National Library of Energy BETA

Sample records for oxide fuel fabrication

  1. Mixed Oxide Fuel Fabrication Facility

    National Nuclear Security Administration (NNSA)

    0%2A en Mixed Oxide (MOX) Fuel Fabrication Facility http:nnsa.energy.govfieldofficessavannah-river-field-officemixed-oxide-mox-fuel-fabrication-facility

  2. Mixed Oxide (MOX) Fuel Fabrication Facility | National Nuclear...

    National Nuclear Security Administration (NNSA)

    Home fieldoffices Savannah River Field Office Mixed Oxide (MOX) Fuel Fabrication ... Mixed Oxide Fuel Fabrication Facility MOX Savannah river site srs Related News Analysis of ...

  3. Mixed Oxide Fuel Fabrication Facility | National Nuclear Security

    National Nuclear Security Administration (NNSA)

    Administration Mixed Oxide Fuel Fabrication Facility Mixed Oxide (MOX) Fuel Fabrication Facility Documents related to the project: Plutonium Disposition Study Options Independent Assessment Phase 1 Report, April 13, 2015 Plutonium Disposition Study Options Independent Assessment Phase 2 Report, August 20, 2015 Final Report of the Plutonium Disposition Red Team, August 13, 2015 Commentary on

  4. Mixed Oxide (MOX) Fuel Fabrication Facility | National Nuclear Security

    National Nuclear Security Administration (NNSA)

    Administration Savannah River Field Office Mixed Oxide (MOX) Fuel Fabrication Facility Documents related to the project: Plutonium Disposition Study Options Independent Assessment Phase 1 Report, April 13, 2015 Plutonium Disposition Study Options Independent Assessment Phase 2 Report, August 20, 2015 Final Report of the Plutonium Disposition Red Team, August 13, 2015 Commentary on Report by High Bridge Associates, Inc., Feb. 12, 2016 Related Topics Mixed Oxide Fuel Fabrication Facility MOX

  5. Method to fabricate high performance tubular solid oxide fuel cells

    DOE Patents [OSTI]

    Chen, Fanglin; Yang, Chenghao; Jin, Chao

    2013-06-18

    In accordance with the present disclosure, a method for fabricating a solid oxide fuel cell is described. The method includes forming an asymmetric porous ceramic tube by using a phase inversion process. The method further includes forming an asymmetric porous ceramic layer on a surface of the asymmetric porous ceramic tube by using a phase inversion process. The tube is co-sintered to form a structure having a first porous layer, a second porous layer, and a dense layer positioned therebetween.

  6. Fabrication of solid oxide fuel cell by electrochemical vapor deposition

    DOE Patents [OSTI]

    Riley, B.; Szreders, B.E.

    1988-04-26

    In a high temperature solid oxide fuel cell (SOFC), the deposition of an impervious high density thin layer of electrically conductive interconnector material, such as magnesium doped lanthanum chromite, and of an electrolyte material, such as yttria stabilized zirconia, onto a porous support/air electrode substrate surface is carried out at high temperatures (/approximately/1100/degree/ /minus/ 1300/degree/C) by a process of electrochemical vapor deposition. In this process, the mixed chlorides of the specific metals involved react in the gaseous state with water vapor resulting in the deposit of an impervious thin oxide layer on the support tube/air electrode substrate of between 20--50 microns in thickness. An internal heater, such as a heat pipe, is placed within the support tube/air electrode substrate and induces a uniform temperature profile therein so as to afford precise and uniform oxide deposition kinetics in an arrangement which is particularly adapted for large scale, commercial fabrication of SOFCs.

  7. Fabrication of solid oxide fuel cell by electrochemical vapor deposition

    DOE Patents [OSTI]

    Brian, Riley; Szreders, Bernard E.

    1989-01-01

    In a high temperature solid oxide fuel cell (SOFC), the deposition of an impervious high density thin layer of electrically conductive interconnector material, such as magnesium doped lanthanum chromite, and of an electrolyte material, such as yttria stabilized zirconia, onto a porous support/air electrode substrate surface is carried out at high temperatures (approximately 1100.degree.-1300.degree. C.) by a process of electrochemical vapor deposition. In this process, the mixed chlorides of the specific metals involved react in the gaseous state with water vapor resulting in the deposit of an impervious thin oxide layer on the support tube/air electrode substrate of between 20-50 microns in thickness. An internal heater, such as a heat pipe, is placed within the support tube/air electrode substrate and induces a uniform temperature profile therein so as to afford precise and uniform oxide deposition kinetics in an arrangement which is particularly adapted for large scale, commercial fabrication of SOFCs.

  8. Method of fabricating a monolithic solid oxide fuel cell

    DOE Patents [OSTI]

    Minh, Nguyen Q.; Horne, Craig R.

    1994-01-01

    In a two-step densifying process of making a monolithic solid oxide fuel cell, a limited number of anode-electrolyte-cathode cells separated by an interconnect layer are formed and partially densified. Subsequently, the partially densified cells are stacked and further densified to form a monolithic array.

  9. Method of fabricating a monolithic solid oxide fuel cell

    DOE Patents [OSTI]

    Minh, N.Q.; Horne, C.R.

    1994-03-01

    In a two-step densifying process of making a monolithic solid oxide fuel cell, a limited number of anode-electrolyte-cathode cells separated by an interconnect layer are formed and partially densified. Subsequently, the partially densified cells are stacked and further densified to form a monolithic array. 10 figures.

  10. Fabrication of advanced oxide fuels containing minor actinide for use in fast reactors

    SciTech Connect (OSTI)

    Miwa, Shuhei; Osaka, Masahiko; Tanaka, Kosuke; Ishi, Yohei; Yoshimochi, Hiroshi; Tanaka, Kenya

    2007-07-01

    R and D of advanced fuel containing minor actinide for use in fast reactors is described related to the composite fuel with MgO matrix. Fabrication tests of MgO composite fuels containing Am were done by a practical process that could be adapted to the presently used commercial manufacturing technology. Am-containing MgO composite fuels having good characteristics, i.e., having no defects, a high density, a homogeneous dispersion of host phase, were obtained. As related technology, burn-up characteristics of a fast reactor core loaded with the present MgO composite fuel were also analyzed, mainly in terms of core criticality. Furthermore, phase relations of MA oxide which was assumed to be contained in MgO matrix fuel were experimentally investigated. (authors)

  11. Evaluation of existing United States` facilities for use as a mixed-oxide (MOX) fuel fabrication facility for plutonium disposition

    SciTech Connect (OSTI)

    Beard, C.A.; Buksa, J.J.; Chidester, K.; Eaton, S.L.; Motley, F.E.; Siebe, D.A.

    1995-12-31

    A number of existing US facilities were evaluated for use as a mixed-oxide fuel fabrication facility for plutonium disposition. These facilities include the Fuels Material Examination Facility (FMEF) at Hanford, the Washington Power Supply Unit 1 (WNP-1) facility at Hanford, the Barnwell Nuclear Fuel Plant (BNFP) at Barnwell, SC, the Fuel Processing Facility (FPF) at Idaho National Engineering Laboratory (INEL), the Device Assembly Facility (DAF) at the Nevada Test Site (NTS), and the P-reactor at the Savannah River Site (SRS). The study consisted of evaluating each facility in terms of available process space, available building support systems (i.e., HVAC, security systems, existing process equipment, etc.), available regional infrastructure (i.e., emergency response teams, protective force teams, available transportation routes, etc.), and ability to integrate the MOX fabrication process into the facility in an operationally-sound manner that requires a minimum amount of structural modifications.

  12. Method of fabricating a monolithic core for a solid oxide fuel cell

    DOE Patents [OSTI]

    Zwick, Stanley A.; Ackerman, John P.

    1985-01-01

    A method is disclosed for forming a core for use in a solid oxide fuel cell that electrochemically combines fuel and oxidant for generating galvanic output. The core has an array of electrolyte and interconnect walls that are substantially devoid of any composite inert materials for support consisting instead only of the active anode, cathode, electrolyte and interconnect materials. Each electrolyte wall consists of cathode and anode materials sandwiching electrolyte material therebetween, and each interconnect wall consists of the cathode and anode materials sandwiching interconnect material therebetween. The electrolyte and interconnect walls define a plurality of substantially parallel core passageways alternately having respectively the inside faces thereof with only the anode material or with only the cathode material exposed. In the wall structure, the electrolyte and interconnect materials are only 0.002-0.01 cm thick; and the cathode and anode materials are only 0.002-0.05 cm thick. The method consists of building up the electrolyte and interconnect walls by depositing each material on individually and endwise of the wall itself, where each material deposit is sequentially applied for one cycle; and where the depositing cycle is repeated many times until the material buildup is sufficient to formulate the core. The core is heat cured to become dimensionally and structurally stable.

  13. Method of Fabrication of High Power Density Solid Oxide Fuel Cells

    DOE Patents [OSTI]

    Pham, Ai Quoc; Glass, Robert S.

    2008-09-09

    A method for producing ultra-high power density solid oxide fuel cells (SOFCs). The method involves the formation of a multilayer structure cells wherein a buffer layer of doped-ceria is deposited intermediate a zirconia electrolyte and a cobalt iron based electrode using a colloidal spray deposition (CSD) technique. For example, a cobalt iron based cathode composed of (La,Sr)(Co,Fe)O(LSCF) may be deposited on a zirconia electrolyte via a buffer layer of doped-ceria deposited by the CSD technique. The thus formed SOFC have a power density of 1400 mW/cm.sup.2 at 600.degree. C. and 900 mW/cm.sup.2 at 700.degree. C. which constitutes a 2-3 times increased in power density over conventionally produced SOFCs.

  14. Neutronic fuel element fabrication

    DOE Patents [OSTI]

    Korton, George

    2004-02-24

    This disclosure describes a method for metallurgically bonding a complete leak-tight enclosure to a matrix-type fuel element penetrated longitudinally by a multiplicity of coolant channels. Coolant tubes containing solid filler pins are disposed in the coolant channels. A leak-tight metal enclosure is then formed about the entire assembly of fuel matrix, coolant tubes and pins. The completely enclosed and sealed assembly is exposed to a high temperature and pressure gas environment to effect a metallurgical bond between all contacting surfaces therein. The ends of the assembly are then machined away to expose the pin ends which are chemically leached from the coolant tubes to leave the coolant tubes with internal coolant passageways. The invention described herein was made in the course of, or under, a contract with the U.S. Atomic Energy Commission. It relates generally to fuel elements for neutronic reactors and more particularly to a method for providing a leak-tight metal enclosure for a high-performance matrix-type fuel element penetrated longitudinally by a multiplicity of coolant tubes. The planned utilization of nuclear energy in high-performance, compact-propulsion and mobile power-generation systems has necessitated the development of fuel elements capable of operating at high power densities. High power densities in turn require fuel elements having high thermal conductivities and good fuel retention capabilities at high temperatures. A metal clad fuel element containing a ceramic phase of fuel intimately mixed with and bonded to a continuous refractory metal matrix has been found to satisfy the above requirements. Metal coolant tubes penetrate the matrix to afford internal cooling to the fuel element while providing positive fuel retention and containment of fission products generated within the fuel matrix. Metal header plates are bonded to the coolant tubes at each end of the fuel element and a metal cladding or can completes the fuel-matrix enclosure by encompassing the sides of the fuel element between the header plates.

  15. Chemical and Radiochemical Composition of Thermally Stabilized Plutonium Oxide from the Plutonium Finishing Plant Considered as Alternate Feedstock for the Mixed Oxide Fuel Fabrication Facility

    SciTech Connect (OSTI)

    Tingey, Joel M.; Jones, Susan A.

    2005-07-01

    Eighteen plutonium oxide samples originating from the Plutonium Finishing Plant (PFP) on the Hanford Site were analyzed to provide additional data on the suitability of PFP thermally stabilized plutonium oxides and Rocky Flats oxides as alternate feedstock to the Mixed Oxide Fuel Fabrication Facility (MFFF). Radiochemical and chemical analyses were performed on fusions, acid leaches, and water leaches of these 18 samples. The results from these destructive analyses were compared with nondestructive analyses (NDA) performed at PFP and the acceptance criteria for the alternate feedstock. The plutonium oxide materials considered as alternate feedstock at Hanford originated from several different sources including Rocky Flats oxide, scrap from the Remote Mechanical C-Line (RMC) and the Plutonium Reclamation Facility (PRF), and materials from other plutonium conversion processes at Hanford. These materials were received at PFP as metals, oxides, and solutions. All of the material considered as alternate feedstock was converted to PuO2 and thermally stabilized by heating the PuO2 powder at 950 C in an oxidizing environment. The two samples from solutions were converted to PuO2 by precipitation with Mg(OH)2. The 18 plutonium oxide samples were grouped into four categories based on their origin. The Rocky Flats oxide was divided into two categories, low- and high-chloride Rocky Flats oxides. The other two categories were PRF/RMC scrap oxides, which included scrap from both process lines and oxides produced from solutions. The two solution samples came from samples that were being tested at Pacific Northwest National Laboratory because all of the plutonium oxide from solutions at PFP had already been processed and placed in 3013 containers. These samples originated at the PFP and are from plutonium nitrate product and double-pass filtrate solutions after they had been thermally stabilized. The other 16 samples originated from thermal stabilization batches before canning at PFP. Samples varied in appearance depending on the original source of material. Rocky Flats items were mostly dark olive green with clumps that crushed easily with a mortar and pestle. PRF/RMC items showed more variability. These items were mostly rust colored. One sample contained white particles that were difficult to crush, and another sample was a dark grey with a mixture of fines and large, hard fragments. The appearance and feel of the fragments indicated they might be an alloy. The color of the solution samples was indicative of the impurities in the sample. The double-pass filtrate solution was a brown color indicative of the iron impurities in the sample. The other solution sample was light gray in color. Radiochemical analyses, including thermal ionization mass spectrometry (TIMS), alpha and gamma energy analysis (AEA and GEA), and kinetic phosphorescence analysis (KPA), indicate that these materials are all weapons-grade plutonium with consistent plutonium isotopics. A small amount of uranium (<0.14 wt%) is also present in these samples. The isotopic composition of the uranium varied widely but was consistent among each category of material. The primary water-soluble anions in these samples were Cl-, NO3-, SO42-, and PO43-. The only major anion observed in the Rocky Flats materials was Cl-, but the PRF/RMC samples had significant quantities of all of the primary anions observed. Prompt gamma measurements provide a representative analysis of the Cl- concentration in the bulk material. The primary anions observed in the solution samples were NO3-, and PO43-. The concentration of these anions did not exceed the mixed oxide (MOX) specification limits. Cations that exceeded the MOX specification limits included Cr, Fe, Ni, Al, Cu, and Si. All of the samples exceeded at least the 75% specification limit in one element.

  16. Integrated Recycling Test Fuel Fabrication

    SciTech Connect (OSTI)

    R.S. Fielding; K.H. Kim; B. Grover; J. Smith; J. King; K. Wendt; D. Chapman; L. Zirker

    2013-03-01

    The Integrated Recycling Test is a collaborative irradiation test that will electrochemically recycle used light water reactor fuel into metallic fuel feedstock. The feedstock will be fabricated into a metallic fast reactor type fuel that will be irradiation tested in a drop in capsule test in the Advanced Test Reactor on the Idaho National Laboratory site. This paper will summarize the fuel fabrication activities and design efforts. Casting development will include developing a casting process and system. The closure welding system will be based on the gas tungsten arc burst welding process. The settler/bonder system has been designed to be a simple system which provides heating and controllable impact energy to ensure wetting between the fuel and cladding. The final major pieces of equipment to be designed are the weld and sodium bond inspection system. Both x-radiography and ultrasonic inspection techniques have been examine experimentally and found to be feasible, however the final remote system has not been designed. Conceptual designs for radiography and an ultrasonic system have been made.

  17. Update On Monolithic Fuel Fabrication Development

    SciTech Connect (OSTI)

    C. R Clark; J. M. Wight; G. C. Knighton; G. A. Moore; J. F. Jue

    2005-11-01

    Efforts to develop a viable monolithic research reactor fuel plate have continued at Idaho National Laboratory. These efforts have concentrated on both fabrication process refinement and scale-up to produce full sized fuel plates. Advancements have been made in the production of U-Mo foil including full sized foils. Progress has also been made in the friction stir welding and transient liquid phase bonding fabrication processes resulting in better bonding, more stable processes and the ability to fabricate larger fuel plates.

  18. Fuel Fabrication Capability Research and Development Plan

    SciTech Connect (OSTI)

    Senor, David J.; Burkes, Douglas

    2013-06-28

    The purpose of this document is to provide a comprehensive review of the mission of the Fuel Fabrication Capability (FFC) within the Global Threat Reduction Initiative (GTRI) Convert Program, along with research and development (R&D) needs that have been identified as necessary to ensuring mission success. The design and fabrication of successful nuclear fuels must be closely linked endeavors.

  19. UPDATE ON MONOLITHIC FUEL FABRICATION METHODS

    SciTech Connect (OSTI)

    C. R. Clark; J. F. Jue; G. A. Moore; N. P. Hallinan; B. H. Park; D. E. Burkes

    2006-10-01

    Efforts to develop a viable monolithic research reactor fuel plate have continued at Idaho National Laboratory. These efforts have concentrated on both fabrication process refinement and scale-up to produce full sized fuel plates. Progress at INL has led to fabrication of hot isostatic pressed uranium-molybdenum bearing monolithic fuel plates. These miniplates are part of the RERTR-8 miniplate irradiation test. Further progress has also been made on friction stir weld processing which has been used to fabricate full size fuel plates which will be irradiated in the ATR and OSIRIS reactors.

  20. Fabrication of thorium bearing carbide fuels

    DOE Patents [OSTI]

    Gutierrez, R.L.; Herbst, R.J.; Johnson, K.W.R.

    Thorium-uranium carbide and thorium-plutonium carbide fuel pellets have been fabricated by the carbothermic reduction process. Temperatures of 1750/sup 0/C and 2000/sup 0/C were used during the reduction cycle. Sintering temperatures of 1800/sup 0/C and 2000/sup 0/C were used to prepare fuel pellet densities of 87% and > 94% of theoretical, respectively. The process allows the fabrication of kilogram quantities of fuel with good reproductibility of chemical and phase composition.

  1. Method of electrode fabrication for solid oxide electrochemical cells

    DOE Patents [OSTI]

    Jensen, Russell R.

    1990-01-01

    A process for fabricating cermet electrodes for solid oxide electrochemical cells by sintering is disclosed. First, a porous metal electrode is fabricated on a solid oxide cell, such as a fuel cell by, for example, sintering, and is then infiltrated with a high volume fraction stabilized zirconia suspension. A second sintering step is used to sinter the infiltrated zirconia to a high density in order to more securely attach the electrode to the solid oxide electrolyte of the cell. High performance fuel electrodes can be obtained with this process. Further electrode performance enhancement may be achieved if stabilized zirconia doped with cerium oxide, chromium oxide, titanium oxide, and/or praseodymium oxide for electronic conduction is used.

  2. Method of electrode fabrication for solid oxide electrochemical cells

    DOE Patents [OSTI]

    Jensen, R.R.

    1990-11-20

    A process for fabricating cermet electrodes for solid oxide electrochemical cells by sintering is disclosed. First, a porous metal electrode is fabricated on a solid oxide cell, such as a fuel cell by, for example, sintering, and is then infiltrated with a high volume fraction stabilized zirconia suspension. A second sintering step is used to sinter the infiltrated zirconia to a high density in order to more securely attach the electrode to the solid oxide electrolyte of the cell. High performance fuel electrodes can be obtained with this process. Further electrode performance enhancement may be achieved if stabilized zirconia doped with cerium oxide, chromium oxide, titanium oxide, and/or praseodymium oxide for electronic conduction is used. 5 figs.

  3. Fuel injector Holes (Fabrication of Micro-Orifices for Fuel Injectors...

    Office of Environmental Management (EM)

    injector Holes (Fabrication of Micro-Orifices for Fuel Injectors) Fuel injector Holes (Fabrication of Micro-Orifices for Fuel Injectors) 2009 DOE Hydrogen Program and Vehicle ...

  4. Solid oxide fuel cell generator

    DOE Patents [OSTI]

    Di Croce, A.M.; Draper, R.

    1993-11-02

    A solid oxide fuel cell generator has a plenum containing at least two rows of spaced apart, annular, axially elongated fuel cells. An electrical conductor extending between adjacent rows of fuel cells connects the fuel cells of one row in parallel with each other and in series with the fuel cells of the adjacent row. 5 figures.

  5. Solid oxide fuel cell generator

    DOE Patents [OSTI]

    Di Croce, A. Michael; Draper, Robert

    1993-11-02

    A solid oxide fuel cell generator has a plenum containing at least two rows of spaced apart, annular, axially elongated fuel cells. An electrical conductor extending between adjacent rows of fuel cells connects the fuel cells of one row in parallel with each other and in series with the fuel cells of the adjacent row.

  6. Solid Oxide Fuel Cells FAQs

    Broader source: All U.S. Department of Energy (DOE) Office Webpages (Extended Search)

    FAQs faq-header-big.jpg SOLID OXIDE FUEL CELLS - BASICS Q: What is a fuel cell? A: A fuel cell is a power generation device that converts the chemical energy of a fuel and oxidant directly into electrical energy, with heat and water as byproducts. Since fuel cells produce electricity through an electrochemical reaction and not through a combustion process, they are inherently more efficient and environmentally friendly than conventional electric power generation processes. Q: What are the

  7. NETL: Solid Oxide Fuel Cells

    Broader source: All U.S. Department of Energy (DOE) Office Webpages (Extended Search)

    Solid Oxide Fuel Cells Solid oxide fuel cells (SOFC) are electrochemical devices that convert chemical energy of a fuel and oxidant directly into electrical energy. Since SOFCs produce electricity through an electrochemical reaction and not through a combustion process, they are much more efficient and environmentally benign than conventional electric power generation processes. Their inherent characteristics make them uniquely suitable to address the environmental, climate change, and water

  8. Fabrication of Small-Orifice Fuel Injectors | Department of Energy

    Broader source: Energy.gov (indexed) [DOE]

    2005 Diesel Engine Emissions Reduction (DEER) Conference Presentations and Posters PDF icon 2005_deer_woodford.pdf More Documents & Publications Fuel injector Holes (Fabrication of Micro-Orifices for Fuel Injectors) Fuel Injector Holes Fuel Injector Holes

  9. Fabrication of thorium bearing carbide fuels

    DOE Patents [OSTI]

    Gutierrez, Rueben L.; Herbst, Richard J.; Johnson, Karl W. R.

    1981-01-01

    Thorium-uranium carbide and thorium-plutonium carbide fuel pellets have been fabricated by the carbothermic reduction process. Temperatures of 1750.degree. C. and 2000.degree. C. were used during the reduction cycle. Sintering temperatures of 1800.degree. C. and 2000.degree. C. were used to prepare fuel pellet densities of 87% and >94% of theoretical, respectively. The process allows the fabrication of kilogram quantities of fuel with good reproducibility of chemicals and phase composition. Methods employing liquid techniques that form carbide microspheres or alloying-techniques which form alloys of thorium-uranium or thorium-plutonium suffer from limitation on the quantities processed of because of criticality concerns and lack of precise control of process conditions, respectively.

  10. Fuel Fabrication Capability Research and Development Plan

    SciTech Connect (OSTI)

    Senor, David J.; Burkes, Douglas

    2014-04-17

    The purpose of this document is to provide a comprehensive review of the mission of the Fuel Fabrication Capability (FFC) within the Global Threat Reduction Initiative Convert Program, along with research and development (R&D) needs that have been identified as necessary to ensuring mission success. The design and fabrication of successful nuclear fuels must be closely linked endeavors. Therefore, the overriding motivation behind the FFC R&D program described in this plan is to foster closer integration between fuel design and fabrication to reduce programmatic risk. These motivating factors are all interrelated, and progress addressing one will aid understanding of the others. The FFC R&D needs fall into two principal categories, 1) baseline process optimization, to refine the existing fabrication technologies, and 2) manufacturing process alternatives, to evaluate new fabrication technologies that could provide improvements in quality, repeatability, material utilization, or cost. The FFC R&D Plan examines efforts currently under way in regard to coupon, foil, plate, and fuel element manufacturing, and provides recommendations for a number of R&D topics that are of high priority but not currently funded (i.e., knowledge gaps). The plan ties all FFC R&D efforts into a unified vision that supports the overall Convert Program schedule in general, and the fabrication schedule leading up to the MP-1 and FSP-1 irradiation experiments specifically. The fabrication technology decision gates and down-selection logic and schedules are tied to the schedule for fabricating the MP-1 fuel plates, which will provide the necessary data to make a final fuel fabrication process down-selection. Because of the short turnaround between MP-1 and the follow-on FSP-1 and MP-2 experiments, the suite of specimen types that will be available for MP-1 will be the same as those available for FSP-1 and MP-2. Therefore, the only opportunity to explore parameter space and alternative processing is between now and 2016 when the candidate processes are down-selected in preparation for the MP-1, FSP-1, and MP-2 plate manufacturing campaigns. A number of key risks identified by the FFC are discussed in this plan, with recommended mitigating actions for those activities within FFC, and identification of risks that are impacted by activities in other areas of the Convert Program. The R&D Plan does not include discussion of FFC initiatives related to production-scale manufacturing of fuel (e.g., establishment of the Pilot Line Production Facility), rather, the goal of this plan is to document the R&D activities needed ultimately to enable high-quality and cost-effective production of the fuel by the commercial fuel fabricator. The intent is for this R&D Plan to be a living document that will be reviewed and updated on a regular basis (e.g., annually) to ensure that FFC R&D activities remain properly aligned to the needs of the Convert Program. This version of the R&D Plan represents the first annual review and revision.

  11. Nondestructive characterization methods for monolithic solid oxide fuel cells

    SciTech Connect (OSTI)

    Ellingson, W.A.

    1993-01-01

    Monolithic solid oxide fuel cells (MSOFCS) represent a potential breakthrough in fuel cell technology, provided that reliable fabrication methods can be developed. Fabrication difficulties arise in several steps of the processing: First is the fabrication of uniform thin (305 {mu}m) single-layer and trilayer green tapes (the trilayer tapes of anode/electrolyte/cathode and anode/interconnect/cathode must have similar coefficients of thermal expansion to sinter uniformly and to have the necessary electrochemical properties); Second is the development of fuel and oxidant channels in which residual stresses are likely to develop in the tapes; Third is the fabrication of a ``complete`` cell for which the bond quality between layers and the quality of the trilayers must be established; and Last, attachment of fuel and oxidant manifolds and verification of seal integrity. Purpose of this report is to assess nondestructive characterization methods that could be developed for application to laboratory, prototype, and full-scale MSOFCs.

  12. Update on US High Density Fuel Fabrication Development

    SciTech Connect (OSTI)

    C.R. Clark; G.A. Moore; J.F. Jue; B.H. Park; N.P. Hallinan; D.M. Wachs; D.E. Burkes

    2007-03-01

    Second generation uranium molybdenum fuel has shown excellent in-reactor irradiation performance. This metallic fuel type is capable of being fabricated at much higher loadings than any presently used research reactor fuel. Due to the broad range of fuel types this alloy system encompasses—fuel powder to monolithic foil and binary fuel systems to multiple element additions—significant amounts of research and development have been conducted on the fabrication of these fuels. This paper presents an update of the US RERTR effort to develop fabrication techniques and the fabrication methods used for the RERTR-9A miniplate test.

  13. 2015 Solid Oxide Fuel Cells Project Portfolio

    Broader source: All U.S. Department of Energy (DOE) Office Webpages (Extended Search)

    2015 Solid Oxide Fuel Cells Project Portfolio Solid Oxide Fuel Cells are energy conversion devices that produce electric power through an electrochemical reaction rather than by...

  14. NETL: Solid Oxide Fuel Cells Publications

    Broader source: All U.S. Department of Energy (DOE) Office Webpages (Extended Search)

    Solid Oxide Fuel Cells Publications This page provides links to SOFC Program related documents and reference materials. Solid Oxide Fuel Cells Program 2015 Project Portfolio The ...

  15. Fabrication of Cerium Oxide and Uranium Oxide Microspheres for Space Nuclear Power Applications

    SciTech Connect (OSTI)

    Jeffrey A. Katalenich; Michael R. Hartman; Robert C. O'Brien

    2013-02-01

    Cerium oxide and uranium oxide microspheres are being produced via an internal gelation sol-gel method to investigate alternative fabrication routes for space nuclear fuels. Depleted uranium and non-radioactive cerium are being utilized as surrogates for plutonium-238 (Pu-238) used in radioisotope thermoelectric generators and for enriched uranium required by nuclear thermal rockets. While current methods used to produce Pu-238 fuels at Los Alamos National Laboratory (LANL) involve the generation of fine powders that pose a respiratory hazard and have a propensity to contaminate glove boxes, the sol-gel route allows for the generation of oxide microsphere fuels through an aqueous route. The sol-gel method does not generate fine powders and may require fewer processing steps than the LANL method with less operator handling. High-quality cerium dioxide microspheres have been fabricated in the desired size range and equipment is being prepared to establish a uranium dioxide microsphere production capability.

  16. Solid oxide fuel cell generator

    DOE Patents [OSTI]

    Draper, Robert; George, Raymond A.; Shockling, Larry A.

    1993-01-01

    A solid oxide fuel cell generator has a pair of spaced apart tubesheets in a housing. At least two intermediate barrier walls are between the tubesheets and define a generator chamber between two intermediate buffer chambers. An array of fuel cells have tubes with open ends engaging the tubesheets. Tubular, axially elongated electrochemical cells are supported on the tubes in the generator chamber. Fuel gas and oxidant gas are preheated in the intermediate chambers by the gases flowing on the other side of the tubes. Gas leakage around the tubes through the tubesheets is permitted. The buffer chambers reentrain the leaked fuel gas for reintroduction to the generator chamber.

  17. Solid oxide fuel cell generator

    DOE Patents [OSTI]

    Draper, R.; George, R.A.; Shockling, L.A.

    1993-04-06

    A solid oxide fuel cell generator has a pair of spaced apart tubesheets in a housing. At least two intermediate barrier walls are between the tubesheets and define a generator chamber between two intermediate buffer chambers. An array of fuel cells have tubes with open ends engaging the tubesheets. Tubular, axially elongated electrochemical cells are supported on the tubes in the generator chamber. Fuel gas and oxidant gas are preheated in the intermediate chambers by the gases flowing on the other side of the tubes. Gas leakage around the tubes through the tubesheets is permitted. The buffer chambers reentrain the leaked fuel gas for reintroduction to the generator chamber.

  18. Solid Oxide Fuel Cells

    Broader source: Energy.gov [DOE]

    Fuel cells are an energy user's dream: an efficient, combustion-less, virtually pollution-free power source, capable of being sited in downtown urban areas or in remote regions that runs almost...

  19. Heating subsurface formations by oxidizing fuel on a fuel carrier

    DOE Patents [OSTI]

    Costello, Michael; Vinegar, Harold J.

    2012-10-02

    A method of heating a portion of a subsurface formation includes drawing fuel on a fuel carrier through an opening formed in the formation. Oxidant is supplied to the fuel at one or more locations in the opening. The fuel is combusted with the oxidant to provide heat to the formation.

  20. Irradiation of Metallic and Oxide Fuels for Actinide Transmutation in the ATR

    SciTech Connect (OSTI)

    MacLean, Heather J.; Hayes, Steven L.

    2007-07-01

    Metallic fuels containing minor actinides and rare earth additions have been fabricated and are prepared for irradiation in the ATR, scheduled to begin during the summer of 2007. Oxide fuels containing minor actinides are being fabricated and will be ready for irradiation in ATR, scheduled to begin during the summer of 2008. Fabrication and irradiation of these fuels will provide detailed studies of actinide transmutation in support of the Global Nuclear Energy Partnership. These fuel irradiations include new fuel compositions that have never before been tested. Results from these tests will provide fundamental data on fuel irradiation performance and will advance the state of knowledge for transmutation fuels. (authors)

  1. MONOLITHIC FUEL FABRICATION PROCESS DEVELOPMENT AT THE IDAHO NATIONAL LABORATORY

    SciTech Connect (OSTI)

    Glenn A. Moore; Francine J. Rice; Nicolas E. Woolstenhulme; W. David SwanK; DeLon C. Haggard; Jan-Fong Jue; Blair H. Park; Steven E. Steffler; N. Pat Hallinan; Michael D. Chapple; Douglas E. Burkes

    2008-10-01

    Within the Reduced Enrichment for Research and Test Reactors (RERTR) program directed by the US Department of Energy (DOE), UMo fuel-foils are being developed in an effort to realize high density monolithic fuel plates for use in high-flux research and test reactors. Namely, targeted are reactors that are not amenable to Low Enriched Uranium (LEU) fuel conversion via utilization of high density dispersion-based fuels, i.e. 8-9 gU/cc. LEU conversion of reactors having a need for >8-9 gU/cc fuel density will only be possible by way of monolithic fuel forms. The UMo fuel foils under development afford fuel meat density of ~16 gU/cc and thus have the potential to facilitate LEU conversions without any significant reactor-performance penalty. Two primary challenges have been established with respect to UMo monolithic fuel development; namely, fuel element fabrication and in-reactor fuel element performance. Both issues are being addressed concurrently at the Idaho National Laboratory. An overview is provided of the ongoing monolithic UMo fuel development effort at the Idaho National Laboratory (INL); including development of complex/graded fuel foils. Fabrication processes to be discussed include: UMo alloying and casting, foil fabrication via hot rolling, fuel-clad interlayer application via co-rolling and thermal spray processes, clad bonding via Hot Isostatic Pressing (HIP) and Friction Bonding (FB), and fuel plate finishing.

  2. Status of high-density fuel plates fabrication

    SciTech Connect (OSTI)

    Wiencek, T.C.; Domagala, R.F.; Thresh, H.R.

    1989-09-01

    Progress has continued on the fabrication of fuel plates with fuel zone loadings approaching 9gU/cm{sup 3}. Using Hot Isostatic Pressing (HIPping) successful diffusion bonds have been made with 110 Al and 6061 Al alloys. These bonds demonstrated the most critical processing step for proof-of-concept hardware. Two types of prototype highly-loaded fuel plates have been fabricated. First, a fuel plate in which 0.030 in. (0.76 mm) uranium compound wires are bonded within an aluminum cladding and second, a dispersion fuel plate with uniform cladding and fuel zone thickness. The successful fabrication of these fuel plates derives from the unique ability of the HIPping process to produce diffusion bonds with minimal deformation. 2 refs., 3 figs.

  3. Advanced Safeguards Approaches for New TRU Fuel Fabrication Facilities

    SciTech Connect (OSTI)

    Durst, Philip C.; Ehinger, Michael H.; Boyer, Brian; Therios, Ike; Bean, Robert; Dougan, A.; Tolk, K.

    2007-12-15

    This second report in a series of three reviews possible safeguards approaches for the new transuranic (TRU) fuel fabrication processes to be deployed at AFCF – specifically, the ceramic TRU (MOX) fuel fabrication line and the metallic (pyroprocessing) line. The most common TRU fuel has been fuel composed of mixed plutonium and uranium dioxide, referred to as “MOX”. However, under the Advanced Fuel Cycle projects custom-made fuels with higher contents of neptunium, americium, and curium may also be produced to evaluate if these “minor actinides” can be effectively burned and transmuted through irradiation in the ABR. A third and final report in this series will evaluate and review the advanced safeguards approach options for the ABR. In reviewing and developing the advanced safeguards approach for the new TRU fuel fabrication processes envisioned for AFCF, the existing international (IAEA) safeguards approach at the Plutonium Fuel Production Facility (PFPF) and the conceptual approach planned for the new J-MOX facility in Japan have been considered as a starting point of reference. The pyro-metallurgical reprocessing and fuel fabrication process at EBR-II near Idaho Falls also provided insight for safeguarding the additional metallic pyroprocessing fuel fabrication line planned for AFCF.

  4. Solid oxide electrochemical cell fabrication process

    DOE Patents [OSTI]

    Dollard, Walter J.; Folser, George R.; Pal, Uday B.; Singhal, Subhash C.

    1992-01-01

    A method to form an electrochemical cell (12) is characterized by the steps of thermal spraying stabilized zirconia over a doped lanthanum manganite air electrode tube (14) to provide an electrolyte layer (15), coating conductive particles over the electrolyte, pressurizing the outside of the electrolyte layer, feeding halide vapors of yttrium and zirconium to the outside of the electrolyte layer and feeding a source of oxygen to the inside of the electrolyte layer, heating to cause oxygen reaction with the halide vapors to close electrolyte pores if there are any and to form a metal oxide coating on and between the particles and provide a fuel electrode (16).

  5. MONOLITHIC FUEL FABRICATION PROCESS DEVELOPMENT AT THE IDAHO NATIONAL LABORATORY_

    SciTech Connect (OSTI)

    G. A. Moore; F. J. Rice; N. E. Woolstenhulme; J-F. Jue; B. H. Park; S. E. Steffler; N. P. Hallinan; M. D. Chapple; M. C. Marshall; B. L. Mackowiak; C. R. Clark; B. H. Rabin

    2009-11-01

    Full-size/prototypic U10Mo monolithic fuel-foils and aluminum clad fuel plates are being developed at the Idaho National Laboratory’s (INL) Materials and Fuels Complex (MFC). These efforts are focused on realizing Low Enriched Uranium (LEU) high density monolithic fuel plates for use in High Performance Research and Test Reactors. The U10Mo fuel foils under development afford a fuel meat density of ~16 gU/cc and thus have the potential to facilitate LEU conversions without any significant reactor-performance penalty. An overview is provided of the ongoing monolithic UMo fuel development effort, including application of a zirconium barrier layer on fuel foils, fabrication scale-up efforts, and development of complex/graded fuel foils. Fuel plate clad bonding processes to be discussed include: Hot Isostatic Pressing (HIP) and Friction Bonding (FB).

  6. Coated U(Mo) Fuel: As-Fabricated Microstructures

    SciTech Connect (OSTI)

    Emmanuel Perez; Dennis D. Keiser, Jr.; Ann Leenaers; Sven Van den Berghe; Tom Wiencek

    2014-04-01

    As part of the development of low-enriched uranium fuels, fuel plates have recently been tested in the BR-2 reactor as part of the SELENIUM experiment. These fuel plates contained fuel particles with either Si or ZrN thin film coating (up to 1 µm thickness) around the U-7Mo fuel particles. In order to best understand irradiation performance, it is important to determine the starting microstructure that can be observed in as-fabricated fuel plates. To this end, detailed microstructural characterization was performed on ZrN and Si-coated U-7Mo powder in samples taken from AA6061-clad fuel plates fabricated at 500°C. Of interest was the condition of the thin film coatings after fabrication at a relatively high temperature. Both scanning electron microscopy and transmission electron microscopy were employed. The ZrN thin film coating was observed to consist of columns comprised of very fine ZrN grains. Relatively large amounts of porosity could be found in some areas of the thin film, along with an enrichment of oxygen around each of the the ZrN columns. In the case of the pure Si thin film coating sample, a (U,Mo,Al,Si) interaction layer was observed around the U-7Mo particles. Apparently, the Si reacted with the U-7Mo and Al matrix during fuel plate fabrication at 500°C to form this layer. The microstructure of the formed layer is very similar to those that form in U-7Mo versus Al-Si alloy diffusion couples annealed at higher temperatures and as-fabricated U-7Mo dispersion fuel plates with Al-Si alloy matrix fabricated at 500°C.

  7. Redundancy of Supply in the International Nuclear Fuel Fabrication Market: Are Fabrication Services Assured?

    SciTech Connect (OSTI)

    Seward, Amy M.; Toomey, Christopher; Ford, Benjamin E.; Wood, Thomas W.; Perkins, Casey J.

    2011-11-14

    For several years, Pacific Northwest National Laboratory (PNNL) has been assessing the reliability of nuclear fuel supply in support of the U.S. Department of Energy/National Nuclear Security Administration. Three international low enriched uranium reserves, which are intended back up the existing and well-functioning nuclear fuel market, are currently moving toward implementation. These backup reserves are intended to provide countries credible assurance that of the uninterrupted supply of nuclear fuel to operate their nuclear power reactors in the event that their primary fuel supply is disrupted, whether for political or other reasons. The efficacy of these backup reserves, however, may be constrained without redundant fabrication services. This report presents the findings of a recent PNNL study that simulated outages of varying durations at specific nuclear fuel fabrication plants. The modeling specifically enabled prediction and visualization of the reactors affected and the degree of fuel delivery delay. The results thus provide insight on the extent of vulnerability to nuclear fuel supply disruption at the level of individual fabrication plants, reactors, and countries. The simulation studies demonstrate that, when a reasonable set of qualification criteria are applied, existing fabrication plants are technically qualified to provide backup fabrication services to the majority of the world's power reactors. The report concludes with an assessment of the redundancy of fuel supply in the nuclear fuel market, and a description of potential extra-market mechanisms to enhance the security of fuel supply in cases where it may be warranted. This report is an assessment of the ability of the existing market to respond to supply disruptions that occur for technical reasons. A forthcoming report will address political disruption scenarios.

  8. Solid oxide fuel cell with monolithic core

    DOE Patents [OSTI]

    McPheeters, C.C.; Mrazek, F.C.

    1988-08-02

    A solid oxide fuel cell in which fuel and oxidant gases undergo an electrochemical reaction to produce an electrical output includes a monolithic core comprised of a corrugated conductive sheet disposed between upper and lower generally flat sheets. The corrugated sheet includes a plurality of spaced, parallel, elongated slots which form a series of closed, linear, first upper and second lower gas flow channels with the upper and lower sheets within which a fuel gas and an oxidant gas respectively flow. Facing ends of the fuel cell are generally V-shaped and provide for fuel and oxidant gas inlet and outlet flow, respectively, and include inlet and outlet gas flow channels which are continuous with the aforementioned upper fuel gas and lower oxidant gas flow channels. The upper and lower flat sheets and the intermediate corrugated sheet are preferably comprised of ceramic materials and are securely coupled together such as by assembly in the green state and sintering together during firing at high temperatures. A potential difference across the fuel cell, or across a stacked array of similar fuel cells, is generated when an oxidant gas such as air and a fuel such as hydrogen gas is directed through the fuel cell at high temperatures, e.g., between 700 C and 1,100 C. 8 figs.

  9. Solid oxide fuel cell with monolithic core

    DOE Patents [OSTI]

    McPheeters, Charles C.; Mrazek, Franklin C.

    1988-01-01

    A solid oxide fuel cell in which fuel and oxidant gases undergo an electrochemical reaction to produce an electrical output includes a monolithic core comprised of a corrugated conductive sheet disposed between upper and lower generally flat sheets. The corrugated sheet includes a plurality of spaced, parallel, elongated slots which form a series of closed, linear, first upper and second lower gas flow channels with the upper and lower sheets within which a fuel gas and an oxidant gas respectively flow. Facing ends of the fuel cell are generally V-shaped and provide for fuel and oxidant gas inlet and outlet flow, respectively, and include inlet and outlet gas flow channels which are continuous with the aforementioned upper fuel gas and lower oxidant gas flow channels. The upper and lower flat sheets and the intermediate corrugated sheet are preferably comprised of ceramic materials and are securely coupled together such as by assembly in the green state and sintering together during firing at high temperatures. A potential difference across the fuel cell, or across a stacked array of similar fuel cells, is generated when an oxidant gas such as air and a fuel such as hydrogen gas is directed through the fuel cell at high temperatures, e.g., between 700.degree. C. and 1100.degree. C.

  10. Characterization of candidate DOE sites for fabricating MOX fuel for lead assemblies

    SciTech Connect (OSTI)

    Holdaway, R.F.; Miller, J.W.; Sease, J.D.; Moses, R.J.; O`Connor, D.G.; Carrell, R.D.; Jaeger, C.D.; Thompson, M.L.; Strasser, A.A.

    1998-03-01

    The Office of Fissile Materials Disposition (MD) of the Department of Energy (DOE) is directing the program to disposition US surplus weapons-usable plutonium. For the reactor option for disposition of this surplus plutonium, MD is seeking to contract with a consortium, which would include a mixed-oxide (MOX) fuel fabricator and a commercial US reactor operator, to fabricate and burn MOX fuel in existing commercial nuclear reactors. This option would entail establishing a MOX fuel fabrication facility under the direction of the consortium on an existing DOE site. Because of the lead time required to establish a MOX fuel fabrication facility and the need to qualify the MOX fuel for use in a commercial reactor, MD is considering the early fabrication of lead assemblies (LAs) in existing DOE facilities under the technical direction of the consortium. The LA facility would be expected to produce a minimum of 1 metric ton heavy metal per year and must be operational by June 2003. DOE operations offices were asked to identify candidate sites and facilities to be evaluated for suitability to fabricate MOX fuel LAs. Savannah River Site, Argonne National Laboratory-West, Hanford, Lawrence Livermore National Laboratory, and Los Alamos National Laboratory were identified as final candidates to host the LA project. A Site Evaluation Team (SET) worked with each site to develop viable plans for the LA project. SET then characterized the suitability of each of the five plans for fabricating MOX LAs using 28 attributes and documented the characterization to aid DOE and the consortium in selecting the site for the LA project. SET concluded that each option has relative advantages and disadvantages in comparison with other options; however, each could meet the requirements of the LA project as outlined by MD and SET.

  11. FABRICATION OF TUBE TYPE FUEL ELEMENT FOR NUCLEAR REACTORS

    DOE Patents [OSTI]

    Loeb, E.; Nicklas, J.H.

    1959-02-01

    A method of fabricating a nuclear reactor fuel element is given. It consists essentially of fixing two tubes in concentric relationship with respect to one another to provide an annulus therebetween, filling the annulus with a fissionablematerial-containing powder, compacting the powder material within the annulus and closing the ends thereof. The powder material is further compacted by swaging the inner surface of the inner tube to increase its diameter while maintaining the original size of the outer tube. This process results in reduced fabrication costs of powdered fissionable material type fuel elements and a substantial reduction in the peak core temperatures while materially enhancing the heat removal characteristics.

  12. Greenfield Alternative Study LEU-Mo Fuel Fabrication Facility

    SciTech Connect (OSTI)

    Washington Division of URS

    2008-07-01

    This report provides the initial “first look” of the design of the Greenfield Alternative of the Fuel Fabrication Capability (FFC); a facility to be built at a Greenfield DOE National Laboratory site. The FFC is designed to fabricate LEU-Mo monolithic fuel for the 5 US High Performance Research Reactors (HPRRs). This report provides a pre-conceptual design of the site, facility, process and equipment systems of the FFC; along with a preliminary hazards evaluation, risk assessment as well as the ROM cost and schedule estimate.

  13. Development of technology of high density LEU dispersion fuel fabrication.

    SciTech Connect (OSTI)

    Wiencek, T.; Totev, T.; Nuclear Engineering Division

    2007-01-01

    Advanced Materials Fabrication Facilities at Argonne National Laboratory have been involved in development of LEU dispersion fuel for research and test reactors from the beginning of RERTR program. This paper presents development of technology of high density LEU dispersion fuel fabrication for full size plate type fuel elements. A brief description of Advanced Materials Fabrication Facilities where development of the technology was carried out is given. A flow diagram of the manufacturing process is presented. U-Mo powder was manufactured by the rotating electrode process. The atomization produced a U-Mo alloy powder with a relatively uniform size distribution and a nearly spherical shape. Test plates were fabricated using tungsten and depleted U-7 wt.% Mo alloy, 4043 Al and Al-2 wt% Si matrices with Al 6061 aluminum alloy for the cladding. During the development of the technology of manufacturing of full size high density LEU dispersion fuel plates special attention was paid to meet the required homogeneity, bonding, dimensions, fuel out of zone and other mechanical characteristics of the plates.

  14. Development of technology of high density LEU dispersion fuel fabrication

    SciTech Connect (OSTI)

    Wiencek, Tom; Totev, Totju

    2008-07-15

    Advanced Materials Fabrication Facilities at Argonne National Laboratory have been involved in development of LEU dispersion fuel for research and test reactors from the beginning of RERTR program. This paper presents development of technology of high density LEU dispersion fuel fabrication for full size plate type fuel elements. A brief description of Advanced Materials Fabrication Facilities where development of the technology was carried out is given. A flow diagram of the manufacturing process is presented. U-Mo powder was manufactured by the rotating electrode process. The atomization produced a U-Mo alloy powder with a relatively uniform size distribution and a nearly spherical shape. Test plates were fabricated using tungsten and depleted U-7 wt.% Mo alloy, 4043 Al and Al-2 wt% Si matrices with Al 6061 aluminum alloy for the cladding. During the development of the technology of manufacturing of full size high density LEU dispersion fuel plates special attention was paid to meet the required homogeneity, bonding, dimensions, fuel out of zone and other mechanical characteristics of the plates. (author)

  15. Nanocrystalline cerium oxide materials for solid fuel cell systems

    SciTech Connect (OSTI)

    Brinkman, Kyle S

    2015-05-05

    Disclosed are solid fuel cells, including solid oxide fuel cells and PEM fuel cells that include nanocrystalline cerium oxide materials as a component of the fuel cells. A solid oxide fuel cell can include nanocrystalline cerium oxide as a cathode component and microcrystalline cerium oxide as an electrolyte component, which can prevent mechanical failure and interdiffusion common in other fuel cells. A solid oxide fuel cell can also include nanocrystalline cerium oxide in the anode. A PEM fuel cell can include cerium oxide as a catalyst support in the cathode and optionally also in the anode.

  16. Interfacial material for solid oxide fuel cell

    DOE Patents [OSTI]

    Baozhen, Li (Essex Junction, VT); Ruka, Roswell J. (Pittsburgh, PA); Singhal, Subhash C. (Murrysville, PA)

    1999-01-01

    Solid oxide fuel cells having improved low-temperature operation are disclosed. In one embodiment, an interfacial layer of terbia-stabilized zirconia is located between the air electrode and electrolyte of the solid oxide fuel cell. The interfacial layer provides a barrier which controls interaction between the air electrode and electrolyte. The interfacial layer also reduces polarization loss through the reduction of the air electrode/electrolyte interfacial electrical resistance. In another embodiment, the solid oxide fuel cell comprises a scandia-stabilized zirconia electrolyte having high electrical conductivity. The scandia-stabilized zirconia electrolyte may be provided as a very thin layer in order to reduce resistance. The scandia-stabilized electrolyte is preferably used in combination with the terbia-stabilized interfacial layer. The solid oxide fuel cells are operable over wider temperature ranges and wider temperature gradients in comparison with conventional fuel cells.

  17. Conceptual study of measures against heat generation for TRU fuel fabrication system

    SciTech Connect (OSTI)

    Kawaguchi, Koichi; Namekawa, Takashi

    2007-07-01

    To lower the reprocessing cost and the environmental burden, the Japan Atomic Energy Agency (JAEA) has developed low decontamination TRU fuel fabrication system. TRU fuel contains MA of 1.2 to 5 wt% and its decay heat is estimated a few tens W/kg-HM. As the heat affects fuel quality through oxidation of fuel material and members, it is necessary to remove decay heat. In this work, authors designed concepts of the measures against heat generation at typical equipments using with the thermal hydraulics analysis technique. As a result, it is shown that it is possible to cool fuel materials with specific heat generation up to 20 W/kg-HM enough, though more detailed study is required for comprehensive equipments. (authors)

  18. Interconnection of bundled solid oxide fuel cells

    DOE Patents [OSTI]

    Brown, Michael; Bessette, II, Norman F; Litka, Anthony F; Schmidt, Douglas S

    2014-01-14

    A system and method for electrically interconnecting a plurality of fuel cells to provide dense packing of the fuel cells. Each one of the plurality of fuel cells has a plurality of discrete electrical connection points along an outer surface. Electrical connections are made directly between the discrete electrical connection points of adjacent fuel cells so that the fuel cells can be packed more densely. Fuel cells have at least one outer electrode and at least one discrete interconnection to an inner electrode, wherein the outer electrode is one of a cathode and and anode and wherein the inner electrode is the other of the cathode and the anode. In tubular solid oxide fuel cells the discrete electrical connection points are spaced along the length of the fuel cell.

  19. Fabrication of high exposure nuclear fuel pellets

    DOE Patents [OSTI]

    Frederickson, James R.

    1987-01-01

    A method is disclosed for making a fuel pellet for a nuclear reactor. A mixture is prepared of PuO.sub.2 and UO.sub.2 powders, where the mixture contains at least about 30% PuO.sub.2, and where at least about 12% of the Pu is the Pu.sup.240 isotope. To this mixture is added about 0.3 to about 5% of a binder having a melting point of at least about 250.degree. F. The mixture is pressed to form a slug and the slug is granulated. Up to about 4.7% of a lubricant having a melting point of at least about 330.degree. F. is added to the granulated slug. Both the binder and the lubricant are selected from a group consisting of polyvinyl carboxylate, polyvinyl alcohol, naturally occurring high molecular weight cellulosic polymers, chemically modified high molecular weight cellulosic polymers, and mixtures thereof. The mixture is pressed to form a pellet and the pellet is sintered.

  20. Sintered electrode for solid oxide fuel cells

    DOE Patents [OSTI]

    Ruka, Roswell J.; Warner, Kathryn A.

    1999-01-01

    A solid oxide fuel cell fuel electrode is produced by a sintering process. An underlayer is applied to the electrolyte of a solid oxide fuel cell in the form of a slurry, which is then dried. An overlayer is applied to the underlayer and then dried. The dried underlayer and overlayer are then sintered to form a fuel electrode. Both the underlayer and the overlayer comprise a combination of electrode metal such as nickel, and stabilized zirconia such as yttria-stabilized zirconia, with the overlayer comprising a greater percentage of electrode metal. The use of more stabilized zirconia in the underlayer provides good adhesion to the electrolyte of the fuel cell, while the use of more electrode metal in the overlayer provides good electrical conductivity. The sintered fuel electrode is less expensive to produce compared with conventional electrodes made by electrochemical vapor deposition processes. The sintered electrodes exhibit favorable performance characteristics, including good porosity, adhesion, electrical conductivity and freedom from degradation.

  1. Connections for solid oxide fuel cells

    DOE Patents [OSTI]

    Collie, Jeffrey C.

    1999-01-01

    A connection for fuel cell assemblies is disclosed. The connection includes compliant members connected to individual fuel cells and a rigid member connected to the compliant members. Adjacent bundles or modules of fuel cells are connected together by mechanically joining their rigid members. The compliant/rigid connection permits construction of generator fuel cell stacks from basic modular groups of cells of any desired size. The connections can be made prior to installation of the fuel cells in a generator, thereby eliminating the need for in-situ completion of the connections. In addition to allowing pre-fabrication, the compliant/rigid connections also simplify removal and replacement of sections of a generator fuel cell stack.

  2. Solid Oxide Fuel Cells Operating on Alternative and Renewable Fuels

    SciTech Connect (OSTI)

    Wang, Xiaoxing; Quan, Wenying; Xiao, Jing; Peduzzi, Emanuela; Fujii, Mamoru; Sun, Funxia; Shalaby, Cigdem; Li, Yan; Xie, Chao; Ma, Xiaoliang; Johnson, David; Lee, Jeong; Fedkin, Mark; LaBarbera, Mark; Das, Debanjan; Thompson, David; Lvov, Serguei; Song, Chunshan

    2014-09-30

    This DOE project at the Pennsylvania State University (Penn State) initially involved Siemens Energy, Inc. to (1) develop new fuel processing approaches for using selected alternative and renewable fuels – anaerobic digester gas (ADG) and commercial diesel fuel (with 15 ppm sulfur) – in solid oxide fuel cell (SOFC) power generation systems; and (2) conduct integrated fuel processor – SOFC system tests to evaluate the performance of the fuel processors and overall systems. Siemens Energy Inc. was to provide SOFC system to Penn State for testing. The Siemens work was carried out at Siemens Energy Inc. in Pittsburgh, PA. The unexpected restructuring in Siemens organization, however, led to the elimination of the Siemens Stationary Fuel Cell Division within the company. Unfortunately, this led to the Siemens subcontract with Penn State ending on September 23rd, 2010. SOFC system was never delivered to Penn State. With the assistance of NETL project manager, the Penn State team has since developed a collaborative research with Delphi as the new subcontractor and this work involved the testing of a stack of planar solid oxide fuel cells from Delphi.

  3. Metallic Fast Reactor Fuel Fabrication for Global Nuclear Energy Partnership

    SciTech Connect (OSTI)

    Douglas E. Burkes; Randall S. Fielding; Douglas L. Porter

    2009-07-01

    Fast reactors are once again being considered for nuclear power generation, in addition to transmutation of long-lived fission products resident in spent nuclear fuels. This re-consideration follows with intense developmental programs for both fuel and reactor design. One of the two leading candidates for next generation fast reactor fuel is metal alloys, resulting primarily from the successes achieved in the 1960s to early 1990s with both the experimental breeding reactor-II and the fast flux test facility. The goal of the current program is to develop and qualify a nuclear fuel system that performs all of the functions of a conventional, fast-spectrum nuclear fuel while destroying recycled actinides, thereby closing the nuclear fuel cycle. In order to meet this goal, the program must develop efficient and safe fuel fabrication processes designed for remote operation. This paper provides an overview of advanced casting processes investigated in the past, and the development of a gaseous diffusion calculation that demonstrates how straightforward process parameter modification can mitigate the loss of volatile minor actinides in the metal alloy melt.

  4. Fabrication of small-orifice fuel injectors for diesel engines.

    SciTech Connect (OSTI)

    Woodford, J. B.; Fenske, G. R.

    2005-04-08

    Diesel fuel injector nozzles with spray hole diameters of 50-75 {micro}m have been fabricated via electroless nickel plating of conventionally made nozzles. Thick layers of nickel are deposited onto the orifice interior surfaces, reducing the diameter from {approx}200 {micro}m to the target diameter. The nickel plate is hard, smooth, and adherent, and covers the orifice interior surfaces uniformly.

  5. SOLID OXIDE FUEL CELL HYBRID SYSTEM FOR DISTRIBUTED POWER GENERATION

    SciTech Connect (OSTI)

    Kurt Montgomery; Nguyen Minh

    2003-08-01

    This report summarizes the work performed by Honeywell during the October 2001 to December 2001 reporting period under Cooperative Agreement DE-FC26-01NT40779 for the U. S. Department of Energy, National Energy Technology Laboratory (DOE/NETL) entitled ''Solid Oxide Fuel Cell Hybrid System for Distributed Power Generation''. The main objective of this project is to develop and demonstrate the feasibility of a highly efficient hybrid system integrating a planar Solid Oxide Fuel Cell (SOFC) and a turbogenerator. The conceptual and demonstration system designs were proposed and analyzed, and these systems have been modeled in Aspen Plus. Work has also started on the assembly of dynamic component models and the development of the top-level controls requirements for the system. SOFC stacks have been fabricated and performance mapping initiated.

  6. Solid oxide MEMS-based fuel cells

    DOE Patents [OSTI]

    Jankowksi, Alan F.; Morse, Jeffrey D.

    2007-03-13

    A micro-electro-mechanical systems (MEMS) based thin-film fuel cells for electrical power applications. The MEMS-based fuel cell may be of a solid oxide type (SOFC), a solid polymer type (SPFC), or a proton exchange membrane type (PEMFC), and each fuel cell basically consists of an anode and a cathode separated by an electrolyte layer. The electrolyte layer can consist of either a solid oxide or solid polymer material, or proton exchange membrane electrolyte materials may be used. Additionally catalyst layers can also separate the electrodes (cathode and anode) from the electrolyte. Gas manifolds are utilized to transport the fuel and oxidant to each cell and provide a path for exhaust gases. The electrical current generated from each cell is drawn away with an interconnect and support structure integrated with the gas manifold. The fuel cells utilize integrated resistive heaters for efficient heating of the materials. By combining MEMS technology with thin-film deposition technology, thin-film fuel cells having microflow channels and full-integrated circuitry can be produced that will lower the operating temperature an will yield an order of magnitude greater power density than the currently known fuel cells.

  7. Tubular solid oxide fuel cell demonstration activities

    SciTech Connect (OSTI)

    Ray, E.R.; Veyo, S.E.

    1995-12-31

    This reports on a solid oxide fuel cell demonstration program in which utilities are provided fully integrated, automatically controlled, packaged solid oxide fuel cell power generation systems. These field units serve to demonstrate to customers first hand the beneficial attributes of the SOFC, to expose deficiencies through experience in order to guide continued development, and to garner real world feedback and data concerning not only cell and stack parameters, but also transportation, installation, permitting and licensing, start-up and shutdown, system alarming, fault detection, fault response, and operator interaction.

