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DOE OSTI2023

An Integrated Framework for Risk Assessment of Safety-related Digital Instrumentation and Control Systems in Nuclear Power Plants: Methodology Refinement and Exploration

This report documents activities performed by Idaho National Laboratory (INL) during Fiscal Year (FY) 2023 for the U.S. Department of Energy (DOE) Light Water Reactor Sustainability (LWRS) Program, Risk Informed Systems Analysis (RISA) Pathway, digital instrumentation and control (DI&C) risk assessment project. In FY 2019, the RISA Pathway initiated a project to develop a risk assessment strategy for delivering a technical basis to support effective, and secure DI&C technologies for digital upgrades/designs. A risk assessment-informed framework was proposed for this strategy, which aims to (1) provide a best-estimate, risk informed capability to quantitatively estimate the safety margin obtained from plant modernization, especially for safety-related DI&C systems, (2) support and supplement existing risk informed DI&C design guides by providing quantitative risk information and evidence, (3) offer a capability of design architecture evaluation of various DI&C systems, (4) assure the long-term safety and reliability of safety-related DI&C systems, and (5) reduce uncertainty in costs and support integration of DI&C systems in the plant. To achieve these technical goals, the LWRS-developed framework provides a means to address relevant technical issues by: (1) defining a risk informed analysis process for DI&C upgrade that integrates hazard analysis, reliability analysis, and consequence analysis, (2) applying risk informed tools to address common cause failures (CCFs) and quantify corresponding failure probabilities for DI&C technologies, particularly software CCFs, (3) evaluating the impact of digital failures at the component level, system level, and plant level, and (4) providing insights and suggestions on designs to manage the risks, thus to support the development and deployment of advanced DI&C technologies in nuclear power plants (NPPs). Adding diversity within a system or components is the primary means to eliminate and mitigate CCFs, but diversity also increases system complexity and may not address all sources of systematic failures. Optimization of diversity and redundancy applications for the safety-critical DI&C systems remains a challenge. To deal with the technical issues in addressing potential software CCFs in safety-related DI&C systems of NPPs and supporting relevant design optimization, the proposed framework provides: (a) A best-estimate, risk informed capability to address new technical digital issues quantitatively, focusing on software CCFs in safety-related DI&C systems of NPPs; (b) A common and a modularized platform for DI&C designers, software developers, cybersecurity analysts, and plant engineers to predict and prevent risk in the early design stage of DI&C systems; (c) Technical bases and risk informed insights to assist users address the risk informed alternatives for evaluation of CCFs in safety-related DI&C systems of NPPs; and (d) A risk informed tool that offers a capability of design architecture evaluation of various DI&C systems to support system design decisions in diversity and redundancy applications. The research and development efforts of this project in FY 2023 are focused on refining current methods on software CCF modeling and estimation and exploring additional innovative approaches to risk assessment of DI&C systems to enable a more comprehensive and complete assessment of various safety-related DI&C design architectures. The primary audience of this report are DI&C designers, engineers, and probabilistic risk assessment (PRA) practitioners. This includes stakeholders, such as the nuclear utilities and regulators who consider the deployment and upgrade of DI&C systems, DI&C software developers and reviewers, and cybersecurity specialists. It should be noted that all the analyses are performed for the demonstration of the methodology, not for the evaluation of an actual digital control system. Results are obtained based on limited design information and testing data.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2021

Achieving performance portability in Gaussian basis set density functional theory on accelerator based architectures in NWChemEx

The numerical integration of the exchange–correlation (XC) potential is one of the primary computational bottlenecks in Gaussian basis set Kohn–Sham density functional theory (KS-DFT). To achieve optimal performance and accuracy, care must be taken in this numerical integration to preserve local sparsity as to allow for near linear weak scaling with system size. This leads to an integration scheme with several performance critical kernels which must be hand optimized for each architecture of interest. As the set of available accelerator hardware goes more diverse, a key challenge for developers of KS-DFT software is to maintain performance portability across a wide range of computational architectures. In this article, we examine a modular software design pattern which decouples the implementation details of performance critical kernels from the expression of high-level algorithmic workflows in a device-agnostic language such as C++; thus allowing for developers to target existing and emerging accelerator hardware within a single code base. We consider the efficacy of such a design pattern in the numerical integration of the XC potential by demonstrating its ability to achieve performance portability across a set of accelerator architectures which are representative of those on current and future U.S. Department of Energy Leadership Computing Facilities.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2024

