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NASA NTRS2014

Logistics Reduction and Repurposing Technology for Long Duration Space Missions

One of NASA's Advanced Exploration Systems (AES) projects is the Logistics Reduction and Repurposing (LRR) project, which has the goal of reducing logistics resupply items through direct and indirect means. Various technologies under development in the project will reduce the launch mass of consumables and their packaging, enable reuse and repurposing of items, and make logistics tracking more efficient. Repurposing also reduces the trash burden onboard spacecraft and indirectly reduces launch mass by one manifest item having two purposes rather than two manifest items each having only one purpose. This paper provides the status of each of the LRR technologies in their third year of development under AES. Advanced clothing systems (ACSs) are being developed to enable clothing to be worn longer, directly reducing launch mass. ACS has completed a ground exercise clothing study in preparation for an International Space Station technology demonstration in 2014. Development of launch packaging containers and other items that can be repurposed on-orbit as part of habitation outfitting has resulted in a logistics-to-living (L2L) concept. L2L has fabricated and evaluated several multi-purpose cargo transfer bags for potential reuse on-orbit. Autonomous logistics management is using radio frequency identification (RFID) to track items and thus reduce crew time for logistics functions. An RFID dense reader prototype is under construction and plans for integrated testing are being made. A heat melt compactor (HMC) second generation unit for processing trash into compact and stable tiles is nearing completion. The HMC prototype compaction chamber has been completed and system development testing is under way. Research has been conducted on the conversion of trash-to-gas (TtG) for high levels of volume reduction and for use in propulsion systems. A steam reformation system was selected for further system definition of the TtG technology.

Broyan, James Lee, Jr.↗

NASA NTRS2014

Logistics Reduction and Repurposing Technology for Long Duration Space Missions

One of NASA's Advanced Exploration Systems (AES) projects is the Logistics Reduction and Repurposing (LRR) project, which has the goal of reducing logistics resupply items through direct and indirect means. Various technologies under development in the project will reduce the launch mass of consumables and their packaging, enable reuse and repurposing of items and make logistics tracking more efficient. Repurposing also reduces the trash burden onboard spacecraft and indirectly reduces launch mass by replacing some items on the manifest. Examples include reuse of trash as radiation shielding or propellant. This paper provides the status of the LRR technologies in their third year of development under AES. Advanced clothing systems (ACS) are being developed to enable clothing to be worn longer, directly reducing launch mass. ACS has completed a ground exercise clothing study in preparation for an International Space Station (ISS) technology demonstration in 2014. Development of launch packaging containers and other items that can be repurposed on-orbit as part of habitation outfitting has resulted in a logistics-to-living (L2L) concept. L2L has fabricated and evaluated several multi-purpose cargo transfer bags (MCTBs) for potential reuse on orbit. Autonomous logistics management (ALM) is using radio frequency identification (RFID) to track items and thus reduce crew requirements for logistics functions. An RFID dense reader prototype is under construction and plans for integrated testing are being made. Development of a heat melt compactor (HMC) second generation unit for processing trash into compact and stable tiles is nearing completion. The HMC prototype compaction chamber has been completed and system development testing is underway. Research has been conducted on the conversion of trash-to-gas (TtG) for high levels of volume reduction and for use in propulsion systems. A steam reformation system was selected for further system definition of the TtG technology. And benefits analysis of all LRR technologies have been updated with the latest test and analysis results.

