of installed capacity, an electrical grid along with a substation at transmission and distribution voltages, a 22-mile gas pipeline network operating at two pressure levels, along with steam and chilled water distribution networks. The new LDES systems will connect to the existing UIUC grid through a new test electrical station, which will have the capacity to accommodate additional connections to test new devices and technologies as part of future CESEA R&D activities. The test electrical station will contain meters, instrumentation, and controls to accurately capture data and allow optimization of control algorithms. CESEA will initially focus on technologies that: i) utilize existing equipment or facilities to perform at least one of the process steps in LDES (charging, storage, or discharging), ii) leverage mature or commercially available components or controls, iii) show potential for cost-leadership in 10+ hour storage at a commercial scale. Initial technologies that were identified to meet these criteria include Compressed Gas Energy Storage (CGES), and TES. CGES stores electricity by raising the pressure of a compressible gas inside a control volume and converting the stored energy to electricity via expansion-generation. CGES is a generalization of CAES that covers any working gas (not just air). A successful CGES demo will help to circumvent many challenges faced by CAES (long development times due to site prospecting, high cost of compression and storage, heat recovery management, etc.) by: 1) utilizing existing infrastructure (compressors, pipelines, underground storage or pressure vessels) used in the transportation and storage of industrial gases for LDES charging and storage; 2) deploying over sites already-developed for industrial applications with minor additional work; 3) leveraging the price structure of commercial industrial gas to cover the costs of electricity used during charging. A previous DOE-sponsored conceptual study (DE-FE-0032018) estimated the levelized cost of energy of a 1.1 MW / 17 MWh CGES system at $0.08/kWh, with a commercial 10x scale system cost estimated at <$0.04/kWh (Giardinella, 2022). The pilot-sized system was estimated to avoid up to 2693 tons of CO2/year.

25 ENERGY STORAGE↗