  8. Tubular solid oxide fuel cell current collector

    DOE Patents [OSTI]

    Bischoff, Brian L.; Sutton, Theodore G.; Armstrong, Timothy R.

    2010-07-20

    An internal current collector for use inside a tubular solid oxide fuel cell (TSOFC) electrode comprises a tubular coil spring disposed concentrically within a TSOFC electrode and in firm uniform tangential electrical contact with the electrode inner surface. The current collector maximizes the contact area between the current collector and the electrode. The current collector is made of a metal that is electrically conductive and able to survive under the operational conditions of the fuel cell, i.e., the cathode in air, and the anode in fuel such as hydrogen, CO, CO.sub.2, H.sub.2O or H.sub.2S.

  9. Impact of the Fuel Molecular Structure on the Oxidation Process...

    Office of Energy Efficiency and Renewable Energy (EERE) Indexed Site

    Conditions and Biodiesel Content Impact of the Fuel Molecular Structure on the Oxidation Process of Real Diesel fuels According to Storage Conditions and Biodiesel Content ...

  10. Advanced Materials for Reversible Solid Oxide Fuel Cell (RSOFC...

    Office of Energy Efficiency and Renewable Energy (EERE) Indexed Site

    Fuel Cell (RSOFC), Dual Mode Operation with Low Degradation Advanced Materials for Reversible Solid Oxide Fuel Cell (RSOFC), Dual Mode Operation with Low Degradation Presented ...

  11. Solid oxide fuel cell process and apparatus

    DOE Patents [OSTI]

    Cooper, Matthew Ellis; Bayless, David J.; Trembly, Jason P.

    2011-11-15

    Conveying gas containing sulfur through a sulfur tolerant planar solid oxide fuel cell (PSOFC) stack for sulfur scrubbing, followed by conveying the gas through a non-sulfur tolerant PSOFC stack. The sulfur tolerant PSOFC stack utilizes anode materials, such as LSV, that selectively convert H.sub.2S present in the fuel stream to other non-poisoning sulfur compounds. The remaining balance of gases remaining in the completely or near H.sub.2S-free exhaust fuel stream is then used as the fuel for the conventional PSOFC stack that is downstream of the sulfur-tolerant PSOFC. A broad range of fuels such as gasified coal, natural gas and reformed hydrocarbons are used to produce electricity.

  12. FULL SIZE U-10MO MONOLITHIC FUEL FOIL AND FUEL PLATE FABRICATION-TECHNOLOGY DEVELOPMENT

    SciTech Connect (OSTI)

    G. A. Moore; J-F Jue; B. H. Rabin; M. J. Nilles

    2010-03-01

    Full-size U10Mo foils are being developed for use in high density LEU monolithic fuel plates. The application of a zirconium barrier layer too the foil is applied using a hot co-rolling process. Aluminum clad fuel plates are fabricated using Hot Isostatic Pressing (HIP) or a Friction Bonding (FB) process. An overview is provided of ongoing technology development activities, including: the co-rolling process, foil shearing/slitting and polishing, cladding bonding processes, plate forming, plate-assembly swaging, and fuel plate characterization. Characterization techniques being employed include, Ultrasonic Testing (UT), radiography, and microscopy.

  13. Electrocatalyst for alcohol oxidation in fuel cells

    DOE Patents [OSTI]

    Adzic, Radoslav R.; Marinkovic, Nebojsa S.

    2001-01-01

    Binary and ternary electrocatalysts are provided for oxidizing alcohol in a fuel cell. The binary electrocatalyst includes 1) a substrate selected from the group consisting of NiWO.sub.4 or CoWO.sub.4 or a combination thereof, and 2) Group VIII noble metal catalyst supported on the substrate. The ternary electrocatalyst includes 1) a substrate as described above, and 2) a catalyst comprising Group VIII noble metal, and ruthenium oxide or molybdenum oxide or a combination thereof, said catalyst being supported on said substrate.

  14. Silicon Based Solid Oxide Fuel Cell Chip for Portable Consumer Electronics -- Final Technical Report

    SciTech Connect (OSTI)

    Alan Ludwiszewski

    2009-06-29

    LSIs fuel cell uses efficient Solid Oxide Fuel Cell (SOFC) technology, is manufactured using Micro Electrical Mechanical System (MEMS) fabrication methods, and runs on high energy fuels, such as butane and ethanol. The companys Fuel Cell on a Chip technology enables a form-factor battery replacement for portable electronic devices that has the potential to provide an order-of-magnitude run-time improvement over current batteries. Further, the technology is clean and environmentally-friendly. This Department of Energy funded project focused on accelerating the commercialization and market introduction of this technology through improvements in fuel cell chip power output, lifetime, and manufacturability.

  15. Fuel cell collector plate and method of fabrication

    DOE Patents [OSTI]

    Braun, James C.; Zabriskie, Jr., John E.; Neutzler, Jay K.; Fuchs, Michel; Gustafson, Robert C.

    2001-01-01

    An improved molding composition is provided for compression molding or injection molding a current collector plate for a polymer electrolyte membrane fuel cell. The molding composition is comprised of a polymer resin combined with a low surface area, highly-conductive carbon and/or graphite powder filler. The low viscosity of the thermoplastic resin combined with the reduced filler particle surface area provide a moldable composition which can be fabricated into a current collector plate having improved current collecting capacity vis-a-vis comparable fluoropolymer molding compositions.

  16. Generator configuration for solid oxide fuel cells

    DOE Patents [OSTI]

    Reichner, Philip

    1989-01-01

    Disclosed are improvements in a solid oxide fuel cell generator 1 having a multiplicity of electrically connected solid oxide fuel cells 2, where a fuel gas is passed over one side of said cells and an oxygen-containing gas is passed over the other side of said cells resulting in the generation of heat and electricity. The improvements comprise arranging the cells in the configuration of a circle, a spiral, or folded rows within a cylindrical generator, and modifying the flow rate, oxygen concentration, and/or temperature of the oxygen-containing gases that flow to those cells that are at the periphery of the generator relative to those cells that are at the center of the generator. In these ways, a more uniform temperature is obtained throughout the generator.

  17. Sintered electrode for solid oxide fuel cells

    DOE Patents [OSTI]

    Ruka, R.J.; Warner, K.A.

    1999-06-01

    A solid oxide fuel cell fuel electrode is produced by a sintering process. An underlayer is applied to the electrolyte of a solid oxide fuel cell in the form of a slurry, which is then dried. An overlayer is applied to the underlayer and then dried. The dried underlayer and overlayer are then sintered to form a fuel electrode. Both the underlayer and the overlayer comprise a combination of electrode metal such as nickel, and stabilized zirconia such as yttria-stabilized zirconia, with the overlayer comprising a greater percentage of electrode metal. The use of more stabilized zirconia in the underlayer provides good adhesion to the electrolyte of the fuel cell, while the use of more electrode metal in the overlayer provides good electrical conductivity. The sintered fuel electrode is less expensive to produce compared with conventional electrodes made by electrochemical vapor deposition processes. The sintered electrodes exhibit favorable performance characteristics, including good porosity, adhesion, electrical conductivity and freedom from degradation. 4 figs.

  18. SOLID STATE ENERGY CONVERSION ALLIANCE DELPHI SOLID OXIDE FUEL CELL

    SciTech Connect (OSTI)

    Steven Shaffer; Sean Kelly; Subhasish Mukerjee; David Schumann; Gail Geiger; Kevin Keegan; John Noetzel; Larry Chick

    2003-12-08

    The objective of Phase I under this project is to develop a 5 kW Solid Oxide Fuel Cell power system for a range of fuels and applications. During Phase I, the following will be accomplished: Develop and demonstrate technology transfer efforts on a 5 kW stationary distributed power generation system that incorporates steam reforming of natural gas with the option of piped-in water (Demonstration System A). Initiate development of a 5 kW system for later mass-market automotive auxiliary power unit application, which will incorporate Catalytic Partial Oxidation (CPO) reforming of gasoline, with anode exhaust gas injected into an ultra-lean burn internal combustion engine. This technical progress report covers work performed by Delphi from January 1, 2003 to June 30, 2003, under Department of Energy Cooperative Agreement DE-FC-02NT41246. This report highlights technical results of the work performed under the following tasks: Task 1 System Design and Integration; Task 2 Solid Oxide Fuel Cell Stack Developments; Task 3 Reformer Developments; Task 4 Development of Balance of Plant (BOP) Components; Task 5 Manufacturing Development (Privately Funded); Task 6 System Fabrication; Task 7 System Testing; Task 8 Program Management; and Task 9 Stack Testing with Coal-Based Reformate.

  19. A U. S. Perspective on Fast Reactor Fuel Fabrication Technology and Experience Part I: Metal Fuels and Assembly Design

    SciTech Connect (OSTI)

    Douglas E. Burkes; Randall S. Fielding; Douglas L. Porter; Douglas C. Crawford; Mitchell K. Meyer

    2009-06-01

    This paper is Part I of a review focusing on the United States experience with metallic fast reactor fuel fabrication and assembly design for the Experimental Breeder Reactor-II and the Fast Flux Test Facility, and it also refers to the impact of development in other nations. Experience with metal fuel fabrication in the United States is extensive, including over 60 years of research conducted by the government, national laboratories, industry, and academia. This experience has culminated into a foundation of research and resulted in significant improvements to the technologies employed to fabricate metallic fast reactor fuel. This part of the review documents the current state of fuel fabrication technologies for metallic fuels, some of the challenges faced by previous researchers, and how these were overcome. Knowledge gained from reviewing previous investigations will aid both researchers and policy makers in forming future decisions relating to nuclear fuel fabrication technologies.

  20. Breakout Group 5: Solid Oxide Fuel Cells | Department of Energy

    Office of Energy Efficiency and Renewable Energy (EERE) Indexed Site

    5: Solid Oxide Fuel Cells Breakout Group 5: Solid Oxide Fuel Cells Report from Breakout Group 5 of the Fuel Cell Pre-Solicitation Workshop, January 23-24, 2008 PDF icon fc_pre-solicitation_workshop_sofc.pdf More Documents & Publications DOE Fuel Cell Pre-Solicitation Workshop Agenda, January 23-24, 2008, Golden, Colorado Breakout Group 2: Membrane Electrode Assemblies Solid Oxide Fuel Cell System (SOFC) Technology R&D Needs (Presentation)

  1. National Energy Technology Laboratory Publishes Solid Oxide Fuel Cell Studies

    Broader source: Energy.gov [DOE]

    A compilation of studies examining cathodes for solid oxide fuel cells is available on the Department of Energy’s National Energy Technology Laboratory website. The report, entitled Recent Solid Oxide Fuel Cell Cathode Studies, provides a concise, portfolio-wide synopsis of cathode research conducted under the Office of Fossil Energy’s Solid Oxide Fuel Cells Program.

  2. Advanced materials for solid oxide fuel cells: Hafnium-Praseodymium-Indium Oxide System

    SciTech Connect (OSTI)

    Bates, J.L.; Griffin, C.W.; Weber, W.J.

    1988-06-01

    The HfO/sub 2/-PrO/sub 1.83/-In/sub 2/O/sub 3/ system has been studied at the Pacific Northwest Laboratory to develop alternative, highly electrically conducting oxides as electrode and interconnection materials for solid oxide fuel cells. A coprecipitation process was developed for synthesizing single-phase, mixed oxide powders necessary to fabricate powders and dense oxides. A ternary phase diagram was developed, and the phases and structures were related to electrical transport properties. Two new phases, an orthorhombic PrInO/sub 3/ and a rhombohedral Hf/sub 2/In/sub 2/O/sub 7/ phase, were identified. The highest electronic conductivity is related to the presence of a bcc, In/sub 2/O/sub 3/ solid solution (ss) containing HfO/sub 2/ and PrO/sub 1.83/. Compositions containing more than 35 mol % of the In/sub 2/O/sub 3/ ss have electrical conductivities greater than 10/sup /minus/1/ (ohm-cm)/sup /minus/1/, and the two or three phase structures that contain this phase appear to exhibit mixed electronic-ionic conduction. The high electrical conductivities and structures similar to the Y/sub 2/O/sub 3/-stabilized ZrO/sub 2/(HfO/sub 2/) electrolyte give these oxides potential for use as cathodes in solid oxide fuel cells. 21 refs.

  3. SOLID STATE ENERGY CONVERSION ALLIANCE DELPHI SOLID OXIDE FUEL CELL

    SciTech Connect (OSTI)

    Steven Shaffer; Sean Kelly; Subhasish Mukerjee; David Schumann; Gail Geiger; Kevin Keegan; Larry Chick

    2004-05-07

    The objective of this project is to develop a 5 kW Solid Oxide Fuel Cell power system for a range of fuels and applications. During Phase I, the following will be accomplished: Develop and demonstrate technology transfer efforts on a 5 kW stationary distributed power generation system that incorporates steam reforming of natural gas with the option of piped-in water (Demonstration System A). Initiate development of a 5 kW system for later mass-market automotive auxiliary power unit application, which will incorporate Catalytic Partial Oxidation (CPO) reforming of gasoline, with anode exhaust gas injected into an ultra-lean burn internal combustion engine. This technical progress report covers work performed by Delphi from July 1, 2003 to December 31, 2003, under Department of Energy Cooperative Agreement DE-FC-02NT41246. This report highlights technical results of the work performed under the following tasks: Task 1 System Design and Integration; Task 2 Solid Oxide Fuel Cell Stack Developments; Task 3 Reformer Developments; Task 4 Development of Balance of Plant (BOP) Components; Task 5 Manufacturing Development (Privately Funded); Task 6 System Fabrication; Task 7 System Testing; Task 8 Program Management; Task 9 Stack Testing with Coal-Based Reformate; and Task 10 Technology Transfer from SECA CORE Technology Program. In this reporting period, unless otherwise noted Task 6--System Fabrication and Task 7--System Testing will be reported within Task 1 System Design and Integration. Task 8--Program Management, Task 9--Stack Testing with Coal Based Reformate, and Task 10--Technology Transfer from SECA CORE Technology Program will be reported on in the Executive Summary section of this report.

  4. Solid oxide fuel cell having monolithic core

    DOE Patents [OSTI]

    Ackerman, J.P.; Young, J.E.

    1983-10-12

    A solid oxide fuel cell is described for electrochemically combining fuel and oxidant for generating galvanic output, wherein the cell core has an array of electrolyte and interconnect walls that are substantially devoid of any composite inert materials for support. Instead, the core is monolithic, where each electrolyte wall consists of thin layers of cathode and anode materials sandwiching a thin layer of electrolyte material therebetween. The electrolyte walls are arranged and backfolded between adjacent interconnect walls operable to define a plurality of core passageways alternately arranged where the inside faces thereof have only the anode material or only the cathode material exposed. Means direct the fuel to the anode-exposed core passageways and means direct the oxidant to the anode-exposed core passageways and means direct the oxidant to the cathode-exposed core passageway; and means also direct the galvanic output to an exterior circuit. Each layer of the electrolyte and interconnect materials is of the order of 0.002 to 0.01 cm thick; and each layer of the cathode and anode materials is of the order of 0.002 to 0.05 cm thick.

  5. Ni modified ceramic anodes for direct-methane solid oxide fuel cells

    DOE Patents [OSTI]

    Xiao, Guoliang; Chen, Fanglin

    2016-01-19

    In accordance with certain embodiments of the present disclosure, a method for fabricating a solid oxide fuel cell is described. The method includes synthesizing a composition having a perovskite present therein. The method further includes applying the composition on an electrolyte support to form an anode and applying Ni to the composition on the anode.

  6. Solid oxide fuel cell having monolithic core

    DOE Patents [OSTI]

    Ackerman, John P.; Young, John E.

    1984-01-01

    A solid oxide fuel cell for electrochemically combining fuel and oxidant for generating galvanic output, wherein the cell core has an array of electrolyte and interconnect walls that are substantially devoid of any composite inert materials for support. Instead, the core is monolithic, where each electrolyte wall consists of thin layers of cathode and anode materials sandwiching a thin layer of electrolyte material therebetween, and each interconnect wall consists of thin layers of the cathode and anode materials sandwiching a thin layer of interconnect material therebetween. The electrolyte walls are arranged and backfolded between adjacent interconnect walls operable to define a plurality of core passageways alternately arranged where the inside faces thereof have only the anode material or only the cathode material exposed. Means direct the fuel to the anode-exposed core passageways and means direct the oxidant to the cathode-exposed core passageway; and means also direct the galvanic output to an exterior circuit. Each layer of the electrolyte and interconnect materials is of the order of 0.002-0.01 cm thick; and each layer of the cathode and anode materials is of the order of 0.002-0.05 cm thick.

  7. Open end protection for solid oxide fuel cells

    DOE Patents [OSTI]

    Zafred, Paolo R.; Dederer, Jeffrey T.; Tomlins, Gregory W.; Toms, James M.; Folser, George R.; Schmidt, Douglas S.; Singh, Prabhakar; Hager, Charles A.

    2001-01-01

    A solid oxide fuel cell (40) having a closed end (44) and an open end (42) operates in a fuel cell generator (10) where the fuel cell open end (42) of each fuel cell contains a sleeve (60, 64) fitted over the open end (42), where the sleeve (60, 64) extends beyond the open end (42) of the fuel cell (40) to prevent degradation of the interior air electrode of the fuel cell by fuel gas during operation of the generator (10).

  8. Fabrication of Micro-Orifices for Diesel Fuel Injectors | Department of

    Broader source: Energy.gov (indexed) [DOE]

    Energy Scuffing resistance of a MoN-Cu nano-composite coating under exteme loading condidtions do not show scuffing within the load limit of the testing device. PDF icon deer08_fenske.pdf More Documents & Publications Fuel injector Holes (Fabrication of Micro-Orifices for Fuel Injectors) Fuel Injector Holes Fuel Injector Holes

  9. Environmental assessment for radioisotope heat source fuel processing and fabrication

    SciTech Connect (OSTI)

    Not Available

    1991-07-01

    DOE has prepared an Environmental Assessment (EA) for radioisotope heat source fuel processing and fabrication involving existing facilities at the Savannah River Site (SRS) near Aiken, South Carolina and the Los Alamos National Laboratory (LANL) near Los Alamos, New Mexico. The proposed action is needed to provide Radioisotope Thermoelectric Generators (RTG) to support the National Aeronautics and Space Administration's (NASA) CRAF and Cassini Missions. Based on the analysis in the EA, DOE has determined that the proposed action does not constitute a major Federal action significantly affecting the quality of the human environment within the meaning of the National Environmental Policy Act (NEPA) of 1969. Therefore, an Environmental Impact Statement is not required. 30 refs., 5 figs.

  10. Electrocatalysts for Alcohol Oxidation in Fuel Cells - Energy Innovation

    Broader source: All U.S. Department of Energy (DOE) Office Webpages (Extended Search)

    Portal Electrocatalysts for Alcohol Oxidation in Fuel Cells Brookhaven National Laboratory Contact BNL About This Technology <p> Higher current indicates higher activity for catalyzing methanol oxidation in a fuel cell. Here the ternary electrocatalyst is comparable to the best commercially available catalyst for methanol oxidation.</p> Higher current indicates higher activity for catalyzing methanol oxidation in a fuel cell. Here the ternary electrocatalyst is comparable to the

  11. Solid Oxide Fuel Cell Systems PVL Line

    SciTech Connect (OSTI)

    Susan Shearer - Stark State College; Gregory Rush - Rolls-Royce Fuel Cell Systems

    2012-05-01

    In July 2010, Stark State College (SSC), received Grant DE-EE0003229 from the U.S. Department of Energy (DOE), Golden Field Office, for the development of the electrical and control systems, and mechanical commissioning of a unique 20kW scale high-pressure, high temperature, natural gas fueled Stack Block Test System (SBTS). SSC worked closely with subcontractor, Rolls-Royce Fuel Cell Systems (US) Inc. (RRFCS) over a 13 month period to successfully complete the project activities. This system will be utilized by RRFCS for pre-commercial technology development and training of SSC student interns. In the longer term, when RRFCS is producing commercial products, SSC will utilize the equipment for workforce training. In addition to DOE Hydrogen, Fuel Cells, and Infrastructure Technologies program funding, RRFCS internal funds, funds from the state of Ohio, and funding from the DOE Solid State Energy Conversion Alliance (SECA) program have been utilized to design, develop and commission this equipment. Construction of the SBTS (mechanical components) was performed under a Grant from the State of Ohio through Ohio's Third Frontier program (Grant TECH 08-053). This Ohio program supported development of a system that uses natural gas as a fuel. Funding was provided under the Department of Energy (DOE) Solid-state Energy Conversion Alliance (SECA) program for modifications required to test on coal synthesis gas. The subject DOE program provided funding for the electrical build, control system development and mechanical commissioning. Performance testing, which includes electrical commissioning, was subsequently performed under the DOE SECA program. Rolls-Royce Fuel Cell Systems is developing a megawatt-scale solid oxide fuel cell (SOFC) stationary power generation system. This system, based on RRFCS proprietary technology, is fueled with natural gas, and operates at elevated pressure. A critical success factor for development of the full scale system is the capability to test fuel cell components at a scale and under conditions that can be accurately extrapolated to full system performance. This requires specially designed equipment that replicates the pressure (up to 6.5 bara), temperature (about 910 C), anode and cathode gas compositions, flows and power generation density of the full scale design. The SBTS fuel cell anode gas is produced through the reaction of pipeline natural gas with a mixture of steam, CO2, and O2 in a catalytic partial oxidation (CPOX) reactor. Production of the fuel cell anode gas in this manner provides the capability to test a fuel cell with varying anode gas compositions ranging from traditional reformed natural gas to a coal-syngas surrogate fuel. Stark State College and RRFCS have a history of collaboration. This is based upon SSCAs commitment to provide students with skills for advanced energy industries, and RRFCS need for a workforce that is skilled in high temperature fuel cell development and testing. A key to this approach is the access of students to unique SOFC test and evaluation equipment. This equipment is designed and developed by RRFCS, with the participation of SSC interns. In the near-term, the equipment will be used by RRFCS for technology development. When this stage is completed, and RRFCS has moved to commercial products, SSC will utilize this equipment for workforce training. The RRFCS fuel cell design is based upon a unique ceramic substrate architecture in which a porous, flat substrate (tube) provides the support structure for a network of solid oxide fuel cells that are electrically connected in series. These tubes are grouped into a {approx}350-tube repeat configuration, called a stack/block. Stack/block testing, performed at system conditions, provides data that can be confidently scaled to full scale performance. This is the basis for the specially designed and developed test equipment that is required for advancing and accelerating the RRFCS SOFC power system development program. All contract DE-EE0003229 objectives were achieved and deliverables completed during the period from March 1, 2010 through March 31, 2011. As a result of program completion, the Stack Block Test System was ready to support installation and electrical operation of a RRFCS solid oxide fuel cell (SOFC) stack block in the second quarter of 2011.

  12. Solid oxide fuel cell matrix and modules

    DOE Patents [OSTI]

    Riley, B.

    1988-04-22

    Porous refractory ceramic blocks arranged in an abutting, stacked configuration and forming a three dimensional array provide a support structure and coupling means for a plurality of solid oxide fuel cells (SOFCs). The stack of ceramic blocks is self-supporting, with a plurality of such stacked arrays forming a matrix enclosed in an insulating refractory brick structure having an outer steel layer. The necessary connections for air, fuel, burnt gas, and anode and cathode connections are provided through the brick and steel outer shell. The ceramic blocks are so designed with respect to the strings of modules that by simple and logical design the strings could be replaced by hot reloading if one should fail. The hot reloading concept has not been included in any previous designs. 11 figs.

  13. Tubular solid oxide fuel cell development program

    SciTech Connect (OSTI)

    Ray, E.R.; Cracraft, C.

    1995-12-31

    This paper presents an overview of the Westinghouse Solid Oxide Fuel Cell (SOFC) development activities and current program status. The Westinghouse goal is to develop a cost effective cell that can operate for 50,000 to 100,000 hours. Progress toward this goal will be discussed and test results presented for multiple single cell tests which have now successfully exceeded 56,000 hours of continuous power operation at temperature. Results of development efforts to reduce cost and increase power output of tubular SOFCs are described.

  14. A metallic fuel cycle concept from spent oxide fuel to metallic fuel

    SciTech Connect (OSTI)

    Fujita, Reiko; Kawashima, Masatoshi; Yamaoka, Mitsuaki; Arie, Kazuo; Koyama, Tadafumi

    2007-07-01

    A Metallic fuel cycle concept for Self-Consistent Nuclear Energy System (SCNES) has been proposed in a companion papers. The ultimate goal of the SCNES is to realize sustainable energy supply without endangering the environment and humans. For future transition period from LWR era to SCNES era, a new metallic fuel recycle concept from LWR spent fuel has been proposed in this paper. Combining the technology for electro-reduction of oxide fuels and zirconium recovery by electrorefining in molten salts in the nuclear recycling schemes, the amount of radioactive waste reduced in a proposed metallic fuel cycle concept. If the recovery ratio of zirconium metal from the spent zirconium waste is 95%, the cost estimation in zirconium recycle to the metallic fuel materials has been estimated to be less than 1/25. (authors)

  15. Materials issues in solid oxide fuel cell systems

    SciTech Connect (OSTI)

    Ziomek-Moroz, M.

    2007-03-02

    Hydrogen is the main fuel for all types of fuel cells except direct methanol fuel cells. Hydrogen can be generated from all manner of fossil fuels, including coal, natural gas, diesel, gasoline, other hydrocarbons, and oxygenates (e.g., methanol, ethanol, butanol, etc.). The presence of carbon oxides in the fuel can cause significant performance problems resulting in decreasing the cell performance of fuel cells, including solid oxide fuel cells (SOFC). In the SOFC, the high (800-1000C) operating temperature yields advantages (e.g., internal fuel reforming) and disadvantages (e.g., material selection and degradation problems). Significant progress in reducing the operating temperature of the SOFC below ~800 C may allow less expensive metallic materials to be used for interconnects. This presentation provides insight on the material performance of ferritic steels in fuels containing carbon oxides and seeks to quantify the extent of possible degradation due to carbon species in the gas stream.

  16. Solid Oxide Fuel Cell Systems for APU Functions and Beyond |...

    Office of Energy Efficiency and Renewable Energy (EERE) Indexed Site

    Solid Oxide Fuel Cell Systems for APU Functions and Beyond Poster presentation from the 2007 Diesel Engine-Efficiency & Emissions Research Conference (DEER 2007). 13-16 August, ...

  17. National Energy Technology Laboratory Publishes Solid Oxide Fuel...

    Office of Energy Efficiency and Renewable Energy (EERE) Indexed Site

    as quickly as possible. The NETL-managed program is currently developing solid oxide fuel cells for large power plants. The same technology is also likely to find...

  18. Solid oxide fuel cell generator with removable modular fuel cell stack configurations

    DOE Patents [OSTI]

    Gillett, James E.; Dederer, Jeffrey T.; Zafred, Paolo R.; Collie, Jeffrey C.

    1998-01-01

    A high temperature solid oxide fuel cell generator produces electrical power from oxidation of hydrocarbon fuel gases such as natural gas, or conditioned fuel gases, such as carbon monoxide or hydrogen, with oxidant gases, such as air or oxygen. This electrochemical reaction occurs in a plurality of electrically connected solid oxide fuel cells bundled and arrayed in a unitary modular fuel cell stack disposed in a compartment in the generator container. The use of a unitary modular fuel cell stack in a generator is similar in concept to that of a removable battery. The fuel cell stack is provided in a pre-assembled self-supporting configuration where the fuel cells are mounted to a common structural base having surrounding side walls defining a chamber. Associated generator equipment may also be mounted to the fuel cell stack configuration to be integral therewith, such as a fuel and oxidant supply and distribution systems, fuel reformation systems, fuel cell support systems, combustion, exhaust and spent fuel recirculation systems, and the like. The pre-assembled self-supporting fuel cell stack arrangement allows for easier assembly, installation, maintenance, better structural support and longer life of the fuel cells contained in the fuel cell stack.

  19. Solid oxide fuel cell generator with removable modular fuel cell stack configurations

    DOE Patents [OSTI]

    Gillett, J.E.; Dederer, J.T.; Zafred, P.R.; Collie, J.C.

    1998-04-21

    A high temperature solid oxide fuel cell generator produces electrical power from oxidation of hydrocarbon fuel gases such as natural gas, or conditioned fuel gases, such as carbon monoxide or hydrogen, with oxidant gases, such as air or oxygen. This electrochemical reaction occurs in a plurality of electrically connected solid oxide fuel cells bundled and arrayed in a unitary modular fuel cell stack disposed in a compartment in the generator container. The use of a unitary modular fuel cell stack in a generator is similar in concept to that of a removable battery. The fuel cell stack is provided in a pre-assembled self-supporting configuration where the fuel cells are mounted to a common structural base having surrounding side walls defining a chamber. Associated generator equipment may also be mounted to the fuel cell stack configuration to be integral therewith, such as a fuel and oxidant supply and distribution systems, fuel reformation systems, fuel cell support systems, combustion, exhaust and spent fuel recirculation systems, and the like. The pre-assembled self-supporting fuel cell stack arrangement allows for easier assembly, installation, maintenance, better structural support and longer life of the fuel cells contained in the fuel cell stack. 8 figs.

  20. Solid oxide fuel cell matrix and modules

    DOE Patents [OSTI]

    Riley, Brian (Willimantic, CT)

    1990-01-01

    Porous refractory ceramic blocks arranged in an abutting, stacked configuration and forming a three dimensional array provide a support structure and coupling means for a plurality of solid oxide fuel cells (SOFCs). Each of the blocks includes a square center channel which forms a vertical shaft when the blocks are arranged in a stacked array. Positioned within the channel is a SOFC unit cell such that a plurality of such SOFC units disposed within a vertical shaft form a string of SOFC units coupled in series. A first pair of facing inner walls of each of the blocks each include an interconnecting channel hole cut horizontally and vertically into the block walls to form gas exit channels. A second pair of facing lateral walls of each block further include a pair of inner half circular grooves which form sleeves to accommodate anode fuel and cathode air tubes. The stack of ceramic blocks is self-supporting, with a plurality of such stacked arrays forming a matrix enclosed in an insulating refractory brick structure having an outer steel layer. The necessary connections for air, fuel, burnt gas, and anode and cathode connections are provided through the brick and steel outer shell. The ceramic blocks are so designed with respect to the strings of modules that by simple and logical design the strings could be replaced by hot reloading if one should fail. The hot reloading concept has not been included in any previous designs.

  1. An Overview of Current and Past W-UO[2] CERMET Fuel Fabrication Technology

    SciTech Connect (OSTI)

    Douglas E. Burkes; Daniel M. Wachs; James E. Werner; Steven D. Howe

    2007-06-01

    Studies dating back to the late 1940s performed by a number of different organizations and laboratories have established the major advantages of Nuclear Thermal Propulsion (NTP) systems, particularly for manned missions. A number of NTP projects have been initiated since this time; none have had any sustained fuel development work that appreciably contributed to fuel fabrication or performance data from this era. As interest in these missions returns and previous space nuclear power researchers begin to retire, fuel fabrication technologies must be revisited, so that established technologies can be transferred to young researchers seamlessly and updated, more advanced processes can be employed to develop successful NTP fuels. CERMET fuels, specifically W-UO2, are of particular interest to the next generation NTP plans since these fuels have shown significant advantages over other fuel types, such as relatively high burnup, no significant failures under severe transient conditions, capability of accommodating a large fission product inventory during irradiation and compatibility with flowing hot hydrogen. Examples of previous fabrication routes involved with CERMET fuels include hot isostatic pressing (HIPing) and press and sinter, whereas newer technologies, such as spark plasma sintering, combustion synthesis and microsphere fabrication might be well suited to produce high quality, effective fuel elements. These advanced technologies may address common issues with CERMET fuels, such as grain growth, ductile to brittle transition temperature and UO2 stoichiometry, more effectively than the commonly accepted ‘traditional’ fabrication routes. Bonding of fuel elements, especially if the fabrication process demands production of smaller element segments, must be investigated. Advanced brazing techniques and compounds are now available that could produce a higher quality bond segment with increased ease in joining. This paper will briefly address the history of CERMET fuel fabrication technology as related to the GE 710 and ANL Nuclear Rocket Programs, in addition to discussing future plans, viable alternatives and preliminary investigations for W-UO2 CERMET fuel fabrication. The intention of the talk is to provide the brief history and tie in an overview of current programs and investigations as related to NTP based W-UO2 CERMET fuel fabrication, and hopefully peak interest in advanced fuel fabrication technologies.

  2. Uranium-233 purification and conversion to stabilized ceramic grade urania for LWBR fuel fabrication (LWBR Development Program)

    SciTech Connect (OSTI)

    Lloyd, R.

    1980-10-01

    High purity ceramic grade urania (/sup 233/UO/sub 2/) used in manufacturing the fuel for the Light Water Breeder Reactor (LWBR) core was made from uranium-233 that was obtained by irradiating thoria under special conditions to result in not more than 10 ppM of uranium-232 in the recovered uranium-233 product. A developmental study established the operating parameters of the conversion process for transforming the uranium-233 into urania powder with the appropriate chemical and physical attributes for use in fabricating the LWBR core fuel. This developmental study included the following: (a) design of an ion exchange purification process for removing the gamma-emitting alpha-decay daughters of uranium-232, to reduce the gamma-radiation field of the uranium-233 during LWBR fuel manufacture; (b) definition of the parameters for precipitating the uranium-233 as ammonium uranate (ADU) and for reducing the ADU with hydrogen to yield a urania conversion product of the proper particle size, surface area and sinterability for use in manufacturing the LWBR fuel; (c) establishment of parameters and design of equipment for stabilizing the urania conversion product to prevent it from undergoing excessive oxidation on exposure to the air during LWBR fuel manufacturing operations; and (d) development of a procedure and a facility to reprocess the unirradiated thoria-urania fuel scrap from the LWBR core manufacturing operations to recover the uranium-233 and convert it into high purity ceramic grade urania for LWBR core fabrication.

  3. Tubular screen electrical connection support for solid oxide fuel cells

    DOE Patents [OSTI]

    Tomlins, Gregory W.; Jaszcar, Michael P.

    2002-01-01

    A solid oxide fuel assembly is made of fuel cells (16, 16', 18, 24, 24', 26), each having an outer interconnection layer (36) and an outer electrode (28), which are disposed next to each other with rolled, porous, hollow, electrically conducting metal mesh conductors (20, 20') between the fuel cells, connecting the fuel cells at least in series along columns (15, 15') and where there are no metal felt connections between any fuel cells.

  4. Hybrid deposition of thin film solid oxide fuel cells and electrolyzers

    DOE Patents [OSTI]

    Jankowski, Alan F.; Makowiecki, Daniel M.; Rambach, Glenn D.; Randich, Erik

    1999-01-01

    The use of vapor deposition techniques enables synthesis of the basic components of a solid oxide fuel cell (SOFC); namely, the electrolyte layer, the two electrodes, and the electrolyte-electrode interfaces. Such vapor deposition techniques provide solutions to each of the three critical steps of material synthesis to produce a thin film solid oxide fuel cell (TFSOFC). The electrolyte is formed by reactive deposition of essentially any ion conducting oxide, such as defect free, yttria stabilized zirconia (YSZ) by planar magnetron sputtering. The electrodes are formed from ceramic powders sputter coated with an appropriate metal and sintered to a porous compact. The electrolyte-electrode interface is formed by chemical vapor deposition of zirconia compounds onto the porous electrodes to provide a dense, smooth surface on which to continue the growth of the defect-free electrolyte, whereby a single fuel cell or multiple cells may be fabricated.

  5. Hybrid deposition of thin film solid oxide fuel cells and electrolyzers

    DOE Patents [OSTI]

    Jankowski, Alan F.; Makowiecki, Daniel M.; Rambach, Glenn D.; Randich, Erik

    1998-01-01

    The use of vapor deposition techniques enables synthesis of the basic components of a solid oxide fuel cell (SOFC); namely, the electrolyte layer, the two electrodes, and the electrolyte-electrode interfaces. Such vapor deposition techniques provide solutions to each of the three critical steps of material synthesis to produce a thin film solid oxide fuel cell (TFSOFC). The electrolyte is formed by reactive deposition of essentially any ion conducting oxide, such as defect free, yttria stabilized zirconia (YSZ) by planar magnetron sputtering. The electrodes are formed from ceramic powders sputter coated with an appropriate metal and sintered to a porous compact. The electrolyte-electrode interface is formed by chemical vapor deposition of zirconia compounds onto the porous electrodes to provide a dense, smooth surface on which to continue the growth of the defect-free electrolyte, whereby a single fuel cell or multiple cells may be fabricated.

  6. Hybrid deposition of thin film solid oxide fuel cells and electrolyzers

    DOE Patents [OSTI]

    Jankowski, A.F.; Makowiecki, D.M.; Rambach, G.D.; Randich, E.

    1998-05-19

    The use of vapor deposition techniques enables synthesis of the basic components of a solid oxide fuel cell (SOFC); namely, the electrolyte layer, the two electrodes, and the electrolyte-electrode interfaces. Such vapor deposition techniques provide solutions to each of the three critical steps of material synthesis to produce a thin film solid oxide fuel cell (TFSOFC). The electrolyte is formed by reactive deposition of essentially any ion conducting oxide, such as defect free, yttria stabilized zirconia (YSZ) by planar magnetron sputtering. The electrodes are formed from ceramic powders sputter coated with an appropriate metal and sintered to a porous compact. The electrolyte-electrode interface is formed by chemical vapor deposition of zirconia compounds onto the porous electrodes to provide a dense, smooth surface on which to continue the growth of the defect-free electrolyte, whereby a single fuel cell or multiple cells may be fabricated. 8 figs.

  7. OXIDATION OF FUELS IN THE COOL FLAME REGIME FOR COMBUSTION AND REFORMING FOR FUEL CELLS.

    SciTech Connect (OSTI)

    NAIDJA,A.; KRISHNA,C.R.; BUTCHER,T.; MAHAJAN,D.

    2002-08-01

    THE REVIEW INTEGRATES RECENT INVESTIGATIONS ON AUTO OXIDATION OF FUEL OILS AND THEIR REFORMING INTO HYDROGEN RICH GAS THAT COULD SERVE AS A FEED FOR FUEL CELLS AND COMBUSTION SYSTEMS.

  8. Recent progress in tubular solid oxide fuel cell technology

    SciTech Connect (OSTI)

    Singhal, S.C.

    1997-12-31

    The tubular design of solid oxide fuel cells (SOFCs) and the materials used therein have been validated by successful, continuous electrical testing over 69,000 h of early technology cells built on a calcia-stabilized zirconia porous support tube (PST). In the latest technology cells, the PST has been eliminated and replaced by a doped lanthanum manganite air electrode tube. These air electrode supported (AES) cells have shown a power density increase of about 33% with a significantly improved performance stability over the previously used PST type cells. These cells have also demonstrated the ability to thermally cycle over 100 times without any mechanical damage or performance loss. In addition, recent changes in processes used to fabricate these cells have resulted in significant cost reduction. This paper reviews the fabrication and performance of the state-of-the-art AES tubular cells. It also describes the materials and processing studies that are underway to further reduce the cell cost, and summarizes the recently built power generation systems that employed state-of-the-art AES cells.

  9. High power density solid oxide fuel cells

    DOE Patents [OSTI]

    Pham, Ai Quoc; Glass, Robert S.

    2004-10-12

    A method for producing ultra-high power density solid oxide fuel cells (SOFCs). The method involves the formation of a multilayer structure cells wherein a buffer layer of doped-ceria is deposited intermediate a zirconia electrolyte and a cobalt iron based electrode using a colloidal spray deposition (CSD) technique. For example, a cobalt iron based cathode composed of (La,Sr)(Co,Fe)O (LSCF) may be deposited on a zirconia electrolyte via a buffer layer of doped-ceria deposited by the CSD technique. The thus formed SOFC have a power density of 1400 mW/cm.sup.2 at 600.degree. C. and 900 mW/cm.sup.2 at 700.degree. C. which constitutes a 2-3 times increased in power density over conventionally produced SOFCs.

  10. Tubular solid oxide fuel cell developments

    SciTech Connect (OSTI)

    Bratton, R.J.; Singh, P.

    1995-08-01

    An overview of the tubular solid oxide fuel cell (SOFC) development at Westinghouse is presented in this paper. The basic operating principles of SOFCs, evolution in tubular cell design and performance improvement, selection criteria for cell component materials, and cell processing techniques are discussed. The commercial goal is to develop a cell that can operate for 5 to 10 years. Results of cell test operated for more than 50,000 hours are presented. Since 1986, significant progress has been made in the evolution of cells with higher power, lower cost and improved thermal cyclic capability. Also in this period, successively larger multi-kilowatt electrical generators systems have been built and successfully operated for more than 7000 hours.

  11. Solid oxide fuel cell power system development

    SciTech Connect (OSTI)

    Kerr, Rick; Wall, Mark; Sullivan, Neal

    2015-06-26

    This report summarizes the progress made during this contractual period in achieving the goal of developing the solid oxide fuel cell (SOFC) cell and stack technology to be suitable for use in highly-efficient, economically-competitive, commercially deployed electrical power systems. Progress was made in further understanding cell and stack degradation mechanisms in order to increase stack reliability toward achieving a 4+ year lifetime, in cost reduction developments to meet the SECA stack cost target of $175/kW (in 2007 dollars), and in operating the SOFC technology in a multi-stack system in a real-world environment to understand the requirements for reliably designing and operating a large, stationary power system.

  12. EA-0534: Radioisotope Heat Source Fuel Processing and Fabrication, Los Alamos, New Mexico

    Broader source: Energy.gov [DOE]

    This EA evaluates the environmental impacts of a proposal to operate existing Pu-238 processing facilities at Savannah River Site, and fabricate a limited quantity of Pu-238 fueled heat sources at...

  13. Nanostructured Solid Oxide Fuel Cell Electrodes

    SciTech Connect (OSTI)

    Sholklapper, Tal Zvi

    2007-12-15

    The ability of Solid Oxide Fuel Cells (SOFC) to directly and efficiently convert the chemical energy in hydrocarbon fuels to electricity places the technology in a unique and exciting position to play a significant role in the clean energy revolution. In order to make SOFC technology cost competitive with existing technologies, the operating temperatures have been decreased to the range where costly ceramic components may be substituted with inexpensive metal components within the cell and stack design. However, a number of issues have arisen due to this decrease in temperature: decreased electrolyte ionic conductivity, cathode reaction rate limitations, and a decrease in anode contaminant tolerance. While the decrease in electrolyte ionic conductivities has been countered by decreasing the electrolyte thickness, the electrode limitations have remained a more difficult problem. Nanostructuring SOFC electrodes addresses the major electrode issues. The infiltration method used in this dissertation to produce nanostructure SOFC electrodes creates a connected network of nanoparticles; since the method allows for the incorporation of the nanoparticles after electrode backbone formation, previously incompatible advanced electrocatalysts can be infiltrated providing electronic conductivity and electrocatalysis within well-formed electrolyte backbones. Furthermore, the method is used to significantly enhance the conventional electrode design by adding secondary electrocatalysts. Performance enhancement and improved anode contamination tolerance are demonstrated in each of the electrodes. Additionally, cell processing and the infiltration method developed in conjunction with this dissertation are reviewed.

  14. Solid Oxide Fuel Cell Technologies: Improved Electrode-Electrode Structures

    Broader source: All U.S. Department of Energy (DOE) Office Webpages (Extended Search)

    for Solid State Electrochemical Devices - Energy Innovation Portal Solid Oxide Fuel Cell Technologies: Improved Electrode-Electrode Structures for Solid State Electrochemical Devices Lawrence Berkeley National Laboratory Contact LBL About This Technology Technology Marketing SummaryBerkeley Lab researchers Lutgard DeJonghe, Steven Visco, and Craig Jacobson have focused their attention on solid oxide fuel cells (SOFC) and related technologies. Fuel cells "burn" hydrogen or

  15. The burnup dependence of light water reactor spent fuel oxidation

    SciTech Connect (OSTI)

    Hanson, B.D.

    1998-07-01

    Over the temperature range of interest for dry storage or for placement of spent fuel in a permanent repository under the conditions now being considered, UO{sub 2} is thermodynamically unstable with respect to oxidation to higher oxides. The multiple valence states of uranium allow for the accommodation of interstitial oxygen atoms in the fuel matrix. A variety of stoichiometric and nonstoichiometric phases is therefore possible as the fuel oxidizers from UO{sub 2} to higher oxides. The oxidation of UO{sub 2} has been studied extensively for over 40 years. It has been shown that spent fuel and unirradiated UO{sub 2} oxidize via different mechanisms and at different rates. The oxidation of LWR spent fuel from UO{sub 2} to UO{sub 2.4} was studied previously and is reasonably well understood. The study presented here was initiated to determine the mechanism and rate of oxidation from UO{sub 2.4} to higher oxides. During the early stages of this work, a large variability in the oxidation behavior of samples oxidized under nearly identical conditions was found. Based on previous work on the effect of dopants on UO{sub 2} oxidation and this initial variability, it was hypothesized that the substitution of fission product and actinide impurities for uranium atoms in the spent fuel matrix was the cause of the variable oxidation behavior. Since the impurity concentration is roughly proportional to the burnup of a specimen, the oxidation behavior of spent fuel was expected to be a function of both temperature and burnup. This report (1) summarizes the previous oxidation work for both unirradiated UO{sub 2} and spent fuel (Section 2.2) and presents the theoretical basis for the burnup (i.e., impurity concentration) dependence of the rate of oxidation (Sections 2.3, 2.4, and 2.5), (2) describes the experimental approach (Section 3) and results (Section 4) for the current oxidation tests on spent fuel, and (3) establishes a simple model to determine the activation energies associated with spent fuel oxidation (Section 5).

  16. Electrode electrolyte interlayers containing cerium oxide for electrochemical fuel cells

    DOE Patents [OSTI]

    Borglum, Brian P.; Bessette, Norman F.

    2000-01-01

    An electrochemical cell is made having a porous fuel electrode (16) and a porous air electrode (13), with solid oxide electrolyte (15) therebetween, where the air electrode surface opposing the electrolyte has a separate, attached, dense, continuous layer (14) of a material containing cerium oxide, and where electrolyte (16) contacts the continuous oxide layer (14), without contacting the air electrode (13).

  17. Options for converting excess plutonium to feed for the MOX fuel fabrication facility

    SciTech Connect (OSTI)

    Watts, Joe A; Smith, Paul H; Psaras, John D; Jarvinen, Gordon D; Costa, David A; Joyce, Jr., Edward L

    2009-01-01

    The storage and safekeeping of excess plutonium in the United States represents a multibillion-dollar lifecycle cost to the taxpayers and poses challenges to National Security and Nuclear Non-Proliferation. Los Alamos National Laboratory is considering options for converting some portion of the 13 metric tons of excess plutonium that was previously destined for long-term waste disposition into feed for the MOX Fuel Fabrication Facility (MFFF). This approach could reduce storage costs and security ri sks, and produce fuel for nuclear energy at the same time. Over the course of 30 years of weapons related plutonium production, Los Alamos has developed a number of flow sheets aimed at separation and purification of plutonium. Flow sheets for converting metal to oxide and for removing chloride and fluoride from plutonium residues have been developed and withstood the test oftime. This presentation will address some potential options for utilizing processes and infrastructure developed by Defense Programs to transform a large variety of highly impure plutonium into feedstock for the MFFF.

  18. Operation of N Reactor and Fuels Fabrication Facilities, Hanford Reservation, Richland, Benton County, Washington: Environmental assessment

    SciTech Connect (OSTI)

    Not Available

    1980-08-01

    Environmental data, calculations and analyses show no significant adverse radiological or nonradiological impacts from current or projected future operations resulting from N Reactor, Fuels Fabrication and Spent Fuel Storage Facilities. Nonoccupational radiation exposures resulting from 1978 N Reactor operations are summarized and compared to allowable exposure limits.

  19. Solid Oxide Fuel Cell Balance of Plant and Stack Component Integration...

    Office of Energy Efficiency and Renewable Energy (EERE) Indexed Site

    Balance of Plant and Stack Component Integration Solid Oxide Fuel Cell Balance of Plant and Stack Component Integration Presentation by Acumentrics Corporation for Solid Oxide Fuel ...

  20. Solid oxide fuel cell operable over wide temperature range

    DOE Patents [OSTI]

    Baozhen, Li (Essex Junction, VT); Ruka, Roswell J. (Pittsburgh, PA); Singhal, Subhash C. (Murrysville, PA)

    2001-01-01

    Solid oxide fuel cells having improved low-temperature operation are disclosed. In one embodiment, an interfacial layer of terbia-stabilized zirconia is located between the air electrode and electrolyte of the solid oxide fuel cell. The interfacial layer provides a barrier which controls interaction between the air electrode and electrolyte. The interfacial layer also reduces polarization loss through the reduction of the air electrode/electrolyte interfacial electrical resistance. In another embodiment, the solid oxide fuel cell comprises a scandia-stabilized zirconia electrolyte having high electrical conductivity. The scandia-stabilized zirconia electrolyte may be provided as a very thin layer in order to reduce resistance. The scandia-stabilized electrolyte is preferably used in combination with the terbia-stabilized interfacial layer. The solid oxide fuel cells are operable over wider temperature ranges and wider temperature gradients in comparison with conventional fuel cells.

  1. Operation of a solid oxide fuel cell on biodiesel with a partial oxidation reformer

    SciTech Connect (OSTI)

    Siefert, N, Shekhawat, D.; Gemmen, R.; Berry, D.

    2010-01-01

    The National Energy Technology Laboratorys Office of Research & Development (NETL/ORD) has successfully demonstrated the operation of a solid oxide fuel cell (SOFC) using reformed biodiesel. The biodiesel for the project was produced and characterized by West Virginia State University (WVSU). This project had two main aspects: 1) demonstrate a catalyst formulation on monolith for biodiesel fuel reforming; and 2) establish SOFC stack test stand capabilities. Both aspects have been completed successfully. For the first aspect, inhouse patented catalyst specifications were developed, fabricated and tested. Parametric reforming studies of biofuels provided data on fuel composition, catalyst degradation, syngas composition, and operating parameters required for successful reforming and integration with the SOFC test stand. For the second aspect, a stack test fixture (STF) for standardized testing, developed by Pacific Northwest National Laboratory (PNNL) and Lawrence Berkeley National Laboratory (LBNL) for the Solid Energy Conversion Alliance (SECA) Program, was engineered and constructed at NETL. To facilitate the demonstration of the STF, NETL employed H.C. Starck Ceramics GmbH & Co. (Germany) anode supported solid oxide cells. In addition, anode supported cells, SS441 end plates, and cell frames were transferred from PNNL to NETL. The stack assembly and conditioning procedures, including stack welding and sealing, contact paste application, binder burn-out, seal-setting, hot standby, and other stack assembly and conditioning methods were transferred to NETL. In the future, fuel cell stacks provided by SECA or other developers could be tested at the STF to validate SOFC performance on various fuels. The STF operated on hydrogen for over 1000 hrs before switching over to reformed biodiesel for 100 hrs of operation. Combining these first two aspects led to demonstrating the biodiesel syngas in the STF. A reformer was built and used to convert 0.5 ml/min of biodiesel into mostly hydrogen and carbon monoxide (syngas.) The syngas was fed to the STF and fuel cell stack. The results presented in this experimental report document one of the first times a SOFC has been operated on syngas from reformed biodiesel.

  2. Stack configurations for tubular solid oxide fuel cells

    DOE Patents [OSTI]

    Armstrong, Timothy R. (Clinton, TN); Trammell, Michael P. (Clinton, TN); Marasco, Joseph A. (Kingston, TN)

    2010-08-31

    A fuel cell unit includes an array of solid oxide fuel cell tubes having porous metallic exterior surfaces, interior fuel cell layers, and interior surfaces, each of the tubes having at least one open end; and, at least one header in operable communication with the array of solid oxide fuel cell tubes for directing a first reactive gas into contact with the porous metallic exterior surfaces and for directing a second reactive gas into contact with the interior surfaces, the header further including at least one busbar disposed in electrical contact with at least one surface selected from the group consisting of the porous metallic exterior surfaces and the interior surfaces.

  3. Fuel electrode containing pre-sintered nickel/zirconia for a solid oxide fuel cell

    DOE Patents [OSTI]

    Ruka, Roswell J.; Vora, Shailesh D.

    2001-01-01

    A fuel cell structure (2) is provided, having a pre-sintered nickel-zirconia fuel electrode (6) and an air electrode (4), with a ceramic electrolyte (5) disposed between the electrodes, where the pre-sintered fuel electrode (6) contains particles selected from the group consisting of nickel oxide, cobalt and cerium dioxide particles and mixtures thereof, and titanium dioxide particles, within a matrix of yttria-stabilized zirconia and spaced-apart filamentary nickel strings having a chain structure, and where the fuel electrode can be sintered to provide an active solid oxide fuel cell.

  4. SEM and TEM Characterization of As-Fabricated U-7Mo Disperson Fuel Plates

    SciTech Connect (OSTI)

    D. D. Keiser, Jr.; B. Yao; E. Perez; Y. H. Sohn

    2009-11-01

    The starting microstructure of a dispersion fuel plate can have a dramatic impact on the overall performance of the plate during irradiation. To improve the understanding of the as-fabricated microstructures of dispersion fuel plates, SEM and TEM analysis have been performed on RERTR-9A archive fuel plates, which went through an additional hot isostatic procsssing (HIP) step during fabrication. The fuel plates had depleted U-7Mo fuel particles dispersed in either Al-2Si or 4043 Al alloy matrix. For the characterized samples, it was observed that a large fraction of the ?-phase U-7Mo alloy particles had decomposed during fabrication, and in areas near the fuel/matrix interface where the transformation products were present significant fuel/matrix interaction had occurred. Relatively thin Si-rich interaction layers were also observed around the U-7Mo particles. In the thick interaction layers, (U)(Al,Si)3 and U6Mo4Al43 were identified, and in the thin interaction layers U(Al,Si)3, U3Si3Al2, U3Si5, and USi1.88-type phases were observed. The U3Si3Al2 phase contained some Mo. Based on the results of this work, exposure of dispersion fuel plates to relatively high temperatures during fabrication impacts the overall microstructure, particularly the nature of the interaction layers around the fuel particles. The time and temperature of fabrication should be carefully controlled in order to produce the most uniform Si-rich layers around the U-7Mo particles.

  5. An integrated approach for the verification of fresh mixed oxide fuel (MOX) assemblies at light water reactor MOX recycle reactors

    SciTech Connect (OSTI)

    Menlove, Howard O; Lee, Sang - Yoon

    2009-01-01

    This paper presents an integrated approach for the verification of mixed oxide (MOX) fuel assemblies prior to their being loaded into the reactor. There is a coupling of the verification approach that starts at the fuel fabrication plant and stops with the transfer of the assemblies into the thermal reactor. The key measurement points are at the output of the fuel fabrication plant, the receipt at the reactor site, and the storage in the water pool as fresh fuel. The IAEA currently has the capability to measure the MOX fuel assemblies at the output of the fuel fabrication plants using a passive neutron coincidence counting systems of the passive neutron collar (PNCL) type. Also. at the MOX reactor pool, the underwater coincidence counter (UWCC) has been developed to measure the MOX assemblies in the water. The UWCC measurement requires that the fuel assembly be lifted about two meters up in the storage rack to avoid interference from the fuel that is stored in the rack. This paper presents a new method to verify the MOX fuel assemblies that are in the storage rack without the necessity of moving the fuel. The detector system is called the Underwater MOX Verification System (UMVS). The integration and relationship of the three measurements systems is described.

  6. solid oxide fuel cells | netl.doe.gov

    Broader source: All U.S. Department of Energy (DOE) Office Webpages (Extended Search)

    solid oxide fuel cells sofc.jpg Imagine an efficient, combustion-less, virtually pollution-free power source capable of being sited in urban areas or in remote regions, running...

  7. Solid Oxide Fuel Cell and Power System Development at PNNL |...

    Office of Energy Efficiency and Renewable Energy (EERE) Indexed Site

    and Power System Development at PNNL Solid Oxide Fuel Cell and Power System Development at PNNL Presented at the DOE-DOD Shipboard APU Workshop on March 29, 2011. PDF icon...

  8. Test plan for thermogravimetric analyses of BWR spent fuel oxidation

    SciTech Connect (OSTI)

    Einziger, R.E.

    1988-12-01

    Preliminary studies indicated the need for additional low-temperature spent fuel oxidation data to determine the behavior of spent fuel as a waste form for a tuffy repository. Short-term thermogravimetric analysis tests were recommended in a comprehensive technical approach as the method for providing scoping data that could be used to (1) evaluate the effects of variables such as moisture and burnup on the oxidation rate, (2) determine operative mechanisms, and (3) guide long-term, low-temperature oxidation testing. The initial test series studied the temperature and moisture effects on pressurized water reactor fuel as a function of particle and grain size. This document presents the test matrix for studying the oxidation behavior of boiling water reactor fuel in the temperature range of 140 to 225{degree}C. 17 refs., 7 figs., 3 tabs.

  9. FY 2014 Solid Oxide Fuel Cell Project Selections

    Broader source: Energy.gov [DOE]

    In FY 2014, nine research projects focused on advancing the reliability, robustness, and endurance of solid oxide fuel cells (SOFC) have been selected for funding by Office of Fossil Energy’s...

  10. Dynamic Modeling in Solid-Oxide Fuel Cells Controller Design

    SciTech Connect (OSTI)

    Lu, Ning; Li, Qinghe; Sun, Xin; Khaleel, Mohammad A.

    2007-06-28

    In this paper, a dynamic model of the solid-oxide fuel cell (SOFC) power unit is developed for the purpose of designing a controller to regulate fuel flow rate, fuel temperature, air flow rate, and air temperature to maintain the SOFC stack temperature, fuel utilization rate, and voltage within operation limits. A lumped model is used to consider the thermal dynamics and the electro-chemial dynamics inside an SOFC power unit. The fluid dynamics at the fuel and air inlets are considered by using the in-flow ramp-rates.

  11. Mixed oxide fuels testing in the advanced test reactor to support plutonium disposition

    SciTech Connect (OSTI)

    Ryskamp, J.M.; Sterbentz, J.W.; Chang, G.S.

    1995-09-01

    An intense worldwide effort is now under way to find means of reducing the stockpile of weapons-grade plutonium. One of the most attractive solutions would be to use WGPu as fuel in existing light water reactors (LWRs) in the form of mixed oxide (MOX) fuel - i.e., plutonia (PUO{sub 2}) mixed with urania (UO{sub 2}). Before U.S. reactors could be used for this purpose, their operating licenses would have to be amended. Numerous technical issues must be resolved before LWR operating licenses can be amended to allow the use of MOX fuel. These issues include the following: (1) MOX fuel fabrication process verification, (2) Whether and how to use burnable poisons to depress MOX fuel initial reactivity, which is higher than that of urania, (3) The effects of WGPu isotopic composition, (4) The feasibility of loading MOX fuel with plutonia content up to 7% by weight, (5) The effects of americium and gallium in WGPu, (6) Fission gas release from MOX fuel pellets made from WGPu, (7) Fuel/cladding gap closure, (8) The effects of power cycling and off-normal events on fuel integrity, (9) Development of radial distributions of burnup and fission products, (10) Power spiking near the interfaces of MOX and urania fuel assemblies, and (11) Fuel performance code validation. We have performed calculations to show that the use of hafnium shrouds can produce spectrum adjustments that will bring the flux spectrum in ATR test loops into a good approximation to the spectrum anticipated in a commercial LWR containing MOX fuel while allowing operation of the test fuel assemblies near their optimum values of linear heat generation rate. The ATR would be a nearly ideal test bed for developing data needed to support applications to license LWRs for operation with MOX fuel made from weapons-grade plutonium. The requirements for planning and implementing a test program in the ATR have been identified.

  12. The low-temperature partial oxidation reforming of fuels for transportation fuel cell systems

    SciTech Connect (OSTI)

    Kumar, R.; Ahmed, S.; Krumpelt, M.

    1996-12-31

    Argonne`s partial-oxidation reformer (APOR) is a compact, lightweight, rapid-start, and dynamically responsive device to convert liquid fuels to H{sub 2} for use in automotive fuel cells. An APOR catalyst for methanol has been developed and tested; catalysts for other fuels are being evaluated. Simple in design, operation, and control, the APOR can help develop efficient fuel cell propulsion systems.

