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DOE OSTI2014

Preliminary Evaluation of Alternate Designs for HFIR Low-Enriched Uranium Fuel

Engineering design studies of the feasibility of conversion of the High Flux Isotope Reactor (HFIR) from high-enriched uranium (HEU) to low-enriched uranium (LEU) fuel are ongoing at Oak Ridge National Laboratory (ORNL) as part of an effort sponsored by the U.S. Department of Energy s Global Threat Reduction Initiative (GTRI)/Reduced Enrichment for Research and Test Reactors (RERTR) program. The fuel type selected by the program for the conversion of the five high-power research reactors in the U.S. that still use HEU fuel is a new U-Mo monolithic fuel. Studies by ORNL have previously indicated that HFIR can be successfully converted using the new fuel provided (1) the reactor power can be increased from 85 MW to 100 MW and (2) the fuel can be fabricated to a specific reference design. Fabrication techniques for the new fuel are under development by the program but are still immature, especially for the complex aspects of the HFIR fuel design. In FY 2012, the program underwent a major shift in focus to emphasize developing and qualifying processes for the fabrication of reliable and affordable LEU fuel. In support of this new focus and in an effort to ensure that the HFIR fuel design is as suitable for reliable fabrication as possible, ORNL undertook the present study to propose and evaluate several alternative design features. These features include (1) eliminating the fuel zone axial contouring in the previous reference design by substituting a permanent neutron absorber in the lower unfueled region of all of the fuel plates, (2) relocating the burnable neutron absorber from the fuel plates of the inner fuel element to the side plates of the inner fuel element (the fuel plates of the outer fuel element do not contain a burnable absorber), (3) relocating the fuel zone inside the fuel plate to be centered on the centerline of the depth of the plate, and (4) reshaping the radial contour of the relocated fuel zone to be symmetric about this centerline. The present studies used current analytical tools to evaluate the various alternate designs for cycle length, scientific performance (e.g., neutron scattering), and steady-state and transient thermal performance using both safety limit and nominal parameter assumptions. The studies concluded that a new reference design combining a permanent absorber in the lower unfueled region of all of the fuel plates, a burnable absorber in the inner element side plates, and a relocated and reshaped (but still radially contoured) fuel zone will allow successful conversion of HFIR. Future collaboration with the program will reveal whether the new reference design can be fabricated reliably and affordably. Following this feedback, additional studies using state-of-the-art developmental analytical tools are proposed to optimize the design of the fuel zone radial contour and the amount and location of both types of neutron absorbers to further flatten thermal peaks while maximizing the performance of the reactor.

Renfro, David G.↗
DOE OSTI2014

Preliminary Evaluation of Alternate Designs for HFIR Low-Enriched Uranium Fuel

Engineering design studies of the feasibility of conversion of the High Flux Isotope Reactor (HFIR) from high-enriched uranium (HEU) to low-enriched uranium (LEU) fuel are ongoing at Oak Ridge National Laboratory (ORNL) as part of an effort sponsored by the U.S. Department of Energy’s Global Threat Reduction Initiative (GTRI)/Reduced Enrichment for Research and Test Reactors (RERTR) program. The fuel type selected by the program for the conversion of the five high-power research reactors in the U.S. that still use HEU fuel is a new U-Mo monolithic fuel. Studies by ORNL have previously indicated that HFIR can be successfully converted using the new fuel provided (1) the reactor power can be increased from 85 MW to 100 MW and (2) the fuel can be fabricated to a specific reference design. Fabrication techniques for the new fuel are under development by the program but are still immature, especially for the “complex” aspects of the HFIR fuel design. In FY 2012, the program underwent a major shift in focus to emphasize developing and qualifying processes for the fabrication of reliable and affordable LEU fuel. In support of this new focus and in an effort to ensure that the HFIR fuel design is as suitable for reliable fabrication as possible, ORNL undertook the present study to propose and evaluate several alternative design features. These features include (1) eliminating the fuel zone axial contouring in the previous reference design by substituting a permanent neutron absorber in the lower unfueled region of all of the fuel plates, (2) relocating the burnable neutron absorber from the fuel plates of the inner fuel element to the side plates of the inner fuel element (the fuel plates of the outer fuel element do not contain a burnable absorber), (3) relocating the fuel zone inside the fuel plate to be centered on the centerline of the depth of the plate, and (4) reshaping the radial contour of the relocated fuel zone to be symmetric about this centerline. The present studies used current analytical tools to evaluate the various alternate designs for cycle length, scientific performance (e.g., neutron scattering), and steady-state and transient thermal performance using both safety limit and nominal parameter assumptions. The studies concluded that a new reference design combining a permanent absorber in the lower unfueled region of all of the fuel plates, a burnable absorber in the inner element side plates, and a relocated and reshaped (but still radially contoured) fuel zone will allow successful conversion of HFIR. Future collaboration with the program will reveal whether the new reference design can be fabricated reliably and affordably. Following this feedback, additional studies using state-of-the-art developmental analytical tools are proposed to optimize the design of the fuel zone radial contour and the amount and location of both types of neutron absorbers to further flatten thermal peaks while maximizing the performance of the reactor.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
DOE OSTI2013

