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This project aims to evaluate and develop the concept of optical basicity to solar molten salts, design an online monitoring system for implementation in commercial plants, and train a diverse workforce for the CSP industry. This is the final report.
Advances in manufacturing technologies and materials are crucial to the commercial deployment of energy technologies. We present the case of concentrating solar power (CSP) with molten salt (MS) thermal storage, where low-cost, high-efficiency heat exchangers (HXs) are needed to achieve cost competitiveness. Here, the materials required to tolerate the extreme operating conditions in CSP systems make it difficult or infeasible to produce them using conventional manufacturing processes. Although it is technically possible to produce HXs with adequate performance using additive manufacturing, specifically laser powder bed fusion (LPBF), here we assess whether doing so is cost-effective. We describe a process-based cost model (PBCM) to estimate the cost of fabricating a MS-to-supercritical carbon dioxide HX using LPBF. The PBCM is designed to identify modifications to designs, process choices, and manufacturing innovations that have the greatest effect on manufacturing cost. Our PBCM identified HX design and LPBF process modifications that reduced projected HX cost from $\$750$ per kilo-Watt thermal (kW-th) ($\$8$ /cm 3 ) to $\$350$ /kW-th ($\$6/$ cm 3 ) using currently available LPBF technology, and down to $\$220$ /kW-th ($\$4$ /cm 3 ) with improvements in LPBF technology that are likely to be achieved in the near term. The PBCM also informed a redesign of the HX design that reduced projected costs to $\$140$ –160/kW-th ($\$3$ /cm 3 ).
Despite over a century of studies, fundamental questions remain about the processes governing crystal nucleation from melts or solutions. Research over the past three decades has presented mounting evidence for kinetic pathways of crystal nucleation that are more complex than envisioned by the simplest forms of classical theory. Such observations have been presented for colloidal and elemental systems with covalent and metallic bonding. Despite the technological and geochemical importance of molten salts, similar studies for these ionically bonded systems are currently lacking. Here we develop a machine learning interatomic potential for a model ionic system: LiF. The potential features quantum-level accuracy for both liquid and multiple solid polymorphs over wide temperature and pressure ranges and accurately reproduces experimentally measured properties. Thanks to the efficiency of the potential, which enables microsecond-scale molecular dynamics simulations, induction times for nucleation of LiF solids from their melts are computed over a range of undercoolings. With the aid of a set of robust local order parameters established here, the simulations reveal that homogeneous crystal nucleation in undercooled melts preferentially initiates from liquid regions showing slow dynamics and high bond orientational order simultaneously, and the second-shell order of both precritical nuclei and the surface of postcritical nuclei is dominated by hexagonal close packing and body-centered cubic local structure, even though the nucleus core is dominated by face-centered cubic structure corresponding to the stable rocksalt crystal structure. Finally, we establish a connection between the crystallization pathway and the equilibrium crystal-melt interface structure.
This report formally documents the completion of the Advanced Reactor Technologies Level 3 Milestone (M3TG-25OR0501104), “Initiate graphite wear studies of graphite samples exposed to molten salt environment,” due August 1, 2025. The report summarizes the ongoing activities aimed at characterizing the friction and wear behavior of graphite in molten LiF–NaF–KF (FLiNaK) salt environment. The wear and friction behavior of self-mated ET-10 nuclear graphite were tested at varying temperatures (550°C and 650°C), contact loads (40 and 80 N) and sliding speeds (1 and 10 mm/s) in a controlled argon environment. The results were compared to the wear and friction behavior of the same graphite material in a dry argon environment. This report presents initial studies on the friction and wear behavior of graphite in sliding contact mode, with future work focused on investigating the graphite matrix materials, as well as rolling and impact contact modes. The outcomes of this report could provide insights into assessing the integrity of the graphitic components of pebble-bed fluoride salt–cooled high-temperature reactors (PB-FHRs) to enhance their safe operation.
In the search for efficient energy storage battery technologies, designing stable electrolytes has been a long-standing challenge. Electrolytes based on molten salt eutectics are known for their stability with minimum parasitic reactions when compared to their widely used organic counterparts. However, the operating temperatures of these molten salt electrolyte-based batteries are dictated by the melting point of the eutectic mixtures. Design and high throughput screening of low melting temperature eutectic molten salt mixtures have been hindered by the lack of computational models. In this work, we develop thermodynamic models to predict the eutectic points of several molten salt mixtures. The framework of the COSMO-SAC model is used for the predictions and is compared with experimental data and other thermodynamic approaches. Rapid thermodynamics-based approaches, as shown in this study, can accelerate the discovery of new materials, complementing experimental techniques.