  13. Fuel cell power supply with oxidant and fuel gas switching

    DOE Patents [OSTI]

    McElroy, James F.; Chludzinski, Paul J.; Dantowitz, Philip

    1987-01-01

    This invention relates to a fuel cell vehicular power plant. Fuel for the fuel stack is supplied by a hydrocarbon (methanol) catalytic cracking reactor and CO shift reactor. A water electrolysis subsystem is associated with the stack. During low power operation part of the fuel cell power is used to electrolyze water with hydrogen and oxygen electrolysis products being stored in pressure vessels. During peak power intervals, viz, during acceleration or start-up, pure oxygen and pure hydrogen from the pressure vessel are supplied as the reaction gases to the cathodes and anodes in place of air and methanol reformate. This allows the fuel cell stack to be sized for normal low power/air operation but with a peak power capacity several times greater than that for normal operation.

  14. Fuel cell power supply with oxidant and fuel gas switching

    DOE Patents [OSTI]

    McElroy, J.F.; Chludzinski, P.J.; Dantowitz, P.

    1987-04-14

    This invention relates to a fuel cell vehicular power plant. Fuel for the fuel stack is supplied by a hydrocarbon (methanol) catalytic cracking reactor and CO shift reactor. A water electrolysis subsystem is associated with the stack. During low power operation part of the fuel cell power is used to electrolyze water with hydrogen and oxygen electrolysis products being stored in pressure vessels. During peak power intervals, viz, during acceleration or start-up, pure oxygen and pure hydrogen from the pressure vessel are supplied as the reaction gases to the cathodes and anodes in place of air and methanol reformate. This allows the fuel cell stack to be sized for normal low power/air operation but with a peak power capacity several times greater than that for normal operation. 2 figs.

  15. Innovative Seals for Solid Oxide Fuel Cells (SOFC)

    SciTech Connect (OSTI)

    Singh, Raj

    2008-06-30

    A functioning SOFC requires different type of seals such as metal-metal, metal-ceramic, and ceramic-ceramic. These seals must function at high temperatures between 600--900{sup o}C and in oxidizing and reducing environments of the fuels and air. Among the different type of seals, the metal-metal seals can be readily fabricated using metal joining, soldering, and brazing techniques. However, the metal-ceramic and ceramic-ceramic seals require significant research and development because the brittle nature of ceramics/glasses can lead to fracture and loss of seal integrity and functionality. Consequently, any seals involving ceramics/glasses require a significant attention and technology development for reliable SOFC operation. This final report is prepared to describe the progress made in the program on the needs, approaches, and performance of high temperature seals for SOFC. In particular, a new concept of self-healing glass seals is pursued for making seals between metal-ceramic material combinations, including some with a significant expansion mismatch.

  16. Solid Oxide Fuel Cell Manufacturing Overview

    Broader source: Energy.gov [DOE]

    Presented at the NREL Hydrogen and Fuel Cell Manufacturing R&D Workshop in Washington, DC, August 11-12, 2011.

  17. FUEL & TARGET FABRICATION Aiken County, South Carolina

    Broader source: All U.S. Department of Energy (DOE) Office Webpages (Extended Search)

    & TARGET FABRICATION Aiken County, South Carolina 300/M AREA 300/M AREA SAVANNAH RIVER SITE COLD WAR HISTORIC PROPERTY DOCUMENTATION ii ABSTRACT This documentation was prepared in accordance with a Memorandum of Agreement (MOA) signed by the Department of Energy-Savannah River (DOE-SR) and the South Carolina Historic Preservation Office (SHPO) dated February 27, 2003, as well as the Consolidated MOA of August 2004. The MOA stipulated that a thematic study and photographic documentation be

  18. Microstructural Examination to Aid in Understanding Friction Bonding Fabrication Technique for Monolithic Nuclear Fuel

    SciTech Connect (OSTI)

    Karen L. Shropshire

    2008-04-01

    Monolithic nuclear fuel is currently being developed for use in research reactors, and friction bonding (FB) is a technique being developed to help in this fuel’s fabrication. Since both FB and monolithic fuel are new concepts, research is needed to understand the impact of varying FB fabrication parameters on fuel plate characteristics. This thesis research provides insight into the FB process and its application to the monolithic fuel design by recognizing and understanding the microstructural effects of varying fabrication parameters (a) FB tool load, and (b) FB tool face alloy. These two fabrication parameters help drive material temperature during fabrication, and thus the material properties, bond strength, and possible formation of interface reaction layers. This study analyzed temperatures and tool loads measured during those FB processes and examined microstructural characteristics of materials and bonds in samples taken from the resulting fuel plates. This study shows that higher tool load increases aluminum plasticization and forging during FB, and that the tool face alloy helps determine the tool’s heat extraction efficacy. The study concludes that successful aluminum bonds can be attained in fuel plates using a wide range of FB tool loads. The range of tool loads yielding successful uranium-aluminum bonding was not established, but it was demonstrated that such bonding can be attained with FB tool load of 48,900 N (11,000 lbf) when using a FB tool faced with a tungsten alloy. This tool successfully performed FB, and with better results than tools faced with other materials. Results of this study correlate well with results reported for similar aluminum bonding techniques. This study’s results also provide support and validation for other nuclear fuel development studies and conclusions. Recommendations are offered for further research.

  19. Catalytic iron oxide for lime regeneration in carbonaceous fuel combustion

    DOE Patents [OSTI]

    Shen, Ming-Shing (Rocky Point, NY); Yang, Ralph T. (Middle Island, NY)

    1980-01-01

    Lime utilization for sulfurous oxides absorption in fluidized combustion of carbonaceous fuels is improved by impregnation of porous lime particulates with iron oxide. The impregnation is achieved by spraying an aqueous solution of mixed iron sulfate and sulfite on the limestone before transfer to the fluidized bed combustor, whereby the iron compounds react with the limestone substrate to form iron oxide at the limestone surface. It is found that iron oxide present in the spent limestone acts as a catalyst to regenerate the spent limestone in a reducing environment. With only small quantities of iron oxide the calcium can be recycled at a significantly increased rate.

  20. Literature on fabrication of tungsten for application in pyrochemical processing of spent nuclear fuels

    SciTech Connect (OSTI)

    Edstrom, C.M.; Phillips, A.G.; Johnson, L.D.; Corle, R.R.

    1980-10-11

    The pyrochemical processing of nuclear fuels requires crucibles, stirrers, and transfer tubing that will withstand the temperature and the chemical attack from molten salts and metals used in the process. This report summarizes the literature that pertains to fabrication (joining, chemical vapor deposition, plasma spraying, forming, and spinning) is the main theme. This report also summarizes a sampling of literature on molbdenum and the work previously performed at Argonne National Laboratory on other container materials used for pyrochemical processing of spent nuclear fuels.

  1. Summary report on fuel development and miniplate fabrication for the RERTR Program, 1978 to 1990

    SciTech Connect (OSTI)

    Wiencek, T.C.

    1995-08-01

    This report summarizes the efforts of the Fabrication Technology Section at Argonne National Laboratory in the program of Reduced Enrichment Research and Test Reactors (RERTR). The main objective of this program was to reduce the amount of high enriched ({approx}93% {sup 235}U) uranium (HEU) used in nonpower reactors. Conversion from low-density (0.8--1.6 g U/cm{sup 3}) HEU fuel elements to highly loaded (up to 7 g U/cm{sup 3}) low-enrichment (<20% {sup 235}U) uranium (LEU) fuel elements allows the same reactor power levels, core designs and sizes to be retained while greatly reducing the possibility of illicit diversion of HEU nuclear fuel. This document is intended as an overview of the period 1978--1990, during which the Section supported this project by fabricating mainly powder metallurgy uranium-silicide dispersion fuel plates. Most of the subjects covered in detail are fabrication-related studies of uranium silicide fuels and fuel plate properties. Some data are included for out-of-pile experiments such as corrosion and compatibility tests. Also briefly covered are most other aspects of the RERTR program such as irradiation tests, full-core demonstrations, and technology transfer. References included are for further information on most aspects of the entire program. A significant portion of the report is devoted to data that were never published in their entirety. The appendices contain a list of previous RERTR reports, ANL fabrication procedures, calculations for phases present in two-phase fuels, chemical analysis of fuels, miniplate characteristics, and a summary of bonding runs made by hot isostatic pressing.

  2. Evaluation of LANL Capabilities for Fabrication of TREAT Conversion Fuel

    SciTech Connect (OSTI)

    Luther, Erik Paul; Leckie, Rafael M.; Dombrowski, David E.

    2014-03-06

    This report estimates costs and schedule associated with scale up and fabrication of a low-enriched uranium (LEU) core for the Transient Reactor Test Facility (TREAT) reactor. This study considers facilities available at Los Alamos National Laboratory, facility upgrades, equipment, installation and staffing costs. Not included are costs associated with raw materials and off-site shipping. These estimates are considered a rough of magnitude. At this time, no specifications for the LEU core have been made and the final schedule needed by the national program. The estimate range (+/-100%) reflects this large uncertainty and is subject to change as the project scope becomes more defined.

  3. An improved characterization method for international accountancy measurements of fresh and irradiated mixed oxide (MOX) fuel: helping achieve continual monitoring and safeguards through the fuel cycle

    SciTech Connect (OSTI)

    Evans, Louise G; Croft, Stephen; Swinhoe, Martyn T; Tobin, S. J.; Boyer, B. D.; Menlove, H. O.; Schear, M. A.; Worrall, Andrew

    2010-11-24

    Nuclear fuel accountancy measurements are conducted at several points through the nuclear fuel cycle to ensure continuity of knowledge (CofK) of special nuclear material (SNM). Non-destructive assay (NDA) measurements are performed on fresh fuel (prior to irradiation in a reactor) and spent nuclear fuel (SNF) post-irradiation. We have developed a fuel assembly characterization system, based on the novel concept of 'neutron fingerprinting' with multiplicity signatures to ensure detailed CofK of nuclear fuel through the entire fuel cycle. The neutron fingerprint in this case is determined by the measurement of the various correlated neutron signatures, specific to fuel isotopic composition, and therefore offers greater sensitivity to variations in fissile content among fuel assemblies than other techniques such as gross neutron counting. This neutron fingerprint could be measured at the point of fuel dispatch (e.g. from a fuel fabrication plant prior to irradiation, or from a reactor site post-irradiation), monitored during transportation of the fuel assembly, and measured at a subsequent receiving site (e.g. at the reactor site prior to irradiation, or reprocessing facility post-irradiation); this would confirm that no unexpected changes to the fuel composition or amount have taken place during transportation and/or reactor operations. Changes may indicate an attempt to divert material for example. Here, we present the current state of the practice of fuel measurements for both fresh mixed oxide (MOX) fuel and SNF (both MOX and uranium dioxide). This is presented in the framework of international safeguards perspectives from the US and UK. We also postulate as to how the neutron fingerprinting concept could lead to improved fuel characterization (both fresh MOX and SNF) resulting in: (a) assured CofK of fuel across the nuclear fuel cycle, (b) improved detection of SNM diversion, and (c) greater confidence in safeguards of SNF transportation.

  4. An improved characterization method for international accountancy measurements of fresh and irradiated mixed oxide (MOX) fuel: helping achieve continual monitoring and safeguards through the fuel cycle

    SciTech Connect (OSTI)

    Evans, Louise G; Croft, Stephen; Swinhoe, Martyn T; Tobin, S. J.; Menlove, H. O.; Schear, M. A.; Worrall, Andrew

    2011-01-13

    Nuclear fuel accountancy measurements are conducted at several points through the nuclear fuel cycle to ensure continuity of knowledge (CofK) of special nuclear material (SNM). Non-destructive assay (NDA) measurements are performed on fresh fuel (prior to irradiation in a reactor) and spent nuclear fuel (SNF) post-irradiation. We have developed a fuel assembly characterization system, based on the novel concept of 'neutron fingerprinting' with multiplicity signatures to ensure detailed CofK of nuclear fuel through the entire fuel cycle. The neutron fingerprint in this case is determined by the measurement of the various correlated neutron signatures, specific to fuel isotopic composition, and therefore offers greater sensitivity to variations in fissile content among fuel assemblies than other techniques such as gross neutron counting. This neutron fingerprint could be measured at the point of fuel dispatch (e.g. from a fuel fabrication plant prior to irradiation, or from a reactor site post-irradiation), monitored during transportation of the fuel assembly, and measured at a subsequent receiving site (e.g. at the reactor site prior to irradiation, or reprocessing facility post-irradiation); this would confirm that no unexpected changes to the fuel composition or amount have taken place during transportation and/ or reactor operations. Changes may indicate an attempt to divert material for example. Here, we present the current state of the practice of fuel measurements for both fresh mixed oxide (MOX) fuel and SNF (both MOX and uranium dioxide). This is presented in the framework of international safeguards perspectives from the US and UK. We also postulate as to how the neutron fingerprinting concept could lead to improved fuel characterization (both fresh MOX and SNF) resulting in: (a) assured CofK of fuel across the nuclear fuel cycle, (b) improved detection of SNM diversion, and (c) greater confidence in safeguards of SNF transportation.

  5. Solid-oxide fuel cell electrolyte

    DOE Patents [OSTI]

    Bloom, Ira D.; Hash, Mark C.; Krumpelt, Michael

    1993-01-01

    A solid-oxide electrolyte operable at between 600.degree. C. and 800.degree. C. and a method of producing the solid-oxide electrolyte are provided. The solid-oxide electrolyte comprises a combination of a compound having weak metal-oxygen interactions with a compound having stronger metal-oxygen interactions whereby the resulting combination has both strong and weak metal-oxygen interaction properties.

  6. Fabrication of catalytic electrodes for molten carbonate fuel cells

    DOE Patents [OSTI]

    Smith, James L.

    1988-01-01

    A porous layer of catalyst material suitable for use as an electrode in a molten carbonate fuel cell includes elongated pores substantially extending across the layer thickness. The catalyst layer is prepared by depositing particulate catalyst material into polymeric flocking on a substrate surface by a procedure such as tape casting. The loaded substrate is heated in a series of steps with rising temperatures to set the tape, thermally decompose the substrate with flocking and sinter bond the catalyst particles into a porous catalytic layer with elongated pores across its thickness. Employed as an electrode, the elongated pores provide distribution of reactant gas into contact with catalyst particles wetted by molten electrolyte.

  7. Automated catalyst processing for cloud electrode fabrication for fuel cells

    DOE Patents [OSTI]

    Goller, Glen J.; Breault, Richard D.

    1980-01-01

    A process for making dry carbon/polytetrafluoroethylene floc material, particularly useful in the manufacture of fuel cell electrodes, comprises of the steps of floccing a co-suspension of carbon particles and polytetrafluoroethylene particles, filtering excess liquids from the co-suspension, molding pellet shapes from the remaining wet floc solids without using significant pressure during the molding, drying the wet floc pellet shapes within the mold at temperatures no greater than about 150.degree. F., and removing the dry pellets from the mold.

  8. Conductivity fuel cell collector plate and method of fabrication

    DOE Patents [OSTI]

    Braun, James C.

    2002-01-01

    An improved method of manufacturing a PEM fuel cell collector plate is disclosed. During molding a highly conductive polymer composite is formed having a relatively high polymer concentration along its external surfaces. After molding the polymer rich layer is removed from the land areas by machining, grinding or similar process. This layer removal results in increased overall conductivity of the molded collector plate. The polymer rich surface remains in the collector plate channels, providing increased mechanical strength and other benefits to the channels. The improved method also permits greater mold cavity thickness providing a number of advantages during the molding process.

  9. PRELIMINARY DATA CALL REPORT ADVANCED BURNER REACTOR START UP FUEL FABRICATION FACILITY

    SciTech Connect (OSTI)

    S. T. Khericha

    2007-04-01

    The purpose of this report is to provide data for preparation of a NEPA Environmental Impact Statement in support the U. S. Department of Energy (DOE) Global Nuclear Energy Partnership (GNEP). One of the GNEP objectives is to reduce the inventory of long lived actinide from the light water reactor (LWR) spent fuel. The LWR spent fuel contains Plutonium (Pu) -239 and other transuranics (TRU) such as Americium-241. One of the options is to transmute or burn these actinides in fast neutron spectra as well as generate the electricity. A sodium-cooled Advanced Recycling Reactor (ARR) concept has been proposed to achieve this goal. However, fuel with relatively high TRU content has not been used in the fast reactor. To demonstrate the utilization of TRU fuel in a fast reactor, an Advanced Burner Reactor (ABR) prototype of ARR is proposed, which would necessarily be started up using weapons grade (WG) Pu fuel. The WG Pu is distinguished by relatively highest proportions of Pu-239 and lesser amount of other actinides. The WG Pu will be used as the startup fuel along with TRU fuel in lead test assemblies. Because such fuel is not currently being produced in the US, a new facility (or new capability in an existing facility) is being considered for fabrication of WG Pu fuel for the ABR. This report is provided in response to Data Call for the construction of startup fuel fabrication facility. It is anticipated that the facility will provide the startup fuel for 10-15 years and will take to 3 to 5 years to construct.

  10. Survey of Worldwide Light Water Reactor Experience with Mixed Uranium-Plutonium Oxide Fuel

    SciTech Connect (OSTI)

    Cowell, B.S.; Fisher, S.E.

    1999-02-01

    The US and the Former Soviet Union (FSU) have recently declared quantities of weapons materials, including weapons-grade (WG) plutonium, excess to strategic requirements. One of the leading candidates for the disposition of excess WG plutonium is irradiation in light water reactors (LWRs) as mixed uranium-plutonium oxide (MOX) fuel. A description of the MOX fuel fabrication techniques in worldwide use is presented. A comprehensive examination of the domestic MOX experience in US reactors obtained during the 1960s, 1970s, and early 1980s is also presented. This experience is described by manufacturer and is also categorized by the reactor facility that irradiated the MOX fuel. A limited summary of the international experience with MOX fuels is also presented. A review of MOX fuel and its performance is conducted in view of the special considerations associated with the disposition of WG plutonium. Based on the available information, it appears that adoption of foreign commercial MOX technology from one of the successful MOX fuel vendors will minimize the technical risks to the overall mission. The conclusion is made that the existing MOX fuel experience base suggests that disposition of excess weapons plutonium through irradiation in LWRs is a technically attractive option.

  11. Fabrication of fuel cell electrodes and other catalytic structures

    DOE Patents [OSTI]

    Smith, J.L.

    1987-02-11

    A porous layer of catalyst material suitable for use as an electrode in a molten carbonate fuel cell includes elongated pores substantially extending across the layer thickness. The catalyst layer is prepared by depositing particulate catalyst material into polymeric flocking on a substrate surface by a procedure such as tape casting. The loaded substrate is heated in a series of steps with rising temperatures to set the tape, thermally decompose the substrate with flocking and sinter bond the catalyst particles into a porous catalytic layer with elongated pores across its thickness. Employed as an electrode, the elongated pores provide distribution of reactant gas into contact with catalyst particles wetted by molten electrolyte. 1 fig.

  12. Serially connected solid oxide fuel cells having monolithic cores

    DOE Patents [OSTI]

    Herceg, Joseph E. (Naperville, IL)

    1987-01-01

    A solid oxide fuel cell for electrochemically combining fuel and oxidant for generating galvanic output, wherein the cell core has an array of cell segments electrically serially connected in the flow direction, each segment consisting of electrolyte walls and interconnect that are substantially devoid of any composite inert materials for support. Instead, the core is monolithic, where each electrolyte wall consists of thin layers of cathode and anode materials sandwiching a thin layer of electrolyte material therebetween. Means direct the fuel to the anode-exposed core passageways and means direct the oxidant to the cathode-exposed core passageways; and means also direct the galvanic output to an exterior circuit. Each layer of the electrolyte composite materials is of the order of 0.002-0.01 cm thick; and each layer of the cathode and anode materials is of the order of 0.002-0.05 cm thick. Between 2 and 50 cell segments may be connected in series.

  13. Fabrication and characterization of micro-orifices for diesel fuel injectors.

    SciTech Connect (OSTI)

    Fenske, G.; Woodford, J.; Wang, J.; El-Hannouny, E.; Schaefer, R.; Hamady, F.; National Vehicle and Fuel Emissions Lab.

    2007-04-01

    Stringent emission standards are driving the development of diesel-fuel injection concepts to mitigate in-cylinder formation of particulates. While research has demonstrated significant reduction in particulate formation using micro-orifice technology, implementation requires development of industrial processes to fabricate micro-orifices with diameters as low as 50 gmm and with large length-to-diameter ratios. This paper reviews the different processes being pursued to fabricate micro-orifices and the advanced techniques applied to characterize the performance of micro-orifices. The latter include the use of phase-contrast x-ray imaging of electroless nickel-plated, micro-orifices and laser imaging of fuel sprays at elevated pressures. The experimental results demonstrate an industrially viable process to create small uniform orifices that improve spray formation for fuel injection.

  14. Nitrogen oxide abatement by distributed fuel addition

    SciTech Connect (OSTI)

    Wendt, J.O.L.; Mereb, J.B.

    1991-09-20

    Reburning is examined as a means of NO{sub x} destruction in a 17 kW down-fired pulverized coal combustor. In reburning, a secondary fuel is introduced downstream of the primary flame to produce a reducing zone, favorable to NO destruction, and air is introduced further downstream to complete the combustion. Emphasis is on natural gas reburning and a bituminous coal primary flame. A parametric examination of reburning employing a statistical experimental design, is conducted, complemented by detailed experiments. Mechanisms governing the inter-conversion of nitrogenous species in the fuel rich reburn zone is explored. The effect of reburning on N{sub 2}O emissions, the effect of primary flame mode (premixed and diffusion) and the effect of distributing the reburning fuel, are also investigated.

  15. MOX Fabrication Isolation Considerations

    SciTech Connect (OSTI)

    Eric L. Shaber; Bradley J Schrader

    2005-08-01

    This document provides a technical position on the preferred level of isolation to fabricate demonstration quantities of mixed oxide transmutation fuels. The Advanced Fuel Cycle Initiative should design and construct automated glovebox fabrication lines for this purpose. This level of isolation adequately protects the health and safety of workers and the general public for all mixed oxide (and other transmutation fuel) manufacturing efforts while retaining flexibility, allowing parallel development and setup, and minimizing capital expense. The basis regulations, issues, and advantages/disadvantages of five potential forms of isolation are summarized here as justification for selection of the preferred technical position.

  16. Nanoparticle scaffolds for syngas-fed solid oxide fuel cells

    SciTech Connect (OSTI)

    Boldrin, Paul; Ruiz-Trejo, Enrique; Yu, Jingwen; Gruar, Robert I.; Tighe, Christopher J.; Chang, Kee-Chul; Ilavsky, Jan; Darr, Jawwad A.; Brandon, Nigel

    2014-12-17

    Incorporation of nanoparticles into devices such as solid oxide fuel cells (SOFCs) may provide benefits such as higher surface areas or finer control over microstructure. However, their use with traditional fabrication techniques such as screen-printing is problematic. Here, we show that mixing larger commercial particles with nanoparticles allows traditional ink formulation and screen-printing to be used while still providing benefits of nanoparticles such as increased porosity and lower sintering temperatures. SOFC anodes were produced by impregnating ceria–gadolinia (CGO) scaffolds with nickel nitrate solution. The scaffolds were produced from inks containing a mixture of hydrothermally-synthesised nanoparticle CGO, commercial CGO and polymeric pore formers. The scaffolds were heat-treated at either 1000 or 1300 °C, and were mechanically stable. In situ ultra-small X-ray scattering (USAXS) shows that the nanoparticles begin sintering around 900–1000 °C. Analysis by USAXS and scanning electron microscopy (SEM) revealed that the low temperature heat-treated scaffolds possessed higher porosity. Impregnated scaffolds were used to produce symmetrical cells, with the lower temperature heat-treated scaffolds showing improved gas diffusion, but poorer charge transfer. Using these scaffolds, lower temperature heat-treated cells of Ni–CGO/200 μm YSZ/CGO-LSCF performed better at 700 °C (and below) in hydrogen, and performed better at all temperatures using syngas, with power densities of up to 0.15 W cm-2 at 800 °C. This approach has the potential to allow the use of a wider range of materials and finer control over microstructure.

  17. Nanoparticle scaffolds for syngas-fed solid oxide fuel cells

    DOE Public Access Gateway for Energy & Science Beta (PAGES Beta)

    Boldrin, Paul; Ruiz-Trejo, Enrique; Yu, Jingwen; Gruar, Robert I.; Tighe, Christopher J.; Chang, Kee-Chul; Ilavsky, Jan; Darr, Jawwad A.; Brandon, Nigel

    2014-12-17

    Incorporation of nanoparticles into devices such as solid oxide fuel cells (SOFCs) may provide benefits such as higher surface areas or finer control over microstructure. However, their use with traditional fabrication techniques such as screen-printing is problematic. Here, we show that mixing larger commercial particles with nanoparticles allows traditional ink formulation and screen-printing to be used while still providing benefits of nanoparticles such as increased porosity and lower sintering temperatures. SOFC anodes were produced by impregnating ceria–gadolinia (CGO) scaffolds with nickel nitrate solution. The scaffolds were produced from inks containing a mixture of hydrothermally-synthesised nanoparticle CGO, commercial CGO and polymericmore » pore formers. The scaffolds were heat-treated at either 1000 or 1300 °C, and were mechanically stable. In situ ultra-small X-ray scattering (USAXS) shows that the nanoparticles begin sintering around 900–1000 °C. Analysis by USAXS and scanning electron microscopy (SEM) revealed that the low temperature heat-treated scaffolds possessed higher porosity. Impregnated scaffolds were used to produce symmetrical cells, with the lower temperature heat-treated scaffolds showing improved gas diffusion, but poorer charge transfer. Using these scaffolds, lower temperature heat-treated cells of Ni–CGO/200 μm YSZ/CGO-LSCF performed better at 700 °C (and below) in hydrogen, and performed better at all temperatures using syngas, with power densities of up to 0.15 W cm-2 at 800 °C. This approach has the potential to allow the use of a wider range of materials and finer control over microstructure.« less

  18. Five Kilowatt Solid Oxide Fuel Cell/Diesel Reformer

    SciTech Connect (OSTI)

    Dennis Witmer; Thomas Johnson

    2008-12-31

    Reducing fossil fuel consumption both for energy security and for reduction in global greenhouse emissions has been a major goal of energy research in the US for many years. Fuel cells have been proposed as a technology that can address both these issues--as devices that convert the energy of a fuel directly into electrical energy, they offer low emissions and high efficiencies. These advantages are of particular interest to remote power users, where grid connected power is unavailable, and most electrical power comes from diesel electric generators. Diesel fuel is the fuel of choice because it can be easily transported and stored in quantities large enough to supply energy for small communities for extended periods of time. This projected aimed to demonstrate the operation of a solid oxide fuel cell on diesel fuel, and to measure the resulting efficiency. Results from this project have been somewhat encouraging, with a laboratory breadboard integration of a small scale diesel reformer and a Solid Oxide Fuel Cell demonstrated in the first 18 months of the project. This initial demonstration was conducted at INEEL in the spring of 2005 using a small scale diesel reformer provided by SOFCo and a fuel cell provided by Acumentrics. However, attempts to integrate and automate the available technology have not proved successful as yet. This is due both to the lack of movement on the fuel processing side as well as the rather poor stack lifetimes exhibited by the fuel cells. Commercial product is still unavailable, and precommercial devices are both extremely expensive and require extensive field support.

  19. Thoria-based cermet nuclear fuel : sintered microsphere fabrication by spray drying.

    SciTech Connect (OSTI)

    Solomon, A.A.; McDeavitt, S.M.; Chandrmouli, V.; Anthonysamy, S.; Kuchibhotla, S.; Downar, T.J.

    2002-01-09

    Cermet nuclear fuels have been demonstrated to have significant potential to enhance fuel performance because of low internal fuel temperatures and low stored energy. The combination of these benefits with the inherent proliferation resistance, high burnup capability, and favorable neutronic properties of the thorium fuel cycle produces intriguing options for advanced nuclear fuel cycles. This paper describes aspects of a Nuclear Energy Research Initiative (NERI) project with two primary goals: (1) Evaluate the feasibility of implementing the thorium fuel cycle in existing or advanced reactors using a zirconium-matrix cermet fuel, and (2) Develop enabling technologies required for the economic application of this new fuel form. Spray drying is a physical process of granulating fine powders that is used widely in the chemical, pharmaceutical, ceramic, and food industries. It is generally used to produce flowable fine powders. Occasionally it is used to fabricate sintered bodies like cemented carbides, but it has not, heretofore, been used to produce sintered microspheres. As a physical process, it can be adapted to many powder types and mixtures and thus, has appeal for nuclear fuels and waste forms of various compositions. It also permits easy recycling of process ''wastes'' and minimal chemical waste streams that can arise in chemical sol/gel processing. On the other hand, for radioactive powders, it presents safety challenges for processing these materials in powder form and in achieving microspheres of high density and perfection.

  20. The effect of chromium oxyhydroxide on solid oxide fuel cells.

    SciTech Connect (OSTI)

    Krumpelt, M.; Cruse, T. A.; Ingram, B. J.; Routbort, J. L.; Wang, S.; Salvador, P. A.; Chen, G.; Carnegie Mellon Univ.; NETL; Ohio Univ.

    2010-01-01

    Hexavalent chromium species like the oxyhydroxide, CrO{sub 2}(OH){sub 2}, or hexoxide, CrO{sub 3}, are electrochemically reduced to Cr{sub 2}O{sub 3} in solid oxide fuel cells and adversely affect the cell operating potentials. Using a narrowly focused beam from the Advanced Photon Source, such chromium oxide deposits were unequivocally identified in the active region of the cathode by X-ray diffraction, suggesting that the triple phase boundaries were partially blocked. Under fuel cell operating conditions, the reaction has an equilibrium potential of about 0.9 V and the rate of chromium oxide deposition is therefore dependent on the operating potential of the cell. It becomes diffusion limited after several hours of steady operation. At low operating potentials, lanthanum manganite cathodes begin to be reduced to MnO, which reacts with the chromium oxide to form the MnCr{sub 2}O{sub 4} spinel.

  1. Fabrication of highly textured lithium cobalt oxide films by rapid thermal annealing

    DOE Patents [OSTI]

    Bates, John B.

    2003-05-13

    Systems and methods are described for fabrication of highly textured lithium cobalt oxide films by rapid thermal annealing. A method of forming a lithium cobalt oxide film includes depositing a film of lithium cobalt oxide on a substrate; rapidly heating the film of lithium cobalt oxide to a target temperature; and maintaining the film of lithium cobalt oxide at the target temperature for a target annealing time of at most, approximately 60 minutes. The systems and methods provide advantages because they require less time to implement and are, therefore less costly than previous techniques.

  2. Fabrication of highly textured lithium cobalt oxide films by rapid thermal annealing

    DOE Patents [OSTI]

    Bates, John B.

    2002-01-01

    Systems and methods are described for fabrication of highly textured lithium cobalt oxide films by rapid thermal annealing. A method of forming a lithium cobalt oxide film includes depositing a film of lithium cobalt oxide on a substrate; rapidly heating the film of lithium cobalt oxide to a target temperature; and maintaining the film of lithium cobalt oxide at the target temperature for a target annealing time of at most, approximately 60 minutes. The systems and methods provide advantages because they require less time to implement and are, therefore less costly than previous techniques.

  3. Fabrication of highly textured lithium cobalt oxide films by rapid thermal annealing

    DOE Patents [OSTI]

    Bates, John B.

    2003-04-29

    Systems and methods are described for fabrication of highly textured lithium cobalt oxide films by rapid thermal annealing. A method of forming a lithium cobalt oxide film includes depositing a film of lithium cobalt oxide on a substrate; rapidly heating the film of lithium cobalt oxide to a target temperature; and maintaining the film of lithium cobalt oxide at the target temperature for a target annealing time of at most, approximately 60 minutes. The systems and methods provide advantages because they require less time to implement and are, therefore less costly than previous techniques.

  4. Development of an External Fuel Processor for a Solid Oxide Fuel Cell

    SciTech Connect (OSTI)

    Daniel Birmingham; Crispin Debellis; Mark Perna; Anant Upadhyayula

    2008-02-28

    A 250 kW External Fuel Processor was developed and tested that will supply the gases needed by a pipeline natural gas fueled, solid oxide fuel cell during all modes of operation. The fuel processor consists of three major subsystems--a desulfurizer to remove fuel sulfur to an acceptable level, a synthesis gas generator to support plant heat-up and low load fuel cell operations, and a start gas generator to supply a non-flammable, reducing gas to the fuel cell during startup and shutdown operations. The desulfurization subsystem uses a selective catalytic sulfur oxidation process that was developed for operation at elevated pressure and removes the fuel sulfur to a total sulfur content of less than 80 ppbv. The synthesis gas generation subsystem uses a waterless, catalytic partial oxidation reactor to produce a hydrogen-rich mixture from the natural gas and air. An operating window was defined that allows carbon-free operation while maintaining catalyst temperatures that will ensure long-life of the reactor. The start gas subsystem generates an oxygen-free, reducing gas from the pipeline natural gas using a low-temperature combustion technique. These physically and thermally integrated subsystems comprise the 250 kW External Fuel Processor. The 250 kW External Fuel Processor was tested at the Rolls-Royce facility in North Canton, Ohio to verify process performance and for comparison with design specifications. A step wise operation of the automatic controls through the startup, normal operation and shutdown sequences allowed the control system to be tuned and verified. A fully automated system was achieved that brings the fuel processor through its startup procedure, and then await commands from the fuel cell generator module for fuel supply and shutdown. The fuel processor performance met all design specifications. The 250 kW External Fuel Processor was shipped to an American Electric Power site where it will be tested with a Rolls-Royce solid oxide fuel cell generator module.

  5. Electrocatalyst for Alcohol Oxidation at Fuel Cell Anodes - Energy

    Broader source: All U.S. Department of Energy (DOE) Office Webpages (Extended Search)

    Innovation Portal Alcohol Oxidation at Fuel Cell Anodes Brookhaven National Laboratory Contact BNL About This Technology Publications: PDF Document Publication Ternary Pt/Rh/SnO2 electrocatalysts for oxidizing ethanol to CO2 (2,641 KB) <p> Scanning transmission electron micrograph showing uniform dispersion of the catalyst particles (bright spots) on the carbon support (dark background). The average particle size is about 1.5&nbsp;nm.</p> Scanning transmission electron

  6. Solid oxide fuel cell steam reforming power system

    DOE Patents [OSTI]

    Chick, Lawrence A.; Sprenkle, Vincent L.; Powell, Michael R.; Meinhardt, Kerry D.; Whyatt, Greg A.

    2013-03-12

    The present invention is a Solid Oxide Fuel Cell Reforming Power System that utilizes adiabatic reforming of reformate within this system. By utilizing adiabatic reforming of reformate within the system the system operates at a significantly higher efficiency than other Solid Oxide Reforming Power Systems that exist in the prior art. This is because energy is not lost while materials are cooled and reheated, instead the device operates at a higher temperature. This allows efficiencies higher than 65%.

  7. LG Solid Oxide Fuel Cell (SOFC) Model Development

    SciTech Connect (OSTI)

    Haberman, Ben; Martinez-Baca, Carlos; Rush, Greg

    2013-03-31

    This report presents a summary of the work performed by LG Fuel Cell Systems Inc. during the project LG Solid Oxide Fuel Cell (SOFC) Model Development (DOE Award Number: DE-FE0000773) which commenced on October 1, 2009 and was completed on March 31, 2013. The aim of this project is for LG Fuel Cell Systems Inc. (formerly known as Rolls-Royce Fuel Cell Systems (US) Inc.) (?LGFCS?) to develop a multi-physics solid oxide fuel cell (SOFC) computer code (MPC) for performance calculations of the LGFCS fuel cell structure to support fuel cell product design and development. A summary of the initial stages of the project is provided which describes the MPC requirements that were developed and the selection of a candidate code, STAR-CCM+ (CD-adapco). This is followed by a detailed description of the subsequent work program including code enhancement and model verification and validation activities. Details of the code enhancements that were implemented to facilitate MPC SOFC simulations are provided along with a description of the models that were built using the MPC and validated against experimental data. The modeling work described in this report represents a level of calculation detail that has not been previously available within LGFCS.

  8. Nondestructive assay of special nuclear material for uranium fuel-fabrication facilities

    SciTech Connect (OSTI)

    Smith, H.A. Jr.; Schillebeeckx, P.

    1997-08-01

    A high-quality materials accounting system and effective international inspections in uranium fuel-fabrication facilities depend heavily upon accurate nondestructive assay measurements of the facility`s nuclear materials. While item accounting can monitor a large portion of the facility inventory (fuel rods, assemblies, storage items), the contents of all such items and mass values for all bulk materials must be based on quantitative measurements. Weight measurements, combined with destructive analysis of process samples, can provide highly accurate quantitative information on well-characterized and uniform product materials. However, to cover the full range of process materials and to provide timely accountancy data on hard-to-measure items and rapid verification of previous measurements, radiation-based nondestructive assay (NDA) techniques play an important role. NDA for uranium fuel fabrication facilities relies on passive gamma spectroscopy for enrichment and U isotope mass values of medium-to-low-density samples and holdup deposits; it relies on active neutron techniques for U-235 mass values of high-density and heterogeneous samples. This paper will describe the basic radiation-based nondestructive assay techniques used to perform these measurements. The authors will also discuss the NDA measurement applications for international inspections of European fuel-fabrication facilities.

  9. Solid Oxide Fuel Cell Hybrid System for Distributed Power Generation

    SciTech Connect (OSTI)

    David Deangelis; Rich Depuy; Debashis Dey; Georgia Karvountzi; Nguyen Minh; Max Peter; Faress Rahman; Pavel Sokolov; Deliang Yang

    2004-09-30

    This report summarizes the work performed by Hybrid Power Generation Systems, LLC (HPGS) during the April to October 2004 reporting period in Task 2.3 (SOFC Scaleup for Hybrid and Fuel Cell Systems) under Cooperative Agreement DE-FC26-01NT40779 for the U. S. Department of Energy, National Energy Technology Laboratory (DOE/NETL), entitled ''Solid Oxide Fuel Cell Hybrid System for Distributed Power Generation''. This study analyzes the performance and economics of power generation systems for central power generation application based on Solid Oxide Fuel Cell (SOFC) technology and fueled by natural gas. The main objective of this task is to develop credible scale up strategies for large solid oxide fuel cell-gas turbine systems. System concepts that integrate a SOFC with a gas turbine were developed and analyzed for plant sizes in excess of 20 MW. A 25 MW plant configuration was selected with projected system efficiency of over 65% and a factory cost of under $400/kW. The plant design is modular and can be scaled to both higher and lower plant power ratings. Technology gaps and required engineering development efforts were identified and evaluated.

  10. Nanofiber Scaffold for Cathode of Solid Oxide Fuel Cell

    SciTech Connect (OSTI)

    Mingjia Zhi; Nicholas Mariani; Randall Gemmen; Kirk Gerdes; Nianqiang Wu

    2010-10-01

    A high performance solid oxide fuel cell cathode using the yttria-stabilized zirconia (YSZ) nanofibers scaffold with the infiltrated La1-xSrxMnO3 (LSM) shows an enhanced catalytic activity toward oxygen reduction. Such a cathode offers a continuous path for charge transport and an increased number of triple-phase boundary sites.

  11. A Blueprint for GNEP Advanced Burner Reactor Startup Fuel Fabrication Facility

    SciTech Connect (OSTI)

    S. Khericha

    2010-12-01

    The purpose of this article is to identify the requirements and issues associated with design of GNEP Advanced Burner Reactor Fuel Facility. The report was prepared in support of providing data for preparation of a NEPA Environmental Impact Statement in support the U. S. Department of Energy (DOE) Global Nuclear Energy Partnership (GNEP). One of the GNEP objectives was to reduce the inventory of long lived actinide from the light water reactor (LWR) spent fuel. The LWR spent fuel contains Plutonium (Pu) -239 and other transuranics (TRU) such as Americium-241. One of the options is to transmute or burn these actinides in fast neutron spectra as well as generate the electricity. A sodium-cooled Advanced Recycling Reactor (ARR) concept was proposed to achieve this goal. However, fuel with relatively high TRU content has not been used in the fast reactor. To demonstrate the utilization of TRU fuel in a fast reactor, an Advanced Burner Reactor (ABR) prototype of ARR was proposed, which would necessarily be started up using weapons grade (WG) Pu fuel. The WG Pu is distinguished by relatively highest proportions of Pu-239 and lesser amount of other actinides. The WG Pu was assumed to be used as the startup fuel along with TRU fuel in lead test assemblies. Because such fuel is not currently being produced in the US, a new facility (or new capability in an existing facility) was being considered for fabrication of WG Pu fuel for the ABR. It was estimated that the facility will provide the startup fuel for 10-15 years and would take 3 to 5 years to construct.

  12. Ionic conductors for solid oxide fuel cells

    DOE Patents [OSTI]

    Krumpelt, Michael; Bloom, Ira D.; Pullockaran, Jose D.; Myles, Kevin M.

    1993-01-01

    An electrolyte that operates at temperatures ranging from 600.degree. C. to 800.degree. C. is provided. The electrolyte conducts charge ionically as well as electronically. The ionic conductors include molecular framework structures having planes or channels large enough to transport oxides or hydrated protons and having net-positive or net-negative charges. Representative molecular framework structures include substituted aluminum phosphates, orthosilicates, silicoaluminates, cordierites, apatites, sodalites, and hollandites.

  13. Electrocatalyst for alcohol oxidation at fuel cell anodes

    DOE Patents [OSTI]

    Adzic, Radoslav; Kowal, Andrzej

    2011-11-02

    In some embodiments a ternary electrocatalyst is provided. The electrocatalyst can be used in an anode for oxidizing alcohol in a fuel cell. In some embodiments, the ternary electrocatalyst may include a noble metal particle having a surface decorated with clusters of SnO.sub.2 and Rh. The noble metal particles may include platinum, palladium, ruthenium, iridium, gold, and combinations thereof. In some embodiments, the ternary electrocatalyst includes SnO.sub.2 particles having a surface decorated with clusters of a noble metal and Rh. Some ternary electrocatalysts include noble metal particles with clusters of SnO.sub.2 and Rh at their surfaces. In some embodiments the electrocatalyst particle cores are nanoparticles. Some embodiments of the invention provide a fuel cell including an anode incorporating the ternary electrocatalyst. In some aspects a method of using ternary electrocatalysts of Pt, Rh, and SnO.sub.2 to oxidize an alcohol in a fuel cell is described.

  14. Selective etchant for oxide sacrificial material in semiconductor device fabrication

    DOE Patents [OSTI]

    Clews, Peggy J.; Mani, Seethambal S.

    2005-05-17

    An etching composition and method is disclosed for removing an oxide sacrificial material during manufacture of semiconductor devices including micromechanical, microelectromechanical or microfluidic devices. The etching composition and method are based on the combination of hydrofluoric acid (HF) and sulfuric acid (H.sub.2 SO.sub.4). These acids can be used in the ratio of 1:3 to 3:1 HF:H.sub.2 SO.sub.4 to remove all or part of the oxide sacrificial material while providing a high etch selectivity for non-oxide materials including polysilicon, silicon nitride and metals comprising aluminum. Both the HF and H.sub.2 SO.sub.4 can be provided as "semiconductor grade" acids in concentrations of generally 40-50% by weight HF, and at least 90% by weight H.sub.2 SO.sub.4.

  15. Digital Sofcell Shanghai ShenLi Goeta solid oxide fuel cell joint...

    Open Energy Info (EERE)

    ShenLi Goeta solid oxide fuel cell joint venture Jump to: navigation, search Name: Digital Sofcell - Shanghai ShenLi - Goeta solid oxide fuel cell joint venture Place: China...

  16. Solid oxide fuel cell with single material for electrodes and interconnect

    DOE Patents [OSTI]

    McPheeters, Charles C.; Nelson, Paul A.; Dees, Dennis W.

    1994-01-01

    A solid oxide fuel cell having a plurality of individual cells. A solid oxide fuel cell has an anode and a cathode with electrolyte disposed therebetween, and the anode, cathode and interconnect elements are comprised of substantially one material.

  17. Hazard analysis for 300 Area N Reactor Fuel Fabrication and Storage Facilty

    SciTech Connect (OSTI)

    Johnson, D.J.; Brehm, J.R.

    1994-01-25

    This hazard analysis (HA) has been prepared for the 300 Area N Reactor Fuel Fabrication and Storage Facility (Facility), in compliance with the requirements of Westinghouse Hanford Company (Westinghouse Hanford) controlled manual WHC-CM-4-46, Nonreactor Facility Safety Analysis Manual, and to the direction of WHC-IP-0690, Safety Analysis and Regulation Desk Instructions, (WHC 1992). An HA identifies potentially hazardous conditions in a facility and the associated potential accident scenarios. Unlike the Facility hazard classification documented in WHC-SD-NR-HC-004, Hazard Classification for 300 Area N Reactor Fuel Fabrication and Storage Facility, (Huang 1993), which is based on unmitigated consequences, credit is taken in an HA for administrative controls or engineered safety features planned or in place. The HA is the foundation for the accident analysis. The significant event scenarios identified by this HA will be further evaluated in a subsequent accident analysis.

  18. Calculation of parameters for inspection planning and evaluation: low enriched uranium conversion and fuel fabrication facilities

    SciTech Connect (OSTI)

    Reardon, P.T.; Mullen, M.F.; Harms, N.L.

    1981-02-01

    As part of Task C.35 (Calculation of Parameters for Inspection Planning and Evaluation) of the US Program of Technical Assistance to IAEA Safeguards, Pacific Northwest Laboratory has performed some quantitative analyses of IAEA inspection activities at low-enriched uranium (LEU) conversion and fuel fabrication facilities. This report presents the results and conclusions of those analyses. Implementation of IAEA safeguards at LEU conversion and fuel fabrication facilities must take into account a variety of practical problems and constraints. One of the key concerns is the problem of flow verification, especially product verification. The objective of this report is to help put the problem of flow verification in perspective by presenting the results of some specific calculations of inspection effort and probability of detection for various product measurement strategies. In order to provide quantitative information about the advantages and disadvantages of the various strategies, eight specific cases were examined.

  19. Electrometallurgical treatment of oxide spent fuel - engineering-scale development.

    SciTech Connect (OSTI)

    Karell, E. J.

    1998-04-22

    Argonne National Laboratory (ANL) has developed the electrometallurgical treatment process for conditioning various Department of Energy (DOE) spent fuel types for long-term storage or disposal. This process uses electrorefining to separate the constituents of spent fuel into three product streams: metallic uranium, a metal waste form containing the cladding and noble metal fission products, and a ceramic waste form containing the transuranics, and rare earth, alkali, and alkaline earth fission products. While metallic fuels can be directly introduced into the electrorefiner, the actinide components of oxide fuels must first be reduced to the metallic form. The Chemical Technology Division of AFT has developed a process to reduce the actinide oxides that uses lithium at 650 C in the presence of molten LiCl, yielding the actinide metals and Li{sub 2}O. A significant amount of work has already been accomplished to investigate the basic chemistry of the lithium reduction process and to demonstrate its applicability to the treatment of light-water reactor- (LWR-) type spent fuel. The success of this work has led to conceptual plans to construct a pilot-scale oxide reduction facility at ANL's Idaho site. In support of the design effort, a series of laboratory- and engineering-scale experiments is being conducted using simulated fuel. These experiments have focused on the engineering issues associated with scaling-up the process and proving compatibility between the reduction and electrorefining steps. Specific areas of investigation included reduction reaction kinetics, evaluation of various fuel basket designs, and issues related to electrorefining the reduced product. This paper summarizes the results of these experiments and outlines plans for future work.

  20. Process for fabricating doped zinc oxide microsphere gel

    DOE Patents [OSTI]

    Arnold, W.D. Jr.; Bond, W.D.; Lauf, R.J.

    1991-11-05

    Disclosed are a new composition and method of making same for a doped zinc oxide microsphere and articles made therefrom for use in an electrical surge arrestor which has increased solid content, uniform grain size and is in the form of a gel. 4 figures.

  1. Process for fabricating doped zinc oxide microsphere gel

    DOE Patents [OSTI]

    Arnold, Jr., Wesley D.; Bond, Walter D.; Lauf, Robert J.

    1991-01-01

    A new composition and method of making same for a doped zinc oxide microsphere and articles made therefrom for use in an electrical surge arrestor which has increased solid content, uniform grain size and is in the form of a gel.

  2. Interim Action Determination Flexible Manufacturing Capability for the Mixed Fuel Fabrication Facility (MFFF)

    Energy Savers [EERE]

    Flexible Manufacturing Capability for the Mixed Fuel Fabrication Facility (MFFF) The Department of Energy (DOE) is preparing the Surplus Plutonium Disposition Supplemental Environmental Impact Statement (SPD SEIS), DOE/EIS-0283-S2. DOE is evaluating, among many other things, the environmental impacts of any design and operations changes to the MFFF, which is under construction at the Savannah River Site near Aiken, South Carolina. DOE evaluated the impacts of construction and operation of the

  3. Solid Oxide Fuel Cell Balance of Plant and Stack Component Integration

    Broader source: Energy.gov [DOE]

    Presentation by Acumentrics Corporation for Solid Oxide Fuel Cell Balance of Plant and Stack Component Integration March 16, 2010

  4. Planar solid oxide fuel cell with staged indirect-internal air and fuel preheating and reformation

    DOE Patents [OSTI]

    2003-10-21

    A solid oxide fuel cell arrangement and method of use that provides internal preheating of both fuel and air in order to maintain the optimum operating temperature for the production of energy. The internal preheat passes are created by the addition of two plates, one on either side of the bipolar plate, such that these plates create additional passes through the fuel cell. This internal preheat fuel cell configuration and method reduce the requirements for external heat exchanger units and air compressors. Air or fuel may be added to the fuel cell as required to maintain the optimum operating temperature through a cathode control valve or an anode control valve, respectively. A control loop comprises a temperature sensing means within the preheat air and fuel passes, a means to compare the measured temperature to a set point temperature and a determination based on the comparison as to whether the control valves should allow additional air or fuel into the preheat or bypass manifolds of the fuel cell.

  5. Degradation of solid oxide fuel cell metallic interconnects in fuels containing sulfur

    SciTech Connect (OSTI)

    Ziomek-Moroz, M.; Hawk, Jeffrey A.

    2005-01-01

    Hydrogen is the main fuel for all types of fuel cells except direct methanol fuel cells. Hydrogen can be generated from all manner of fossil fuels, including coal, natural gas, diesel, gasoline, other hydrocarbons, and oxygenates (e.g., methanol, ethanol, butanol, etc.). Impurities in the fuel can cause significant performance problems and sulfur, in particular, can decrease the cell performance of fuel cells, including solid oxide fuel cells (SOFC). In the SOFC, the high (800-1000°C) operating temperature yields advantages (e.g., internal fuel reforming) and disadvantages (e.g., material selection and degradation problems). Significant progress in reducing the operating temperature of the SOFC from ~1000 ºC to ~750 ºC may allow less expensive metallic materials to be used for interconnects and as balance of plant (BOP) materials. This paper provides insight on the material performance of nickel, ferritic steels, and nickel-based alloys in fuels containing sulfur, primarily in the form of H2S, and seeks to quantify the extent of possible degradation due to sulfur in the gas stream.

  6. Santa Clara County Planar Solid Oxide Fuel Cell Demonstration Project

    SciTech Connect (OSTI)

    Fred Mitlitsky; Sara Mulhauser; David Chien; Deepak Shukla; David Weingaertner

    2009-11-14

    The Santa Clara County Planar Solid Oxide Fuel Cell (PSOFC) project demonstrated the technical viability of pre-commercial PSOFC technology at the County 911 Communications headquarters, as well as the input fuel flexibility of the PSOFC. PSOFC operation was demonstrated on natural gas and denatured ethanol. The Santa Clara County Planar Solid Oxide Fuel Cell (PSOFC) project goals were to acquire, site, and demonstrate the technical viability of a pre-commercial PSOFC technology at the County 911 Communications headquarters. Additional goals included educating local permit approval authorities, and other governmental entities about PSOFC technology, existing fuel cell standards and specific code requirements. The project demonstrated the Bloom Energy (BE) PSOFC technology in grid parallel mode, delivering a minimum 15 kW over 8760 operational hours. The PSOFC system demonstrated greater than 81% electricity availability and 41% electrical efficiency (LHV net AC), providing reliable, stable power to a critical, sensitive 911 communications system that serves geographical boundaries of the entire Santa Clara County. The project also demonstrated input fuel flexibility. BE developed and demonstrated the capability to run its prototype PSOFC system on ethanol. BE designed the hardware necessary to deliver ethanol into its existing PSOFC system. Operational parameters were determined for running the system on ethanol, natural gas (NG), and a combination of both. Required modeling was performed to determine viable operational regimes and regimes where coking could occur.

  7. Tubular solid oxide fuel cell prospect

    SciTech Connect (OSTI)

    Veyo, S.E.

    1996-05-01

    Driven by technological achievement and rational projection of commercial product cost, expectations for tubular SOFC commercialization are improving. Tubular SOFCs have surpassed 7 yrs operation and have recently demonstrated remarkable toughness in thermal cycling. Customer-owned systems with 25 kW stacks utilizing air electrode supported (AES) cells continue to operate directly on natural gas without degradation after multiple thermal cycles and over 4000 hrs operation. AES cell operation at elevated pressure corroborates theoretical estimates of performance gain without evidence of deleterious effect. Commercial class AES cell of 22 mm dia and 1500 mm length, is now in production for application to 100 kW, 50% efficient (ac/LHV), atmospheric pressure systems. This same cell applied to pressurized systems in combination with conventional turbo machinery (gas turbines) can yield an efficiency approaching 70% for power plants as small as 5 MW. Total installed system cost for commercial 5 MW SOFC/CT units for distributed power generation and on-site cogeneration should approach $1000/kW. A major challenge is formation of funded projects to demonstrate at the turn of the century prototype MW class SOFC/CT combined cycle power plants and to complete the development of commercial fuel cell manufacturing processes.

  8. Fuel Fabrication Capability WBS 01.02.01.05 - HIP Bonding Experiments Final Report

    SciTech Connect (OSTI)

    Dickerson, Patricia O'Donnell; Summa, Deborah Ann; Liu, Cheng; Tucker, Laura Arias; Chen, Ching-Fong; Aikin, Beverly; Aragon, Daniel Adrian; Beard, Timothy Vance; Montalvo, Joel Dwayne; Pena, Maria Isela; Dombrowski, David E.

    2015-06-10

    The goals of this project were to demonstrate reliable, reproducible solid state bonding of aluminum 6061 alloy plates together to encapsulate DU-10 wt% Mo surrogate fuel foils. This was done as part of the CONVERT Fuel Fabrication Capability effort in Process Baseline Development . Bonding was done using Hot Isotatic Pressing (HIP) of evacuated stainless steel cans (a.k.a HIP cans) containing fuel plate components and strongbacks. Gross macroscopic measurements of HIP cans prior to HIP and after HIP were used as part of this demonstration, and were used to determine the accuracy of a finitie element model of the HIP bonding process. The quality of the bonding was measured by controlled miniature bulge testing for Al-Al, Al-Zr, and Zr-DU bonds. A special objective was to determine if the HIP process consistently produces good quality bonding and to determine the best characterization techniques for technology transfer.

  9. Method and device for fabricating dispersion fuel comprising fission product collection spaces

    DOE Patents [OSTI]

    Shaber, Eric L; Fielding, Randall S

    2015-05-05

    A method of fabricating a nuclear fuel comprising a fissile material, one or more hollow microballoons, a phenolic resin, and metal matrix. The fissile material, phenolic resin and the one or more hollow microballoons are combined. The combined fissile material, phenolic resin and the hollow microballoons are heated sufficiently to form at least some fissile material carbides creating a nuclear fuel particle. The resulting nuclear fuel particle comprises one or more fission product collection spaces. In a preferred embodiment, the fissile material, phenolic resin and the one or more hollow microballoons are combined by forming the fissile material into microspheres. The fissile material microspheres are then overcoated with the phenolic resin and microballoon. In another preferred embodiment, the fissile material, phenolic resin and the one or more hollow microballoons are combined by overcoating the microballoon with the fissile material, and phenolic resin.

  10. Fuel-cladding chemical interaction correlation for mixed-oxide fuel pins

    SciTech Connect (OSTI)

    Lawrence, L.A.

    1986-10-01

    A revised wastage correlation was developed for FCCI with fabrication and operating parameters. The expansion of the data base to 305 data sets provided sufficient data to employ normal statistical techniques for calculation of confidence levels without unduly penalizing predictions. The correlation based on 316 SS cladding also adequately accounts for limited measured depths of interaction for fuel pins with D9 and HTq cladding.

  11. Environmental resistance of oxide tags fabricated on 304L stainless steel via nanosecond pulsed laser irradiation

    DOE Public Access Gateway for Energy & Science Beta (PAGES Beta)

    Lawrence, Samantha Kay; Adams, David P.; Bahr, David F.; Moody, Neville R.

    2015-11-14

    Nanosecond pulsed laser irradiation was used to fabricate colored, mechanically robust oxide “tags” on 304L stainless steel. Immersion in simulated seawater solution, salt fog exposure, and anodic polarization in a 3.5% NaCl solution were employed to evaluate the environmental resistance of these oxide tags. Single layer oxides outside a narrow thickness range (~ 100–150 nm) are susceptible to dissolution in chloride containing environments. The 304L substrates immediately beneath the oxides corrode severely—attributed to Cr-depletion in the melt zone during laser processing. For the first time, multilayered oxides were fabricated with pulsed laser irradiation in an effort to expand the protectivemore » thickness range while also increasing the variety of film colors attainable in this range. Layered films grown using a laser scan rate of 475 mm/s are more resistant to both localized and general corrosion than oxides fabricated at 550 mm/s. Furthermore, in the absence of pre-processing to mitigate Cr-depletion, layered films can enhance environmental stability of the system.« less

  12. Iron aluminide alloy container for solid oxide fuel cells

    DOE Patents [OSTI]

    Judkins, Roddie Reagan; Singh, Prabhakar; Sikka, Vinod Kumar

    2000-01-01

    A container for fuel cells is made from an iron aluminide alloy. The container alloy preferably includes from about 13 to about 22 weight percent Al, from about 2 to about 8 weight percent Cr, from about 0.1 to about 4 weight percent M selected from Zr and Hf, from about 0.005 to about 0.5 weight percent B or from about 0.001 to about 1 weight percent C, and the balance Fe and incidental impurities. The iron aluminide container alloy is extremely resistant to corrosion and metal loss when exposed to dual reducing and oxidizing atmospheres at elevated temperatures. The alloy is particularly useful for containment vessels for solid oxide fuel cells, as a replacement for stainless steel alloys which are currently used.

  13. Electrical contact structures for solid oxide electrolyte fuel cell

    DOE Patents [OSTI]

    Isenberg, Arnold O. (Forest Hills, PA)

    1984-01-01

    An improved electrical output connection means is provided for a high temperature solid oxide electrolyte type fuel cell generator. The electrical connection of the fuel cell electrodes to the electrical output bus, which is brought through the generator housing to be connected to an electrical load line maintains a highly uniform temperature distribution. The electrical connection means includes an electrode bus which is spaced parallel to the output bus with a plurality of symmetrically spaced transversely extending conductors extending between the electrode bus and the output bus, with thermal insulation means provided about the transverse conductors between the spaced apart buses. Single or plural stages of the insulated transversely extending conductors can be provided within the high temperatures regions of the fuel cell generator to provide highly homogeneous temperature distribution over the contacting surfaces.

  14. Serially connected solid oxide fuel cells having monolithic cores

    DOE Patents [OSTI]

    Herceg, J.E.

    1985-05-20

    Disclosed is a solid oxide fuel cell for electrochemically combining fuel and oxidant for generating galvanic output. The cell core has an array of cell segments electrically serially connected in the flow direction, each segment consisting of electrolyte walls and interconnect that are substantially devoid of any composite inert materials for support. Instead, the core is monolithic, where each electrolyte wall consists of thin layers of cathode and anode materials sandwiching a thin layer of electrolyte material therebetween. Means direct the fuel to the anode-exposed core passageways and means direct the oxidant to the cathode-exposed core passageways; and means also direct the galvanic output to an exterior circuit. Each layer of the electrolyte composite materials is of the order of 0.002 to 0.01 cm thick; and each layer of the cathode and anode materials is of the order of 0.002 to 0.05 cm thick. Between 2 and 50 cell segments may be connected in series.

  15. Method and apparatus for assembling solid oxide fuel cells

    DOE Patents [OSTI]

    Szreders, B.E.; Campanella, N.

