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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Temperature response and brine availability to heated boreholes in bedded salt

Abstract There is a growing need for disposal of high‐level nuclear waste. To reduce uncertainty associated with brine availability to repository excavations in salt formations, a collaboration between Sandia, Los Alamos, and Lawrence Berkeley National Laboratories is performing a series of borehole‐scale coupled process tests. Here, we report on the first round of the Brine Availability Test in Salt (BATS) project, a “shakedown” experiment called Phase 1s. Experimental testing included placing a resistive heater, a 260‐W radiative heater, and a 750‐W radiative heater within previously drilled horizontal boreholes at the Waste Isolation Pilot Plant (WIPP) while monitoring temperature and water inflow. The experiments successfully achieved the targeted temperature of 120 °C when using the 750‐W radiative heater. Simulations using FEHM (Finite Element Heat and Mass transfer code) and TOUGH‐FLAC (Transport Of Unsaturated Groundwater and Heat–Fast Lagrangian Analysis of Continua) were able to accurately predict the coupled thermo–hydro–mechanical–chemical response of salt, matching the observed temperature and brine production. Due to the extremely low permeability of salt, these systems take many years to reach steady state when perturbed by mining activities. Long‐term numerical simulations are used to develop the initial pressure and saturation conditions. The inclusion of a damaged rock zone with higher permeability around the borehole also affects the saturation and pressure distributions and plays an important role in dissipating the potential for thermal pressurization. Knowledge gained from this round of experimentation and simulation will be used to conduct the next BATS project experiment in new boreholes at WIPP.

58 GEOSCIENCES↗
DOE OSTI2020

Utilizing Temperature and Brine Inflow Measurements to Constrain Reservoir Parameters During a Salt Heater Test

Brine availability in salt has multiple implications for the safety and design of a nuclear waste storage facility. Brine availability includes both the distribution and transport of brine through a damaged zone around boreholes or drifts excavated into the salt. Coupled thermal, hydrological, mechanical, and chemical processes taking place within heated bedded salt are complex; as part of DECOVALEX 2023 Task E this study takes a parsimonious modeling approach utilizing analytical and numerical one-dimensional simulations to match field measurements of temperature and brine inflow around a heater. The one-dimensional modeling results presented arrive at best-fit thermal conductivity of intact salt, and the permeability and porosity of damaged salt of 5.74 W/m∙K, 10 –17 m 2 , and ≈ 0.02, respectively.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2026

Providing Thermal Stability for an Exascale Supercomputer: A Case Study of Frontier's Cooling System

High performance computing (HPC) systems frequently produce large dynamic power swings, even under typical operating conditions, that can present a significant challenge for their direct-liquid cooling systems. Further, the primary cooling loops that must remove this waste heat have response times measured in minutes while the underlying HPC component thermal stress is measured in seconds. The per-socket power demand for both compute processing units (CPUs) and graphic processing units ( GPUs) continues to increase with each successive generation while case temperatures are declining. New HPC systems are expected to exacerbate the challenge of these dynamic power swings and the impact on effective and timely cooling systems. This paper describes the cooling and controls system for Oak Ridge National Laboratory’s Frontier Supercomputer, the first sustained exascale system, as a case study for this situation. The cooling and control system for Frontier demonstrates specific success, but with a number of trade-offs and decisions that suggest further design and operating optimizations for the community at large to consider.

