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NASA NTRS1991

A Rocket Powered Single-Stage-to-Orbit Launch Vehicle With U.S. and Soviet Engineers

A single-stage-to-orbit launch vehicle is used to assess the applicability of Soviet Energia high-pressure-hydrocarbon engine to advanced U.S. manned space transportation systems. Two of the Soviet engines are used with three Space Shuttle Main Engines. When applied to a baseline vehicle that utilized advanced hydrocarbon engines, the higher weight of the Soviet engines resulted in a 20 percent loss of payload capability and necessitated a change in the crew compartment size and location from mid-body to forebody in order to balance the vehicle. Various combinations of Soviet and Shuttle engines were evaluated for comparison purposes, including an all hydrogen system using all Space Shuttle Main Engines. Operational aspects of the baseline vehicle are also discussed. A new mass properties program entitles Weights and Moments of Inertia (WAMI) is used in the study.

MacConochie, Ian O.↗

NASA NTRS2010

Robotic Lunar Landers for Science and Exploration

NASA Marshall Space Flight Center (MSFC) and The Johns Hopkins University Applied Physics Laboratory (APL) have been conducting mission studies and performing risk reduction activities for NASA s robotic lunar lander flight projects. This paper describes some of the lunar lander concepts derived from these studies conducted by the MSFC/APL Robotic Lunar Lander Development Project team. In addition, the results to date of the lunar lander development risk reduction efforts including high pressure propulsion system testing, structure and mechanism development and testing, long cycle time battery testing and combined GN&C and avionics testing will be addressed. The most visible elements of the risk reduction program are two autonomous lander flight test vehicles: a compressed air system with limited flight durations and a second version using hydrogen peroxide propellant to achieve significantly longer flight times and the ability to more fully exercise flight sensors and algorithms.

Chavers, D. G.↗

NASA NTRS2007

Cost-Efficient Storage of Cryogens

NASA's cryogenic infrastructure that supports launch vehicle operations and propulsion testing is reaching an age where major refurbishment will soon be required. Key elements of this infrastructure are the large double-walled cryogenic storage tanks used for both space vehicle launch operations and rocket propulsion testing at the various NASA field centers. Perlite powder has historically been the insulation material of choice for these large storage tank applications. New bulk-fill insulation materials, including glass bubbles and aerogel beads, have been shown to provide improved thermal and mechanical performance. A research testing program was conducted to investigate the thermal performance benefits as well as to identify operational considerations and associated risks associated with the application of these new materials in large cryogenic storage tanks. The program was divided into three main areas: material testing (thermal conductivity and physical characterization), tank demonstration testing (liquid nitrogen and liquid hydrogen), and system studies (thermal modeling, economic analysis, and insulation changeout). The results of this research work show that more energy-efficient insulation solutions are possible for large-scale cryogenic storage tanks worldwide and summarize the operational requirements that should be considered for these applications.

Fesmire, J. E.↗

NASA NTRS2023

Additive Manufacturing Process Development DOE for NASA HR-1 using Laser Blown Powder Directed Energy Deposition

NASA HR-1 is a Fe-Ni-Cr alloy that is used for high pressure hydrogen applications such as rocket engines, energy, and oil and gas. This investigation was focused on conducting a design of experiment program aimed at mapping the parameter process window for NASA HR-1 using the laser blown powder directed energy deposition (LP-DED) process. A two phased design of experiments (DOE), the first phase of the experiment was focused on optimizing single bead tracks while the second phase of the experiment was focused on optimizing bead overlap hatching in a multi pass bead build up. During the first phase of the deposition parameters, namely laser power, travel speed, and powder feed rate were varied. A down selection from the single bead parameter set was made and hatching experiments were conducted that focused on the overlap distance. In this paper the approach for conducting the DOE and results are discussed. The results focused on measurement of bead geometry, the as-built microstructural evolution, and porosity within the samples. The team at MSFC saw a variety of results across the process map created during the first phase of experimentation and were able to down select a parameter that created an optimal bead shape with a minimal amount of build porosity. It was determined that laser power and robot travel speed were the most sensitive parameters. The results from this investigation will inform future laser powder directed energy deposition parameter developments.