    1988-05-11

    This invention relates generally to solid oxide fuel power generators and is particularly directed to improvements in the assembly and coupling of solid oxide fuel cell modules. A plurality of jet air tubes are supported and maintained in a spaced matrix array by a positioning/insertion assembly for insertion in respective tubes of a solid oxide fuel cell (SOFC) in the assembly of an SOFC module. The positioning/insertion assembly includes a plurality of generally planar, elongated, linear vanes which are pivotally mounted at each end thereof to a support frame. A rectangular compression assembly of adjustable size is adapted to receive and squeeze a matrix of SOFC tubes so as to compress the inter-tube nickel felt conductive pads which provide series/parallel electrical connection between adjacent SOFCs, with a series of increasingly larger retainer frames used to maintain larger matrices of SOFC tubes in position. Expansion of the SOFC module housing at the high operating temperatures of the SOFC is accommodated by conductive, flexible, resilient expansion, connector bars which provide support and electrical coupling at the top and bottom of the SOFC module housing. 17 figs.

  16. Status Report on the Fabrication of Fuel Cladding Chemical Interaction Test Articles for ATR Irradiations

    SciTech Connect (OSTI)

    Field, Kevin G.; Howard, Richard H.

    2015-09-28

    FeCrAl alloys are a promising new class of alloys for light water reactor (LWR) applications due to their superior oxidation and corrosion resistance in high temperature environments. The current R&D efforts have focused on the alloy composition and processing routes to generate nuclear grade FeCrAl alloys with optimized properties for enhanced accident tolerance while maintaining properties needed for normal operation conditions. Therefore, the composition and processing routes must be optimized to maintain the high temperature steam oxidation (typically achieved by increasing the Cr and Al content) while still exhibiting properties conducive to normal operation in a LWR (such as radiation tolerance where reducing Cr content is favorable). Within this balancing act is the addition of understanding the influence on composition and processing routes on the FeCrAl alloys for fuel-cladding chemical interactions (FCCI). Currently, limited knowledge exists on FCCI for the FeCrAl-UO2 clad-fuel system. To overcome the knowledge gaps on the FCCI for the FeCrAl-UO2 clad-fuel system a series of fueled irradiation tests have been developed for irradiation in the Advanced Test Reactor (ATR) housed at the Idaho National Laboratory (INL). The first series of tests has already been reported. These tests used miniaturized 17x17 PWR fuel geometry rodlets of second-generation FeCrAl alloys fueled with industrial Westinghouse UO2 fuel. These rodlets were encapsulated within a stainless steel housing.To provide high fidelity experiments and more robust testing, a new series of rodlets have been developed deemed the Accident Tolerant Fuel Experiment #1 Oak Ridge National Laboratory FCCI test (ATF-1 ORNL FCCI). The main driving factor, which is discussed in detail, was to provide a radiation environment where prototypical fuel-clad interface temperatures are met while still maintaining constant contact between industrial fuel and the candidate cladding alloys, hence promoting FCCI between the fuel-clad systems. The other factor was to develop a test bed where multiple candidate alloys could be evaluated within a single irradiation test train, thereby reducing overall costs and increasing efficiency in alloy screening efforts. A collaboration between ORNL and INL was developed to facilitate the completion of the test bed for FCCI testing. The report highlights the activities related to the development of the ATF-1 ORNL FCCI rodlets for irradiation in INL’s ATR as part of the on-going ATF-1 experiments.

  17. Solid oxide fuel cell having a glass composite seal

    DOE Patents [OSTI]

    De Rose, Anthony J.; Mukerjee, Subhasish; Haltiner, Jr., Karl Jacob

    2013-04-16

    A solid oxide fuel cell stack having a plurality of cassettes and a glass composite seal disposed between the sealing surfaces of adjacent cassettes, thereby joining the cassettes and providing a hermetic seal therebetween. The glass composite seal includes an alkaline earth aluminosilicate (AEAS) glass disposed about a viscous glass such that the AEAS glass retains the viscous glass in a predetermined position between the first and second sealing surfaces. The AEAS glass provides geometric stability to the glass composite seal to maintain the proper distance between the adjacent cassettes while the viscous glass provides for a compliant and self-healing seal. The glass composite seal may include fibers, powders, and/or beads of zirconium oxide, aluminum oxide, yttria-stabilized zirconia (YSZ), or mixtures thereof, to enhance the desirable properties of the glass composite seal.

  18. New Catalysts for Direct Methanol Oxidation Fuel Cells

    SciTech Connect (OSTI)

    Adzic, Radoslav

    1998-08-01

    A new class of efficient electrocatalytic materials based on platinum - metal oxide systems has been synthetized and characterized by several techniques. Best activity was found with NiWO{sub 4}-, CoWO{sub 4}-, and RuO{sub 2}- srpported platinum catalysts. A very similar activity at room temperature was observed with the electrodes prepared with the catalyst obtained from International Fuel Cells Inc. for the same Pt loading. Surprisingly, the two tungstates per se show a small activity for methanol oxidation without any Pt loading. Synthesis of NiWO{sub 4} and CoWO{sub 4} were carried out by solid-state reactions. FTIR spectroscopy shows that the tungstates contain a certain amount of physically adsorbed water even after heating samples at 200{degrees}C. A direct relationship between the activity for methanol oxidation and the amount of adsorbed water on those oxides has been found. The Ru(0001) single crystal shows a very small activity for CO adsorption and oxidation, in contrast to the behavior of polycrystalline Ru. In situ extended x-ray absorption fine structure spectroscopy (EXAFS) and x-ray absorption near edge spectroscopy (XANES) showed that the OH adsorption on Ru in the Pt-Ru alloy appears to be the limiting step in methanol oxidation. This does not occur for Pt-RuO{SUB 2} electrocatalyst, which explains its advantages over the Pt-Ru alloys. The IFCC electrocatalyst has the properties of the Pt-Ru alloy.

  19. Electrode design for low temperature direct-hydrocarbon solid oxide fuel cells

    SciTech Connect (OSTI)

    Chen, Fanglin; Zhao, Fei; Liu, Qiang

    2015-10-06

    In certain embodiments of the present disclosure, a solid oxide fuel cell is described. The solid oxide fuel cell includes a hierarchically porous cathode support having an impregnated cobaltite cathode deposited thereon, an electrolyte, and an anode support. The anode support includes hydrocarbon oxidation catalyst deposited thereon, wherein the cathode support, electrolyte, and anode support are joined together and wherein the solid oxide fuel cell operates a temperature of 600.degree. C. or less.

  20. Extended Durability Testing of an External Fuel Processor for a Solid Oxide Fuel Cell (SOFC)

    SciTech Connect (OSTI)

    Mark Perna; Anant Upadhyayula; Mark Scotto

    2012-11-05

    Durability testing was performed on an external fuel processor (EFP) for a solid oxide fuel cell (SOFC) power plant. The EFP enables the SOFC to reach high system efficiency (electrical efficiency up to 60%) using pipeline natural gas and eliminates the need for large quantities of bottled gases. LG Fuel Cell Systems Inc. (formerly known as Rolls-Royce Fuel Cell Systems (US) Inc.) (LGFCS) is developing natural gas-fired SOFC power plants for stationary power applications. These power plants will greatly benefit the public by reducing the cost of electricity while reducing the amount of gaseous emissions of carbon dioxide, sulfur oxides, and nitrogen oxides compared to conventional power plants. The EFP uses pipeline natural gas and air to provide all the gas streams required by the SOFC power plant; specifically those needed for start-up, normal operation, and shutdown. It includes a natural gas desulfurizer, a synthesis-gas generator and a start-gas generator. The research in this project demonstrated that the EFP could meet its performance and durability targets. The data generated helped assess the impact of long-term operation on system performance and system hardware. The research also showed the negative impact of ambient weather (both hot and cold conditions) on system operation and performance.

  1. Method for producing electricity from a fuel cell having solid-oxide ionic electrolyte

    DOE Patents [OSTI]

    Mason, David M.

    1984-01-01

    Stabilized quadrivalent cation oxide electrolytes are employed in fuel cells at elevated temperatures with a carbon and/or hydrogen containing fuel anode and an oxygen cathode. The fuel cell is operated at elevated temperatures with conductive metallic coatings as electrodes and desirably having the electrolyte surface blackened. Of particular interest as the quadrivalent oxide is zirconia.

  2. Air feed tube support system for a solid oxide fuel cell generator

    DOE Patents [OSTI]

    Doshi, Vinod B. (Monroeville, PA); Ruka, Roswell J. (Pittsburgh, PA); Hager, Charles A. (Zelienople, PA)

    2002-01-01

    A solid oxide fuel cell generator (12), containing tubular fuel cells (36) with interior air electrodes (18), where a supporting member (82) containing a plurality of holes (26) supports oxidant feed tubes (51), which pass from an oxidant plenum (52") into the center of the fuel cells, through the holes (26) in the supporting member (82), where a compliant gasket (86) around the top of the oxidant feed tubes and on top (28) of the supporting member (82) helps support the oxidant feed tubes and center them within the fuel cells, and loosen the tolerance for centering the air feed tubes.

  3. Solid oxide fuel cell having compound cross flow gas patterns

    DOE Patents [OSTI]

    Fraioli, Anthony V.

    1985-01-01

    A core construction for a fuel cell is disclosed having both parallel and cross flow passageways for the fuel and the oxidant gases. Each core passageway is defined by electrolyte and interconnect walls. Each electrolyte wall consists of cathode and anode materials sandwiching an electrolyte material. Each interconnect wall is formed as a sheet of inert support material having therein spaced small plugs of interconnect material, where cathode and anode materials are formed as layers on opposite sides of each sheet and are electrically connected together by the interconnect material plugs. Each interconnect wall in a wavy shape is connected along spaced generally parallel line-like contact areas between corresponding spaced pairs of generally parallel electrolyte walls, operable to define one tier of generally parallel flow passageways for the fuel and oxidant gases. Alternate tiers are arranged to have the passageways disposed normal to one another. Solid mechanical connection of the interconnect walls of adjacent tiers to the opposite sides of the common electrolyte wall therebetween is only at spaced point-like contact areas, 90 where the previously mentioned line-like contact areas cross one another.

  4. Solid oxide fuel cell having compound cross flow gas patterns

    DOE Patents [OSTI]

    Fraioli, A.V.

    1983-10-12

    A core construction for a fuel cell is disclosed having both parallel and cross flow passageways for the fuel and the oxidant gases. Each core passageway is defined by electrolyte and interconnect walls. Each electrolyte wall consists of cathode and anode materials sandwiching an electrolyte material. Each interconnect wall is formed as a sheet of inert support material having therein spaced small plugs of interconnect material, where cathode and anode materials are formed as layers on opposite sides of each sheet and are electrically connected together by the interconnect material plugs. Each interconnect wall in a wavy shape is connected along spaced generally parallel line-like contact areas between corresponding spaced pairs of generally parallel electrolyte walls, operable to define one tier of generally parallel flow passageways for the fuel and oxidant gases. Alternate tiers are arranged to have the passageways disposed normal to one another. Solid mechanical connection of the interconnect walls of adjacent tiers to the opposite sides of the common electrolyte wall therebetween is only at spaced point-like contact areas, 90 where the previously mentioned line-like contact areas cross one another.

  5. Release and disposal of materials during decommissioning of Siemens MOX fuel fabrication plant at Hanau, Germany

    SciTech Connect (OSTI)

    Koenig, Werner; Baumann, Roland

    2007-07-01

    In September 2006, decommissioning and dismantling of the Siemens MOX Fuel Fabrication Plant in Hanau were completed. The process equipment and the fabrication buildings were completely decommissioned and dismantled. The other buildings were emptied in whole or in part, although they were not demolished. Overall, the decommissioning process produced approximately 8500 Mg of radioactive waste (including inactive matrix material); clearance measurements were also performed for approximately 5400 Mg of material covering a wide range of types. All the equipment in which nuclear fuels had been handled was disposed of as radioactive waste. The radioactive waste was conditioned on the basis of the requirements specified for the projected German final disposal site 'Schachtanlage Konrad'. During the pre-conditioning, familiar processes such as incineration, compacting and melting were used. It has been shown that on account of consistently applied activity containment (barrier concept) during operation and dismantling, there has been no significant unexpected contamination of the plant. Therefore almost all the materials that were not a priori destined for radioactive waste were released without restriction on the basis of the applicable legal regulations (chap. 29 of the Radiation Protection Ordinance), along with the buildings and the plant site. (authors)

  6. Diesel-fueled solid oxide fuel cell auxiliary power units for heavy-duty vehicles

    SciTech Connect (OSTI)

    Krause, T.; Kumar, R.; Krumpelt, M.

    2000-05-15

    This paper explores the potential of solid oxide fuel cells (SOFCS) as 3--10 kW auxiliary power units for trucks and military vehicles operating on diesel fuel. It discusses the requirements and specifications for such units, and the advantages, challenges, and development issues for SOFCS used in this application. Based on system design and analysis, such systems should achieve efficiencies approaching 40% (lower heating value), with a relatively simple system configuration. The major components of such a system are the fuel cell stack, a catalytic autothermal reformer, and a spent gas burner/air preheater. Building an SOFC-based auxiliary power unit is not straightforward, however, and the tasks needed to develop a 3--10 kW brassboard demonstration unit are outlined.

  7. Safeguards instrumentation for continuous unattended monitoring in plutonium fuel fabrication plants

    SciTech Connect (OSTI)

    Menlove, H.O.; Miller, M.C.; Ohtani, T.; Seya, M.; Takahashi, S.

    1993-06-01

    Nondestructive assay (NDA) systems have been developed for use in an automated mixed oxide fabrication facility. Unique features have been developed for the NDA systems to accommodate robotic sample handling and remote operation. In addition, the systems have been designed to obtain International Atomic Energy Agency inspection data without the need for an inspector at the facility at the time of the measurements. The equipment is being designed to operate continuously in an unattended mode with data storage for periods of up to one month. The design, performance characteristics, and authentication of the NDA systems are described. The data related to reliability, precision, and accuracy are presented.

  8. Effect of Substrate Thickness on Oxide Scale Spallation for Solid Oxide Fuel Cells

    SciTech Connect (OSTI)

    Liu, Wenning N.; Sun, Xin; Stephens, Elizabeth V.; Khaleel, Mohammad A.

    2011-07-01

    In this paper, the effect of the ferritic substrate's thickness on the delamination/spallation of the oxide scale was investigated experimentally and numerically. At the high-temperature oxidation environment of solid oxide fuel cells (SOFCs), a combination of growth stress with thermal stresses may lead to scale delamination/buckling and eventual spallation during SOFC stack cooling, even leading to serious degradation of cell performance. The growth stress is induced by the growth of the oxide scale on the scale/substrate interface, and thermal stress is induced by a mismatch of the coefficient of thermal expansion between the oxide scale and the substrate. The numerical results show that the interfacial shear stresses, which are the driving force of scale delamination between the oxide scale and the ferritic substrate, increase with the growth of the oxide scale and also with the thickness of the ferritic substrate; i.e., the thick ferritic substrate can easily lead to scale delamination and spallation. Experimental observation confirmed the predicted results of the delamination and spallation of the oxide scale on the ferritic substrate.

  9. Solid oxide fuel cell with multi-unit construction and prismatic design

    DOE Patents [OSTI]

    McPheeters, C.C.; Dees, D.W.; Myles, K.M.

    1999-03-16

    A single cell unit of a solid oxide fuel cell is described that is individually fabricated and sintered prior to being connected to adjacent cells to form a solid oxide fuel cell. The single cell unit is comprised of a shaped anode sheet positioned between a flat anode sheet and an anode-electrolyte-cathode (A/E/C) sheet, and a shaped cathode sheet positioned between the A/E/C sheet and a cathode-interconnect-anode (C/I/A) sheet. An alternate embodiment comprises a shaped cathode sheet positioned between an A/E/C sheet and a C/I/A sheet. The shaped sheets form channels for conducting reactant gases. Each single cell unit is individually sintered to form a finished sub-assembly. The finished sub-assemblies are connected in electrical series by interposing connective material between the end surfaces of adjacent cells, whereby individual cells may be inspected for defects and interchanged with non-defective single cell units. 7 figs.

  10. Solid oxide fuel cell with multi-unit construction and prismatic design

    DOE Patents [OSTI]

    McPheeters, Charles C.; Dees, Dennis W.; Myles, Kevin M.

    1999-01-01

    A single cell unit of a solid oxide fuel cell that is individually fabricated and sintered prior to being connected to adjacent cells to form a solid oxide fuel cell. The single cell unit is comprised of a shaped anode sheet positioned between a flat anode sheet and an anode-electrolyte-cathode (A/E/C) sheet, and a shaped cathode sheet positioned between the A/E/C sheet and a cathode-interconnect-anode (C/I/A) sheet. An alternate embodiment comprises a shaped cathode sheet positioned between an A/E/C sheet and a C/I/A sheet. The shaped sheets form channels for conducting reactant gases. Each single cell unit is individually sintered to form a finished sub-assembly. The finished sub-assemblies are connected in electrical series by interposing connective material between the end surfaces of adjacent cells, whereby individual cells may be inspected for defects and interchanged with non-defective single cell units.

  11. US-Russian collaboration in MPC & A enhancements at the Elektrostal Uranium Fuel-Fabrication Plant

    SciTech Connect (OSTI)

    Smith, H.; Murray, W.; Whiteson, R.

    1997-11-01

    Enhancement of the nuclear materials protection, control, and accounting of (MPC&A) at the Elektrostal Machine-Building Plant (ELEMASH) has proceeded in two phases. Initially, Elektrostal served as the model facility at which to test US/Russian collaboration and to demonstrate MPC&A technologies available for safeguards enhancements at Russian facilities. This phase addressed material control and accounting (MC&A) in the low-enriched uranium (LEU) fuel-fabrication processes and the physical protection (PP) of part of the (higher-enrichment) breeder-fuel process. The second phase, identified later in the broader US/Russian agreement for expanded MPC&A cooperation. includes implementation of appropriate MC&A and PP systems in the breeder-fuel fabrication processes. Within the past year, an automated physical protection system has been installed and demonstrated in building 274, and an automated MC&A system has been designed and is being installed and will be tested in the LEU process. Attention has now turned to assuring longterm sustainability for the first phase and beginning MPC&A upgrades for the second phase. Sustainability measures establish the infrastructure for operation, maintenance, and repair of the installed systems-with US support for the lifetime of the US/Russian Agreement, but evolving toward full Russian operation of the system over the long term. For phase 2, which will address higher enrichments, projects have been identified to characterize the facilities, design MPC&A systems, procure appropriate equipment, and install and test final systems. One goal in phase 2 will be to build on initial work to create shared, plant-wide MPC&A assets for operation, maintenance, and evaluation of all safeguards systems.

  12. Supplemental information for a notice of construction for the Fueled Clad Fabrication System, the Radioisotope Power Systems Facility, and the Fuel Assembly Area

    SciTech Connect (OSTI)

    Not Available

    1989-08-01

    This ''Notice of Construction'' has been submitted by the US Department of Energy-Richland Operations Office (P.O. Box 550, Richland, Washington 99352), pursuant to WAC 402-80-070, for three new sources of radionuclide emissions at the Hanford Site in Washington State (Figure 1). The three new sources, the Fueled Clad Fabrication System (FCFS) the Radioisotope Power Systems Facility (RPSF) and the Fuel Assembly Area (FAA) will be located in one facility, the Fuels and materials Examination Facility (FMEF) of the 400 Area. The FMEF was originally designed to provide for post- irradiation examination and fabrication of breeder reactor fuels. These FMEF missions were cancelled before the introduction of any fuel materials or any irradiated material. The current plans are to use the facility to fabricate power supplies to be used in space applications and to produce Fast Flux Test Facility (FFTF) fuel and target assemblies. The FCFS and the RPSF will produce materials and assemblies for application in space. The FAA project will produce FFTF fuel and target assemblies. The FCFS and the RPSF will share the same building, stack, and, in certain cases, the same floor space. Given this relationship, to the extent possible, these systems will be dealt with separately. The FAA is a comparatively independent operation though it will share the FMEF complex.

  13. Prevention of significant deterioration permit application for the Fueled Clad Fabrication System, the Radioisotope Power Systems Facility, and the Fuel Assembly Area

    SciTech Connect (OSTI)

    Not Available

    1989-08-01

    This New Source Review'' has been submitted by the US Department of Energy-Richland Operations Office (PO Box 550, Richland, Washington 99352), pursuant to WAC 173-403-050 and in compliance with the Department of Ecology Guide to Processing A Prevention Of Significant Deterioration (PSD) Permit'' for three new sources of radionuclide emissions at the Hanford Site in Washington State. The three new sources, the Fueled Clad Fabrication System (FCFS), the Radioisotope Power Systems Facility (RPSF), and the Fuel Assembly Area (FAA), will be located in one facility, the Fuels and Materials Examination Facility (FMEF) of the 400 Area. The FMEF was originally designed to provide for post-irradiation examination and fabrication of breeder reactor fuels. These FMEF missions were cancelled before the introduction of any fuel materials or any irradiated material. The current plans are to use the facility to fabricate power supplies for use in space applications and to produce Fast Flux Test Facility (FFTF) fuel and target assemblies. The FCFS and the RPSF will produce materials and assemblies for application in space. The FAA project will produce FFTF fuel and target assemblies. The FCFS and the RPSF will share the same building, stack, and, in certain cases, the same floor space. Given this relationship, these systems will be dealt with separately to the extent possible. The FAA is a comparatively independent operation though it will share the FMEF complex.

  14. Solid Oxide Fuel Cell System (SOFC) Technology R&D Needs (Presentation...

    Office of Energy Efficiency and Renewable Energy (EERE) Indexed Site

    System (SOFC) Technology R&D Needs (Presentation) Solid Oxide Fuel Cell System (SOFC) Technology R&D Needs (Presentation) Presented at the DOE Fuel Cell Pre-Solicitation Workshop...

  15. Manufacturing Cost Analysis of 1 kW and 5 kW Solid Oxide Fuel...

    Office of Energy Efficiency and Renewable Energy (EERE) Indexed Site

    Manufacturing Cost Analysis of 1 kW and 5 kW Solid Oxide Fuel Cell (SOFC) for Auxiliary ... of fuel cell manufacturing costs at varied volumes and alternative system designs. ...

  16. Seven Projects That Will Advance Solid Oxide Fuel Cell Research Selected by

    Energy Savers [EERE]

    DOE for Further Development | Department of Energy Seven Projects That Will Advance Solid Oxide Fuel Cell Research Selected by DOE for Further Development Seven Projects That Will Advance Solid Oxide Fuel Cell Research Selected by DOE for Further Development July 27, 2012 - 1:00pm Addthis Washington, D.C. - Seven projects that will help develop low-cost solid oxide fuel cell (SOFC) technology for environmentally responsible central power generation from the Nation's abundant fossil energy

  17. Advanced Materials for Reversible Solid Oxide Fuel Cell (RSOFC), Dual Mode

    Office of Energy Efficiency and Renewable Energy (EERE) Indexed Site

    Operation with Low Degradation | Department of Energy for Reversible Solid Oxide Fuel Cell (RSOFC), Dual Mode Operation with Low Degradation Advanced Materials for Reversible Solid Oxide Fuel Cell (RSOFC), Dual Mode Operation with Low Degradation Presented at the Department of Energy Fuel Cell Projects Kickoff Meeting, September 1 - October 1, 2009 PDF icon petri_versa%20_power_kickoff.pdf More Documents & Publications Reversible Fuel Cells Workshop Summary Report Progress on the

  18. Oxidative alteration of spent fuel in a silica-rich environment...

    Office of Scientific and Technical Information (OSTI)

    SEMAEM investigation and geochemical modeling Citation Details In-Document Search Title: Oxidative alteration of spent fuel in a silica-rich environment: SEMAEM ...

  19. Electrical Generation for More-Electric Aircraft using Solid Oxide Fuel Cells

    Broader source: Energy.gov [DOE]

    This study, completed by Pacific Northwest National Laboratory, examines approaches to providing electrical power on board commercial aircraft using solid oxide fuel (SOFC) technology.

  20. Air electrode composition for solid oxide fuel cell

    DOE Patents [OSTI]

    Kuo, Lewis; Ruka, Roswell J.; Singhal, Subhash C.

    1999-01-01

    An air electrode composition for a solid oxide fuel cell is disclosed. The air electrode material is based on lanthanum manganite having a perovskite-like crystal structure ABO.sub.3. The A-site of the air electrode composition comprises a mixed lanthanide in combination with rare earth and alkaline earth dopants. The B-site of the composition comprises Mn in combination with dopants such as Mg, Al, Cr and Ni. The mixed lanthanide comprises La, Ce, Pr and, optionally, Nd. The rare earth A-site dopants preferably comprise La, Nd or a combination thereof, while the alkaline earth A-site dopant preferably comprises Ca. The use of a mixed lanthanide substantially reduces raw material costs in comparison with compositions made from high purity lanthanum starting materials. The amount of the A-site and B-site dopants is controlled in order to provide an air electrode composition having a coefficient of thermal expansion which closely matches that of the other components of the solid oxide fuel cell.

  1. Air electrode composition for solid oxide fuel cell

    DOE Patents [OSTI]

    Kuo, L.; Ruka, R.J.; Singhal, S.C.

    1999-08-03

    An air electrode composition for a solid oxide fuel cell is disclosed. The air electrode material is based on lanthanum manganite having a perovskite-like crystal structure ABO{sub 3}. The A-site of the air electrode composition comprises a mixed lanthanide in combination with rare earth and alkaline earth dopants. The B-site of the composition comprises Mn in combination with dopants such as Mg, Al, Cr and Ni. The mixed lanthanide comprises La, Ce, Pr and, optionally, Nd. The rare earth A-site dopants preferably comprise La, Nd or a combination thereof, while the alkaline earth A-site dopant preferably comprises Ca. The use of a mixed lanthanide substantially reduces raw material costs in comparison with compositions made from high purity lanthanum starting materials. The amount of the A-site and B-site dopants is controlled in order to provide an air electrode composition having a coefficient of thermal expansion which closely matches that of the other components of the solid oxide fuel cell. 3 figs.

  2. Fabrication of Yttria stabilized zirconia thin films on poroussubstrates for fuel cell applications

    SciTech Connect (OSTI)

    Leming, Andres

    2003-06-16

    A process for the deposition of yttria stabilized zirconia (YSZ) films, on porous substrates, has been developed. These films have possible applications as electrolyte membranes in fuel cells. The films were deposited from colloidal suspensions through the vacuum infiltration technique. Films were deposited on both fully sintered and partially sintered substrates. A critical cracking thickness for the films was identified and strategies are presented to overcome this barrier. Green film density was also examined, and a method for improving green density by changing suspension pH and surfactant was developed. A dependence of film density on film thickness was observed, and materials interactions are suggested as a possible cause. Non-shorted YSZ films were obtained on co-fired substrates, and a cathode supported solid oxide fuel cell was constructed and characterized.

  3. Cover and startup gas supply system for solid oxide fuel cell generator

    DOE Patents [OSTI]

    Singh, Prabhakar; George, Raymond A.

    1999-01-01

    A cover and startup gas supply system for a solid oxide fuel cell power generator is disclosed. Hydrocarbon fuel, such as natural gas or diesel fuel, and oxygen-containing gas are supplied to a burner. Combustion gas exiting the burner is cooled prior to delivery to the solid oxide fuel cell. The system mixes the combusted hydrocarbon fuel constituents with hydrogen which is preferably stored in solid form to obtain a non-explosive gas mixture. The system may be used to provide both non-explosive cover gas and hydrogen-rich startup gas to the fuel cell.

  4. Cover and startup gas supply system for solid oxide fuel cell generator

    DOE Patents [OSTI]

    Singh, P.; George, R.A.

    1999-07-27

    A cover and startup gas supply system for a solid oxide fuel cell power generator is disclosed. Hydrocarbon fuel, such as natural gas or diesel fuel, and oxygen-containing gas are supplied to a burner. Combustion gas exiting the burner is cooled prior to delivery to the solid oxide fuel cell. The system mixes the combusted hydrocarbon fuel constituents with hydrogen which is preferably stored in solid form to obtain a non-explosive gas mixture. The system may be used to provide both non-explosive cover gas and hydrogen-rich startup gas to the fuel cell. 4 figs.

  5. Uranium silicide pellet fabrication by powder metallurgy for accident tolerant fuel evaluation and irradiation

    SciTech Connect (OSTI)

    Harp, Jason Michael; Lessing, Paul Alan; Hoggan, Rita Elaine

    2015-06-21

    In collaboration with industry, Idaho National Laboratory is investigating uranium silicide for use in future light water reactor fuels as a more accident resistant alternative to uranium oxide base fuels. Specifically this project was focused on producing uranium silicide (U3Si2) pellets by conventional powder metallurgy with a density greater than 94% of the theoretical density. This work has produced a process to consistently produce pellets with the desired density through careful optimization of the process. Milling of the U3Si2 has been optimized and high phase purity U3Si2 has been successfully produced. Results are presented from sintering studies and microstructural examinations that illustrate the need for a finely ground reproducible particle size distribution in the source powder. The optimized process was used to produce pellets for the Accident Tolerant Fuel-1 irradiation experiment. The average density of these pellets was 11.54 ±0.06 g/cm3. Additional characterization of the pellets by scaning electron microscopy and X-ray diffraction has also been performed. As a result, pellets produced in this work have been encapsulated for irradiation, and irradiation in the Advanced Test Reactor is expected soon.

  6. Uranium silicide pellet fabrication by powder metallurgy for accident tolerant fuel evaluation and irradiation

    DOE Public Access Gateway for Energy & Science Beta (PAGES Beta)

    Harp, Jason Michael; Lessing, Paul Alan; Hoggan, Rita Elaine

    2015-06-21

    In collaboration with industry, Idaho National Laboratory is investigating uranium silicide for use in future light water reactor fuels as a more accident resistant alternative to uranium oxide base fuels. Specifically this project was focused on producing uranium silicide (U3Si2) pellets by conventional powder metallurgy with a density greater than 94% of the theoretical density. This work has produced a process to consistently produce pellets with the desired density through careful optimization of the process. Milling of the U3Si2 has been optimized and high phase purity U3Si2 has been successfully produced. Results are presented from sintering studies and microstructural examinationsmore » that illustrate the need for a finely ground reproducible particle size distribution in the source powder. The optimized process was used to produce pellets for the Accident Tolerant Fuel-1 irradiation experiment. The average density of these pellets was 11.54 ±0.06 g/cm3. Additional characterization of the pellets by scaning electron microscopy and X-ray diffraction has also been performed. As a result, pellets produced in this work have been encapsulated for irradiation, and irradiation in the Advanced Test Reactor is expected soon.« less

  7. Solid oxide fuel cell with single material for electrodes and interconnect

    DOE Patents [OSTI]

    McPheeters, C.C.; Nelson, P.A.; Dees, D.W.

    1994-07-19

    A solid oxide fuel cell is described having a plurality of individual cells. A solid oxide fuel cell has an anode and a cathode with electrolyte disposed there between, and the anode, cathode and interconnect elements are comprised of substantially one material. 9 figs.

  8. Storage of LWR spent fuel in air: Volume 1: Design and operation of a spent fuel oxidation test facility

    SciTech Connect (OSTI)

    Thornhill, C.K.; Campbell, T.K.; Thornhill, R.E.

    1988-12-01

    This report describes the design and operation and technical accomplishments of a spent-fuel oxidation test facility at the Pacific Northwest Laboratory. The objective of the experiments conducted in this facility was to develop a data base for determining spent-fuel dry storage temperature limits by characterizing the oxidation behavior of light-water reactor (LWR) spent fuels in air. These data are needed to support licensing of dry storage in air as an alternative to spent-fuel storage in water pools. They are to be used to develop and validate predictive models of spent-fuel behavior during dry air storage in an Independent Spent Fuel Storage Installation (ISFSI). The present licensed alternative to pool storage of spent fuel is dry storage in an inert gas environment, which is called inerted dry storage (IDS). Licensed air storage, however, would not require monitoring for maintenance of an inert-gas environment (which IDS requires) but does require the development of allowable temperature limits below which UO/sub 2/ oxidation in breached fuel rods would not become a problem. Scoping tests at PNL with nonirradiated UO/sub 2/ pellets and spent-fuel fragment specimens identified the need for a statistically designed test matrix with test temperatures bounding anticipated maximum acceptable air-storage temperatures. This facility was designed and operated to satisfy that need. 7 refs.

  9. PRESSURIZED SOLID OXIDE FUEL CELL/GAS TURBINE POWER SYSTEM

    SciTech Connect (OSTI)

    W.L. Lundberg; G.A. Israelson; R.R. Moritz; S.E. Veyo; R.A. Holmes; P.R. Zafred; J.E. King; R.E. Kothmann

    2000-02-01

    Power systems based on the simplest direct integration of a pressurized solid oxide fuel cell (SOFC) generator and a gas turbine (GT) are capable of converting natural gas fuel energy to electric power with efficiencies of approximately 60% (net AC/LHV), and more complex SOFC and gas turbine arrangements can be devised for achieving even higher efficiencies. The results of a project are discussed that focused on the development of a conceptual design for a pressurized SOFC/GT power system that was intended to generate 20 MWe with at least 70% efficiency. The power system operates baseloaded in a distributed-generation application. To achieve high efficiency, the system integrates an intercooled, recuperated, reheated gas turbine with two SOFC generator stages--one operating at high pressure, and generating power, as well as providing all heat needed by the high-pressure turbine, while the second SOFC generator operates at a lower pressure, generates power, and provides all heat for the low-pressure reheat turbine. The system cycle is described, major system components are sized, the system installed-cost is estimated, and the physical arrangement of system components is discussed. Estimates of system power output, efficiency, and emissions at the design point are also presented, and the system cost of electricity estimate is developed.

  10. Probabilistic Based Design Methodology for Solid Oxide Fuel Cell Stacks

    SciTech Connect (OSTI)

    Sun, Xin; Tartakovsky, Alexandre M.; Khaleel, Mohammad A.

    2009-05-01

    A probabilistic-based component design methodology is developed for solid oxide fuel cell (SOFC) stack. This method takes into account the randomness in SOFC material properties as well as the stresses arising from different manufacturing and operating conditions. The purpose of this work is to provide the SOFC designers a design methodology such that desired level of component reliability can be achieved with deterministic design functions using an equivalent safety factor to account for the uncertainties in material properties and structural stresses. Multi-physics-based finite element analyses were used to predict the electrochemical and thermal mechanical responses of SOFC stacks with different geometric variations and under different operating conditions. Failures in the anode and the seal were used as design examples. The predicted maximum principal stresses in the anode and the seal were compared with the experimentally determined strength characteristics for the anode and the seal respectively. Component failure probabilities for the current design were then calculated under different operating conditions. It was found that anode failure probability is very low under all conditions examined. The seal failure probability is relatively high, particularly for high fuel utilization rate under low average cell temperature. Next, the procedures for calculating the equivalent safety factors for anode and seal were demonstrated such that uniform failure probability of the anode and seal can be achieved. Analysis procedures were also included for non-normal distributed random variables such that more realistic distributions of strength and stress can be analyzed using the proposed design methodology.

  11. Optimization and Demonstration of a Solid Oxide Regenerative Fuel Cell System

    SciTech Connect (OSTI)

    James F. McElroy; Darren B. Hickey; Fred Mitlitsky

    2006-09-30

    Single cell solid oxide regenerative fuel cells (SORFCs) have been demonstrated for over 1000 hours of operation at degradation rates as low as 0.5% per thousand hours for current densities as high as 300mA/cm{sup 2}. Efficiency levels (fuel cell power out vs. electrolysis power in) have been demonstrated in excess of 80% at 100mA/cm{sup 2}. All testing has been performed with metallic based interconnects and non-noble metal electrodes in order to limit fabrication costs for commercial considerations. The SORFC cell technology will be scaled up to a 1kW sized stack which will be demonstrated in Year 2 of the program. A self contained SORFC system requires efficient thermal management in order to maintain operating temperatures during exothermic and endothermic operational modes. The use of LiF as a phase change material (PCM) was selected as the optimum thermal storage medium by virtue of its superior thermal energy density by volume. Thermal storage experiments were performed using LiF and a simulated SORFC stack. The thermal storage concept was deemed to be technically viable for larger well insulated systems, although it would not enable a high efficiency thermally self-sufficient SORFC system at the 1 kW level.

  12. Research and development of americium-containing mixed oxide fuel for fast reactors

    SciTech Connect (OSTI)

    Tanaka, Kosuke; Osaka, Masahiko; Sato, Isamu; Miwa, Shuhei; Koyama, Shin-ichi; Ishi, Yohei; Hirosawa, Takashi; Obayashi, Hiroshi; Yoshimochi, Hiroshi; Tanaka, Kenya

    2007-07-01

    The present status of the R and D program for americium-containing MOX fuel is reported. Successful achievements for development of fabrication technology with remote handling and evaluation of irradiation behavior together with evaluation of thermo-chemical properties based on the out-of-pile experiments are mentioned with emphasis on effects of Am addition on the MOX fuel properties. (authors)

  13. Application of modified direct denitration to support the ORNL coupled-end-to-end demonstration in production of mixed oxides suitable for pellet fabrication

    SciTech Connect (OSTI)

    Walker, E.A.; Vedder, R.J.; Felker, L.K.; Marschman, S.C.

    2007-07-01

    The current and future development of the Modified Direct Denitration (MDD) process is in support of Oak Ridge National Laboratory's (ORNL) Coupled End-to-End (CETE) research, development, and demonstration (R and D) of proposed advanced fuel reprocessing and fuel fabrication processes. This work will involve the co-conversion of the U/Pu/Np product streams from the UREX+3 separation flow sheet utilizing the existing MDD glove-box setup and the in-cell co-conversion of the U/Pu/Np/Am/Cm product streams from the UREX+1a flow sheet. Characterization equipment is being procured and installed. Oxide powder studies are being done on calcination/reduction variables, as well as pressing and sintering of pellets to permit metallographic examinations. (authors)

  14. Integrating catalytic coal gasifiers with solid oxide fuel cells

    SciTech Connect (OSTI)

    Siefert, N.; Shamsi, A.; Shekhawat, D.; Berry, D.

    2010-01-01

    A review was conducted for coal gasification technologies that integrate with solid oxide fuel cells (SOFC) to achieve system efficiencies near 60% while capturing and sequestering >90% of the carbon dioxide [1-2]. The overall system efficiency can reach 60% when a) the coal gasifier produces a syngas with a methane composition of roughly 25% on a dry volume basis, b) the carbon dioxide is separated from the methane-rich synthesis gas, c) the methane-rich syngas is sent to a SOFC, and d) the off-gases from the SOFC are recycled back to coal gasifier. The thermodynamics of this process will be reviewed and compared to conventional processes in order to highlight where available work (i.e. exergy) is lost in entrained-flow, high-temperature gasification, and where exergy is lost in hydrogen oxidation within the SOFC. The main advantage of steam gasification of coal to methane and carbon dioxide is that the amount of exergy consumed in the gasifier is small compared to conventional, high temperature, oxygen-blown gasifiers. However, the goal of limiting the amount of exergy destruction in the gasifier has the effect of limiting the rates of chemical reactions. Thus, one of the main advantages of steam gasification leads to one of its main problems: slow reaction kinetics. While conventional entrained-flow, high-temperature gasifiers consume a sizable portion of the available work in the coal oxidation, the consumed exergy speeds up the rates of reactions. And while the rates of steam gasification reactions can be increased through the use of catalysts, only a few catalysts can meet cost requirements because there is often significant deactivation due to chemical reactions between the inorganic species in the coal and the catalyst. Previous research into increasing the kinetics of steam gasification will be reviewed. The goal of this paper is to highlight both the challenges and advantages of integrating catalytic coal gasifiers with SOFCs.

  15. Long-term, low-temperature oxidation of PWR spent fuel: Interim transition report

    SciTech Connect (OSTI)

    Einziger, R.E.; Buchanan, H.C.

    1988-05-01

    Since some of the fuel rods will be breached and eventually most of the cladding will corrode, exposing fuel, one factor influencing the ability of spent fuel to retain radionuclides is its oxidation state in the expected moist air atmosphere. Oxidation of the fuel could split the cladding, exposing additional fuel and changing the leaching characteristics. Thermodynamically, there is no reason why UO{sub 2} should not oxidize completely to UO{sub 3} at repository temperatures. The underlying uncertainty is the rate of oxidation. Extrapolation of higher temperature data indicates that insufficient oxidation to convert all of the fuel to U{sub 3}O{sub 8} will occur during the first 10,000 years. However, lower oxidation states, such as U{sub 4}O{sub 9} and U{sub 3}O{sub 7}, might form. To date, the tests have run between 3200 and 4100 hours out of a planned 16,000-hour duration. Some preliminary conclusions can be drawn: (1) Moisture content of the air has no significant effect on oxidation rate, (2) the data have an uncertainty of 15 to 20%, which must be accounted for in the interpretation of single sample tests, and (3) below 175{degree}C, the oxidation rate is dependent on the particle size in the sample. The smaller particles oxidize more rapidly. 19 refs., 23 figs., 7 tabs.

  16. Microstructural Characterization of U-7Mo/Al-Si Alloy Matrix Dispersion Fuel Plates Fabricated at 500°C

    SciTech Connect (OSTI)

    Dennis D. Keiser, Jr.; Jan-Fong Jue; Bo Yao; Emmanuel Perez; Yongho Sohn; Curtis R. Clark

    2011-05-01

    The starting microstructure of a dispersion fuel plate will impact the overall performance of the plate during irradiation. To improve the understanding of the as-fabricated microstructures of U–Mo dispersion fuel plates, particularly the interaction layers that can form between the fuel particles and the matrix, scanning electron microscopy (SEM) and transmission electron microscopy (TEM) analyses have been performed on samples from depleted U–7Mo (U–7Mo) dispersion fuel plates with either Al–2 wt.% Si(Al–2Si) or AA4043 alloy matrix. It was observed that in the thick interaction layers, U(Al, Si)3 and U6Mo4Al43 were present, and in the thin interaction layers, (U, Mo) (Al, Si)3, U(Al, Si)4, U3Si3Al2, U3Si5, and possibly USi-type phases were observed. The U3Si3Al2 phase contained some Mo. Based on the results of this investigation, the time that a dispersion fuel plate is exposed to a relatively high temperature during fabrication will impact the nature of the interaction layers around the fuel particles. Uniformly thin, Si-rich layers will develop around the U–7Mo particles for shorter exposure times, and thicker, Si-depleted layers will develop for the longer exposure times.

  17. Novel Electrode Materials for Low-Temperature Solid-Oxide Fuel Cells

    SciTech Connect (OSTI)

    Shaowu Zha; Meilin Liu

    2005-03-23

    Composites electrodes consisting of silver and bismuth vanadates exhibit remarkable catalytic activity for oxygen reduction at 500-550 C and greatly reduce the cathode-electrolyte (doped ceria) resistances of low temperature SOFCs, down to about 0.53 {omega}cm{sup 2} at 500 C and 0.21 {omega}cm{sup 2} at 550 C. The observed power densities of 231, 332, and 443 mWcm-2 at 500, 525 and 550 C, respectively, make it possible to operate SOFCs at temperatures about 500 C. Fuel cell performance depends strongly on the anode microstructure, which is determined by the anode compositions and fabrication conditions. Four types of anodes with two kinds of NiO and GDC powders were investigated. By carefully adjusting the anode microstructure, the GDC electrolyte/anode interfacial polarization resistances reduced dramatically. The interfacial resistance at 600 C decreased from 1.61 {omega} cm{sup 2} for the anodes prepared using commercially available powders to 0.06 {omega} cm{sup 2} for those prepared using powders derived from a glycine-nitrate process. Although steam reforming or partial oxidation is effective in avoiding carbon deposition of hydrocarbon fuels, it increases the operating cost and reduces the energy efficiency. Anode-supported SOFCs with an electrolyte of 20 {micro}m-thick Gd-doped ceria (GDC) were fabricated by co-pressing. A catalyst (1 %wt Pt dispersed on porous Gd-doped ceria) for pre-reforming of propane was developed with relatively low steam to carbon (S/C) ratio ({approx}0.5), coupled with direct utilization of the reformate in low-temperature SOFCs. Propane was converted to smaller molecules during pre-reforming, including H{sub 2}, CH{sub 4}, CO, and CO{sub 2}. A peak power density of 247 mW/cm{sup 2} was observed when pre-reformed propane was directly fed to an SOFC operated at 600 C. No carbon deposition was observed in the fuel cell for a continuous operation of 10 hours at 600 C. The ability of producing vastly different microstructures and morphologies of the very same material is critical to the fabrication of functionally graded electrodes for solid-state electrochemical devices such as SOFCs and lithium batteries. By carefully adjusting deposition parameters, we have successfully produced oxide nano-powders with the size of 30 {approx} 200 nm. Porous films with various microstructures and morphologies are also deposited on several substrates by systematic adjustment of the deposition parameters. Highly porous, excellently bonded and nano-structured electrodes fabricated by combustion CVD exhibit extremely high surface area and remarkable catalytic activities. Using in situ potential dependent FTIR emission spectroscopy, we have found evidence for two, possibly three distinct di-oxygen species present on the electrode surface. We have successfully identified which surface oxygen species is present under a particular electrical or chemical condition and have been able to deduce the reaction mechanisms. This technique will be used to probe the gas-solid interactions at or near the TPB and on the surfaces of mixed-conducting electrodes in an effort to understand the molecular processes relevant to the intrinsic catalytic activity. Broad spectral features are assigned to the electrochemical-polarization-induced changes in the optical properties of the electrode surface layer.

  18. Microstructural Characterization of High Burn-up Mixed Oxide Fast Reactor Fuel

    SciTech Connect (OSTI)

    Melissa C. Teague; Brian P. Gorman; Steven L. Hayes; Douglas L. Porter; Jeffrey King

    2013-10-01

    High burn-up mixed oxide fuel with local burn-ups of 3.423.7% FIMA (fissions per initial metal atom) were destructively examined as part of a research project to understand the performance of oxide fuel at extreme burn-ups. Optical metallography of fuel cross-sections measured the fuel-to-cladding gap, clad thickness, and central void evolution in the samples. The fuel-to-cladding gap closed significantly in samples with burn-ups below 79% FIMA. Samples with burn-ups in excess of 79% FIMA had a reopening of the fuel-to-cladding gap and evidence of joint oxide-gain (JOG) formation. Signs of axial fuel migration to the top of the fuel column were observed in the fuel pin with a peak burn-up of 23.7% FIMA. Additionally, high burn-up structure (HBS) was observed in the two highest burn-up samples (23.7% and 21.3% FIMA). The HBS layers were found to be 35 times thicker than the layers found in typical LWR fuel. The results of the study indicate that formation of JOG and or HBS prevents any significant fuel-cladding mechanical interaction from occurring, thereby extending the potential life of the fuel elements.

  19. Molten salt extraction of transuranic and reactive fission products from used uranium oxide fuel

    DOE Patents [OSTI]

    Herrmann, Steven Douglas

    2014-05-27

    Used uranium oxide fuel is detoxified by extracting transuranic and reactive fission products into molten salt. By contacting declad and crushed used uranium oxide fuel with a molten halide salt containing a minor fraction of the respective uranium trihalide, transuranic and reactive fission products partition from the fuel to the molten salt phase, while uranium oxide and non-reactive, or noble metal, fission products remain in an insoluble solid phase. The salt is then separated from the fuel via draining and distillation. By this method, the bulk of the decay heat, fission poisoning capacity, and radiotoxicity are removed from the used fuel. The remaining radioactivity from the noble metal fission products in the detoxified fuel is primarily limited to soft beta emitters. The extracted transuranic and reactive fission products are amenable to existing technologies for group uranium/transuranic product recovery and fission product immobilization in engineered waste forms.

  20. Report on Development of Concepts for the Advanced Casting System in Support of the Deployment of a Remotely Operable Research Scale Fuel Fabrication Facility for Metal Fuel

    SciTech Connect (OSTI)

    Ken Marsden

    2007-03-01

    Demonstration of recycle processes with low transuranic losses is key to the successful implementation of the Global Nuclear Energy Partnership strategy to manage spent fuel. It is probable that these recycle processes will include remote fuel fabrication. This report outlines the strategy to develop and implement a remote metal fuel casting process with minimal transuranic losses. The approach includes a bench-scale casting system to develop materials, methods, and perform tests with transuranics, and an engineering-scale casting system to demonstrate scalability and remote operability. These systems will be built as flexible test beds allowing exploration of multiple fuel casting approaches. The final component of the remote fuel fabrication demonstration culminates in the installation of an advanced casting system in a hot cell to provide integrated remote operation experience with low transuranic loss. Design efforts and technology planning have begun for the bench-scale casting system, and this will become operational in fiscal year 2008, assuming appropriate funding. Installation of the engineering-scale system will follow in late fiscal year 2008, and utilize materials and process knowledge gained in the bench-scale system. Assuming appropriate funding, the advanced casting system will be installed in a remote hot cell at the end of fiscal year 2009.

  1. Generation and Solid Oxide Fuel Cell Carbon Sequestration in Northwest Indiana

    SciTech Connect (OSTI)

    Kevin Peavey; Norm Bessette

    2007-09-30

    The objective of the project is to develop the technology capable of capturing all carbon monoxide and carbon dioxide from natural gas fueled Solid Oxide Fuel Cell (SOFC) system. In addition, the technology to electrochemically oxidize any remaining carbon monoxide to carbon dioxide will be developed. Success of this R&D program would allow for the generation of electrical power and thermal power from a fossil fuel driven SOFC system without the carbon emissions resulting from any other fossil fueled power generationg system.

  2. Fundamental Studies of Irradiation-Induced Defect Formation and Fission Product Dynamics in Oxide Fuels

    SciTech Connect (OSTI)

    James Stubbins

    2012-12-19

    The objective of this research program is to address major nuclear fuels performance issues for the design and use of oxide-type fuels in the current and advanced nuclear reactor applications. Fuel performance is a major issue for extending fuel burn-up which has the added advantage of reducing the used fuel waste stream. It will also be a significant issue with respect to developing advanced fuel cycle processes where it may be possible to incorporate minor actinides in various fuel forms so that they can be 'burned' rather than join the used fuel waste stream. The potential to fission or transmute minor actinides and certain long-lived fission product isotopes would transform the high level waste storage strategy by removing the need to consider fuel storage on the millennium time scale.

  3. The Case for Natural Gas Fueled Solid Oxide Fuel Cell Power Systems for Distributed Generation

    SciTech Connect (OSTI)

    Chick, Lawrence A.; Weimar, Mark R.; Whyatt, Greg A.; Powell, Michael R.

    2015-02-01

    Natural-gas-fueled solid oxide fuel cell (NGSOFC) power systems yield electrical conversion efficiencies exceeding 60% and may become a viable alternative for distributed generation (DG) if stack life and manufacturing economies of scale can be realized. Currently, stacks last approximately 2 years and few systems are produced each year because of the relatively high cost of electricity from the systems. If mass manufacturing (10,000 units per year) and a stack life of 15 years can be reached, the cost of electricity from an NGSOFC system is estimated to be about 7.7 ¢/kWh, well within the price of commercial and residential retail prices at the national level (9.9-10¢/kWh and 11-12 ¢/kWh, respectively). With an additional 5 ¢/kWh in estimated additional benefits from DG, NGSOFC could be well positioned to replace the forecasted 59-77 gigawatts of capacity loss resulting from coal plant closures due to stricter emissions regulations and low natural gas prices.

  4. Method of fabricating a monolithic core for a solid oxide fuela cell

    DOE Patents [OSTI]

    Zwick, S.A.; Ackerman, J.P.

    1983-10-12

    A method is disclosed for forming a core for use in a solid oxide fuel cell that electrochemically combines fuel and oxidant for generating galvanic output. The core has an array of electrolyte and interconnect walls that are substantially devoid of any composite inert materials for support consisting instead only of the active anode, cathode, electrolyte and interconnect materials. Each electrolyte wall consists of cathode and anode materials sandwiching electrolyte material therebetween, and each interconnect wall consists of the cathode and anode materials sandwiching interconnect material therebetween. The electrolyte and interconnect walls define a plurality of substantially parallel core passageways alternately having respectively the inside faces thereof with only the anode material or with only the cathode material exposed. In the wall structure, the electrolyte and interconnect materials are only 0.002 to 0.01 cm thick; and the cathode and anode materials are only 0.002 to 0.05 cm thick. The method consists of building up the electrolyte and interconnect walls by depositing each material on individually and endwise of the wall itself, where each material deposit is sequentially applied for one cycle; and where the depositing cycle is repeated many times until the material buildup is sufficient to formulate the core. The core is heat cured to become dimensionally and structurally stable.

  5. Comparative Study of Laboratory-Scale and Prototypic Production-Scale Fuel Fabrication Processes and Product Characteristics

    SciTech Connect (OSTI)

    Douglas W. Marshall

    2014-10-01

    An objective of the High Temperature Gas Reactor fuel development and qualification program for the United States Department of Energy has been to qualify fuel fabricated in prototypic production-scale equipment. The quality and characteristics of the tristructural isotropic coatings on fuel kernels are influenced by the equipment scale and processing parameters. Some characteristics affecting product quality were suppressed while others have become more significant in the larger equipment. Changes to the composition and method of producing resinated graphite matrix material has eliminated the use of hazardous, flammable liquids and enabled it to be procured as a vendor-supplied feed stock. A new method of overcoating TRISO particles with the resinated graphite matrix eliminates the use of hazardous, flammable liquids, produces highly spherical particles with a narrow size distribution, and attains product yields in excess of 99%. Compact fabrication processes have been scaled-up and automated with relatively minor changes to compact quality to manual laboratory-scale processes. The impact on statistical variability of the processes and the products as equipment was scaled are discussed. The prototypic production-scale processes produce test fuels that meet fuel quality specifications.

  6. HIGH-TEMPERATURE TUBULAR SOLID OXIDE FUEL CELL GENERATOR DEVELOPMENT

    SciTech Connect (OSTI)

    S.E. Veyo

    1998-09-01

    During the Westinghouse/USDOE Cooperative Agreement period of November 1, 1990 through November 30, 1997, the Westinghouse solid oxide fuel cell has evolved from a 16 mm diameter, 50 cm length cell with a peak power of 1.27 watts/cm to the 22 mm diameter, 150 cm length dimensions of today's commercial prototype cell with a peak power of 1.40 watts/cm. Accompanying the increase in size and power density was the elimination of an expensive EVD step in the manufacturing process. Demonstrated performance of Westinghouse's tubular SOFC includes a lifetime cell test which ran for a period in excess of 69,000 hours, and a fully integrated 25 kWe-class system field test which operated for over 13,000 hours at 90% availability with less than 2% performance degradation over the entire period. Concluding the agreement period, a 100 kW SOFC system successfully passed its factory acceptance test in October 1997 and was delivered in November to its demonstration site in Westervoort, The Netherlands.

  7. Formation of thin walled ceramic solid oxide fuel cells

    DOE Patents [OSTI]

    Claar, Terry D. (Tisle, IL); Busch, Donald E. (Hinsdale, IL); Picciolo, John J. (Lockport, IL)

    1989-01-01

    To reduce thermal stress and improve bonding in a high temperature monolithic solid oxide fuel cell (SOFC), intermediate layers are provided between the SOFC's electrodes and electrolyte which are of different compositions. The intermediate layers are comprised of a blend of some of the materials used in the electrode and electrolyte compositions. Particle size is controlled to reduce problems involving differential shrinkage rates of the various layers when the entire structure is fired at a single temperature, while pore formers are provided in the electrolyte layers to be removed during firing for the formation of desired pores in the electrode layers. Each layer includes a binder in the form of a thermosetting acrylic which during initial processing is cured to provide a self-supporting structure with the ceramic components in the green state. A self-supporting corrugated structure is thus formed prior to firing, which the organic components of the binder and plasticizer removed during firing to provide a high strength, high temperature resistant ceramic structure of low weight and density.

  8. Method and apparatus for assembling solid oxide fuel cells

    DOE Patents [OSTI]

    Szreders, Bernard E.; Campanella, Nicholas

    1989-01-01

    A plurality of jet air tubes are supported and maintained in a spaced matrix array by a positioning/insertion assembly for insertion in respective tubes of a solid oxide fuel cell (SOFC) in the assembly of an SOFC module. The positioning/insertion assembly includes a plurality of generally planar, elongated, linear vanes which are pivotally mounted at each end thereof to a support frame. The vanes, which each include a plurality of spaced slots along the facing edges thereof, may be pivotally displaced from a generally vertical orientation, wherein each jet air tube is positioned within and engaged by the aligned slots of a plurality of paired upper and lower vanes to facilitate their insertion in respective aligned SOFC tubes arranged in a matrix array, to an inclined orientation, wherein the jet air tubes may be removed from the positioning/insertion assembly after being inserted in the SOFC tubes. A rectangular compression assembly of adjustable size is adapted to receive and squeeze a matrix of SOFC tubes so as to compress the inter-tube nickel felt conductive pads which provide series/parallel electrical connection between adjacent SOFCs, with a series of increasingly larger retainer frames used to maintain larger matrices of SOFC tubes in position. Expansion of the SOFC module housing at the high operating temperatures of the SOFC is accommodated by conductive, flexible, resilient expansion, connector bars which provide support and electrical coupling at the top and bottom of the SOFC module housing.

  9. Apparatus tube configuration and mounting for solid oxide fuel cells

    DOE Patents [OSTI]

    Zymboly, Gregory E. (Murrysville, PA)

    1993-01-01

    A generator apparatus (10) is made containing long, hollow, tubular, fuel cells containing an inner air electrode (64), an outer fuel electrode (56), and solid electrolyte (54) therebetween, placed between a fuel distribution board (29) and a board (32) which separates the combustion chamber (16) from the generating chamber (14), where each fuel cell has an insertable open end and in insertable, plugged, closed end (44), the plugged end being inserted into the fuel distribution board (29) and the open end being inserted through the separator board (32) where the plug (60) is completely within the fuel distribution board (29).

  10. Zinc Oxide Thin Films Fabricated with Direct Current Magnetron Sputtering Deposition Technique

    SciTech Connect (OSTI)

    Hoon, Jian-Wei; Chan, Kah-Yoong; Krishnasamy, Jegenathan; Tou, Teck-Yong

    2011-03-30

    Zinc oxide (ZnO) is a very promising material for emerging large area electronic applications including thin-film sensors, transistors and solar cells. We fabricated ZnO thin films by employing direct current (DC) magnetron sputtering deposition technique. ZnO films with different thicknesses ranging from 100 nm to 1020 nm were deposited on silicon (Si) substrate. The deposition pressure was varied from 12 mTorr to 25 mTorr. The influences of the film thickness and the deposition pressure on structural properties of the ZnO films were investigated using Mahr surface profilometer and atomic force microscopy (AFM). The experimental results reveal that the film thickness and the deposition pressure play significant role in the structural formation of the deposited ZnO thin films. ZnO films deposited on Si substrates are promising for variety of thin-film sensor applications.

  11. Autothermal and partial oxidation reformer-based fuel processor, method for improving catalyst function in autothermal and partial oxidation reformer-based processors

    DOE Patents [OSTI]

    Ahmed, Shabbir; Papadias, Dionissios D.; Lee, Sheldon H. D.; Ahluwalia, Rajesh K.

    2013-01-08

    The invention provides a fuel processor comprising a linear flow structure having an upstream portion and a downstream portion; a first catalyst supported at the upstream portion; and a second catalyst supported at the downstream portion, wherein the first catalyst is in fluid communication with the second catalyst. Also provided is a method for reforming fuel, the method comprising contacting the fuel to an oxidation catalyst so as to partially oxidize the fuel and generate heat; warming incoming fuel with the heat while simultaneously warming a reforming catalyst with the heat; and reacting the partially oxidized fuel with steam using the reforming catalyst.

  12. FY 2014 Solid Oxide Fuel Cell Project Selections | Department...

    Office of Energy Efficiency and Renewable Energy (EERE) Indexed Site

    The project will include fabrication and testing of cells, modeling the thermodynamics and ... and evaluate their performance in comparison to more established cathode materials. ...

  13. Solid oxide fuel cells for transportation: A clean, efficient alternative for propulsion

    SciTech Connect (OSTI)

    Kumar, R.; Krumpelt, M.; Myles, K.M.

    1993-04-01

    Fuel cells show great promise for providing clean and efficient transportation power. Of the fuel cell propulsion systems under investigation, the solid oxide fuel cell (SOFC) is particularly attractive for heavy duty transportation applications that have a relatively long duty cycle, such as locomotives, trucks, and barges. Advantages of the SOFC include a simple, compact system configuration; inherent fuel flexibility for hydrocarbon and alternative fuels; and minimal water management. The specific advantages of the SOFC for powering a railroad locomotive are examined. Feasibility, practicality, and safety concerns regarding SOFCs in transportation applications are discussed, as am the major R&D issues.

