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DOE OSTI2021

A Novel Multiagent Resource Sharing Algorithm for Control of Advanced Energy Systems

This paper implements a novel resource sharing control strategy on a fuel cell–gas turbine hybrid power system at the National Energy Technology Laboratory’s Hybrid Performance Facility (Hyper). In a fuel cell–gas turbine hybrid power system, the simultaneous interaction of the gas turbine and the fuel cell creates a tightly coupled environment characterized by conflicting dynamics. In this paper, a model-free control approach is applied to solve the tightly coupled control problem posed by this challenging environment. Specifically, this control problem is presented as a resource sharing problem that can be solved using a resource sharing algorithm that is defined based on the distribution construction concept. This algorithm creates computational agents and solves the problem through the distribution and redistribution of shared resources defined as blocks. Furthermore, two agents were created; the first agent (agent 1) controls the gas turbine speed by adjusting the electric load, and the second agent (agent 2) controls the cathode mass flow through the fuel cell using the cold-air bypass valve. A parametric study was performed over the course of 15 experimental tests for both agents 1 and 2 through an evaluation of the responses based on setpoint changes. The algorithm was shown to have behavior comparable to a previously implemented multi-input multioutput state-space controller, which was designed through a model-based control approach. The resource sharing algorithm was able to find stable performance during run-time operations without any prior system knowledge identification on the power plant and without creating models used in traditional control strategies.

25 ENERGY STORAGE↗

DOE OSTI2022

Innovative, Versatile and Cost-Effective Solid Oxide Fuel Cell Stack Concept

This report summarizes the work performed for the U. S. Department of Energy/National Energy Technology Laboratory (DOE/NETL) under Cooperative Agreement DE-FE0026211 entitled “Innovative, Versatile and Cost-Effective Solid Oxide Fuel Cell Stack Concept”. The overall objective of this project was to develop and evaluate a solid oxide fuel cell (SOFC) stack configuration based on a novel prime-surface interconnect design for a broad range of power generation applications. The prime-surface is a one-piece metallic interconnect that incorporates both fuel and oxidant flow fields with peaks on one side of the interconnect serving as flow channels (valleys) on the other side. (One example is the egg-carton shaped interconnect design.) This stack technology has several attractive features including reduced stack weight and volume, decreased performance losses in stacking, improved sealing, versatility in incorporation of different types of cell construction (thin-film cells or sintered cells) and flexibility in gas flow configuration (cross-flow, co-flow or counter-flow). These features lead to lower cost, better performance, and enhanced reliability for the stack. The R&D work of this project focused on demonstrating fabrication, operability and cost effectiveness of the stack design and was conducted by University of California, San Diego (UCSD) in conjunction with OxEon Energy (OxEon). The key technical activities of this project involved prime-surface interconnect design and fabrication development; supported thin-film cell structure development; stack development; stack operation demonstration; and stack cost assessment. The results of these activities are summarized in this report.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2024

Selective ion transport through hydrated micropores in polymer membranes

Abstract Ion-conducting polymer membranes are essential in many separation processes and electrochemical devices, including electrodialysis 1 , redox flow batteries 2 , fuel cells 3 and electrolysers 4,5 . Controlling ion transport and selectivity in these membranes largely hinges on the manipulation of pore size. Although membrane pore structures can be designed in the dry state 6 , they are redefined upon hydration owing to swelling in electrolyte solutions. Strategies to control pore hydration and a deeper understanding of pore structure evolution are vital for accurate pore size tuning. Here we report polymer membranes containing pendant groups of varying hydrophobicity, strategically positioned near charged groups to regulate their hydration capacity and pore swelling. Modulation of the hydrated micropore size (less than two nanometres) enables direct control over water and ion transport across broad length scales, as quantified by spectroscopic and computational methods. Ion selectivity improves in hydration-restrained pores created by more hydrophobic pendant groups. These highly interconnected ion transport channels, with tuned pore gate sizes, show higher ionic conductivity and orders-of-magnitude lower permeation rates of redox-active species compared with conventional membranes, enabling stable cycling of energy-dense aqueous organic redox flow batteries. This pore size tailoring approach provides a promising avenue to membranes with precisely controlled ionic and molecular transport functions.