Reference Piping and Instrumentation Diagrams for Heat Transport Systems for Methanol Plants

This report aims to bridge the gap between advanced nuclear reactor vendors and methanol producers seeking decarbonization. It equips both parties with tools and preliminary information for integrating clean heat from advanced reactors into novel methanol production processes. The proposed investigation in this report involves a three-step approach: 1. Design of Current and Decarbonized Process Models for Methanol Production. This report initiates process modeling of two novel methanol production pathways, with their overall energy requirements comparative to classical methanol production (see Figure ES1). The two process models provide the foundation for analyzing integration of hermos-electric generation from advanced nuclear reactors. 2. Identification of Coupling Points to Integrate Advanced Reactors. This report investigates the integration with two advanced reactor technologies: light-water reactors (LWRs) and high-temperature gas reactors (HTGRs). The key coupling points between advanced nuclear reactors and the production facilities associated with the two decarbonized methanol process pathways are identified. 3. Preliminary Heat and Electricity Transfer Design from Reactors to Methanol Production Sites. The preliminary designs for piping and instrumentation to transfer heat from the boundary of advanced reactor technology location to the boundary of methanol production site are evaluated within the context of decarbonized pathways. The pipe analysis for heat transfer adheres to relevant codes and specifications from American Society of Mechanical Engineering. A simplified design for transmission of electricity to the industrial site has been provided.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2025

VISION: a modular AI assistant for natural human-instrument interaction at scientific user facilities

Scientific user facilities, such as synchrotron beamlines, are equipped with a wide array of hardware and software tools that require a codebase for human-computer-interaction. This often necessitates developers to be involved to establish connection between users/researchers and the complex instrumentation. The advent of generative AI presents an opportunity to bridge this knowledge gap, enabling seamless communication and efficient experimental workflows. Here we present a modular architecture for the Virtual Scientific Companion by assembling multiple AI-enabled cognitive blocks that each scaffolds large language models (LLMs) for a specialized task. With VISION, we performed LLM-based operation on the beamline workstation with low latency and demonstrated the first voice-controlled experiment at an x-ray scattering beamline. The modular and scalable architecture allows for easy adaptation to new instruments and capabilities. Development on natural language-based scientific experimentation is a building block for an impending future where a science exocortex—a synthetic extension to the cognition of scientists—may radically transform scientific practice and discovery.

36 MATERIALS SCIENCE↗

NASA NTRS1994

A modular solid state detector for measuring high energy heavy ion fragmentation near the beam axis

A multi-element solid state detector has been designed to measure fluences of fragments produced near the beam axis by high energy heavy ion beams in thick targets. The detector is compact and modular, so as to be readily reconfigured according to the range of fragment charges and energies to be measured. Preamplifier gain settings and detector calibrations are adjustable remotely under computer control. We describe the central detector, its associated detectors and electronics, triggering scheme, data acquisition and particle identification techniques, illustrated by data taken with 600 MeV/u 56Fe beams and thick polyethylene targets at the LBL Bevalac. The applications of this work to space radiation protection are discussed.

NASA Center HQS↗

DOE OSTI2018

Development of a lithium fluoride zinc sulfide based neutron multiplicity counter

Past 3He shortages led to investigations into replacement options for neutron detectors in systems that previously used 3He-based technologies. The goal of this research was to investigate the feasibility of a full-scale lithium fluoride with silver activated zinc sulfide (LiF/ZnS) based neutron multiplicity counter. The LiF/ZnS based neutron multiplicity counter (LiNMC) was developed based on an iterative process between modeling and experimental measurements. Each active region of the LiNMC contains five sheets of LiF/ZnS sandwiched between six sheets of wavelength shifting plastic to form neutron detection stacks. The wavelength shifted scintillation light was collected by photomultiplier tubes located on each end of the stacks. Twelve such detector stacks were placed around a sample chamber in a square arrangement with lithiated high density polyethylene blocks in the corners to reflect high energy neutrons and capture low energy neutrons. Preliminary calibration with a 252Cf neutron source showed that the LiNMC was able to achieve 36% neutron detection efficiency (ε) and an 11.7 μs neutron die-away time (τ) for a doubles Figure-of-merit (ε2/ τ) of 109. This is the highest doubles Figure-of-merit performance measured to-date for a 3He-free neutron multiplicity counter system. By the end of this project, the LiNMC’s basic components were integrated into a single laboratory scale system capable of proof-of-concept measurements.

