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DOE OSTI2021

Nuclear Data Assessment for Advanced Reactors

Advanced reactor concepts being developed throughout the industry are significantly different from light-water reactor (LWR) designs with respect to geometry, materials, and operating conditions, and consequently, with respect to their reactor physics behavior. Given the limited operating experience with non-LWRs, the accurate simulation of reactor physics and the quantification of associated uncertainties are important for ensuring that the nuclear design for advanced reactor concepts include appropriate margins. Nuclear data are a major source of input uncertainties in reactor physics analysis. As part of a project sponsored by the US Nuclear Regulatory Commission at Oak Ridge National Laboratory (ORNL), key nuclear data relevant to reactor safety analysis in selected advanced reactor technologies were identified, and their impacts on important key figures of merit were assessed based on (1) a review of available advanced reactor specifications, (2) analysis of previous studies performed at ORNL and other research institutions, and (3) sensitivity and uncertainty analyses performed for six selected benchmarks—three experimental and three computational—to quantify the impacts of the identified key nuclear data on several key metrics. This report summarizes the key nuclear data—nominal data and nuclear data uncertainties— considering the most important nuclear reactions in the fuel and in various materials for the moderator, coolant, and structure of the considered advanced reactors.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2024

Scale effects on core design, fuel costs, and spent fuel volume of pressurized water reactors

The desire to improve the economic competitiveness and deployment pace of nuclear energy through modularization, manufacturing, and series production had led to the development of smaller size reactors. As the standard 17x17 fuel technology is mainly maintained in the pressurized water reactors (PWRs) category, this translates into a lower number of fuel assemblies in the core and sometimes a reduced fuel height. To assess the impact of such scale change in core design on fuel cycle cost and spent fuel volume, a scoping analysis tool is developed based on infinite lattice calculations, leakage, fuel management reduced models, and levelized unit cost of electricity (LCOE) estimate. As such, cost dynamics driven by fuel specific power, burnup, core leakage, feed, cycle length, fuel assembly height as well as uranium market data are captured with consistent set of assumptions and analysis methods. A selection of 5 reactor designs representative of leading PWR developers is assessed and compared. Pursuing higher specific powers and optimal burnups are highlighted as the main fuel cost reduction drivers, nevertheless, practical limitations and opportunities must be evaluated to establish the feasibility of such enhanced fuel operation. In consequence, a detailed core design is performed using SIMULATE3 code for 5 PWR variations including natural and forced coolant circulation modes, two reactor scales, power densities of 73, 112, and 123 kW/l and higher discharge burnups. Design and optimization are performed at the lattice level, for the reflector, and at the core loading level. Satisfactory steady-state operation including power distribution, coolant operating limits, and reactivity requirements are analyzed and reported in this paper. The fuel economics of the detailed core designs confirm the scoping analysis findings. Despite the unlocked power uprates in small PWRs, the achievable burnup for a given fuel specific power requires more enrichment and shorter fuel height results in higher fabrication costs per mass of fuel, which makes scaling down core size a more expensive endeavor on the fuel cycle front. Spent fuel volumes are reported for the PWRs designed in this paper. Furthermore, these volumes are driven by the core average discharge burnup regardless of the scale in consideration. Additional cost and core performance aspects related to heavy reflector gains, fuel-reflector substitution, and disposal cost policy in the U.S. are examined.

42 ENGINEERING↗

DOE OSTI2021

Oil and Gas Produced Water Reuse: Opportunities, Treatment Needs, and Challenges

Advances in water treatment technologies paired with potential restrictions on oil and gas (O&G) produced water disposal could incentivize the beneficial reuse of treated produced water in the O&G industry. However, the remote nature of O&G operations limits the applicability of many of these solutions, which may be spatially inefficient, require operator supervision, or are ill-suited for the complex nature of produced water. Furthermore, the responsible, sustainable reuse of produced water as an alternative water source requires standardized analytical techniques for characterizing and determining the toxicity of treated produced water and improving our understanding of the fate and transport of various constituents. In the past decade, we made little progress in economically treating produced water for beneficial reuse outside of oilfield operations; the sole major breakthrough has been in the development of salt-tolerant fracturing chemicals that allow for reuse of produced water for fracking operations. Guided research should assist in the development of fit-for-purpose solutions to maximize the reuse of treated produced water. This is exemplified by the case studies presented here that detail currently operating treatment facilities for reclamation and reuse of produced water.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

NASA NTRS1999

A Cooperative Human-Adaptive Traffic Simulation (CHATS)

