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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 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Conformable, Composite Tank for Liquid Hydrogen Storage in Heavy-duty Ground Transportation

Raytheon Technologies Research Center (RTRC), with its partners, Argonne National Labs and University of Dayton Research Institute proposed to design and manufacture a conformable composite tank prototype to store liquid Hydrogen (LH2) for heavy-duty truck applications. A dual-wall tank concept was proposed where an outer shell covers and protects an inner pressure vessel that stores liquid hydrogen. The inner pressure vessel is liner-less and designed with a conformable concept, derived from prior RTRC ARPA-E program where multiple vessels are coalesced into one, maximizing space utilization and reducing surface area for heat leak. The gap between the dual wall is evacuated of air pressure, and filled with multi-layer insulation to minimize radiative heat transfer. Fiber reinforced composites were proposed for light-weighting and conformable shape manufacture. To minimize LH2 leakage, carbon nanotubes-infused composites were proposed, in addition to use of thin plies. The project was divided into two 18-month budget periods (BP), BP1 and BP2, separated by a Go/No-Go gate review. The high-level goal for BP1 was to demonstrate the feasibility of the overall approach, the tank design, material selection, and manufacturing methodology, build and test a prototype tank; and the goal for BP2 was to design and manufacture a conformal tank per DOE requirements (minimum 20 kg of LH2) and perform a successful test of the tank. The program was terminated about two-thirds of the way through BP1. The outcome of this program would have permitted long-haul trucks and construction vehicles to use liquid Hydrogen, reducing the emission of green-house gases. This technology is applicable to other transportation sectors as well.

08 HYDROGEN↗
DOE OSTI2014

A BASIS FOR MODIFYING THE TANK 12 COMPOSITE SAMPLING DESIGN

The SRR sampling campaign to obtain residual solids material from the Savannah River Site (SRS) Tank Farm Tank 12 primary vessel resulted in obtaining appreciable material in all 6 planned source samples from the mound strata but only in 5 of the 6 planned source samples from the floor stratum. Consequently, the design of the compositing scheme presented in the Tank 12 Sampling and Analysis Plan, Pavletich (2014a), must be revised. Analytical Development of SRNL statistically evaluated the sampling uncertainty associated with using various compositing arrays and splitting one or more samples for compositing. The variance of the simple mean of composite sample concentrations is a reasonable standard to investigate the impact of the following sampling options. Composite Sample Design Option (a). Assign only 1 source sample from the floor stratum and 1 source sample from each of the mound strata to each of the composite samples. Each source sample contributes material to only 1 composite sample. Two source samples from the floor stratum would not be used. Composite Sample Design Option (b). Assign 2 source samples from the floor stratum and 1 source sample from each of the mound strata to each composite sample. This infers that one source sample from the floor must be used twice, with 2 composite samples sharing material from this particular source sample. All five source samples from the floor would be used. Composite Sample Design Option (c). Assign 3 source samples from the floor stratum and 1 source sample from each of the mound strata to each composite sample. This infers that several of the source samples from the floor stratum must be assigned to more than one composite sample. All 5 source samples from the floor would be used. Using fewer than 12 source samples will increase the sampling variability over that of the Basic Composite Sample Design, Pavletich (2013). Considering the impact to the variance of the simple mean of the composite sample concentrations, the recommendation is to construct each sample composite using four or five source samples. Although the variance using 5 source samples per composite sample (Composite Sample Design Option (c)) was slightly less than the variance using 4 source samples per composite sample (Composite Sample Design Option (b)), there is no practical difference between those variances. This does not consider that the measurement error variance, which is the same for all composite sample design options considered in this report, will further dilute any differences. Composite Sample Design Option (a) had the largest variance for the mean concentration in the three composite samples and should be avoided. These results are consistent with Pavletich (2014b) which utilizes a low elevation and a high elevation mound source sample and two floor source samples for each composite sample. Utilizing the four source samples per composite design, Pavletich (2014b) utilizes aliquots of Floor Sample 4 for two composite samples.