Broyan, James L.↗

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

Oxidation Behavior and Property Degradation of Nuclear Graphites

During its multidecade operation in the core of nuclear reactors, graphite components are subjected to aggressive and continuous exposure to a high field of ionizing and neutron irradiation, high temperature, and various types of present and postulated chemical attacks. High density, high crystallinity polygranular synthetic graphite is unique among other materials for its extraordinary capacity of resisting and adapting to the aggression inflicted by high temperature, high energy neutron bombardment and ionizing gamma radiation. But, as a carbonaceous material, even though of very high purity, graphite is reactive towards common oxidizing agents: oxygen, carbon dioxide, water. Safe operation of HTGRs relies, among other aspects, on engineered safeguard systems for efficient and continuous protection of graphite components against oxidation. Graphite oxidation behavior was, and continues to be, an important direction of theoretical and experimental research, engineering analyses, models and simulations, and design and safety regulations. The avalanche of publications, reports, experimental data, computer codes, and regulatory documents related to oxidation behavior of nuclear graphite is now accelerating to new levels, prompted by the increased interest for nuclear energy as a clean, carbon-free energy source. Even though public’s perception of nuclear energy advantages may still be influenced by the memories of past accidents of nuclear reactors from generations II and III, the community of informed scientists and engineers, regulators and statemen knows that generation IV of nuclear reactors is designed at very high safety standards, doubled by great advances of scientific knowledge and technological progress. One of routes of these recent advances is directed at better understanding of graphite oxidation behavior, its relationship with graphite manufacturing and microstructural properties, along with the effects of various environmental factors and process variables. Together, the recent progress in manufacturing, properties characterization, and modeling of intricated physical and chemical processes that concur to the oxidation behavior led to development of powerful simulation codes able to analyze various scenarios of normal operation and hypothetical off-normal events, and thus to clearly specify the allowable parameters envelopes for the designers, constructors, and operators of current and future modular HTGRs. This review begins with an introduction on manufacturing methods, structure, and properties of nuclear graphite, including basic requirements that this specialty graphite type must satisfy for nuclear use. It continues with a chapter on environmental effects on nuclear graphite, where emphasis is placed less on irradiation and much more on oxidation phenomena, their safety implications, and the basic traits of chronic and acute oxidation by air (oxygen) and water (humidity, steam). Particular attention is placed on the three graphite grades of interest for this document (IG-110, NBG-18, PCEA). A chapter on properties degradation induced by oxidation follows, with focus on density, dimensional, and mechanical properties changes. The next chapter is intended as a brief review of various approaches used for modeling of graphite oxidation behavior. It summarizes the progress of oxidation models, from the early attempts to complex computational approaches interfaced with specialized computer codes designed for nuclear reactor simulations. Last, a list is presented of knowledge gaps where more research is needed. A short summary concludes the review.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Electrically enhanced thermochemical cycles for hydrogen generation

In two-step metal-oxide (MO) solar thermochemical cycles, high temperature solar thermal energy is first converted to chemical energy in the form of a reduced MO. The reduced MO is then reoxidized in a second step with steam (or carbon dioxide) to produce hydrogen (or carbon monoxide) at a lower temperature. Solar thermochemical cycles of this type circumvent heat-to-electrical conversion required for electrochemical water splitting and promise high efficiencies. However, significant challenges remain to implementation. Ultra-high temperatures and efficiency-sapping low per-cycle conversion stand out as particularly difficult hurdles. Hybrid approaches utilizing both thermal and electrical energy provide some of the advantages of each, and can facilitate lower temperature operation and offer better per-pass utilization than thermochemical alone. However, early concepts for implementing the thermo-electrochemical approach introduced substantial new challenges including difficult separations, corrosive environments, and energy losses from large temperature swings and phase changes. We are currently investigating two different options for implementation. In the first, a MO that reduces at lower temperature is selected. As the reduced MO lacks the full thermodynamic driving force to effectively split water, the reaction is driven forward by an electrically-assisted proton-conducting membrane that separates and recovers hydrogen as it is produced. This approach produces a pure hydrogen stream, is mechanically simple, and has unique thermodynamic advantages. The second option seeks to more directly couple the electrical boost to the solid MO to drive either the reduction or oxidation step, or both, through the utilization of layered MO materials and advanced reactors. This approach could be applied to both water and carbon dioxide splitting. The results of process modeling and optimization will be presented, and progress towards demonstrating the concepts at the laboratory scale will be discussed.

08 HYDROGEN↗

DOE OSTI2025

An Active Oxygen Electrode for Proton-Conducting Solid Oxide Electrolysis Cells with High Faradaic Efficiency

Addressing the challenges posed by inferior electrochemical performance at low temperatures and the uncertain Faradaic efficiency (FE) represents a pivotal undertaking in the development of high performance and efficient proton-conducting solid oxide electrolysis cells (P-SOECs). In this work, a novel oxygen electrode material BaCo0.8Zr0.1Zn0.1O3-d (BCZZ) is first designed and synthesized. At 600 °C, P-SOECs with BCZZ oxygen electrode achieve an electrolysis current density of 1.98 A cm-2 with an ˜90% FE at 1.3 V. Utilizing 1-inch P-SOECs as a reliable platform, the effect of extrinsic operating conditions (i.e., steam concentration, voltage, current density, and temperature) and intrinsic properties of P-SOECs (i.e., electrolyte material and electrolyte thickness) on FE are further systemically investigated, both experimentally and theoretically.