LBS GatlingGun13A

The High Energy Density Laboratory Physics (HEDLP)-funded Eagle nebula project, in collaboration with the LLNL/ University of Nevada Photoionization / Black Hole Physics effort, has successfully executed the first day of Laboratory Basic Science (LBS) Long Duration Radiator shots, performed at the University of Rochester Laboratory for Laser Energetics Omega EP Laser. This experiment employed a novel technique used a copper multi-hohlraum target with 3 hohlraum filled with a 4mg/cc TPX foam fill to act as a gas surrogate. Each hohlraum was driven with an Omega EP UV beam with either a 6ns pulse with 3.3kJ energy or 10ns pulse with 4.3 kJ. Each hohlraum was heated in succession to generate an 18ns or 30ns, 100 eV x-ray source for future laboratory astrophysics studies. The x-ray source was characterized with the CEA μDMX diagnostic and VISAR using a Quartz shock sample with a CH ablator over a single hohlraum. The Shot day was successful with six hohlraum shots on Omega EP with two 30ns x-ray drive shots. The data indicated that the novel foam-filled multi-hohlraum (‘Gatling Gun’) long –duration source performed as designed with all three hohlraums lighting up without significant inter-hohlraum interference (Figure 1). In addition the x-ray drive source was able to illuminate a Ti photoionization demonstration physics package with a 90 to 100 eV x-ray drive, generating Ti L-shell band radiation as expected. This source will next be applied to study ablation-driven hydrodynamics experiments relevant to the Eagle nebula and use the source and further develop the photoionization studies with a controlled 30ns x-ray source.

42 ENGINEERING↗
DOE OSTI2025

Scalable Data Center Capacity for DOE's AI Prototype: A Rapidly Available Gigawatt Data Center for DOE

The multilaboratory Gigawatt Data Center working group was commissioned to identify approaches to rapidly establish federal data centers with scalable capacities up to 1,000 MW. These state-of-the-art facilities will serve as hubs for interdisciplinary collaboration, industry partnerships, and transformative applications of artificial intelligence. The proposed strategic shift includes facilitating multilaboratory collaboration, prioritizing operational efficiency, expanding public–private partnerships, optimizing investments, ensuring long-term contractual flexibility, supporting open science and secure data enclaves, and exploiting high-speed national networks. Owing to their extensive experience and best practices, the US Department of Energy national laboratories are uniquely positioned to lead this initiative. We recommend conducting a feasibility analysis to rapidly identify the optimal sites for this initiative, and the effort will likely involve private industry for design, construction, financing, and operational integration. We also propose establishing multiple geographically diverse sites to ensure energy resilience, high operational reliability, and a diverse user base, thereby effectively addressing the nation’s critical needs.

42 ENGINEERING↗
DOE OSTI2025

Advancing Development of Emissions Detection (Final Report)