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

Tank 22 Settled Sludge Core Sample Characterization and Testing

The Savannah River National Laboratory (SRNL) was requested by Savannah River Remediation (SRR) Engineering (SRR-E) to provide sample characterization and analyses of Tank 22 settled sludge core sample and the supernatant liquids (supernate) in support of Tank 22 re-baseline data, inhalation dose potential/hydrogen generation and suspension/removal of settled sludge from the bottom of Tank 22. The approximately 9.5 inches of intact Tank 22 core sample from SRR-E, after extrusion in the SRNL Shielded Cells, showed three visually different stratification layers or regions of solids in the extruded core material. Part of the initial physical characterization of these three segments of the Tank 22 core sample included density, weight percent total solids, particle size distribution, X-ray diffractions and scanning electron microscope of each segment material. Given the dissimilarity of the three Tank 22 segment materials after the physical characterization results and the fact that there was no clear line of demarcation to indicate where each segment began and ended across the entire length of the core sample, SRNL in conjunction with the SRR-E customer decided to blend all three segments of the material to form a composite Tank 22 core sample for further analysis and characterization without taking into consideration the proportional weight or mass contribution of each segment. This compositing approach assumes that the errors introduced in any characterization of the Tank 22 core sample will be comparable to the errors when the three segments are separated and combined proportionally by weight to form the composite Tank 22 sample. This compositing approach maximized the quantity of composited Tank 22 material needed for radionuclide and other physical characterizations.

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

Melt-Spun PAN Precursor for Cost-Effective Carbon Fibers in High Pressure Compressed Gas Tankage

The objective of this program was to synthesize melt-spinnable polyacrylonitrile (PAN) precursor that will lead to carbon fiber 25% less expensive than carbon fiber produced from conventional PAN precursor when produced in large volumes. The carbon fiber produced from this precursor needs to achieve ≥ 700 ksi tensile strength with this cost reduction to replace the incumbent fiber. In this program, the technology for producing precursor and then converted carbon fiber (CF) capable of meeting the 700 ksi target was to be demonstrated at a small scale in tows, containing ≥ 100 filaments. If this program moved on to a “Phase 2”, the processes would be scaled up to produce and test Type IV compressed gas storage tanks capable of meeting the 700-bar ultimate targeted FOA performance level. Precursor fiber production typically contributes a large fraction (~50%) to finished CF manufactured cost. Presently, all high strength CFs are manufactured from solution spun PAN precursor, accomplished at low temperatures using large amounts of environmentally unfriendly solvents that impart major impact to line speed and costs involved with handling and reclaiming the solvents and associated “waste streams” required in spinning and extracting those solvents. PAN melt spinning was demonstrated by the company BASF in CF precursor production and used in production of some other acrylic fibers, but significant production challenges remain for meeting the established CF metrics. Melt spinning requires use of plasticizers to suppress the melt temperature of the predominantly PAN formulation to a point sufficiently below the temperature of significant cross-linking. Fortunately, BASF and this team’s earlier work had demonstrated acrylic formulations melt spun with combinations of plasticizing solvents at much lower solvent levels. This project team made significant progress in understanding technical issues and identifying formulation pathways in earlier work in this area where >250ksi strength was achieved. The goal of this program was to pursue a more comprehensive approach with a larger, more diverse team having greater equipment design and overall production capabilities to push rapidly beyond the science to resolve remaining “engineering” issues associated with establishing stable, continuous processes for precursor fiber leading to enhanced, cost-effective CF and composite tank production.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Characterization of Tank 51 Sludge Slurry Samples (HTF-51-17-67, -68, -69, -74, -75, and -76) in Support of Sludge Batch 10 Processing

The Savannah River National Laboratory (SRNL) was requested by Savannah River Remediation (SRR) Engineering (SRR-E) to provide sample characterization and analyses of Tank 51 sludge samples in support of Sludge Batch (SB) 10. The six Tank 51 sludge samples were sampled and delivered to SRNL in August of 2017. These six Tank 51 sludge samples, after undergoing physical characterizations which included rheology, weight percent total solid, dissolved solids and density measurements, were combined into one composite Tank 51 sample and analyzed for corrosion controls analytes, select radionuclides, chemical elements, density and weight percent total solids.