08 - HYDROGEN↗

DOE OSTI2025

Solid State Solar Thermochemical Fuel (SoFuel) for Long Duration Storage

Efficient thermal storage systems, when coupled with renewable energy, enable the decarbonization of numerous industrial processes requiring high temperature steam or air, and provide a path for seasonal building heating, especially for colder climates. Existing thermal storage systems face a significant challenge due to losses inherent to all high temperature systems. A viable route to long-term storage is to use thermochemical reactions to convert concentrated solar energy to a fuel that is shelf-stable and can be stored at room temperature, thus eliminating losses associated with high temperature storage. The Solid-State Solar Thermochemical Fuel (SoFuel) technology developed by Michigan State University, Oregon State University, and Mississippi State University provides reactors and processes with minimal sensible heat losses and allows storing solar energy as a solid-state fuel at room temperature for long duration. The production of SoFuel occurs within a cylindrical cavity reduction chemical reactor that captures concentrated solar radiation from a solar field. Reactive magnesium manganese oxide (Mg-Mn-O) resides within the cylindrical cavity chemical reactor and undergoes thermal reduction as the temperature exceeds 1350°C. The thermally reduced Mg-Mn-O pellets (the SoFuel) are cooled down through a recuperative process and stored within a bin until used. The SoFuel can directly supply up to 1100C heat to an adjacent power plant for electricity generation or industrial heating. Oxidation of SoFuel pellets occurs in a counter flow reactor and supplies heat to the user for electricity generation or industrial processing, after which the fuel is returned to the concentrating solar field where it is regenerated for re-use. Both reactors can be controlled well using a variety of strategies. With the low cost of the material, its cyclability, and the possibility of using the pelletized with on-sun reactors, or with electricity that would be curtailed, this project offers a viable option of medium- and long-term thermal energy storage.

25 ENERGY STORAGE↗

DOE OSTI2024

Solid State Solar Thermochemical Fuel (SoFuel) for Long Duration Storage

Efficient thermal storage systems, when coupled with renewable energy, enable the decarbonization of numerous industrial processes requiring high temperature steam or air, and provide a path for seasonal building heating, especially for colder climates. Existing thermal storage systems face a significant challenge due to losses inherent to all high temperature systems. A viable route to long-term storage is to use thermochemical reactions to convert concentrated solar energy to a fuel that is shelf-stable and can be stored at room temperature, thus eliminating losses associated with high temperature storage. The Solid-State Solar Thermochemical Fuel (SoFuel) technology developed by Michigan State University, Oregon State University, and Mississippi State University provides reactors and processes with minimal sensible heat losses and allows storing solar energy as a solid-state fuel at room temperature for long duration. The production of SoFuel occurs within a cylindrical cavity reduction chemical reactor that captures concentrated solar radiation from a solar field. Reactive magnesium manganese oxide (Mg-Mn-O) resides within the cylindrical cavity chemical reactor and undergoes thermal reduction as the temperature exceeds 1350°C. The thermally reduced Mg-Mn-O pellets (the SoFuel) are cooled down through a recuperative process and stored within a bin until used. The SoFuel can directly supply up to 1100°C heat to an adjacent power plant for electricity generation or industrial heating. Oxidation of SoFuel pellets occurs in a counter flow reactor and supplies heat to the user for electricity generation or industrial processing, after which the fuel is returned to the concentrating solar field where it is regenerated for re-use. Both reactors can be controlled well using a variety of strategies. With the low cost of the material, its cyclability, and the possibility of using the pelletized with on-sun reactors, or with electricity that would be curtailed, this project offers a viable option of medium- and long-term thermal energy storage.