42 ENGINEERING↗
DOE OSTI2021

Recent Cryogenic Carbon Capture™ Field Test Results

Sustainable Energy Solutions (SES) has been developing Cryogenic Carbon Capture™ (CCC) since 2008. In that time, two processes have been developed, the External Cooling Loop and Compressed Flue Gas CCC processes (CCC-ECL and CCC-CFG, respectively). The CCC-ECL process cools the flue gas with an external refrigerant loop. This process currently captures up to 1 tonne of CO2 per day (TPD). SES has tested CCC-ECL on real flue gas slip streams from subbituminous coal, bituminous coal, biomass, natural gas, shredded tires, and municipal waste fuels at field sites that include utility power stations, heating plants, cement kilns, and pilot-scale research reactors. The CO2 concentrations from these tests ranged from 5 to 22% on a dry basis. CO2 capture ranged from 95-99+% during these tests. Several other condensable species were also captured including NO2, SO2 and PMxx at 95+%. NO was also captured at a modest rate. The CCC-CFG process has been scaled up to a 0.25 ton per day system. This system has been tested on real flue gas streams including subbituminous coal, bituminous coal, and natural gas at field sites that include utility power stations, heating plants, and pilot-scale research reactors. CO2 concentrations for these tests ranged from 5 to 15% on a dry basis. CO2 capture ranged from 95-99+% during these tests. Several other condensable species were also captured including NO2, SO2, and PMxx at 95+%. NO was also captured at 90+%. Hg capture was also verified and the resulting effluent from CCC-CFG was below a 1ppt concentration. This paper will focus on discussion of the capabilities of CCC generally, the results of CCC-ECL field testing, and future steps surrounding the development of this technology. Test results that will be presented have been collected during 9 months of testing at a commercial power plant under funding from the US Department of Energy (DOE) and the host utility. Testing of one of the systems at a commercial cement plant in the United States will also be discussed. During this testing, the system captured CO2 from the cement plant and stored the CO2 in pressurized tanks. These tanks were provided to a partner company that later used the CO2 in a CO2 utilization demonstration. The CO2 was utilized to cure concrete manufactured using cement from the same plant where the CO2 was captured. This integrated capture and utilization demonstration was the first time that the cement industry has shown in the field that it can sequester its CO2 emissions in its main product stream. This represents a potential game changing solution for industrial CO2 emissions. Operational data and host-site feedback indicate that the CCC process is ideally suited for deployment into a variety of commercial environments. A few areas of de-risking remain to make sure the technology can meet very strict industrial reliability standards. These areas of de-risking are identified and discussed. The product CO2 is shown to meet specification for many uses including industrial and merchant applications. The technology is nearing readiness for deployment at commercial scale and several initial target markets have been identified.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2023

Automated Laboratory Kilogram-Scale Graphene Production from Coal

The flash Joule heating (FJH) method converts many carbon feedstocks into graphene in milliseconds to seconds using an electrical pulse. This opens an opportunity for processing low or negative value resources, such as coal and plastic waste, into high value graphene. Here, in this work, a lab-scale automation FJH system that allows the synthesis of 1.1 kg of turbostratic flash graphene from coal-based metallurgical coke (MC) in 1.5 h is demonstrated. The process is based on the automated conversion of 5.7 g of MC per batch using an electrical pulse width modulation system to conduct the bottom-up upcycle of MC into flash graphene. This study then compare this method to two other scalable graphene synthesis techniques by both a life cycle assessment and a technoeconomic assessment.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2024

Compositional Variation Tests on DuraMelter 100 with LAW Sub-Envelope C1 Feed (LAWC22) Glass in Support of the LAW Pilot Melter (Final Report)

The Vitreous State Laboratory at The Catholic University of America (VSL) is developing and testing glass formulations for RPP-WTP waste envelopes to provide data to meet the RPP-WTP contract requirements and to support system design activities. That work is based upon small-scale batch melts (“crucible melts”) using waste envelope simulants. Selected formulations have also been tested in small-scale continuously-fed joule-heated melters (DM10 and DM100 systems) and, ultimately, in the LAW Pilot Melter. Such melter tests provide information on key process factors such as feed processing behavior, dynamic effects during processing, sulfate incorporation, processing rates, off-gas amounts and compositions, foaming control, etc., that cannot be reliably obtained from crucible melts. This sequential scale-up approach in the vitrification testing program ensures that maximum benefit is obtained from the more costly pilot-scale tests and that the most effective use is made of that resource. The principal objective of the work described in this report was to collect the necessary small-scale melter test data with a LAW Sub-Envelope C1 waste simulant in order to support the next series of tests with the same melter feed on the LAW Pilot Melter. This work was conducted under a corresponding Test Specification and Test Plan.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2022