  14. Solid oxide fuel cells for transportation: A clean, efficient alternative for propulsion

    SciTech Connect (OSTI)

    Kumar, R.; Krumpelt, M.; Myles, K.M.

    1993-01-01

    Fuel cells show great promise for providing clean and efficient transportation power. Of the fuel cell propulsion systems under investigation, the solid oxide fuel cell (SOFC) is particularly attractive for heavy duty transportation applications that have a relatively long duty cycle, such as locomotives, trucks, and barges. Advantages of the SOFC include a simple, compact system configuration; inherent fuel flexibility for hydrocarbon and alternative fuels; and minimal water management. The specific advantages of the SOFC for powering a railroad locomotive are examined. Feasibility, practicality, and safety concerns regarding SOFCs in transportation applications are discussed, as am the major R D issues.

  15. Combination nickel foam expanded nickel screen electrical connection supports for solid oxide fuel cells

    DOE Patents [OSTI]

    Draper, Robert; Prevish, Thomas; Bronson, Angela; George, Raymond A.

    2007-01-02

    A solid oxide fuel assembly is made, wherein rows (14, 25) of fuel cells (17, 19, 21, 27, 29, 31), each having an outer interconnection (20) and an outer electrode (32), are disposed next to each other with corrugated, electrically conducting expanded metal mesh member (22) between each row of cells, the corrugated mesh (22) having top crown portions and bottom portions, where the top crown portion (40) have a top bonded open cell nickel foam (51) which contacts outer interconnections (20) of the fuel cells, said mesh and nickel foam electrically connecting each row of fuel cells, and where there are no more metal felt connections between any fuel cells.

  16. Solid oxide fuel cell processing using plasma arc spray deposition techniques. Final report

    SciTech Connect (OSTI)

    Ray, E.R.; Spengler, C.J.; Herman, H.

    1991-07-01

    The Westinghouse Electric Corporation, in conjunction with the Thermal Spray Laboratory of the State University of New York, Stony Brook, investigated the fabrication of a gas-tight interconnect layer on a tubular solid oxide fuel cell with plasma arc spray deposition. The principal objective was to determine the process variables for the plasma spray deposition of an interconnect with adequate electrical conductivity and other desired properties. Plasma arc spray deposition is a process where the coating material in powder form is heated to or above its melting temperature, while being accelerated by a carrier gas stream through a high power electric arc. The molten powder particles are directed at the substrate, and on impact, form a coating consisting of many layers of overlapping, thin, lenticular particles or splats. The variables investigated were gun power, spray distance, powder feed rate, plasma gas flow rates, number of gun passes, powder size distribution, injection angle of powder into the plasma plume, vacuum or atmospheric plasma spraying, and substrate heating. Typically, coatings produced by both systems showed bands of lanthanum rich material and cracking with the coating. Preheating the substrate reduced but did not eliminate internal coating cracking. A uniformly thick, dense, adherent interconnect of the desired chemistry was finally achieved with sufficient gas- tightness to allow fabrication of cells and samples for measurement of physical and electrical properties. A cell was tested successfully at 1000{degree}C for over 1,000 hours demonstrating the mechanical, electrical, and chemical stability of a plasma-arc sprayed interconnect layer.

  17. Solid oxide fuel cell processing using plasma arc spray deposition techniques

    SciTech Connect (OSTI)

    Ray, E.R.; Spengler, C.J.; Herman, H.

    1991-07-01

    The Westinghouse Electric Corporation, in conjunction with the Thermal Spray Laboratory of the State University of New York, Stony Brook, investigated the fabrication of a gas-tight interconnect layer on a tubular solid oxide fuel cell with plasma arc spray deposition. The principal objective was to determine the process variables for the plasma spray deposition of an interconnect with adequate electrical conductivity and other desired properties. Plasma arc spray deposition is a process where the coating material in powder form is heated to or above its melting temperature, while being accelerated by a carrier gas stream through a high power electric arc. The molten powder particles are directed at the substrate, and on impact, form a coating consisting of many layers of overlapping, thin, lenticular particles or splats. The variables investigated were gun power, spray distance, powder feed rate, plasma gas flow rates, number of gun passes, powder size distribution, injection angle of powder into the plasma plume, vacuum or atmospheric plasma spraying, and substrate heating. Typically, coatings produced by both systems showed bands of lanthanum rich material and cracking with the coating. Preheating the substrate reduced but did not eliminate internal coating cracking. A uniformly thick, dense, adherent interconnect of the desired chemistry was finally achieved with sufficient gas- tightness to allow fabrication of cells and samples for measurement of physical and electrical properties. A cell was tested successfully at 1000{degree}C for over 1,000 hours demonstrating the mechanical, electrical, and chemical stability of a plasma-arc sprayed interconnect layer.

  18. A rational minor actinide (MA) recycling concept based on innovative oxide fuel with high AM content

    SciTech Connect (OSTI)

    Tanaka, Kenya; Sato, Isamu; Ishii, Tetsuya; Yoshimochi, Hiroshi; Asaga, Takeo; Kurosaki, Ken

    2007-07-01

    A rational MA recycle concept based on high Am content fuel has been proposed. A design study of an Am- MOX fabrication plant, which is a key facility for the MA recycle concept, has been done and the facility concept was clarified from the viewpoint of basic process viability. Preliminary cost estimation suggested that the total construction cost of the MA recycle facilities including Am-MOX, Np-MOX and MA recovery could be comparable with that of the large scale LWR-MOX fabrication plant required for plutonium in LWR fuel cycle. (authors)

  19. Oxidative alteration of spent fuel in a silica-rich environment: SEM/AEM

    Office of Scientific and Technical Information (OSTI)

    investigation and geochemical modeling (Conference) | SciTech Connect Oxidative alteration of spent fuel in a silica-rich environment: SEM/AEM investigation and geochemical modeling Citation Details In-Document Search Title: Oxidative alteration of spent fuel in a silica-rich environment: SEM/AEM investigation and geochemical modeling Correctly identifying the possible alteration products and accurately predicting their occurrence in a repository-relevant environment are the key for the

  20. Environmental resistance of oxide tags fabricated on 304L stainless steel via nanosecond pulsed laser irradiation

    SciTech Connect (OSTI)

    Lawrence, Samantha Kay; Adams, David P.; Bahr, David F.; Moody, Neville R.

    2015-11-14

    Nanosecond pulsed laser irradiation was used to fabricate colored, mechanically robust oxide “tags” on 304L stainless steel. Immersion in simulated seawater solution, salt fog exposure, and anodic polarization in a 3.5% NaCl solution were employed to evaluate the environmental resistance of these oxide tags. Single layer oxides outside a narrow thickness range (~ 100–150 nm) are susceptible to dissolution in chloride containing environments. The 304L substrates immediately beneath the oxides corrode severely—attributed to Cr-depletion in the melt zone during laser processing. For the first time, multilayered oxides were fabricated with pulsed laser irradiation in an effort to expand the protective thickness range while also increasing the variety of film colors attainable in this range. Layered films grown using a laser scan rate of 475 mm/s are more resistant to both localized and general corrosion than oxides fabricated at 550 mm/s. Furthermore, in the absence of pre-processing to mitigate Cr-depletion, layered films can enhance environmental stability of the system.

  1. CRACK GROWTH ANALYSIS OF SOLID OXIDE FUEL CELL ELECTROLYTES

    SciTech Connect (OSTI)

    S. Bandopadhyay; N. Nagabhushana

    2003-10-01

    Defects and Flaws control the structural and functional property of ceramics. In determining the reliability and lifetime of ceramics structures it is very important to quantify the crack growth behavior of the ceramics. In addition, because of the high variability of the strength and the relatively low toughness of ceramics, a statistical design approach is necessary. The statistical nature of the strength of ceramics is currently well recognized, and is usually accounted for by utilizing Weibull or similar statistical distributions. Design tools such as CARES using a combination of strength measurements, stress analysis, and statistics are available and reasonably well developed. These design codes also incorporate material data such as elastic constants as well as flaw distributions and time-dependent properties. The fast fracture reliability for ceramics is often different from their time-dependent reliability. Further confounding the design complexity, the time-dependent reliability varies with the environment/temperature/stress combination. Therefore, it becomes important to be able to accurately determine the behavior of ceramics under simulated application conditions to provide a better prediction of the lifetime and reliability for a given component. In the present study, Yttria stabilized Zirconia (YSZ) of 9.6 mol% Yttria composition was procured in the form of tubes of length 100 mm. The composition is of interest as tubular electrolytes for Solid Oxide Fuel Cells. Rings cut from the tubes were characterized for microstructure, phase stability, mechanical strength (Weibull modulus) and fracture mechanisms. The strength at operating condition of SOFCs (1000 C) decreased to 95 MPa as compared to room temperature strength of 230 MPa. However, the Weibull modulus remains relatively unchanged. Slow crack growth (SCG) parameter, n = 17 evaluated at room temperature in air was representative of well studied brittle materials. Based on the results, further work was planned to evaluate the strength degradation, modulus and failure in more representative environment of the SOFCs.

  2. Filled glass composites for sealing of solid oxide fuel cells.

    SciTech Connect (OSTI)

    Tandon, Rajan; Widgeon, Scarlett Joyce; Garino, Terry J.; Brochu, Mathieu; Gauntt, Bryan D.; Corral, Erica L.; Loehman, Ronald E.

    2009-04-01

    Glasses filled with ceramic or metallic powders have been developed for use as seals for solid oxide fuel cells (SOFC's) as part of the U.S. Department of Energy's Solid State Energy Conversion Alliance (SECA) Program. The composites of glass (alkaline earth-alumina-borate) and powders ({approx}20 vol% of yttria-stabilized zirconia or silver) were shown to form seals with SOFC materials at or below 900 C. The type and amount of powder were adjusted to optimize thermal expansion to match the SOFC materials and viscosity. Wetting studies indicated good wetting was achieved on the micro-scale and reaction studies indicated that the degree of reaction between the filled glasses and SOFC materials, including spinel-coated 441 stainless steel, at 750 C is acceptable. A test rig was developed for measuring strengths of seals cycled between room temperature and typical SOFC operating temperatures. Our measurements showed that many of the 410 SS to 410 SS seals, made using silver-filled glass composites, were hermetic at 0.2 MPa (2 atm.) of pressure and that seals that leaked could be resealed by briefly heating them to 900 C. Seal strength measurements at elevated temperature (up to 950 C), measured using a second apparatus that we developed, indicated that seals maintained 0.02 MPa (0.2 atm.) overpressures for 30 min at 750 C with no leakage. Finally, the volatility of the borate component of sealing glasses under SOFC operational conditions was studied using weight loss measurements and found by extrapolation to be less than 5% for the projected SOFC lifetime.

  3. A reduced temperature solid oxide fuel cell with three-dimensionally ordered macroporous cathode

    SciTech Connect (OSTI)

    Liang, B.; Suzuki, T.; Hamamoto, K.; Yamaguchi, T.; Sumi, H.; Fujishiro, Y.; Ingram, B. J.; Carter, J. D.

    2012-01-01

    Three-dimensionally ordered macroporous cathode was fabricated for a zirconia based micro-tubular solid oxide fuel cells (SOFCs). Three different cathodes (cathode A, no pore former; cathode B, with pore former (1.5 {micro}m in diameter); cathode C, with pore former (0.8 {micro}m in diameter)) were compared to investigate how the microstructure of it affected the cell performance at various operating temperatures. Micro-sized pores were well distributed within cathode B and C. The total porosity of cathode A is 35%, while it respectively reached 42 and 50% for cathodes B and C. At the same time, the specific surface area of them was 28.8 and 52.0% larger than that of the cathode A. As a result, the peak power density of the zirconia based cell, with cathode C, was 0.25 and 0.56 W cm{sup -2} at 550 and 600 C, while the respective value was just 0.11 and 0.30 W cm{sup -2} for the cell with cathode A. Thus, optimizing microstructure of cathode should be one of the best approaches for lowering the operating temperature for SOFCs.

  4. DOE Selects Research Projects to Advance Solid Oxide Fuel Cell Technology

    Broader source: Energy.gov [DOE]

    The Department of Energy’s (DOE) National Energy Technology Laboratory (NETL) has selected for funding 16 solid oxide fuel cell (SOFC) technology research projects. Fuel cells are a modular, efficient, and virtually pollution-free power generation technology. In Fiscal Year 2015, NETL issued two funding opportunities announcements (FOAs) to support programs that enable the development and deployment of this energy technology.

  5. Decay Heat Calculations for PWR and BWR Assemblies Fueled with Uranium and Plutonium Mixed Oxide Fuel using SCALE

    SciTech Connect (OSTI)

    Ade, Brian J; Gauld, Ian C

    2011-10-01

    In currently operating commercial nuclear power plants (NPP), there are two main types of nuclear fuel, low enriched uranium (LEU) fuel, and mixed-oxide uranium-plutonium (MOX) fuel. The LEU fuel is made of pure uranium dioxide (UO{sub 2} or UOX) and has been the fuel of choice in commercial light water reactors (LWRs) for a number of years. Naturally occurring uranium contains a mixture of different uranium isotopes, primarily, {sup 235}U and {sup 238}U. {sup 235}U is a fissile isotope, and will readily undergo a fission reaction upon interaction with a thermal neutron. {sup 235}U has an isotopic concentration of 0.71% in naturally occurring uranium. For most reactors to maintain a fission chain reaction, the natural isotopic concentration of {sup 235}U must be increased (enriched) to a level greater than 0.71%. Modern nuclear reactor fuel assemblies contain a number of fuel pins potentially having different {sup 235}U enrichments varying from {approx}2.0% to {approx}5% enriched in {sup 235}U. Currently in the United States (US), all commercial nuclear power plants use UO{sub 2} fuel. In the rest of the world, UO{sub 2} fuel is still commonly used, but MOX fuel is also used in a number of reactors. MOX fuel contains a mixture of both UO{sub 2} and PuO{sub 2}. Because the plutonium provides the fissile content of the fuel, the uranium used in MOX is either natural or depleted uranium. PuO{sub 2} is added to effectively replace the fissile content of {sup 235}U so that the level of fissile content is sufficiently high to maintain the chain reaction in an LWR. Both reactor-grade and weapons-grade plutonium contains a number of fissile and non-fissile plutonium isotopes, with the fraction of fissile and non-fissile plutonium isotopes being dependent on the source of the plutonium. While only RG plutonium is currently used in MOX, there is the possibility that WG plutonium from dismantled weapons will be used to make MOX for use in US reactors. Reactor-grade plutonium in MOX fuel is generally obtained from reprocessed irradiated nuclear fuel, whereas weapons-grade plutonium is obtained from decommissioned nuclear weapons material and thus has a different plutonium (and other actinides) concentration. Using MOX fuel instead of UOX fuel has potential impacts on the neutronic performance of the nuclear fuel and the design of the nuclear fuel must take these differences into account. Each of the plutonium sources (RG and WG) has different implications on the neutronic behavior of the fuel because each contains a different blend of plutonium nuclides. The amount of heat and the number of neutrons produced from fission of plutonium nuclides is different from fission of {sup 235}U. These differences in UOX and MOX do not end at discharge of the fuel from the reactor core - the short- and long-term storage of MOX fuel may have different requirements than UOX fuel because of the different discharged fuel decay heat characteristics. The research documented in this report compares MOX and UOX fuel during storage and disposal of the fuel by comparing decay heat rates for typical pressurized water reactor (PWR) and boiling water reactor (BWR) fuel assemblies with and without weapons-grade (WG) and reactor-grade (RG) MOX fuel.

  6. Innovative Self-Healing Seals for Solid Oxide Fuel Cells (SOFC)

    SciTech Connect (OSTI)

    Raj Singh

    2012-06-30

    Solid oxide fuel cell (SOFC) technology is critical to several national initiatives. Solid State Energy Conversion Alliance (SECA) addresses the technology needs through its comprehensive programs on SOFC. A reliable and cost-effective seal that works at high temperatures is essential to the long-term performance of the SOFC for 40,000 hours at 800°C. Consequently, seals remain an area of highest priority for the SECA program and its industry teams. An innovative concept based on self-healing glasses was advanced and successfully demonstrated through seal tests for 3000 hours and 300 thermal cycles to minimize internal stresses under both steady state and thermal transients for making reliable seals for the SECA program. The self-healing concept requires glasses with low viscosity at the SOFC operating temperature of 800°C but this requirement may lead to excessive flow of the glass in areas forming the seal. To address this challenge, a modification to glass properties by addition of particulate fillers is pursued in the project. The underlying idea is that a non-reactive ceramic particulate filler is expected to form glass-ceramic composite and increase the seal viscosity thereby increasing the creep resistance of the glass-composite seals under load. The objectives of the program are to select appropriate filler materials for making glass-composite, fabricate glass-composites, measure thermal expansion behaviors, and determine stability of the glass-composites in air and fuel environments of a SOFC. Self-healing glass-YSZ composites are further developed and tested over a longer time periods under conditions typical of the SOFCs to validate the long-term stability up to 2000 hours. The new concepts of glass-composite seals, developed and nurtured in this program, are expected to be cost-effective as these are based on conventional processing approaches and use of the inexpensive materials.

  7. Transmutation, Burn-Up and Fuel Fabrication Trade-Offs in Reduced-Moderation Water Reactor Thorium Fuel Cycles - 13502

    SciTech Connect (OSTI)

    Lindley, Benjamin A.; Parks, Geoffrey T.; Franceschini, Fausto

    2013-07-01

    Multiple recycle of long-lived actinides has the potential to greatly reduce the required storage time for spent nuclear fuel or high level nuclear waste. This is generally thought to require fast reactors as most transuranic (TRU) isotopes have low fission probabilities in thermal reactors. Reduced-moderation LWRs are a potential alternative to fast reactors with reduced time to deployment as they are based on commercially mature LWR technology. Thorium (Th) fuel is neutronically advantageous for TRU multiple recycle in LWRs due to a large improvement in the void coefficient. If Th fuel is used in reduced-moderation LWRs, it appears neutronically feasible to achieve full actinide recycle while burning an external supply of TRU, with related potential improvements in waste management and fuel utilization. In this paper, the fuel cycle of TRU-bearing Th fuel is analysed for reduced-moderation PWRs and BWRs (RMPWRs and RBWRs). RMPWRs have the advantage of relatively rapid implementation and intrinsically low conversion ratios. However, it is challenging to simultaneously satisfy operational and fuel cycle constraints. An RBWR may potentially take longer to implement than an RMPWR due to more extensive changes from current BWR technology. However, the harder neutron spectrum can lead to favourable fuel cycle performance. A two-stage fuel cycle, where the first pass is Th-Pu MOX, is a technically reasonable implementation of either concept. The first stage of the fuel cycle can therefore be implemented at relatively low cost as a Pu disposal option, with a further policy option of full recycle in the medium term. (authors)

  8. Models for the Configuration and Integrity of Partially Oxidized Fuel Rod Cladding at High Temperatures

    SciTech Connect (OSTI)

    Siefken, L.J.

    1999-01-01

    Models were designed to resolve deficiencies in the SCDAP/RELAP5/MOD3.2 calculations of the configuration and integrity of hot, partially oxidized cladding. These models are expected to improve the calculations of several important aspects of fuel rod behavior. First, an improved mapping was established from a compilation of PIE results from severe fuel damage tests of the configuration of melted metallic cladding that is retained by an oxide layer. The improved mapping accounts for the relocation of melted cladding in the circumferential direction. Then, rules based on PIE results were established for calculating the effect of cladding that has relocated from above on the oxidation and integrity of the lower intact cladding upon which it solidifies. Next, three different methods were identified for calculating the extent of dissolution of the oxidic part of the cladding due to its contact with the metallic part. The extent of dissolution effects the stress and thus the integrity of the oxidic part of the cladding. Then, an empirical equation was presented for calculating the stress in the oxidic part of the cladding and evaluating its integrity based on this calculated stress. This empirical equation replaces the current criterion for loss of integrity which is based on temperature and extent of oxidation. Finally, a new rule based on theoretical and experimental results was established for identifying the regions of a fuel rod with oxidation of both the inside and outside surfaces of the cladding. The implementation of these models is expected to eliminate the tendency of the SCDAP/RELAP5 code to overpredict the extent of oxidation of the upper part of fuel rods and to underpredict the extent of oxidation of the lower part of fuel rods and the part with a high concentration of relocated material. This report is a revision and reissue of the report entitled, Improvements in Modeling of Cladding Oxidation and Meltdown.

  9. Cathode and electrolyte materials for solid oxide fuel cells and ion transport membranes

    DOE Patents [OSTI]

    Jacobson, Allan J; Wang, Shuangyan; Kim, Gun Tae

    2014-01-28

    Novel cathode, electrolyte and oxygen separation materials are disclosed that operate at intermediate temperatures for use in solid oxide fuel cells and ion transport membranes based on oxides with perovskite related structures and an ordered arrangement of A site cations. The materials have significantly faster oxygen kinetics than in corresponding disordered perovskites.

  10. Pressurized solid oxide fuel cell integral air accumular containment

    DOE Patents [OSTI]

    Gillett, James E.; Zafred, Paolo R.; Basel, Richard A.

    2004-02-10

    A fuel cell generator apparatus contains at least one fuel cell subassembly module in a module housing, where the housing is surrounded by a pressure vessel such that there is an air accumulator space, where the apparatus is associated with an air compressor of a turbine/generator/air compressor system, where pressurized air from the compressor passes into the space and occupies the space and then flows to the fuel cells in the subassembly module, where the air accumulation space provides an accumulator to control any unreacted fuel gas that might flow from the module.

  11. Fuel Preprocessor (FPP) for a Solid Oxide Fuel Cell Auxiliary Power Unit

    SciTech Connect (OSTI)

    M. Namazian, S. Sethuraman and G. Venkataraman

    2004-12-31

    Auxiliary Power Units (APUs), driven by truck engines, consume over 800 million gallon of diesel fuel while idling. Use of separate SOFC based APUs are an excellent choice to reduce the cost and pollution associated with producing auxiliary power. However, diesel fuel is a challenging fuel to use in fuel cell systems because it has heavy hydrocarbons that can transform into carbon deposits and gums that can block passages and deactivate fuel reformer and fuel cell reactor elements. The work reported herein addresses the challenges associated with the diesel fuel sulfur and carbon producing contaminants in a Fuel Preprocessor (FPP). FPP processes the diesel fuel onboard and ahead of the reformer to reduce its carbon deposition tendency and its sulfur content, thus producing a fuel suitable for SOFC APU systems. The goal of this DOE supported Invention and Innovation program was to design, develop and test a prototype Fuel Preprocessor (FPP) that efficiently and safely converts the diesel fuel into a clean fuel suitable for a SOFC APU system. The goals were achieved. A 5 kWe FPP was designed, developed and tested. It was demonstrated that FPP removes over 80% of the fuel sulfur and over 90% of its carbon residues and it was demonstrated that FPP performance exceeds the original project goals.

  12. Nitrogen oxide removal using diesel fuel and a catalyst

    DOE Patents [OSTI]

    Vogtlin, George E.; Goerz, David A.; Hsiao, Mark; Merritt, Bernard T.; Penetrante, Bernie M.; Reynolds, John G.; Brusasco, Ray

    2000-01-01

    Hydrocarbons, such as diesel fuel, are added to internal combustion engine exhaust to reduce exhaust NO.sub.x in the presence of a amphoteric catalyst support material. Exhaust NO.sub.x reduction of at least 50% in the emissions is achieved with the addition of less than 5% fuel as a source of the hydrocarbons.

  13. Pyroprocessing of Oxidized Sodium-Bonded Fast Reactor Fuel -- an Experimental Study of Treatment Options for Degraded EBR-II Fuel

    SciTech Connect (OSTI)

    S. D. Herrmann; L. A. Wurth; N. J. Gese

    2013-09-01

    An experimental study was conducted to assess pyrochemical treatment options for degraded EBR-II fuel. As oxidized material, the degraded fuel would need to be converted back to metal to enable electrorefining within an existing electrometallurgical treatment process. A lithium-based electrolytic reduction process was studied to assess the efficacy of converting oxide materials to metal with a particular focus on the impact of zirconium oxide and sodium oxide on this process. Bench-scale electrolytic reduction experiments were performed in LiCl-Li2O at 650 C with combinations of manganese oxide (used as a surrogate for uranium oxide), zirconium oxide, and sodium oxide. The experimental study illustrated how zirconium oxide and sodium oxide present different challenges to a lithium-based electrolytic reduction system for conversion of select metal oxides to metal.

  14. Co-Rolled U10Mo/Zirconium-Barrier-Layer Monolithic Fuel Foil Fabrication Process

    SciTech Connect (OSTI)

    G. A. Moore; M. C. Marshall

    2010-01-01

    Integral to the current UMo fuel foil processing scheme being developed at Idaho National Laboratory (INL) is the incorporation of a zirconium barrier layer for the purpose of controlling UMo-Al interdiffusion at the fuel-meat/cladding interface. A hot “co-rolling” process is employed to establish a ~25-µm-thick zirconium barrier layer on each face of the ~0.3-mm-thick U10Mo fuel foil.

  15. Automated brush plating process for solid oxide fuel cells

    DOE Patents [OSTI]

    Long, Jeffrey William

    2003-01-01

    A method of depositing a metal coating (28) on the interconnect (26) of a tubular, hollow fuel cell (10) contains the steps of providing the fuel cell (10) having an exposed interconnect surface (26); contacting the inside of the fuel cell (10) with a cathode (45) without use of any liquid materials; passing electrical current through a contacting applicator (46) which contains a metal electrolyte solution; passing the current from the applicator (46) to the cathode (45) and contacting the interconnect (26) with the applicator (46) and coating all of the exposed interconnect surface.

  16. Towards Fuel-Efficient DPF Systems: Understanding the Soot Oxidation...

    Office of Energy Efficiency and Renewable Energy (EERE) Indexed Site

    Burning Modes and Oxidation Rates of Soot: Relevance to Diesel Particulate Traps Soot Nanostructure: Definition, Quantification, and Implications DPF Performance with Biodiesel ...

  17. MATERIAL AND PROCESS DEVELOPMENT LEADING TO ECONOMICAL HIGH-PERFORMANCE THIN-FILM SOLID OXIDE FUEL CELLS

    SciTech Connect (OSTI)

    Jie Guan; Atul Verma; Nguyen Minh

    2003-04-01

    This document summarizes the technical progress from September 2002 to March 2003 for the program, Material and Process Development Leading to Economical High-Performance Thin-Film Solid Oxide Fuel Cells, contract number DE-AC26-00NT40711. The causes have been identified for the unstable open circuit voltage (OCV) and low performance exhibited by the anode-supported lanthanum gallate based cells from the earlier development. Promising results have been obtained in the area of synthesis of electrolyte and cathode powders, which showed excellent sintering and densification at low temperatures. The fabrication of cells using tapecalendering process for anode-supported thin lanthanum gallate electrolyte cells and their performance optimization is in progress.

  18. Opportunities for mixed oxide fuel testing in the advanced test reactor to support plutonium disposition

    SciTech Connect (OSTI)

    Terry, W.K.; Ryskamp, J.M.; Sterbentz, J.W.

    1995-08-01

    Numerous technical issues must be resolved before LWR operating licenses can be amended to allow the use of MOX fuel. These issues include the following: (1) MOX fuel fabrication process verification; (2) Whether and how to use burnable poisons to depress MOX fuel initial reactivity, which is higher than that of urania; (3) The effects of WGPu isotopic composition; (4) The feasibility of loading MOX fuel with plutonia content up to 7% by weight; (5) The effects of americium and gallium in WGPu; (6) Fission gas release from MOX fuel pellets made from WGPu; (7) Fuel/cladding gap closure; (8) The effects of power cycling and off-normal events on fuel integrity; (9) Development of radial distributions of burnup and fission products; (10) Power spiking near the interfaces of MOX and urania fuel assemblies; and (11) Fuel performance code validation. The Advanced Test Reactor (ATR) at the Idaho National Engineering Laboratory possesses many advantages for performing tests to resolve most of the issues identified above. We have performed calculations to show that the use of hafnium shrouds can produce spectrum adjustments that will bring the flux spectrum in ATR test loops into a good approximation to the spectrum anticipated in a commercial LWR containing MOX fuel while allowing operation of the test fuel assemblies near their optimum values of linear heat generation rate. The ATR would be a nearly ideal test bed for developing data needed to support applications to license LWRs for operation with MOX fuel made from weapons-grade plutonium. The requirements for planning and implementing a test program in the ATR have been identified. The facilities at Argonne National Laboratory-West can meet all potential needs for pre- and post-irradiation examination that might arise in a MOX fuel qualification program.

  19. Cerium-modified doped strontium titanate compositions for solid oxide fuel cell anodes and electrodes for other electrochemical devices

    DOE Patents [OSTI]

    Marina, Olga A [Richland, WA; Stevenson, Jeffry W [Richland, WA

    2010-11-23

    The present invention provides novel compositions that find advantageous use in making electrodes for electrochemical cells and electrochemical devices such as solid oxide fuel cells, electrolyzers, sensors, pumps and the like, the compositions comprising cerium-modified doped strontium titanate. The invention also provides novel methods for making and using anode material compositions and solid oxide fuel cells and solid oxide fuel cell assemblies having anodes comprising the compositions.

  20. Copper-substituted perovskite compositions for solid oxide fuel cell cathodes and oxygen reduction electrodes in other electrochemical devices

    DOE Patents [OSTI]

    Rieke, Peter C.; Coffey, Gregory W.; Pederson, Larry R.; Marina, Olga A.; Hardy, John S.; Singh, Prabhaker; Thomsen, Edwin C.

    2010-07-20

    The present invention provides novel compositions that find advantageous use in making electrodes for electrochemical cells. Also provided are electrochemical devices that include active oxygen reduction electrodes, such as solid oxide fuel cells, sensors, pumps and the like. The compositions comprises a copper-substituted ferrite perovskite material. The invention also provides novel methods for making and using the electrode compositions and solid oxide fuel cells and solid oxide fuel cell assemblies having cathodes comprising the compositions.

  1. Cerium-modified doped strontium titanate compositions for solid oxide fuel cell anodes and electrodes for other electrochemical devices

    DOE Patents [OSTI]

    Marina, Olga A [Richland, WA; Stevenson, Jeffry W [Richland, WA

    2010-03-02

    The present invention provides novel compositions that find advantageous use in making electrodes for electrochemical cells and electrochemical devices such as solid oxide fuel cells, electrolyzers, sensors, pumps and the like, the compositions comprising cerium-modified doped strontium titanate. The invention also provides novel methods for making and using anode material compositions and solid oxide fuel cells and solid oxide fuel cell assemblies having anodes comprising the compositions.

  2. Cladding inner surface wastage for mixed-oxide liquid metal reactor fuel pins

    SciTech Connect (OSTI)

    Lawrence, L.A.; Bard, F.E.; Cannon, N.S.

    1990-11-01

    Cladding inner surface wastage was measured on reference fuel pins with stainless steel and D9 cladding irradiated beyond goal burnup in the Fast Flux Test Facility. Measurements were compared to the Experimental Breeder Reactor No. 2 based fuel-cladding chemical interaction correlation developed for uranium-plutonium oxide fuels with 20% cold-worked stainless steel cladding. The fuel-cladding chemical interaction was also measured in fuel pins irradiated with HT9 cladding. Comparison of the measurements with the design correlation showed the correlation adequately accounted for the extent of interaction in the Fast Flux Test Facility fuel pins with cold-worked stainless steel D9, and HT9 cladding. 9 refs., 6 figs.

  3. Expanded nickel screen electrical connection supports for solid oxide fuel cells

    DOE Patents [OSTI]

    Draper, Robert; Antol, Ronald F.; Zafred, Paolo R.

    2002-01-01

    A solid oxide fuel assembly is made, wherein rows (14, 24) of fuel cells (16, 18, 20, 26, 28, 30), each having an outer interconnection (36) and an outer electrode (32), are disposed next to each other with corrugated, electrically conducting expanded metal mesh (22) between each row of cells, the corrugated mesh (22) having top crown portions (40) and bottom shoulder portions (42), where the top crown portion (40) contacts outer interconnections (36) of the fuel cells (16, 18, 20) in a first row (14), and the bottom shoulder portions (42) contacts outer electrodes (32) of the fuel cells in a second row (24), said mesh electrically connecting each row of fuel cells, and where there are no metal felt connections between any fuel cells.

  4. Modeling of selected ceramic processing parameters employed in the fabrication of 238PuO2 fuel pellets

    DOE Public Access Gateway for Energy & Science Beta (PAGES Beta)

    Brockman, R. A.; Kramer, D. P.; Barklay, C. D.; Cairns-Gallimore, D.; Brown, J. L.; Huling, J. C.; Van Pelt, C. E.

    2011-10-01

    Recent deep space missions utilize the thermal output of the radioisotope plutonium-238 as the fuel in the thermal to electrical power system. Since the application of plutonium in its elemental state has several disadvantages, the fuel employed in these deep space power systems is typically in the oxide form such as plutonium-238 dioxide (238PuO2). As an oxide, the processing of the plutonium dioxide into fuel pellets is performed via ''classical'' ceramic processing unit operations such as sieving of the powder, pressing, sintering, etc. Modeling of these unit operations can be beneficial in the understanding and control of processing parameters withmore » the goal of further enhancing the desired characteristics of the 238PuO2 fuel pellets. A finite element model has been used to help identify the time-temperature-stress profile within a pellet during a furnace operation taking into account that 238PuO2 itself has a significant thermal output. The results of the modeling efforts will be discussed.« less

  5. LMFBR fuel-design environment for endurance testing, primarily of oxide fuel elements with local faults

    SciTech Connect (OSTI)

    Warinner, D.K.

    1980-01-01

    The US Department of Energy LMFBR Lines-of-Assurance are briefly stated and local faults are given perspective with an historical review and definition to help define the constraints of LMFBR fuel-element designs. Local-fault-propagation (fuel-element failure-propagation and blockage propagation) perceptions are reviewed. Fuel pin designs and major LMFBR parameters affecting pin performance are summarized. The interpretation of failed-fuel data is aided by a discussion of the effects of nonprototypicalities. The fuel-pin endurance expected in the US, USSR, France, UK, Japan, and West Germany is outlined. Finally, fuel-failure detection and location by delayed-neutron and gaseous-fission-product monitors are briefly discussed to better realize the operational limits.

  6. Modified cermet fuel electrodes for solid oxide electrochemical cells

    DOE Patents [OSTI]

    Ruka, Roswell J.; Spengler, Charles J.

    1991-01-01

    An exterior porous electrode (10), bonded to a solid oxygen ion conducting electrolyte (13) which is in contact with an interior electrode (14), contains coarse metal particles (12) of nickel and/or cobalt, having diameters from 3 micrometers to 35 micrometers, where the coarse particles are coated with a separate, porous, multiphase layer (17) containing fine metal particles of nickel and/or cobalt (18), having diameters from 0.05 micrometers to 1.75 micrometers and conductive oxide (19) selected from cerium oxide, doped cerium oxide, strontium titanate, doped strontium titanate and mixtures thereof.

  7. Generator module architecture for a large solid oxide fuel cell power plant

    DOE Patents [OSTI]

    Gillett, James E.; Zafred, Paolo R.; Riggle, Matthew W.; Litzinger, Kevin P.

    2013-06-11

    A solid oxide fuel cell module contains a plurality of integral bundle assemblies, the module containing a top portion with an inlet fuel plenum and a bottom portion receiving air inlet feed and containing a base support, the base supports dense, ceramic exhaust manifolds which are below and connect to air feed tubes located in a recuperator zone, the air feed tubes passing into the center of inverted, tubular, elongated, hollow electrically connected solid oxide fuel cells having an open end above a combustion zone into which the air feed tubes pass and a closed end near the inlet fuel plenum, where the fuel cells comprise a fuel cell stack bundle all surrounded within an outer module enclosure having top power leads to provide electrical output from the stack bundle, where the fuel cells operate in the fuel cell mode and where the base support and bottom ceramic air exhaust manifolds carry from 85% to all 100% of the weight of the stack, and each bundle assembly has its own control for vertical and horizontal thermal expansion control.

  8. Solid oxide fuel cell having monolithic cross flow core and manifolding

    DOE Patents [OSTI]

    Poeppel, Roger B.; Dusek, Joseph T.

    1984-01-01

    This invention discloses a monolithic core construction having the flow passageways for the fuel and for the oxidant gases extended transverse to one another, whereby full face core manifolding can be achieved for these gases and their reaction products. The core construction provides that only anode material surround each fuel passageway and only cathode material surround each oxidant passageway, each anode and each cathode further sandwiching at spaced opposing sides electrolyte and interconnect materials to define electrolyte and interconnect walls. Webs of the cathode and anode material hold the electrolyte and interconnect walls spaced apart to define the flow passages. The composite anode and cathode wall structures are further alternately stacked on one another (with the separating electrolyte or interconnect material typically being a single common layer) whereby the fuel passageway and the oxidant passageways are disposed transverse to one another.

  9. Solid oxide fuel cell having monolithic cross flow core and manifolding

    DOE Patents [OSTI]

    Poeppel, R.B.; Dusek, J.T.

    1983-10-12

    This invention discloses a monolithic core construction having the flow passageways for the fuel and for the oxidant gases extended transverse to one another, whereby full face core manifolding can be achieved for these gases and their reaction products. The core construction provides that only anode material surround each fuel passageway and only cathode material surround each oxidant passageway, each anode and each cathode further sandwiching at spaced opposing sides electrolyte and interconnect materials to define electrolyte and interconnect walls. Webs of the cathode and anode material hold the electrolyte and interconnect walls spaced apart to define the flow passages. The composite anode and cathode wall structures are further alternately stacked on one another (with the separating electrolyte or interconnect material typically being a single common layer) whereby the fuel passageways and the oxidant passageways are disposed transverse to one another.

  10. Nitrogen oxide abatement by distributed fuel addition. Final report

    SciTech Connect (OSTI)

    Wendt, J.O.L.; Mereb, J.B.

    1991-09-20

    Reburning is examined as a means of NO{sub x} destruction in a 17 kW down-fired pulverized coal combustor. In reburning, a secondary fuel is introduced downstream of the primary flame to produce a reducing zone, favorable to NO destruction, and air is introduced further downstream to complete the combustion. Emphasis is on natural gas reburning and a bituminous coal primary flame. A parametric examination of reburning employing a statistical experimental design, is conducted, complemented by detailed experiments. Mechanisms governing the inter-conversion of nitrogenous species in the fuel rich reburn zone is explored. The effect of reburning on N{sub 2}O emissions, the effect of primary flame mode (premixed and diffusion) and the effect of distributing the reburning fuel, are also investigated.

  11. Method of fabricating conducting oxide-silicon solar cells utilizing electron beam sublimation and deposition of the oxide

    DOE Patents [OSTI]

    Feng, Tom; Ghosh, Amal K.

    1979-01-01

    In preparing tin oxide and indium tin oxide-silicon heterojunction solar cells by electron beam sublimation of the oxide and subsequent deposition thereof on the silicon, the engineering efficiency of the resultant cell is enhanced by depositing the oxide at a predetermined favorable angle of incidence. Typically the angle of incidence is between 40.degree. and 70.degree. and preferably between 55.degree. and 65.degree. when the oxide is tin oxide and between 40.degree. and 70.degree. when the oxide deposited is indium tin oxide. gi The Government of the United States of America has rights in this invention pursuant to Department of Energy Contract No. EY-76-C-03-1283.

  12. Durability Prediction of Solid Oxide Fuel Cell Anode Material under Thermo-Mechanical and Fuel Gas Contaminants Effects

    SciTech Connect (OSTI)

    Iqbal, Gulfam; Guo, Hua; Kang , Bruce S.; Marina, Olga A.

    2011-01-10

    Solid Oxide Fuel Cells (SOFCs) operate under harsh environments, which cause deterioration of anode material properties and service life. In addition to electrochemical performance, structural integrity of the SOFC anode is essential for successful long-term operation. The SOFC anode is subjected to stresses at high temperature, thermal/redox cycles, and fuel gas contaminants effects during long-term operation. These mechanisms can alter the anode microstructure and affect its electrochemical and structural properties. In this research, anode material degradation mechanisms are briefly reviewed and an anode material durability model is developed and implemented in finite element analysis. The model takes into account thermo-mechanical and fuel gas contaminants degradation mechanisms for prediction of long-term structural integrity of the SOFC anode. The proposed model is validated experimentally using a NexTech ProbostatTM SOFC button cell test apparatus integrated with a Sagnac optical setup for simultaneously measuring electrochemical performance and in-situ anode surface deformation.

  13. In situ fabrication of blue ceramic coatings on wrought Al Alloy 2024 by plasma electrolytic oxidation

    SciTech Connect (OSTI)

    Wang Zhijiang; Nie Xueyuan; Hu, Henry; Hussein, Riyad O.

    2012-03-15

    In situ formation of ceramic coatings on 2024 Al alloy with a blue color was successfully achieved using a plasma electrolytic oxidation process working at atmospheric pressure. This novel blue ceramic coating overcomes the shortcomings of surface treatments resulting from conventional dyeing processes by depositing organic dyes into the porous structure of anodic film, which has poor resistance to abrasion and rapid fading when exposed to sunlight. X-ray diffraction, scanning electron microscopy, and energy dispersive spectroscopy were employed to characterize the microstructure of the blue ceramic coating. The fabricated ceramic coating was composed of CoAl{sub 2}O{sub 4}, {alpha}-Al{sub 2}O{sub 3}, and {gamma}-Al{sub 2}O{sub 3.} By controlling the working parameters, the distribution of the CoAl{sub 2}O{sub 4} phase on the surface can be adjusted, and plays a key role in the appearance of the coating. Electrochemical testing, thermal cycling method, and pin-on-disk sliding wear testing were employed to evaluate corrosion, thermal cycling, and wear resistance of the ceramic coatings. The results indicate that the blue ceramic coating has a similar polarization resistance to that of conventional anodic film and can significantly enhance the corrosion resistance of aluminum alloy. There are no destructive horizontal cracks observed within the blue ceramic coating when subjected to 120 times of thermal cycling, which heats the samples up to 573 K and followed by submersion in water at room temperature for 10 min. Compared with the aluminum substrate as well as a conventional anodic film coated aluminum sample, the wear resistance of the blue ceramic coating coated sample was significantly increased while the coefficient of friction was decreased from 0.34 to 0.14.

  14. Pressurized solid oxide fuel cell/gas turbine combined cycle systems

    SciTech Connect (OSTI)

    George, R.A.

    1997-12-31

    Over the last 10 years, Westinghouse Electric Corporation has made great strides in advancing tubular solid oxide fuel cell (SOFC) technology towards commercialization by the year 2001. In 1993, Westinghouse initiated a program to develop pressurized solid oxide fuel cell/gas turbine (PSOFC/GT) combined cycle power systems because of the ultra-high electrical efficiencies, 60-75% (net AC/LHV CH4), inherent with these systems. This paper will discuss SOFC technology advancements in recent years, and the final phase development program which will focus on the development and demonstration of PSOFC/GT power systems for distributed power applications.

  15. Catalytic membranes for CO oxidation in fuel cells

    DOE Patents [OSTI]

    Sandi-Tapia, Giselle; Carrado Gregar, Kathleen; Kizilel, Riza

    2010-06-08

    A hydrogen permeable membrane, which includes a polymer stable at temperatures of about 200 C having clay impregnated with Pt or Au or Ru or Pd particles or mixtures thereof with average diameters of less than about 10 nanometers (nms) is disclosed. The membranes are useful in fuel cells or any device which requires hydrogen to be separated from carbon monoxide.

  16. Electro-catalytic oxidation device for removing carbon from a fuel reformate

    DOE Patents [OSTI]

    Liu, Di-Jia

    2010-02-23

    An electro-catalytic oxidation device (ECOD) for the removal of contaminates, preferably carbonaceous materials, from an influent comprising an ECOD anode, an ECOD cathode, and an ECOD electrolyte. The ECOD anode is at a temperature whereby the contaminate collects on the surface of the ECOD anode as a buildup. The ECOD anode is electrically connected to the ECOD cathode, which consumes the buildup producing electricity and carbon dioxide. The ECOD anode is porous and chemically active to the electro-catalytic oxidation of the contaminate. The ECOD cathode is exposed to oxygen, and made of a material which promotes the electro-chemical reduction of oxygen to oxidized ions. The ECOD electrolyte is non-permeable to gas, electrically insulating and a conductor to oxidized. The ECOD anode is connected to the fuel reformer and the fuel cell. The ECOD electrolyte is between and in ionic contact with the ECOD anode and the ECOD cathode.

  17. Solid oxide fuel cell power plant with an anode recycle loop turbocharger

    SciTech Connect (OSTI)

    Saito, Kazuo; Skiba, Tommy; Patel, Kirtikumar H.

    2015-07-14

    An anode exhaust recycle turbocharger (100) has a turbocharger turbine (102) secured in fluid communication with a compressed oxidant stream within an oxidant inlet line (218) downstream from a compressed oxidant supply (104), and the anode exhaust recycle turbocharger (100) also includes a turbocharger compressor (106) mechanically linked to the turbocharger turbine (102) and secured in fluid communication with a flow of anode exhaust passing through an anode exhaust recycle loop (238) of the solid oxide fuel cell power plant (200). All or a portion of compressed oxidant within an oxidant inlet line (218) drives the turbocharger turbine (102) to thereby compress the anode exhaust stream in the recycle loop (238). A high-temperature, automotive-type turbocharger (100) replaces a recycle loop blower-compressor (52).

  18. LANL disassembles "pits," makes mixed-oxide fuel

    Broader source: All U.S. Department of Energy (DOE) Office Webpages (Extended Search)

    disassembles "pits" LANL disassembles "pits," makes mixed-oxide fuel LANL has successfully disassembled nuclear weapons "pits" and converted them into more than 240 kilograms of plutonium oxide. October 7, 2011 Los Alamos National Laboratory sits on top of a once-remote mesa in northern New Mexico with the Jemez mountains as a backdrop to research and innovation covering multi-disciplines from bioscience, sustainable energy sources, to plasma physics and new

  19. Purification of uranium alloys by differential solubility of oxides and production of purified fuel precursors

    DOE Patents [OSTI]

    McLean, W. II; Miller, P.E.

    1997-12-16

    A method is described for purifying metallic alloys of uranium for use as nuclear reactor fuels in which the metal alloy is first converted to an oxide and then dissolved in nitric acid. Initial removal of metal oxide impurities not soluble in nitric acid is accomplished by filtration or other physical means. Further purification can be accomplished by carbonate leaching of uranyl ions from the partially purified solution or using traditional methods such as solvent extraction. 3 figs.

  20. Purification of uranium alloys by differential solubility of oxides and production of purified fuel precursors

    DOE Patents [OSTI]

    McLean, II, William (Oakland, CA); Miller, Philip E. (Livermore, CA)

    1997-01-01

    A method for purifying metallic alloys of uranium for use as nuclear reactor fuels in which the metal alloy is first converted to an oxide and then dissolved in nitric acid. Initial removal of metal oxide impurities not soluble in nitric acid is accomplished by filtration or other physical means. Further purification can be accomplished by carbonate leaching of uranyl ions from the partially purified solution or using traditional methods such as solvent extraction.

  1. Manifold, bus support and coupling arrangement for solid oxide fuel cells

    DOE Patents [OSTI]

    Parry, G.W.

    1988-04-21

    Individual, tubular solid oxide fuel cells (SOFCs) are assembled into bundles called a module within a housing, with a plurality of modules arranged end-to-end in a linear, stacked configuration called a string. A common set of piping comprised of a suitable high temperature resistant material (1) provides fuel and air to each module housing, (2) serves as electrically conducting buses, and (3) provides structural support for a string of SOFC modules. Ceramic collars are used to connect fuel and air inlet piping to each of the electrodes in an SOFC module and provide (1) electrical insulation for the current carrying bus bars and gas manifolds, (2) damping for the fuel and air inlet piping, and (3) proper spacing between the fuel and air inlet piping to prevent contact between these tubes and possible damage to the SOFC. 11 figs.

  2. Molten carbonate fuel cell cathode with mixed oxide coating

    DOE Patents [OSTI]

    Hilmi, Abdelkader; Yuh, Chao-Yi

    2013-05-07

    A molten carbonate fuel cell cathode having a cathode body and a coating of a mixed oxygen ion conductor materials. The mixed oxygen ion conductor materials are formed from ceria or doped ceria, such as gadolinium doped ceria or yttrium doped ceria. The coating is deposited on the cathode body using a sol-gel process, which utilizes as precursors organometallic compounds, organic and inorganic salts, hydroxides or alkoxides and which uses as the solvent water, organic solvent or a mixture of same.

  3. Synthesis and Stability of a Nanoparticle-Infiltrated Solid OxideFuel Cell Electrode

    SciTech Connect (OSTI)

    Sholklapper, Tal Z.; Radmilovic, Velimir; Jacobson, Craig P.; Visco, Steven J.; De Jonghe, Lutgard C.

    2006-11-20

    Nanoparticulate catalysts infiltrated into SOFC (Solid OxideFUel Cell) electrodes can significantly enhance the cell performance, butthe stability of these electrodes has been an open issue. An infiltrationprocedure is reported that leads to a stable scandia-stablized zirconia(SSZ) cathode electrode performance.

  4. Solid Oxide Fuel Cell Successfully Powers Truck Cab and Sleeper in DOE-Sponsored Test

    Broader source: Energy.gov [DOE]

    In a test sponsored by the U.S. Department of Energy, a Delphi auxiliary power unit employing a solid oxide fuel cell (SOFC) successfully operated the electrical system and air conditioning of a Peterbilt Model 386 truck under conditions simulating idling conditions for 10 hours.

  5. Solid oxide fuel cell systems with hot zones having improved reactant distribution

    DOE Patents [OSTI]

    Poshusta, Joseph C.; Booten, Charles W.; Martin, Jerry L.

    2012-11-06

    A Solid Oxide Fuel Cell (SOFC) system having a hot zone with a center cathode air feed tube for improved reactant distribution, a CPOX reactor attached at the anode feed end of the hot zone with a tail gas combustor at the opposing end for more uniform heat distribution, and a counter-flow heat exchanger for efficient heat retention.

  6. Recovery Act. Solid Oxide Fuel Cell Diesel Auxilliary Power Unit Demonstration

    SciTech Connect (OSTI)

    Geiger, Gail E.

    2013-09-30

    Solid Oxide Fuel Cell Diesel Auxilliary Power Unit Demonstration Project. Summarizing development of Delphi’s next generation SOFC system as the core power plant to prove the viability of the market opportunity for a 3-5 kW diesel SOFC system. Report includes test and demonstration results from testing the diesel APU in a high visibility fleet customer vehicle application.

  7. Solid oxide fuel cell systems with hot zones having improved reactant distribution

    DOE Patents [OSTI]

    Poshusta, Joseph C; Booten, Charles W; Martin, Jerry L

    2013-12-24

    A Solid Oxide Fuel Cell (SOFC) system having a hot zone with a center cathode air feed tube for improved reactant distribution, a CPOX reactor attached at the anode feed end of the hot zone with a tail gas combustor at the opposing end for more uniform heat distribution, and a counter-flow heat exchanger for efficient heat retention.

  8. HIGH EFFICIENCY, LOW EMISSIONS, SOLID OXIDE FUEL CELL SYSTEMS FOR MULTIPLE APPLICATIONS

    SciTech Connect (OSTI)

    Sara Ward; Michael A. Petrik

    2004-07-28

    Technology Management Inc. (TMI), teamed with the Ohio Office of Energy Efficiency and Renewable Energy, has engineered, constructed, and demonstrated a stationary, low power, multi-module solid oxide fuel cell (SOFC) prototype system operating on propane and natural gas. Under Phase I, TMI successfully operated two systems in parallel, in conjunction with a single DC-AC inverter and battery bus, and produced net AC electricity. Phase II testing expanded to include alternative and renewable fuels typically available in rural regions of Ohio. The commercial system is expected to have ultra-low pollution, high efficiency, and low noise. The TMI SOFC uses a solid ceramic electrolyte operating at high temperature (800-1000 C) which electrochemically converts gaseous fuels (hydrogen or mixed gases) and oxygen into electricity. The TMI system design oxidizes fuel primarily via electrochemical reactions and uses no burners (which pollute and consume fuel)--resulting in extremely clean exhaust. The use of proprietary sulfur tolerant materials developed by TMI allows system operation without additional fuel pre-processing or sulfur removal. Further, the combination of high operating temperatures and solid state operation increases the potential for higher reliability and efficiencies compared to other types of fuel cells. Applications for the TMI SOFC system cover a wide range of transportation, building, industrial, and military market sectors. A generic technology, fuel cells have the potential to be embodied into multiple products specific to Department of Energy (DOE) Office of Energy Efficiency and Renewable Energy (EERE) program areas including: Fuel Cells and Microturbines, School Buildings, Transportation, and Bioenergy. This program focused on low power stationary applications using a multi-module system operating on a range of common fuels. By producing clean electricity more efficiently (thus using less fuel), fuel cells have the triple effect of cleaning up the environment, reducing the amount of fuel consumed and, for energy intensive manufacturers, boosting their profits (by reducing energy expenses). Compared to conventional power generation technologies such as internal combustion engines, gas turbines, and coal plants, fuel cells are extremely clean and more efficient, particularly at smaller scales.

  9. Solid oxide fuel cell with transitioned cross-section for improved anode gas management at the open end

    DOE Patents [OSTI]

    Zafred, Paolo R.; Draper, Robert

    2012-01-17

    A solid oxide fuel cell (400) is made having a tubular, elongated, hollow, active section (445) which has a cross-section containing an air electrode (452) a fuel electrode (454) and solid oxide electrolyte (456) between them, where the fuel cell transitions into at least one inactive section (460) with a flattened parallel sided cross-section (462, 468) each cross-section having channels (472, 474, 476) in them which smoothly communicate with each other at an interface section (458).

  10. URANIUM OXIDE-CONTAINING FUEL ELEMENT COMPOSITION AND METHOD OF MAKING SAME

    DOE Patents [OSTI]

    Handwerk, J.H.; Noland, R.A.; Walker, D.E.

    1957-09-10

    In the past, bodies formed of a mixture of uranium dioxide and aluminum powder have been used in fuel elements; however, these mixtures were found not to be suitable when exposed to temperatures of about 600 deg C, because at such high temperatures the fuel elements were distorted. If uranosic oxide, U/sub 3/O/sub 8/, is substituted for UO/sub 2/, the mechanical properties are not impaired when these materials are used at about 600 deg C and no distortion takes place. The uranosic oxide and aluminum, both in powder form, are first mixed, and after a homogeneous mixture has been obtained, are shaped into fuel elements by extrusion at elevated temperature. Magnesium powder may be used in place of the aluminum.

  11. FUNDAMENTAL STUDIES OF THE DURABILITY OF MATERIALS FOR INTERCONNECTS IN SOLID OXIDE FUEL CELLS

    SciTech Connect (OSTI)

    Frederick S. Pettit; Gerald H. Meier

    2003-06-30

    This report describes the result of the first eight months of effort on a project directed at improving metallic interconnect materials for solid oxide fuel cells (SOFCs). The results include cyclic oxidation studies of a group of ferritic alloys, which are candidate interconnect materials. The exposures have been carried out in simulated fuel cell atmospheres. The oxidation morphologies have been characterized and the ASR has been measured for the oxide scales. The effect of fuel cell electric current density on chromia growth rates has been considered The thermomechanical behavior of the scales has been investigated by stress measurements using x-ray diffraction and interfacial fracture toughness measurements using indentation. The ultimate goal of this thrust is to use knowledge of changes in oxide thickness, stress and adhesion to develop accelerated testing methods for evaluating SOFC interconnect alloys. Finally a theoretical assessment of the potential for use of ''new'' metallic materials as interconnect materials has been conducted and is presented in this report. Alloys being considered include materials based on pure nickel, materials based on the ''Invar'' concept, and coated materials to optimize properties in both the anode and cathode gases.

  12. Fabrication and Characterization of New Hybrid Organic Light Emitting Diode (OLED): Europium-picrate-triethylene oxide Complex

    SciTech Connect (OSTI)

    Sarjidan, M. A. Mohd; Abu Zakaria, N. Z. A.; Abd. Majid, W. H. [Solid State Research Laboratory, Department of Physics, University of Malaya, 50603, Kuala Lumpur (Malaysia); Kusrini, Eny; Saleh, M. I. [School of Chemical Sciences, Universiti Sains Malaysia, 11800 Penang (Malaysia)

    2009-07-07

    Thin-film light emitting devices based on organic materials have attracted vast interest in applications such as light emitting diode (LED) and flat-panel display. The organic material can be attached with inorganic material to enhance the performance of the light emitting device. A hybrid OLED based on a new complex of europium picrate (Eu-pic) with triethylene oxide (EO3) ligand is fabricated. The OLED is fabricated by using spin coating technique with acetone as the solvent and aluminum as the top electrode. The optical, photoluminescence (PL) and electrical properties of the sample are carried out by UV-Vis spectroscopy (Jasco V-750), luminescence spectroscopy (Perkin Elmer LS-500) and source measure unit (SMU)(Keithly), respectively.

  13. Preparation of low oxygen-to-metal mixed oxide fuels for the advanced fast reactor

    SciTech Connect (OSTI)

    Kato, Masato; Nakamichi, Shinya; Takano, Tatsuo

    2007-07-01

    The preparation process for homogeneous mixed oxide pellets with a precise O/M ratio was established. The process was used to prepare pellets for heat treatments in two stages which consisted of the sintering process at high oxygen potential and the annealing process done in the atmosphere of controlled oxygen partial pressure. In the annealing process, it was found that abnormal growth of pores and occurrence of cracks were caused inside the pellet, and it was necessary for prevention of the microstructure change to control the oxygen potential of the atmosphere. Mixed oxide pellets with minor actinides were fabricated by the process and were provided to irradiation tests. (authors)

  14. The underwater coincidence counter for plutonium measurements in mixed-oxide fuel assemblies manual

    SciTech Connect (OSTI)

    G. W. Eccleston; H. O. Menlove; M. Abhold; M. Baker; J. Pecos

    1999-05-01

    This manual describes the Underwater Coincidence Counter (UWCC) that has been designed for the measurement of plutonium in mixed-oxide (MOX) fuel assemblies prior to irradiation. The UWCC uses high-efficiency {sup 3}He neutron detectors to measure the spontaneous-fission and induced-fission rates in the fuel assembly. Measurements can be made on MOX fuel assemblies in air or underwater. The neutron counting rate is analyzed for singles, doubles, and triples time correlations to determine the {sup 240}Pu effective mass per unit length of the fuel assembly. The system can verify the plutonium loading per unit length to a precision of less than 1% in a measurement time of 2 to 3 minutes. System design, components, performance tests, and operational characteristics are described in this manual.

  15. Mechanisms Underpinning Degradation of Protective Oxides and Thermal Barrier Coatings in High Hydrogen Content (HHC) - Fueled Turbines

    SciTech Connect (OSTI)

    Mumm, Daniel

    2013-08-31

    The overarching goal of this research program has been to evaluate the potential impacts of coal-derived syngas and high-hydrogen content fuels on the degradation of turbine hot-section components through attack of protective oxides and thermal barrier coatings. The primary focus of this research program has been to explore mechanisms underpinning the observed degradation processes, and connections to the combustion environments and characteristic non-combustible constituents. Based on the mechanistic understanding of how these emerging fuel streams affect materials degradation, the ultimate goal of the program is to advance the goals of the Advanced Turbine Program by developing materials design protocols leading to turbine hot-section components with improved resistance to service lifetime degradation under advanced fuels exposures. This research program has been focused on studying how: (1) differing combustion environments – relative to traditional natural gas fired systems – affect both the growth rate of thermally grown oxide (TGO) layers and the stability of these oxides and of protective thermal barrier coatings (TBCs); and (2) how low levels of fuel impurities and characteristic non-combustibles interact with surface oxides, for instance through the development of molten deposits that lead to hot corrosion of protective TBC coatings. The overall program has been comprised of six inter-related themes, each comprising a research thrust over the program period, including: (i) evaluating the role of syngas and high hydrogen content (HHC) combustion environments in modifying component surface temperatures, heat transfer to the TBC coatings, and thermal gradients within these coatings; (ii) understanding the instability of TBC coatings in the syngas and high hydrogen environment with regards to decomposition, phase changes and sintering; (iii) characterizing ash deposition, molten phase development and infiltration, and associated corrosive/thermo-chemical attack mechanisms; (iv) developing a mechanics-based analysis of the driving forces for crack growth and delamination, based on molten phase infiltration, misfit upon cooling, and loss of compliance; (v) understanding changes in TGO growth mechanisms associated with these emerging combustion product streams; and (vi) identifying degradation resistant alternative materials (including new compositions or bi-layer concepts) for use in mitigating the observed degradation modes. To address the materials stability concerns, this program integrated research thrusts aimed at: (1) Conducting tests in simulated syngas and HHC environments to evaluate materials evolution and degradation mechanisms; assessing thermally grown oxide development unique to HHC environmental exposures; carrying out high-resolution imaging and microanalysis to elucidate the evolution of surface deposits (molten phase formation and infiltration); exploring thermo-chemical instabilities; assessing thermo-mechanical drivers and thermal gradient effects on degradation; and quantitatively measuring stress evolution due to enhanced sintering and thermo-chemical instabilities induced in the coating. (2) Executing experiments to study the melting and infiltration of simulated ash deposits, and identifying reaction products and evolving phases associated with molten phase corrosion mechanisms; utilizing thermal spray techniques to fabricate test coupons with controlled microstructures to study mechanisms of instability and degradation; facilitating thermal gradient testing; and developing new materials systems for laboratory testing; (3) Correlating information on the resulting combustion environments to properly assess materials exposure conditions and guide the development of lab-scale simulations of material exposures; specification of representative syngas and high-hydrogen fuels with realistic levels of impurities and contaminants, to explore differences in heat transfer, surface degradation, and deposit formation; and facilitating combustion rig testing of materials test coupons.

