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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Development of a conduction-based model for analyzing frozen startup of alkali-metal heat pipes

One key area of interest in heat pipe modeling/simulation is to analyze the startup behavior of the liquid-metal heat pipes (LMHPs) from a frozen state. This so-called ‘frozen startup’ process involves a complex set of nonlinear mass and heat transport phenomena, including phase transitions from solid to liquid and vapor, multiphase interactions, microporous wick flow, and compressible vapor dynamics. The complexity of these processes makes it challenging to simulate LMHP’s frozen startup using conventional numerical methods or commercial computational fluid dynamics (CFD) software. This paper presents a simplified conduction-based modeling approach that can provide practical insights into the entire LMHP frozen startup process, while alleviating the challenges of modeling its complex physics. The theoretical foundation and physical assumptions of the proposed model are based solely on heat-conduction equation, allowing for a more tractable simulation without sacrificing essential physical accuracy. The proposed model was implemented in a commercial CFD software, and its prediction was compared with the experimental data obtained from sodium heat-pipe startup experiments. The comparison highlights the proposed model's ability to capture the transient thermal behavior of LMHP during frozen startup. This study not only validates the conduction-based frozen startup modeling method but also shows its potential as a practical and efficient tool for understanding the startup performance of the LMHP systems.

Microreactor↗
DOE OSTI2022

A CONDUCTION-BASED HEAT PIPE MODEL FOR ANALYZING THE ENTIRE PROCESS OF LIQUID-METAL HEAT PIPE STARTUP

The Heat Pipe-cooled Microreactor (HPM) is one of the micro nuclear reactor designs under active study at the U.S. Idaho National Laboratory. Among the major concerns of HPM research is to understand the startup behavior of the heat pipe-cooled system associated with the startup of the liquid-metal heat pipes initialing from frozen state. The startup of liquid-metal heat pipes typically involves a number of nonlinear mass and heat transport processes including the phase change from solid to liquid and vapor. Hence, it is still a huge challenge to simulate the liquid-metal heat pipe startup using conventional CFD methods and software. The major difficulties of numerical CFD modeling come from the phase-change process, multiphase interaction, microporous wick flow, and compressible gas dynamics that occur during startup of the liquid-metal heat pipes. This paper proposes a simplified conduction-based method to provide practical insights into the entire startup process of the liquid-metal heat pipes while mitigating the challenges of addressing all the complex physics. We discuss the theoretical basis and modeling assumptions to analyze the liquid-metal heat pipe startup from frozen state based solely on heat-conduction equations. Then, the proposed model is implemented into the commercial CFD software to verify the model performance. The model prediction results are discussed via the comparison with the experimental data obtained from sodium heat-pipe startup experiments.

42 ENGINEERING↗
DOE OSTI2019

A Model for Lean Corporate/ Startup Interfaces: Unlocking Resources of Midcap Corporations Providing a Pathway to Advanced Energy Technologies

Commercializing energy technologies through traditional market pathways is challenging for early-stage energy innovators. Development cycles in energy are long and expensive, and adoption is difficult, making energy technologies of limited interest to venture capital relative to industries with faster growth and shorter product life cycles such as life sciences and software. As such, partnerships with established corporations are one of the most promising, and in some cases only, go-to-market pathways for energy technologies. Startups often seek to work with, large well-known Fortune 500 (and similar) companies. However, the size and risk aversion of those firms often makes partnering challenging. It can take well over 12 months for a large corporation to agree to commercial terms and get internal board / management approval to move forward with a binding agreement with a startup for even a simple starting partnership. This timeline is prohibitive for most early-stage companies who are both time and money constrained, and often working in highly competitive commodity sectors. Mid-cap corporations ($\$ $100M to $\$ $10B) are a promising but untapped resource for partnering with technology developers because they are often nimbler, tend to be fiercely competitive, and are looking for new revenue or cost-saving opportunities. These factors make them both more receptive to disruptive technologies, and more capable of integrating them. However, while Fortune 500 companies often have venturing groups that facilitate the initial connection process, most midcap incumbents do not have the resources to create standalone corporate venture groups. As a result, although they could help each other significantly (startup technologies make midcaps more competitive; midcaps offer a faster commercialization pathway to startups), midcap companies and startups rarely work together. In 2017, ADL Ventures (ADL) received Award #DE-EE0008111 from DOE EERE’s Innovative Pathways program to unlock the domain expertise and material resources of midcap companies. The goal of the award was to support energy technology commercialization via an innovation platform for startups to interface with midcap corporations. During the grant period, we have developed a novel open innovation platform that allows financially conservative incumbents to efficiently engage with energy innovators and startups, thereby unlocking the incumbents’ domain expertise, strategic capital, R&D facilities, supply chain, and pathways to market. We have executed full-scale open innovation challenges for three clients, exceeding the initial proposed goal of two. We also built a diversified opportunity pipeline which resulted in four projects contracted for 2020, meeting the goals of the proposal, with others pending.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2022