Parker Shake↗

DOE OSTI2010

FY2010 Oak Ridge National Laboratory Annual Progress Report for the Power Electronics and Electric Machinery Program

The U.S. Department of Energy (DOE) and the U.S. Council for Automotive Research (composed of automakers Ford, General Motors, and Chrysler) announced in January 2002 a new cooperative research effort. Known as FreedomCAR (derived from ''Freedom'' and ''Cooperative Automotive Research''), it represents DOE's commitment to developing public-private partnerships to fund high risk, high payoff research into advanced automotive technologies. Efficient fuel cell technology, which uses hydrogen to power automobiles without air pollution, is a very promising pathway to achieve the ultimate vision. The new partnership replaces and builds upon the Partnership for a New Generation of Vehicles initiative that ran from 1993 through 2001. The Oak Ridge National Laboratory's (ORNL's) Advanced Power Electronics and Electric Machines (APEEM) subprogram within the DOE Vehicle Technologies Program (VTP) provides support and guidance for many cutting-edge automotive technologies now under development. Research is focused on developing revolutionary new power electronics (PE) and electric motor technologies that will leapfrog current on-the-road technologies. The research and development (R&D) is also aimed at achieving a greater understanding of and improvements in the way the various new components of tomorrow's automobiles will function as a unified system to improve fuel efficiency. In supporting the development of advanced vehicle propulsion systems, the APEEM subprogram has enabled the development of technologies that will significantly improve efficiency, costs, and fuel economy. The APEEM subprogram supports the efforts of the FreedomCAR and Fuel Partnership through a three phase approach intended to: (1) identify overall propulsion and vehicle related needs by analyzing programmatic goals and reviewing industry's recommendations and requirements and then develop the appropriate technical targets for systems, subsystems, and component research and development activities; (2) develop and validate individual subsystems and components, including electric motors and PE; and (3) determine how well the components and subsystems work together in a vehicle environment or as a complete propulsion system and whether the efficiency and performance targets at the vehicle level have been achieved. The research performed under this subprogram will help remove technical and cost barriers to enable the development of technology for use in such advanced vehicles as hybrid electric vehicles (HEVs), plug-in HEVs (PHEVs), battery electric vehicles, and fuel-cell-powered automobiles that meet the goals of the VTP. A key element in making these advanced vehicles practical is providing an affordable electric traction drive system. This will require attaining weight, volume, and cost targets for the PE and electrical machines subsystems of the traction drive system. Areas of development include: (1) novel traction motor designs that result in increased power density and lower cost; (2) inverter technologies involving new topologies to achieve higher efficiency, with the ability to accommodate higher temperature environments while achieving high reliability; (3) converter concepts that use methods of reducing the component count and integrating functionality to decrease size, weight, and cost; (4) new onboard battery charging concepts that result in decreased cost and size; (5) more effective thermal control through innovative packaging technologies; and (6) integrated motor/inverter concepts. ORNL's Power Electronics and Electric Machines Research Program conducts fundamental research, evaluates hardware, and assists in the technical direction of the VTP APEEM subprogram. In this role, ORNL serves on the FreedomCAR Electrical and Electronics Technical Team, evaluates proposals for DOE, and lends its technological expertise to the direction of projects and evaluation of developing technologies. ORNL also executes specific projects for DOE. The following report discusses those projects carried out in FY 2010 and conveys highlights of their accomplishments. Numerous project reviews, technical reports, and papers have been published for these efforts, and they are indicated at the end of each section for readers interested in pursuing details of the work.