  16. Hot Isostatic Press Manufacturing Process Development for Fabrication of RERTR Monolithic Fuel Plates

    SciTech Connect (OSTI)

    Crapps, Justin M.; Clarke, Kester D.; Katz, Joel D.; Alexander, David J.; Aikin, Beverly; Vargas, Victor D.; Montalvo, Joel D.; Dombrowski, David E.; Mihaila, Bogdan

    2012-06-06

    We use experimentation and finite element modeling to study a Hot Isostatic Press (HIP) manufacturing process for U-10Mo Monolithic Fuel Plates. Finite element simulations are used to identify the material properties affecting the process and improve the process geometry. Accounting for the high temperature material properties and plasticity is important to obtain qualitative agreement between model and experimental results. The model allows us to improve the process geometry and provide guidance on selection of material and finish conditions for the process strongbacks. We conclude that the HIP can must be fully filled to provide uniform normal stress across the bonding interface.

  17. Effect of Water Radiolysis Caused by Dispersed Radionuclides on Oxidative Dissolution of Spent Fuel in a Final Repository

    SciTech Connect (OSTI)

    Liu Jinsong; Neretnieks, Ivars

    2001-08-15

    When released out of a canister, the radionuclides originally incorporated in the spent fuel can still deposit radiation energy (even more efficiently) into the pore water, cause water radiolysis, and produce oxidants in the buffering material. This phenomenon is termed secondary water radiolysis. The oxidants thus produced can possibly diffuse back to oxidize the spent fuel and to increase the oxidative dissolution rate of the fuel.The effect of the secondary water radiolysis has been identified and preliminarily addressed by a mass-balance model. To explore whether the effect is significant on spent-fuel dissolution, the upper-boundary limit of the effect has been set up by considering a scenario that is very unlikely to occur. Several extreme assumptions have been made: First, the canister fails completely 10{sup 3} yr after deposition; second, the spent fuel is oxidized instantaneously; and third, the radionuclides considered are those that dominantly contribute to radiolysis between 10{sup 3} to 10{sup 5} yr. With these assumptions, the spent-fuel dissolution rate can be increased dramatically if 10% or more of the oxidants produced by the secondary water radiolysis diffuse back to oxidize the spent fuel. It thus indicates that the effect of the secondary water radiolysis could be significant with some extreme assumptions. With more realistic assumptions, the effect could possibly become minimal. The subject is worth further investigation.

  18. Iron-based perovskite cathodes for solid oxide fuel cells

    DOE Patents [OSTI]

    Ralph, James M.; Rossignol, Cecile C.R.; Vaughey, John T.

    2007-01-02

    An A and/or A' site deficient perovskite of general formula of (A.sub.1-xA'.sub.x).sub.1-yFeO.sub.3-.delta. or of general formula A.sub.1-x-yA'.sub.xFeO.sub.3-67, wherein A is La alone or with one or more of the rare earth metals or a rare earth metal other than Ce alone or a combination of rare earth metals and X is in the range of from 0 to about 1; A' is Sr or Ca or mixtures thereof and Y is in the range of from about 0.01 to about 0.3; .delta. represents the amount of compensating oxygen loss. If either A or A' is zero the remaining A or A' is deficient. A fuel cell incorporating the inventive perovskite as a cathode is disclosed as well as an oxygen separation membrane. The inventive perovskite is preferably single phase.

  19. Solid oxide fuel cells, and air electrode and electrical interconnection materials therefor

    DOE Patents [OSTI]

    Bates, J.L.

    1992-09-01

    In one aspect of the invention, an air electrode material for a solid oxide fuel cell comprises Y[sub 1[minus]a]Q[sub a]MnO[sub 3], where Q is selected from the group consisting of Ca and Sr or mixtures thereof and a' is from 0.1 to 0.8. Preferably, a' is from 0.4 to 0.7. In another aspect of the invention, an electrical interconnection material for a solid oxide fuel cell comprises Y[sub 1[minus]b]Ca[sub b]Cr[sub 1[minus]c]Al[sub c]O[sub 3], where b' is from 0.1 to 0.6 and c' is from 0 to 9.3. Preferably, b' is from 0.3 to 0.5 and c' is from 0.05 to 0.1. A composite solid oxide electrochemical fuel cell incorporating these materials comprises: a solid oxide air electrode and an adjacent solid oxide electrical interconnection which commonly include the cation Y, the air electrode comprising Y[sub 1[minus]a]Q[sub a]MnO[sub 3], where Q is selected from the group consisting of Ca and Sr or mixtures thereof and a' is from 0.1 to 0.8, the electrical interconnection comprising Y[sub 1[minus]b]Ca[sub b]Cr[sub 1[minus]c]Al[sub c]O[sub 3], where b' is from 0.1 to 0.6 and c' is from 0.0 to 0.3; a yttrium stabilized solid electrolyte comprising (1[minus]d)ZrO[sub 2]-(d)Y[sub 2]O[sub 3] where d' is from 0.06 to 0.5; and a solid fuel electrode comprising X-ZrO[sub 2], where X' is an elemental metal. 5 figs.

  20. Solid oxide fuel cells, and air electrode and electrical interconnection materials therefor

    DOE Patents [OSTI]

    Bates, J. Lambert

    1992-01-01

    In one aspect of the invention, an air electrode material for a solid oxide fuel cell comprises Y.sub.1-a Q.sub.a MnO.sub.3, where "Q" is selected from the group consisting of Ca and Sr or mixtures thereof and "a" is from 0.1 to 0.8. Preferably, "a" is from 0.4 to 0.7. In another aspect of the invention, an electrical interconnection material for a solid oxide fuel cell comprises Y.sub.1-b Ca.sub.b Cr.sub.1-c Al.sub.c O.sub.3, where "b" is from 0.1 to 0.6 and "c" is from 0 to 9.3. Preferably, "b" is from 0.3 to 0.5 and "c" is from 0.05 to 0.1. A composite solid oxide electrochemical fuel cell incorporating these materials comprises: a solid oxide air electrode and an adjacent solid oxide electrical interconnection which commonly include the cation Y, the air electrode comprising Y.sub.1-a Q.sub.a MnO.sub.3, where "Q" is selected from the group consisting of Ca and Sr or mixtures thereof and "a" is from 0.1 to 0.8, the electrical interconnection comprising Y.sub.1-b Ca.sub.b Cr.sub.1-c Al.sub.c O.sub.3, where "b" is from 0.1 to 0.6 and "c" is from 0.0 to 0.3; a yttrium stabilized solid electrolyte comprising (1-d)ZrO.sub.2 -(d)Y.sub.2 O.sub.3 where "d" is from 0.06 to 0.5; and a solid fuel electrode comprising X-ZrO.sub.2, where "X" is an elemental metal.

  1. Grain Boundary Percolation Modeling of Fission Gas Release in Oxide Fuels

    SciTech Connect (OSTI)

    Paul C. Millett; Michael R. Tonks; S. B. Biner

    2012-05-01

    We present a new approach to fission gas release modeling in oxide fuels based on grain boundary network percolation. The method accounts for variability in the bubble growth and coalescence rates on individual grain boundaries, and the resulting effect on macroscopic fission gas release. Two-dimensional representa- tions of fuel pellet microstructures are considered, and the resulting gas release rates are compared with traditional two-stage Booth models, which do not account for long-range percolation on grain boundary net- works. The results show that the requirement of percolation of saturated grain boundaries can considerably reduce the total gas release rates, particularly when gas resolution is considered.

  2. Reliability of fast reactor mixed-oxide fuel during operational transients

    SciTech Connect (OSTI)

    Boltax, A.; Neimark, L.A.; Tsai, Hanchung ); Katsuragawa, M.; Shikakura, S. . Oarai Engineering Center)

    1991-07-01

    Results are presented from the cooperative DOE and PNC Phase 1 and 2 operational transient testing programs conducted in the EBR-2 reactor. The program includes second (D9 and PNC 316 cladding) and third (FSM, AST and ODS cladding) generation mixed-oxide fuel pins. The irradiation tests include duty cycle operation and extended overpower tests. the results demonstrate the capability of second generation fuel pins to survive a wide range of duty cycle and extended overpower events. 15 refs., 9 figs., 4 tabs.

  3. Method of fabricating an integral gas seal for fuel cell gas distribution assemblies

    DOE Patents [OSTI]

    Dettling, Charles J.; Terry, Peter L.

    1988-03-22

    A porous gas distribution plate assembly for a fuel cell, such as a bipolar assembly, includes an inner impervious region wherein the bipolar assembly has good surface porosity but no through-plane porosity and wherein electrical conductivity through the impervious region is maintained. A hot-pressing process for forming the bipolar assembly includes placing a layer of thermoplastic sealant material between a pair of porous, electrically conductive plates, applying pressure to the assembly at elevated temperature, and allowing the assembly to cool before removing the pressure whereby the layer of sealant material is melted and diffused into the porous plates to form an impervious bond along a common interface between the plates holding the porous plates together. The distribution of sealant within the pores along the surface of the plates provides an effective barrier at their common interface against through-plane transmission of gas.

  4. Integral gas seal for fuel cell gas distribution assemblies and method of fabrication

    DOE Patents [OSTI]

    Dettling, Charles J.; Terry, Peter L.

    1985-03-19

    A porous gas distribution plate assembly for a fuel cell, such as a bipolar assembly, includes an inner impervious region wherein the bipolar assembly has good surface porosity but no through-plane porosity and wherein electrical conductivity through the impervious region is maintained. A hot-pressing process for forming the bipolar assembly includes placing a layer of thermoplastic sealant material between a pair of porous, electrically conductive plates, applying pressure to the assembly at elevated temperature, and allowing the assembly to cool before removing the pressure whereby the layer of sealant material is melted and diffused into the porous plates to form an impervious bond along a common interface between the plates holding the porous plates together. The distribution of sealant within the pores along the surface of the plates provides an effective barrier at their common interface against through-plane transmission of gas.

  5. Fabrication of superconducting metal-oxide textiles by heating impregnated polymeric material in a weakly oxidizing atmosphere

    SciTech Connect (OSTI)

    Van den Sype, J.S.

    1993-07-13

    A process is described for producing crystalline fibers, textiles or shapes comprised of YBa[sub 2]Cu[sub 3]O[sub 7[minus]x] where x varies from about 0 to about 0.4, said process comprising: (a) impregnating a preformed organic polymeric material with three metal compounds to provide metal elements in said material in substantially the atomic ratio occurring in said YBa[sub 2]Cu[sub 3]O[sub 7[minus]x]; (b) heating said impregnated material in a weakly oxidizing atmosphere containing from about 0.05% to about 2% oxygen by volume to a temperature sufficiently high to at least partially pyrolize and oxidize said organic material and at least partially oxidize said metal compounds substantially without ignition of said organic material and without formation of a molten phase or reaching a decomposition temperature of said YBa[sub 2]Cu[sub 3]O[sub 7[minus]x]; and (c) cooling the resulting material in at least a moderately oxidizing atmosphere to room temperature so as to obtain said fibers, textiles or shapes.

  6. SPS Fabrication of Tungsten-Rhenium Alloys in Support of NTR Fuels Development

    SciTech Connect (OSTI)

    Jonathan A. Webb; Indrajit Charit; Cory Sparks; Darryl P. Butt; Megan Frary; Mark Carroll

    2011-02-01

    Abstract. Tungsten metal slugs were fabricated via Spark Plasma Sintering (SPS) of powdered metals at temperatures ranging from 1575 K to 1975 K and hold times of 5 minutes to 30 minutes, using powders with an average diameter of 7.8 ?m. Sintered tungsten specimens were found to have relative densities ranging from 83 % to 94 % of the theoretical density for tungsten. Consolidated specimens were also tested for their Vickers Hardness Number (VHN), which was fitted as a function of relative density; the fully consolidated VHN was extrapolated to be 381.45 kg/mm2. Concurrently, tungsten and rhenium powders with average respective diameters of 0.5 ?m and 13.3 ?m were pre-processed either by High-Energy-Ball-Milling (HEBM) or by homogeneous mixing to yield W-25at.%Re mixtures. The powder batches were sintered at temperatures of 1975 K and 2175 K for hold times ranging from 0 minutes to 60 minutes yielding relative densities ranging from 94% to 97%. The combination of HEBM and sintering showed a significant decrease in the inter-metallic phases compared to that of the homogenous mixing and sintering.

  7. Manifold, bus support and coupling arrangement for solid oxide fuel cells

    DOE Patents [OSTI]

    Parry, Gareth W. (East Windsor, CT)

    1989-01-01

    Individual, tubular solid oxide fuel cells (SOFCs) are assembled into bundles called a module within a housing, with a plurality of modules arranged end-to-end in a linear, stacked configuration called a string. A common set of piping comprised of a suitable high temperture resistant material (1) provides fuel and air to each module housing, (2) serves as electrically conducting buses, and (3) provides structural support for a string of SOFC modules. The piping thus forms a manfold for directing fuel and air to each module in a string and makes electrical contact with the module's anode and cathode to conduct the DC power generated by the SOFC. The piping also provides structureal support for each individual module and maintains each string of modules as a structurally integral unit for ensuring high strength in a large 3-dimensional array of SOFC modules. Ceramic collars are used to connect fuel and air inlet piping to each of the electrodes in an SOFC module and provide (1) electrical insulation for the current carrying bus bars and gas manifolds, (2) damping for the fuel and air inlet piping, and (3) proper spacing between the fuel and air inlet piping to prevent contact between these tubes and possible damage to the SOFC.

  8. Tubular solid oxide fuel cells with porous metal supports and ceramic interconnections

    DOE Patents [OSTI]

    Huang, Kevin; Ruka, Roswell J.

    2012-05-08

    An intermediate temperature solid oxide fuel cell structure capable of operating at from 600.degree. C. to 800.degree. C. having a very thin porous hollow elongated metallic support tube having a thickness from 0.10 mm to 1.0 mm, preferably 0.10 mm to 0.35 mm, a porosity of from 25 vol. % to 50 vol. % and a tensile strength from 700 GPa to 900 GPa, which metallic tube supports a reduced thickness air electrode having a thickness from 0.010 mm to 0.2 mm, a solid oxide electrolyte, a cermet fuel electrode, a ceramic interconnection and an electrically conductive cell to cell contact layer.

  9. Oxygen reduction and transportation mechanisms in solid oxide fuel cell cathodes

    SciTech Connect (OSTI)

    Li YH, Gemmen R, Liu XB

    2010-06-01

    In recent years, various models have been developed for describing the reaction mechanisms in solid oxide fuel cell (SOFC) especially for the cathode electrode. However, many fundamental issues regarding the transport of oxygen and electrode kinetics have not been fully understood. This review tried to summarize the present status of the SOFC cathode modeling efforts, and associated experimental approaches on this topic. In addition, unsolved problems and possible future research directions for SOFC cathode kinetics had been discussed

  10. Glass Fiber Mesh Method of Joining for Solid Oxide Fuel Cells - Energy

    Broader source: All U.S. Department of Energy (DOE) Office Webpages (Extended Search)

    Innovation Portal Glass Fiber Mesh Method of Joining for Solid Oxide Fuel Cells Pacific Northwest National Laboratory Contact PNNL About This Technology A simple schematic shows the physical properties of each component and how/where the seal is applied to form an insulating barrier. A simple schematic shows the physical properties of each component and how/where the seal is applied to form an insulating barrier. Test results conclude that the glass fiber method of sealing is stronger when

  11. Glass-Ceramic Seal for Solid-Oxide Fuel Cells - Energy Innovation Portal

    Broader source: All U.S. Department of Energy (DOE) Office Webpages (Extended Search)

    Glass and Glass Products (2010 MECS) Glass and Glass Products (2010 MECS) Manufacturing Energy and Carbon Footprint for Glass Sector (NAICS 3272, 327993) Energy use data source: 2010 EIA MECS (with adjustments) Footprint Last Revised: February 2014 View footprints for other sectors here. Manufacturing Energy and Carbon Footprint PDF icon Glass and Glass Products More Documents & Publications MECS 2006 - Glass Textiles

    Glass-Ceramic Seal for Solid-Oxide Fuel Cells Pacific Northwest

  12. Fabrication of heterojunction solar cells by improved tin oxide deposition on insulating layer

    DOE Patents [OSTI]

    Feng, Tom (Morris Plains, NJ); Ghosh, Amal K. (New Providence, NJ)

    1980-01-01

    Highly efficient tin oxide-silicon heterojunction solar cells are prepared by heating a silicon substrate, having an insulating layer thereon, to provide a substrate temperature in the range of about 300.degree. C. to about 400.degree. C. and thereafter spraying the so-heated substrate with a solution of tin tetrachloride in a organic ester boiling below about 250.degree. C. Preferably the insulating layer is naturally grown silicon oxide layer.

  13. Cost Study for Manufacturing of Solid Oxide Fuel Cell Power Systems

    SciTech Connect (OSTI)

    Weimar, Mark R.; Chick, Lawrence A.; Gotthold, David W.; Whyatt, Greg A.

    2013-09-30

    Solid oxide fuel cell (SOFC) power systems can be designed to produce electricity from fossil fuels at extremely high net efficiencies, approaching 70%. However, in order to penetrate commercial markets to an extent that significantly impacts world fuel consumption, their cost will need to be competitive with alternative generating systems, such as gas turbines. This report discusses a cost model developed at PNNL to estimate the manufacturing cost of SOFC power systems sized for ground-based distributed generation. The power system design was developed at PNNL in a study on the feasibility of using SOFC power systems on more electric aircraft to replace the main engine-mounted electrical generators [Whyatt and Chick, 2012]. We chose to study that design because the projected efficiency was high (70%) and the generating capacity was suitable for ground-based distributed generation (270 kW).

  14. Mixed-oxide fuel decay heat analysis for BWR LOCA safety evaluation

    SciTech Connect (OSTI)

    Chiang, R. T.

    2013-07-01

    The mixed-oxide (MOX) fuel decay heat behavior is analyzed for Boiling Water Reactor (BWR) Loss of Coolant Accident (LOCA) safety evaluation. The physical reasoning on why the decay heat power fractions of MOX fuel fission product (FP) are significantly lower than the corresponding decay heat power fractions of uranium-oxide (UOX) fuel FP is illustrated. This is primarily due to the following physical phenomena. -The recoverable energies per fission of plutonium (Pu)-239 and Pu-241 are significantly higher than those of uranium (U)-235 and U-238. Consequently, the fission rate required to produce the same amount of power in MOX fuel is significantly lower than that in UOX fuel, which leads to lower subsequent FP generation rate and associated decay heat power in MOX fuel than those in UOX fuel. - The effective FP decay energy per fission of Pu-239 is significantly lower than the corresponding effective FP decay energy per fission of U-235, e.g., Pu-239's 10.63 Mega-electron-Volt (MeV) vs. U-235's 12.81 MeV at the cooling time 0.2 second. This also leads to lower decay heat power in MOX fuel than that in UOX fuel. The FP decay heat is shown to account for more than 90% of the total decay heat immediately after shutdown. The FP decay heat results based on the American National Standard Institute (ANSI)/American Nuclear Society (ANS)-5.1-1979 standard method are shown very close to the corresponding FP decay heat results based on the ANSI/ANS-5.1-2005 standard method. The FP decay heat results based on the ANSI/ANS-5.1-1979 simplified method are shown very close to but mostly slightly lower than the corresponding FP decay heat results based on the ANSI/ANS-5.1-1971 method. The FP decay heat results based on the ANSI/ANS-5.1-1979 simplified method or the ANSI/ANS-5.1-1971 method are shown significantly larger than the corresponding FP decay heat results based on the ANSI/ANS-5.1-1979 standard method or the ANSI/ANS-5.1-2005 standard method. (authors)

  15. Fundamental Studies of the Durability of Materials for Interconnects in Solid Oxide Fuel Cells

    SciTech Connect (OSTI)

    Frederick S. Pettit; Gerald H. Meier

    2006-06-30

    Ferritic stainless steels are a leading candidate material for use as an SOFC interconnect, but have the problem of forming volatile chromia species that lead to cathode poisoning. This project has focused both on optimization of ferritic alloys for SOFC applications and evaluating the possibility of using alternative materials. The initial efforts involved studying the oxidation behavior of a variety of chromia-forming ferritic stainless steels in the temperature range 700-900 C in atmospheres relevant to solid oxide fuel cell operation. The alloys exhibited a wide variety of oxidation behavior based on composition. A method for reducing the vaporization is to add alloying elements that lead to the formation of a thermally grown oxide layer over the protective chromia. Several commercial steels form manganese chromate on the surface. This same approach, combined with observations of TiO{sub 2} overlayer formation on the chromia forming, Ni-based superalloy IN 738, has resulted in the development of a series of Fe-22 Cr-X Ti alloys (X=0-4 wt%). Oxidation testing has indicated that this approach results in significant reduction in chromia evaporation. Unfortunately, the Ti also results in accelerated chromia scale growth. Fundamental thermo-mechanical aspects of the durability of solid oxide fuel cell (SOFC) interconnect alloys have also been investigated. A key failure mechanism for interconnects is the spallation of the chromia scale that forms on the alloy, as it is exposed to fuel cell environments. Indentation testing methods to measure the critical energy release rate (Gc) associated with the spallation of chromia scale/alloy systems have been evaluated. This approach has been used to evaluate the thermomechanical stability of chromia films as a function of oxidation exposure. The oxidation of pure nickel in SOFC environments was evaluated using thermogravimetric analysis (TGA) to determine the NiO scaling kinetics and a four-point probe was used to measure the area-specific resistance (ASR) to estimate the electrical degradation of the interconnect. In addition to the baseline study of pure nickel, steps were taken to decrease the ASR through alloying and surface modifications. Finally, high conductivity composite systems, consisting of nickel and silver, were studied. These systems utilize high conductivity silver pathways through nickel while maintaining the mechanical stability that a nickel matrix provides.

  16. Neutron Emission Characteristics of Two Mixed-Oxide Fuels: Simulations and Initial Experiments

    SciTech Connect (OSTI)

    D. L. Chichester; S. A. Pozzi; J. L. Dolan; M. Flaska; J. T. Johnson; E. H. Seabury; E. M. Gantz

    2009-07-01

    Simulations and experiments have been carried out to investigate the neutron emission characteristics of two mixed-oxide (MOX) fuels at Idaho National Laboratory (INL). These activities are part of a project studying advanced instrumentation techniques in support of the U.S. Department of Energy's Fuel Cycle Research and Development program and it's Materials Protection, Accounting, and Control for Transmutation (MPACT) campaign. This analysis used the MCNP-PoliMi Monte Carlo simulation tool to determine the relative strength and energy spectra of the different neutron source terms within these fuels, and then used this data to simulate the detection and measurement of these emissions using an array of liquid scintillator neutron spectrometers. These calculations accounted for neutrons generated from the spontaneous fission of the actinides in the MOX fuel as well as neutrons created via (alpha,n) reactions with oxygen in the MOX fuel. The analysis was carried out to allow for characterization of both neutron energy as well as neutron coincidences between multiple detectors. Coincidences between prompt gamma rays and neutrons were also analyzed. Experiments were performed at INL with the same materials used in the simulations to benchmark and begin validation tests of the simulations. Data was collected in these experiments using an array of four liquid scintillators and a high-speed waveform digitizer. Advanced digital pulse-shape discrimination algorithms were developed and used to collect this data. Results of the simulation and modeling studies are presented together with preliminary results from the experimental campaign.

  17. AFIP-4 Fabrication Summary Report

    SciTech Connect (OSTI)

    Glenn A. Moore

    2010-02-01

    The AFIP-4 (ATR Full –size-plate In center flux trap Position) experiment was designed to evaluate the performance of monolithic fuels at a scale prototypic of research reactor fuel plates. Twelve qualified fueled plates were fabricated for the AFIP-4 experiment; to be irradiated in the INL Advanced Test Reactor (ATR). This report provides details of the fuel fabrication efforts; including material selection, fabrication processes, and fuel plate qualification.

  18. AFIP-6 Fabrication Summary Report

    SciTech Connect (OSTI)

    Glenn A. Moore; M. Craig Marshall

    2011-09-01

    The AFIP-6 (ATR Full-size plate In center flux trap Position) experiment was designed to evaluate the performance of monolithic fuels at a scale prototypic of research reactor fuel plates. Two qualified fueled plates were fabricated for the AFIP-6 experiment; to be irradiated in the INL Advanced Test Reactor (ATR). This report provides details of the fuel fabrication efforts, including material selection, fabrication processes, and fuel plate qualification.

  19. AFIP-2 Fabrication Summary Report

    SciTech Connect (OSTI)

    Glenn Moore

    2010-02-01

    The Advanced Test Reactor (ATR) Full-size Plate In Center Flux Trap Position (AFIP)-2 experiment was designed to evaluate the performance of monolithic fuels at a scale prototypic of research reactor fuel plates. Two qualified fueled plates were fabricated for the AFIP 2 experiment to be irradiated in the Idaho National Laboratory ATR. This report provides details of the fuel fabrication efforts, including material selection, fabrication processes, and fuel plate qualification.

  20. Microstructural characterization of a thin film ZrN diffusion barrier in an As-fabricated U7Mo/Al matrix dispersion fuel plate

    SciTech Connect (OSTI)

    Keiser, Dennis D.; Perez, Emmanuel; Wiencek, Tom; Leenaers, Ann; Van den Berghe, Sven

    2015-03-01

    The United States High Performance Research Reactor Fuel Development program is developing low enriched uranium fuels for application in research and test reactors. One concept utilizes U7 wt.% Mo (U7Mo) fuel particles dispersed in Al matrix, where the fuel particles are coated with a 1 ?m-thick ZrN coating. The ZrN serves as a diffusion barrier to eliminate a deleterious reaction that can occur between U7Mo and Al when a dispersion fuel is irradiated under aggressive reactor conditions. To investigate the final microstructure of a physically-vapor-deposited ZrN coating in a dispersion fuel plate after it was fabricated using a rolling process, characterization samples were taken from a fuel plate that was fabricated at 500 C using ZrN-coated U7Mo particles, Al matrix and AA6061 cladding. Scanning electron and transmission electron microscopy analysis were performed. Data from these analyses will be used to support future microstructural examinations of irradiated fuel plates, in terms of understanding the effects of irradiation on the ZrN microstructure, and to determine the role of diffusion barrier microstructure in eliminating fuel/matrix interactions during irradiation. The as-fabricated coating was determined to be cubic-ZrN (cF8) phase. It exhibited a columnar microstructure comprised of nanometer-sized grains and a region of relatively high porosity, mainly near the Al matrix. Small impurity-containing phases were observed at the U7Mo/ZrN interface, and no interaction zone was observed at the ZrN/Al interface. The bonding between the U7Mo and ZrN appeared to be mechanical in nature. A relatively high level of oxygen was observed in the ZrN coating, extending from the Al matrix in the ZrN coating in decreasing concentration. The above microstructural characteristics are discussed in terms of what may be most optimal for a diffusion barrier in a dispersion fuel plate application.

  1. Methods for using novel cathode and electrolyte materials for solid oxide fuel cells and ion transport membranes

    DOE Patents [OSTI]

    Jacobson, Allan J.; Wang, Shuangyan; Kim, Gun Tae

    2016-01-12

    Methods using novel cathode, electrolyte and oxygen separation materials operating at intermediate temperatures for use in solid oxide fuel cells and ion transport membranes include oxides with perovskite related structures and an ordered arrangement of A site cations. The materials have significantly faster oxygen kinetics than in corresponding disordered perovskites.

  2. Zero Emission Power Plants Using Solid Oxide Fuel Cells and Oxygen Transport Membranes

    SciTech Connect (OSTI)

    Shockling, Larry A.; Huang, Keqin; Gilboy, Thomas E.; Christie, G. Maxwell; Raybold, Troy M.

    2001-11-06

    Siemens Westinghouse Power Corp. (SWPC) is engaged in the development of Solid Oxide Fuel Cell stationary power systems. SWPC has combined DOE Developmental funds with commercial customer funding to establish a record of successful SOFC field demonstration power systems of increasing size. SWPC will soon deploy the first unit of a newly developed 250 kWe Combined Heat Power System. It will generate electrical power at greater than 45% electrical efficiency. The SWPC SOFC power systems are equipped to operate on lower number hydrocarbon fuels such as pipeline natural gas, which is desulfurized within the SOFC power system. Because the system operates with a relatively high electrical efficiency, the CO2 emissions, {approx}1.0 lb CO2/ kW-hr, are low. Within the SOFC module the desulfurized fuel is utilized electrochemically and oxidized below the temperature for NOx generation. Therefore the NOx and SOx emissions for the SOFC power generation system are near negligible. The byproducts of the power generation from hydrocarbon fuels that are released into the environment are CO2 and water vapor. This forward looking DOE sponsored Vision 21 program is supporting the development of methods to capture and sequester the CO2, resulting in a Zero Emission power generation system. To accomplish this, SWPC is developing a SOFC module design, to be demonstrated in operating hardware, that will maintain separation of the fuel cell anode gas, consisting of H2, CO, H2O and CO2, from the vitiated air. That anode gas, the depleted fuel stream, containing less than 18% (H2 + CO), will be directed to an Oxygen Transport Membrane (OTM) Afterburner that is being developed by Praxair, Inc.. The OTM is supplied air and the depleted fuel. The OTM will selectively transport oxygen across the membrane to oxidize the remaining H2 and CO. The water vapor is then condensed from the totally 1.5.DOC oxidized fuel stream exiting the afterburner, leaving only the CO2 in gaseous form. That CO2 can then be compressed and sequestered, resulting in a Zero Emission power generation system operating on hydrocarbon fuel that adds only water vapor to the environment. Praxair has been developing oxygen separation systems based on dense walled, mixed electronic, oxygen ion conducting ceramics for a number of years. The oxygen separation membranes find applications in syngas production, high purity oxygen production and gas purification. In the SOFC afterburner application the chemical potential difference between the high temperature SOFC depleted fuel gas and the supplied air provides the driving force for oxygen transport. This permeated oxygen subsequently combusts the residual fuel in the SOFC exhaust. A number of experiments have been carried out in which simulated SOFC depleted fuel gas compositions and air have been supplied to either side of single OTM tubes in laboratory-scale reactors. The ceramic tubes are sealed into high temperature metallic housings which precludes mixing of the simulated SOFC depleted fuel and air streams. In early tests, although complete oxidation of the residual CO and H2 in the simulated SOFC depleted fuel was achieved, membrane performance degraded over time. The source of degradation was found to be contaminants in the simulated SOFC depleted fuel stream. Following removal of the contaminants, stable membrane performance has subsequently been demonstrated. In an ongoing test, the dried afterburner exhaust composition has been found to be stable at 99.2% CO2, 0.4% N2 and 0.6%O2 after 350 hours online. Discussion of these results is presented. A test of a longer, commercial demonstration size tube was performed in the SWPC test facility. A similar contamination of the simulated SOFC depleted fuel stream occurred and the performance degraded over time. A second test is being prepared. Siemens Westinghouse and Praxair are collaborating on the preliminary design of an OTM equipped Afterburner demonstration unit. The intent is to test the afterburner in conjunction with a reduced size SOFC test module that has the anode gas separation features incorporated into the hardware.

  3. Fundamental Study of the Oxidation Characteristics and Pollutant Emissions of Model Biodiesel Fuels

    SciTech Connect (OSTI)

    Feng, Q.; Wang, Y. L.; Egolfopoulos, Fokion N.; Tsotsis, T. T.

    2010-07-18

    In this study, the oxidation characteristics of biodiesel fuels are investigated with the goal of contributing toward the fundamental understanding of their combustion characteristics and evaluating the effect of using these alternative fuels on engine performance as well as on the environment. The focus of the study is on pure fatty acid methyl-esters (FAME,) that can serve as surrogate compounds for real biodiesels. The experiments are conducted in the stagnation-flow configuration, which allows for the systematic evaluation of fundamental combustion and emission characteristics. In this paper, the focus is primarily on the pollutant emission characteristics of two C{sub 4} FAMEs, namely, methyl-butanoate and methyl-crotonate, whose behavior is compared with that of n-butane and n-pentane. To provide insight into the mechanisms of pollutant formation for these fuels, the experimental data are compared with computed results using a model with consistent C1-C4 oxidation and NOx formation kinetics.

  4. Solid State Energy Conversion Alliance (SECA) Solid Oxide Fuel Cell Program

    SciTech Connect (OSTI)

    Nguyen Minh

    2006-07-31

    This report summarizes the work performed for Phase I (October 2001 - August 2006) under Cooperative Agreement DE-FC26-01NT41245 for the U. S. Department of Energy, National Energy Technology Laboratory (DOE/NETL) entitled 'Solid State Energy Conversion Alliance (SECA) Solid Oxide Fuel Cell Program'. The program focuses on the development of a low-cost, high-performance 3-to-10-kW solid oxide fuel cell (SOFC) system suitable for a broad spectrum of power-generation applications. During Phase I of the program significant progress has been made in the area of SOFC technology. A high-efficiency low-cost system was designed and supporting technology developed such as fuel processing, controls, thermal management, and power electronics. Phase I culminated in the successful demonstration of a prototype system that achieved a peak efficiency of 41%, a high-volume cost of $724/kW, a peak power of 5.4 kW, and a degradation rate of 1.8% per 500 hours. . An improved prototype system was designed, assembled, and delivered to DOE/NETL at the end of the program. This prototype achieved an extraordinary peak efficiency of 49.6%.

  5. Basic properties of a liquidt in anode solid oxide fuel cell

    SciTech Connect (OSTI)

    Harry Abernathy; RandallGemmen; KirkGerdes; Mark Koslowske; ThomasTao

    2010-12-17

    An unconventional high temperature fuel cell system, the liquidt in anode solid oxide fuel cell(LTA-SOFC), is discussed. A thermodynamic analysis of a solid oxide fuel cell with a liquid metal anode is developed. Pertinent thermo chemical and thermo physical properties of liquid tin in particular are detailed. An experimental setup for analysis of LTA-SOFC anode kinetics is described, and data for a planar cell under hydrogen indicated an effective oxygen diffusion coefficient of 5.310?5 cm2 s?1 at 800 ?C and 8.910?5 cm2 s?1 at 900 ?C. This value is similar to previously reported literature values for liquid tin. The oxygen conductivity through the tin, calculated from measured diffusion coefficients and theoretical oxygen solubility limits, is found to be on the same order of thatofyttria-stabilizedzirconia(YSZ), a traditional SOFC electrolyte material. As such,the ohmicloss due to oxygen transport through the tin layer must be considered in practical system cell design since the tin layer will usually be at least as thick as the electrolyte.

  6. Plasma reforming and partial oxidation of hydrocarbon fuel vapor to produce synthesis gas and/or hydrogen gas

    DOE Patents [OSTI]

    Kong, Peter C.; Detering, Brent A.

    2003-08-19

    Methods and systems for treating vapors from fuels such as gasoline or diesel fuel in an internal combustion engine, to form hydrogen gas or synthesis gas, which can then be burned in the engine to produce more power. Fuel vapor, or a mixture of fuel vapor and exhaust gas and/or air, is contacted with a plasma, to promote reforming reactions between the fuel vapor and exhaust gas to produce carbon monoxide and hydrogen gas, partial oxidation reactions between the fuel vapor and air to produce carbon monoxide and hydrogen gas, or direct hydrogen and carbon particle production from the fuel vapor. The plasma can be a thermal plasma or a non-thermal plasma. The plasma can be produced in a plasma generating device which can be preheated by contact with at least a portion of the hot exhaust gas stream, thereby decreasing the power requirements of the plasma generating device.

  7. Plasma Reforming And Partial Oxidation Of Hydrocarbon Fuel Vapor To Produce Synthesis Gas And/Or Hydrogen Gas

    DOE Patents [OSTI]

    Kong, Peter C.; Detering, Brent A.

    2004-10-19

    Methods and systems are disclosed for treating vapors from fuels such as gasoline or diesel fuel in an internal combustion engine, to form hydrogen gas or synthesis gas, which can then be burned in the engine to produce more power. Fuel vapor, or a mixture of fuel vapor and exhaust gas and/or air, is contacted with a plasma, to promote reforming reactions between the fuel vapor and exhaust gas to produce carbon monoxide and hydrogen gas, partial oxidation reactions between the fuel vapor and air to produce carbon monoxide and hydrogen gas, or direct hydrogen and carbon particle production from the fuel vapor. The plasma can be a thermal plasma or a non-thermal plasma. The plasma can be produced in a plasma generating device which can be preheated by contact with at least a portion of the hot exhaust gas stream, thereby decreasing the power requirements of the plasma generating device.

  8. Radiation re-solution of fission gas in non-oxide nuclear fuel

    SciTech Connect (OSTI)

    Matthews, Christopher; Schwen, Daniel; Klein, Andrew C.

    2015-02-01

    Renewed interest in fast nuclear reactors is creating a need for better understanding of fission gas bubble behavior in non-oxide fuels to support very long fuel lifetimes. Collisions between fission fragments and their subsequent cascades can knock fission gas atoms out of bubbles and back into the fuel lattice. We showed that these collisions can be treated as using the so-called ‘‘homogenous’’ atom-by-atom re-solution theory and calculated using the Binary Collision Approximation code 3DOT. The calculations showed that there is a decrease in the re-solution parameter as bubble radius increases until about 50 nm, at which the re-solution parameter stays nearly constant. Furthermore, our model shows ion cascades created in the fuel result in many more implanted fission gas atoms than collisions directly with fission fragments. This calculated re-solution parameter can be used to find a re-solution rate for future bubble simulations.

  9. Short time proton dynamics in bulk ice and in porous anode solid oxide fuel cell materials

    SciTech Connect (OSTI)

    Basoli, Francesco; Senesi, Roberto; Kolesnikov, Alexander I; Licoccia, Silvia

    2014-01-01

    Oxygen reduction and incorporation into solid electrolytes and the reverse reaction of oxygen evolution play a cru-cial role in Solid Oxide Fuel Cell (SOFC) applications. However a detailed un derstanding of the kinetics of the cor-responding reactions, i.e. on reaction mechanisms, rate limiting steps, reaction paths, electrocatalytic role of materials, is still missing. These include a thorough characterization of the binding potentials experienced by protons in the lattice. We report results of Inelastic Neutron Scattering (INS) measurements of the vibrational state of the protons in Ni- YSZ highly porous composites (75% to 90% ), a ceramic-metal material showing a high electrical conductivity and ther mal stability, which is known to be most effectively used as anodes for solid ox ide fuel cells. The results are compared with INS and Deep Inelastic Neutron Scattering (DINS) experiments on the proton binding states in bulk ice.

  10. Optimization design of electrodes for anode-supported solid oxide fuel cells via genetic algorithm

    SciTech Connect (OSTI)

    Shi, J.; Xue, X.

    2011-01-01

    Porous electrode is the critical component of solid-oxide fuel cells (SOFCs) and provides a functional material backbone for multi-physicochemical processes. Model based electrode designs could significantly improve SOFC performance. This task is usually performed via parameter studies for simple case and assumed property distributions for graded electrodes. When nonlinearly coupled multiparameters of electrodes are considered, it could be very difficult for the model based parameter study method to effectively and systematically search the design space. In this research, the optimization approach with a genetic algorithm is demonstrated for this purpose. An anode-supported proton conducting SOFC integrated with a fuel supply system is utilized as a physical base for the model development and the optimization design. The optimization results are presented, which are difficult to obtain for parametric study method.

  11. Performance of solid oxide fuel cells approaching the two-dimensional limit

    SciTech Connect (OSTI)

    Kerman, K. Ramanathan, S.

    2014-05-07

    We model electrochemical kinetics and physical conduction mechanisms for carrier transport in electrolyte membranes to determine the limits of dimensionality reduction (down to 1?nm) on maximum power output of solid oxide fuel cells with symmetric Pt electrodes. Using Y-doped ZrO{sub 2}, we find a minimum thickness of ?6?nm to realize near ideal chemical potential in such fuel cells, which is limited by electronic breakdown when approaching the dielectric breakdown strength. For larger electrolyte thicknesses, the greatest source of electronic leakage influencing power loss is from Ohmic transport of minority carriers and emission of trapped carriers. For porous metallic electrodes, an ideal microstructure with the particle size comparable to particle spacing dimensions is found to accurately model experimental results. The role of electronic trap states in the electrolyte band gap on power density characteristics is highlighted.

  12. Solid oxide fuel cells having porous cathodes infiltrated with oxygen-reducing catalysts

    DOE Patents [OSTI]

    Liu, Meilin; Liu, Ze; Liu, Mingfei; Nie, Lifang; Mebane, David Spencer; Wilson, Lane Curtis; Surdoval, Wayne

    2014-08-12

    Solid-oxide fuel cells include an electrolyte and an anode electrically coupled to a first surface of the electrolyte. A cathode is provided, which is electrically coupled to a second surface of the electrolyte. The cathode includes a porous backbone having a porosity in a range from about 20% to about 70%. The porous backbone contains a mixed ionic-electronic conductor (MIEC) of a first material infiltrated with an oxygen-reducing catalyst of a second material different from the first material.

  13. Rapid thermal cycling of metal-supported solid oxide fuel cellmembranes

    SciTech Connect (OSTI)

    Matus, Yuriy B.; De Jonghe, Lutgard C.; Jacobson, Craig P.; Visco, Steven J.

    2004-01-02

    Solid oxide fuel cell (SOFC) membranes were developed in which zirconia-based electrolyte thin films were supported by a composite metal/ceramic electrode, and were subjected to rapid thermal cycling between 200 and 800 C. The effects of this cycling on membrane performance were evaluated. The membranes, not yet optimized for performance, showed a peak power density of 350mW/cm2at 900 C in laboratory-sized SOFCs that was not affected by the thermal cycling. This resistance to cycling degradation is attributed to the close matching of thermal expansion coefficient of the cermet support electrode with that of the zirconia electrolyte.

  14. Cassettes for solid-oxide fuel cell stacks and methods of making the same

    DOE Patents [OSTI]

    Weil, K. Scott; Meinhardt, Kerry D; Sprenkle, Vincent L

    2012-10-23

    Solid-oxide fuel cell (SOFC) stack assembly designs are consistently investigated to develop an assembly that provides optimal performance, and durability, within desired cost parameters. A new design includes a repeat unit having a SOFC cassette and being characterized by a three-component construct. The three components include an oxidation-resistant, metal window frame hermetically joined to an electrolyte layer of a multi-layer, anode-supported ceramic cell and a pre-cassette including a separator plate having a plurality of vias that provide electrical contact between an anode-side collector within the pre-cassette and a cathode-side current collector of an adjacent cell. The third component is a cathode-side seal, which includes a standoff that supports a cathode channel spacing between each of the cassettes in a stack. Cassettes are formed by joining the pre-cassette and the window frame.

  15. Detailed chemical kinetic mechanism for the oxidation of biodiesel fuels blend surrogate.

    SciTech Connect (OSTI)

    Herbinet, O; Pitz, W J; Westbrook, C K

    2009-07-21

    Detailed chemical kinetic mechanisms were developed and used to study the oxidation of two large unsaturated esters: methyl-5-decenoate and methyl-9-decenoate. These models were built from a previous methyl decanoate mechanism and were compared with rapeseed oil methyl esters oxidation experiments in a jet stirred reactor. A comparative study of the reactivity of these three oxygenated compounds was performed and the differences in the distribution of the products of the reaction were highlighted showing the influence of the presence and the position of a double bond in the chain. Blend surrogates, containing methyl decanoate, methyl-5-decenoate, methyl-9-decenoate and n-alkanes, were tested against rapeseed oil methyl esters and methyl palmitate/n-decane experiments. These surrogate models are realistic kinetic tools allowing the study of the combustion of biodiesel fuels in diesel and homogeneous charge compression ignition engines.

  16. Detailed chemical kinetic mechanism for the oxidation of biodiesel fuels blend surrogate

    SciTech Connect (OSTI)

    Herbinet, Olivier; Pitz, William J.; Westbrook, Charles K.

    2010-05-15

    Detailed chemical kinetic mechanisms were developed and used to study the oxidation of two large unsaturated esters: methyl-5-decenoate and methyl-9-decenoate. These models were built from a previous methyl decanoate mechanism and were compared with rapeseed oil methyl esters oxidation experiments in a jet-stirred reactor. A comparative study of the reactivity of these three oxygenated compounds was performed and the differences in the distribution of the products of the reaction were highlighted showing the influence of the presence and the position of a double bond in the chain. Blend surrogates, containing methyl decanoate, methyl-5-decenoate, methyl-9-decenoate and n-alkanes, were tested against rapeseed oil methyl esters and methyl palmitate/n-decane experiments. These surrogate models are realistic kinetic tools allowing the study of the combustion of biodiesel fuels in diesel and homogeneous charge compression ignition engines. (author)

  17. Field test of short-notice random inspections for inventory-change verification at a low-enriched-uranium fuel-fabrication plant: Preliminary summary

    SciTech Connect (OSTI)

    Fishbone, L.G. |; Moussalli, G.; Naegele, G.; Ikonomou, P.; Hosoya, M.; Scott, P.; Fager, J.; Sanders, C.; Colwell, D.; Joyner, C.J.

    1994-04-01

    An approach of short-notice random inspections (SNRIs) for inventory-change verification can enhance the effectiveness and efficiency of international safeguards at natural or low-enriched uranium (LEU) fuel fabrication plants. According to this approach, the plant operator declares the contents of nuclear material items before knowing if an inspection will occur to verify them. Additionally, items about which declarations are newly made should remain available for verification for an agreed time. This report details a six-month field test of the feasibility of such SNRIs which took place at the Westinghouse Electric Corporation Commercial Nuclear Fuel Division. Westinghouse personnel made daily declarations about both feed and product items, uranium hexafluoride cylinders and finished fuel assemblies, using a custom-designed computer ``mailbox``. Safeguards inspectors from the IAEA conducted eight SNRIs to verify these declarations. Items from both strata were verified during the SNRIs by means of nondestructive assay equipment. The field test demonstrated the feasibility and practicality of key elements of the SNRI approach for a large LEU fuel fabrication plant.

  18. Composite solid oxide fuel cell anode based on ceria and strontium titanate

    DOE Patents [OSTI]

    Marina, Olga A.; Pederson, Larry R.

    2008-12-23

    An anode and method of making the same wherein the anode consists of two separate phases, one consisting of a doped strontium titanate phase and one consisting of a doped cerium oxide phase. The strontium titanate phase consists of Sr.sub.1-xM.sub.xTiO.sub.3-.delta., where M is either yttrium (Y), scandium (Sc), or lanthanum (La), where "x" may vary typically from about 0.01 to about 0.5, and where .delta. is indicative of some degree of oxygen non-stoichiometry. A small quantity of cerium may also substitute for titanium in the strontium titanate lattice. The cerium oxide consists of N.sub.yCe.sub.1-yO.sub.2-.delta., where N is either niobium (Nb), vanadium (V), antimony (Sb) or tantalum (Ta) and where "y" may vary typically from about 0.001 to about 0.1 and wherein the ratio of Ti in said first phase to the sum of Ce and N in the second phase is between about 0.2 to about 0.75. Small quantities of strontium, yttrium, and/or lanthanum may additionally substitute into the cerium oxide lattice. The combination of these two phases results in better performance than either phase used separately as an anode for solid oxide fuel cell or other electrochemical device.

  19. Modeling of autoignition and NO sensitization for the oxidation of IC engine surrogate fuels

    SciTech Connect (OSTI)

    Anderlohr, J.M. |; Bounaceur, R.; Battin-Leclerc, F.; Pires Da Cruz, A.

    2009-02-15

    This paper presents an approach for modeling with one single kinetic mechanism the chemistry of the autoignition and combustion processes inside an internal combustion engine, as well as the chemical kinetics governing the postoxidation of unburned hydrocarbons in engine exhaust gases. Therefore a new kinetic model was developed, valid over a wide range of temperatures including the negative temperature coefficient regime. The model simulates the autoignition and the oxidation of engine surrogate fuels composed of n-heptane, iso-octane, and toluene, which are sensitized by the presence of nitric oxides. The new model was obtained from previously published mechanisms for the oxidation of alkanes and toluene where the coupling reactions describing interactions between hydrocarbons and NO{sub x} were added. The mechanism was validated against a wide range of experimental data obtained in jet-stirred reactors, rapid compression machines, shock tubes, and homogeneous charge compression ignition engines. Flow rate and sensitivity analysis were performed in order to explain the low temperature chemical kinetics, especially the impact of NO{sub x} on hydrocarbon oxidation. (author)

  20. Method of improving fuel cell performance by removing at least one metal oxide contaminant from a fuel cell electrode

    DOE Patents [OSTI]

    Kim, Yu Seung; Choi, Jong-Ho; Zelenay, Piotr

    2009-08-18

    A method of removing contaminants from a fuel cell catalyst electrode. The method includes providing a getter electrode and a fuel cell catalyst electrode having at least one contaminant to a bath and applying a voltage sufficient to drive the contaminant from the fuel cell catalyst electrode to the getter electrode. Methods of removing contaminants from a membrane electrode assembly of a fuel cell and of improving performance of a fuel cell are also provided.

  1. Performance of fast reactor mixed-oxide fuels pins during extended overpower transients

    SciTech Connect (OSTI)

    Tsai, H.; Neimark, L.A. ); Asaga, T.; Shikakura, S. )

    1991-02-01

    The Operational Reliability Testing (ORT) program, a collaborative effort between the US Department of Energy and the Power Reactor and Nuclear Fuel Development Corp. (PNC) of Japan, was initiated in 1982 to investigate the behavior of mixed-oxide fuel pin under various slow-ramp transient and duty-cycle conditions. In the first phase of the program, a series of four extended overpower transient tests, with severity sufficient to challenge the pin cladding integrity, was conducted. The objectives of the designated TOPI-1A through -1D tests were to establish the cladding breaching threshold and mechanisms, and investigate the thermal and mechanical effects of the transient on pin behavior. The tests were conducted in EBR-2, a normally steady-state reactor. The modes of transient operation in EBR-2 were described in a previous paper. Two ramp rates, 0.1%/s and 10%/s, were selected to provide a comparison of ramp-rate effects on fuel behavior. The test pins chosen for the series covered a range of design and pre-test irradiation parameters. In the first test (1A), all pins maintained their cladding integrity during the 0.1%/s ramp to 60% peak overpower. Fuel pins with aggressive designs, i.e., high fuel- smear density and/or thin cladding, were, therefore, included in the follow-up 1B and 1C tests to enhance the likelihood of achieving cladding breaching. In the meantime, a higher pin overpower capability, to greater than 100%, was established by increasing the reactor power limit from 62.5 to 75 MWt. In this paper, the significant results of the 1B and 1C tests are presented. 4 refs., 5 figs., 1 tab.

  2. OXIDATION OF MERCURY ACROSS SCR CATALYSTS IN COAL-FIRED POWER PLANTS BURNING LOW RANK FUELS

    SciTech Connect (OSTI)

    Constance Senior

    2004-12-31

    The objectives of this program were to measure the oxidation of mercury in flue gas across SCR catalyst in a coal-fired power plant burning low rank fuels using a slipstream reactor containing multiple commercial catalysts in parallel and to develop a greater understanding of mercury oxidation across SCR catalysts in the form of a simple model. The Electric Power Research Institute (EPRI) and Argillon GmbH provided co-funding for this program. REI used a multicatalyst slipstream reactor to determine oxidation of mercury across five commercial SCR catalysts at a power plant that burned a blend of 87% subbituminous coal and 13% bituminous coal. The chlorine content of the blend was 100 to 240 {micro}g/g on a dry basis. Mercury measurements were carried out when the catalysts were relatively new, corresponding to about 300 hours of operation and again after 2,200 hours of operation. NO{sub x}, O{sub 2} and gaseous mercury speciation at the inlet and at the outlet of each catalyst chamber were measured. In general, the catalysts all appeared capable of achieving about 90% NO{sub x} reduction at a space velocity of 3,000 hr{sup -1} when new, which is typical of full-scale installations; after 2,200 hours exposure to flue gas, some of the catalysts appeared to lose NO{sub x} activity. For the fresh commercial catalysts, oxidation of mercury was in the range of 25% to 65% at typical full-scale space velocities. A blank monolith showed no oxidation of mercury under any conditions. All catalysts showed higher mercury oxidation without ammonia, consistent with full-scale measurements. After exposure to flue gas for 2,200 hours, some of the catalysts showed reduced levels of mercury oxidation relative to the initial levels of oxidation. A model of Hg oxidation across SCRs was formulated based on full-scale data. The model took into account the effects of temperature, space velocity, catalyst type and HCl concentration in the flue gas.

  3. Systemic inflammatory changes and increased oxidative stress in rural Indian women cooking with biomass fuels

    SciTech Connect (OSTI)

    Dutta, Anindita; Department of Experimental Hematology, Chittaranjan National Cancer Institute, 37, S.P. Mukherjee Road, Kolkata-700 026 ; Ray, Manas Ranjan; Banerjee, Anirban

    2012-06-15

    The study was undertaken to investigate whether regular cooking with biomass aggravates systemic inflammation and oxidative stress that might result in increase in the risk of developing cardiovascular disease (CVD) in rural Indian women compared to cooking with a cleaner fuel like liquefied petroleum gas (LPG). A total of 635 women (median age 36 years) who cooked with biomass and 452 age-matched control women who cooked with LPG were enrolled. Serum interleukin-6 (IL-6), C-reactive protein (CRP), tumor necrosis factor-alpha (TNF-?) and interleukin-8 (IL-8) were measured by ELISA. Generation of reactive oxygen species (ROS) by leukocytes was measured by flow cytometry, and erythrocytic superoxide dismutase (SOD) was measured by spectrophotometry. Hypertension was diagnosed following the Seventh Report of the Joint Committee. Tachycardia was determined as pulse rate > 100 beats per minute. Particulate matter of diameter less than 10 and 2.5 ?m (PM{sub 10} and PM{sub 2.5}, respectively) in cooking areas was measured using real-time aerosol monitor. Compared with control, biomass users had more particulate pollution in indoor air, their serum contained significantly elevated levels of IL-6, IL-8, TNF-? and CRP, and ROS generation was increased by 37% while SOD was depleted by 41.5%, greater prevalence of hypertension and tachycardia compared to their LPG-using neighbors. PM{sub 10} and PM{sub 2.5} levels were positively associated with markers of inflammation, oxidative stress and hypertension. Inflammatory markers correlated with raised blood pressure. Cooking with biomass exacerbates systemic inflammation, oxidative stress, hypertension and tachycardia in poor women cooking with biomass fuel and hence, predisposes them to increased risk of CVD development compared to the controls. Systemic inflammation and oxidative stress may be the mechanistic factors involved in the development of CVD. -- Highlights: ? Effect of chronic biomass smoke exposure on cardiovascular health was investigated. ? Serum markers of systemic inflammation and oxidative stress were studied. ? Biomass using women had increased systemic inflammation and oxidative stress. ? Indoor air pollution and observed changes were positively associated.

  4. Atomistic Simulations of Mass and Thermal Transport in Oxide Nuclear Fuels

    SciTech Connect (OSTI)

    Andersson, Anders D.; Uberuaga, Blas P.; Du, Shiyu; Liu, Xiang-Yang; Nerikar, Pankaj; Stanek, Christopher R.; Tonks, Michael; Millet, Paul; Biner, Bulent

    2012-06-04

    In this talk we discuss simulations of the mass and thermal transport in oxide nuclear fuels. Redistribution of fission gases such as Xe is closely coupled to nuclear fuel performance. Most fission gases have low solubility in the fuel matrix, specifically the insolubility is most pronounced for large fission gas atoms such as Xe, and as a result there is a significant driving force for segregation of gas atoms to grain boundaries or dislocations and subsequently for nucleation of gas bubbles at these sinks. The first step of the fission gas redistribution is diffusion of individual gas atoms through the fuel matrix to existing sinks, which is governed by the activation energy for bulk diffusion. Fission gas bubbles are then formed by either separate nucleation events or by filling voids that were nucleated at a prior stage; in both cases their formation and latter growth is coupled to vacancy dynamics and thus linked to the production of vacancies via irradiation or thermal events. In order to better understand bulk Xe behavior (diffusion mechanisms) in UO{sub 2{+-}x} we first calculate the relevant activation energies using density functional theory (DFT) techniques. By analyzing a combination of Xe solution thermodynamics, migration barriers and the interaction of dissolved Xe atoms with U, we demonstrate that Xe diffusion predominantly occurs via a vacancy-mediated mechanism, though other alternatives may exist in high irradiation fields. Since Xe transport is closely related to diffusion of U vacancies, we have also studied the activation energy for this process. In order to explain the low value of 2.4 eV found for U migration from independent damage experiments (not thermal equilibrium) the presence of vacancy clusters must be included in the analysis. Next a continuum transport model for Xe and U is formulated based on the diffusion mechanisms established from DFT. After combining this model with descriptions of the interaction between Xe and grain boundaries derived from separate atomistic calculations, we simulate Xe redistribution for a few simple microstructures using finite element methods (FEM), as implemented in the MOOSE framework from Idaho National Laboratory. Thermal transport together with the power distribution determines the temperature distribution in the fuel rod and it is thus one of the most influential properties on nuclear fuel performance. The fuel thermal conductivity changes as function of time due to microstructure evolution (e.g. fission gas redistribution) and compositional changes. Using molecular dynamics simulations we have studied the impact of different types of grain boundaries and fission gas bubbles on UO{sub 2} thermal conductivity.

  5. A solid oxide fuel cell power system: 1992--1993 field operation

    SciTech Connect (OSTI)

    Veyo, S.E.; Kusunoki, A.; Takeuchi, S.; Kaneko, S.; Yokoyama, H.

    1994-05-01

    Westinghouse has deployed fully integrated, automatically controlled, packaged solid oxide fuel cell (SOFC) power generation systems in order to obtain useful customer feedback. Recently, Westinghouse has deployed 20 kW class natural gas fueled SOFC generator modules integrated into two 25 kW SOFC systems, the first with The UTILITIES, a Japanese consortium. The UTILITIES 25 kW SOFC system is the focus of this paper. The unit was shipped to the Rokko Island Test Center for Advanced Energy Systems (near Kobe, Japan) operated by Kansai Electric Power Co.; testing was initiated February 1992. Module A operated for 2601 hours at an ave output 16.6 kW dc; final shutdown was induced by current stability problems with dissipator (restart not possible because of damaged cells). Module B operated for 1579 hours at ave output 17.8 kWdc. The unit was damaged by operation at excessively high fuel utilization > 91%. It was rebuilt and returned to Rokko Island. This module B2 operated for 1843 hours on PNG; shutdown was cuased by air supply failure. After a new blower and motor were installed July 1993, the system was restarted August 5, 1993 and operated continuously until November 10, 1993, when an automatic shutdown was induced as part of a MITI licensing inspection. After restart, the unit passed 6000 hours of operation on desulfurized PNG on January 25, 1994. Westinghouse`s future plans are outlined.

  6. The Modeling of a Standalone Solid-Oxide Fuel Cell Auxiliary Power Unit

    SciTech Connect (OSTI)

    Lu, Ning; Li, Qinghe; Sun, Xin; Khaleel, Mohammad A.