3He-free↗

DOE OSTI2021

Towards Neutron Transformation Searches

To probe the origins of the baryon asymmetry, baryon number violation, the last unconfirmed Sakharov condition, must be definitively observed experimentally. Similarly, the nature of dark matter is currently unknown, and calls out for new candidates to be investigated. Each of these issues can be considered through the study of neutron transformations.Some rare baryon number violating processes, such as neutron-antineutron transformations, are expected to probe baryogenesis. Here, I show progress on this discovery target through construction of more accurate Monte Carlo models, the design of future detectors, creation of more complete atmospheric neutrino background simulations, and use of automated analysis techniques within the the NNBAR/HIBEAM experimental program at the European Spallation Source (ESS) and the Deep Underground Neutrino Experiment (DUNE). First simulation-based sensitivities for these experiments will be discussed. Modeling of rare neutron-antineutron transformation and subsequent annihilation will be discussed at length for multiple nuclei useful to these and other collaborations. To go along with this work, more comprehensive lepton-scattering nuclear models must be integrated into neutrino event generators for proper atmospheric neutrino background simulations. I discuss the first furnishing of these backgrounds for DUNE, and I highlight a potential path forward for the community in this vein using precisionmore » electron scattering modeling as a facsimile.Aspects of other potentially related neutron – mirror-neutron oscillations pertinent to dark matter and the neutron lifetime anomaly will also be considered for the ESS HIBEAM experiment. Here, I will present the first experimental sensitivity calculations for a broad range of modular experimental setups which will serve as research and design stepping stones toward NNBAR while producing a multitude of physics results over short time scales.« less

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

NASA NTRSDate not supplied

NASA Life Sciences Portal (NLSP): Supporting Scientific Transparency and Reproducibility

NASA’s Life Sciences Ports (NLSP) serves the scientific community by providing curated data from space life science experiment. The Human Research Program (HRP) with the help of NLSP is currently transforming their life sciences data archive systems and processes to improve compliance with the FAIR principles [1]. Some of these improvements will at the same time support the twin pillars of Open Science [2]: transparency of methods and reproducibility of results. Scientific transparency is marked by the easily intelligible communication of what has been investigated: what were the procedures for collecting sample and the characteristics of samples collected? what kinds of measurements were made, what were the environmental conditions of the measurements? What were the analysis techniques of the collected data? Reproducibility of the results and findings from the investigation requires a high level of transparency for all but the simplest investigations; the slightest deviation in communicating and replicating complex experimental procedures or data analyses can often yield quite different data and even findings, thwarting their validation. One of the ways the NLSP is aiming to improve the communication of scientific information is through the use of ontology-driven metadata. Ontologies are powerful, graph-based knowledge representation structures, which can be leveraged to increase data interoperability, the area of the FAIR principles in which many data systems most lack compliance. Over the past decade, there has been a concerted effort in the biomedical community to develop modular and narrowly focused domain and application-specific ontologies in a common, open-source framework, the Open Biological and Biomedical Ontology (OBO) Foundry [3]. The open sharing and modular nature of this effort promises huge increases in harmonized data sharing for systems that leverage these models. Which is in line with the FAIR Data Principles of Findability, Accessibility, Interoperability, and Reuse for scientific data management and stewardship. 1. Wilkinson, M.D., et al., The FAIR Guiding Principles for scientific data management and stewardship. Sci Data, 2016. 3: p. 160018. 2. National Academies of Sciences, E. and Medicine, Open Science by Design: Realizing a Vision for 21st Century Research. 2018, Washington, DC: The National Academies Press. 232. 3. Smith, B., et al., The OBO Foundry: coordinated evolution of ontologies to support biomedical data integration. Nat Biotechnol, 2007. 25(11): p. 1251-5.