This document is the final report to the U.S. Department of Energy (DOE for contract DE-FE0031873) awarded to Colorado State University (CSU). CSU and partners at Harrisburg University of Science and Technology, University of Texas Arlington, and University of Texas at Austin organized several testing rounds to provide knowledge focused on advancing the detection capabilities of emissions monitoring devices. With this funding opportunity the research group began by establishing the Advancing the Development of Emission Detection (ADED) program, with the goal focused on enhancing the accuracy, reliability, and field applicability of methane detection technologies. This effort aimed to address the critical challenges of identifying and quantifying methane emissions while enabling industry stakeholders to meet regulatory compliance and environmental sustainability goals. The program engaged with industry, government, and technology stakeholders to promote adoption and consensus on testing techniques for methane detection solutions. Methane, a potent greenhouse gas, contributes significantly to global warming, and the oil and natural gas (O&G) sector is a primary source of methane emissions. Regulatory measures such as leak detection and repair (LDAR) programs have been implemented to address emissions. However, traditional LDAR approaches, reliant on handheld and component-level measurements, are resource-intensive. To address these limitations and move with evolving regulations, advanced methane technologies are emerging. These solutions include ground-based sensors, mobile systems (e.g., drones, vehicles, and aircraft), and satellite-based platforms. They offer innovative capabilities for autonomous monitoring, larger spatial coverage, and emission quantification using methods such as tracer gas techniques and inverse modeling with Gaussian plume analysis. The ADED program began with creating protocols for methane controlled release (CR) testing these continuous monitoring (CM) and survey technologies that detect and monitor methane emissions at O&G facilities. The protocols were then implemented throughout testing of CM and survey devices at CSU’s Methane Emissions Technology Evaluation Center (METEC) facility from 2021 through 2024. As apart of the protocol, solutions that tested under the ADED program installed their solutions at METEC, documented their system under test, and provided detection reports to the METEC team for analysis. The METEC team would provide the solutions with analyzed reports of their emissions and ground truth data of the releases conducted during their testing session. Under the ADED program, CMs were also tested at O&G facilities for a six week test run of challenge release (ChR) releases. The findings from the ADED program underscore the critical role of collaborative research and innovation in tackling methane emissions, offering a pathway for the oil and gas sector to achieve significant environmental and economic benefits. Results from METEC testing saw improvement of performance and accuracy across all solutions over the extent of the ADED experiments. The results also showed a variance in CM solution performance between CRs and ChRs. That variance pushed the team to further analyze the differences between CR testing environments and field conditions. With the drive from regulations and that variance in field conditions, the ADED team began designing a new CR testing protocol and additions to the METEC testing facility. The METEC team is furthering the progress made through the ADED program with awarded funding from DE-FE0032276. This funding pushes the development of METEC’s addition with new equipment, allowing for an updated facility layout. METEC still facilitates for traditional facilities, with a legacy pad, while expanding an new design based on how O&G infrastructure has Final Report - Contract Number: DE-FE0031873 been changed over the last decade. Throughout the ADED program the team has also been working with international partners to ensure staying in the trend globally. International partners have been essential in moving the new protocol forward to implement into CR testing at the METEC facility in Spring 2025.

42 ENGINEERING↗
DOE OSTI2025

Advancing Additive Manufacturing Through Artificial Intelligence–Powered, High-Throughput, Nondestructive Characterization and Process Optimization

This Cooperative Research and Development Agreement (CRADA) between Oak Ridge National Laboratory (ORNL) and ZEISS Industrial Metrology has demonstrated the transformative potential of artificial intelligence (AI)-enabled x-ray computed tomography (XCT) to accelerate the qualification and certification of additively manufactured (AM) parts. At the core of this effort is Simurgh, an AI-powered XCT reconstruction framework jointly advanced by ORNL and ZEISS that integrates computer-aided design (CAD) models, physics-based simulations, and deep learning to overcome the long-standing challenges of metal artifact correction, long scan durations, and limited flaw detectability in dense and geometrically complex components. Simurgh enables high-throughput, high-quality 3D reconstruction from sparse and fast scans, which reduces XCT acquisition times by more than an order of magnitude and simultaneously improves defect detection limits by up to fourfold compared with industry-standard approaches. This capability reduces scan costs by more than 50%, lowers labor overhead, and makes XCT characterization economically viable for routine industrial use. By enabling reliable flaw detection in minutes rather than hours, Simurgh facilitates real-time feedback loops for process parameter optimization, which was highlighted in a recent npj Computational Materials (a Nature journal) issue. In the published study, more than 100 alloy coupons were characterized within a single day. This work represents a tenfold acceleration in the development of novel AM alloys and processes compared with conventional workflows. The ZEISS collaboration has also demonstrated the scalability of Simurgh to diverse application domains, including aerospace, nuclear, automotive, and biomedical components; in these applications, ensuring structural integrity is paramount. By drastically reducing barriers to XCT adoption, this partnership has laid the foundation for digital twins and data-driven certification pipelines and directly addressed bottlenecks in qualifying new materials and designs. Together, ORNL and ZEISS have shown that Simurgh advances the state of the art in nondestructive evaluation and aligns with the broader mission of enabling Industry 4.0 manufacturing ecosystems, in which intelligent, cost-effective, rapid quality assurance is integral to accelerating innovation and ensuring safety in critical applications.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Gerischer Electrochemistry Today