Science & Technology - Other Topics↗

DOE OSTI2022

Steady-state radiochemical transport model of the molten salt reactor experiment

A radiochemical transport model of the Molten Salt Reactor Experiment (MSRE) was formulated based on the material derivative featuring system level 1-D flow providing spatial dependence accounting for multiple phenomena including radioactive decay, chemical removal, and fuel depletion across custom volume regions. Further, the steady-state version, which is based on a system of ODE's, can be solved efficiently and is useful for sensitivity studies utilizing Monte Carlo sampling. Accounting for multiple phenomena in a fully coupled model is necessary to understand the complexities of transport and distribution of radionuclides throughout the primary loop of a flowing fuel reactor.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗

DOE OSTI2022

Manning condensation in ion exchange membranes: A review on ion partitioning and diffusion models

Here, the rational design of ion exchange membranes (IEMs) is becoming more pertinent as their usage becomes broader and as their staple applications (i.e., electrodialysis, flow batteries, and fuel cells) improve in commercial viability. Such efforts would be catalyzed by an improved fundamental understanding of ion transport in IEMs. This review discusses recent progress in modeling ion partitioning and diffusion in IEMs in an effort to relate IEM performance metrics to fundamental membrane properties over which researchers and membrane manufacturers possess direct and sometimes precise control. Central focus is given to the Donnan-Manning model for ion partitioning and the Manning-Meares model for ion diffusion in IEMs. These two frameworks, which are derived from Manning's counter-ion condensation theory for polyelectrolyte solutions, have been widely used within the IEM literature since their recent introduction. To explore this topic, the mathematical derivation of both models is revisited, followed by a survey of experimental and computational discussions of counter-ion condensation in IEMs. Alternative models which fulfill similar roles in predicting IEM transport properties are compared. This review concludes by highlighting the uniquely favorable positions of the Donnan-Manning and Manning-Meares models and discussing their prospects as leading predictors of IEM partitioning and diffusive properties.

25 ENERGY STORAGE↗

DOE OSTI2025

Nanoscopic Plugs Block Hydrogen Crossover in Submicron Thick Proton-Conducting SiO 2 Membranes for Water Electrolysis

Zero-gap electrolyzers based on submicron thick proton-conducting oxide membranes (POMs) represent a promising approach to increasing the efficiency of H 2 production from water electrolysis while moving away from conventional perfluorosulfonic acid (PFSA) membranes. A critical barrier to the commercialization of such electrolyzers is that the ultrathin nature of POMs, which is necessary to achieve low cell resistance, makes them more susceptible to defects that can lead to unacceptably high rates of H 2 crossover. Herein, we demonstrate an approach to mitigate this problem through selective deposition of carbon-containing silicon oxide (SiO x C y ) “nanoplugs” into the defects of submicron thick SiO 2 membranes using a facile electrochemically mediated deposition process. Selective deposition of nanoplugs within the defects was verified by multiple characterization techniques, while scanning electrochemical microscopy (SECM) was used to confirm selective plugging of H 2 -crossover hotspots associated with defects at identical locations. Thanks to the use of nanoplugs, the H 2 permeance of 250 nm thick SiO 2 membranes was reduced by 5 to 6 orders of magnitude compared to the unmodified atomic layer deposition (ALD) SiO 2 membranes while having negligible impact on the ionic resistance of the membrane. These plug-modified membranes also enabled safe and stable operation of a zero-gap full cell electrolysis cell, in contrast to cells lacking nanoplugs that produced anode effluent streams having H 2 concentrations near or exceeding the lower flammability limit (LFL) of H 2 . Furthermore, beyond water electrolysis, this defect-sealing strategy has the potential to be broadly implemented in other applications, such as fuel cells and flow batteries, offering a versatile solution to mitigate crossover-related performance losses.

ALD SiO2↗

DOE OSTI2024

Aryl ether-free polymer electrolytes for electrochemical and energy devices

Anion exchange polymers (AEPs) play a crucial role in green hydrogen production through anion exchange membrane water electrolysis. The chemical stability of AEPs is paramount for stable system operation in electrolysers and other electrochemical devices. Given the instability of aryl ethercontaining AEPs under high pH conditions, recent research has focused on quaternized aryl ether-free variants. The primary goal of this review is to provide a greater depth of knowledge on the synthesis of aryl ether-free AEPs targeted for electrochemical devices. Synthetic pathways that yield polyaromatic AEPs include acid-catalysed polyhydroxyalkylation, metal-promoted coupling reactions, ionene synthesis via nucleophilic substitution, alkylation of polybenzimidazole, and Diels–Alder polymerization. Polyolefinic AEPs are prepared through addition polymerization, ring-opening metathesis, radiation grafting reactions, and anionic polymerization. Discussions cover structure–property–performance relationships of AEPs in fuel cells, redox flow batteries, and water and CO 2 electrolysers, along with the current status of scale-up synthesis and commercialization.

