Review and Assessment of Commercial Vendors/Options for Feeding and Pumping Biomass Slurries for Hydrothermal Liquefaction

The National Advanced Biofuels Consortium is working to develop improved methods for producing high-value hydrocarbon fuels. The development of one such method, the hydrothermal liquefaction (HTL) process, is being led by the Pacific Northwest National Laboratory (PNNL). The HTL process uses a wet biomass slurry at elevated temperatures (i.e., 300 to 360°C [570 to 680°F]) and pressures above the vapor pressure of water (i.e., 15 to 20 MPa [2200 to 3000 psi] at these temperatures) to facilitate a condensed-phase reaction medium. The process has been successfully tested at bench-scale and development and testing at a larger scale is required to prove the viability of the process at production levels. Near-term development plans include a pilot-scale system on the order of 0.5 to 40 gpm, followed by a larger production-scale system on the order of 2000 dry metric tons per day (DMTPD). A significant challenge to the scale-up of the HTL process is feeding a highly viscous fibrous biomass wood/corn stover feedstock into a pump system that provides the required 3000 psi of pressure for downstream processing. In October 2011, PNNL began investigating commercial feed and pumping options that would meet these HTL process requirements. Initial efforts focused on generating a HTL feed and pump specification and then providing the specification to prospective vendors to determine the suitability of their pumps for the pilot-scale and production-scale plants. Six vendors were identified that could provide viable equipment to meet HTL feed and/or pump needs. Those six vendors provided options consisting three types of positive displacement pumps (i.e., diaphragm, piston, and lobe pumps). Vendors provided capabilities and equipment related to HTL application. This information was collected, assessed, and summarized and is provided as appendices to this report

Technical Needs for Enhancing Risk Monitors with Equipment Condition Assessment for Advanced Small Modular Reactors

Advanced small modular reactors (aSMRs) can provide the United States with a safe, sustainable, and carbon-neutral energy source. The controllable day-to-day costs of aSMRs are expected to be dominated by operation and maintenance costs. Health and condition assessment coupled with online risk monitors can potentially enhance affordability of aSMRs through optimized operational planning and maintenance scheduling. Currently deployed risk monitors are an extension of probabilistic risk assessment (PRA). For complex engineered systems like nuclear power plants, PRA systematically combines event likelihoods and the probability of failure (POF) of key components, so that when combined with the magnitude of possible adverse consequences to determine risk. Traditional PRA uses population-based POF information to estimate the average plant risk over time. Currently, most nuclear power plants have a PRA that reflects the as-operated, as-modified plant; this model is updated periodically, typically once a year. Risk monitors expand on living PRA by incorporating changes in the day-by-day plant operation and configuration (e.g., changes in equipment availability, operating regime, environmental conditions). However, population-based POF (or population- and time-based POF) is still used to populate fault trees. Health monitoring techniques can be used to establish condition indicators and monitoring capabilities that indicate the component-specific POF at a desired point in time (or over a desired period), which can then be incorporated in the risk monitor to provide a more accurate estimate of the plant risk in different configurations. This is particularly important for active systems, structures, and components (SSCs) proposed for use in aSMR designs. These SSCs may differ significantly from those used in the operating fleet of light-water reactors (or even in LWR-based SMR designs). Additionally, the operating characteristics of aSMRs can present significantly different requirements, including the need to operate in different coolant environments, higher operating temperatures, and longer operating cycles between planned refueling and maintenance outages. These features, along with the relative lack of operating experience for some of the proposed advanced designs, may limit the ability to estimate event probability and component POF with a high degree of certainty. Incorporating real-time estimates of component POF may compensate for a relative lack of established knowledge about the long-term component behavior and improve operational and maintenance planning and optimization. The particular eccentricities of advanced reactors and small modular reactors provide unique challenges and needs for advanced instrumentation, control, and human-machine interface (ICHMI) techniques such as enhanced risk monitors (ERM) in aSMRs. Several features of aSMR designs increase the need for accurate characterization of the real-time risk during operation and maintenance activities. A number of technical gaps in realizing ERM exist, and these gaps are largely independent of the specific reactor technology. As a result, the development of a framework for ERM would enable greater situational awareness regardless of the specific class of reactor technology. A set of research tasks are identified in a preliminary research plan to enable the development, testing, and demonstration of such a framework. Although some aspects of aSMRs, such as specific operational characteristics, will vary and are not now completely defined, the proposed framework is expected to be relevant regardless of such uncertainty. The development of an ERM framework will provide one of the key technical developments necessary to ensure the economic viability of aSMRs