Semiconductor photoelectrochemistry is a dynamic and interdisciplinary field at the forefront of research in solar fuels, energy conversion, and catalysis. Here, this Perspective captures the collective insights from the second Gerischer Electrochemistry Today Symposium, held at Colorado State University in Fort Collins, CO, in August 2024, which convened leading researchers, early-career scientists, and industry partners to define the critical next steps for the field. Through interactive sessions, technical talks, panel discussions, and training initiatives─including a Semiconductor Electrochemistry Bootcamp─the symposium emphasized three pillars of advancement: (i) facilitating the exchange of new ideas in semiconductor electrochemistry and charge separation; (ii) fostering the development of future researchers, research topics, and participation in the semiconductor workforce; and (iii) building community. This Energy Focus distills key themes from the meeting and identifies major knowledge gaps in the following areas: mechanisms of charge separation and recombination, role of defects and disorder, dynamic and operando characterization methods, interfacial chemistry and surface passivation, theoretical and modeling limitations, and standardization and benchmarking. The inclusive and collaborative structure of the symposium enabled the generation of this comprehensive report that will serve as a roadmap for fundamental and applied research in the rapidly evolving field of semiconductor electrochemistry over the next decade.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Dynamic Retrieval Augmented Generation of Ontologies using Artificial Intelligence (DRAGON-AI)

Ontologies are fundamental components of informatics infrastructure in domains such as biomedical, environmental, and food sciences, representing consensus knowledge in an accurate and computable form. However, their construction and maintenance demand substantial resources and necessitate substantial collaboration between domain experts, curators, and ontology experts. We present Dynamic Retrieval Augmented Generation of Ontologies using AI (DRAGON-AI), an ontology generation method employing Large Language Models (LLMs) and Retrieval Augmented Generation (RAG). DRAGON-AI can generate textual and logical ontology components, drawing from existing knowledge in multiple ontologies and unstructured text sources.We assessed performance of DRAGON-AI on de novo term construction across ten diverse ontologies, making use of extensive manual evaluation of results. Our method has high precision for relationship generation, but has slightly lower precision than from logic-based reasoning. Our method is also able to generate definitions deemed acceptable by expert evaluators, but these scored worse than human-authored definitions. Notably, evaluators with the highest level of confidence in a domain were better able to discern flaws in AI-generated definitions. We also demonstrated the ability of DRAGON-AI to incorporate natural language instructions in the form of GitHub issues.These findings suggest DRAGON-AI's potential to substantially aid the manual ontology construction process. However, our results also underscore the importance of having expert curators and ontology editors drive the ontology generation process.

96 KNOWLEDGE MANAGEMENT AND PRESERVATION↗
DOE OSTI2022

Residential Façade Upgrades: Market Assessment and Recommendations

In support of DOE’s move toward transformational whole-building upgrades and enclosure solutions, the Pacific Northwest National Laboratory (PNNL) and National Renewable Energy Laboratory (NREL) are partnering and collaborating with leading building science researchers and home-performance entities to identify and characterize technical and economic barriers to façade retrofits in an effort to identify market-viable façade solutions and opportunities for an actionable plan to transform the market. The project includes partnerships with Building Science Corporation (BSC) and a combination of strategic implementation partners with home-performance and retrofit expertise and industry contacts. The project will include expert advisory and review consultation from Lawrence Berkeley National Laboratory’s (LBNL’s) Residential Windows & Attachments team and Oak Ridge National Laboratory’s Building Envelope team. The project consists of three parts: 1. a market analysis that captures the current state of the façade retrofit market and includes housing characteristics and retrofit costs, façade retrofit approaches and materials, contractor business models and workforce requirements to support advanced façade approaches; 2. an economic analysis focused on the viability of advanced façade retrofit approaches and materials; and 3. field demonstration of façade retrofits that include enhanced insulation/air-sealing and window technologies in multiple climate zones. This report represents the market analysis, as outlined in item 1 above. The goal of this analysis is to provide a techno-economic study that supports comprehensive retrofits of residential enclosures that include traditional approaches, and integrated wall assemblies and windows that result in durable, energy efficient, and marketable strategies. This study will provide a better knowledge base regarding the viable market for façade retrofit strategies, identify the barriers to uptake, analyze economic opportunities, and develop documentation specifically aimed to overcome technical and market barriers associated with installation.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2022