    2006-10-27

    In this research, a Simulink model of a standalone vehicular solid-oxide fuel cell (SOFC) auxiliary power unit (APU) is developed. The SOFC APU model consists of three major components: a controller model; a power electronics system model; and an SOFC plant model, including an SOFC stack module; two heat exchanger modules; and a combustor module. This paper discusses the development of the nonlinear dynamic models for the SOFC stacks, the heat exchangers and the combustors. When coupling with a controller model and a power electronic circuit model, the developed SOFC plant model is able to model the thermal dynamics and the electrochemical dynamics inside the SOFC APU components as well as the transient responses to the electric loading changes. It has been shown that having such a model for the SOFC APU will benefit design engineers to adjust design parameters to optimize the performance. The modeling results of the heat-up stage of an SOFC APU and the output voltage response to a sudden load change are presented in the paper. The fuel flow regulation based on fuel utilization is also briefly discussed.

  7. Batch fabrication of mesoporous boron-doped nickel oxide nanoflowers for electrochemical capacitors

    SciTech Connect (OSTI)

    Yang, Jing-He; Yu, Qingtao; Li, Yamin; Mao, Liqun; Ma, Ding

    2014-11-15

    Highlights: A new facile liquid-phase method has been employed for synthesis boron-doped NiO nanoflowers. The specific surface area of NiO is as high as 200 m{sup 2} g{sup ?1}. NiO nanoflowers exhibit a high specific capacitance of ?1309 F g{sup ?1} at a charge and discharge current density of 3 A g{sup ?1}. NiO nanoflowers have excellent cycling ability and even after 2500 cycles there is no significant reduction in specific capacitance. - Abstract: Boron-doped nickel oxide (B-NiO) nanoflowers are prepared by simple thermal decomposition of nickel hydroxide. B-NiO is porous sphere with a diameter of about 400 nm. B-NiO nanoflowers are composed of approximately 30 nm nanoplates and the thickness of the nanosheets is approximately 3 nm. The specific surface area of the material is as high as 200 m{sup 2} g{sup ?1} and the pore size distribution curves of B-NiO has three typical peaks in the range of mesoporous (5 nm, 13 nm and 18 nm). As an electrode for supercapacitors, the crystalline B-NiO nanoflowers have favorable characteristics, for instance, a specific capacitance of 1309 F g{sup ?1} at a current density of 3 A g{sup ?1} and no significant reduction in Coulombic efficiency after 2500 cycles at 37.5 A g{sup ?1}. This remarkable electrochemical performance will make B-NiO nanoflowers a promising electrode material for high performance supercapacitors.

  8. High-temperature Chemical Compatibility of As-fabricated TRIGA Fuel and Type 304 Stainless Steel Cladding

    SciTech Connect (OSTI)

    Dennis D. Keiser, Jr.; Jan-Fong Jue; Eric Woolstenhulme; Kurt Terrani; Glenn A. Moore

    2012-09-01

    Chemical interaction between TRIGA fuel and Type-304 stainless steel cladding at relatively high temperatures is of interest from the point of view of understanding fuel behavior during different TRIGA reactor transient scenarios. Since TRIGA fuel comes into close contact with the cladding during irradiation, there is an opportunity for interdiffusion between the U in the fuel and the Fe in the cladding to form an interaction zone that contains U-Fe phases. Based on the equilibrium U-Fe phase diagram, a eutectic can develop at a composition between the U6Fe and UFe2 phases. This eutectic composition can become a liquid at around 725°C. From the standpoint of safe operation of TRIGA fuel, it is of interest to develop better understanding of how a phase with this composition may develop in irradiated TRIGA fuel at relatively high temperatures. One technique for investigating the development of a eutectic phase at the fuel/cladding interface is to perform out-of-pile diffusion-couple experiments at relatively high temperatures. This information is most relevant for lightly irradiated fuel that just starts to touch the cladding due to fuel swelling. Similar testing using fuel irradiated to different fission densities should be tested in a similar fashion to generate data more relevant to more heavily irradiated fuel. This report describes the results for TRIGA fuel/Type-304 stainless steel diffusion couples that were annealed for one hour at 730 and 800°C. Scanning electron microscopy with energy- and wavelength-dispersive spectroscopy was employed to characterize the fuel/cladding interface for each diffusion couple to look for evidence of any chemical interaction. Overall, negligible fuel/cladding interaction was observed for each diffusion couple.

  9. Electrical Generation for More-Electric Aircraft Using Solid Oxide Fuel Cells

    SciTech Connect (OSTI)

    Whyatt, Greg A.; Chick, Lawrence A.

    2012-04-01

    This report examines the potential for Solid-Oxide Fuel Cells (SOFC) to provide electrical generation on-board commercial aircraft. Unlike a turbine-based auxiliary power unit (APU) a solid oxide fuel cell power unit (SOFCPU) would be more efficient than using the main engine generators to generate electricity and would operate continuously during flight. The focus of this study is on more-electric aircraft which minimize bleed air extraction from the engines and instead use electrical power obtained from generators driven by the main engines to satisfy all major loads. The increased electrical generation increases the potential fuel savings obtainable through more efficient electrical generation using a SOFCPU. However, the weight added to the aircraft by the SOFCPU impacts the main engine fuel consumption which reduces the potential fuel savings. To investigate these relationships the Boeing 787­8 was used as a case study. The potential performance of the SOFCPU was determined by coupling flowsheet modeling using ChemCAD software with a stack performance algorithm. For a given stack operating condition (cell voltage, anode utilization, stack pressure, target cell exit temperature), ChemCAD software was used to determine the cathode air rate to provide stack thermal balance, the heat exchanger duties, the gross power output for a given fuel rate, the parasitic power for the anode recycle blower and net power obtained from (or required by) the compressor/expander. The SOFC is based on the Gen4 Delphi planar SOFC with assumed modifications to tailor it to this application. The size of the stack needed to satisfy the specified condition was assessed using an empirically-based algorithm. The algorithm predicts stack power density based on the pressure, inlet temperature, cell voltage and anode and cathode inlet flows and compositions. The algorithm was developed by enhancing a model for a well-established material set operating at atmospheric pressure to reflect the effect of elevated pressure and to represent the expected enhancement obtained using a promising cell material set which has been tested in button cells but not yet used to produce full-scale stacks. The predictions for the effect of pressure on stack performance were based on literature. As part of this study, additional data were obtained on button cells at elevated pressure to confirm the validity of the predictions. The impact of adding weight to the 787-8 fuel consumption was determined as a function of flight distance using a PianoX model. A conceptual design for a SOFC power system for the Boeing 787 is developed and the weight estimated. The results indicate that the power density of the stacks must increase by at least a factor of 2 to begin saving fuel on the 787 aircraft. However, the conceptual design of the power system may still be useful for other applications which are less weight sensitive.

  10. Hydrous pyrolysis/oxidation process for in situ destruction of chlorinated hydrocarbon and fuel hydrocarbon contaminants in water and soil

    DOE Patents [OSTI]

    Knauss, Kevin G.; Copenhaver, Sally C.; Aines, Roger D.

    2000-01-01

    In situ hydrous pyrolysis/oxidation process is useful for in situ degradation of hydrocarbon water and soil contaminants. Fuel hydrocarbons, chlorinated hydrocarbons, polycyclic aromatic hydrocarbons, petroleum distillates and other organic contaminants present in the soil and water are degraded by the process involving hydrous pyrolysis/oxidation into non-toxic products of the degradation. The process uses heat which is distributed through soils and water, optionally combined with oxygen and/or hydrocarbon degradation catalysts, and is particularly useful for remediation of solvent, fuel or other industrially contaminated sites.

  11. Method of fabrication of electrodes and electrolytes

    DOE Patents [OSTI]

    Jankowski, Alan F.; Morse, Jeffrey D.

    2004-01-06

    Fuel cell stacks contain an electrolyte layer surrounded on top and bottom by an electrode layer. Porous electrodes are prepared which enable fuel and oxidant to easily flow to the respective electrode-electrolyte interface without the need for high temperatures or pressures to assist the flow. Rigid, inert microspheres in combination with thin-film metal deposition techniques are used to fabricate porous anodes, cathodes, and electrolytes. Microshperes contained in a liquid are randomly dispersed onto a host structure and dried such that the microsperes remain in position. A thin-film deposition technique is subsequently employed to deposit a metal layer onto the microsperes. After such metal layer deposition, the microspheres are removed leaving voids, i.e. pores, in the metal layer, thus forming a porous electrode. Successive repetitions of the fabrication process result in the formation of a continuous fuel cell stack. Such stacks may produce power outputs ranging from about 0.1 Watt to about 50 Watts.

  12. Effect of pre-oxidation and environmental aging on the seal strength of a novel high-temperature solid oxide fuel cell (SOFC) sealing glass with metallic interconnect

    SciTech Connect (OSTI)

    Chou, Y. S.; Stevenson, Jeffry W.; Singh, Prabhakar

    2008-09-15

    A novel high-temperature alkaline-earth silicate sealing glass was developed for solid oxide fuel cell (SOFC) applications. The glass was used to join two ferritic stainless steel coupons for strength evaluation. The steel coupons were pre-oxidized at elevated temperatures to promote thick oxide layers to simulate long-term exposure conditions. In addition, seals to as-received metal coupons were also tested after aging in oxidizing or reducing environments to simulate the actual SOFC environment. Room temperature tensile testing showed strength degradation when using pre-oxidized coupons, and more extensive degradation after aging in air. Fracture surface and microstructural analysis confirmed that the cause of degradation was formation of SrCrO4 at the outer sealing edges exposed to air.

  13. Electrocatalytic Activity of Transition Metal Oxide-Carbon Composites for Oxygen Reduction in Alkaline Batteries and Fuel Cells

    SciTech Connect (OSTI)

    Malkhandi, S; Trinh, P; Manohar, AK; Jayachandrababu, KC; Kindler, A; Prakash, GKS; Narayanan, SR

    2013-06-07

    Conductive transition metal oxides (perovskites, spinels and pyrochlores) are attractive as catalysts for the air electrode in alkaline rechargeable metal-air batteries and fuel cells. We have found that conductive carbon materials when added to transition metal oxides such as calcium-doped lanthanum cobalt oxide, nickel cobalt oxide and calcium-doped lanthanum manganese cobalt oxide increase the electrocatalytic activity of the oxide for oxygen reduction by a factor of five to ten. We have studied rotating ring-disk electrodes coated with (a) various mass ratios of carbon and transition metal oxide, (b) different types of carbon additives and (c) different types of transition metal oxides. Our experiments and analysis establish that in such composite catalysts, carbon is the primary electro- catalyst for the two-electron electro-reduction of oxygen to hydroperoxide while the transition metal oxide decomposes the hydroperoxide to generate additional oxygen that enhances the observed current resulting in an apparent four-electron process. These findings are significant in that they change the way we interpret previous reports in the scientific literature on the electrocatalytic activity of various transition metal oxide- carbon composites for oxygen reduction, especially where carbon is assumed to be an additive that just enhances the electronic conductivity of the oxide catalyst. (C) 2013 The Electrochemical Society. All rights reserved.

  14. Oxidation of Zircaloy Fuel Cladding in Water-Cooled Nuclear Reactors

    SciTech Connect (OSTI)

    Digby Macdonald; Mirna Urquidi-Macdonald; Yingzi Chen; Jiahe Ai; Pilyeon Park; Han-Sang Kim

    2006-12-12

    Our work involved the continued development of the theory of passivity and passivity breakdown, in the form of the Point Defect Model, with emphasis on zirconium and zirconium alloys in reactor coolant environments, the measurement of critically-important parameters, and the development of a code that can be used by reactor operators to actively manage the accumulation of corrosion damage to the fuel cladding and other components in the heat transport circuits in both BWRs and PWRs. In addition, the modified boiling crevice model has been further developed to describe the accumulation of solutes in porous deposits (CRUD) on fuel under boiling (BWRs) and nucleate boiling (PWRs) conditions, in order to accurately describe the environment that is contact with the Zircaloy cladding. In the current report, we have derived expressions for the total steady-state current density and the partial anodic and cathodic current densities to establish a deterministic basis for describing Zircaloy oxidation. The models are deterministic because the relevant natural laws are satisfied explicitly, most importantly the conversation of mass and charge and the equivalence of mass and charge (Faradays law). Cathodic reactions (oxygen reduction and hydrogen evolution) are also included in the models, because there is evidence that they control the rate of the overall passive film formation process. Under open circuit conditions, the cathodic reactions, which must occur at the same rate as the zirconium oxidation reaction, are instrumental in determining the corrosion potential and hence the thickness of the barrier and outer layers of the passive film. Controlled hydrodynamic methods have been used to measure important parameters in the modified Point Defect Model (PDM), which is now being used to describe the growth and breakdown of the passive film on zirconium and on Zircaloy fuel sheathing in BWRs and PWRs coolant environments. The modified PDMs recognize the existence of a thick oxide outer layer over a thin barrier layer. From thermodynamic analysis, it is postulated that a hydride barrier layer forms under PWR coolant conditions whereas an oxide barrier layer forms under BWR primary coolant conditions. Thus, the introduction of hydrogen into the solution lowers the corrosion potential of zirconium to the extent that the formation of ZrH2 is predicted to be spontaneous rather than the ZrO2. Mott-Schottky analysis shows that the passive film formed on zirconium is n-type, which is consistent with the PDM, corresponding to a preponderance of oxygen/hydrogen vacancies and/or zirconium interstitials in the barrier layer. The model parameter values were extracted from electrochemical impedance spectroscopic data for zirconium in high temperature, de-aerated and hydrogenated environments by optimization. The results indicate that the corrosion resistance of zirconium is dominated by the porosity and thickness of the outer layer for both cases. The impedance model based on the PDM provides a good account of the growth of the bi-layer passive films described above, and the extracted model parameter values might be used, for example, for predicting the accumulation of general corrosion damage to Zircaloy fuel sheath in BWR and PWR operating environments. Transients in current density and film thickness for passive film formation on zirconium in dearated and hydrogenated coolant conditions have confirmed that the rate law afforded by the Point Defect Model (PDM) adequately describes the growth and thinning of the passive film. The experimental results demonstrate that the kinetics of oxygen or hydrogen vacancy generation at the metal/film interface control the rate of film growth, when the potential is displaced in the positive direction, whereas the kinetics of dissolution of the barrier layer at the barrier layer/solution interface control the rate of passive film thinning when the potential is stepped in the negative direction. In addition, the effects of second phase particles (SPPs) on the electrochemistry of passive zirconium in the

  15. Modeling of selected ceramic processing parameters employed in the fabrication of 238PuO2 fuel pellets

    SciTech Connect (OSTI)

    Brockman, R. A.; Kramer, D. P.; Barklay, C. D.; Cairns-Gallimore, D.; Brown, J. L.; Huling, J. C.; Van Pelt, C. E.

    2011-10-01

    Recent deep space missions utilize the thermal output of the radioisotope plutonium-238 as the fuel in the thermal to electrical power system. Since the application of plutonium in its elemental state has several disadvantages, the fuel employed in these deep space power systems is typically in the oxide form such as plutonium-238 dioxide (238PuO2). As an oxide, the processing of the plutonium dioxide into fuel pellets is performed via ''classical'' ceramic processing unit operations such as sieving of the powder, pressing, sintering, etc. Modeling of these unit operations can be beneficial in the understanding and control of processing parameters with the goal of further enhancing the desired characteristics of the 238PuO2 fuel pellets. A finite element model has been used to help identify the time-temperature-stress profile within a pellet during a furnace operation taking into account that 238PuO2 itself has a significant thermal output. The results of the modeling efforts will be discussed.

  16. fuel

    National Nuclear Security Administration (NNSA)

    4%2A en Cheaper catalyst may lower fuel costs for hydrogen-powered cars http:www.nnsa.energy.govblogcheaper-catalyst-may-lower-fuel-costs-hydrogen-powered-cars

  17. fuel

    National Nuclear Security Administration (NNSA)

    4%2A en Cheaper catalyst may lower fuel costs for hydrogen-powered cars http:nnsa.energy.govblogcheaper-catalyst-may-lower-fuel-costs-hydrogen-powered-cars

  18. ZERO EMISSION POWER PLANTS USING SOLID OXIDE FUEL CELLS AND OXYGEN TRANSPORT MEMBRANES

    SciTech Connect (OSTI)

    G. Maxwell Christie; Troy M. Raybold

    2003-06-10

    Over 16,700 hours of operational experience was gained for the Oxygen Transport Membrane (OTM) elements of the proposed SOFC/OTM zero-emission power generation concept. It was repeatedly demonstrated that OTMs with no additional oxidation catalysts were able to completely oxidize the remaining depleted fuel in a simulated SOFC anode exhaust at an O{sub 2} flux that met initial targets. In such cases, neither residual CO nor H{sub 2} were detected to the limits of the gas chromatograph (<10 ppm). Dried OTM afterburner exhaust streams contained up to 99.5% CO{sub 2}. Oxygen flux through modified OTMs was double or even triple that of the standard OTMs used for the majority of testing purposes. Both the standard and modified membranes in laboratory-scale and demonstration-sized formats exhibited stable performance over extended periods (2300 to 3500 hours or 3 to 5 months). Reactor contaminants, were determined to negatively impact OTM performance stability. A method of preventing OTM performance degradation was developed and proven to be effective. Information concerning OTM and seal reliability over extended periods and through various chemical and thermal shocks and cycles was also obtained. These findings were used to develop several conceptual designs for pilot (10 kWe) and commercial-scale (250 kWe) SOFC/OTM zero emission power generation systems.

  19. Combined Theoretical and Experimental Analysis of Processes Determining Cathode Performance in Solid Oxide Fuel Cells

    SciTech Connect (OSTI)

    Kukla, Maija M.; Kotomin, Eugene Alexej; Merkle, R.; Mastrikov, Yuri; Maier, J.

    2013-02-11

    Solid oxide fuel cells (SOFC) are under intensive investigation since the 1980s as these devices open the way for ecologically clean direct conversion of the chemical energy into electricity, avoiding the efficiency limitation by Carnots cycle for thermochemical conversion. However, the practical development of SOFC faces a number of unresolved fundamental problems, in particular concerning the kinetics of the electrode reactions, especially oxygen reduction reaction. We review recent experimental and theoretical achievements in the current understanding of the cathode performance by exploring and comparing mostly three materials: (La,Sr)MnO3 (LSM), (La,Sr)(Co,Fe)O3 (LSCF) and (Ba,Sr)(Co,Fe)O3 (BSCF). Special attention is paid to a critical evaluation of advantages and disadvantages of BSCF, which shows the best cathode kinetics known so far for oxides. We demonstrate that it is the combined experimental and theoretical analysis of all major elementary steps of the oxygen reduction reaction which allows us to predict the rate determining steps for a given material under specific operational conditions and thus control and improve SOFC performance.

  20. FRAPCON-2: A Computer Code for the Calculation of Steady State Thermal-Mechanical Behavior of Oxide Fuel Rods

    SciTech Connect (OSTI)

    Berna, G. A; Bohn, M. P.; Rausch, W. N.; Williford, R. E.; Lanning, D. D.

    1981-01-01

    FRAPCON-2 is a FORTRAN IV computer code that calculates the steady state response of light Mater reactor fuel rods during long-term burnup. The code calculates the temperature, pressure, deformation, and tai lure histories of a fuel rod as functions of time-dependent fuel rod power and coolant boundary conditions. The phenomena modeled by the code include (a) heat conduction through the fuel and cladding, (b) cladding elastic and plastic deformation, (c) fuel-cladding mechanical interaction, (d) fission gas release, (e} fuel rod internal gas pressure, (f) heat transfer between fuel and cladding, (g) cladding oxidation, and (h) heat transfer from cladding to coolant. The code contains necessary material properties, water properties, and heat transfer correlations. FRAPCON-2 is programmed for use on the CDC Cyber 175 and 176 computers. The FRAPCON-2 code Is designed to generate initial conditions for transient fuel rod analysis by either the FRAP-T6 computer code or the thermal-hydraulic code, RELAP4/MOD7 Version 2.

  1. Co-flow anode/cathode supply heat exchanger for a solid-oxide fuel cell assembly

    DOE Patents [OSTI]

    Haltiner, Jr., Karl J.; Kelly, Sean M.

    2005-11-22

    In a solid-oxide fuel cell assembly, a co-flow heat exchanger is provided in the flow paths of the reformate gas and the cathode air ahead of the fuel cell stack, the reformate gas being on one side of the exchanger and the cathode air being on the other. The reformate gas is at a substantially higher temperature than is desired in the stack, and the cathode gas is substantially cooler than desired. In the co-flow heat exchanger, the temperatures of the reformate and cathode streams converge to nearly the same temperature at the outlet of the exchanger. Preferably, the heat exchanger is formed within an integrated component manifold (ICM) for a solid-oxide fuel cell assembly.

  2. Performance of Anode-Supported Solid Oxide Fuel Cell with Thin Bi-Layer Electrolyte by Pulsed Laser Deposition

    SciTech Connect (OSTI)

    Lu, Zigui; Hardy, John S.; Templeton, Jared W.; Stevenson, Jeffry W.; Fisher, Daniel; Wu, Naijuan; Ignatiev, Alex

    2012-07-15

    Anode-supported yttria stabilized zirconia (YSZ)/samaria doped ceria (SDC) bi-layer electrolytes with uniform thickness and high density were fabricated by pulsed laser deposition at 1000 degrees C. Fuel cells with such bi-layer electrolytes were fabricated and tested, yielding open circuit voltages from 0.94 to 1.0 V at 600-700 degrees C. Power densities from 0.4 to 1.0 W cm{sup -2} at 0.7 V were achieved in air at temperatures of 600-700 degrees C. Cell performance was improved in flowing oxygen, with an estimated peak power density of over 2 W cm{sup -2} at 650 degrees C, assuming the same overall resistance over the entire range of current density. The high cell performance was attributed to the very low ohmic resistance of the fuel cell, owing to the small thickness of the electrolyte. Stable performance was also demonstrated in that the voltage of the fuel cell showed very little change at a constant current density of 1 A cm{sup -2} during more than 400 hours of operation at 650 degrees C in flowing oxygen. SEM analysis of the fuel cell after testing showed that the bi-layer electrolyte had retained its chemical and mechanical integrity.

  3. Design, Fabrication, and Operation of Innovative Microalgae Culture Experiments for the Purpose of Producing Fuels: Final Report, Phase I

    SciTech Connect (OSTI)

    Not Available

    1985-01-01

    A conceptual design was developed for a 1000-acre (water surface) algae culture facility for the production of fuels. The system is modeled after the shallow raceway system with mixing foils that is now being operated at the University of Hawaii. A computer economic model was created to calculate the discounted breakeven price of algae or fuels produced by the culture facility. A sensitivity analysis was done to estimate the impact of changes in important biological, engineering, and financial parameters on product price.

  4. Exergy & Economic Analysis of Catalytic Coal Gasifiers Coupled with Solid Oxide Fuel Cells

    SciTech Connect (OSTI)

    Siefert, Nicholas; Litster, Shawn

    2012-01-01

    The National Energy Technology Laboratory (NETL) has undertaken a review of coal gasification technologies that integrate with solid oxide fuel cells (SOFC) to achieve system efficiencies near 60% while capturing and sequestering >90% of the carbon dioxide. One way to achieve an overall system efficiency of greater than 60% is in a power plant in which a catalytic coal gasifier produces a syngas with a methane composition of roughly 25% on a dry volume basis and this is sent to a SOFC, with CO{sub 2} capture occurring either before or after the SOFC. Integration of a catalytic gasifier with a SOFC, as opposed to a conventional entrained flow gasifier, is improved due to (a) decreased exergy destruction inside a catalytic, steam-coal gasifier producing a high-methane content syngas, and (b) decreased exergy destruction in the SOFC due to the ability to operate at lower air stoichiometric flow ratios. For example, thermal management of the SOFC is greatly improved due to the steam-methane reforming in the anode of the fuel cell. This paper has two main goals. First, we converted the levelized cost of electricity (LCOE) estimates of various research groups into an average internal rate of return on investment (IRR) in order to make comparisons between their results, and to underscore the increased rate of return on investment for advanced integrated gasification fuel cell systems with carbon capture & sequestration (IGFC-CCS) compared with conventional integrated gasification combined cycle (IGCC-CCS) systems and pulverized coal combustion (PCC-CCS) systems. Using capital, labor, and fuel costs from previous researchers and using an average price of baseload electricity generation of $61.50 / MW-hr, we calculated inflation-adjusted IRR values of up to 13%/yr for catalytic gasification with pressurized fuel cell and carbon dioxide capture and storage (CCS), whereas we calculate an IRR of ∼4%/yr and ∼2%/yr for new, conventional IGCC-CCS and PCC-CCS, respectively. If the carbon dioxide is used for enhanced oil recovery rather than for saline aquifer storage, then the IRR values improve to 16%/yr, 10%/yr, and 8%/yr, respectively. For comparison, the IRR of a new conventional IGCC or PCC power plant without CO{sub 2} capture are estimated to be 11%/yr and 15.0%/yr, respectively. Second, we conducted an exergy analysis of two different configurations in which syngas from a catalytic gasifier fuels a SOFC. In the first case, the CO{sub 2} is captured before the SOFC, and the anode tail gas is sent back to the catalytic gasifier. In the second case, the anode tail gas is oxy-combusted using oxygen ion ceramic membranes and then CO{sub 2} is captured for sequestration. In both cases, we find that the system efficiency is greater than 60%. These values compare well with previous system analysis. In future work, we plan to calculate the IRR of these two cases and compare with previous economic analyses conducted at NETL.

  5. Fuels

    Broader source: All U.S. Department of Energy (DOE) Office Webpages (Extended Search)

    Fueling the Next Generation of Vehicle Technology Fueling the Next Generation of Vehicle Technology February 6, 2013 - 11:20am Addthis Professor Jack Brouwer, Associate Director and Chief Technology Officer of the National Fuel Cell Research Center, points out the tri-generation facility that uses biogas from Orange County Sanitation District’s wastewater treatment plant to produce hydrogen, heat and power. | Photo courtesy of the Energy Department. Professor Jack Brouwer, Associate

  6. Field test of short-notice random inspections for inventory-change verification at a low-enriched-uranium fuel-fabrication plant

    SciTech Connect (OSTI)

    Fishbone, L.G. |; Moussalli, G.; Naegele, G.

    1995-05-01

    An approach of short-notice random inspections (SNRIs) for inventory-change verification can enhance the effectiveness and efficiency of international safeguards at natural or low-enriched uranium (LEU) fuel fabrication plants. According to this approach, the plant operator declares the contents of nuclear material items before knowing if an inspection will occur to verify them. Additionally, items about which declarations are newly made should remain available for verification for an agreed time. Then a statistical inference can be made from verification results for items verified during SNRIs to the entire populations, i.e. the entire strata, even if inspectors were not present when many items were received or produced. A six-month field test of the feasibility of such SNRIs took place at the Westinghouse Electric Corporation Commercial Nuclear Fuel Division during 1993. Westinghouse personnel made daily declarations about both feed and product items, uranium hexafluoride cylinders and finished fuel assemblies, using a custom-designed computer ``mailbox``. Safeguards inspectors from the IAEA conducted eight SNRIs to verify these declarations. They arrived unannounced at the plant, in most cases immediately after travel from Canada, where the IAEA maintains a regional office. Items from both strata were verified during the SNRIs by meant of nondestructive assay equipment.

  7. On the possibility of using uranium-beryllium oxide fuel in a VVER reactor

    SciTech Connect (OSTI)

    Kovalishin, A. A.; Prosyolkov, V. N.; Sidorenko, V. D.; Stogov, Yu. V.

    2014-12-15

    The possibility of using UO{sub 2}-BeO fuel in a VVER reactor is considered with allowance for the thermophysical properties of this fuel. Neutron characteristics of VVER fuel assemblies with UO{sub 2}-BeO fuel pellets are estimated.

  8. Effects of Zircaloy oxidation and steam dissociation on PWR core heat-up under conditions simulating uncovered fuel rods

    SciTech Connect (OSTI)

    Viskanta, R.; Mohanty, A.K.

    1986-04-01

    The studies described in this report identify the regimes of slow transients in a partially uncovered core of a PWR. The threshold height and onset time for oxidation of the cladding of a fuel rod have been evaluated. The effects of oxidation in increasing the decay heat load, component temperature, reduction of cladding thickness and generation of hydrogen have been estimated. The condition for steam starvation has been determined. At high uncovered core heights, typically say 2.8 m for a geometry simulating the TMI-2 type of reactor, the solid and coolant temperatures can reach the limits of steam dissociation. The effects of radiation heat exchange between cladding and coolant, Zircaloy oxidation, steam dissociation, gap conductance between fuel and cladding and system pressure on the heatup of fuel rods have been investigated. The time for uncovering a certain core height is taken as the independent parameter. It is seen that if the uncovering process is allowed to continue beyond 9 minutes corresponding to an uncovered height of 1.9 m, onset of cladding oxidation can be a reality. These values provide a guideline for the response time of the emergency core cooling systems. 10 refs., 22 figs.

  9. Proliferation resistance and the advanced fuel cycle facility (AFCF)

    SciTech Connect (OSTI)

    DeMuth, Scott; Thomas, Kenneth; Tobin, Stephen

    2007-07-01

    The planned Advanced Fuel Cycle Facility (AFCF) is intended to support the Global Nuclear Energy Partnership (GNEP) by demonstrating separation and fuel fabrication processes required to support an Advanced Burner Reactor. The processes, materials and safeguards will be selected and designed to enhance proliferation resistance beyond that of the existing plutonium based mixed oxide (MOX) fuel cycle. This paper explores the concept of proliferation resistance and how the AFCF will advance the related state of the art. (authors)

  10. Exploration of alloy 441 chemistry for solid oxide fuel cell interconnect application

    SciTech Connect (OSTI)

    Paul D. Jablonski; Christopher J. Cowen; John S. Sears

    2010-02-01

    Alloy 441 stainless steel (UNS S 44100) is being considered for application as an SOFC interconnect material. There are several advantages to the selection of this alloy over other iron-based or nickel-based alloys: first and foremost alloy 441ss is a production alloy which is both low in cost and readily available. Second, the coefficient of thermal expansion (CTE) more closely matches the CTE of the adjoining ceramic components of the fuel cell. Third, this alloy forms the Laves phase at typical SOFC operating temperatures of 600800 C. It is thought that the Laves phase preferentially consumes the Si present in the alloy microstructure. As a result it has been postulated that the long-term area specific resistance (ASR) performance degradation often seen with other ferritic stainless steels, which is associated with the formation of electrically resistive Si-rich oxide subscales, may be avoidable with alloy 441ss. In this paper we explore the physical metallurgy of alloy 441, combining computational thermodynamics with experimental verification, and discuss the results with regards to Laves phase formation under SOFC operating conditions. We show that the incorporation of the Laves phase into the microstructure cannot in itself remove sufficient Si from the ferritic matrix in order to completely avoid the formation of Si-rich oxide subscales. However, the thickness, morphology, and continuity of the Si-rich subscale that forms in this alloy is modified in comparison to non-Laves forming ferritic stainless steel alloys and therefore may not be as detrimental to long-term SOFC performance.

  11. Exploration of alloy 441 chemistry for solid oxide fuel cell interconnect application

    SciTech Connect (OSTI)

    Jablonski PD, Cowen CJ, Sears JS

    2010-02-01

    Alloy 441 stainless steel (UNS S 44100) is being considered for application as an SOFC interconnect material. There are several advantages to the selection of this alloy over other iron-based or nickel-based alloys: first and foremost alloy 441ss is a production alloy which is both low in cost and readily available. Second, the coefficient of thermal expansion (CTE) more closely matches the CTE of the adjoining ceramic components of the fuel cell. Third, this alloy forms the Laves phase at typical SOFC operating temperatures of 600800 ?C. It is thought that the Laves phase preferentially consumes the Si present in the alloy microstructure. As a result it has been postulated that the long-term area specific resistance (ASR) performance degradation often seen with other ferritic stainless steels, which is associated with the formation of electrically resistive Si-rich oxide subscales, may be avoidable with alloy 441ss. In this paper we explore the physical metallurgy of alloy 441, combining computational thermodynamics with experimental verification, and discuss the results with regards to Laves phase formation under SOFC operating conditions. We show that the incorporation of the Laves phase into the microstructure cannot in itself remove sufficient Si from the ferritic matrix in order to completely avoid the formation of Si-rich oxide subscales. However, the thickness, morphology, and continuity of the Si-rich subscale that forms in this alloy is modified in comparison to non-Laves forming ferritic stainless steel alloys and therefore may not be as detrimental to long-term SOFC performance

  12. Depleted uranium oxides and silicates as spent nuclear fuel waste package fill materials

    SciTech Connect (OSTI)

    Forsberg, C.W.

    1996-09-10

    A new repository waste package (WP) concept for spent nuclear fuel (SNF) is being investigated that uses depleted uranium (DU) to improve performance and reduce the uncertainties of geological disposal of SNF. The WP would be filled with SNF and then filled with depleted uranium (DU) ({approximately}0.2 wt % {sup 235}U) dioxide (UO{sub 2}) or DU silicate-glass beads. Fission products and actinides can not escape the SNF UO{sub 2} crystals until the UO{sub 2} dissolves or is transformed into other chemical species. After WP failure, the DU fill material slows dissolution by three mechanisms: (1) saturation of AT groundwater with DU and suppression of SNF dissolution, (2) maintenance of chemically reducing conditions in the WP that minimize SNF solubility by sacrificial oxidation of DU from the +4 valence state, and (3) evolution of DU to lower-density hydrated uranium silicates. The fill expansion seals the WP from water flow. The DU also isotopically exchanges with SNF uranium as the SNF degrades to reduce long-term nuclear-criticality concerns.

  13. Lanthanum manganite-based air electrode for solid oxide fuel cells

    DOE Patents [OSTI]

    Ruka, Roswell J.; Kuo, Lewis; Li, Baozhen

    1999-01-01

    An air electrode material for a solid oxide fuel cell is disclosed. The electrode material is based on lanthanum manganite having a perovskite-like crystal structure ABO.sub.3. The A-site of the air electrode material preferably comprises La, Ca, Ce and at least one lanthanide selected from Sm, Gd, Dy, Er, Y and Nd. The B-site of the electrode material comprises Mn with substantially no dopants. The ratio of A:B is preferably slightly above 1. A preferred air electrode composition is of the formula La.sub.w Ca.sub.x Ln.sub.y Ce.sub.z MnO.sub.3, wherein Ln comprises at least one lanthanide selected from Sm, Gd, Dy, Er, Y and Nd, w is from about 0.55 to about 0.56, x is from about 0.255 to about 0.265, y is from about 0.175 to about 0.185, and z is from about 0.005 to about 0.02. The air electrode material possesses advantageous chemical and electrical properties as well as favorable thermal expansion and thermal cycle shrinkage characteristics.

  14. Lanthanum manganite-based air electrode for solid oxide fuel cells

    DOE Patents [OSTI]

    Ruka, R.J.; Kuo, L.; Li, B.

    1999-06-29

    An air electrode material for a solid oxide fuel cell is disclosed. The electrode material is based on lanthanum manganite having a perovskite-like crystal structure ABO[sub 3]. The A-site of the air electrode material preferably comprises La, Ca, Ce and at least one lanthanide selected from Sm, Gd, Dy, Er, Y and Nd. The B-site of the electrode material comprises Mn with substantially no dopants. The ratio of A:B is preferably slightly above 1. A preferred air electrode composition is of the formula La[sub w]Ca[sub x]Ln[sub y]Ce[sub z]MnO[sub 3], wherein Ln comprises at least one lanthanide selected from Sm, Gd, Dy, Er, Y and Nd, w is from about 0.55 to about 0.56, x is from about 0.255 to about 0.265, y is from about 0.175 to about 0.185, and z is from about 0.005 to about 0.02. The air electrode material possesses advantageous chemical and electrical properties as well as favorable thermal expansion and thermal cycle shrinkage characteristics. 10 figs.

  15. Enhancement of the inherent self-protection of the fast sodium reactor cores with oxide fuel

    SciTech Connect (OSTI)

    Eliseev, V.A.; Malisheva, I.V.; Matveev, V.I.; Egorov, A.V.; Maslov, P.A.

    2013-07-01

    With the development and research into the generation IV fast sodium reactors, great attention is paid to the enhancement of the core inherent self-protection characteristics. One of the problems dealt here is connected with the reduction of the reactivity margin so that the control rods running should not result in the core overheating and melting. In this paper we consider the possibilities of improving the core of BN-1200 with oxide fuel by a known method of introducing an axial fertile layer into the core. But unlike earlier studies this paper looks at the possibility of using such a layer not only for improving breeding, but also for reducing sodium void reactivity effect (SVRE). This proposed improvement of the BN-1200 core does not solve the problem of strong interference in control and protection system (CPS) rods of BN-1200, but they reduce significantly the reactivity margin for burn-up compensation. This helps compensate all the reactivity balances in the improved core configurations without violating constraints on SVRE value.

  16. Global Failure Criteria for Positive/Electrolyte/Negative Structure of Planar Solid Oxide Fuel Cell

    SciTech Connect (OSTI)

    Liu, Wenning N.; Sun, Xin; Khaleel, Mohammad A.; Qu, Jianmin

    2009-07-15

    Due to mismatch of the coefficients of thermal expansion of various layers in the positive/electrolyte/negative (PEN) structures of solid oxide fuel cells (SOFC), thermal stresses and warpage on the PEN are unavoidable due to the temperature changes from the stress-free sintering temperature to room temperature during the PEN manufacturing process. In the meantime, additional mechanical stresses will also be created by mechanical flattening during the stack assembly process. In order to ensure the structural integrity of the cell and stack of SOFC, it is necessary to develop failure criteria for SOFC PEN structures based on the initial flaws occurred during cell sintering and stack assembly. In this paper, the global relationship between the critical energy release rate and critical curvature and maximum displacement of the warped cells caused by the temperature changes as well as mechanical flattening process is established so that possible failure of SOFC PEN structures may be predicted deterministically by the measurement of the curvature and displacement of the warped cells.

  17. Tungsten-rhenium composite tube fabricated by CVD for application in 1800/sup 0/C high thermal efficiency fuel processing furnace

    SciTech Connect (OSTI)

    Svedberg, R.C.; Bowen, W.W.; Buckman, R.W. Jr.

    1980-04-01

    Chemical Vapor Deposit (CVD) rhenium was selected as the muffle material for an 1800/sup 0/C high thermal efficiency fuel processing furnace. The muffle is exposed to high vacuum on the heater/insulation/instrumentation side and to a flowing argon-8 V/0 hydrogen gas mixture at one atmosphere pressure on the load volume side. During operation, the muffle cycles from room temperature to 1800/sup 0/C and back to room temperature once every 24 hours. Operational life is dependent on resistance to thermal fatigue during the high temperature exposure. For a prototypical furnace, the muffle is approximately 13 cm I.D. and 40 cm in length. A small (about one-half size) rhenium closed end tube overcoated with tungsten was used to evaluate the concept. The fabrication and testing of the composite tungsten-rhenium tube and prototypic rhenium muffle is described.

  18. Selective Separation of Cs and Sr from LiCl-Based Salt for Electrochemical Processing of Oxide Spent Nuclear Fuel

    SciTech Connect (OSTI)

    P Sachdev

    2008-07-01

    Electrochemical processing technology is currently being used for the treatment of metallic spent fuel from the Experimental Breeder Reactor-II at Idaho National Laboratory. The treatment of oxide-based spent nuclear fuel via electrochemical processing is possible provided there is a front-end oxide reduction step. During this reduction process, certain fission products, including Cs and Sr, partition into the salt phase and form chlorides. Both solid state and molten LiCl-zeolite-A ion exchange tests were conducted for selectively removing Cs and Sr from LiCl-based salt. The solid-state tests produced in excess of 99% removal of Cs and Sr. The molten state tests failed due to phase transformation of the zeolite structure when in contact with the molten LiCl salt.

  19. Solid Oxide Fuel Cell System (SOFC) Technology R&D Needs (Presentation)

    Broader source: Energy.gov [DOE]

    Presented at the DOE Fuel Cell Pre-Solicitation Workshop held January 23-24, 2008 in Golden, Colorado.

  20. Influence of solid fuel on the carbon-monoxide and nitrogen-oxide emissions on sintering

    SciTech Connect (OSTI)

    M.F. Vitushchenko; N.L. Tatarkin; A.I. Kuznetsov; A.E. Vilkov

    2007-07-01

    Laboratory and industrial research now underway at the sintering plant of AO Mittal Steel Temirtau is focusing on the preparation of fuel of optimal granulometric composition, the replacement of coke fines, and the adaptation of fuel-input technology so as to reduce fuel consumption and toxic emissions without loss of sinter quality.

  1. Effects of surface chemistry and microstructure of electrolyte on oxygen reduction kinetics of solid oxide fuel cells

    SciTech Connect (OSTI)

    Park, Joong Sun; An, Jihwan; Lee, Min Hwan; Prinz, Friedrich B.; Lee, Wonyoung

    2015-07-10

    In this study, we report systematic investigation of the surface properties of yttria-stabilized zirconia (YSZ) electrolytes with the control of the grain boundary (GB) density at the surface, and its effects on electrochemical activities. The GB density of thin surface layers deposited on single crystal YSZ substrates is controlled by changing the annealing temperature (750-1450 °C). Higher oxygen reduction reactions (ORR) kinetics is observed in samples annealed at lower temperatures. The higher ORR activity is ascribed to the higher GB density at the YSZ surface where 'mobile' oxide ion vacancies are more populated. Meanwhile, oxide ion vacancies concurrently created with yttrium segregation at the surface at the higher annealing temperature are considered inactive to oxygen incorporation reactions. Our results provide additional insight into the interplay between the surface chemistry, microstructures, and electrochemical activity. They potentially provide important guidelines for engineering the electrolyte electrode interfaces of solid oxide fuel cells for higher electrochemical performance.

  2. Sintering behavior of lanthanide-containing glass-ceramic sealants for solid oxide fuel cells

    SciTech Connect (OSTI)

    Goel, Ashutosh; Reddy, Allu Amarnath; Pascual, Maria J.; Gremillard, Laurent; Malchere, Annie; Ferreira, Jose M.

    2012-05-01

    This article reports on the influence of different lanthanides (La, Nd, Gd and Yb) on sintering behavior of alkaline-earth aluminosilicate glass-ceramics sealants for their application in solid oxide fuel cells (SOFC). All the glasses have been prepared by melt-quench technique. The in situ follow up of sintering behavior of glass powders has been done by high temperature - environmental scanning electron microscope (HT-ESEM) and hot-stage microscope (HSM) while the crystalline phase evolution and assemblage has been analyzed by x-ray diffraction (XRD) and scanning electron microscopy (SEM). All the glass compositions exhibit a glass-in-glass phase separation followed by two stage sintering resulting in well sintered glass powder compacts after heat treatment at 850 C for 1 h. Diopside (CaMgSi{sub 2}O{sub 6}) based phases constituted the major crystalline part in glass-ceramics followed by some minor phases. The increase in lanthanide content in glasses suppressed their tendency towards devitrification, thus, resulting in glass-ceramics with high amount of residual glassy phase (50-96 wt.%) which is expected to facilitate their self-healing behavior during SOFC operation. The electrical conductivity of the investigated glass-ceramics varied between (1.19 and 7.33) x 10{sup -7} S cm{sup -1} (750-800 C), and depended on the ionic field strength of lanthanide cations. Further experimentation with respect to the long term thermal and chemical stability of residual glassy phase under SOFC operation conditions along with high temperature viscosity measurements will be required in order to elucidate the potential of these glass-ceramics as self-healing sealants.

  3. Performance of solid oxide fuel cells operated with coal syngas provided directly from a gasification process

    SciTech Connect (OSTI)

    Hackett, Gregory A.; Gerdes, Kirk R.; Song, Xueyan; Chen, Yun; Shutthanandan, V.; Engelhard, Mark H.; Zhu, Zihua; Thevuthasan, Suntharampillai; Gemmen, Randall

    2012-09-15

    Solid oxide fuel cells (SOFCs) are presently being developed for gasification integrated power plants that generate electricity from coal at 50+% efficiency. The interaction of trace metals in coal syngas with the Ni-based SOFC anodes is being investigated through thermodynamic analyses and in laboratory experiments, but direct test data from coal syngas exposure are sparsely available. This research effort evaluates the significance of SOFC performance losses associated with exposure of a SOFC anode to direct coal syngas. SOFC specimen of industrially relevant composition are operated in a unique mobile test skid that was deployed to the research gasifier at the National Carbon Capture Center (NCCC) in Wilsonville, AL. The mobile test skid interfaces with a gasifier slipstream to deliver hot syngas (up to 300C) directly to a parallel array of 12 button cell specimen, each of which possesses an active area of approximately 2 cm2. During the 500 hour test period, all twelve cells were monitored for performance at four discrete operating current densities, and all cells maintained contact with a data acquisition system. Of these twelve, nine demonstrated good performance throughout the test, while three of the cells were partially compromised. Degradation associated with the properly functioning cells was attributed to syngas exposure and trace material attack on the anode structure that was accelerated at increasing current densities. Cells that were operated at 0 and 125 mA/cm degraded at 9.1 and 10.7% per 1000 hours, respectively, while cells operated at 250 and 375 mA/cm degraded at 18.9 and 16.2% per 1000 hours, respectively. Post-trial spectroscopic analysis of the anodes showed carbon, sulfur, and phosphorus deposits; no secondary Ni-metal phases were found.

  4. Fuel cell-fuel cell hybrid system

    DOE Patents [OSTI]

    Geisbrecht, Rodney A.; Williams, Mark C.

    2003-09-23

    A device for converting chemical energy to electricity is provided, the device comprising a high temperature fuel cell with the ability for partially oxidizing and completely reforming fuel, and a low temperature fuel cell juxtaposed to said high temperature fuel cell so as to utilize remaining reformed fuel from the high temperature fuel cell. Also provided is a method for producing electricity comprising directing fuel to a first fuel cell, completely oxidizing a first portion of the fuel and partially oxidizing a second portion of the fuel, directing the second fuel portion to a second fuel cell, allowing the first fuel cell to utilize the first portion of the fuel to produce electricity; and allowing the second fuel cell to utilize the second portion of the fuel to produce electricity.

  5. Coprocessed nuclear fuels containing (U, Pu) values as oxides, carbides or carbonitrides

    DOE Patents [OSTI]

    Lloyd, M.H.

    1981-01-09

    Method for direct coprocessing of nuclear fuels derived from a product stream of fuels reprocessing facility containing uranium, plutonium, and fission product values comprising nitrate stabilization of said stream vacuum concentration to remove water and nitrates, neutralization to form an acid deficient feed solution for the internal gelation mode of sol-gel technology, green spherule formation, recovery and treatment for loading into a fuel element by vibra packed or pellet formation technologies.

  6. Coprocessed nuclear fuels containing (U, Pu) values as oxides, carbides or carbonitrides

    DOE Patents [OSTI]

    Lloyd, Milton H. (Oak Ridge, TN)

    1983-01-01

    Method for direct coprocessing of nuclear fuels derived from a product stream of a fuels reprocessing facility containing uranium, plutonium, and fission product values comprising nitrate stabilization of said stream vacuum concentration to remove water and nitrates, neutralization to form an acid deficient feed solution for the internal gelation mode of sol-gel technology, green spherule formation, recovery and treatment for loading into a fuel element by vibra packed or pellet formation technologies.

  7. Effects of Fuel Dilution with Biodiesel on Lubricant Acidity, Oxidation and

    Broader source: Energy.gov (indexed) [DOE]

    Corrosion | Department of Energy In-cylinder fuel injection to produce rich exhaust for regeneration of lean NOx trap catalyst and diesel particulate filter results in substantial fuel dilution of lubricating oil cause changes of lubricating oil properties and scuffing of engine components. PDF icon deer08_watson.pdf More Documents & Publications Impact of Biodiesel on Ash Emissions and Lubricant Properties Affecting Fuel Economy and Engine Wear Reducing Lubricant Ash Impact on Exhaust

  8. Fabrication of gas impervious edge seal for a bipolar gas distribution assembly for use in a fuel cell

    DOE Patents [OSTI]

    Kaufman, Arthur; Werth, John

    1986-01-01

    A bipolar gas reactant distribution assembly for use in a fuel cell is disclosed, the assembly having a solid edge seal to prevent leakage of gaseous reactants wherein a pair of porous plates are provided with peripheral slits generally parallel to, and spaced apart from two edges of the plate, the slit being filled with a solid, fusible, gas impervious edge sealing compound. The plates are assembled with opposite faces adjacent one another with a layer of a fusible sealant material therebetween the slits in the individual plates being approximately perpendicular to one another. The plates are bonded to each other by the simultaneous application of heat and pressure to cause a redistribution of the sealant into the pores of the adjacent plate surfaces and to cause the edge sealing compound to flow and impregnate the region of the plates adjacent the slits and comingle with the sealant layer material to form a continuous layer of sealant along the edges of the assembled plates.

  9. Low circumferential voltage gradient self supporting electrode for solid oxide fuel cells

    DOE Patents [OSTI]

    Reichner, Philip

    1989-01-01

    The porous, self-supporting, elongated electrode is made, having at least two chambers through its axial length, the chambers separated by an electronically conductive member. This electrode can be an air electrode of a fuel cell, having a superimposed solid electrolyte and fuel electrode.

  10. All ceramic structure for molten carbonate fuel cell

    DOE Patents [OSTI]

    Smith, James L. (Lemont, IL); Kucera, Eugenia H. (Downers Grove, IL)

    1992-01-01

    An all-ceramic molten carbonate fuel cell having a composition formed of a multivalent metal oxide or oxygenate such as an alkali metal, transition metal oxygenate. The structure includes an anode and cathode separated by an electronically conductive interconnect. The electrodes and interconnect are compositions ceramic materials. Various combinations of ceramic compositions for the anode, cathode and interconnect are disclosed. The fuel cell exhibits stability in the fuel gas and oxidizing environments. It presents reduced sealing and expansion problems in fabrication and has improved long-term corrosion resistance.

  11. Assessment of Startup Fuel Options for the GNEP Advanced Burner Reactor (ABR)

    SciTech Connect (OSTI)

    Jon Carmack; Kemal O. Pasamehmetoglu; David Alberstein

    2008-02-01

    The Global Nuclear Energy Program (GNEP) includes a program element for the development and construction of an advanced sodium cooled fast reactor to demonstrate the burning (transmutation) of significant quantities of minor actinides obtained from a separations process and fabricated into a transuranic bearing fuel assembly. To demonstrate and qualify transuranic (TRU) fuel in a fast reactor, an Advanced Burner Reactor (ABR) prototype is needed. The ABR would necessarily be started up using conventional metal alloy or oxide (U or U, Pu) fuel. Startup fuel is needed for the ABR for the first 2 to 4 core loads of fuel in the ABR. Following start up, a series of advanced TRU bearing fuel assemblies will be irradiated in qualification lead test assemblies in the ABR. There are multiple options for this startup fuel. This report provides a description of the possible startup fuel options as well as possible fabrication alternatives available to the program in the current domestic and international facilities and infrastructure.

  12. MOX Lead Assembly Fabrication at the Savannah River Site

    SciTech Connect (OSTI)

    Geddes, R.L.; Spiker, D.L.; Poon, A.P.

    1997-12-01

    The U. S. Department of Energy (DOE) announced its intent to prepare an Environmental Impact Statement (EIS) under the National Environmental Policy Act (NEPA) on the disposition of the nations weapon-usable surplus plutonium.This EIS is tiered from the Storage and Disposition of Weapons-Usable Fissile Material Programmatic Environmental Impact Statement issued in December 1996,and the associated Record of Decision issued on January, 1997. The EIS will examine reasonable alternatives and potential environmental impacts for the proposed siting, construction, and operation of three types of facilities for plutonium disposition. The three types of facilities are: a pit disassembly and conversion facility, a facility to immobilize surplus plutonium in a glass or ceramic form for disposition, and a facility to fabricate plutonium oxide into mixed oxide (MOX) fuel.As an integral part of the surplus plutonium program, Oak Ridge National Laboratory (ORNL) was tasked by the DOE Office of Fissile Material Disposition(MD) as the technical lead to organize and evaluate existing facilities in the DOE complex which may meet MD`s need for a domestic MOX fuel fabrication demonstration facility. The Lead Assembly (LA) facility is to produce 1 MT of usable test fuel per year for three years. The Savannah River Site (SRS) as the only operating plutonium processing site in the DOE complex, proposes two options to carry out the fabrication of MOX fuel lead test assemblies: an all Category I facility option and a combined Category I and non-Category I facilities option.

  13. Comparing highly ordered monolayers of nanoparticles fabricated using electrophoretic deposition: Cobalt ferrite nanoparticles versus iron oxide nanoparticles

    DOE Public Access Gateway for Energy & Science Beta (PAGES Beta)

    Dickerson, James H.; Krejci, Alex J.; Garcia, Adriana -Mendoza; Sun, Shouheng; Pham, Viet Hung

    2015-08-01

    Ordered assemblies of nanoparticles remain challenging to fabricate, yet could open the door to many potential applications of nanomaterials. Here, we demonstrate that locally ordered arrays of nanoparticles, using electrophoretic deposition, can be extended to produce long-range order among the constituents. Voronoi tessellations along with multiple statistical analyses show dramatic increases in order compared with previously reported assemblies formed through electric field-assisted assembly. As a result, based on subsequent physical measurements of the nanoparticles and the deposition system, the underlying mechanisms that generate increased order are inferred.

  14. Note: Application of CR-39 plastic nuclear track detectors for quality assurance of mixed oxide fuel pellets

    SciTech Connect (OSTI)

    Kodaira, S. Kurano, M.; Hosogane, T.; Ishikawa, F.; Kageyama, T.; Sato, M.; Kayano, M.; Yasuda, N.

    2015-05-15

    A CR-39 plastic nuclear track detector was used for quality assurance of mixed oxide fuel pellets for next-generation nuclear power plants. Plutonium (Pu) spot sizes and concentrations in the pellets are significant parameters for safe use in the plants. We developed an automatic Pu detection system based on dense α-radiation tracks in the CR-39 detectors. This system would greatly improve image processing time and measurement accuracy, and will be a powerful tool for rapid pellet quality assurance screening.

  15. Experimental characterization of glass-ceramic seal properties and their constitutive implementation in solid oxide fuel cell stack models

    SciTech Connect (OSTI)

    Stephens, Elizabeth V.; Vetrano, John S.; Koeppel, Brian J.; Chou, Y. S.; Sun, Xin; Khaleel, Mohammad A.

    2009-09-05

    This paper discusses experimental determination of solid oxide fuel cell (SOFC) glass-ceramic seal material properties and seal/interconnect interfacial properties to support development and optimization of SOFC designs through modeling. Material property experiments such as dynamic resonance, dilatometry, flexure, creep, tensile, and shear tests were performed on PNNLs glass-ceramic sealant material, designated as G18, to obtain property data essential to constitutive and numerical model development. Characterization methods for the physical, mechanical, and interfacial properties of the sealing material, results, and their application to the constitutive implementation in SOFC stack modeling are described.

  16. Solid oxide fuel cell with internal reforming, catalyzed interconnect for use therewith, and methods

    DOE Patents [OSTI]

    Liu, Di-Jia; Guan, Jie; Minh, Nguyen

    2010-06-08

    A catalyzed interconnect for an SOFC electrically connects an anode and an anodic current collector and comprises a metallic substrate, which provides space between the anode and anodic current collector for fuel gas flow over at least a portion of the anode, and a catalytic coating on the metallic substrate comprising a catalyst for catalyzing hydrocarbon fuel in the fuel gas to hydrogen rich reformate. An SOFC including the catalyzed anodic inter-connect, a method for operating an SOFC, and a method for making a catalyzed anodic interconnect are also disclosed.

  17. Role of fuel/oxidizer ratio on the synthesis conditions of CuAl{sub 2}O{sub 3} nanocomposite prepared through solution combustion synthesis

    SciTech Connect (OSTI)

    Nasiri, H.; Bahrami Motlagh, E.; Vahdati Khaki, J.; Zebarjad, S.M.

    2012-11-15

    Highlights: ? With increasing the fuel to oxidizer ratio synthesis products changed from CuO to Cu{sub 2}O. ? With increasing the fuel to oxidizer ratio the combustion temperature decreased. ? Maximum ratio that synthesis could occur was achieved. ? The stoichiometric ratio had the maximum combustion temperature. ? Solution with graphite had lower combustion temperature. -- Abstract: The role of fuel/oxidizer ratio in the synthesis conditions of CuAl{sub 2}O{sub 3} nanocomposite, which was prepared through solution combustion synthesis, method was investigated. For this purpose, copper and aluminum nitrates as well as urea were used as oxidizer and fuel, respectively. The fuel/oxidizer (F/O) ratios were selected from the range of 0.91.75. The products were analyzed using X-ray diffraction, SEM and TEM techniques. During the process the temperature was recorded as a function of time. The results showed that by increasing the F/O ratio up to the stoichiometric amount, the combustion temperature increases. Further increment of F/O ratio resulted in a decrease in the combustion temperature. Microscopic evaluations, using SEM and TEM, proved feasibility of the production of CuAl{sub 2}O{sub 3} through this method.

  18. Long-term oxidation behavior of spinel-coated ferritic stainless steel for solid oxide fuel cell interconnect applications

    SciTech Connect (OSTI)

    Stevenson, Jeffry W.; Yang, Zhenguo; Xia, Guanguang; Nie, Zimin; Templeton, Joshua D.

    2013-06-01

    Long-term tests (>8,000 hours) indicate that AISI 441 ferritic stainless steel coated with a Mn-Co spinel protection layer is a promising candidate material system for IT-SOFC interconnect applications. While uncoated AISI 441 showed a substantial increase in area-specific electrical resistance (ASR), spinel-coated AISI 441 exhibited much lower ASR values (11-13 mOhm-cm2). Formation of an insulating silica sublayer beneath the native chromia-based scale was not observed, and the spinel coatings reduced the oxide scale growth rate and blocked outward diffusion of Cr from the alloy substrate. The structure of the scale formed under the spinel coatings during the long term tests differed from that typically observed on ferritic stainless steels after short term oxidation tests. While short term tests typically indicate a dual layer scale structure consisting of a chromia layer covered by a layer of Mn-Cr spinel, the scale grown during the long term tests consisted of a chromia matrix with discrete regions of Mn-Cr spinel distributed throughout the matrix. The presence of Ti in the chromia scale matrix and/or the presence of regions of Mn-Cr spinel within the scale may have increased the scale electrical conductivity, which would explain the fact that the observed ASR in the tests was lower than would be expected if the scale consisted of pure chromia.

  19. Reforming of fuel inside fuel cell generator

    DOE Patents [OSTI]

    Grimble, Ralph E.

    1988-01-01

    Disclosed is an improved method of reforming a gaseous reformable fuel within a solid oxide fuel cell generator, wherein the solid oxide fuel cell generator has a plurality of individual fuel cells in a refractory container, the fuel cells generating a partially spent fuel stream and a partially spent oxidant stream. The partially spent fuel stream is divided into two streams, spent fuel stream I and spent fuel stream II. Spent fuel stream I is burned with the partially spent oxidant stream inside the refractory container to produce an exhaust stream. The exhaust stream is divided into two streams, exhaust stream I and exhaust stream II, and exhaust stream I is vented. Exhaust stream II is mixed with spent fuel stream II to form a recycle stream. The recycle stream is mixed with the gaseous reformable fuel within the refractory container to form a fuel stream which is supplied to the fuel cells. Also disclosed is an improved apparatus which permits the reforming of a reformable gaseous fuel within such a solid oxide fuel cell generator. The apparatus comprises a mixing chamber within the refractory container, means for diverting a portion of the partially spent fuel stream to the mixing chamber, means for diverting a portion of exhaust gas to the mixing chamber where it is mixed with the portion of the partially spent fuel stream to form a recycle stream, means for injecting the reformable gaseous fuel into the recycle stream, and means for circulating the recycle stream back to the fuel cells.

  20. Reforming of fuel inside fuel cell generator

    DOE Patents [OSTI]

    Grimble, R.E.

    1988-03-08

    Disclosed is an improved method of reforming a gaseous reformable fuel within a solid oxide fuel cell generator, wherein the solid oxide fuel cell generator has a plurality of individual fuel cells in a refractory container, the fuel cells generating a partially spent fuel stream and a partially spent oxidant stream. The partially spent fuel stream is divided into two streams, spent fuel stream 1 and spent fuel stream 2. Spent fuel stream 1 is burned with the partially spent oxidant stream inside the refractory container to produce an exhaust stream. The exhaust stream is divided into two streams, exhaust stream 1 and exhaust stream 2, and exhaust stream 1 is vented. Exhaust stream 2 is mixed with spent fuel stream 2 to form a recycle stream. The recycle stream is mixed with the gaseous reformable fuel within the refractory container to form a fuel stream which is supplied to the fuel cells. Also disclosed is an improved apparatus which permits the reforming of a reformable gaseous fuel within such a solid oxide fuel cell generator. The apparatus comprises a mixing chamber within the refractory container, means for diverting a portion of the partially spent fuel stream to the mixing chamber, means for diverting a portion of exhaust gas to the mixing chamber where it is mixed with the portion of the partially spent fuel stream to form a recycle stream, means for injecting the reformable gaseous fuel into the recycle stream, and means for circulating the recycle stream back to the fuel cells. 1 fig.