25 ENERGY STORAGE↗

DOE OSTI2020

Experimental Measurements of NOx Emissions in a Rotating Detonation Engine

An experimental study of NOx emissions in a rotating detonation engine is presented in this paper. Rotating detonation engines produce a pressure gain in the combustion process which leads to increased efficiency compared to conventional constant pressure, deflagration based combustion. However, in order for rotating detonation engines to become a viable alternative to conventional combustion, they must meet NOx emissions regulations. Emissions from rotating detonation engines are not currently well understood. A parametric study was performed to determine time averaged NOx emissions in a rotating detonation engine over a range of operating conditions. The effects of inlet pre-heat, equivalence ratio, flow rate, and fuel composition are investigated.

Ferguson, Donald↗

DOE OSTI2023

Proton exchange membrane material and methods of making the same

Hydrocarbon proton exchange membranes are disclosed that are composed of a material including a hydrophobic main chain, and acidic side chains. The main chain includes a polyaryl structure that is substantially free of ether linkages and also includes a fluoromethyl substituted carbon. The acidic side chains include a hydrocarbon tether terminated by a strongly acidic group, such as a fluoroalkyl sulfonate group. Chemical stability of the material is increased by removing the ether linkages from the main chain. The hydrophobic main chain and substantially hydrophilic side chains create a phase-separated morphology that affords enhanced transport of protons and water across the membrane even at low relative humidity levels. These materials are advantageous as membranes for use in fuel cells, redox flow batteries, water hydrolysis systems, sensors, electrochemical hydrogen compressors, actuators, water purifiers, gas separators, etc.

Bae, Chulsung↗

DOE OSTI2022

A preconceptual design of an inverted Stable-Salt Reactor

This paper presents a preconceptual design of an inverted stable-salt reactor (SSR), with the unique feature that the static fuel salt is accommodated in one single bulk fuel container, while the coolant salt is circulating through the core via flow tubes penetrating the fuel container.The inverted SSR is expected to substantially decrease the capital cost compared to the state-of-the-art SSR such as the SSR-W designed by Moltex Energy, because one single gas vent at the top of the fuel container is required in the inverted SSR to prevent the leakage of the radioactive fission product gases instead of one gas vent in each of the hundreds of thousands of fuel tubes in SSR-W. In addition, the operation of the inverted SSR is largely simplified. However, numerous challenges associated with the design of the inverted SSR still remain to be overcome. Preliminary neutronics and thermal-hydraulics performance characteristics of the inverted SSR are assessed in this study. A viable core configuration of the inverted SSR is identified, and the superior characteristics of the inverted SSR, including a better neutron economy and a lower maximum fuel temperature, are demonstrated in this paper. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2022

Development of Explainable Data-Driven Turbulence Models with Application to Liquid Fuel Nuclear Reactors

Liquid fuel nuclear reactors offer innovative possibilities in terms of nuclear reactor designs and passive safety systems. Molten Salts Reactors (MSRs) with a fast spectrum are a particular type of these reactors using liquid fuel. MSFRs often involve large open cavities in their core in which the liquid fuel circulates at a high speed to transport the heat generated by the nuclear reactions into the heat exchangers. This high-speed flow yields a turbulent field with large Reynolds numbers in the reactor core. Since the nuclear power, the neutron precursor’s transport and the thermal exchanges are strongly coupled in the MSFR’s core cavity, having accurate turbulent models for the liquid fuel flow is necessary to avoid introducing significant errors in the numerical simulations of these reactors. Nonetheless, high-accuracy simulations of the turbulent flow field in the reactor cavity of these reactors are usually prohibitively expensive in terms of computational resources, especially when performing multiphysics numerical calculations. Therefore, in this work, we propose a novel method using a modified genetic algorithm to optimize the calculation of the Reynolds Shear Stress Tensor (RST) used for turbulence modeling. The proposed optimization methodology is particularly suitable for advanced liquid fuel reactors such as the MSFRs since it allows the development of high-accuracy but still low-computational-cost turbulence models for the liquid fuel. We demonstrate the applicability of this approach by developing high accuracy Reynolds-Averaged Navier–Stokes (RANS) models (averaged flow error less than 5%) for a low and a large aspect ratio in a Backward-Facing Step (BFS) section particularly challenging for RANS models. The newly developed turbulence models better capture the flow field after the boundary layer tipping, over the extent of the recirculation bubble, and near the boundary layer reattachment region in both BFS configurations. The main reason for these improvements is that the developed models better capture the flow field turbulent anisotropy in the bulk region of the BFS. Then, we illustrate the interest in using this turbulence modeling approach for the case of an MSFR by quantifying the impact of the turbulence modeling on the reactor key parameters.