14 SOLAR ENERGY↗

DOE OSTI2021

Verification of numerical models for seismic fluid-structure interaction analysis of internal components in liquid-filled advanced reactors

Earthquake shaking of a liquid-filled advanced reactor induces fluid-structure interaction (FSI) between the reactor vessel (tank), its internal components, and the contained liquid. Seismic design, qualification, and risk assessment of such reactors must consider fluid-structure responses, their geometries and support conditions, and three-directional seismic inputs, all of which require numerical simulations. Numerical models used for analysis of safety-related nuclear equipment must be verified and validated. Here, this paper verifies numerical models of submerged components using analytical solutions. Seismic FSI analysis of the numerical models is performed using the Arbitrary Lagrangian-Eulerian (ALE) and Incompressible Computational Fluid Dynamics (ICFD) solvers in LS-DYNA. Prior analytical solutions are reworked in this paper, and calculation errors are identified and corrected. The solutions address frequencies of two concentric cylindrical pipes filled with liquid: the inner pipe is a submerged component, and the outer pipe contains the liquid. A unitless frequency coefficient is defined and presented for pipes of different materials, filled with different liquids, and with a range of dimensions for application to advanced reactors. The numerical models are verified here by comparing the lateral frequencies of submerged components with those calculated using the corrected analytical solutions. Recommendations for verification of numerical models of internal components in advanced reactors for seismic FSI analysis are provided. Although the unitless frequency coefficients and verification procedures are developed for application to advanced nuclear reactors, they are broadly applicable to FSI analysis of submerged components in liquid-filled vessels such as storage tanks, boilers, and steam generators.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2022

Report on General Hydrogen Safety

Hydrogen is an important resource for many different industries throughout the world, including refining, manufacturing, and as a direct energy source. Hydrogen production, through methods such as steam methane reforming, has been developed over several decades. There is a large global demand for hydrogen from these industries and safe production and distribution are paramount for hydrogen systems. Codes and standards have been developed to reduce the risk associated with hydrogen accidents to the public. These codes and standards are similar to those in other industries in which there is inherent risk to the public, such as gasoline and natural gas production and distribution. Although there will always be a risk to the public in these types of fuels, the codes and standards are developed to reduce the likelihood of an accident occurring and reduce the severity of impact, should one occur. This report reviews the current state of hydrogen in the United States and outlines the codes and standards that ensure safe operation of hydrogen systems. The total hydrogen demand and use in different industries is identified. Additionally, the current landscape of hydrogen production and fueling stations in the United States is outlined. The safety of hydrogen systems is discussed through an overview of the purpose, methods, and content included in codes and standards. As outlined in this safety overview, the risk to the public in operation of hydrogen generation facilities and fueling stations is reduced through implementation of appropriate measures. Codes, such as NFPA 2, ensure that the risk associated with a hydrogen system is no greater than the risk presented by gasoline refueling stations.

08 HYDROGEN↗

DOE OSTI2020

Update on the United States Advanced Ultra-Supercritical Program with Full Scale Component Fabrication to Develop Utility Scale Power Plants with 760°C Steam Temperature

Following the successful completion of a 15-year effort to develop and test materials that would allow coal-fired power plants to be operated at advanced ultra-supercritical (A-USC) steam conditions, a United States-based consortium is presently engaged in Phase 2 of a project which includes an advanced manufacturing effort to complete US-based supply chain development for full commercial scale (800-850 MWe) A-USC components made of nickel-based alloys, components operating at up to 760°C. The project, funded under U.S. Department of Energy Award No. DE-FE0025064, falls under the US DOE overall goal to Develop cost-effective, reliable technologies to improve the efficiency of new and existing coal-fired power plants. A-USC steam cycles have the potential to improve cycle efficiency, reduce fuel costs, and reduce greenhouse gas emissions. Current development and demonstration efforts are focused on enabling the construction of A-USC plants, operating with steam temperatures as high as 1400°F (760°C) and steam pressures up to 5000 psi (35 MPa), which can potentially increase cycle efficiencies to 47% HHV (higher heating value), or approximately 50% LHV (lower heating value), and reduce CO 2 emissions by roughly 25%, compared to today’s U.S. fleet. A-USC technology provides a lower-cost method to reduce CO 2 emissions, compared to CO 2 capture technologies, while retaining a viable coal option for owners of coal generation assets. Among the specific goals of Phase 2 of the ComTest Project are to: validate that components made from advanced nickel-based alloys can operate and perform under A-USC conditions accelerate the development of a U.S.-based supply chain for the full complement of A-USC components close the remaining gaps and reduce the risks for manufacturing components from advanced materials for commercial demonstration fabricate full-scale versions of selected key components made of nickel-based alloys validate a qualified U.S. supply chain, to provide greater cost certainty for components obtain American Society of Mechanical Engineers (ASME) code approval for new materials, components and processes Additional benefit: Manufacturing technology will be applicable to other advanced fossil energy high temperature cycles, and can support increased flexibility of existing power plants The ComTest project is managed by Energy Industries of Ohio, and technically directed by the Electric Power Research Institute, Inc., with General Electric designing the A-USC components. As stated earlier, the current phase of the effort is primarily funded by the U.S. Department of Energy, through the National Energy Technology Laboratory. This presentation outlines the motivation for the project, explains the project’s structure and schedule, and provides some of the technical details on the design of the ComTest components.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2020