NASA is considering the development of a Cooperative Human-Adaptive Traffic Simulation (CHATS), to examine and evaluate performance of the National Airspace System (NAS) as the aviation community moves toward free flight. CHATS will be specifically oriented toward simulating strategic decision-making by airspace users and by the service provider s traffic management personnel, within the context of different airspace and rules assumptions. It will use human teams to represent these interests and make decisions, and will rely on computer modeling and simulation to calculate the impacts of these decisions. The simulation objectives will be to examine: 1. evolution of airspace users and the service provider s strategies, through adaptation to new operational environments; 2. air carriers competitive and cooperative behavior; 3. expected benefits to airspace users and the service provider as compared to the current NAS; 4. operational limitations of free flight concepts due to congestion and safety concerns. This paper describes an operational concept for CHATS, and presents a high-level functional design which would utilize a combination of existing and new models and simulation capabilities.

Phillips, Charles T.↗

NASA NTRS2017

Robust Targeting for the Smartphone Video Guidance Sensor

The Smartphone Video Guidance Sensor (SVGS) is a miniature, self-contained autonomous rendezvous and docking sensor developed using a commercial off the shelf Android-based smartphone. It aims to provide a miniaturized solution for rendezvous and docking, enabling small satellites to conduct proximity operations and formation flying while minimizing interference with a primary payload. Previously, the sensor was limited by a slow (2 Hz) refresh rate and its use of retro-reflectors, both of which contributed to a limited operating environment. To advance the technology readiness level, a modified approach was developed, combining a multi-colored LED target with a focused target-detection algorithm. Alone, the use of an LED system was determined to be much more reliable, though slower, than the retro-reflector system. The focused target-detection system was developed in response to this problem to mitigate the speed reduction of using color. However it also improved the reliability. In combination these two methods have been demonstrated to dramatically increase sensor speed and allow the sensor to select the target even with significant noise interfering with the sensor, providing millimeter level precision at a range of two meters with a 1U target.

Carter, C.↗

NASA NTRS2017

Robust Targeting for the Smartphone Video Guidance Sensor

The Smartphone Video Guidance Sensor (SVGS) is a miniature, self-contained autonomous rendezvous and docking sensor developed using a commercial off the shelf Android-based smartphone. It aims to provide a miniaturized solution for rendezvous and docking, enabling small satellites to conduct proximity operations and formation flying while minimizing interference with a primary payload. Previously, the sensor was limited by a slow (2 Hz) refresh rate and its use of retro-reflectors, both of which contributed to a limited operating environment. To advance the technology readiness level, a modified approach was developed, combining a multi-colored LED target with a focused target-detection algorithm. Alone, the use of an LED system was determined to be much more reliable, though slower, than the retro-reflector system. The focused target-detection system was developed in response to this problem to mitigate the speed reduction of using color. However, it also improved the reliability. In combination these two methods have been demonstrated to dramatically increase sensor speed and allow the sensor to select the target even with significant noise interfering with the sensor, providing millimeter level accuracy at a range of two meters with a 1U target.

Carter, Christopher↗

NASA NTRSDate not supplied

Validation of Transient Spacecraft Refueling Model with Gateway Breadboard Test Data

The ability to refuel spacecraft on-orbit is a key enabling technology for deep space human exploration. On-orbit refueling requires priming a pressurized liquid propellant from a source tank into fluid transfer lines at vacuum conditions, which could result in excessive surge pressures beyond the system’s qualified operating limits and potentially damage hardware. Another source of potentially damaging surge pressures is the water hammer transient that occurs when the isolation valves are closed to pause or end the refueling operation. Therefore, it is imperative to employ numerical models during the development of flight hardware to parametrically characterize system performance over a wide range of operating conditions to minimize the risk of exceeding pressure limits during flight. Since rapid pressure transients can be difficult to model accurately, it is important to validate those models with test data. As part of the Gateway bipropellant refueling system development, a simplified fluidic breadboard system was created using water as a simulant for fuel to support early program risk reduction of refueling operations. The objectives of breadboard testing were to gather performance data to characterize and demonstrate critical refueling operations and to validate numerical models that can be extended to predicting flight system performance. A description of the breadboard test article and the results of numerical model validation is presented. The model is shown to have very good agreement with test data.