West Virginia University Industrial Assessment Center (Final Progress Report)

The Industrial Assessment Center at West Virginia University has been successful in workforce development, and in generation of energy savings for manufacturing facilities during the period 2016 to 2021. Graduate and undergraduate students have benefited from energy assessment experience and most of them have found good positions as energy engineers and analysts in the industrial sector. Several peer reviewed research papers in archival journals as well as conference papers on the topic of energy engineering and assessment have been published. The implemented energy savings for manufacturing facilities have been significant in the areas of lighting, compressed air, process heating, steam, HVAC, chillers and cooling towers, and motors. In addition, water use reduction, smart manufacturing applications to save energy, cyber security evaluation, energy management, productivity improvements and waste reduction opportunities that lead to energy intensity reductions have been explored. The students have obtained an opportunity to interact with energy efficiency and productivity improvement professionals at various conferences and workshops and their research has generated important results. In summary, the West Virginia University Industrial Assessment Center (WVU-IAC) has fulfilled its mission in regard to workforce development, energy efficiency for manufacturing facilities, and laid a strong platform enhancing sustainability through reductions in carbon emissions achieved through energy efficiency and energy management initiatives and reductions in water usage and waste reduction. During the project period (2016-2021) the WVU-IAC has made numerous energy efficiency, water use reduction, waste reduction, and productivity improvement recommendations, a significant number of them having been implemented by the manufacturing facilities. The research adds significant understanding to the area of energy efficiency, water and waste reduction, and productivity improvement. The technical effectiveness and economic feasibility of the methods and techniques investigated and demonstrated through this project have been exemplary, resulting in significant recommended and implemented resource savings and reductions in carbon emissions. The project has been of significant benefit to the public owing to replication of results within the industrial sector, thus reducing operating costs for businesses that result in increase of growth and employment, as well as community benefits in terms of reductions in carbon emissions.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Assessment of Active Metal Removal from Pyroprocessing Salt by Electrodeposition

Active metals present in used nuclear fuel dissolve into the salt during pyroprocessing, but are not recovered during electrorefining or drawdown operations due to their chemical stability in the salt. The accumulation of 137 Cs and 90 Sr in process salt over time increases the heat load and ionizing radiation level of the salt such that it must be replaced frequently, resulting in a significant amount of salt waste. An effective means of removing active metals from the molten salt to enable recycle of the electrolyte (e.g., LiCl/KCl) would increase the efficiency of pyroprocessing and decrease the volume of salt waste requiring disposal.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Paper #50 Preliminary Sizing of Active Magnetic Bearings for sCO2 Waste-Heat Recovery Application

The team of Southwest Research Institute (SwRI) and GE Vernova (GE) is executing a project developing conceptual designs of high-temperature active magnetic bearings (AMBs) for sCO2 machinery applications. The goals of the project are to develop conceptual designs for radial and thrust AMBs capable of operating in sCO2 environments up to 1000°F. A waste-heat recovery (WHR) application with hermetic machinery is used as a reference case to apply AMBs. This application was previously investigated to compare hermetic machinery enabled by process-lubricated bearings and high-speed motors/generators with traditional machinery configurations using oil-lubricated bearings, gearboxes, and grid-frequency electric machines. In this paper, AMBs are sized for the WHR application machinery. Load capacity estimates are made using first-principle-derived formulas that consider operation at elevated temperatures. Estimates of linearized AMB system coefficients are also made to aid future controller development. Rotor models are developed that account for AMB rotor geometry and housing space requirements. Rotordynamics studies are performed to identify reasonable target values for closed-loop AMB stiffness and closed-loop AMB damping. These target values will be used in future control studies.