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

Characterization and CST Batch Contact Equilibrium Testing of Modified Tank 9H Process Supernate Samples in Support of TCCR

The Tank Closure Cesium Removal (TCCR) system uses ion exchange columns filled with crystalline silicotitanate (CST) media to process radioactive waste solutions for the removal of ¹³⁷Cs. TCCR currently focuses on dissolving Savannah River Site (SRS) radioactive tank waste (primarily sodium saltcake solids) within Tank 10H followed by at-tank ion exchange column treatment. Two supernate batches from Tank 10H have been processed through the TCCR unit and processing of a third batch is expected soon. After processing of this supernate batch, plans are to replace the CST columns and process dissolved salt solution from Tank 9H through Tank 10H and then through the new CST columns installed in the TCCR unit. The new columns are expected to contain either a media similar to an archived CST batch (IE-911) or the R9120-B CST media used in the current TCCR columns (the two materials are fundamentally the same; just different specifications, product names, and preconditioning steps). Samples of Tank 9H dissolved saltcake were received at the Savannah River National Laboratory (SRNL) and characterized. The Tank 9H supernate contained a high sodium concentration (~9.6 M Na⁺) and will require dilution to near 6 M [Na⁺] prior to processing through the TCCR unit. The cesium concentration in Tank 9H is currently significantly higher than was observed with Tank 10H. Three dilutions of the Tank 9H supernate were conducted to mimic possible dilutions that could be conducted in the tank farm prior to TCCR processing using inhibited water, sodium hydroxide, and sodium nitrate solutions. Dilution #1 was prepared by diluting the Tank 9H supernate by a factor of 1.6 with inhibited water, Dilution #2 was prepared by diluting the Tank 9H supernate by a factor of 3.7 with a mixed sodium hydroxide/sodium nitrate diluent, and Dilution #3 was prepared by also diluting by a factor of 3.7 but with sodium hydroxide only. All three dilutions have similar Na⁺ concentrations (~6 M), but Dilutions #2 and #3 contain significantly less cesium. Major and key minor components of the diluted Tank 9H supernate samples are provided in Table ES-1. Batch contact equilibrium tests were conducted with the Tank 9H dilutions and the two different CST media batches being considered for use in the new TCCR columns. Results are summarized in Table ES-2 and compared to ZAM model predictions. The highest cesium distribution coefficient and percent removal were observed with Dilution #3. IE-911 CST (an archived CST media batch) was more effective at removing cesium than the more recently prepared R9120-B CST media, though both media samples removed >88% of the cesium and the differences may not be statistically different considering the overall uncertainty. Based on the results, maximum cesium loadings were calculated for each CST media type and Tank 9H dilution. In general, maximum cesium loadings from dilutions of this supernate batch are quite high (approaching 0.1 mmol total Cs⁺/g CST for Dilution #1). The highest calculated maximum ¹³⁷Cs loading for the Tank 9H dilutions using the ZAM model with input of the tank compositions and batch contact results was 207 Ci/kg CST (Dilution #1 with IE-911 CST). In all cases, higher maximum cesium loading values were predicted for IE-911 CST versus R9120-B, although the differences varied considerably between the dilutions. The maximum loading value for IE-911 CST with Tank 9H Dilution #1 was only 7% higher than the maximum loading for R9120-B. The maximum loading value for IE-911 CST with Dilution #3 was 24% higher than the maximum loading for R9120-B. Dilution #2 was intermediate between these values. Note that these maximum loading values are the theoretical calculated values, and actual operating conditions will cause differences. A CST binder dilution (correction) factor near 0.7 (relative to pure powder CST) was required for each batch contact test with IE-911 engineered CST using the three Tank 9H dilutions. Correction factors calculated for R9120-B CST ranged from 0.56 to 0.66 for the three dilutions. Following the batch contact tests, the CST samples were isolated from the Tank 9H solution, washed, dried, and digested in acid following established procedures. The analysis results are provided in Table ES-3. Total cesium loading values determined by CST digestion were similar to the calculated loading values based on solution analysis (Table ES-2) for all samples. In addition, the CST was observed to load calcium (R9120-B sample only), iron, strontium, lead, uranium, and plutonium after contact with the waste supernate, as has been observed previously.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2023