08 HYDROGEN↗

DOE OSTI2017

Final Report - Stationary and Emerging Market Fuel Cell System Cost Assessment

The U.S. Department of Energy (DOE) is focused on providing a portfolio of technology solutions to meet energy security challenges of the future. Fuel cells are a part of this portfolio of technology offerings. To help meet these challenges and supplement the understanding of the current research, Battelle has executed a five-year program that evaluated the total system costs and total ownership costs of two technologies: (1) an ~80 °C polymer electrolyte membrane fuel cell (PEMFC) technology and (2) a solid oxide fuel cell (SOFC) technology, operating with hydrogen or reformate for different applications. Previous research conducted by Battelle, and more recently by other research institutes, suggests that fuel cells can offer customers significant fuel and emission savings along with other benefits compared to incumbent alternatives. For this project, Battelle has applied a proven cost assessment approach to assist the DOE Fuel Cell Technologies Program in making decisions regarding research and development, scale-up, and deployment of fuel cell technology. The cost studies and subsequent reports provide accurate projections of current system costs and the cost impact of state-of-the-art technologies in manufacturing, increases in production volume, and changes to system design on system cost and life cycle cost for several near-term and emerging fuel cell markets. The studies also provide information on types of manufacturing processes that must be developed to commercialize fuel cells and also provide insights into the optimization needed for use of off-the-shelf components in fuel cell systems. Battelle’s analysis is intended to help DOE prioritize investments in research and development of components to reduce the costs of fuel cell systems while considering systems optimization.

08 HYDROGEN↗

DOE OSTI2024

Technical and Economic Assessment and Gap Analysis of Advanced Nuclear Reactor Integration with a Reference Oil Refinery

Efforts to identify the most-economic methods to decarbonize several sectors of the U.S. economy are underway. Industrial processes such as crude-oil refining rely heavily on energy-dense and easily stored and transported fossil fuels for powering their operations. Refineries use large amounts of energy, primarily derived from fossil sources to separate crude-oil components, break down heavier hydrocarbons into lighter compounds, remove impurities, reform hydrocarbon molecules, and generate steam and electricity for pumps and compressors and other various auxiliary systems. Crude-oil refining operations such as distillation, cracking, desulfurization, reforming, utilities systems and some offsite facilities collectively account for most of the energy consumption. Other operations such as hydrocracking or hydrotreating also require hydrogen for developing hydrogenation reactions which involve substantial heating to keep the reactors at high-temperature and pressure levels. All heat and energy demands are typically provided by natural gas (NG), oil, or other fuels, which makes refinery industry one of the most-difficult sectors to decarbonize. Nuclear power is a viable and energy-dense source of clean electricity, heat, and hydrogen to provide the large, sustainable energy supply that the refining industry demands. The U.S. Department of Energy’s (DOE’s) Integrated Energy Systems (IES) program is working to perform research and development, design, economic siting, and risk analysis. This state-of-the-art work will enable the first on-site demonstrations and commercial deployments of advanced small modular nuclear reactors (SMNRs) integrated with industries such as chemical production, refining, iron and steel making, and more. IES seeks to demonstrate the ability of advanced nuclear reactors to meet the heat and power demands of these industries while reducing carbon emissions in a sustainable and cost-competitive way. The primary objective of this research effort is to analyze industrial-scale SMNR integration intended to decarbonize refining facilities. The foreseen outcome is the provision of reliable, cost-competitive, and sustainable clean energy, alongside a reduction of carbon emissions. Specifically, the focus of this work lies on meeting the reference facilities’ heat and electricity demands with nuclear power while also supplying clean hydrogen via integrated high-temperature steam electrolysis (HTSE). This report presents a comprehensive technical and economic assessment of the integration of advanced nuclear reactors into a reference refinery, leveraging financial incentives from the Inflation Reduction Act (IRA). The evaluation aims to explore the potential economic benefits and challenges associated with incorporating advanced nuclear reactors into refinery operations, particularly in terms of energy efficiency, economic implications and environmental impact. By examining both the technical feasibility and economic viability, this analysis seeks to identify existing gaps and propose solutions for successful nuclear integration implementation. The findings are intended to provide valuable insights for stakeholders considering the adoption of advanced nuclear reactors in the refining sector. A refinery reference-plant was developed, using an open-source refinery model, Petroleum Refinery Lifecycle Inventory Model (PRELIM) and expert assessment, as a base case for comparison with various nuclear integration options. The capacity of 100 kbd/day (KBD) of heavy crude-oil feed was selected to represent a general coking-type refinery with deep conversion capabilities (incorporating heavy-oil upgrading with FCC, coking, and associated hydrotreating process units), using a heavy crude-oil feed, which represents about 70% of U.S. refineries configurations. A summary of all cases considered in this study is shown in Table 1.