Refueling↗

DOE OSTI2025

Rheology and engine performance of very low sulfur fuel oil blended with 10% fast pyrolysis and hydrothermal liquefaction oils in a 2-stroke crosshead engine

The performance and emissions for a downscaled single-cylinder 2-stroke crosshead engine were determined for a very low sulfur fuel oil (VLSFO) when blended with 10 wt.% fast pyrolysis (FP) or hydrothermal liquefaction (HTL) bio-intermediates. The FP and HTL oils were derived from biomass and were observed to contain lower molecular weight (MW) hydrocarbons than neat VLSFO (which was evaluated as a baseline comparison). The addition of either biofuel reduced the overall viscosity of the VLSFO. Aging tests at 50, 90, and 120°C showed that the dynamic viscosity of VLSFO increased with exposure time up to two weeks. Similar trends were observed for the FP and HTL blends, but a pronounced spike in viscosity occurred for these fuels during the early period of exposure. None of the viscosity increases exceeded the operational limits of fuel system pumps. Engine performance studies were conducted under low, medium and high load operational settings. The relative performance of the test fuels was highly dependent on operating condition. In general, the engine results for the three test fuels were similar, but modest improvements in brake thermal efficiency and brake specific fuel consumption were observed, which may be attributed to the heightened reactivity of low molecular weight fraction of the FP and HTL oils.

09 BIOMASS FUELS↗

DOE OSTI2023

Investigation of oxygen ion mobility through Zr x Ta 2 O 2x+5 (ZTOx) and Hf 6 Ta 2 O 17 (HTO) at elevated temperatures

Thermal Protection Systems (TPS) allow for technology to withstand high heat, which is especially critical for aerospace applications. As technology advances, better TPS are required to keep up with more extreme operating temperatures. Ultra-High Temperature Ceramics (UHTCs) are of interest because of their high melting points above 3000°C, but they suffer from oxidation when exposed to the atmosphere. A standard remedy to prevent oxidation is the use an oxide coating to shield from oxygen in the atmosphere while still allowing high operating temperatures and thermal cycling. However, standard oxide coatings such as yttria stabilized zirconia (YSZ) have limited operating temperatures before they allow oxygen to diffuse into the substrate material. A recently proposed alternative material has the formula A 6 B 2 O 17 (A: Zr or Hf) (B: Ta or Nb). In this study, determination of the oxygen protection ability of Hf 6 Ta 2 O 17 (HTO), Zr 6 Ta 2 O 17 (ZTO6), and various Zr x Ta 2 O 2x+5 (ZTOx) was determined using Electrochemical Impedance Spectroscopy (EIS). Optimal synthesis and sintering conditions were determined for ZTO6 and several of its ZTO variations. Activation energy for oxygen mobility was also determined. The importance of ball milling was found to be crucial to achieve high sintering density with these ceramics. The sintering study revealed that the ideal temperature of the ZTO variations increased with increased Zr/Ta ratio in the formulation. It was determined that both HTO and the ZTO variations conduct oxygen ions less than current ceramic coatings such as YSZ, with HTO conducting the least, with results confirming the validity of both HTO and ZTO materials as candidates for TPS coatings based on their low oxygen ion conductivity.

36 MATERIALS SCIENCE↗

NASA NTRS1972

Wind tunnel investigation of a large scale 35 deg swept wing jet transport model with an external blowing triple slotted flap

An investigation was conducted to determine the aerodynamic characteristics of a large-scale subsonic jet transport model with an externally jet-augmented flap system that would augment lift and provide direct-lift control. The model had a 35 deg swept wing of aspect ratio 7.82 and two side-by-side engines mounted on a single pylon under each wing close to the fuselage. The lift of the flap system was augmented by jet engine exhaust impingement on the triple-slotted flap surfaces. The rearmost flap provided direct lift control. Results were obtained for several combinations of flap deflections at gross thrust coefficients from 0 to 2.0. Three-component longitudinal data are presented with four engines operating. Limited longitudinal and lateral data are presented for asymmetric and symmetric thrust conditions with three engines operating. For the same overall flap deflection, lift coefficient and maximum lift coefficient were improved 13 and 7 percent compared to coefficients obtained with a double-slotted flap configuration. A maximum lift coefficient of 6.3 was obtained at a gross thrust coefficient of 2.0. At the same flap deflection lateral and directional trim moment requirements with an engine inoperative were reduced 55 and 33 percent, respectively, compared to those with the engines located farther outboard on the wing. Trim moment requirements in pitch were also reduced significantly. However, pitching-moment instability occurred and increased with gross thrust coefficient.