Life Sciences data↗

NASA NTRSDate not supplied

NASA Life Sciences Portal (NLSP): Supporting Scientific Transparency and Reproducibility

Life Sciences data↗

DOE OSTI2023

Risk Analysis of Various Design Architectures for High Safety-significant Safety-related Digital Instrumentation and Control Systems of Nuclear Power Plants during Accident Scenarios

This report documents the plus-up activities performed by Idaho National Laboratory (INL) during Fiscal Year (FY) 2022 for the U.S. Department of Energy (DOE) Light Water Reactor Sustainability (LWRS) Program, Risk Informed Systems Analysis (RISA) Pathway, digital instrumentation and control (DI&C) risk assessment project. In FY 2019, the RISA Pathway initiated a project to develop a risk assessment strategy for delivering a strong technical basis to support effective, licensable, and secure DI&C technologies for digital upgrades/designs. An integrated risk assessment technology for the DI&C systems was proposed for this strategy, which aims to (1) provide a best-estimate, risk-informed capability to quantitatively and accurately estimate the safety margin obtained from plant modernization, especially for the high safety-significant safety-related (HSSSR) DI&C systems, (2) support and supplement existing advanced risk-informed DI&C design guides by providing quantitative risk information and evidence, (3) offer a capability of design architecture evaluation of various DI&C systems to support system design decisions and diversity and redundancy applications, (4) assure the long-term safety and reliability of HSSSR DI&C systems, and (5) reduce uncertainty in costs and support integration of DI&C systems in the plant. To achieve these technical goals and deal with the expensive licensing justifications from regulatory insights, the LWRS-developed framework instructs nuclear vendors and utilities on how to effectively lower the costs associated with digital compliance and speed industry advances by: (1) defining an integrated risk-informed analysis process for DI&C upgrade, including hazard analysis, reliability analysis, and consequence analysis, (2) applying systematic and risk-informed tools to address common cause failures (CCFs) and quantify corresponding failure probabilities for DI&C technologies, particularly software CCFs, (3) evaluating the impact of digital failures at the component level, system level, and plant level, and (4) providing insights and suggestions on designs to manage the risks, thus to support the development, licensing, and deployment of advanced DI&C technologies on nuclear power plant (NPPs). Adding diversity within system or components is the main means to eliminate and mitigate CCFs, but diversity also increases plant complexity and errors and may not address all sources of systematic failures. How to optimize the diversity and redundancy applications for the safety-critical DI&C systems remains a challenge. To deal with the technical issues in addressing potential software CCFs in HSSSR DI&C systems of NPPs and supporting relevant design optimization, the framework provides: ? An integrated best-estimate, risk-informed capability to address new technical digital issues quantitatively, accurately, and efficiently in plan modernization progress, such as software CCFs in HSSSR DI&C systems of NPPs ? A common and a modularized platform for DI&C designers, software developers, cybersecurity analysts, and plant engineers to efficiently predict and prevent risk in the early design stage of DI&C systems ? Technical bases and risk-informed insights to assist U.S. Nuclear Regulatory Commission (NRC) and industry to address and fulfill the risk-informed alternatives for evaluation of CCFs in HSSSR DI&C systems of NPPs ? An integrated risk-informed tool that offers a capability of design architecture evaluation of various DI&C systems to support system design decisions in diversity and redundancy applications. The plus-up research and development efforts of this project in FY 2022 are focused on methodology improvement of software CCF modeling and estimation, prevention analysis, importance analysis and risk analysis of various design architectures of HSSSR DI&C systems. This work greatly enhances the capability of the LWRS-developed framework for the risk assessment and design optimization of safety-critical DI&C systems. It should be noted that all the analyses are performed for the demonstration of the LWRS-developed framework, not for the evaluation of relevant systems. Results are obtained based on very limited design information and testing data.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2018