13 HYDRO ENERGY↗

NASA NTRS1976

The aerosol distribution in Uranus' atmosphere - Interpretation of the hydrogen spectrum

New observations of Uranus' combined H2 spectrum have been obtained. An analysis, emphasizing the leverage provided by the S3(0) quadrupole line, leads to strong constraints on Uranus' bulk aerosol distribution with depth. Using an inhomogeneous model atmosphere program which includes Rayleigh scattering for gases and a 1 plus cos theta phase function for cloud layers, it is shown that Uranus' H2 spectrum implies a cloud layer (or dense aerosol) at a depth from 500 to 700 km-amagat H2. It also implies negligible aerosol scattering in the 280 to 450 km-amagat H2 region and a thin haze at 100 to 200 km-amagat H2 depths. The low albedo in very strong CH4 bands indicates that there is negligible aerosol scattering in Uranus' radiative zone. Hydrogen appears to be more abundant than the sum of all other atmospheric gases. The C/H ratio deep in Uranus' atmosphere is strongly enhanced over the solar value. Accurate limb-darkening measurements in and near strong CH4 bands would be effective in specifying Uranus' aerosol distribution in greater detail.

Trafton, L.↗

DOE OSTI2013

Photoelectrochemical Hydrogen Production (Final Report)

The objectives of this project, covering two phases and an additional extension phase, were the development of thin film-based hybrid photovoltaic (PV)/photoelectrochemical (PEC) devices for solar-powered water splitting. The hybrid device, comprising a low-cost photoactive material integrated with amorphous silicon (a-Si:H or a-Si in short)-based solar cells as a driver, should be able to produce hydrogen with a 5% solar-to-hydrogen conversion efficiency (STH) and be durable for at least 500 hours. Three thin film material classes were studied and developed under this program: silicon-based compounds, copper chalcopyrite-based compounds, and metal oxides . With the silicon-based compounds, more specifically the amorphous silicon carbide (a-SiC), we achieved a STH efficiency of 3.7% when the photoelectrode was coupled to an a-Si tandem solar cell, and a STH efficiency of 6.1% when using a crystalline Si PV driver. The hybrid PV/a-SiC device tested under a current bias of -3~4 mA/cm 2 , exhibited a durability of up to ~800 hours in 0.25 M H 2 SO 4 electrolyte. Other than the PV driver, the most critical element affecting the photocurrent (and hence the STH efficiency) of the hybrid PV/a-SiC device was the surface energetics at the a-SiC/electrolyte interface. Without surface modification, the photocurrent of the hybrid PEC device was ~1 mA/cm 2 or lower due to a surface barrier that limits the extraction of photogenerated carriers. We conducted an extensive search for suitable surface modification techniques/materials, of which the deposition of low work function metal nanoparticles was the most successful. Metal nanoparticles of ruthenium (Ru), tungsten (W) or titanium (Ti) led to an anodic shift in the onset potential. We have also been able to develop hybrid devices of various configurations in a monolithic fashion and optimized the current matching via altering the energy bandgap and thickness of each constituent cell. As a result, the short-circuit photocurrent density of the hybrid device (measured in a 2-electrode configuration) increased significantly without assistance of any external bias, i.e. from ≤1 mA/cm 2 to ~5 mA/cm 2 . With the copper chalcopyrite compounds, we have achieved a STH efficiency of 3.7% in a coplanar configuration with 3 a-Si solar cells and one CuGaSe 2 photocathode. This material class exhibited good durability at a photocurrent density level of -4 mA/cm 2 (“5% STH” equivalent) at a fixed potential (-0.45 V RHE ). A poor band-edge alignment with the hydrogen evolution reaction (HER) potential was identified as the main limitation for high STH efficiency. Three new pathways have