FFTF Acceptance and Startup Testing for GAIN

The Fast Flux Test Facility (FFTF) is the most recent liquid metal reactor (LMR) to be designed, constructed, and operated by the U.S. Department of Energy (DOE). The 400-MWt sodium-cooled, fast-neutron flux reactor plant was designed for irradiation testing of nuclear reactor fuels and materials for liquid metal fast breeder reactors. Following the demise of the breeder reactor program in the United States, FFTF continued to play a key role in providing a test bed for demonstrating performance of advanced fuel designs and demonstrating operation, maintenance, and safety of advanced liquid metal reactors. FFTF operations ceased in April 1992 after a determination by DOE that no combination of proposed missions was financially feasible over a ten-year period. The reactor is currently deactivated and in a long-term surveillance and maintenance (S&M) mode. This report provides information on the extensive and rigorous process that was used to conduct turnover from construction followed by acceptance and startup testing of the FFTF. This paper is in support of the Gateway for Accelerated Innovation in Nuclear (GAIN), which provides the nuclear energy community with access to the technical, regulatory, and financial support necessary to move new or advanced nuclear reactor designs toward commercialization while ensuring the continued safe, reliable, and economic operation of the existing nuclear fleet. The information obtained from the design, startup, and operation of the FFTF provides valuable insight for follow-on reactor projects, such as the Versatile Test Reactor (VTR), in the areas of plant system and component design, component fabrication, fuel design and performance, prototype testing, site construction, reactor startup and operations, and reactor deactivation and decommissioning (D&D). The focus of this report is on the process used to startup the FFTF and to ensure that operations could be conducted efficiently and safely. A reference section is provided of documents detailing the successful turnover and testing process implemented for startup of the reactor and its supporting systems. The documents listed can be retrieved upon request and are believed useful for future reactor startup endeavors.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2019

Reduced model for direct induction startup scenario development on MAST-U and NSTX-U

A reduced semi-empirical model using time-dependent axisymmetric vacuum field calculations is used to develop the prefill and feed-forward coil current targets required for reliable direct induction (DI) startup on the new MA-class spherical tokamaks, MAST-U and NSTX-U. The calculations are constrained by operational limits unique to each device, such as the geometry of the conductive elements and active coils, power supply specifications and coil heating and stress limits. The calculations are also constrained by semi-empirical models for sufficient breakdown, current drive, equilibrium and stability of the plasma developed from a shared database. A large database of DI startup on NSTX and NSTX-U is leveraged to quantify the requirements for achieving a reliable breakdown (I p ~ 20 kA). It is observed that without pre-ionization, STs access the large E/P regime at modest loop voltage (V loop ) where the electrons in the weakly ionized plasma are continually accelerating along the open field lines. This ensures a rapid (order millisecond) breakdown of the neutral gas, even without pre-ionization or high-quality field nulls. The timescale of the initial increase in I p on NSTX is reproduced in the reduced model provided a mechanism for impeding the applied electric field is included. Most discharges that fail in the startup phase are due to an inconsistency in the evolution of the plasma current (I p ) and equilibrium field or loss of vertical stability during the burn-through phase. Here, the requirements for the self-consistent evolution of the fields in the weakly and fully-ionized plasma states are derived from demonstrated DI startup on NSTX, NSTX-U and MAST. The predictive calculations completed for MAST-U and NSTX-U illustrate that the maximum I p ramp rate (dI p /dt) in the early startup phase is limited by the voltage limits on the poloidal field coils on MAST-U and passive vertical stability on NSTX-U.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2019