The redox effect of activation reactions in molten salts has been previously qualitatively defined but never quantified. Here, we quantify the corrosion effects of neutron activation of FLiBe. Rates of change of activation products are computed for FHR and ARC. The impact of activation reactions on salt chemistry is quantitatively compared to other environmental effects of similar consequences on the salt. The results are applied to a redox control case-study and an irradiation-corrosion experiment. The results are presented in a manner useful to the reactor chemist and designer concerned with corrosion and chemistry control and tritium management in irradiated FLiBe, and design of salt-irradiation experiments.
Molten salt reactors (MSRs) are an attractive advanced reactor technology because of their increased fuel utilization and efficiency, the ease of fueling, and the potential to use alternative fuel cycles, including thorium and breeder/burner scenarios. Since an MSR has never been domestically operated for commercial electricity production, minimal infrastructure exists to support performance and materials testing, reactor licensing (including research, test, and operating reactors), and technology development in general. These factors could present challenges for the commercialization of the proposed design technology. Several research and development efforts and investments have begun to identify and supplement the infrastructure to accommodate the molten salt concept, including the United States Department of Energy Office of Nuclear Energy Molten Salt Reactor Program. This report reviews safeguards technology and domestic infrastructure to support the evaluation of nuclear safeguards (primarily material control and accounting) measures and approaches for salt-fueled MSRs. Recommendations for potential priority infrastructure investments, including safeguards measurement test beds and future research, are presented.
This joint report assesses the pyroprocessing of used nuclear fuel from molten fluoride salts being conducted between Idaho National Laboratory and Argonne National Laboratory. The goal of this report is to identify the research and development gaps needed to reduce the technical risks of extending pyroprocessing technologies and unit operations to molten fluoride salts used in molten salt reactors (MSRs). Assessing and performing the tasks outlined in this report will help mitigate the technical risks and design appropriate flowsheets for reprocessing fuel and coolant salts. These suggested tasks will provide necessary data to implement the development of unit operations. Sections are highlighted to identify processes that need to be assessed and unit operations that may be used in fluoride-based chemistries. Research and development needs are listed and discussed including re-fluorination methods, electrowinning for separations, reference electrode development, materials compatibility, salt purification/re-fluorination, and waste disposition. This report will examine the technical challenges associated with pyroprocessing in molten fluoride-based salt and outline approaches to increase the technical readiness level of pyroprocessing in molten fluoride salts.
Next-generation concentrating solar power (CSP) tower technologies target operating temperatures exceeding 700°C to increase the thermal-to-electric conversion efficiency. Molten chloride salts are one possible alternative to current commercial molten nitrate salts to enable the higher operating temperature. This paper analyzes the predicted optical, thermal-fluids, and structural performance of traditional external tubular solar receiver configurations applied with a chloride salt heat transfer fluid (HTF) and inlet/outlet temperatures of 500°C/735°C, and considers sensitivity analysis and optimization relative to receiver sizing, tube sizing, number of panels, flow circuit configurations, and solar flux concentration under constraints on internal velocity, pressure drop, wall thickness, and required creep-fatigue lifetime. The high temperature conditions increase the significance of inelastic deformation mechanisms such as creep relative to that expected in commercial 565°C nitrate salt designs. High-temperature creep and creep-fatigue damage in the metal alloy tubes are the key factors that limit allowable solar flux concentration and achievable receiver thermal efficiency at the near-800°C wall temperature conditions. For a traditional external cylindrical receiver configuration, the design parameters and conditions capable of satisfying all constraints produced, at best, a design point receiver efficiency of 78.2%, or 80.5% when excluding receiver intercept efficiency. Variation in the optimal receiver performance relative to uncertainty in the binding maximum velocity, minimum wall thickness, and minimum lifetime constraints is presented.