Update on the United States Advanced Ultra-Supercritical Program with Full Scale Component Fabrication to Develop Utility Scale Power Plants with 760°C Steam Temperature

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2023

Technology Maturation of Wireless Harsh Environment Sensors For Improved Condition Based Monitoring Of Coal Fired Power Generation

The overall goal of this project was to demonstrate and develop the usage of high-temperature (HT) harsh-environment (HE) wireless surface acoustic wave resonator (SAWR) sensor technology to promote reliable maintenance through condition-based maintenance (CBM) for field applications in harsh service conditions associated with power plant environments. The project aimed to advance the HT HE wireless SAWR sensor technology from TRL 5 to TRL 7. In addition to HT HE wireless temperature sensing, efforts were dedicated during this project to investigate, develop and increase the TRL from 3 to 5 for the following technologies: (a) HT HE strain sensors to address additional CBM monitoring needs, such as boiler tube mechanical / thermal stresses, which can provide early indications for boiler tube cracking and failure; and (b) HT aluminum nitride (AlN) and scandium aluminum nitride (ScAlN) based piezoelectric thin film fabrication and implementation of SAW sensors, with the goal of releasing the need to use single crystal piezoelectric materials for SAWRs and thus broaden possible technology applications to non-planar and harder to modify surfaces. To achieve the goals mentioned above, UMaine and its partner, Environetix Technologies Corporation, established partnerships with the following power plants: Longview Power (Maidsville, WV), a coal-fired power plant; Penobscot Energy Recovery Corp (PERC, Orrington, ME), a waste-to-energy power plant; and the UMaine Steam Plant (Orono, ME), an oil / natural gas power plant. To realize wireless HT HE SAWR sensor systems in these harsh service conditions, the University of Maine research team worked with Environetix and these power plants to define, design, fabricate, test and validate a mature prototype wireless temperature SAWR sensor system for boiler tube applications within the HT HE of the reheater pass damper chamber to directly and wirelessly monitor the temperature at eighteen independent boiler tube locations. The system included three levels, or “tiers”, of wireless communication to enable remote monitoring: Tier 1, the wireless link in the reheater pass damper chamber directly accessing the sensors on the boilers; Tier 2, the wireless local area network link, transmitting processed sensor information within the power plant to the Tier 3, a commercial wireless signal carrier company for secure remote data monitoring outside of the power plant. Regarding the wireless sensor system installed at Longview Power, temperature information from the boilers was continuously transmitted from the Longview boilers at Maidsville, WV, to Environetix headquarters, Orono, ME, over a 34 month period, when the system was finally decommissioned. Strain sensors and piezoelectric ScAlN thin film sensors were successfully installed on the exhaust duct at the UMaine Steam Power plant. The advances in wireless strain sensors and thin film piezoelectric film fabrication and testing were performed mostly in UMaine laboratories and field tested at the UMaine Steam Plant, due to its close proximity to UMaine/Environetix, access to the plant facility, and due to difficulties in accessing the other power plants during the COVID shut-down period. The project accomplished the TRL level increase of the targeted CBM technologies through the successful fabrication, installation, test, and validation of dedicated and commercial wireless sensor systems, utilizing the three different power plants. The outcomes of this project, including the wireless sensor data capability, are expected to yield an advance for CBM in harsh power plant environments. The reduction of maintenance costs, improved safety during plant operation, and increased power plant efficiency will lead to increased revenues (i.e., fewer forced outages) due to better process monitoring enabled by the wireless HT HE SAWR temperature sensor technology.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2022