Spatially resolved degradation during startup and shutdown in polymer electrolyte membrane fuel cell operation

Polymer electrolyte membrane fuel cells have durability limitations associated with the startup and shutdown of the fuel cell, which is critical for real-world vehicle commercialization. During startup or shutdown, there exists an active region (hydrogen/air) and a passive region (air/air) between the cell inlet and outlet. Internal currents are generated in the passive region causing high-potential excursion in the cathode leading to accelerated carbon corrosion. In this study, a segmented cathode hardware is used to evaluate the effect of platinum loading on both cathode and anode, and carbon support material on degradation due to repeated series of startups or shutdowns. Here, in situ losses in the performance and electrochemical surface area were measured spatially, and ex situ analysis of the catalyst layer thickness and platinum particle size was performed to understand the effect of startup or shutdown on different membrane electrode assembly materials. Startup degrades the region near anode outlet more, while shutdown degrades the region near anode inlet more compared to the rest of the electrode. While various system mitigation strategies have been reported in the literature to limit this degradation, one materials mitigation strategy is to limit the anode's ability to reduce oxygen to water through increasing the ratio of platinum loading in the cathode to the anode, or by using a bi-functional catalyst.

25 ENERGY STORAGE↗
DOE OSTI2019

Reduced Model for Direct Induction Startup Scenario Development on MAST-U and NSTX-U

A reduced semi-empirical model using time-dependent axisymmetric vacuum field calculations is used to develop the prefill and feed-forward coil current targets required for reliable direct induction (DI) startup on the new MA-class spherical tokamaks, MAST-U and NSTX-U. The calculations are constrained by operational limits unique to each device, such as the geometry of the conductive elements and active coils, power supply specifications and coil heating and stress limits. The calculations are also constrained by semi-empirical models for sufficient breakdown, current drive, equilibrium and stability of the plasma developed from a shared database. A large database of DI startup on NSTX and NSTX-U is leveraged to quantify the requirements for achieving a reliable breakdown (Ip ~ 20 kA). It is observed that without pre-ionization, STs access the large E/P regime at modest loop voltage (Vloop) where the electrons in the weakly ionized plasma are continually accelerating along the open field lines. This ensures a rapid (order millisecond) breakdown of the neutral gas, even without pre-ionization or high-quality field nulls. The timescale of the initial increase in Ip on NSTX is reproduced in the reduced model provided a mechanism for impeding the applied electric field is included. Most discharges that fail in the startup phase are due to an inconsistency in the evolution of the plasma current (Ip) and equilibrium field or loss of vertical stability during the burn-through phase. The requirements for the self-consistent evolution of the fields in the weakly and full-ionized plasma states are derived from demonstrated DI startup on NSTX, NSTX-U and MAST. The predictive calculations completed for MAST-U and NSTX-U illustrate that the maximum Ip ramp rate (dIp/dt) in the early startup phase is limited by the voltage limits on the poloidal field coils on MAST-U and passive vertical stability on NSTX-U.