Lipham, Robert↗
DOE OSTI2020

Evaluation of Nuclear Spent Fuel Disposal in Clay-Bearing Rock - Process Model Development and Experimental Studies

The DOE R&D program under the Spent Fuel Waste Science Technology (SFWST) campaign has made key progress in modeling and experimental approaches towards the characterization of chemical and physical phenomena that could impact the long-term safety assessment of heat-generating nuclear waste disposition in deep clay/shale/argillaceous rock. International collaboration activities such as heater tests and postmortem analysis of samples recovered from these have elucidated key information regarding changes in the engineered barrier system (EBS) material exposed to years of thermal loads. Chemical and structural analyses of sampled bentonite material from such tests has as well as experiments conducted on these are key to the characterization of thermal effects affecting bentonite clay barrier performance and the extent of sacrificial zones in the EBS during the thermal period. Thermal, hydrologic, and chemical data collected from heater tests and laboratory experiments has been used in the development, validation, and calibration of THMC simulators to model near-field coupled processes. This information leads to the development of simulation approaches (e.g., continuum vs. discrete) to tackle issues related to flow and transport at various scales of the host-rock and EBS design concept. Consideration of direct disposal of large capacity dual-purpose canisters (DPCs) as part of the back-end SNF waste disposition strategy has generated interest in improving our understanding of the effects of elevated temperatures on the EBS design. This is particularly important for backfilled repository concepts where temperature plays a key role in the EBS behavior and long-term performance. This report describes multiple R&D efforts on disposal in argillaceous geologic media through development and application of coupled THMC process models, experimental studies on clay/metal/cement barrier and host-rock (argillite) material interactions, molecular dynamic (MD) simulations of water transport during (swelling) clay dehydration, first-principles studies of metaschoepite (UO 2 corrosion product) stability, and advances in thermodynamic plus surface complexation database development. Drift-scale URL experiments provides key data for testing hydrological-chemical (HC) model involving strong couplings of fluid mixing and barrier material chemical interactions. The THM modeling focuses on heater test experiments in argillite rock and gas migration in bentonite as part of international collaboration activities at underground research laboratories (URLs). In addition, field testing at an URL involves in situ analysis of fault slip behavior and fault permeability. Pore-scale modeling of gas bubble migration is also being investigated within the gas migration modeling effort. Interaction experiments on bentonite samples from heater test under ambient and elevated temperatures permit the evaluation of ion exchange, phase stability, and mineral transformation changes that could impact clay swelling. Advances in the development, testing, and implementation of a spent nuclear fuel (SNF) degradation model coupled with canister corrosion focus on the effects of hydrogen gas generation and its integration with Geologic Disposal Safety Assessment (GDSA). GDSA integration activities includes evaluation of groundwater chemistries in shale formations.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2022

Solvent-driven aqueous separations for hypersaline brine concentration and resource recovery

Solvent-driven separation processes can extract water and high-value minerals from high salinity or contaminated brines, simultaneously reducing the environmental impact of brine disposal and enabling resource recovery. The efficient dewatering of hypersaline brines is essential for the sustainable minimal and zero liquid discharge processing of industrial wastewaters. Fractional crystallization can selectively extract ions from contaminated waste streams, allowing critical materials to be recycled, including transition and lanthanide metals required for renewable energy generation and storage. Mass transfer in solvent-driven water extraction occurs across a liquid–liquid interface, eliminating the scaling and fouling of membrane and heat exchanger surfaces and limiting the need for extensive pretreatment. Solvent-driven fractional crystallization can leverage sequential treatment and control of process conditions to rapidly recover salts without requiring evaporation of water. Despite promising applications, the principles and potential of solvent-driven aqueous separations remain poorly understood. This critical review explores the opportunities presented by solvent-based aqueous separations from the molecular to process scale, evaluating the chemistry of solvation and system design in the broader context of desalination, resource recovery, water softening, and mineral production.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