Data Compression in the NEXT-100 Data Acquisition System

NEXT collaboration detectors are based on energy measured by an array of photomultipliers (PMT) and topological event filtering based on an array of silicon photomultipliers (SiPMs). The readout of the PMT sensors for low-frequency noise effects and detector safety issues requires a grounded cathode connection that makes the readout AC-couple with variations in the signal baseline. Strict detector requirements of energy resolution better than 1% FWHM require a precise baseline reconstruction that is performed offline for data analysis and detector performance characterization. Baseline variations make it inefficient to apply traditional lossy data compression techniques, such as zero-suppression, that help to minimize data throughput and, therefore, the dead time of the system. However, for the readout of the SiPM sensors with less demanding requirements in terms of accuracy, a traditional zero-suppression is currently applied with a configuration that allows for a compression ratio of around 71%. The third stage in the NEXT detectors program, the NEXT-100 detector, is a 100 kg detector that instruments approximately five times more PMT sensors and twice the number of SiPM sensors than its predecessor, the NEXT-White detector, putting more pressure in the DAQ throughput, expected to be over 900 MB/s with the current configuration, which will worsen the dead time of the acquisition data system. This paper describes the data compression techniques applied to the sensor data in the NEXT-100 detector, which reduces data throughput and minimizes dead time while maintaining the event rate to the level of its predecessor, around 50 Hz.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2012

Demonstration of Mixing and Transferring Settling Cohesive Slurry Simulants in the AY-102 Tank - 12323

In support of Hanford's feed delivery of high level waste (HLW) to the Waste Treatment and Immobilization Plant (WTP), pilot-scale testing and demonstrations with simulants containing cohesive particles were performed as a joint collaboration between Savannah River National Laboratory (SRNL) and the Pacific Northwest National Laboratory (PNNL) staff. The objective of the demonstrations was to determine the impact that cohesive particle interactions in the simulants, and the resulting non- Newtonian rheology, have on tank mixing and batch transfer of large and dense seed particles. The work addressed the impacts cohesive simulants have on mixing and batch transfer performance in a pilot-scale system. Kaolin slurries with a range of wt% concentrations to vary the Bingham yield stress were used in all the non-Newtonian simulants. To study the effects of just increasing the liquid viscosity (no yield stress) on mixing and batch transfers, a glycerol/water mixture was used. Stainless steel 100 micron particles were used as seed particles due to their density and their contrasting color to the kaolin and glycerol. Testing results show that water always transfers less seed particles, and is conservative when compared to fluids with a higher yield stress and/or higher viscosity at the same mixing/transfer parameters. The impact of non-Newtonian fluid properties depends on the magnitude of the yield stress. A higher yield stress in the carrier fluid resulted in more seed particles being transferred to the RTs. A dimensional analysis highlighting the role of a yield stress (due to cohesive particle interactions) defined four regions of behavior and indicates how the results obtained in this study can be applied to the full-scale mixing behavior of a high level waste tank. The analysis indicates that the regions of behavior for full-scale mixing have been adequately represented by the current small-scale tests. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2019

Methodology Development for Cybersecurity Robustness and Vulnerability Assessment of University Research Reactors

In 2012, the U.S. Nuclear Regulatory Commission (NRC) formed a working group in collaboration with the Test, Research and Training Reactors (TRTR) group to review cyber security programs at US nuclear nonpower reactor (NPR) facilities. Following their review of cyber security at four different university NPR (i.e. university research reactor (URR)) facilities, the NRC staff made recommendations for improvements at URR including 1) augmenting the URR licensees’ understanding of the protective features provided with their physical security systems, 2) educating URR facility staff on cyber security issues, and 3) developing guidance to help the URR facilities maintain adequate cyber security going forward. This three-year project to develop and implement a cyber-security risk assessment methodology and defense-in-depth mitigation strategy for application at URR facilities provides solutions effectively addressing each of the recommendations given in the NRC review referenced above. In support of this project, cyber security documentation and guidance from the NRC, Department of Homeland Security (DHS) Industrial Control Systems (ICS) Cyber Emergency Response Team (CERT), National Institute of Standards and Technology (NIST), and the International Atomic Energy Agency (IAEA), were reviewed. Most of this documentation did not take the unique resources, configuration, and infrastructure associated with URR facilities into account. The NRC-TRTR effective practices document provides useful guidance for implementing cyber security protections at URR, but lacks a structured framework for systematically auditing facility digital control assets (DCA) and evaluating associated cyber threats, vulnerabilities, and risk. The outcomes from this project, therefore, seek to build on the general resources above by providing a straightforward DCA auditing and risk assessment methodology, as well as mitigation strategies, that may be implemented to address the risk of cyber-attack at URR facilities.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2026

Integrating Carbon Capture, Utilization, & Sequestration into Chemical Pulp Mills