Liquid hydrogen storage system for heavy duty trucks: Configuration, performance, cost, and safety

In this work, we investigate the potential of liquid hydrogen storage (LH 2 ) on-board Class-8 heavy duty trucks to resolve many of the range, weight, volume, refueling time and cost issues associated with 350 or 700-bar compressed H 2 storage in Type-3 or Type-4 composite tanks. We present and discuss conceptual storage system configurations capable of supplying H 2 to fuel cells at 5-bar with or without on-board LH 2 pumps. Structural aspects of storing LH 2 in double walled, vacuum insulated, and low-pressure Type-1 tanks are investigated. Structural materials and insulation methods are discussed for service at cryogenic temperatures and mitigation of heat leak to prevent LH 2 boiloff. Failure modes of the liner and shell are identified and analyzed using the regulatory codes and detailed finite element (FE) methods. The conceptual systems are subjected to a Failure modes and effects analysis (FMEA) and a safety, codes, and standards (SCS) review to rank failures and identify safety gaps. The results indicate that the conceptual systems can reach 19.6% usable gravimetric capacity, 40.9 g-H 2 /L usable volumetric capacity and $174-183/kg-H 2 cost (2016 USD) when manufactured 100,000 systems annually.

08 HYDROGEN↗
DOE OSTI2017

Analysis of Hanford Cast Stone Supplemental LAW using Composition Adjusted SRS Tank 50 Salt Solution

Vitrification is the primary disposition path for Low Activity Waste (LAW) at the Department of Energy (DOE) Hanford Site. A cementitious waste form is one of the alternatives being considered for the supplemental immobilization of the LAW that will not be treated by the primary vitrification facility. Washington River Protection Solutions (WRPS) has been directed to generate and collect data on cementitious or pozzolanic waste forms such as Cast Stone.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2015

Advanced waste form and Melter development for treatment of troublesome high-level wastes

A number of waste components in US defense high level radioactive wastes (HLW) have proven challenging for current Joule heated ceramic melter (JHCM) operations and have limited the ability to increase waste loadings beyond already realized levels. Many of these “troublesome" waste species cause crystallization in the glass melt that can negatively impact product quality or have a deleterious effect on melter processing. Recent efforts at US Department of Energy laboratories have focused on understanding crystallization behavior within HLW glass melts and investigating approaches to mitigate the impacts of crystallization so that increases in waste loading can be realized. Advanced glass formulations have been developed to highlight the unique benefits of next-generation melter technologies such as the Cold Crucible Induction Melter (CCIM). Crystal-tolerant HLW glasses have been investigated to allow sparingly soluble components such as chromium to crystallize in the melter but pass out of the melter before accumulating.The Hanford site AZ-101 tank waste composition represents a waste group that is waste loading limited primarily due to high concentrations of Fe 2 O 3 (also with high Al 2 O 3 concentrations). Systematic glass formulation development utilizing slightly higher process temperatures and higher tolerance to spinel crystals demonstrated that an increase in waste loading of more than 20% could be achieved for this waste composition, and by extension higher loadings for wastes in the same group. An extended duration CCIM melter test was conducted on an AZ-101 waste simulant using the CCIM platform at the Idaho National Laboratory (INL). The melter was continually operated for approximately 80 hours demonstrating that the AZ-101 high waste loading glass composition could be readily processed using the CCIM technology. The resulting glass was close to the targeted composition and exhibited excellent durability in both the as poured state and after being slowly cooled according to the canister centerline cooling (CCC) profile. Glass formulation development was also completed on other Hanford tank wastes that were identified to further challenge waste loading due to the presence of appreciable quantities (>750 g) of plutonium in the waste tanks. In addition to containing appreciable Pu quantities, the C-102 waste tank and the 244-TX waste tank contain high concentrations of aluminum and iron, respectively that will further challenge vitrification processing. Glass formulation testing also demonstrated that high waste loadings could be achieved with these tank compositions using the attributes afforded by the CCIM technology.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2018