DECOVALEX-2023 Task E Specification (Rev. 0)

This report is the Task E specification (Revision 0) for DECOVALEX-2023. Task E is focused on understanding thermal, hydrological, mechanical and chemical (THMC) processes, especially related to predicting brine migration in heated salt. The main test case being used is the ongoing Brine Availability Test in Salt (BATS) heater test located underground at the Waste Isolation Pilot Plant (WIPP) in Carlsbad, New Mexico. This report provides short motivational background, a summary of relevant experiments and data, and a step-by-step plan for the analysis by the teams participating in Task E (Rev. 0 includes detailed description of steps 0 and 1). This document will be revised, and more detail will be added to later steps during DECOVALEX-2023.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Additively Manufactured Solid-State Luminaire

This project addresses several key barriers to wide-spread adoption of additive manufacturing (AM) technology as applied to solid state lighting luminaires. The solution will utilize cutting edge AM approaches for integrating structure with thermal management solutions, electronic functionality, and optics. The research team (Eaton, Lighting Research Center (LRC) at Rensselaer Polytechnic Institute, Xerox Research Centre of Canada (XRCC)) utilize their AM and lighting expertise to investigate breakthrough manufacturing approaches that will significantly reduce cost, eliminate manufacturing process waste, and improve luminaire efficacy. The team has identified critical areas of research and proposed novel technical approaches to achieve these goals. Key areas of focus in Budget Period 1 (BP1) of the project quantified the impact of applying AM methodologies to the main, discrete subsystem components (Heat Sink, Housing, Optics, Electronics). Budget Period 2 (BP2) research explored similar impact on a fully integrated, AM modular luminaire concept. Final Achievement of the Target Metrics for the project are as follows: Material Reduction: achieved > 57.45% (target is 50%) Manufacturing Process: achieved > 51% reduction (target is 50%) Application Efficacy: achieved 126 lm/W (target is 130 lm/W) First Cost vs Baseline: demonstrated 49% improvement in project timing, 59% improvement in man hour savings and 89% worse BOM costs (due to deficiencies in current “state of the art” equipment). The BOM costs improve to 53% savings if state of the art processes and equipment could have been used.

3D Printing↗
DOE OSTI2025

A heat and mass transfer model for evaluation of damaged cesium chloride radiological sources

Radiological sources are vital to many applications, and typically contain byproducts from waste streams which decay over time to form complex mixtures of elements. Daughter products resulting from these decay processes can introduce complicating factors to the integrity and safety of the vessel that contains the radiological material. Sources containing cesium 137 ( 137 Cs) are of particular interest, because the decay of this isotope produces barium metal which reacts readily and exothermically with oxygen. This work employs physics-based numerical tools to examine the thermal response of a radiological source containing a mixture of cesium and barium in the event that vessel walls are damaged and atmospheric gases contact source material. A parametric study was conducted to determine the sensitivity of the response to various factors, including vessel geometry, source material age, the degree of vessel damage, and other parameters. Here, it was found that the peak temperatures that occurred within the source material strongly depend on these parameters, particularly vessel geometry and age, which determine whether a breach would be a relatively minor accident or a catastrophic incident. Finally, the model’s sensitivity to uncertain thermophysical properties is discussed.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
DOE OSTI2024

Liquid Fed Pyrolysis of Polyethylene Films: Environmental and Economic Assessments of Co-located and Remotely-Located U.S. Facilities