been identified to solve this issue. First, PV driver with bandgap lower than that of amorphous silicon were investigated. Crystalline silicon was identified as possible bottom cell. Mechanical stacks made with one Si solar cell and one CuGaSe 2 photocathode were built. A 400 mV anodic shift was observed with the Si cell, leading to photocurrent density of -5 mA/cm 2 at 0V RHE (compared to 0 mA/cm 2 at the same potential without PV driver). We also investigated the use of p-n junctions to shift CuGaSe 2 flatband potential anodically. Reactively sputtered zinc oxy-sulfide thin films was evaluated as n-type buffer and deposited on CuGaSe 2 . Ruthenium nanoparticles were then added as HER catalyst. A 250 mV anodic shift was observed with the p-n junction, leading to photocurrent density at 0V RHE of -1.5 mA/cm 2 . Combining this device with a Si solar cell in a mechanical stack configuration shifted the onset potential further (+400 mV anodically), leading to photocurrent density of -7 mA/cm 2 at 0V RHE . Finally, we developed wide bandgap copper chalcopyrite thin film materials. We demonstrated that Se can be substituted with S using a simple annealing step. Photocurrent densities in the 5-6 mA/cm 2 range were obtained with red 2.0eV CuInGaS 2 photocathodes. With the metal oxide compounds, we have demonstrated that a WO 3 -based hybrid photoelectrode was feasible. Specifically, we showed that WO 3 paired with an a-Si tandem solar cell can generate short circuit photocurrent density of 2.5 mA/cm 2 , equivalent to STH efficiency of 3.1%. Long-term durability tests demonstrated WO 3 ability to split water over extended periods, for up to 600 hours at current density levels of 2.0-2.5 mA/cm 2 . Efforts have been done to decrease WO 3 bandgap using foreign elements incorporation. We did not manage to reduce the bandgap of WO 3 with this method. However, more promising results have been achieved with bilayered systems, where only the top part of WO 3 films was modified. Also, we have demonstrated that alloying WO 3 with CuO can form 2.2eV bandgap CuWO 4 . Incorporating conductive carbon nanotubes in CuWO 4 reduced its intrinsic bulk resistance. Saturation photocurrent densities in the 0.4-0.5 mA/cm 2 range were achieved. Recently, in collaboration with University of Texas at Arlington, we have identified new quaternary metal oxides with CuWO 4 as primary material host. Our experimental work on ceramics confirmed the theoretical calculations that crowned bismuth as a possible candidate to improve CuWO 4 water splitting efficiency.

08 HYDROGEN↗

DOE OSTI2010

N-(N-[2-(3,5-Difluorophenyl)acetyl]-(S)-alanyl)-(S)-phenylglycine tert-butyl ester (DAPT): an inhibitor of γ-secretase, revealing fine electronic and hydrogen-bonding features

The title compound, C{sub 23}H{sub 26}F{sub 2}N{sub 2}O{sub 4}, is a dipeptidic inhibitor of γ-secretase, one of the enzymes involved in Alzheimer’s dis@@ease. The mol@@ecule adopts a compact conformation, without intra@@molecular hydrogen bonds. In the crystal structure, one of the amide N atoms forms the only inter@@molecular N—H⋯O hydrogen bond; the second amide N atom does not form hydrogen bonds. High-resolution synchrotron diffraction data permitted the unequivocal location and refinement without restraints of all H atoms, and the identification of the characteristic shift of the amide H atom engaged in the hydrogen bond from its ideal position, resulting in a more linear hydrogen bond. Significant residual densities for bonding electrons were revealed after the usual SHELXL refinement, and modeling of these features as additional inter@@atomic scatterers (IAS) using the program PHENIX led to a significant decrease in the R factor from 0.0411 to 0.0325 and diminished the r.m.s. deviation level of noise in the final difference Fourier map from 0.063 to 0.037 e Å{sup −3}.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2016