The increasing use of renewable energy sources is leading to increased cycling of fossil-fueled power plants (FFPP) that are designed to operate at base-loaded conditions. Integrating energy storage facilities with the FFPPs can be helpful in reducing load-following operation of FFPPs. Decentralized deployment of energy storage facilities at the FFPP level has considerable advantages due to possibilities of smaller storage capacities, immediate benefits realized by the host power plant due to the increase in the efficiency, cleaner emission and higher plant life to name a few. Most importantly, deployment at the FFPP level can exploit the existing equipment items and facilities at the host power plant, thus reducing the CAPEX and reducing the storage capacity. However, realization of these benefits will critically depend on novel configuration/integration strategies with the least impact on the power plant operation and its configuration. Furthermore, dynamics of the entire integrated system including both the FFPP and the storage technologies must be taken into account to obtain the cost-optimal solution. With these motivations, the objective of this project was to complete a focused evaluation of decentralized deployments of energy storage facilities at the FFPP level. Promising thermal, chemical, mechanical, and electro-chemical storage technologies were evaluated with due consideration of their transient response to obtain various optimal system concepts that can minimize the levelized cost of storage. For thermal storage, cryogenic energy storage along with high temperature heat storage in molten salt as well as phase change material were evaluated. For mechanical storage, cryogenic air storage and pumped hydro storages were evaluated. For chemical storage, hydrogen storage was evaluated. For electrochemical storage, the team evaluated sodium sulfur, vanadium redox flow battery as well as Li-ion batteries. Integration of these storage technologies with the natural gas combined cycle (NGCC) and supercritical pulverized coal (SCPC) plants was considered. Six technologies, namely molten salt, cryogenics, compressed air, pumped hydro, H2 storage and Li-ion battery storage, were downselected based on their levelized cost of storage. It was observed that the ranking of the optimal storage technology can differ based on the host power plant technology even when same demand/supply/price profile for electricity are considered. It was also observed that as the variability in power demand varies, the ranking of the optimal storage technologies vary. However, for the same demand and LMP profile, top six optimal storage technologies for NGCC vs SCPC plants did not differ much even though LCOS for the same technology and optimal size of a given storage technology did differ. Detailed techno-economic assessment of these six technologies was undertaken.
To advance MSR MC&A practices, Argonne National Laboratory developed and optimized robust flow enhanced electrochemical sensors (FEES) and multielectrode array voltammetry sensors (MAVS) which provide accurate near-real time measurements of actinides in molten salts. Flow-enhanced electrochemical sensors are installed directly into MSR flow conduits for inline salt chemistry measurement, while MAVS are deployed in quiescent salt conditions enabling online species concentration determination in stationary salt vessels. This report summarizes efforts to improve electrochemical sensor technological readiness through (1) sensor testing in complex, high concentration molten salt systems to demonstrate low uncertainty actinide measurements in MSR-representative solutions and (2) demonstrations of sensor performance in challenging real-world conditions in collaboration with partner MSR institutions.
Deploying commercial molten salt reactors (MSRs) requires closing technological gaps associated with supplying fuel salt, maintaining fuel salt, and dispositioning used fuel salt at the end of a reactor campaign and operation. A workshop was held to identify the technological gaps in synthesizing, purifying, and supplying fuel salts and recovering and recycling resource materials from used fuel.
Achieving atomic-level understanding of crystallization of molten salts is of importance to a wide range of technological applications. Recent work [Fan et al., Proc. Natl. Acad. Sci. USA 122, e2425702122 (2025)] revealed that crystal nucleation in molten LiF salt is a multistage process according to the molecular-dynamics (MD) simulations based on an atomic cluster expansion (ACE) machine-learning interatomic potential (MLIP). In order to understand the influence of increasing cation size on nucleation pathways and nucleation rates of molten fluoride salts, here we develop two new ACE MLIPs for NaF and KF. The two ACE MLIPs feature DFT-SCAN-level accuracy for liquid and multiple solid polymorphs over a wide temperature (0–2000 K) and pressure (0–100 GPa) range, and also reproduce well a number of experimental data for solid and liquid equilibrium properties. The efficiency of the two ACE MLIPs enable million-atom-scale or microsecond-scale MD simulations. The two general-purpose ACE MLIPs are expected to be useful for atomistic simulations for different purposes, in addition to studying crystallization of molten NaF and KF salts.