The U.S. pulp and paper industry presents a unique and largely untapped opportunity for large- scale carbon dioxide removal (CDR). Unlike most industrial sectors, pulp mills rely heavily on biomass, meaning that much of their carbon emissions originate from atmospheric CO₂ that was recently captured by plants. If this biogenic CO₂ can be captured and permanently stored, pulp mills can be transformed from carbon emitters into net carbon removal facilities. This project was motivated by that opportunity and aimed to develop and evaluate integrated, low-cost strategies for capturing, utilizing, and sequestering CO₂ within existing chemical pulping operations. The scope of this work focused on four complementary innovations designed to integrate seamlessly into kraft pulp mill infrastructure: (1) in situ CO₂ capture within the recovery cycle, (2) oxy-fuel retrofitting of the rotary lime kiln to produce a high-purity CO₂ stream, (3) ex situ CO₂ capture and mineralization using pulp mill residues (dregs, grits, and lime mud), and (4) beneficial reuse of these residues as mineral carbonate fertilizers. The project combined process modeling, laboratory experimentation, life cycle assessment (LCA), and field trials to evaluate the technical feasibility, economic viability, and environmental impact of these approaches. The results demonstrate that pulp mills can serve as effective platforms for carbon removal when equipped with integrated carbon capture systems. Process modeling showed that combining sodium spiking with oxy-fuel calcination significantly enhances CO₂ capture efficiency while reducing costs by up to 31% compared to conventional configurations. Experimental work further revealed that calcination behavior in high-CO₂ environments differs substantially from traditional systems, leading to the development of a new kinetic model that predicts reaction rates under these conditions. This model provides essential design guidance for next-generation decarbonized lime kilns. In parallel, the project demonstrated that alkaline mineral residues generated during pulping operations can be repurposed as a sustainable alternative to agricultural lime. Across a wide range of soils in the southeastern United States, these materials performed equivalently to commercial lime in adjusting soil pH while offering lower greenhouse gas emissions and reduced cost. Field and greenhouse studies confirmed that crop and tree growth responses were comparable, supporting their viability as a drop-in replacement. This co-product pathway provides a practical utilization strategy that offsets costs and improves overall system economics. A major contribution of this project is the first comprehensive life cycle assessment of carbon removal in pulp and paper systems across multiple system boundaries. Results show that retrofitted mills can achieve carbon removal efficiencies ranging from 12% to 92%, depending on how the system is defined. This finding highlights a critical issue in carbon accounting: reported performance is highly sensitive to methodological choices. By explicitly quantifying these differences, this work provides valuable guidance for policymakers, carbon registries, and project developers working to standardize carbon removal metrics. From a commercialization perspective, the technologies investigated in this project are well- aligned with existing industrial infrastructure, minimizing the need for entirely new facilities. 3 DE-EE0009413 Industry engagement throughout the project—including collaboration with pulp and paper companies, equipment manufacturers, and carbon removal developers—has accelerated the transition from research to deployment. Notably, a commercial developer is actively pursuing carbon capture projects at pulp mills in the southeastern United States and has cited this research as a contributing foundation. The emergence of voluntary carbon markets and long-term offtake agreements further strengthens the business case for implementation. The broader public benefits of this work are significant. By enabling large-scale carbon removal using existing industrial systems, this approach offers a near-term pathway to reduce atmospheric CO₂ concentrations while supporting domestic manufacturing and rural economies. The reuse of industrial residues as fertilizers reduces reliance on mined materials, lowers costs for farmers, and decreases environmental impacts associated with conventional lime production. In addition, the project has supported workforce development by training graduate students and researchers in carbon capture technologies, helping to build capacity in a critical area of national interest. In conclusion, this project demonstrates that integrated carbon capture, utilization, and sequestration in pulp mills is both technically feasible and economically promising. By combining process innovation, experimental validation, and systems-level analysis, the work advances the understanding of how biomass-based industries can contribute to climate mitigation. The findings provide a strong foundation for commercial deployment and offer a scalable solution for transforming a major U.S. industry into a source of durable carbon removal.