Performance testing of a prototype Pd-Ag diffuser

The fusion fuel cycle has gained significant attention over the last decade as interest in fusion programs has increased. One of the critical components of the fusion process is the tritium fuel cycle. The tritium fuel cycle is designed to supply and recycle process tritium at a specific throughput rate. One of the most important processes within the tritium fuel cycle is the clean-up of the of the process tritium. This step will initially separate the hydrogen isotopes (H2, D2, and T2) from the rest of the process gas using Pd-Ag diffusers or permeators. The Pd-Ag diffuser is an integral component for any tritium purification system; whether part of the United States’ defense mission or fusion programs. Domestic manufacturers of Pd-Ag diffusers are extremely limited and only a few manufacturers exist. Johnson-Matthey (JM) Pd-Ag diffusers (permeators) have previously been evaluated for the separation of hydrogen isotopes from non-hydrogen gas species in the process. JM is no longer manufacturing Pd-Ag diffusers and a replacement vendor needs to be identified to support future needs. A prototype Pd-Ag diffuser has been manufactured by Power and Energy, and is considered a potential replacement for the JM diffuser for tritium service. New diffuser designs for a tritium facility for any fusion energy applications must be characterized by evaluating their operating envelope prior to installation in a tritium processing facility. The prototype Pd-Ag diffuser was characterized to determine the overall performance as a function of the permeation of hydrogen through the membrane. The tests described in this report consider the effects of feed gas compositions, feed flow rates, pump configuration and internal tube pressure on the permeation of H2 through the Pd-Ag tubes.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2016

AREVA NP MR Cladding benefits for proposed US NRC RIA and LOCA requirements

M5 is the reference alloy of AREVA NP for PWR cladding applications. It is a zirconium-based alloy containing 1% niobium, no tin, and well-controlled oxygen, iron, and sulfur contents. It has a fully recrystallized microstructure. The absence of tin in M5 results in a very low corrosion rate and hydrogen pick-up during normal operation, even at high burn-up and in high duty irradiation conditions. Due to this low hydrogen pick-up under irradiation (typically less than 100 ppm, End of Life), M5 retains a very good strength and an exceptional residual ductility during and after the accident. This allows utilities implementing M5 to simplify the safety analysis and to demonstrate significant margins regarding fuel related criteria. Simplified methods are easier for plants to implement and maintain for future plant operations and core design management. This paper specifically presents 3 examples on the safety improvement brought by M5 cladding. First, during a reactivity-induced accident (RIA), the properties of M5 are such that bounding analyses for future cycles are significantly simplified, in particular by demonstrating that fuel dispersal will not occur. The major aspects of the AREVA NP RIA methodology are presented. A second focus is made on the low hydrogen embrittlement of M5 and on its high ductility after quenching during a loss-of-coolant accident (LOCA). In a third part, the breakaway oxidation testing program currently under development in Paimboeuf (France) is described, including details about the testing devices and qualification. The tests have demonstrated that M5 cladding does not have breakaway at least up to 5000 s oxidation duration at 1000 C. degrees, which is much higher than the LOCA duration.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

NASA NTRS1976

Process sensitivity studies of the Westinghouse Sulfur Cycle for hydrogen generation

The effect of variations of acid concentration, pressure, and temperature on the thermal process efficiency of the Westinghouse Sulfur Cycle was examined using the University of Kentucky's HYDRGN program. Modifications to the original program were made to duplicate the process flow sheet and take into account combined-cycle heat-to-work efficiencies for electrochemical work requirements, aqueous solutions, and heat-of-mixing effects. A total of 125 process variations were considered (acid concentration: 50-90 w/o; pressure: 15-750 psia; temperature: 922-1366 K (2000 F)). The methods of analysis, results, and conclusions are presented.