Aoyagi, K.↗

NASA NTRS1995

Investigation of cleanliness verification techniques for rocket engine hardware

Oxidizer propellant systems for liquid-fueled rocket engines must meet stringent cleanliness requirements for particulate and nonvolatile residue. These requirements were established to limit residual contaminants which could block small orifices or ignite in the oxidizer system during engine operation. Limiting organic residues in high pressure oxygen systems is particularly important. The current method of cleanliness verification used by Rocketdyne requires an organic solvent flush of the critical hardware surfaces. The solvent is filtered and analyzed for particulate matter, followed by gravimetric determination of the nonvolatile residue (NVR) content of the filtered solvent. The organic solvents currently specified for use (1,1,1-trichloroethane and CFC-113) are ozone-depleting chemicals slated for elimination by December 1995. A test program is in progress to evaluate alternative methods for cleanliness verification that do not require the use of ozone-depleting chemicals and that minimize or eliminate the use of solvents regulated as hazardous air pollutants or smog precursors. Initial results from the laboratory test program to evaluate aqueous-based methods and organic solvent flush methods for NVR verification are provided and compared with results obtained using the current method. Evaluation of the alternative methods was conducted using a range of contaminants encountered in the manufacture of rocket engine hardware.

Fritzemeier, Marilyn L.↗

NASA NTRS1994

Investigation of Cleanliness Verification Techniques for Rocket Engine Hardware

Oxidizer propellant systems for liquid-fueled rocket engines must meet stringent cleanliness requirements for particulate and nonvolatile residue. These requirements were established to limit residual contaminants which could block small orifices or ignite in the oxidizer system during engine operation. Limiting organic residues in high pressure oxygen systems, such as in the Space Shuttle Main Engine (SSME), is particularly important. The current method of cleanliness verification for the SSME uses an organic solvent flush of the critical hardware surfaces. The solvent is filtered and analyzed for particulate matter followed by gravimetric determination of the nonvolatile residue (NVR) content of the filtered solvent. The organic solvents currently specified for use (1, 1, 1-trichloroethane and CFC-113) are ozone-depleting chemicals slated for elimination by December 1995. A test program is in progress to evaluate alternative methods for cleanliness verification that do not require the use of ozone-depleting chemicals and that minimize or eliminate the use of solvents regulated as hazardous air pollutants or smog precursors. Initial results from the laboratory test program to evaluate aqueous-based methods and organic solvent flush methods for NVR verification are provided and compared with results obtained using the current method. Evaluation of the alternative methods was conducted using a range of contaminants encountered in the manufacture of rocket engine hardware.

Fritzemeier, Marilyn L.↗

DOE OSTI2021

Evidence of Completion of Milestone 3: Experimental Testbed

Construction and deployment of the experimental testbed encountered scheduling delays, and completion was subsequently further delayed by curtailment of LANL operations due to the COVID–19 pandemic. Between March and October, LANL was in a state of “Limited Operations” such that only certain “mission–critical” work was performed with approximately 25% on–site staffing. In spite of this, much of the lab space preparation was executed and the five initial model house” units were constructed and installed during this period. Still, the pace of construction was impacted by difficulty in coordinating personnel and minimizing contact between workers.

24 POWER TRANSMISSION AND DISTRIBUTION↗

NASA NTRS1990

Thermal analyses of power subsystem components

The hiatus in the Space Shuttle (Orbiter) program provided time for an in-depth examination of all the subsystems and their past performance. Specifically, problems with reliability and/or operating limits were and continue to be of major engineering concern. The Orbiter Auxiliary Power Unit (APU) currently operates with electric resistance line heaters which are controlled with thermostats. A design option simplification of this heater subsystem is being considered which would use self-regulating heaters. A determination of the properties and thermal operating characteristics of these self-regulating heaters was needed. The Orbiter fuel cells are cooled with a freon loop. During a loss of external heat exchanger coolant flow, the single pump circulating the freon is to be left running. It was unknown what temperature and flow rate transient conditions of the freon would provide the required fuel cell cooling and for how long. The overall objective was the development of the thermal characterization and subsequent analysis of both the proposed self-regulating APU heater and the fuel cell coolant loop subsystem. The specific objective of the APU subsystem effort was to determine the feasibility of replacing the current heater and thermostat arrangement with a self-regulating heater. The specific objective of the fuel cell coolant subsystem work was to determine the tranient coolant temperature and associated flow rates during a loss-of-external heat exchanger flow.