42 ENGINEERING↗

DOE OSTI2024

Evaluation of flow-induced plate deflection for University of Missouri research reactor low-enriched uranium fuel element

The University of Missouri Research Reactor (MURR), located on the campus of the University of Missouri in Columbia, Missouri, is one of the six United States (U.S.) High Performance Research Reactors (USHPRR), including one critical facility, that are actively collaborating with the U.S. Department of Energy (DOE) National Nuclear Security Administration (NNSA) Office of Material Management and Minimization (M3) Reactor Conversion Program to convert from highly enriched uranium (HEU, ≥20 wt% U-235) fuel to low-enriched uranium (LEU, <20 wt% U-235) fuel. A new type of very high-density LEU fuel based on a monolithic alloy of uranium and 10 wt% molybdenum (U-10Mo) is expected to allow conversion of some USHPRR, including MURR. In the design of its fuel elements, MURR is using thin parallel curved fuel plates separated by coolant channels. In this work, fluid-structure interaction (FSI) analysis of the MURR LEU fuel element is performed at the element level (as compared to the plate level analysis), which models all components of the LEU fuel element, including fuel plates and the supporting structures. Therefore, the effect of supporting structures on the flow distribution within the element and the fuel plate deflection are evaluated. In addition to the element nominal flow rate and dimensions, the tolerances in the geometry of the coolant channel and plate thickness, the effect of a comb on plate deflection, and the uncertainty of the flow rate per element are evaluated. For the LEU fuel plates, which are thinner than the current HEU plates, the predicted plate deflection is found to be small compared to the fabrication and assembly tolerances. Thus, the FSI-induced deflections are not expected to noticeably reduce the coolant flow rate or predicted safety margins in the limiting channels for the MURR LEU fuel element. In addition to the simulation work, a hydraulic performance test of the MURR LEU fuel element is currently being planned to support conversion to the use of LEU fuel.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

Resilience of uranium mononitride/zirconium carbide composites and uranium-zirconium carbonitride in hot hydrogen for nuclear thermal propulsion

Nuclear thermal rockets require fuels capable of withstanding flowing hydrogen propellant up to 3200 K. Presently, there has not been a fuel type that reliably operates at these conditions. A promising candidate anticipated to endure this demanding environment is a ceramic-ceramic composite comprising of uranium mononitride and zirconium carbide. Further, this investigation assesses the behavior and resilience of variations of this composite and its resultant homogenized form (uranium-zirconium carbonitride) under two hot hydrogen conditions (2273 K and 3000 K). The findings revealed that composites that homogenize into UZrCN exhibit superior structural integrity in hydrogen compared to heterogeneous counterparts. Consequently, this study underscores the potential of homogenized uranium-zirconium carbonitride for enhanced performance in nuclear thermal propulsion applications.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2023

Benchmark Specifications for TREAT Tests M5, M6, and M7

Detailed information describing three TREAT tests performed on metallic fuels has been collected and organized for use as a benchmark in evaluating the performance of metallic fuel models and codes. The tests, designated M5, M6, and M7, subjected EBR-II-irradiated fuel pins to a single type of overpower transient (at prototypical conditions with full coolant flow and an exponential power rise on an 8 second period) in flowing sodium loops. Six fuel pins were tested; five were ternary (U-19Pu-10Zr) alloy fuel clad in D9 with burnup ranging from 0.8 to 9.8 at. %, and one was binary alloy fuel (U-10Zr) clad in HT9 with 2.9 at. % burnup. The information gathered from the test records is expected to be useful for pre-transient characterization of the irradiated fuel pins as well as the transient analysis of the metallic fuel when subjected to severe accident conditions. This report presents benchmark specifications for the M5, M6, and M7 TREAT tests, identifies where primary sources of benchmark-related information can be found, and includes background information to help a user of the data understand their applicability and limitations.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

Development of an In Situ Fission Gas Release Instrument for Fuel Sample Irradiations in the High Flux Isotope Reactor

Experimental measurement of gaseous fission product release with respect to temperature and burnup is a critical aspect of understanding nuclear fuel performance, validating predictive models, and qualifying new fuels. To measure this phenomenon in real-time, Oak Ridge National Laboratory has developed an instrument for measuring in situ fission gas release from small-scale fuel samples irradiated in the High Flux Isotope Reactor (HFIR). The instrument uses a continuous flow of Heover the fuel samples to sweep gaseous fission products from a sealed capsule in the HFIR Be reflector to an instrument station adjacent to the reactor. The instrument station houses two high-purity germanium (HPGe) detectors that measure decay gamma rays from fission products passing through a room temperature dwell chamber placed over the detector crystal. The sealed capsules in the reactor are designed to modulate fuel sample temperatures between 700 and 1,100°C by changing the Ar/He gas mixture surrounding the capsules during irradiation. N-type thermocouples are incorporated into the capsule housing to record real-time fuel temperatures. The capsules are heated primarily by prompt gamma rays emitted from the HFIR core with minimal heat contributions from fission in the fuel samples to minimize temperature gradients in the specimens for separate-effects characterization of the material. This paper describes modeling of time-dependent nuclear heating and fission product formation in fuel samples, thermal characteristics of the in-core capsules, and expected gaseous fission product gamma spectra at the HPGe instrument station.