Carty, R.↗

DOE OSTI2010

Integrated Ceramic Membrane System for Hydrogen Production

Phase I was a technoeconomic feasibility study that defined the process scheme for the integrated ceramic membrane system for hydrogen production and determined the plan for Phase II. The hydrogen production system is comprised of an oxygen transport membrane (OTM) and a hydrogen transport membrane (HTM). Two process options were evaluated: 1) Integrated OTM-HTM reactor – in this configuration, the HTM was a ceramic proton conductor operating at temperatures up to 900°C, and 2) Sequential OTM and HTM reactors – in this configuration, the HTM was assumed to be a Pd alloy operating at less than 600°C. The analysis suggested that there are no technical issues related to either system that cannot be managed. The process with the sequential reactors was found to be more efficient, less expensive, and more likely to be commercialized in a shorter time than the single reactor. Therefore, Phase II focused on the sequential reactor system, specifically, the second stage, or the HTM portion. Work on the OTM portion was conducted in a separate program. Phase IIA began in February 2003. Candidate substrate materials and alloys were identified and porous ceramic tubes were produced and coated with Pd. Much effort was made to develop porous substrates with reasonable pore sizes suitable for Pd alloy coating. The second generation of tubes showed some improvement in pore size control, but this was not enough to get a viable membrane. Further improvements were made to the porous ceramic tube manufacturing process. When a support tube was successfully coated, the membrane was tested to determine the hydrogen flux. The results from all these tests were used to update the technoeconomic analysis from Phase I to confirm that the sequential membrane reactor system can potentially be a low-cost hydrogen supply option when using an existing membrane on a larger scale. Phase IIB began in October 2004 and focused on demonstrating an integrated HTM/water gas shift (WGS) reactor to increase CO conversion and produce more hydrogen than a standard water gas shift reactor would. Substantial improvements in substrate and membrane performance were achieved in another DOE project (DE-FC26-07NT43054). These improved membranes were used for testing in a water gas shift environment in this program. The amount of net H2 generated (defined as the difference of hydrogen produced and fed) was greater than would be produced at equilibrium using conventional water gas shift reactors up to 75 psig because of the shift in equilibrium caused by continuous hydrogen removal. However, methanation happened at higher pressures, 100 and 125 psig, and resulted in less net H2 generated than would be expected by equilibrium conversion alone. An effort to avoid methanation by testing in more oxidizing conditions (by increasing CO2/CO ratio in a feed gas) was successful and net H2 generated was higher (40-60%) than a conventional reactor at equilibrium at all pressures tested (up to 125 psig). A model was developed to predict reactor performance in both cases with and without methanation. The required membrane area depends on conditions, but the required membrane area is about 10 ft2 to produce about 2000 scfh of hydrogen. The maximum amount of hydrogen that can be produced in a membrane reactor decreased significantly due to methanation from about 2600 scfh to about 2400 scfh. Therefore, it is critical to eliminate methanation to fully benefit from the use of a membrane in the reaction. Other modeling work showed that operating a membrane reactor at higher temperature provides an opportunity to make the reactor smaller and potentially provides a significant capital cost savings compared to a shift reactor/PSA combination.

08 HYDROGEN↗

DOE OSTI2018

Electron-stimulated reactions in nanoscale water films adsorbed on (alpha)-Al2O3(0001)

The radiation-induced decomposition and desorption of nanoscale amorphous solid water (D2O) films adsorbed on -Al2O3(0001) surface was studied at low temperature in ultrahigh vacuum using temperature programmed desorption (TPD) and electron stimulated desorption (ESD) with a mono-energetic, low energy electron source. ESD yields of molecular products ( D2, O2 and D¬2O) and the total sputtering yield increased with increasing D2O coverage up to ~15 water monolayers (i.e. ~15 1015 cm-2) to a coverage-independent level for thicker water films. Experiments with isotopically-layered water films (D2O and H2O) demonstrated that the highest water decomposition yields occurred at the interfaces of the nanoscale water films with the alumina substrate and vacuum. However, the increased reactivity of the water/alumina interface is relatively small compared to the enhancements in the non-thermal reactions previously observed at the water/Pt(111) and water/TiO2(110) interfaces. We propose that the relatively low activity of Al2O3(0001) for the radiation-induced production of molecular hydrogen is associated with lower reactivity of this surface with hydrogen atoms, which are likely precursors for the molecular hydrogen.