Direct induction↗
DOE OSTI2024

Approach to startup inventory for viable commercial fusion power plant

With the increasing efforts to commercialize fusion power, private and government organizations are investing heavily in the development of technology to support a viable fusion power plant. Deuterium-Tritium (DT) fueled reactors are more prevalent than other proposed designs, requiring tritium processing and handling technology for safe operations and self-sufficiency. Further, each fusion power plant will need a specific-to-design startup inventory of tritium to begin operations. This startup inventory is required prior to breeding and is the minimum tritium inventory required to fill each processing component in the fuel cycle, to offset radioactive decay losses, and to avoid a zero-fuel situation for continuous operation. We present an approach to calculate the startup tritium inventory for a 500 MW th reactor, with considerations for reserve inventory for maintenance and commissioning. A baseline startup inventory was calculated to be approximately 327 gs. This value was obtained using modest assumptions about the technology and operating parameters of a fusion power plant. The required operating reserve inventory or the inventory necessary to keep a fusion power plant operational using only direct internal recycling for 24 h for the same plant design is approximately 642 gs. The approach and findings of this paper will enable fusion energy stakeholders to better utilize the existing scarce global tritium supply.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2023

An Ultra-Fast Inrush-Current-Free Startup Method for Grid-tie Inverter without Voltage Sensors

This paper proposes an ultra-fast inrush-currentfree startup method for grid-tie inverters without voltage sensors and phase-locked loop (PLL). Traditionally, the grid-tie inverter needs the voltage measured from points of common couplings (PCC) to generate the phase angle via PLL for inverter pulsewidth- modulation (PWM) signals. The startup procedure is slow and inrush current occurs if the initial PWM does not match the unknown grid voltage well. This paper proposes a startup method that only uses measured inverter ac currents to generate the initial PWM by controlling the current to zero. The generated PWM pattern can be used to reproduce the real grid voltage regardless of the grid impedance. The zero-crossing points of the grid voltage are detected and then used for grid synchronization. The proposed startup procedure only needs a few cycles (16.67 ms/cycle) to reliably synchronize the inverter to the grid without any inrush current. Simulation and experimental results are presented to verify the effectiveness of this control strategy.

He, Yuchen↗
DOE OSTI2023

Startup process for a dual active bridge converter to prevent over-voltage failure and thermal run-away

A system and method for controlling a dual active bridge based DC/DC converter. A controller implements a startup control scheme and DC bus pre-charge routine to prevent damage to the converter upon startup. During startup of the converter, the startup control process can be used to prevent excessive phase-shift and the DC bus pre-charge routine adjusts the pulse width modulated duty cycle by increasing the dead time between signals, resulting in a decreased DC bus capacitor.

Singh, Braj K.↗
DOE OSTI2024

Switching-cycle-based Startup for Grid-connected Inverters

Conventional inverter startups, or grid synchronization, are hindered by slow dynamics and inrush current issues, which impede the integration of more renewable energy resources into the power grid. This paper overcomes the barriers by introducing a novel switching cycle-based startup approach for grid-connected inverters, eliminating the need for voltage sensors and phase-locked loops (PLLs). The proposed method surpasses the bandwidth constraints of traditional PLL-based techniques and achieves grid synchronization in just two switching cycles. Relying solely on sensed three-phase currents, synchronization is accomplished without inrush currents or the need for additional hardware or increased software complexity, resulting in a faster inverter startup. The paper also presents a sensitivity analysis to discuss the impact of critical parameters on the method's accuracy. As a result, the effectiveness of the proposed technique is demonstrated through simulation and experimental results.

14 SOLAR ENERGY↗
DOE OSTI2025

Impact of molten salt inflow on the temperature distribution in thermal energy storage tanks at startup for central receiver concentrating solar power plants