CHI Research. Final Technical Report

The spherical tokamak is a leading candidate for a Fusion Nuclear Science Facility (FNSF) due to its compact size and modular configuration. It is highly desirable for the FNSF to be compact in size and simpler in configuration. Since the central solenoid cannot be used for driving current during the steady-state phase, the tokamak design would also be simplified if it could be built without the solenoid, and it would allow access to lower aspect ratio configurations. Great progress has been made in developing Transient CHI as a viable solenoid-free plasma start-up method. These are: (a) The generation of closed flux current in HIT-II and NSTX, and the successful coupling of this current to induction from the central solenoid, (b) the generation of 0.1 MA closed flux current in HIT-II and demonstration of CHI plasma quality similar to that produced inductively, (c) the generation of a record 0.2 MA of closed flux current in NSTX and the coupling of the CHI-produced discharge in NSTX to induction with subsequent transitioning to a high-performance H-mode discharge when neutral beams were injected and (e) CHI-started discharges to which induction has been applied have ramped-up to 1 MA in NSTX with record low flux consumption. Modeling of the CHI process using TSC and NIMROD has led to a much-improved understanding of the physics of magnetic reconnection leading to large volume flux closure. The NIMROD results indicate that this reconnection mechanism scales to arbitrarily high toroidal field and can be either axisymmetric Sweet-Parker like reconnection or it can be enhanced through plasmoid formation. Motivated by the exciting experimental and modeling results from HIT-II and NSTX, we explored the application of CHI to a reactor configuration, and identified methods for enabling CHI capability in a FNSF-sized experiment. In the first, proven, concept referred to as "NSTX-like", the entire blanket structure is insulated from the vessel using insulating supports. In the second configuration referred to as "DIII-D - like", a toroidal insulated electrode is placed on top of the blanket structure to shield the insulator from neutrons, allowing more than six years of full power operations before insulator replacement. The second concept requires an experimental test for concept validation. To test this second concept, during the period of 2013 to 2016, we designed and implemented a new simpler design CHI configuration on QUEST. Initial TSC modeling and experimental results suggests that work on QUEST may lead to a simpler Transient CHI configuration for a ST-FNSF. Transient CHI is now also in the process of being implemented on the PEGASUS ST at the University of Washington to study very high-current start-up potential of transient CHI.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2018

Advanced Gasification and Novel Transformational Coal Conversion Technologies Development: Final Technical Report

This report summarizes the work carried out in furtherance of the NETL/DOE award, OTM-Enhanced Coal Syngas for Carbon Capture Power Systems and Fuel Synthesis Applications. The overall objective of the project was to further develop Oxygen Transport Membrane (OTM) technology and assess the potential for integration in coal power generation. OTM technology has the potential to enhance the quality of syngas produced by coal gasifiers, reduce the amount of cryogenic-derived oxygen required in Integrated Gasification Combined Cycle (IGCC) power plants, and allow for coal and natural gas integration. Process simulations and techno-economic analyses were carried out to estimate the cost and performance of OTM enhanced IGCC plants, IG-NGCC plants, and OTM enhanced Fischer Tropsch (FT) Liquids from coal and natural gas plants. The OTM enhanced power plants achieved higher carbon capture rates, higher efficiencies, and lower cost of electricity compared to the base cases. The most significant benefits were achieved for cases which used low rank coal as the feed. Fischer-Tropsch coal to liquids plants with iron-based catalysts and natural gas integration utilizing OTM technology showed improved carbon conversion, improved thermal efficiency and lower cost of production. With respect to OTM core technology development, significant advances have been made in several areas. The development and implementation of a third-generation membrane materials and manufacturing process has resulted in the availability of robust and reliable, high performance membranes, that can be manufactured at high yield. Progress towards the goal of higher pressure operation has been demonstrated with the development of improved metal-ceramic seals and components of the panel array module that integrate membrane-seal assemblies with primary and secondary reforming catalysts have been further developed and demonstrated. Work concluded with the successful start-up and operation of a multi-panel pilot-scale system which is the final step in technology development ahead of demonstration.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2019

Initial Performance Evaluation and Ranking of Thermal Energy Storage Options for Light Water Reactor Integration to Support Modeling and Simulation