Petrik, Nikolay G.↗

DOE OSTI2016

Advancements in FeCrAl Alloys for Enhanced Accident Tolerant Fuel Cladding for Light Water Reactors

Advanced FeCrAl alloys are being considered as an enhanced accident tolerant fuel (ATF) cladding for light water reactor (LWR) applications as they can exhibit slower reaction kinetics with high temperature steam and have a reduced production of hydrogen during accident scenarios compared both to historic 304L cladding and Zircaloy. Both of these attributes are key towards producing a fuel-form with enhanced accident tolerance over the current Zr-based-UO{sub 2} fuel form in deployment. A multi-year, multi-laboratory effort has been established to rapidly advance FeCrAl alloys as an ATF concept. This effort has focused on optimizing the microstructure and composition of these alloys in an attempt to provide performance on-par with or better than the current Zr-based cladding in both normal operating conditions and under accident scenarios. To date, a significant database supporting key performance factors in both scenarios has been developed. Based on this database, a compositional and microstructural window has been identified providing the insight for an optimized, advanced nuclear-grade FeCrAl alloy for LWRs. This work will provide a comprehensive overview of the systematic effort to advance FeCrAl alloys as an enhanced ATF cladding in commercial LWRs. Efforts undertaken by this multi-year, multi-laboratory program have shown the viability of using FeCrAl alloys as an ATF cladding in LWRs. Most importantly, it has been shown the oxidation resistance, decreased hydrogen production, and reduced heat generation of FeCrAl alloys strongly contribute to its ATF capability. Furthermore, it has been shown that the normal operational performance of a FeCrAl cladding can rival that of Zr-based alloys. Finally, it was found that optimizing the performance of FeCrAl cladding materials requires balancing the starting composition and microstructure in order to satisfy key performance indicators such as oxidation resistance and radiation tolerance. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

NASA NTRSDate not supplied

Development of Laser Powder Bed Fusion NASA HR-2 for Hydrogen Sensitive Liquid Rocket Engine Applications

The National Aeronautics and Space Administration (NASA) has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the late 2000’s. AM has provided new design and manufacturing opportunities to reduce cost and schedule, consolidate parts, and optimize performance. Laser Powder Bed Fusion (L-PBF) is one of the most commonly used AM processes to fabricate components that have complex shape and need fine feature resolution. Due to exposure to high pressure gaseous hydrogen, mechanical property degradation caused by hydrogen environment embrittlement (HEE) is a critical concern for many materials in liquid hydrogen propulsion systems. NASA has identified the need to develop and advance new materials in unique engine applications using liquid hydrogen as a propellant. One such material being developed at NASA Marshall Space Flight Center is L-PBF NASA HR-2 (Hydrogen Resistant-2), a high-strength Fe-Ni-based superalloy resistant to HEE. The chemistry of NASA HR-2 was formulated to meet requirements for key liquid rocket engine (LRE) components that operate in high-pressure hydrogen environments. Initial development and material characterization found NASA HR-2 has excellent L-PBF printability and its microstructure evolves well after heat treatment. This new alloy has undergone fundamental metallurgical evaluations, heat treatment studies, detailed microstructure characterization, and mechanical testing across a range of temperatures. Tensile testing was performed in pressurized gaseous hydrogen (GH2) environment to assess its resistance to HEE. L-PBF NASA HR-2 has an average yield stress of 95 ksi, ultimate tensile stress of 165 ksi, and very high fracture elongation at 34 - 36% when tested in a 5 ksi high pressure hydrogen environment. The tensile property data confirms hydrogen has little influence on its ductility, strength, and fracture behavior. L-PBF NASA HR-2 is a promising option for many hydrogen sensitive LRE components that require exceptional resistance to HEE. The development of L-PBF NASA HR-2 is funded under the grants provided by Jacobs TIPI program and the Liquid Engine Office at NASA Marshall Space Flight Center. This paper will provide an overview of the L-PBF process development, material characterization, mechanical and thermophysical properties, and LRE hardware development for NASA HR-2.

NASA HR-2↗

NASA NTRSDate not supplied

Development of Laser Powder Bed Fusion NASA HR-2 for Hydrogen Sensitive Liquid Rocket Engine Applications

NASA HR-2↗