Concentrating Solar Power (CSP) systems with molten salt thermal energy storage (TES) tanks are one of the most promising, renewable-based energy conversion technologies for larger-scale power generation. The TES tank is one of the most critical components in CSP plants due to its high-temperature operation (up to 565 °C), daily thermal cycling, and intermittent solar radiation conditions. The plant startup is one of the most challenging operation conditions that could lead to damaging thermal gradients due to low salt inventory levels. In this study an analytical model for the sparger ring was developed and integrated with a detailed computational fluid dynamics model of a commercial-scaled molten salt tank. The integrated model allows an accurate representation of the tank operation to evaluate the effect of molten salt inflow on the mixing process. The tank filling process during plant startup was analyzed considering sparger rings with variations in design features, including inlet orifice configurations, number of orifices, direction of the inlets, and orifice diameter. The results demonstrated that higher temperature gradients are obtained in the tank floor during the plant startup. A sparger ring configuration with a predetermined orifice inlet inclination (30°, 45° and 60°) leads to significant temperature differences in the floor, between 57 °C and 62 °C, but better homogeneity in the temperature of the salt inventory. Lower salt inflow velocities result in a more homogeneous floor temperature, with maximum temperature differences under 38 °C. The sparger ring configuration with 52 orifices of 1-in. diameter and vertical flow showed better homogeneity in the temperature differences as a function of the salt level and lower temperature gradients in the tank floor. Because large temperature gradients in the tank's floor have been identified as one of the main factors contributing to tank failures, assessing various sparger ring design features is fundamental to determining proper inflow conditions that lead to low-temperature gradients and reducing failure susceptibility.

14 SOLAR ENERGY↗
DOE OSTI2021

Startup Test Plan and Predictions for Highly Enriched Uranium to Low-Enriched Uranium Fuel Conversion at the University of Missouri Research Reactor

Nonpower reactors licensed by the U.S. Nuclear Regulatory Commission require a startup test plan as part of any facility modification to verify operability prior to resumption of operations. In order to support conversion of the University of Missouri Research Reactor from the use of highly enriched uranium to low-enriched uranium (LEU) fuel, a startup test plan has been devised to measure certain reactor physics parameters for the initial all-fresh LEU core licensing documentation that will be submitted. These parameters include the approach to critical, primary coolant void coefficient of reactivity, flux trap void coefficient of reactivity, determination of flux trap sample reactivity worth, radial and axial thermal neutron flux mapping, control blade worth calibration, primary and pool coolant temperature coefficient of reactivity, and flux mapping of experimental positions. Here, predictions for these parameters made using the Monte Carlo N-Particle Version 5 (MCNP5) radiation transport code are reported. These predictions will support the startup tests by providing a baseline set of expectations and additional insight into the performance of the LEU core.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Employing MACS/ViBRANT as a Surrogate MARVEL Reactor for Startup Reactivity Tuning and Supervisory Control Processes

Advanced nuclear reactors are a key part of the future of nuclear energy both in the United States and globally. They offer unique benefits for various energy-demanding applications, including use in remote locations, compact size, modular manufacturing, remote monitoring, low and/or variable power rating operation, and reliance on novel technologies to enhance operational safety. To achieve economic feasibility, advanced reactors must significantly reduce their workforces in comparison with the current fleet. Achieving this reduction will occur through reducing staff workloads using technology to achieve autonomous or semi-autonomous operations, demonstrated by comprehensive testing and validation activities. These operations will require both software and hardware platforms during the design and testing phases. While simulations are useful during the design phase, their performance can significantly deviate during actual deployment on hardware. This report presents the outcomes of a collaborative technical initiative between the U.S. Department of Energy (DOE) Microreactor Program (MRP) and Advanced Sensors and Instrumentation (ASI) Program. The collaboration utilized the Microreactor Automated Control System (MACS) hardware platform to bridge the gap between theoretical reactor design and actual startup and control operations. Two key use cases were investigated: facilitating the startup testing period and demonstrating supervisory control. The first use case details the key Microreactor Applications Research Validation and Evaluation (MARVEL) reactor startup physics testing activities conducted using the MACS platform. These activities included drum worth measurements, shutdown margin assessment, temperature feedback analysis, and scram time evaluation, as well as unique testing that would apply to the MARVEL reactor to demonstrate the testing methodologies in a low-risk environment. The MACS platform, serving as a surrogate representation of the MARVEL reactor, proved instrumental in performing these tests. The exercise revealed aspects that led to optimized processes, refined hardware design, and enhanced base software capabilities. By maturing methods and technologies in this manner, the initiative promises to reduce wasted time in the actual on-site reactor deployment effort, thereby saving significant time and resources. The second use case focuses on the development and implementation of supervisory control methods aimed at managing core tilt, which can result from asymmetrical operations or manufacturing imperfections in fuel rods or reactivity control devices. A key objective was to assess and compare the use of artificial intelligence (AI) for supervisory control. The effort aimed to define the role of supervisory control to enhance performance without risking control instability. This effort explored three distinct approaches: rules-based (RB) methods, optimization techniques, and reinforcement learning (RL) algorithms. Each approach was evaluated for its ease of implementation, its usability, and its effectiveness in responding to asymmetries in neutron flux. Comparative analysis of these approaches provided valuable insights into their applicability and effectiveness, offering a robust framework for advanced reactor operations. Together, these two use cases highlight the potential of hardware test beds to help streamline the design, operation, and control of advanced nuclear reactors. This collaborative effort underscores the importance of continued innovation and experimentation in achieving the next generation of safe, reliable, and economically viable nuclear energy solutions.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Modeling Nuclear Thermal Propulsion Startup Transients