This report provides an in-depth analysis of current thermal storage technologies in the marketplace as of 2019 and develops a phenomenological identification ranking table (PIRT) and Figure of Merit (FOM) study for near-term thermal energy storage technologies with light water reactor technology. Particular focus was given the NuScale reactor as part of the Joint Use Modular Plant (JUMP) program between INL, NuScale, and the Utah Associated Municipal Project (UAMPs). Ancillary service industries and technologies are explored in detail to ascertain thermodynamic requirements for integration with thermal energy storage technologies. These industries include steel manufacturing, hydrogen production, desalination, pulp and paper manufacturing. It was determined that a large percentage of these industries can make use of existing nuclear output temperatures and pressures. Storage technologies that can maintain these values are advantageous for coupling purposes. The report then analyzes ten thermal energy storage technologies, with thirteen specific systems discussed in detail regarding their potential to integrate with LWR technology. A ranking tool identified important characteristics of thermal storage and ranked each of the technologies. Concrete, molten salt, and thermal oil sensible heat storages, and steam accumulators evaluated highly. After including cost estimations and qualitatively comparing these technologies, it is recommended that either molten salt or thermal oil is used for implementation with the JUMP module. The TES project cost will likely cost between $14,000,000 and $50,000,000. The potential flexibility of a two-tank sensible heat storage system should be able to demonstrate various new uses for nuclear heat. From power peaking via steam or liquid air heat topping to process heat applications, a two-tank system should be able to best provide a constant power transfer capability to the auxiliary energy consumer. Through commencement of this work, a more refined thermal storage selection process for Nuscale and existing nuclear power plants can be conducted. The ranking system developed here can be used to re-evaluate the energy storage options periodically depending on the projected installation dates. Current results suggest two-tank thermal energy storage is the most relevant technology in the near-term.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS1989

Monte Carlo simulation of particle acceleration at astrophysical shocks

A Monte Carlo code was developed for the simulation of particle acceleration at astrophysical shocks. The code is implemented in Turbo Pascal on a PC. It is modularized and structured in such a way that modification and maintenance are relatively painless. Monte Carlo simulations of particle acceleration at shocks follow the trajectories of individual particles as they scatter repeatedly across the shock front, gaining energy with each crossing. The particles are assumed to scatter from magnetohydrodynamic (MHD) turbulence on both sides of the shock. A scattering law is used which is related to the assumed form of the turbulence, and the particle and shock parameters. High energy cosmic ray spectra derived from Monte Carlo simulations have observed power law behavior just as the spectra derived from analytic calculations based on a diffusion equation. This high energy behavior is not sensitive to the scattering law used. In contrast with Monte Carlo calculations diffusive calculations rely on the initial injection of supra-thermal particles into the shock environment. Monte Carlo simulations are the only known way to describe the extraction of particles directly from the thermal pool. This was the triumph of the Monte Carlo approach. The question of acceleration efficiency is an important one in the shock acceleration game. The efficiency of shock waves efficient to account for the observed flux of high energy galactic cosmic rays was examined. The efficiency of the acceleration process depends on the thermal particle pick-up and hence the low energy scattering in detail. One of the goals is the self-consistent derivation of the accelerated particle spectra and the MHD turbulence spectra. Presumably the upstream turbulence, which scatters the particles so they can be accelerated, is excited by the streaming accelerated particles and the needed downstream turbulence is convected from the upstream region. The present code is to be modified to include a better description of particle scattering (pitch-angle instead of hard-sphere) and as iterative procedure for treating the self-excitation of the MHD turbulence.

Campbell, Roy K.↗

DOE OSTI2019

Controllable 3D Manufacturing System

Next generation Small Modular Reactor (SMR) requires new and improved techniques, instrumentations and strategies to deal with the anticipated high radiation and high temperature environment (esp. in reactors). Component manufacturing technologies will be required that take full advantage of the new 3-D printing methods employed by additive manufacturing technologies. These manufacturing methods must be capable of producing components or sub components on a limited production basis and with nuclear quality. Based on our success in developing a variety of award-winning high energy and high power ultrafast fiber lasers and our pioneered work in fs laser 3D manufacturing (US patents, 9643361 and 9770760), PolarOnyx proposes to use tunable fiber lasers to develop smart AM & SM system to make nuclear quality components for SMR. In Phase I, we have achieved critical milestones and experimentally demonstrated the most critical functions of the proposed controllable laser AM: • Developed and investigated a series of NDI sensing technologies. Combination of IR thermal image and high resolution visible camera provides a powerful tool to characterize thermal distribution and defects. • Built an in-line laser induced breakdown spectroscopy (LIBS) to real time detect compositions of powder and parts, and melting temperature of the melting pool. It proves the LIBS is a very powerful tool to precisely guide the process. • Filed a patent (Application number 16378485) for integrating IR and visible images and LIBS for intelligent AM system. • Developed control algorithm and proved it works well for overhang experiment. • Achieved high density (>99%) and excellent mechanical properties. • Succeeded in developing a working and reliable calibration method to extract true temperature distribution during AM process. • Demonstrated spatial and temporal pulse shaping methods, and impact on microstructures. • Filed one utility patent • Laid out a solid path for phase II to work on controllable 3D manufacturing system development and optimization and to make components with nuclear quality. Our proprietary fs fiber laser based AM processing offers an ultimate solution for manufacturing high temperature components with high strength for nuclear systems. The 3D AM system in conjunction with the intelligent sensing and control is energy efficient and cost effective for the growing nuclear industries. Successful development of the proposed AM technology will provide a vital tool to solve existing and potential issues. This technology will be directly applied in the 3D printing area with combined market share of $10(s) of billions. The achievement in this research will have significant and wide social, scientific, and economic impacts by providing affordable low cost intelligent AM/SM systems, laser micromachining systems, improving energy efficiency, and reducing fabrication and operational cost. Having demonstrated the proof of concept in Phase I, we will prototype the controllable AM/SM system and investigate the efficiency and qualification of fabricating various nuclear quality components in Phase II.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS2010