Mulligan, Padhraic L [ORNL] (ORCID:000000025826540↗

DOE OSTI2020

Autoclave grid-to-rod fretting wear evaluation of a candidate cladding coating for accident-tolerant fuel

In pressurized water reactors (PWRs), water flow induced vibrations cause contact and rubbing between the fuel rods and the supporting grid, a phenomenon known as Grid-to-Rod-Fretting (GTRF). GTRF may produce progressive wear damage on the fuel claddings leading to subsequent leakage of radioactive fission products. Various accident-tolerant fuel (ATF) concepts are being developed for higher resistance to the high temperature steam and one approach is to apply a cladding coating. Here, fretting wear behavior of a candidate Cr-coating was investigated using a unique bench-scale autoclave testing rig mimicking the environment in an industrial full-assembly PWR simulator. The contact was under a realistically low load (~0.5 N) lubricated by deionized water at a temperature of 204 °C under a pressure of 20-23 bars. Results demonstrated that the Cr-coating significantly improved the cladding's wear resistance when tested against a commercial ZIRLO grid with or without pre-oxidization. In addition, the Cr-coating also reduced wear on the non-oxidized ZIRLO grid but slightly increased the wear on the pre-oxidized grid.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2022

Turbulent flow characteristics in an 84-pin rod bundle for typical and damaged spacer grids

Hexagonal rod bundles arranged in a tightly packed triangular lattice are extensively used for heat transfer and energy generation applications. Staggered spacer grids are used to maintain the structural integrity of gas-cooled fast reactor (GFR) fuel assemblies, while inducing localized turbulence in flow. Damage to these spacer grids results in a disruption of flow fields within these hexagonal fuel bundles. Experimental flow visualizations are critical to identify the differences in local flow properties that the structural damage may cause. This experimental research investigates the flow-field characteristics at a near-wall and center plane in a prototypical 84-pin GFR fuel assembly. Newly installed typical spacers and spacers subject to naturally occurring damage due to material degradation over prolonged experimentation were investigated. Velocity fields were acquired by utilizing the matched-index-of-refraction method to obtain time-resolved particle image velocimetry measurements for a Reynolds number of 12 000. Reynolds decomposition statistical results divulged differences in the time-averaged velocity, velocity fluctuations, flow anisotropy, and Reynolds stress distributions. Galilean decomposition demarcated the influence of spacer grid damage on the velocity fields. To extract turbulent structures and elucidate mechanisms of flow instabilities, proper orthogonal decomposition analysis was employed. Reduced order flow reconstructions enabled the application of vortex identification algorithms to determine the spatial and statistical characteristics of vortices generated. This research work provides unique experimental data on the spacer grid condition-dependent flow. The results offer a deeper understanding of fluid dynamics behavior to support GFR rod bundle design efforts and computational fluid dynamics model validation.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Single-phase, natural circulation annular flow measurements for cartridge loop irradiation experiments

The nuclear industry is increasingly considering cartridge-style experiments for irradiation testing of advanced reactor fuels and materials under flowing conditions. Cartridge loops do not require the extensive support infrastructure that are necessary for external flow loops and minimize the possibility of coolant solidification over the long distance from the reactor to the external facilities. However, there is a general lack of quality flow data for internally heated fluids in an annular configuration representative of a cartridge-type irradiation experiment, particularly one with natural circulation. To address this data need, a series of experiments was conducted to measure the natural circulation flow rates of pressurized water in a sealed, internally heated vessel with annular flow conditions that represent a molten salt or sodium cartridge loop. Temperatures and flow rates were measured under steady-state and transient conditions. Here, this paper describes the facility, methods, and results of the experiments, including the determination of nondimensional parameters. A simple 1D model of the natural convection flow rates agrees well with the experimental results. Applying this model to simulate a liquid salt cartridge experiment predicts that natural circulation flow might be able to provide liquid salt Reynolds numbers similar to those of some molten salt reactor concepts at relevant power densities.

42 ENGINEERING↗