The nonproliferation of nuclear material and the development of safeguards technologies to sample and analyze fuel salt is a challenge for molten salt reactor (MSR) developers. We seek online monitoring using combined spectroscopic methods of two distinct material phases from MSR’s. Molten salt transformed to aerosol phase allows for Light Induced Breakdown spectroscopy (LIBS) without adverse splashing (ARPA-E). Vaporized used nuclear fuel through chlorine-based volatility (CBV) allows for uranium separation based on boiling point differences
This report describes the technologies that were developed as part of the Continuous Particle Monitoring and Removal for Molten Chloride CSP Systems project that was funded by the EERE Solar Energy Technologies Office during FY2021. This project consisted of two main tasks: (1) the development electrical resistance tomography (ERT) sensors to provide particle sensing capabilities for CSP-relevant molten chloride salts, and (2) the development of vortex separation technologies to enable efficient removal of particles from the salt. Both of these tasks are crucial because, although the Gen3 CSP chloride heat transfer fluid is inexpensive and can achieve high temperatures, major issues with erosion corrosion and clogging can arise from the presence of MgO particles within the salt. The particle monitoring and removal technologies were both demonstrated over the course of this project. The ERT sensors were able to achieve their performance targets by providing accurate particle concentration measurements over a range from 0.0 to 8.0 wt%. The vortex separators were able to demonstrate separation of particles from molten salt streams, but the separation efficiencies were lower than the targeted level of 90%. With further development and deployment, these technologies will ultimately help to enable successful long-term operations of CSP systems that make use of high-temperature chloride salts.
A novel inert sample transfer system was developed and employed to enable, for the first time, the analysis of air-sensitive salt samples in a two-volume ablation cell using simultaneous laser-induced breakdown spectroscopy (LIBS) and laser ablation (LA)-inductively coupled plasma (ICP)-time-of-flight (TOF)-mass spectrometry (MS) analysis. Molten salts are of growing interest as a medium for advanced nuclear reactors and nuclear fuel reprocessing technologies continue to be developed around their use. However, compositional analysis of molten salt samples can be challenging because of their air-sensitive nature and varying solubilities leading to inaccurate measurements when digested. LA-based analysis provides an alternate method to digestion and can provide rapid elemental information with little sample preparation. In this study, LIBS and LA-ICP-TOF-MS were used to analyze the Ce content in frozen salt samples taken from a series of electrochemical experiments. Calibrations were built for each technique, and the resulting limits of detection for Ce were estimated to be 107 and 58 µg g −1 for LIBS and LA-ICP-TOF-MS, respectively. Test samples from the electrochemical experiments were analyzed using these calibrations. The results matched bulk digestion-based ICP-optical emission spectroscopy values, and daily trends in Ce concentration changes were identified. Additionally, the LIBS and LA-ICP-TOF-MS analysis was demonstrated for identifying microgram per gram levels of components and detecting trace contaminants. The impurities detected by LIBS included Al, Mg, Ca, and Na. The impurities detected by LA-ICP-TOF-MS included W, Ag, Al, Fe, Ni, Mo, Nd, Sm, Th, and U.
With the rapid development of advanced reactors and numerous companies requesting pre-application engagements with the Nuclear Regulatory Commission (NRC), there is need for the NRC to best prepare themselves for new challenges presented by advanced technologies. One specific reactor type of interest is the molten salt reactor (MSR) that uses liquid salt as the fuel for the reactor. Liquid salt fuel reactors have specific challenges with regards to performing material control and accounting (MC&A). The challenges result from the fuel form being a continuous fissile material form rather than discrete units like is found with fuel assemblies in traditional light water reactors (LWRs). The goal of this document is to provide the NRC with guidance on the different approaches and technologies that may be proposed by reactor designers to address these problems to prepare staff for regulatory reviews.
Concentrating solar power (CSP) is one of the few scalable technologies capable of delivering dispatchable renewable power. Therefore, many expect it to shoulder a significant share of system balancing in a renewable electricity future powered by cheap, intermittent PV and wind power: the IEA, for example, projects 73 GW CSP by 2030 and several hundred GW by 2050 in its Net-Zero by 2050 pathway. In this paper, we assess how fast CSP can be expected to scale up and how long time it would take to get new, high-efficiency CSP technologies to market, based on observed trends and historical patterns. We find that to meaningfully contribute to net-zero pathways the CSP sector needs to reach and exceed the maximum historical annual growth rate of 30%/year last seen between 2010-2014 and maintain it for at least two decades. Any CSP deployment in the 2020s will rely mostly on mature existing technologies, namely parabolic trough and molten-salt towers, but likely with adapted business models such as hybrid CSP-PV stations, combining the advantages of higher-cost dispatchable and low-cost intermittent power. New third-generation CSP designs are unlikely to play a role in markets during the 2020s, as they are still at or before the pilot stage and, judging from past pilot-to-market cycles for CSP, they will likely not be ready for market deployment before 2030. CSP can contribute to low-cost zero-emission energy systems by 2050, but to make that happen, at the scale foreseen in current energy models, ambitious technology-specific policy support is necessary, as soon as possible and in several countries.