Technical Readiness and Gaps Analysis of Commercial Optical Materials and Measurement Systems for Advanced Small Modular Reactors

This report intends to support Department of Energy’s Office of Nuclear Energy (DOE-NE) Nuclear Energy Research and Development Roadmap and industry stakeholders by evaluating optical-based instrumentation and control (I&C) concepts for advanced small modular reactor (AdvSMR) applications. These advanced designs will require innovative thinking in terms of engineering approaches, materials integration, and I&C concepts to realize their eventual viability and deployability. The primary goals of this report include: 1. Establish preliminary I&C needs, performance requirements, and possible gaps for AdvSMR designs based on best available published design data. 2. Document commercial off-the-shelf (COTS) optical sensors, components, and materials in terms of their technical readiness to support essential AdvSMR in-vessel I&C systems. 3. Identify technology gaps by comparing the in-vessel monitoring requirements and environmental constraints to COTS optical sensor and materials performance specifications. 4. Outline a future research, development, and demonstration (RD&D) program plan that addresses these gaps and develops optical-based I&C systems that enhance the viability of future AdvSMR designs. The development of clean, affordable, safe, and proliferation-resistant nuclear power is a key goal that is documented in the Nuclear Energy Research and Development Roadmap. This roadmap outlines RD&D activities intended to overcome technical, economic, and other barriers, which currently limit advances in nuclear energy. These activities will ensure that nuclear energy remains a viable component to this nation’s energy security

EM-21 Retrieval Knowledge Center: Waste Retrieval Challenges

EM-21 is the Waste Processing Division of the Office of Engineering and Technology, within the U.S. Department of Energy’s (DOE) Office of Environmental Management (EM). In August of 2008, EM-21 began an initiative to develop a Retrieval Knowledge Center (RKC) to provide the DOE, high level waste retrieval operators, and technology developers with centralized and focused location to share knowledge and expertise that will be used to address retrieval challenges across the DOE complex. The RKC is also designed to facilitate information sharing across the DOE Waste Site Complex through workshops, and a searchable database of waste retrieval technology information. The database may be used to research effective technology approaches for specific retrieval tasks and to take advantage of the lessons learned from previous operations. It is also expected to be effective for remaining current with state-of-the-art of retrieval technologies and ongoing development within the DOE Complex. To encourage collaboration of DOE sites with waste retrieval issues, the RKC team is co-led by the Savannah River National Laboratory (SRNL) and the Pacific Northwest National Laboratory (PNNL). Two RKC workshops were held in the Fall of 2008. The purpose of these workshops was to define top level waste retrieval functional areas, exchange lessons learned, and develop a path forward to support a strategic business plan focused on technology needs for retrieval. The primary participants involved in these workshops included retrieval personnel and laboratory staff that are associated with Hanford and Savannah River Sites since the majority of remaining DOE waste tanks are located at these sites. This report summarizes and documents the results of the initial RKC workshops. Technology challenges identified from these workshops and presented here are expected to be a key component to defining future RKC-directed tasks designed to facilitate tank waste retrieval solutions

Review and Assessment of Commercial Vendors/Options for Feeding and Pumping Biomass Slurries for Hydrothermal Liquefaction

The National Advanced Biofuels Consortium is working to develop improved methods for producing high-value hydrocarbon fuels. The development of one such method, the hydrothermal liquefaction (HTL) process, is being led by the Pacific Northwest National Laboratory (PNNL). The HTL process uses a wet biomass slurry at elevated temperatures (i.e., 300 to 360°C [570 to 680°F]) and pressures above the vapor pressure of water (i.e., 15 to 20 MPa [2200 to 3000 psi] at these temperatures) to facilitate a condensed-phase reaction medium. The process has been successfully tested at bench-scale and development and testing at a larger scale is required to prove the viability of the process at production levels. Near-term development plans include a pilot-scale system on the order of 0.5 to 40 gpm, followed by a larger production-scale system on the order of 2000 dry metric tons per day (DMTPD). A significant challenge to the scale-up of the HTL process is feeding a highly viscous fibrous biomass wood/corn stover feedstock into a pump system that provides the required 3000 psi of pressure for downstream processing. In October 2011, PNNL began investigating commercial feed and pumping options that would meet these HTL process requirements. Initial efforts focused on generating a HTL feed and pump specification and then providing the specification to prospective vendors to determine the suitability of their pumps for the pilot-scale and production-scale plants. Six vendors were identified that could provide viable equipment to meet HTL feed and/or pump needs. Those six vendors provided options consisting three types of positive displacement pumps (i.e., diaphragm, piston, and lobe pumps). Vendors provided capabilities and equipment related to HTL application. This information was collected, assessed, and summarized and is provided as appendices to this report