09 BIOMASS FUELS↗
DOE OSTI2024

Process Intensification for Nanostructure Aluminum Extrusions

A new technology called Shear Assisted Processing and Extrusion (ShAPE™), pioneered at the Pacific Northwest National Laboratory (PNNL), has the potential to revolutionize the US extrusion industry. Maturation of the ShAPE™ process would create a new cross cutting US manufacturing technology that advances three key the objectives within AMO; namely, nanomaterials processing, process intensification, and materials for extreme and harsh environments. PNNL and SCM Metals Products, Inc. (SCM), a division of Kymera International, will collaborate to mature the ShAPE™ extrusion process beyond TRL 3 to increase the likelihood of its adoption by industry. PNNL’s custom (one-of-a-kind in the world) ShAPE™ machine will be used to extrude round rods of high strength aluminum alloy feedstock powder provided by SCM. As proof-of-concept, PNNL has previously extruded 5 mm diameter rods with SCM aluminum alloy powder AL-12.4TM. This project aims to scale up the process to a diameter of 25 mm while retaining the excellent mechanical properties achieved for the 5 mm diameter rods. The degree of process intensification with ShAPE™ will also be estimated. The primary objectives of this project are as follows. 1) Fabricate 25 mm diameter nanostructured extrusions in bulk, directly from AL-12.4TM aluminum alloy powder without the need for canning, degassing, compaction, and other intermediate steps typical of powder metallurgy extrusion. 2) Achieve a microstructure with an ultrafine grained (UFG <1 µm) aluminum matrix having refined and homogenously distributed nanoscale second phases. 3) Show that the ram force can be significantly reduced compared to conventional powder metallurgy extrusion of the same material and estimate the extent of process intensification that may be possible with ShAPE™. 4) Demonstrate improved high-temperature mechanical properties compared to conventional extrusion of the same material. The following tasks will be undertaken to achieve these objectives. PNNL will develop the die set and process parameters necessary to fabricate Al-12.4TM extrusions with a 25 mm diameter. Microstructural analysis will be performed by PNNL while mechanical testing will be conducted by SCM. With information learned from the process development and characterization, PNNL will perform an estimate of the degree of process intensification that may be possible with ShAPE™.

42 ENGINEERING↗
DOE OSTI2024

Fabrication and Testing of DOE Standard Canister Closure Leak Test Assembly

DOE manages over 300 types of SNF, most of which are located at the INL site. “Road-ready dry storage” is a management concept where SNF is packaged into dry, sealed canisters, which are then placed in on-site storage in anticipation of later removal. The Idaho Cleanup Project and INL are collaborating on the Road-Ready Capability Demonstration Project, which will develop and demonstrate the designs, technology, processes, and regulatory framework for packaging DOE SNF for road-ready dry storage. In support of establishing a large-scale road-ready dry storage program at the INL site, the demonstration will package a select amount of DOE-managed SNF into DOE Standard Canisters. The closure process for the DOE Standard Canisters will include fuel and basket loading, welding, inspection, leak testing, and if needed, repair. As a follow-up to previous discussion on the design of the DOE Closure Leak Test Assembly, this report describes recent fabrication and testing efforts performed at INL. DOE Standard Canisters are sealed by two sequential gas tungsten arc welds. Both are performed by remotely operated and semi-autonomous welding systems. The first weld is a circumferential pipe weld that completes assembly of the canister body and lid assembly. The second and final closure weld connects the vent plug to the vent port with an identical butt joint to the circumferential pipe weld. After the second weld is performed on the vent port, these welds are helium leak tested using an inside-out technique. In addition to the commercially available vacuum and leak detector systems, the DOE Standard Canister Closure Leak Test Assembly was designed for both remote and manual operation. This report describes fabrication and performance testing associated with the inside-out technique. INL staff designed and tested systems to accomplish these tasks. Hardware fabrication occurred at INL facilities. Forthcoming work includes design optimization, integration to existing systems, and implementation to packaging demonstration operations.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

Technology Development and Integration for Volume Production of High Purity Rare Earth Metals from Phosphate Processing

Under this project and in collaboration with Pacific Northwest National Laboratory (PNNL), Oak Ridge National Laboratory (ORNL), Florida International University (FIU), and Mosaic, the FIPR Institute successfully developed and demonstrated on laboratory batch scale a complete processing technology for production of high-purity rare earth elements (REE) in the form of mixed rare earth oxides (MREO) and rare earth metals (REM) using phosphoric acid sludge (a byproduct from phosphate mining) as the REE feedstock. Based on the research results, a technical research plan has been developed with expanded team members to elevate the technology readiness level (TRL) of the subject technology from 4 to 6 by conducting continuous testing of the processing flowsheet with the ultimate goal of producing about 900 tons per year of REM using the phosphate mining byproduct. Those 900 tons of REM would contain approximately 180 tons of Y, 120 tons of Nd, 50 tons of Gd, 37 tons of Dy, 33 tons of Sm, and 31 tons of Pr, meeting the US demand of roughly 39%, 6%, 42%, 48%, 101% and 7% for these elements, respectively. The advanced technologies for REE separation and purification involves three technology companies: K-Technologies, Inc. would test their continuous-ion-exchange/continuous-ion chromatography technologies on both the REE leachate and solvent extraction concentrate for 4 production of high-purity individual or binary REM. Rare Earth Salts would test their innovative electrochemical technology on the REE leachate or re-dissolved MREO in dilute acid for production of high-purity individual or binary REM. Rare Earth Technologies, Inc. would evaluate their advanced chromatographic separation technology on the dissolved MREO product for production of high-purity individual or binary REM.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Computational scheme for burnup credit applied to long term waste disposal - 14448