A poster for the 2021 intern poster session. This poster details the RELAP-7/Griffin model developed for transient simulations to compare the effects of startup sequencing on the propellant efficiency, startup time, and maximum core temperature of a nuclear thermal propulsion (NTP) system. The sequencing parameters under consideration in this study are the ramping rates of both reactivity insertion and hydrogen propellant mass flow rate. Recommendations are made regarding startup sequencing based on the results produced by this model.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2026

Modeling heat pipe startup and noncondensable gases in Sockeye

For this work, a one-dimensional gas mixture flow model was developed and implemented in the heat pipe code Sockeye to model the effects of noncondensable gases. Additionally, a startup model based on the dusty gas model was implemented to model the transition from rarefied gas dynamics to continuum flow, which occurs during the frozen startup of high-temperature heat pipes. Multiple startup and noncondensable gas models were tested against experimental data for sodium heat pipes, showing excellent agreement. Additionally, the newly developed gas mixture model for modeling noncondensable gas is further tested with a theoretical case study with arbitrary heating configurations. Finally, several recommendations and conclusions are made from the studies in this work to guide future heat pipe modeling efforts.

97 - MATHEMATICS AND COMPUTING↗
DOE OSTI2021

Recipes for a Successful Exit for Clean- and Hard-tech Startups

This study demonstrates the combinations of multiple causal factors that formulate a startup’s strategy to successfully “exit”, namely “recipes for a successful exit,” in the clean- and hard-tech sector. We identify seven key causal factors (i.e., causal conditions) that impact startup success, including commercial readiness, investor interactions, favorable industry, non-financial support, straightforward development path, experienced team, and visibility to investors. We also investigate the combinations of selective causal conditions that can provide further synergetic impact. We conduct the fuzzy-set qualitative comparative analysis (fsQCA) on seven US clean and hard-tech startups that exited between 2005 and 2016. The successful companies all demonstrate distinctive characteristics based on three general categories (1) robust ecosystem; (2) heavy-lifting team; or (3) external opportunity. Across these three categories, commercial readiness and strong investor interactions are necessary conditions for all exit cases. But there are important differences that drive success in each category, such as the interaction with non-financial support (in the robust ecosystem case), experienced team (in the heavy-lifting team case), and favorable industry (in the external opportunity case). Furthermore, our findings are meant to support entrepreneurs in reaching an exit by optimizing the given internal and external circumstances, and policymakers to build a robust ecosystem that can increase the success rate of the clean- and hardtech development.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2024

Extension of Local Helicity Injection Startup Studies to the Urania Experiment (Final Technical Report)

Initiating high-current plasma in a spherical tokamak (ST) without a central solenoid is a critical issue for the development of the ST configuration. The goal of the research funded through this grant was focused on addressing this challenge by demonstrating scalable startup to high plasma current (I p ), while developing a physical understanding and predictive models for non-solenoidal tokamak plasma startup using Local Helicity Injection (LHI). A major objective of this research and development activity was to use scaling experiments to validate a physics understanding that will support deployment of high-current (~1 MA) startup techniques to fusion-scale facilities such as NSTX-U and beyond.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