Bottom-up assessment of industrial heat pump applications in U.S. Food manufacturing

Decarbonization of the industrial process heat supply through electrification could contribute significantly to climate change mitigation efforts. In the U.S. 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 the major U.S. food manufacturing sectors in different timeframes. The results show that the annual technical potential energy and CO 2 savings by electrifying process heat supply are 325 PJ (or approximately 20% of the total final energy demand in U.S. food manufacturing) and 31 MtCO 2 (equivalent to the annual CO 2 emissions from over 6 million cars in the U.S.) in 2050, respectively; however, these incur additional costs in each sector. 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 food 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 needed. In conclusion, this study provides novel insights that should inform policymakers’ and executives’ decisions about the electrification of the current and future U.S. industrial heat supply in relevant industrial sectors.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2020

Experimental investigation of turbulent wake flows in a helically wrapped rod bundle in presence of localized blockages

In nuclear sodium fast reactors, bundles of rods are tightly packed into a triangular lattice, enclosed in a hexagonal duct, and each pin is spirally wrapped with a thin wire. Flow blockages can potentially impact the local flow characteristics and heat transfer mechanisms in the bundle due to its small subchannel size. The effects of the blockage on the flow structures and heat transfer mechanisms are important aspects that require an accurate investigation. In this study, the flow-field characteristics in the vicinity of a blockage located in the exterior subchannel of rod bundles with helically wrapped wires were experimentally investigated. The velocity fields in the exterior subchannel were acquired by applying matched-index-of-refraction and time-resolved particle image velocimetry (TR-PIV) techniques for Reynolds numbers of Re 1 = 4000 and Re 2 = 17 000, i.e., equivalent to Rew 1 = 19 600 and Rew 2 = 83 200, respectively, based on the blockage width. The results from the TR-PIV measurements revealed an arch-shaped vortex with a large flow recirculation and a pair of counter-rotating vortices in the wake region downstream of the blockage, which is commonly observed in the wake flow of bluff bodies. The relative lateral distance and angle between the two vortices decreased when the Reynolds numbers increased. Profiles of maximum turbulence intensity along the shear layers illustrated the transition process including the growth, peak, and decay along the flow direction. From the spectral analysis of the turbulent velocities extracted at points along the shear layer, the Strouhal numbers ( St ) representing the vortex shedding frequency were found to be St = 0.25 and St = 0.56 for the left and right shear layers, respectively. Characteristics of shear layers generated by the blockage in the exterior subchannel were investigated via the two-point cross correlation of fluctuating velocities. The patiotemporal cross correlations of turbulent velocities, computed at points in the region where the left shear layer exhibited rolling effects and vortex breakdowns, were considerably wider and longer. The convection velocity U c was estimated to be ~0.82 U m to 0.93 U m . Proper orthogonal decomposition (POD) analysis was applied to the instantaneous velocity fields to extract the statistically dominant flow structures. It was found that POD modes 2–3 and 4–5 formed the pair modes when the corresponding POD temporal coefficients depicted sinusoidal shapes and exhibited nearly circular orbits in the phase space. Spectral analysis of the POD temporal coefficients confirmed the vortex shedding frequencies detected in the analysis of turbulent velocities.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2026