Infrared Sensor on Unmanned Aircraft Transmits Time-Critical Wildfire Data

Since 2006, NASA fs Dryden Flight Research Center (DFRC) and Ames Research Center have been perfecting and demonstrating a new capability for geolocation of wildfires and the real-time delivery of data to firefighters. Managed for the Western States Fire Mission, the Ames-developed Autonomous Modular Scanner (AMS), mounted beneath a wing of DFRC fs MQ-9 Ikhana remotely piloted aircraft, contains an infrared sensor capable of discriminating temperatures within 0.5 F (approx. = 0.3 C), up to 1,000 F (approx. = 540 C). The AMS operates like a digital camera with specialized filters to detect light energy at visible, infrared, and thermal wavelengths. By placing the AMS aboard unmanned aircraft, one can gather information and imaging for thousands of square miles, and provide critical information about the location, size, and terrain around fires to commanders in the field. In the hands of operational agencies, the benefits of this NASA research and development effort can support nationwide wildfire fighting efforts. The sensor also provides data for post-burn and vegetation regrowth analyses. The MQ-9 Unmanned Aircraft System (UAS), a version of the Predator-B, can operate over long distances, staying aloft for over 24 hours, and controlled via a satellite-linked command and control system. This same link is used to deliver the fire location data directly to fire incident commanders, in less than 10 minutes from the time of overflight. In the current method, similarly equipped short-duration manned aircraft, with limited endurance and range, must land, hand-carry, and process data, and then deliver information to the firefighters, sometimes taking several hours in the process. Meanwhile, many fires would have moved over great distances and changed direction. Speed is critical. The fire incident commanders must assess a very dynamic situation, and task resources such as people, ground equipment, and retardant-dropping aircraft, often in mountainous terrain obscured by dense smoke.