Summary of the Preliminary Optical ICHMI Design Study: A Preliminary Engineering Design Study for a Standpipe Viewport

This summary report examines an in-vessel optical access concept intended to support standoff optical instrumentation, control and human-machine interface (ICHMI) systems for future advanced small modular reactor (AdvSMR) applications. Optical-based measurement and sensing systems for AdvSMR applications have several key benefits over traditional instrumentation and control systems used to monitor reactor process parameters, such as temperature, flow rate, pressure, and coolant chemistry (Anheier et al. 2013). Direct and continuous visualization of the in-vessel components can be maintained using external cameras. Many optical sensing techniques can be performed remotely using open optical beam path configurations. Not only are in-vessel cables eliminated by these configurations, but also sensitive optical monitoring components (e.g., electronics, lasers, detectors, and cameras) can be placed outside the reactor vessel in the instrument vault, containment building, or other locations where temperatures and radiation levels are much lower. However, the extreme AdvSMR environment present challenges for optical access designs and optical materials. Optical access is not provided in any commercial nuclear power plant or featured in any reactor design, although successful implementation of optical access has been demonstrated in test reactors (Arkani and Gharib 2009). This report outlines the key engineering considerations for an AdvSMR optical access concept. Strict American Society of Mechanical Engineers (ASME) construction codes must be followed for any U.S. nuclear facility component (ASME 2013); however, the scope of this study is to evaluate the preliminary engineering issues for this concept, rather than developing a nuclear-qualified design. In addition, this study does not consider accident design requirements. In-vessel optical access using a standpipe viewport concept serves as a test case to explore the engineering challenges and performance requirements for sodium fast reactor (SFR) and high-temperature gas reactor (HTGR) AdvSMR applications. The expected environmental conditions for deployment are reviewed for both AdvSMR designs. Optical and mechanical materials that maximize component lifetime are evaluated for the standpipe viewport design under these conditions. Optical components and opto-mechanical designs that provide robust optical-to-metal seals and stress-free optical component mounting are identified, and then key performance specifications are developed for a sapphire optical viewport concept. Design strategies are examined that protect the internal optical surfaces from liquid-coolant condensation and impurity deposits. Finally, a conceptual standpipe viewport design that is suggestive of how this concept could be assembled using standard nuclear-qualified pipe components, is presented

Technical Needs for Enhancing Risk Monitors with Equipment Condition Assessment for Advanced Small Modular Reactors

Advanced small modular reactors (aSMRs) can provide the United States with a safe, sustainable, and carbon-neutral energy source. The controllable day-to-day costs of aSMRs are expected to be dominated by operation and maintenance costs. Health and condition assessment coupled with online risk monitors can potentially enhance affordability of aSMRs through optimized operational planning and maintenance scheduling. Currently deployed risk monitors are an extension of probabilistic risk assessment (PRA). For complex engineered systems like nuclear power plants, PRA systematically combines event likelihoods and the probability of failure (POF) of key components, so that when combined with the magnitude of possible adverse consequences to determine risk. Traditional PRA uses population-based POF information to estimate the average plant risk over time. Currently, most nuclear power plants have a PRA that reflects the as-operated, as-modified plant; this model is updated periodically, typically once a year. Risk monitors expand on living PRA by incorporating changes in the day-by-day plant operation and configuration (e.g., changes in equipment availability, operating regime, environmental conditions). However, population-based POF (or population- and time-based POF) is still used to populate fault trees. Health monitoring techniques can be used to establish condition indicators and monitoring capabilities that indicate the component-specific POF at a desired point in time (or over a desired period), which can then be incorporated in the risk monitor to provide a more accurate estimate of the plant risk in different configurations. This is particularly important for active systems, structures, and components (SSCs) proposed for use in aSMR designs. These SSCs may differ significantly from those used in the operating fleet of light-water reactors (or even in LWR-based SMR designs). Additionally, the operating characteristics of aSMRs can present significantly different requirements, including the need to operate in different coolant environments, higher operating temperatures, and longer operating cycles between planned refueling and maintenance outages. These features, along with the relative lack of operating experience for some of the proposed advanced designs, may limit the ability to estimate event probability and component POF with a high degree of certainty. Incorporating real-time estimates of component POF may compensate for a relative lack of established knowledge about the long-term component behavior and improve operational and maintenance planning and optimization. The particular eccentricities of advanced reactors and small modular reactors provide unique challenges and needs for advanced instrumentation, control, and human-machine interface (ICHMI) techniques such as enhanced risk monitors (ERM) in aSMRs. Several features of aSMR designs increase the need for accurate characterization of the real-time risk during operation and maintenance activities. A number of technical gaps in realizing ERM exist, and these gaps are largely independent of the specific reactor technology. As a result, the development of a framework for ERM would enable greater situational awareness regardless of the specific class of reactor technology. A set of research tasks are identified in a preliminary research plan to enable the development, testing, and demonstration of such a framework. Although some aspects of aSMRs, such as specific operational characteristics, will vary and are not now completely defined, the proposed framework is expected to be relevant regardless of such uncertainty. The development of an ERM framework will provide one of the key technical developments necessary to ensure the economic viability of aSMRs