Solar Heat for Industrial Processes: Integration with Chemical Reactors

The integration of solar thermal systems with chemical reactors has been proposed as part of a larger effort to develop and deploy solar heat for industrial processes (SHIP) technologies. A strong motivation for SHIP processes and technologies is the potential for high thermal efficiency coupled with low-cost thermal energy storage (TES) which can enable commercial deployment of such systems. While there are different ways to categorize SHIP technologies, one important such distinction is between directly irradiated systems and indirect off-sun process driven by a SHIP system. While directly irradiated systems can provide high thermal efficiencies and high fluxes, they usually require complex engineering solutions due to the need for redesigning the established processes and unit operations. In most cases, it is also more challenging to couple such a process to a TES system, losing some of the benefits of SHIP. On the other hand, using a SHIP system to drive an industrial process off-sun can allow better integration with existing process chains, easier TES capabilities, and potential for more applications fitting a specific SHIP technology. However, the integration of SHIP systems with the industrial processes is not fully explored in detail, especially in the case of high-temperature processes such as reforming, cracking, cement manufacturing, and iron/steelmaking. Many of these systems require heating fluxes of >50 kW/m^2, supplied via combustion of hydrocarbons in a fire box and benefitting from radiative heat transfer between the flue gases and the reaction zones. As such, using SHIP systems for such processes is more complex than providing the same thermal input in the form of a heat transfer medium (HTM) entering the reactor, kiln, or furnace. Moreover, in case convective heat transfer using SHIP is envisioned, for example using supercritical CO2 as the HTM from a particle receiver, the thermal integration might be more challenging than initially envisioned: lower heat transfer coefficients and limited approach temperature might require large flow rates, causing a mismatch between the process thermal requirements and the thermal capacity of the SHIP system. In addition, even if the heat exchange between SHIP and reactor is effective, there is still a cold leg HTM at the reaction temperature or slightly below it. Chemical plants usually include a set of heat exchangers, heat recovery steam generators, and even power generation units - in a tightly integrated design - to recover the flue gases which are eventually vented. With SHIP systems mostly operating on a closed HTM loop, bottoming the cold leg is crucial. In this talk, we will present different modeling results for a variety of syngas production reactions, using catalytic and chemical looping processes, and discuss some of the challenges and design considerations for off-sun chemical reactors using SHIP systems.

14 SOLAR ENERGY↗

DOE OSTI2022

Design for Carbon Conversion Product Pathways with Nuclear Power Plant Integration (PCC)

Coal is a globally abundant resource that historically has been used for power generation via combustion. As the power industry replaces coal with cleaner methods of generation, energy rich coal could be used in other chemical and fuel applications. This study presents a coal utilization option in which coal combustion is replaced with a carbon-free nuclear power plant and the coal is upgraded to valuable products for a variety of markets. Coal is prepared for conversion first by the pyrolysis process, which will optimize solid, liquid, and gaseous products based on the market size and potential product value, maximizing the monetary value of coal. This process is designed using bituminous coal from the Appalachian region as a basis to provide a pathway to preserve or transition coal-related jobs and create new jobs associated with the clean energy transition. Process modeling will be used to determine each component’s sensitivities, costs, inputs, and outputs Advanced and light-water reactors are considerations to supply the heat, steam, and electricity to the process. This paper focuses on the technical and market analysis used to determine the optimal processes and product pathways for the carbon refinery. Product pathways are on activated carbon, formic acid synthesis, and methanol synthesis for further upgrading to marketable chemical and polymer products.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2021

Layer-structured triple-conducting electrocatalyst for water-splitting in protonic ceramic electrolysis cells: Conductivities vs. activity

Electron, proton and oxygen-triple-conducting materials are becoming the dominant steam electrode candidate to break the rate limit on the water-splitting reaction that throttles the performance of protonic ceramic electrolysis cells (PCECs). In this study, based on Pr 2 NiO 4+δ Ruddlesden-Popper phase, we manipulate these conductivities by Pr-site Ba substitution to probe the correlation of each conductivity with the kinetics of the elementary reaction steps. It is found that the proton conductivity is vital to sustain an extended active surface area for faster adsorption of reactants and desorption of products. The effect of oxygen conductivity is surprisingly found insignificant in the water-splitting reaction. On the contrary, surface oxygen removal is discovered as the most rate-limiting process. The electronic conductivity is not a direct limiting factor. However, an electron transfer process between the current collector and the electrode junction could introduce extra resistance that is perceptible at a high operating temperature range. The best water-splitting activity is obtained on a proton conductivity/oxygen surface desorption capability well-balanced sample after Ba substitution. As a result, a water-splitting reaction resistance of 0.022 Ωcm 2 , a current density of 1.96 A/cm 2 at 700 °C is achieved on Pr 1.7 Ba 0.3 NiO 4+δ , one of the best performances for PCECs.

25 ENERGY STORAGE↗