Investigation of Tank 241-AW-104 Composite Floating Layer

Seven grab samples and one field blank were taken from Tank 241-AW-104 (AW-104) on June 2, 2017, and received at 222-S Laboratory on June 5, 2017. A visible layer with brown solids was observed floating on the top of two surface tank waste samples (4AW-17-02 and 4AW 17 02DUP). The floating layer from both samples was collected, composited, and submitted for chemical analyses and solid phase characterization in order to understand the composition of the floating layer. Tributyl phosphate and tridecane were higher in the floating layer than in the aqueous phase. Density in the floating layer was slightly lower than the mean density of all grab samples. Sodium nitrate and sodium carbonate were major components with a trace of gibbsite and very small size agglomerates were present in the solids of the floating layer. The supernate consisted of organics, soluble salt, and particulates.

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

Method Development and Implementation for Characterizing Uncertainties in Tank Leak Volumes for Composite Analysis.

The purpose of this environmental calculation file (ECF) is to provide a summary of methodology, inputs, assumptions, and results of a Special Analysis (SA) titled “Method Development and Implementation for Characterizing Uncertainties in Tank Leak Volumes for the Updated Composite Analysis.” This SA is one of the three SAs conducted in Fiscal Year (FY) 2024 for the Composite Analysis (CA) for the Hanford Site (DOE/RL-2019-52, Composite Analysis for Low-Level Waste Disposal in the Hanford Site Central Plateau (FY 2020)), and it is performed following the Unreviewed Composite Analysis Question Evaluation procedure, UCAQ-24-01-E (UCAQ-24-01-E, Rev. 0).

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2018

Investigation of Tank 241-AW-104 Composite Floating Layer

Seven grab samples and one field blank were taken June 2, 2017. A visible layer with brown solids was observed floating on the top of two surface tank waste samples (4AW-17-02 and 4AW 17 02DUP). The floating layers were collected, composited, and submitted for chemical analyses and solid phase characterization in order to understand the composition of the floating layer. Tributyl phosphate and tridecane were higher in the floating layer than in the aqueous phase. Density in the floating layer was slightly lower than the mean density of all grab samples. Sodium nitrate and sodium carbonate were major components with a trace of gibbsite and very small size agglomerates were present in the solids of the floating layer. The supernate consisted of organics, soluble salt, and particulates. These agglomerates include uranium extruded from the supernate by the floating organics.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2023

Temperature Rise on Liner Surfaces of Fuel Cell Electric Vehicle Tanks during Fueling Process

Herein, the temperature of the inner tank walls, or plastic liners, of composite pressure tanks in fuel cell electric vehicles during fueling using three‐dimensional computational fluid dynamics (CFD) models is evaluated. The liner materials are limited to 85.0 °C to prevent thermal stress causing material failure that would result in a hydrogen leak. Therefore, the temperature of hydrogen gas must be limited to below 85.0 °C during the fueling process as dictated by the current fueling protocol. However, there are limited experimental or simulation data confirming that the temperature changes do not exceed the threshold. Herein, the liner temperatures with CFD tank models for two sizes of type IV tanks representative of the upper and lower system bounds that are close to the SAE J2601 fueling protocol (36.0 and 244.0 L) are evaluated. First, each model's reliability is validated with experimental data and then analyzed, and the data are used to evaluate the maximum hydrogen and liner temperatures under real‐world fueling conditions. The evaluation shows that the maximum liner surface temperature of each tank model is at least 7 °C lower than that of the hydrogen. Additionally, there is at least 12 °C difference found between the upper limit and actual liner temperatures.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2018