The application of burnup credit (BUC) to criticality safety evaluations (CSE) of geological repositories for long term disposal of spent nuclear fuel (SNF) is under consideration in Switzerland. Therefore, in collaboration with the national waste management organization, PSI is conducting research towards the development of a BUC methodology tailored for Swiss specific applications. As part of this research, a computational sequence from the in-core burnup phase, through the interim storage, until final disposal is being established. The tools selected for this methodology, referred to as BUCSS-R (Burnup Credit System for Swiss reactors and Repositories), are CASMO for the in-core fuel depletion, the decay module of SERPENT for the decay calculations, and MCNP for the criticality calculations. In connection to BUCSS-R, a computational interface to validated reference core models of the Swiss reactors is being developed. The purpose is to apply reconstructed depletion histories based on real core operation conditions with CASMO assembly calculations, to transfer the pin wise nuclide compositions at discharge to the subsequent SERPENT decay calculations, and afterwards to the final MCNP criticality calculations. An objective of this paper is to present the elements of the BUCSS-R methodology, and to show a first application to so-called bounding analyses of a preliminary Swiss disposal canister design loaded with fuel assembly types operated in a Swiss PWR reactor. The rationale for these bounding analyses is that before starting the integration of methodologies for bias and uncertainty quantifications, the span of the k-eff variation between fresh and burnt fuel loadings should first be quantified in a realistic manner. The obtained results are reported in this paper together with studies performed in order to evaluate the effects from burnup levels and nuclides credit at flooded conditions on the k-eff values. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2020

Dual Phase Soft Magnetic Laminates for Low-cost, Non/Reduced-Rare-Earth Containing Electrical Machines

To accelerate the mass market adoption of electric drive vehicles, the key technology barriers in electric motors are (1) magnet cost and rare-earth element price volatility; (2) non-rare-earth electric motor performance; and (3) materials property optimization. The goal of this project was to address these barriers by advancing a unique and innovative dual phase soft magnetic material technology and demonstrating the material in a 30-kW synchronous reluctance motor without using any permanent magnet for electric vehicles. Dual phase magnetic materials offer the electric motor designer the ability to locally control the magnetic saturation level in a motor laminate, while at the same time enhancing the mechanical strength of the laminate material, resulting in an enhancement in motor performance and efficiency. Scalable dual phase soft magnetic laminates manufacturing technologies were developed in collaboration with multiple US manufacturers. 1000 lbs of alloy sheet with a thickness of 0.25mm and width of 280 mm was manufactured within the specifications. Batch sizes of up to 240 laminates per run were produced from the alloy sheet. Two prototype motors with dual phase soft magnetic laminates were designed, built, and tested. The major goal of building the subscale prototype as a pathway to develop scalable manufacturing technologies for the dual phase soft magnetic laminates was met. The additional goal of building and testing the subscale prototype in order to validate the calculated performance with the tested motor performance was also met. For the full-scale 30kW continuous power synchronous reluctance motor prototype, the tested performance met the targets in terms of continuous power at the operating speeds up to 8000 rpm. Post-test studies were conducted and the root causes for the discrepancy between the predicted and tested peak power, continuous power at high speed range, and efficiency were identified. Further modeling study showed that the dual phase rotor machine has a 27% higher torque to active weight ratio than an equivalent performance silicon steel rotor machine. Application space and multiple discussions with traction motor and electric vehicle manufacturers for commercialization of the dual phase soft magnetic material technology were identified and conducted. An initial cost model was established based on the developed manufacturing technologies with the US manufacturers. Future paths for further cost reduction were identified, including increasing the market volume by broadening the applications of the dual phase soft magnetic laminate technology for electric machines in other energy sections such as oil & gas, heating, ventilation, and air conditioning (HVAC), and power generation.

33 ADVANCED PROPULSION SYSTEMS↗