Pestana, Mark↗

DOE OSTI2022

High Temperature Steam Electrolysis Process Performance and Cost Estimates

Technology readiness levels (TRLs) of electrolysis systems have dramatically increased in recent years as the interest in clean hydrogen production and decarbonization of transportation, industrial and other sectors increases across the globe. This is especially true of high temperature steam electrolysis (HTSE) / solid oxide electrolysis cell (SOEC) systems which show promise of much higher system efficiencies than other more developed electrolysis technologies. This possibility of higher efficiencies of HTSE / SOEC systems has been previously assumed to be theoretically possible but in recent years it has become less theoretical and more realistic as an increasing amount of suppliers complete lab and pilot tests showing very promising results. Research in the areas of manufacturing techniques, material selection, electrode and electrolyte compositions, and balance of plant size and integration continues at a fast pace as an increasing number of suppliers both internationally and domestically become involved. The advantages of HTSE become more pronounced when HTSE is coupled with nuclear power plants (NPPs). This is because thermal energy produced by the nuclear reactor can be used in a series of heat transfer loops and heat exchangers to vaporize HTSE feedwater, which drastically improves the economics of the process. Idaho National Laboratory (INL) has been very involved in the research and modeling of HTSE systems for a number of years, in collaboration with other national laboratories, academia, and industry stakeholders both on the hydrogen production as well as the hydrogen demand side. The modeling completed over the years on a large variety of projects has led to a wealth of knowledge at INL including in the area of the technoeconomic assessment (TEA) of HTSE systems. TEAs include process modeling of the HTSE systems to calculate system energy requirements and equipment sizing, followed by estimation of capital and operating costs to enable calculation of the levelized cost of hydrogen (LCOH). The TEA work performed has produced incremental improvements and tuning of the methods, assumptions, models, and results of the analyses as well as providing some opportunities for validating these results. The purpose of this document is to record the current baseline HTSE analyses led by INL to show the current status of assumptions and costs of these systems. Given the rapid development of this technology, the variety of suppliers entering the space, and the increasing attention government and industry are giving to such systems, this document may be updated on a periodic basis with updated analysis and assumptions. This document compiles various analyses results and approaches completed over a period of years into a single document to be used as a baseline going forward. It represents what the INL HTSE analysis group assumes to be the internal best estimate of the current operation, costs, and landscape of the HTSE industry state of the art capability for current SOEC technology in an Nth-of-a-Kind (NOAK) plant, which in this study is defined as existence of the manufacturing capacity to support previous deployment of N = 100 count of 25 MWe modular HTSE blocks (with modular equipment component cost reductions specified as following a 95% learning curve). That said, This is a public document and as such so no proprietary data was used or included in this report. There may be HTSE suppliers that have performance specifications, and cost estimates, and test data that differ from the analysis presented in this document. This document is meant to be a best conservative estimate of the technology and not an absolute reference.

08 HYDROGEN↗

NASA NTRS2006

A Low Cost Spacecraft Architecture for Robotic Lunar Exploration Projects

A program of frequent, capable, but affordable lunar robotic missions prior to return of humans to the moon can contribute to the Vision for Space Exploration (VSE) NASA is tasked to execute. The Lunar Reconnaissance Orbiter (LRO) and its secondary payload are scheduled to orbit the moon, and impact it, respectively, in 2008. It is expected that the sequence of missions occurring for approximately the decade after 2008 will place an increasing emphasis on soft landed payloads. These missions are requited to explore intrinsic characteristics of the moon, such as hydrogen distribution in the regolith, and levitated dust, to demonstrate the ability to access and process in-situ resources, and to demonstrate functions critical to supporting human presence, such as automated precision navigation and landing. Additional factors governing the design of spacecraft to accomplish this diverse set of objectives are: operating within a relatively modest funding profile, the need tb visit multiple sites (both polar and equatorial) repeatedly, and to use the current generation of launch vehicles. In the US, this implies use of the Evolved Expendable Launch Vehicles, or EELVs, although this design philosophy may be extended to launch vehicles of other nations, as well. Many of these factors are seemingly inconsistent with each other. For example, the cost of a spacecraft usually increases with mass; therefore the desire to fly frequent, modestly priced spacecraft seems to imply small spacecraft (< 1 Mt, injected mass). On the other hand, the smallest of the EELVs will inject approx. 3 Mt. on a Trans Lunar Injection (TLI) trajectory md would therefore be wasteful or launching a single, small spacecraft. Increasing the technical capability of a spacecraft (such as autonomous navigation and soft landing) also usually increases cost. A strategy for spacecraft design that meets these conflicting requirements is presented. Taken together, spacecraft structure and propulsion subsystems constitute the majority of spacecraft mass; saving development and integration cost on these elements is critical to controlling cost. Therefore, a low cost, modular design for spacecraft structure and propulsion subsystems is presented which may be easily scaled up or down for either insertion into lunar orbit or braking for landing on the lunar surface. In order to effectively use the approx.3 Mt mass-to-TLI of the EELV, two low cost spacecraft will be manifested on the same launch. One spacecraft will be located on top of the other for launch and the two will have to be released in sequence in order to achieve all mission objectives. The two spacecraft could both be landers, both orbiters, or one lander and one orbiter. In order to achieve mass efficiency, the body of the spacecraft will serve the dual purposes of carrying launch loads and providing attachment points for all the spacecraft subsystems. In order to avoid unaffordable technology development costs, small liquid propulsion components and autonomous, scene-matching navigation cameras may be adapted from military missile programs in order to execute precision soft landings.

Lemke, Lawrence G.↗