The Development of the Corrosion Control Limits for Direct Feed Low-Activity Waste Melter-Off Gas Returns to Hanford Tank Farms - 18196

The Savannah River National Laboratory has been developing a corrosion model to facilitate implementation of Hanford's Direct Feed Low Waste (DFLAW) flowsheet. Laboratory testing and statistical analysis have been used to determine the necessary corrosion controls for returning effluent from the Hanford Waste Treatment and Immobilization Plant's Low Activity Waste Vitrification melter off-gas treatment system to the tank farms. The stream compositions are projected to contain components at relative concentrations that are significantly more corrosive toward carbon steel, specifically halide and sulfate anions, than the current waste compositions in the tank farms. Administrative programs are in place to mitigate potential corrosion mechanisms and thereby maintain the structural and leak integrity functions of these waste tanks throughout their intended service life. Waste chemistry and temperature control are the means by which corrosion degradation of the waste tanks is minimized. The current administrative specification for chemical composition and temperature for the underground carbon steel waste tanks is not designed to control the higher halide or sulfate composition. The content of the DFLAW waste streams will be diverse and depend on several factors, such as the melter feed composition and melter idle time. Other factors, such as effluent management of the off gas water collections, will impact the variability of the return streams even more. The work performed by the Savannah River National Laboratory has confirmed that the halide ions are the most aggressive species in the return stream compositions projected using a flowsheet simulation, and nitrite is the most effective inhibitor at pH 10 and 40 deg. C. This test program has employed statistically designed test matrices to determine the dependent variables and the interaction terms between the variables that are significant for the corrosion model and definition of the corrosion control specifications. The first phase of testing focused on identifying aggressive species in off-gas condensate return compositions that present a propensity for localized corrosion attack, namely pitting corrosion. The second phase of testing focused on developing a corrosion model from the interaction terms that will predict the susceptibility of pitting in the double shell tank system based on waste composition and the required amount of corrosion inhibitor. The data collected from this testing program in conjunction with other testing programs, both at the Savannah River Site and the Hanford Site, along with operations knowledge, has determined the chemistry ranges and chemical species requirements for corrosion control in the Hanford double-shell tank system for the effluents generated in the Hanford Waste Treatment and Immobilization Plant's Low Activity Waste facility during the DFLAW phase of operations. (authors)

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

Thermoplastic Composite Compressed Gas Storage (CGS) Tanks

This report summarizes the progress made on utilizing polyamide carbon fiber tapes for composite overwrapped pressure vessels (CPVs) using Automated Fiber Placement (AFP). This project is joint development project run through the Institute for Advance Composite Manufacturing Innovation (IACMI) with DuPont, Steelhead Composites, University of Dayton Research Institute, and the Composites Prototyping Center. Over the course of this program, the Team developed and/or demonstrated the materials and processes that are required to produce vessels for compressed gas storage, including polyamide matrix formulation, unidirectional polyamide/carbon fiber tape production, and automated fiber placement on a vessel liner. In addition, a cost of manufacture analysis was performed that compares Type III and Type IV vessels made with both thermoplastic and thermoset chemistries. This report summarizes the myriad of technical advances made during this project, culminating with production and testing of an aluminum-lined Type III pressure vessel. Each step was optimized locally so as to produce the best material. The end result was a test vessel that, while demonstrating some of the benefits of thermoplastic matrix composites, did not perform as well as those produced by filament winding of carbon fiber/epoxy prepregs. This was most likely due to the Team’s focus on local optimization rather than globally optimizing the entire process from beginning to end. Should further work be contemplated, a more focused effort on global optimization should be pursued.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