Technical Readiness and Gaps Analysis of Commercial Optical Materials and Measurement Systems for Advanced Small Modular Reactors

This report intends to support Department of Energy’s Office of Nuclear Energy (DOE-NE) Nuclear Energy Research and Development Roadmap and industry stakeholders by evaluating optical-based instrumentation and control (I&C) concepts for advanced small modular reactor (AdvSMR) applications. These advanced designs will require innovative thinking in terms of engineering approaches, materials integration, and I&C concepts to realize their eventual viability and deployability. The primary goals of this report include: 1. Establish preliminary I&C needs, performance requirements, and possible gaps for AdvSMR designs based on best available published design data. 2. Document commercial off-the-shelf (COTS) optical sensors, components, and materials in terms of their technical readiness to support essential AdvSMR in-vessel I&C systems. 3. Identify technology gaps by comparing the in-vessel monitoring requirements and environmental constraints to COTS optical sensor and materials performance specifications. 4. Outline a future research, development, and demonstration (RD&D) program plan that addresses these gaps and develops optical-based I&C systems that enhance the viability of future AdvSMR designs. The development of clean, affordable, safe, and proliferation-resistant nuclear power is a key goal that is documented in the Nuclear Energy Research and Development Roadmap. This roadmap outlines RD&D activities intended to overcome technical, economic, and other barriers, which currently limit advances in nuclear energy. These activities will ensure that nuclear energy remains a viable component to this nation’s energy security

Scaling Theory for Pulsed Jet Mixed Vessels, Sparging, and Cyclic Feed Transport Systems for Slurries

This document is a previously unpublished work based on a draft report prepared by Pacific Northwest National Laboratory (PNNL) for the Hanford Waste Treatment and Immobilization Plant (WTP) in 2012. Work on the report stopped when WTP’s approach to testing changed. PNNL is issuing a modified version of the document a year later to preserve and disseminate the valuable technical work that was completed. This document establishes technical bases for evaluating the mixing performance of Waste Treatment Plant (WTP) pretreatment process tanks based on data from less-than-full-scale testing, relative to specified mixing requirements. The technical bases include the fluid mechanics affecting mixing for specified vessel configurations, operating parameters, and simulant properties. They address scaling vessel physical performance, simulant physical performance, and “scaling down” the operating conditions at full scale to define test conditions at reduced scale and “scaling up” the test results at reduced scale to predict the performance at full scale. Essentially, this document addresses the following questions: • Why and how can the mixing behaviors in a smaller vessel represent those in a larger vessel? • What information is needed to address the first question? • How should the information be used to predict mixing performance in WTP? The design of Large Scale Integrated Testing (LSIT) is being addressed in other, complementary documents

Scaling Theory for Pulsed Jet Mixed Vessels, Sparging, and Cyclic Feed Transport Systems for Slurries

This document is a previously unpublished work based on a draft report prepared by Pacific Northwest National Laboratory (PNNL) for the Hanford Waste Treatment and Immobilization Plant (WTP) in 2012. Work on the report stopped when WTP’s approach to testing changed. PNNL is issuing a modified version of the document a year later to preserve and disseminate the valuable technical work that was completed. This document establishes technical bases for evaluating the mixing performance of Waste Treatment Plant (WTP) pretreatment process tanks based on data from less-than-full-scale testing, relative to specified mixing requirements. The technical bases include the fluid mechanics affecting mixing for specified vessel configurations, operating parameters, and simulant properties. They address scaling vessel physical performance, simulant physical performance, and “scaling down” the operating conditions at full scale to define test conditions at reduced scale and “scaling up” the test results at reduced scale to predict the performance at full scale. Essentially, this document addresses the following questions: • Why and how can the mixing behaviors in a smaller vessel represent those in a larger vessel? • What information is needed to address the first question? • How should the information be used to predict mixing performance in WTP? The design of Large Scale Integrated Testing (LSIT) is being addressed in other, complementary documents