Polyethylene (PE) films are one of the highest production volume plastic products, but they have very low recycling rates. A novel liquid fed pyrolysis process (LFP) is an advanced recycling technology that can be applied to waste PE films. In this work, two environmental and six economic metrics were evaluated for the LFP process under different scenarios with a baseline production capacity of 8,400 Metric Tons (MT) of pyrolysis products/year. The studied scenarios considered process improvement such as heat integration, changing the final product yields, and location of the LFP process facility (i.e., co-located at a petrochemical facility or located remotely). Results show that producing refined pyrolysis wax in remote areas is the most environmentally favorable and profitable scenario. The LFP process co-located at a petrochemical facility and selling only liquid and gaseous pyrolysis products to the facility would require a capacity of >18,000 MT/year to be economically feasible. Heat integration led to greenhouse gas emission savings of at least 14%, 19%, and 32% for the pyrolysis oil, gas, and wax products, respectively. Fianlly, the LFP process in remote and less populated locations producing a high yield of refined wax may be a feasible solution for increasing recycling rates of PE films.

Advanced recycling↗
DOE OSTI2025

Uncertainty propagation and sensitivity analysis for constrained optimization of nuclear waste vitrification

Abstract The vitrification of high‐level waste (HLW) by heating a mixture of glass‐forming chemicals (GFCs) with the waste can be improved using a constrained optimization problem. This study explores how different uncertainty propagation (UP) methods implemented with the optimization process can affect the glass formulation of nuclear waste glasses. UP is the effort of propagating uncertain inputs through a system to understand and quantify output distributions. Uncertainty intervals are crafted from output distributions to inform the optimization algorithm. UP is often implemented with Monte Carlo (MC) sampling for large nonlinear systems, which can be difficult to implement within a constrained optimization algorithm that requires derivative information. Other UP methods often used for optimization under uncertainty (OUU) can be designed to work within an established constrained optimization framework. Methods of UP are evaluated in this study including iterative sampling approaches, first‐order approximations, and surrogate modeling with machine learning (ML). A method of dimensional reduction based on global sensitivity analysis is introduced to support the UP methods for the large dimensionality of the problem. Analytical UP methods able to achieve similar optimums 10 times faster than the baseline MC approach, and produce 93.9% similar output distributions are reported.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2021

A Hybrid Heavy-Duty Diesel Power System for Off-Road Applications - Concept Definition

A multi-year Power System R&D project was initiated with the objective of developing an off-road hybrid heavy-duty concept diesel engine with front end accessory drive-integrated energy storage. This off-road hybrid engine system is expected to deliver 15-20% reduction in fuel consumption over current Tier 4 Final-based diesel engines and consists of a downsized heavy-duty diesel engine containing advanced combustion technologies, capable of elevated peak cylinder pressures and thermal efficiencies, exhaust waste heat recovery via SuperTurbo™ turbocompounding, and hybrid energy recovery through both mechanical (high speed flywheel) and electrical systems. The first year of this project focused on the definition of the hybrid elements using extensive dynamic system simulation over transient work cycles, with hybrid supervisory controls development focusing on energy recovery and transient load assist, in Caterpillar’s DYNASTY™ software environment. Three key off-road applications were the focus of the hybrid concept definition with an aim of understanding the system’s modular capability for the diverse off-road heavy-duty market. Core engine performance 1D and 3D simulations isolated the efficiency contributions from the downsized engine, turbocompounding, and in-cylinder thermal barrier coatings. A fuel consumption improvement range of 14 to 24% was predicted, resulting in successful project progression to the design and experimental validation phase. Furthermore, an overview of the experimental engine and hybrid system status concludes the discussion along with the multi-year project’s next steps.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2023

Circular Plastics Technologies: Depolymerization of Polymers Into Parent Monomers

While most commodity plastics were not designed to easily depolymerize, some common plastics can be broken down into their parent monomers in the presence of heat, pressure, catalysts, and/or solvent. Here, we provide a high-level overview of the depolymerization technologies that have been studied and/or scaled as promising monomer-loop recycling processes for selective plastic waste streams. Namely, commodity plastics that are considered unzippable/depolymerizable include polyethylene terephthalate, polyamides, polymethyl methacrylate, and polystyrene. Monomer-loop recycling technologies are one of several pathways toward a circular economy for plastics.

circularity↗