Morehouse, Jeffrey H.↗

DOE OSTI2024

Interfacial Analysis of Blister Formation in U-10Mo Mini-Plates

A thorough investigation of potential failure mechanisms builds confidence in the performance of monolithic U-10wt%Mo (U-10Mo) fuel plates. The lowenriched uranium (LEU) fuel system is currently undergoing qualification as a high U-density fuel that can be used to convert United States high-performance research reactors from high-enriched uranium (HEU) operation. This will require establishing fuel operational limits such that fission products and a coolable geometry are retained, even during off-normal reactor operation conditions [1]. Such off-normal conditions can subject the fuel plates to temperatures where the internal pressure of precipitated fission gasses result in a permanent deformed, raised area of the cladding, referred to as a blister. These blisters can reduce the local coolability of a fuel plate and can even close coolant channels of a fuel assembly, so blistered plates are considered failed regardless of whether the fuel is truly breached. Historically, a marginto- failure is established through out-of-pile blister threshold testing of irradiated fuel plates. This is accomplished by incrementally heating irradiated fuel plates until blisters are observed. This reveals the temperature threshold that would have resulted in a blister if a plate experienced them at those irradiation conditions [2]. While the blister testing itself reveals the temperatures at which the cladding mechanical integrity was exceeded, a more thorough investigation of the interface evolution in proximity to formed blisters may reveal mechanisms as to the blister formation and retention of fission gases. Previous studies have explored potential underlying mechanisms in historical plates that may have been close to blistering [3]; however, this work is the first exploration of blister tested irradiated plates, fabricated by a commercial vendor—another requirement for qualification of the fuel system [1]. The Mini-plate 1 (MP-1) experiment was the first in a series of irradiation and post-irradiation examination (PIE) campaigns to qualify the U-10Mo monolithic fuel system. It consisted of commercially fabricated 25.4×101.5 mm Al-clad mini-plates with a monolithic U-10Mo foil coated in a Zr diffusion barrier. The primary MP-1 PIE campaign was previously completed. Among the suit of examinations was a blister testing campaign, where plates were incrementally annealed in 25°C increments until blisters were observed or a maximum temperature of 550°C was reached [4]. The previously blistered plates from this campaign were revisited in this work.

25228↗

NASA NTRS1985

Operational life improvement of SSME high-pressure turbopumps

The current Space Shuttle Main Engine (SSME) Phase I engine demonstrated excellent flight performance but showed limited operational life of the high-pressure fuel turbopumps (HPFTP). Design improvements, supporting analyses, and test results of the SSME Phase II development program are presented. The HPFTP improvements include reduction of turbine operating temperature by 110 to 130 R by reconstructing the seals and the flow contours; modifications of the first- and second-stage turbine blades by recontouring the shank, shotpeening the shank surface, and applying a multilayered, plasma-spray coating to the shank on the downstream side to reduce the effect of the disk coolant; and reduction of the tendency for thermal cracks in the turbine by changing weld configuration to avoid the concentration of stresses in local areas. The high-pressure oxidizer turbopump has been also modified to improve bearing life and to eliminate subsynchronous whirl.

Hale, J. R.↗

DOE OSTI2026

Scaled melter testing of alternative reductants for Low-Activity Waste vitrification: Melter feed properties and processing behavior

This study examines the use of boron nitride (BN) and coke dust as alternative reductants for low-activity waste vitrification in scaled melter systems, intended to enhance operational flexibility at the Hanford Waste Treatment and Immobilization Plant. The baseline reductant, sucrose, while widely considered advantageous for glass production rates, produces challenging off gas emissions during processing. Early crucible-scale testing indicated that BN and coke effectively control foaming and glass redox, while significantly reducing acetonitrile emissions. Both real tank waste and simulant waste melter feeds were tested with BN and coke in this study. Rheological properties for melter feeds with both reductants were within operational limits, although the particle size of coke should be controlled and sufficient agitation is necessary to ensure smooth operations. While promising for handling and reduction of emissions, both simulant melter feeds demonstrated lower average glass production rates in the simulant melter system compared with sucrose. In the radioactive system, the rates were more comparable to previously measured low activity waste feeds on the order of 1285 kg m 2 day −1 for BN and 1671 kg m −2 day −1 for coke. Further scale-up testing is required to interpret the processing rates in the context of the full scale melter systems and evaluate the cost-benefit impact of these reductants on efficiency and sustainability.

Rigby, Jessica C. [Pacific Northwest National Labo↗

NASA NTRS1977

Dynamics of high-bypass-engine thrust reversal using a variable-pitch fan

The test program demonstrated that successful and rapid forward-to reverse-thrust transients can be performed without any significant engine operational limitations for fan blade pitch changes through either feather pitch or flat pitch. For through-feather-pitch operation with a flight inlet, fan stall problems were encountered, and a fan blade overshoot technique was used to establish reverse thrust.

Schaefer, J. W.↗