  1. Novel catalysts for hydrogen fuel cell applications:Final report

    Office of Scientific and Technical Information (OSTI)

    (FY03-FY05). (Technical Report) | SciTech Connect Technical Report: Novel catalysts for hydrogen fuel cell applications:Final report (FY03-FY05). Citation Details In-Document Search Title: Novel catalysts for hydrogen fuel cell applications:Final report (FY03-FY05). The goal of this project was to develop novel hydrogen-oxidation electrocatalyst materials that contain reduced platinum content compared to traditional catalysts by developing flexible synthesis techniques to fabricate supported

  2. Electrochemical/Pyrometallurgical Waste Stream Processing and Waste Form Fabrication

    SciTech Connect (OSTI)

    Steven Frank; Hwan Seo Park; Yung Zun Cho; William Ebert; Brian Riley

    2015-07-01

    This report summarizes treatment and waste form options being evaluated for waste streams resulting from the electrochemical/pyrometallurgical (pyro ) processing of used oxide nuclear fuel. The technologies that are described are South Korean (Republic of Korea – ROK) and United States of America (US) ‘centric’ in the approach to treating pyroprocessing wastes and are based on the decade long collaborations between US and ROK researchers. Some of the general and advanced technologies described in this report will be demonstrated during the Integrated Recycle Test (IRT) to be conducted as a part of the Joint Fuel Cycle Study (JFCS) collaboration between US Department of Energy (DOE) and ROK national laboratories. The JFCS means to specifically address and evaluated the technological, economic, and safe guard issues associated with the treatment of used nuclear fuel by pyroprocessing. The IRT will involve the processing of commercial, used oxide fuel to recover uranium and transuranics. The recovered transuranics will then be fabricated into metallic fuel and irradiated to transmutate, or burn the transuranic elements to shorter lived radionuclides. In addition, the various process streams will be evaluated and tested for fission product removal, electrolytic salt recycle, minimization of actinide loss to waste streams and waste form fabrication and characterization. This report specifically addresses the production and testing of those waste forms to demonstrate their compatibility with treatment options and suitability for disposal.

  3. Demonstration of a Highly Efficient Solid Oxide Fuel Cell Power System Using Adiabatic Steam Reforming and Anode Gas Recirculation

    SciTech Connect (OSTI)

    Powell, Michael R.; Meinhardt, Kerry D.; Sprenkle, Vincent L.; Chick, Lawrence A.; Mcvay, Gary L.

    2012-05-01

    Solid oxide fuel cells (SOFC) are currently being developed for a wide variety of applications because of their high efficiency at multiple power levels. Applications for SOFCs encompass a large range of power levels including 1-2 kW residential combined heat and power applications, 100-250 kW sized systems for distributed generation and grid extension, and MW-scale power plants utilizing coal. This paper reports on the development of a highly efficient, small-scale SOFC power system operating on methane. The system uses adiabatic steam reforming of methane and anode gas recirculation to achieve high net electrical efficiency. The anode exit gas is recirculated and all of the heat and water required for the endothermic reforming reaction are provided by the anode gas emerging from the SOFC stack. Although the single-pass fuel utilization is only about 55%, because of the anode gas recirculation the overall fuel utilization is up to 93%. The demonstrated system achieved gross power output of 1650 to 2150 watts with a maximum net LHV efficiency of 56.7% at 1720 watts. Overall system efficiency could be further improved to over 60% with use of properly sized blowers.

  4. Analysis of Actual Operating Conditions of an Off-grid Solid Oxide Fuel Cell

    SciTech Connect (OSTI)

    Dennis Witmer; Thomas Johnson; Jack Schmid

    2008-12-31

    Fuel cells have been proposed as ideal replacements for other technologies in remote locations such as Rural Alaska. A number of suppliers have developed systems that might be applicable in these locations, but there are several requirements that must be met before they can be deployed: they must be able to operate on portable fuels, and be able to operate with little operator assistance for long periods of time. This project was intended to demonstrate the operation of a 5 kW fuel cell on propane at a remote site (defined as one without access to grid power, internet, or cell phone, but on the road system). A fuel cell was purchased by the National Park Service for installation in their newly constructed visitor center at Exit Glacier in the Kenai Fjords National Park. The DOE participation in this project as initially scoped was for independent verification of the operation of this demonstration. This project met with mixed success. The fuel cell has operated over 6 seasons at the facility with varying degrees of success, with one very good run of about 1049 hours late in the summer of 2006, but in general the operation has been below expectations. There have been numerous stack failures, the efficiency of electrical generation has been lower than expected, and the field support effort required has been far higher than expected. Based on the results to date, it appears that this technology has not developed to the point where demonstrations in off road sites are justified.

  5. EA-0510: High-Temperature Solid Oxide Fuel Cell (Sofc) Generator Development Project (METC), Churchill, Pennsylvania

    Broader source: Energy.gov [DOE]

    This EA evaluates the environmental impacts of a proposal to enter into a 5-year cooperative agreement with the Westinghouse Electric Corporation for the development of high-temperature solid oxide...

  6. Multivariable Robust Control of a Simulated Hybrid Solid Oxide Fuel Cell Gas Turbine Plant

    SciTech Connect (OSTI)

    Tsai, Alex; Banta, Larry; Tucker, David; Gemmen, Randall

    2010-08-01

    This work presents a systematic approach to the multivariable robust control of a hybrid fuel cell gas turbine plant. The hybrid configuration under investigation built by the National Energy Technology Laboratory comprises a physical simulation of a 300kW fuel cell coupled to a 120kW auxiliary power unit single spool gas turbine. The public facility provides for the testing and simulation of different fuel cell models that in turn help identify the key difficulties encountered in the transient operation of such systems. An empirical model of the built facility comprising a simulated fuel cell cathode volume and balance of plant components is derived via frequency response data. Through the modulation of various airflow bypass valves within the hybrid configuration, Bode plots are used to derive key input/output interactions in transfer function format. A multivariate system is then built from individual transfer functions, creating a matrix that serves as the nominal plant in an H{sub {infinity}} robust control algorithm. The controller’s main objective is to track and maintain hybrid operational constraints in the fuel cell’s cathode airflow, and the turbo machinery states of temperature and speed, under transient disturbances. This algorithm is then tested on a Simulink/MatLab platform for various perturbations of load and fuel cell heat effluence. As a complementary tool to the aforementioned empirical plant, a nonlinear analytical model faithful to the existing process and instrumentation arrangement is evaluated and designed in the Simulink environment. This parallel task intends to serve as a building block to scalable hybrid configurations that might require a more detailed nonlinear representation for a wide variety of controller schemes and hardware implementations.

  7. Effect of Creep of Ferritic Interconnect on Long-Term Performance of Solid Oxide Fuel Cell Stacks

    SciTech Connect (OSTI)

    Liu, Wenning N.; Sun, Xin; Khaleel, Mohammad A.

    2010-08-01

    High-temperature ferritic alloys are potential candidates as interconnect (IC) materials and spacers due to their low cost and coefficient of thermal expansion (CTE) compatibility with other components for most of the solid oxide fuel cells (SOFCs) . However, creep deformation becomes relevant for a material when the operating temperature exceeds or even is less than half of its melting temperature (in degrees of Kelvin). The operating temperatures for most of the SOFCs under development are around 1,073 K. With around 1,800 K of the melting temperature for most stainless steel, possible creep deformation of ferritic IC under the typical cell operating temperature should not be neglected. In this paper, the effects of IC creep behavior on stack geometry change and the stress redistribution of different cell components are predicted and summarized. The goal of the study is to investigate the performance of the fuel cell stack by obtaining the changes in fuel- and air-channel geometry due to creep of the ferritic stainless steel IC, therefore indicating possible changes in SOFC performance under long-term operations. The ferritic IC creep model was incorporated into software SOFC-MP and Mentat-FC, and finite element analyses were performed to quantify the deformed configuration of the SOFC stack under the long-term steady-state operating temperature. It was found that the creep behavior of the ferritic stainless steel IC contributes to narrowing of both the fuel- and the air-flow channels. In addition, stress re-distribution of the cell components suggests the need for a compliant sealing material that also relaxes at operating temperature.

  8. Effects of surface chemistry and microstructure of electrolyte on oxygen reduction kinetics of solid oxide fuel cells

    DOE Public Access Gateway for Energy & Science Beta (PAGES Beta)

    Park, Joong Sun; An, Jihwan; Lee, Min Hwan; Prinz, Friedrich B.; Lee, Wonyoung

    2015-07-10

    In this study, we report systematic investigation of the surface properties of yttria-stabilized zirconia (YSZ) electrolytes with the control of the grain boundary (GB) density at the surface, and its effects on electrochemical activities. The GB density of thin surface layers deposited on single crystal YSZ substrates is controlled by changing the annealing temperature (750-1450 °C). Higher oxygen reduction reactions (ORR) kinetics is observed in samples annealed at lower temperatures. The higher ORR activity is ascribed to the higher GB density at the YSZ surface where 'mobile' oxide ion vacancies are more populated. Meanwhile, oxide ion vacancies concurrently created withmore » yttrium segregation at the surface at the higher annealing temperature are considered inactive to oxygen incorporation reactions. Our results provide additional insight into the interplay between the surface chemistry, microstructures, and electrochemical activity. They potentially provide important guidelines for engineering the electrolyte electrode interfaces of solid oxide fuel cells for higher electrochemical performance.« less

  9. Efficacy of a solution-based approach for making sodalite waste forms for an oxide reduction salt utilized in the reprocessing of used uranium oxide fuel

    SciTech Connect (OSTI)

    Riley, Brian J.; Pierce, David A.; Frank, Steven M.; Maty, Josef; Burns, Carolyne A.

    2015-04-01

    This paper describes the various approaches attempted to make solution-derived sodalite with a LiCl-Li2O oxide reduction salt used to dissolve used uranium oxide fuel so the uranium can be recovered and recycled. The approaches include modified sol-gel and solutionbased synthesis processes. As-made products were mixed with 5 and 10 mass% of a Na2O-B2O3- SiO2 glass binder and these, along with product without a binder, were heated using either a cold-press-and-sinter method or hot uniaxial pressing. The results demonstrate the limitation of sodalite yield due to the fast intermediate reactions between Na+ and Cl- to form halite in solution and Li2O and SiO2 to form lithium silicates (e.g., Li2SiO3 or Li2Si2O5) in the calcined and sintered pellets. The results show that pellets can be made with high sodalite fractions in the crystalline product (~92 mass%) and low porosities using a solution-based approach and this LiCl-Li2O salt but that the incorporation of Li into the sodalite is low.

  10. Efficacy of a Solution-Based Approach for Making Sodalite Waste Forms for an Oxide Reduction Salt Utilized in the Reprocessing of Used Uranium Oxide Fuel

    SciTech Connect (OSTI)

    Riley, Brian J.; Pierce, David A.; Frank, Steven M.; Matyas, Josef; Burns, Carolyn A.

    2015-04-01

    This paper describes various approaches for making sodalite with a LiCl-Li2O oxide reduction salt used to recover uranium from used oxide fuel. The approaches include sol-gel and solution-based synthesis processes. As-made products were mixed with 5 and 10 mass% of a Na2O-B2O3-SiO2 glass binder and these, along with product without a binder, were heated using either a cold-press-and-sinter method or hot uniaxial pressing. The results demonstrate the limitation of sodalite yield due to the fast intermediate reactions between Na+ and Cl- to form halite in solution and Li2O and SiO2 to form lithium silicates (e.g., Li2SiO3 or Li2Si2O5) in the calcined and sintered pellets. The results show that pellets can be made with high sodalite fractions (~92 mass%) and low porosities using a solution-based approach and this LiCl-Li2O salt.

  11. Efficacy of a solution-based approach for making sodalite waste forms for an oxide reduction salt utilized in the reprocessing of used uranium oxide fuel

    DOE Public Access Gateway for Energy & Science Beta (PAGES Beta)

    Riley, Brian J.; Pierce, David A.; Frank, Steven M.; Matyáš, Josef; Burns, Carolyne A.

    2015-04-01

    This paper describes the various approaches attempted to make solution-derived sodalite with a LiCl-Li2O oxide reduction salt used to dissolve used uranium oxide fuel so the uranium can be recovered and recycled. The approaches include modified sol-gel and solutionbased synthesis processes. As-made products were mixed with 5 and 10 mass% of a Na2O-B2O3- SiO2 glass binder and these, along with product without a binder, were heated using either a cold-press-and-sinter method or hot uniaxial pressing. The results demonstrate the limitation of sodalite yield due to the fast intermediate reactions between Na+ and Cl- to form halite in solution and Li2Omore » and SiO2 to form lithium silicates (e.g., Li2SiO3 or Li2Si2O5) in the calcined and sintered pellets. The results show that pellets can be made with high sodalite fractions in the crystalline product (~92 mass%) and low porosities using a solution-based approach and this LiCl-Li2O salt but that the incorporation of Li into the sodalite is low.« less

  12. Oxide

    Energy Science and Technology Software Center (OSTI)

    2014-07-15

    Oxide is a modular framework for feature extraction and analysis of executable files. Oxide is useful in a variety of reverse engineering and categorization tasks relating to executable content.

  13. Effects of cooling time on a closed LWR fuel cycle

    SciTech Connect (OSTI)

    Arnold, R. P.; Forsberg, C. W.; Shwageraus, E.

    2012-07-01

    In this study, the effects of cooling time prior to reprocessing spent LWR fuel has on the reactor physics characteristics of a PWR fully loaded with homogeneously mixed U-Pu or U-TRU oxide (MOX) fuel is examined. A reactor physics analysis was completed using the CASM04e code. A void reactivity feedback coefficient analysis was also completed for an infinite lattice of fresh fuel assemblies. Some useful conclusions can be made regarding the effect that cooling time prior to reprocessing spent LWR fuel has on a closed homogeneous MOX fuel cycle. The computational analysis shows that it is more neutronically efficient to reprocess cooled spent fuel into homogeneous MOX fuel rods earlier rather than later as the fissile fuel content decreases with time. Also, the number of spent fuel rods needed to fabricate one MOX fuel rod increases as cooling time increases. In the case of TRU MOX fuel, with time, there is an economic tradeoff between fuel handling difficulty and higher throughput of fuel to be reprocessed. The void coefficient analysis shows that the void coefficient becomes progressively more restrictive on fuel Pu content with increasing spent fuel cooling time before reprocessing. (authors)

  14. Direct Internal Reformation and Mass Transport in the Solid Oxide Fuel Cell Anode: A Pore-Scale Lattice Boltzmann Study with Detailed Reaction Kinetics

    SciTech Connect (OSTI)

    Grew, Kyle N.; Joshi, Abhijit S.; Chiu, W. K. S.

    2010-11-30

    The solid oxide fuel cell (SOFC) allows the conversion of chemical energy that is stored in a given fuel, including light hydrocarbons, to electrical power. Hydrocarbon fuels, such as methane, are logistically favourable and provide high energy densities. However, the use of these fuels often results in a decreased efficiency and life. An improved understanding of the reactive flow in the SOFC anode can help address these issues. In this study, the transport and heterogeneous internal reformation of a methane based fuel is addressed. The effect of the SOFC anode's complex structure on transport and reactions is shown to exhibit a complicated interplay between the local molar concentrations and the anode structure. Strong coupling between the phenomenological microstructures and local reformation reaction rates are recognised in this study, suggesting the extension to actual microstructures may provide new insights into the reformation processes.

  15. Study on Equilibrium Characteristics of Thorium-Plutonium-Minor Actinides Mixed Oxides Fuel in PWR

    SciTech Connect (OSTI)

    Waris, A.; Permana, S.; Kurniadi, R.; Su'ud, Z.; Sekimoto, H.

    2010-06-22

    A study on characteristics of thorium-plutonium-minor actinides utilization in the pressurized water reactor (PWR) with the equilibrium burnup model has been conducted. For a comprehensive evaluation, several fuel cycles scenario have been included in the present study with the variation of moderator-to-fuel volume ratio (MFR) of PWR core design. The results obviously exhibit that the neutron spectra grow to be harder with decreasing of the MFR. Moreover, the neutron spectra also turn into harder with the rising number of confined heavy nuclides. The required {sup 233}U concentration for criticality of reactor augments with the increasing of MFR for all heavy nuclides confinement and thorium and uranium confinement in PWR.

  16. Carbon microspheres from ethanol at low temperature: Fabrication, characterization and their use as an electrocatalyst support for methanol oxidation

    SciTech Connect (OSTI)

    Lian, Suoyuan; School of Light Industry and Chemical Engineering, Dalian Polytechnic University, Dalian 116034 ; Ming, Hai; Huang, Hui; Kang, Zhenhui; Liu, Yang

    2012-11-15

    Highlights: ► Carbon microbeads were prepared by the carbonization of ethanol at low temperature. ► The low temperature carbonization of ethanol was catalyzed by iodine. ► Carbon microbeads can serve as ideal candidate for catalyst supports. -- Abstract: Carbon microspheres (CMSs) with a diameter range of 2–3 μm were prepared by the iodine-catalyzed carbonization of ethanol at low temperatures by solvothermal synthesis. The reaction time, concentrations of reactants, temperatures, different alcohols as carbon precursors and reaction environments were systematically altered to determine the optimal synthesis conditions. The size and shape were characterized by scanning and transmission electron microscopy and their structure was characterized by X-ray powder diffraction and Raman spectroscopy. Energy dispersive X-ray spectroscopy, Fourier transform infrared and X-ray photoelectron spectroscopy showed that abundant oxygen-containing functional groups remain on the surface of the carbon spheres. The formation mechanism involves iodine promotion of the oxidation of ethanol, which results in formation of the CMSs. The specific activity of the CMS-supported Pt catalyst is higher than that of a commercial Pt catalyst from E-TEK or the unsupported Pt catalyst.

  17. Universal fuel basket for use with an improved oxide reduction vessel and electrorefiner vessel

    DOE Patents [OSTI]

    Herrmann, Steven D.; Mariani, Robert D.

    2002-01-01

    A basket, for use in the reduction of UO.sub.2 to uranium metal and in the electrorefining of uranium metal, having a continuous annulus between inner and outer perforated cylindrical walls, with a screen adjacent to each wall. A substantially solid bottom and top plate enclose the continuous annulus defining a fuel bed. A plurality of scrapers are mounted adjacent to the outer wall extending longitudinally thereof, and there is a mechanism enabling the basket to be transported remotely.

  18. Solid Oxide Fuel Cell Development for Auxiliary Power in Heavy Duty Vehicle Applications

    SciTech Connect (OSTI)

    Daniel T. Hennessy

    2010-06-15

    Changing economic and environmental needs of the trucking industry is driving the use of auxiliary power unit (APU) technology for over the road haul trucks. The trucking industry in the United States remains the key to the economy of the nation and one of the major changes affecting the trucking industry is the reduction of engine idling. Delphi Automotive Systems, LLC (Delphi) teamed with heavy-duty truck Original Equipment Manufacturers (OEMs) PACCAR Incorporated (PACCAR), and Volvo Trucks North America (VTNA) to define system level requirements and develop an SOFC based APU. The project defines system level requirements, and subsequently designs and implements an optimized system architecture using an SOFC APU to demonstrate and validate that the APU will meet system level goals. The primary focus is on APUs in the range of 3-5 kW for truck idling reduction. Fuels utilized were derived from low-sulfur diesel fuel. Key areas of study and development included sulfur remediation with reformer operation; stack sensitivity testing; testing of catalyst carbon plugging and combustion start plugging; system pre-combustion; and overall system and electrical integration. This development, once fully implemented and commercialized, has the potential to significantly reduce the fuel idling Class 7/8 trucks consume. In addition, the significant amounts of NOx, CO2 and PM that are produced under these engine idling conditions will be virtually eliminated, inclusive of the noise pollution. The environmental impact will be significant with the added benefit of fuel savings and payback for the vehicle operators / owners.

  19. Reduction of nitrogen oxide emissions from fossil fuels. (Latest citations from Pollution abstracts). Published Search

    SciTech Connect (OSTI)

    1997-05-01

    The bibliography contains citations concerning the removal of nitrogen compounds from fossil fuels and their post-combustion emissions. Removal methods include biological denitrification, fluidized bed combustion, and flue gas denitrification. Applications to utilities, petroleum refineries, and other industries are presented. The design of nitrogen control systems and process optimization are described. (Contains 50-250 citations and includes a subject term index and title list.) (Copyright NERAC, Inc. 1995)

  20. Reduction of nitrogen oxide emissions from fossil fuels. (Latest citations from Pollution abstracts). Published Search

    SciTech Connect (OSTI)

    1996-01-01

    The bibliography contains citations concerning the removal of nitrogen compounds from fossil fuels and their post-combustion emissions. Removal methods include biological denitrification, fluidized bed combustion, and flue gas denitrification. Applications to utilities, petroleum refineries, and other industries are presented. The design of nitrogen control systems and process optimization are described. (Contains 50-250 citations and includes a subject term index and title list.) (Copyright NERAC, Inc. 1995)

  1. Electrical Stability of a Novel Refractory Sealing Glass in a Dual Environment for Solid Oxide Fuel Cell Applications

    SciTech Connect (OSTI)

    Chou, Y. S.; Stevenson, Jeffry W.; Meinhardt, Kerry D.

    2010-03-01

    A novel refractory alkaline-earth silicate (Sr-Ca-Y-B-Si) sealing glass was developed for solid oxide fuel cell (SOFC) applications. The glass was sealed between two metallic interconnect plates and tested for electrical stability at elevated temperatures and duel environments under DC loading. The isothermal aging results showed very stable electrical resistivity with values 5-9 orders of magnititudes higher than typical SOFC function materials at 850 degrees C for ~700 hr. For comparison, the state-of-the-art sealing glass (G18, Ba-Ca-Al-B-Si) was also evaluated in a similar condition and showed less stable in accelerated tests at 830 degrees C for ~100 hr. Interfacial microstruicture was characterized and possible reactions were discussed.

  2. Reversible Poisoning of the Nickel/Zirconia Solid Oxide Fuel Cell Anodes by Hydrogen Chloride in Coal Gas

    SciTech Connect (OSTI)

    Marina, Olga A.; Pederson, Larry R.; Thomsen, Edwin C.; Coyle, Christopher A.; Yoon, Kyung J.

    2010-10-15

    The performance of anode-supported solid oxide fuel cells (SOFC) was evaluated in synthetic coal gas containing HCl in the temperature range 650 to 850oC. Exposure to up to 800 ppm HCl resulted in reversible poisoning of the Ni/zirconia anode by chlorine species adsorption, the magnitude of which decreased with increased temperature. Performance losses increased with the concentration of HCl to ~100 ppm, above which losses were insensitive to HCl concentration. Cell voltage had no effect on poisoning. No evidence was found for long-term degradation that can be attributed to HCl exposure. Similarly, no evidence of microstructural changes or formation of new solid phases as a result of HCl exposure was found. From thermodynamic calculations, solid nickel chloride phase formation was shown to be highly unlikely in coal gas. Further, the presence of HCl at even the highest anticipated concentrations in coal gas would minimally increase the volatility of nickel.

  3. Development of Metal Oxide Nanostructure-based Optical Sensors for Fossil Fuel Derived Gases Measurement at High Temperature

    SciTech Connect (OSTI)

    Chen, Kevin

    2014-08-31

    This final technical report details research works performed supported by a Department of Energy grant (DE-FE0003859), which was awarded under the University Coal Research Program administrated by National Energy Technology Laboratory. This research program studied high temperature fiber sensor for harsh environment applications. It developed two fiber optical sensor platform technology including regenerative fiber Bragg grating sensors and distributed fiber optical sensing based on Rayleigh backscattering optical frequency domain reflectometry. Through the studies of chemical and thermal regenerative techniques for fiber Bragg grating (FBG) fabrication, high-temperature stable FBG sensors were successfully developed and fabricated in air-hole microstructured fibers, high-attenuation fibers, rare-earth doped fibers, and standard telecommunication fibers. By optimizing the laser processing and thermal annealing procedures, fiber grating sensors with stable performance up to 1100oC have been developed. Using these temperature-stable FBG gratings as sensor platform, fiber optical flow, temperature, pressure, and chemical sensors have been developed to operate at high temperatures up to 800oC. Through the integration of on-fiber functional coating, the use of application-specific air-hole microstructural fiber, and application of active fiber sensing scheme, distributed fiber sensor for temperature, pressure, flow, liquid level, and chemical sensing have been demonstrated with high spatial resolution (1-cm or better) with wide temperature ranges. These include the demonstration of 1) liquid level sensing from 77K to the room temperature, pressure/temperature sensing from the room temperature to 800C and from the 15psi to 2000 psi, and hydrogen concentration measurement from 0.2% to 10% with temperature ranges from the room temperature to 700C. Optical sensors developed by this program has broken several technical records including flow sensors with the highest operation temperature up to 750oC, first distributed chemical measurements at the record high temperature up to 700oC, first distributed pressure measurement at the record high temperature up to 800oC, and the fiber laser sensors with the record high operation temperature up to 700oC. The research performed by this program dramatically expand the functionality, adaptability, and applicability of distributed fiber optical sensors with potential applications in a number of high-temperature energy systems such as fossil-fuel power generation, high-temperature fuel cell applications, and potential for nuclear energy systems.

  4. Calculation of contact angles at triple phase boundary in solid oxide fuel cell anode using the level set method

    SciTech Connect (OSTI)

    Sun, Xiaojun; Hasegawa, Yosuke; Kohno, Haruhiko; Jiao, Zhenjun; Hayakawa, Koji; Okita, Kohei; Shikazono, Naoki

    2014-10-15

    A level set method is applied to characterize the three dimensional structures of nickel, yttria stabilized zirconia and pore phases in solid oxide fuel cell anode reconstructed by focused ion beam-scanning electron microscope. A numerical algorithm is developed to evaluate the contact angles at the triple phase boundary based on interfacial normal vectors which can be calculated from the signed distance functions defined for each of the three phases. Furthermore, surface tension force is estimated from the contact angles by assuming the interfacial force balance at the triple phase boundary. The average contact angle values of nickel, yttria stabilized zirconia and pore are found to be 143156, 83138 and 82123, respectively. The mean contact angles remained nearly unchanged after 100 hour operation. However, the contact angles just after reduction are different for the cells with different sintering temperatures. In addition, standard deviations of the contact angles are very large especially for yttria stabilized zirconia and pore phases. The calculated surface tension forces from mean contact angles were close to the experimental values found in the literature. Slight increase of surface tensions of nickel/pore and nickel/yttria stabilized zirconia were observed after operation. Present data are expected to be used not only for the understanding of the degradation mechanism, but also for the quantitative prediction of the microstructural temporal evolution of solid oxide fuel cell anode. - Highlights: A level set method is applied to characterize the 3D structures of SOFC anode. A numerical algorithm is developed to evaluate the contact angles at the TPB. Surface tension force is estimated from the contact angles. The average contact angle values are found to be 143o-156o, 83o-138o and 82o-123o. Present data are expected to understand degradation and predict evolution of SOFC.

  5. Partial Oxidation Gas Turbine for Power and Hydrogen Co-Production from Coal-Derived Fuel in Industrial Applications

    SciTech Connect (OSTI)

    Joseph Rabovitser

    2009-06-30

    The report presents a feasibility study of a new type of gas turbine. A partial oxidation gas turbine (POGT) shows potential for really high efficiency power generation and ultra low emissions. There are two main features that distinguish a POGT from a conventional gas turbine. These are associated with the design arrangement and the thermodynamic processes used in operation. A primary design difference of the POGT is utilization of a non?catalytic partial oxidation reactor (POR) in place of a conventional combustor. Another important distinction is that a much smaller compressor is required, one that typically supplies less than half of the air flow required in a conventional gas turbine. From an operational and thermodynamic point of view a key distinguishing feature is that the working fluid, fuel gas provided by the OR, has a much higher specific heat than lean combustion products and more energy per unit mass of fluid can be extracted by the POGT expander than in the conventional systems. The POGT exhaust stream contains unreacted fuel that can be combusted in different bottoming ycle or used as syngas for hydrogen or other chemicals production. POGT studies include feasibility design for conversion a conventional turbine to POGT duty, and system analyses of POGT based units for production of power solely, and combined production of power and yngas/hydrogen for different applications. Retrofit design study was completed for three engines, SGT 800, SGT 400, and SGT 100, and includes: replacing the combustor with the POR, compressor downsizing for about 50% design flow rate, generator replacement with 60 90% ower output increase, and overall unit integration, and extensive testing. POGT performances for four turbines with power output up to 350 MW in POGT mode were calculated. With a POGT as the topping cycle for power generation systems, the power output from the POGT ould be increased up to 90% compared to conventional engine keeping hot section temperatures, pressures, and volumetric flows practically identical. In POGT mode, the turbine specific power (turbine net power per lb mass flow from expander exhaust) is twice the value of the onventional turbine. POGT based IGCC plant conceptual design was developed and major components have been identified. Fuel flexible fluid bed gasifier, and novel POGT unit are the key components of the 100 MW IGCC plant for co producing electricity, hydrogen and/or yngas. Plant performances were calculated for bituminous coal and oxygen blown versions. Various POGT based, natural gas fueled systems for production of electricity only, coproduction of electricity and hydrogen, and co production of electricity and syngas for gas to liquid and hemical processes were developed and evaluated. Performance calculations for several versions of these systems were conducted. 64.6 % LHV efficiency for fuel to electricity in combined cycle was achieved. Such a high efficiency arise from using of syngas from POGT exhaust s a fuel that can provide required temperature level for superheated steam generation in HRSG, as well as combustion air preheating. Studies of POGT materials and combustion instabilities in POR were conducted and results reported. Preliminary market assessment was performed, and recommendations for POGT systems applications in oil industry were defined. POGT technology is ready to proceed to the engineering prototype stage, which is recommended.

  6. Fabrication of metal shells

    SciTech Connect (OSTI)

    O'Holleran, T.P.; Henderson, T.M.; Downs, R.L.; Nolen, R.L.

    1980-01-01

    Small hollow metal spheres are needed as targets for particle-beam fusion experiments and as the inner fuel container for multi-shell targets. For the multishell application, shells fabricated of materials with high atomic numbers, e.g., gold, are of particular interest because they may effectively reduce preheating of the fuel. Because the shells must also contain the fuel mixture (deuterium and tritium) at high pressures, high strength materials, e.g., iron, are also of considerable interest. With the objective of proof of principle we have investigated several techniques of fabricating shells of metal or materials containing large fractions of high atomic number elements. These techniques, our experimental results and their evaluation are presented.

  7. Compliant alkali silicate sealing glass for solid oxide fuel cell applications: thermal cycle stability and chemical compatibility

    SciTech Connect (OSTI)

    Chou, Y. S.; Thomsen, Edwin C.; Williams, Riley T.; Choi, Jung-Pyung; Canfield, Nathan L.; Bonnett, Jeff F.; Stevenson, Jeffry W.; Shyam, Amit; Lara-Curzio, E.

    2011-03-01

    An alkali silicate glass (SCN-1) is currently being evaluated as a candidate sealing glass for solid oxide fuel (SOFC) applications. The glass containing ~17 mole% alkalis (K2O and Na2O) remains vitreous and compliant during SOFC operation, unlike conventional SOFC sealing glasses, which experience substantial devitrification after the sealing process. The non-crystallizing compliant sealing glass has lower glass transition and softening temperatures since the microstructure remains glassy without significant crystallite formation, and hence can relieve or reduce residual stresses and also has the potential for crack healing. Sealing approaches based on compliant glass will also need to satisfy all the mechanical, thermal, chemical, physical, and electrical requirements for SOFC applications, not only in bulk properties but also at sealing interfaces. In this first of a series of papers we will report the thermal cycle stability of the glass when sealed between two SOFC components, i.e., a NiO/YSZ anode supported YSZ bilayer and a coated ferritic stainless steel interconnect material. High temperature leak rates were monitored versus thermal cycles between 700-850oC using back pressures ranging from 0.2 psi to 1.0 psi. Isothermal stability was also evaluated in a dual environment consisting of flowing dilute H2 fuel versus ambient air. In addition, chemical compatibility at the alumina and YSZ interfaces was examined with scanning electron microscopy and energy dispersive spectroscopy. The results shed new light on the topic of SOFC glass seal development.

  8. Combined Theoretical and Experimental Investigation and Design of H2S Tolerant Anode for Solid Oxide Fuel Cells

    SciTech Connect (OSTI)

    Gerardine G. Botte; Damilola Daramola; Madhivanan Muthuvel

    2009-01-07

    A solid oxide fuel cell (SOFC) is a high temperature fuel cell and it normally operates in the range of 850 to 1000 C. Coal syngas has been considered for use in SOFC systems to produce electric power, due to its high temperature and high hydrogen and carbon monoxide content. However, coal syngas also has contaminants like carbon dioxide (CO{sub 2}) and hydrogen sulfide (H{sub 2}S). Among these contaminants, H{sub 2}S is detrimental to electrode material in SOFC. Commonly used anode material in SOFC system is nickel-yttria stabilized zirconia (Ni-YSZ). The presence of H{sub 2}S in the hydrogen stream will damage the Ni anode and hinder the performance of SOFC. In the present study, an attempt was made to understand the mechanism of anode (Ni-YSZ) deterioration by H{sub 2}S. The study used computation methods such as quantum chemistry calculations and molecular dynamics to predict the model for anode destruction by H{sub 2}S. This was done using binding energies to predict the thermodynamics and Raman spectroscopy to predict molecular vibrations and surface interactions. On the experimental side, a test stand has been built with the ability to analyze button cells at high temperature under syngas conditions.

  9. Pore Scale Modeling of the Reactive Transport of Chromium in the Cathode of a Solid Oxide Fuel Cell

    SciTech Connect (OSTI)

    Ryan, Emily M.; Tartakovsky, Alexandre M.; Recknagle, Kurtis P.; Khaleel, Mohammad A.; Amon, Cristina

    2011-01-01

    We present a pore scale model of a solid oxide fuel cell (SOFC) cathode. Volatile chromium species are known to migrate from the current collector of the SOFC into the cathode where over time they decrease the voltage output of the fuel cell. A pore scale model is used to investigate the reactive transport of chromium species in the cathode and to study the driving forces of chromium poisoning. A multi-scale modeling approach is proposed which uses a cell level model of the cathode, air channel and current collector to determine the boundary conditions for a pore scale model of a section of the cathode. The pore scale model uses a discrete representation of the cathode to explicitly model the surface reactions of oxygen and chromium with a cathode material. The pore scale model is used to study the reaction mechanisms of chromium by considering the effects of reaction rates, diffusion coefficients, chromium vaporization, and oxygen consumption on chromiums deposition in the cathode. The study shows that chromium poisoning is most significantly affected by the chromium reaction rates in the cathode and that the reaction rates are a function of the local current density in the cathode.

  10. Anode protection system for shutdown of solid oxide fuel cell system

    DOE Patents [OSTI]

    Li, Bob X; Grieves, Malcolm J; Kelly, Sean M

    2014-12-30

    An Anode Protection Systems for a SOFC system, having a Reductant Supply and safety subsystem, a SOFC anode protection subsystem, and a Post Combustion and slip stream control subsystem. The Reductant Supply and safety subsystem includes means for generating a reducing gas or vapor to prevent re-oxidation of the Ni in the anode layer during the course of shut down of the SOFC stack. The underlying ammonia or hydrogen based material used to generate a reducing gas or vapor to prevent the re-oxidation of the Ni can be in either a solid or liquid stored inside a portable container. The SOFC anode protection subsystem provides an internal pressure of 0.2 to 10 kPa to prevent air from entering into the SOFC system. The Post Combustion and slip stream control subsystem provides a catalyst converter configured to treat any residual reducing gas in the slip stream gas exiting from SOFC stack.

  11. Fuels for Sodium-cooled Fast Reactors: U.S. Perspective

    SciTech Connect (OSTI)

    Douglas C. Crawford; Douglas L. Porter; Steven L. Hayes

    2007-09-01

    The U.S. experience with mixed oxide, metal, and mixed carbide fuels is substantial, comprised of irradiation of over 50,000 MOX rods, over 130,000 metal rods, and 600 mixed carbide rods, in EBR-II and FFTF alone. All three types have all been demonstrated capable of fuel utilization at or above 200 GWd/MTHM. To varying degrees, life-limiting phenomena for each type have been identified and investigated, and there are no disqualifying safety-related fuel behaviors. All three fuel types appear capable of meeting SFR fuel requirements, with reliability of MOX and metal fuel well established. Improvements in irradiation performance of cladding and duct alloys has been a key development in moving these fuel designs toward higher-burnup potential. Selection of one fuel system over another will depend on circumstances particular to the application and on issues other than fuel performance, such as fabrication cost or overall system safety performance.

  12. Solid Oxide Fuel Cell Cathodes. Unraveling the Relationship Between Structure, Surface Chemistry and Oxygen Reduction

    SciTech Connect (OSTI)

    Gopalan, Srikanth

    2013-03-31

    In this work we have considered oxygen reduction reaction on LSM and LSCF cathode materials. In particular we have used various spectroscopic techniques to explore the surface composition, transition metal oxidation state, and the bonding environment of oxygen to understand the changes that occur to the surface during the oxygen reduction process. In a parallel study we have employed patterned cathodes of both LSM and LSCF cathodes to extract transport and kinetic parameters associated with the oxygen reduction process.

  13. Subtask 2: Water oxidation complex | Center for Bio-Inspired Solar Fuel

    Broader source: All U.S. Department of Energy (DOE) Office Webpages (Extended Search)

    Production 2: Water oxidation complex All papers by year Subtask 1 Subtask 2 Subtask 3 Subtask 4 Subtask 5 Kupitz, Christopher; Basu, Shibom; Grotjohann, Ingo; Fromme, Raimund; Zatsepin, Nadia A.; Rendek, Kimberly N.; Hunter, Mark; Shoeman, Robert L.; White, Thomas A.; Wang, Dingjie; James, Daniel; Yang, Jay-How; Cobb, Danielle E.; Brenda, Reeder; Raymond, G. Sierra; Liu, Haiguang; Barty, Anton; Aquila, Andrew L.; Deponte, Daniel; Kirian, Richard A.; Bari, Sadia; Bergkamp, Jesse J.;

  14. FRAPCON-2: a computer code for the calculation of steady state thermal-mechanical behavior of oxide fuel rods. Technical report

    SciTech Connect (OSTI)

    Berna, G.A.; Bohn, M.P.; Rausch, W.N.; Williford, R.E.; Lanning, D.D.

    1981-01-01

    FRAPCON-2 is a FORTRAN IV computer code that calculates the steady state response of light water reactor fuel rods during long-term burnup. The code calculates the temperature, pressure, deformation, and failure histories of a fuel rod as functions of time-dependent fuel rod power and coolant boundary conditions. The phenomena modeled by the code include: (a) heat conduction through the fuel and cladding, (b) cladding elastic and plastic deformation, (c) fuel-cladding mechanical interaction, (d) fission gas release, (e) fuel rod internal gas pressure, (f) heat transfer between fuel and cladding, (g) cladding oxidation, and (h) heat transfer from cladding to coolant. The code contains necessary material properties, water properties, and heat transfer correlations. FRAPCON-2 is programmed for use on the CDC Cyber 175 and 176 computers. The FRAPCON-2 code is designed to generate initial conditions for transient fuel rod analysis by either the FRAP-T6 computer code or the thermal-hydraulic code, RELAP4/MOD7 Version2.

  15. High Performance Fuel Desing for Next Generation Pressurized Water Reactors

    SciTech Connect (OSTI)

    Mujid S. Kazimi; Pavel Hejzlar

    2006-01-31

    The use of internally and externally cooled annular fule rods for high power density Pressurized Water Reactors is assessed. The assessment included steady state and transient thermal conditions, neutronic and fuel management requirements, mechanical vibration issues, fuel performance issues, fuel fabrication methods and econmic assessment. The investigation was donducted by a team from MIT, Westinghouse, Gamma Engineering, Framatome ANP, and AECL. The analyses led to the conclusion that raising the power density by 50% may be possible with this advanced fuel. Even at the 150% power level, the fuel temperature would be a few hundred degrees lower than the current fuel temperatre. Significant economic and safety advantages can be obtained by using this fuel in new reactors. Switching to this type of fuel for existing reactors would yield safety advantages, but the economic return is dependent on the duration of plant shutdown to accommodate higher power production. The main feasiblity issue for the high power performance appears to be the potential for uneven splitting of heat flux between the inner and outer fuel surfaces due to premature closure of the outer fuel-cladding gap. This could be overcome by using a very narrow gap for the inner fuel surface and/or the spraying of a crushable zirconium oxide film at the fuel pellet outer surface. An alternative fuel manufacturing approach using vobropacking was also investigated but appears to yield lower than desirable fuel density.

  16. Small-Scale Low Cost Solid Oxide Fuel Cell Power Systems

    SciTech Connect (OSTI)

    S.D. Vora

    2005-09-30

    Tasks carried out during the reporting period March 2005-August 2005 are summarized. During this reporting period, the primary focus was on tasks leading to the fabrication of a proof-of-concept (POC) unit with HPD5R1 cells. Assembly of the POC unit was completed and the initial operation was started. Optimization of HPD cell design, investigation of scandia doped zirconia and low temperature operation of YSZ electrolyte based cells continued. Development of seal to be used in a ''once-thru'' design or an ''up-down'' design was started. Attachment 1 describes the progress in cell development and Attachments 2 and 3 deal with status of generator and BOP design. Operation of POC is summarized in Attachment 4. Plans for future work are summarized in Attachment 5.

  17. Reference Alloy Waste Form Fabrication and Initiation of Reducing Atmosphere and Reductive Additives Study on Alloy Waste Form Fabrication

    SciTech Connect (OSTI)

    S.M. Frank; T.P. O'Holleran; P.A. Hahn

    2011-09-01

    This report describes the fabrication of two reference alloy waste forms, RAW-1(Re) and RAW-(Tc) using an optimized loading and heating method. The composition of the alloy materials was based on a generalized formulation to process various proposed feed streams resulting from the processing of used fuel. Waste elements are introduced into molten steel during alloy fabrication and, upon solidification, become incorporated into durable iron-based intermetallic phases of the alloy waste form. The first alloy ingot contained surrogate (non-radioactive), transition-metal fission products with rhenium acting as a surrogate for technetium. The second alloy ingot contained the same components as the first ingot, but included radioactive Tc-99 instead of rhenium. Understanding technetium behavior in the waste form is of particular importance due the longevity of Tc-99 and its mobility in the biosphere in the oxide form. RAW-1(Re) and RAW-1(Tc) are currently being used as test specimens in the comprehensive testing program investigating the corrosion and radionuclide release mechanisms of the representative alloy waste form. Also described in this report is the experimental plan to study the effects of reducing atmospheres and reducing additives to the alloy material during fabrication in an attempt to maximize the oxide content of waste streams that can be accommodated in the alloy waste form. Activities described in the experimental plan will be performed in FY12. The first aspect of the experimental plan is to study oxide formation on the alloy by introducing O2 impurities in the melt cover gas or from added oxide impurities in the feed materials. Reducing atmospheres will then be introduced to the melt cover gas in an attempt to minimize oxide formation during alloy fabrication. The second phase of the experimental plan is to investigate melting parameters associated with alloy fabrication to allow the separation of slag and alloy components of the melt.

  18. Optimized cell configurations for stable LSCF-based solid oxide fuel cells

    DOE Patents [OSTI]

    Kim, Jin Yong (Richland, WA); Sprenkle, Vincent L. (Richland, WA); Canfield, Nathan L. (Richland, WA); Meinhardt, Kerry D. (Kennewick); WA, Chick, Lawrence A. (West Richland, WA)

    2012-05-22

    Lanthanum strontium cobalt iron oxides (La(1-x)SrxCoyFe1-yO3-f; (LSCF) have excellent power density (>500 mW/cm2 at 750.degree. C.). When covered with a metallization layer, LSCF cathodes have demonstrated increased durability and stability. Other modifications, such as the thickening of the cathode, the preparation of the device by utilizing a firing temperature in a designated range, and the use of a pore former paste having designated characteristics and combinations of these features provide a device with enhanced capabilities.

  19. Iridium−Ruthenium Alloyed Nanoparticles for the Ethanol Oxidation Fuel Cell Reactions

    SciTech Connect (OSTI)

    Su D.; Du, W.; Deskins, N.A.; Teng, X.

    2012-06-01

    In this study, carbon supported Ir-Ru nanoparticles with average sizes ranging from 2.9 to 3.7 nm were prepared using a polyol method. The combined characterization techniques, that is, scanning transmission electron microscopy equipped with electron energy loss spectroscopy, high resolution transmission electron microscopy, energy dispersive X-ray spectroscopy, and X-ray diffraction, were used to determine an Ir-Ru alloy nanostructure. Both cyclic voltammetry and chronoamperometry (CA) results demonstrate that Ir{sub 77}Ru{sub 23}/C bears superior catalytic activities for the ethanol oxidation reaction compared to Ir/C and commercial Pt/C catalysts. In particular, the Ir{sub 77}Ru{sub 23}/C catalyst shows more than 21 times higher mass current density than that of Pt/C after 2 h reaction at a potential of 0.2 V vs Ag/AgCl in CA measurement. Density functional theory simulations also demonstrate the superiority of Ir-Ru alloys compared to Ir for the ethanol oxidation reaction.

  20. Electrochemical fabrication of capacitors

    DOE Patents [OSTI]

    Mansour, Azzam N. (Fairfax Sta., VA); Melendres, Carlos A. (Lemont, IL)

    1999-01-01

    A film of nickel oxide is anodically deposited on a graphite sheet held in osition on an electrochemical cell during application of a positive electrode voltage to the graphite sheet while exposed to an electrolytic nickel oxide solution within a volumetrically variable chamber of the cell. An angularly orientated x-ray beam is admitted into the cell for transmission through the deposited nickel oxide film in order to obtain structural information while the film is subject to electrochemical and in-situ x-ray spectroscopy from which optimum film thickness, may be determined by comparative analysis for capacitor fabrication purposes.

  1. Direct hydrocarbon fuel cells

    DOE Patents [OSTI]

    Barnett, Scott A.; Lai, Tammy; Liu, Jiang

    2010-05-04

    The direct electrochemical oxidation of hydrocarbons in solid oxide fuel cells, to generate greater power densities at lower temperatures without carbon deposition. The performance obtained is comparable to that of fuel cells used for hydrogen, and is achieved by using novel anode composites at low operating temperatures. Such solid oxide fuel cells, regardless of fuel source or operation, can be configured advantageously using the structural geometries of this invention.

  2. Fabrication and Pre-irradiation Characterization of a Minor Actinide and Rare Earth Containing Fast Reactor Fuel Experiment for Irradiation in the Advanced Test Reactor

    SciTech Connect (OSTI)

    Timothy A. Hyde

    2012-06-01

    The United States Department of Energy, seeks to develop and demonstrate the technologies needed to transmute the long-lived transuranic actinide isotopes contained in spent nuclear fuel into shorter lived fission products, thereby decreasing the volume of material requiring disposal and reducing the long-term radiotoxicity and heat load of high-level waste sent to a geologic repository. This transmutation of the long lived actinides plutonium, neptunium, americium and curium can be accomplished by first separating them from spent Light Water Reactor fuel using a pyro-metalurgical process, then reprocessing them into new fuel with fresh uranium additions, and then transmuted to short lived nuclides in a liquid metal cooled fast reactor. An important component of the technology is developing actinide-bearing fuel forms containing plutonium, neptunium, americium and curium isotopes that meet the stringent requirements of reactor fuels and materials.

  3. Performance and Fabrication Status of TREAT LEU Conversion Conceptual Design Concepts

    SciTech Connect (OSTI)

    IJ van Rooyen; SR Morrell; AE Wright; E. P Luther; K Jamison; AL Crawford; HT III Hartman

    2014-10-01

    Resumption of transient testing at the TREAT facility was approved in February 2014 to meet U.S. Department of Energy (DOE) objectives. The National Nuclear Security Administration’s Global Threat Reduction Initiative Convert Program is evaluating conversion of TREAT from its existing highly enriched uranium (HEU) core to a new core containing low enriched uranium (LEU). This paper describes briefly the initial pre-conceptual designs screening decisions with more detailed discussions on current feasibility, qualification and fabrication approaches. Feasible fabrication will be shown for a LEU fuel element assembly that can meet TREAT design, performance, and safety requirements. The statement of feasibility recognizes that further development, analysis, and testing must be completed to refine the conceptual design. Engineering challenges such as cladding oxidation, high temperature material properties, and fuel block fabrication along with neutronics performance, will be highlighted. Preliminary engineering and supply chain evaluation provided confidence that the conceptual designs can be achieved.

  4. Neutronics Benchmarks for the Utilization of Mixed-Oxide Fuel: Joint US/Russian Progress Report for Fiscal 1997. Volume 3 - Calculations Performed in the Russian Federation

    SciTech Connect (OSTI)

    1998-06-01

    This volume of the progress report provides documentation of reactor physics and criticality safety studies conducted in the Russian Federation during fiscal year 1997 and sponsored by the Fissile Materials Disposition Program of the US Department of Energy. Descriptions of computational and experimental benchmarks for the verification and validation of computer programs for neutron physics analyses are included. All benchmarks include either plutonium, uranium, or mixed uranium and plutonium fuels. Calculated physics parameters are reported for all of the contaminated benchmarks that the United States and Russia mutually agreed in November 1996 were applicable to mixed-oxide fuel cycles for light-water reactors.

  5. Multilayered YSZ/GZO films with greatly enhanced ionic conduction for low temperature solid oxide fuel cells

    SciTech Connect (OSTI)

    Li, Bin; Zhang, Jiaming; Kaspar, Tiffany C.; Shutthanandan, V.; Ewing, Rodney C.; Lian, Jie

    2013-01-01

    Strain confinement in heterostructured films significantly affects ionic conductivity of the electrolytes for solid oxide fuel cells based on a multi-layered design strategy. Nearly ideal tensile strain can be achieved by a dedicated manipulation of the lattice mismatch between adjacent layers and fine control of the layer thicknesses to minimize the formation of dislocations and thus to achieve optimized ionic conduction. This strategy was demonstrated by a model system of multilayered 8 mol%Y2O3 stabilized ZrO2 (YSZ) with Gd2Zr2O7 (GZO) films, which were epitaxially grown on Al2O3 (0001) substrates by pulsed laser deposition (PLD) with the {111} planes of YSZ/GZO along the Al2O3 [0 1 ?1 0] direction. The tensile strain (3%) resulting from the lattice mismatch can be confined in individual YSZ layers with the formation of a coherent, dislocation-free interface upon the manipulation of the layer thickness below a critical value, e.g., down to 5 nm. The strained heterostructure displays a two order-of-magnitude increase in oxide-ion conductivity as compared with bulk YSZ, and a high ionic conductivity of 0.01 S cm?1 at 475 C can be achieved, five times greater than that of Gd-doped ceria/zirconia. The approach of strain confinement by fine control of lattice mismatch and layer thickness represents a promising strategy in developing advanced electrolytes enabling the miniaturization of solid-state ionic devices that can be operated at low temperatures below 500 C.

  6. Impact of the Fuel Molecular Structure on the Oxidation Process of Real Diesel fuels According to Storage Conditions and Biodiesel Content

    Broader source: Energy.gov [DOE]

    Hydrocarbon profilers can provide a clear understanding of complex interactions between fuel chemistry, storage conditions, and quantity of biodiesel over time.

  7. Fuel Cells

    Broader source: All U.S. Department of Energy (DOE) Office Webpages (Extended Search)

    Fuel Cells Fact Sheets Research Team Members Key Contacts Fuel Cells The Solid State Energy Conversion Alliance (SECA) program is responsible for coordinating Federal efforts to facilitate development of a commercially relevant and robust solid oxide fuel cell (SOFC) system. Specific objectives include achieving an efficiency of greater than 60 percent, meeting a stack cost target of $175 per kW, and demonstrating lifetime performance degradation of less than 0.2 percent per 1000 hours over a

  8. Deformation Behavior of Laser Welds in High Temperature Oxidation Resistant Fe-Cr-Al Alloys for Fuel Cladding Applications

    SciTech Connect (OSTI)

    Field, Kevin G; Gussev, Maxim N; Yamamoto, Yukinori; Snead, Lance Lewis

    2014-11-01

    Ferritic-structured Fe-Cr-Al alloys are being developed and show promise as oxidation resistant accident tolerant light water reactor fuel cladding. This study focuses on investigating the weldability of three model alloys in a range of Fe-(13-17.5)Cr-(3-4.4)Al in weight percent with a minor addition of yttrium using laser-welding techniques. A detailed study on the mechanical performance of bead-on-plate welds has been carried out to determine the performance of welds as a function of alloy composition. Laser welding resulted in a defect free weld devoid of cracking or inclusions for all alloys studied. Results indicated a reduction in the yield strength within the fusion zone compared to the base metal. Yield strength reduction was found to be primarily constrained to the fusion zone due to grain coarsening with a less severe reduction in the heat affected zone. No significant correlation was found between the deformation behavior/mechanical performance of welds and the level of Cr or Al in the alloy ranges studied.

  9. Microstructural and chemical evolution near anode triple phase boundary in Ni/YSZ solid oxide fuel cells

    SciTech Connect (OSTI)

    Chen, Yun; Chen, Song; Hackett, Gregory; Finklea, Harry; Song, Xueyan; Gerdes, Kirk

    2011-12-12

    In this study, we report the micro-structural and chemical evolution of anode grain boundaries and triple phase boundary (TPB) junctions of Ni/YSZ anode supported solid oxide fuel cells. A NiO phase was found to develop along the Ni/YSZ interfaces extending to TPBs in the operated cells. The thickness of the NiO ribbon phase remains constant at ~ 5 nm in hydrogen for operating durations up to 540 h. When operating on synthesis gas, an increase in interphase thickness was observed from ~ 11 nm for 24 h of operation to ~ 51 nm for 550 h of operation. YSZ phases are observed to be stable in H{sub 2} over 540 h of operation. However, for the cell operated in syngas for 550 h, a 510 nm tetragonal YSZ (t-YSZ) interfacial layer was identified that originated from the Ni/YSZ interfaces. Yttrium species seem to segregate to the interfaces during operation, leading to the formation of t-YSZ in the Y-depleted regions.

  10. The Orientation Distributions of Lines, Surfaces, and Interfaces Around Three-Phase Boundaries in Solid Oxide Fuel Cell Cathodes

    SciTech Connect (OSTI)

    Dillon, Shen; Helmick, Lam; Miller, Herbert M.; Johnson, Christopher; Wilson, Lane; Gemmen, Randall; Petrova, Rumyana; Barmak, Katayun; Gerdes, Kirk; Rohrer, Gregory S.; Salvador, Paul A.

    2011-11-01

    Three-dimensional electron backscatter diffraction was used to measure the crystallographic distribution of the electrochemically relevant triple phase boundary lines and surfaces near them in SOFC cathodes made up of a porous mixture of yttria-stabilized zirconia and lanthanum strontium manganese oxide, both before and after mild electrochemical loading. All distributions were observed to be nearly isotropic, but non-random textures above the detection threshold were observed. The distributions differ between the two cells, as do the phase fractions and the electrochemical history. The different distributions are interpreted as evidence that steady-state distributions vary locally with phase fractions or that they evolve during the initial operation of the fuel cell. The rates at which triple lines, pore surfaces, and interface boundaries in the porous mixture approach a steady-state value appear to decrease with the average amount of mass transport required to reorient that specific feature. This work provides initial insights into the crystallography of interfaces in a multiphase ceramic material.

  11. Simultaneous recovery of all actinides from spent nuclear fuel by carbamoyl-methylphosphine oxide in fluorinated diluents

    SciTech Connect (OSTI)

    Ozawa, M.; Iwai, T.; Babain, V.; Shadrin, A.

    2008-07-01

    Bifunctional organophosphorus extractants dissolved in polar fluorinated diluents were studied, aiming at directly recovering all f-elements from the dissolver solution of spent nuclear fuel. Octyl(phenyl)-N,N-diisobutyl-carbamoyl-methylphosphine oxide (0{phi}D[iB] CMPO, 0.2-0.8 M) with 30% TBP dissolved in meta-nitrobenzotrifluoride (Fluoropole-732) dramatically expanded its extraction region without splitting out a heterogeneous third phase. Distribution ratios of U, Np, and Pu were sufficiently high for 0.4-0.8 M CMPO in this solvent system. Combination of salt-free, methylamine carbonate (MAC), citric acid, and hydrazine reagents were evaluated to obtain fractional stripping of f-elements such as TRU group and U. Static multistage extraction using artificial FBR dissolver solution supported the process feasibility. When all f-elements are extracted simultaneously, and TRU and U recovered separately with a single extraction cycle, the new extraction process, named ORGA-process, can be expected to be highly proliferation-resistant and systematically and economically advantageous. (authors)

  12. Electrochemical, Structural and Surface Characterization of Nickel/Zirconia Solid Oxide Fuel Cell Anodes in Coal Gas Containing Antimony

    SciTech Connect (OSTI)

    Marina, Olga A.; Pederson, Larry R.; Coyle, Christopher A.; Thomsen, Edwin C.; Nachimuthu, Ponnusamy; Edwards, Danny J.

    2011-02-27

    The interaction of antimony with the nickel-zirconia solid oxide fuel cell (SOFC) anode has been investigated. Tests with both anode-supported and electrolyte-supported button cells were performed at 700 and 800oC in synthetic coal gas containing 10 ppb to 9 ppm antimony. Minor performance loss was observed immediately after Sb introduction to coal gas resulting in ca. 5 % power output drop. While no further degradation was observed during the following several hundred hours of testing, cells abruptly and irreversibly failed after 800-1500 hours depending on Sb concentration and test temperature. Antimony was found to interact strongly with nickel and result in extensive alteration phase formation, consistent with expectations based on thermodynamic properties. Nickel antimonide phases, NiSb and Ni5Sb2, were partially coalesced into large grains and eventually affected electronic percolation through the anode support. Initial degradation was attributed to diffusion of antimony to the active anode/electrolyte interface to form an adsorption layer.

  13. Creep Behavior of Glass/Ceramic Sealant and its Effect on Long-term Performance of Solid Oxide Fuel Cells

    SciTech Connect (OSTI)

    Liu, Wenning N.; Sun, Xin; Koeppel, Brian J.; Stephens, Elizabeth V.; Khaleel, Mohammad A.

    2009-10-14

    The creep behavior of glass or glass-ceramic sealant materials used in solid oxide fuel cells (SOFCs) becomes relevant under SOFC operating temperatures. In this paper, the creep of glass-ceramic sealants was experimentally examined, and a standard linear solid model was applied to capture the creep behavior of glass ceramic sealant materials developed for planar SOFCs at high temperatures. The parameters of this model were determined based on the creep test results. Furthermore, the creep model was incorporated into finite-element software programs SOFC-MP and Mentat-FC developed at Pacific Northwest National Laboratory for multi-physics simulation of SOFCs. The effect of creep of glass ceramic sealant materials on the long-term performance of SOFC stacks was investigated by studying the stability of the flow channels and the stress redistribution in the glass seal and on the various interfaces of the glass seal with other layers. Finite element analyses were performed to quantify the stresses in various parts. The stresses in glass seals were released because of creep behavior during operations.

  14. Development of Ni1-xCoxO as the cathode/interconnect contact for solid oxide fuel cells

    SciTech Connect (OSTI)

    Lu, Zigui; Xia, Guanguang; Templeton, Joshua D.; Li, Xiaohong S.; Nie, Zimin; Yang, Zhenguo; Stevenson, Jeffry W.

    2011-06-01

    A new type of material, Ni1-xCoxO, was developed for solid oxide fuel cell (SOFC) cathode/interconnect contact applications. The phase structure, coefficient of thermal expansion, sintering behavior, electrical property, and mechanical bonding strength of these materials were evaluated against the requirements of the SOFC cathode/interconnect contact. A dense cathode/interconnect contact layer was developed through reaction sintering from Ni and Co metal powders. An area specific resistance (ASR) as low as 5.5 mohm.cm2 was observed after 1000 h exposure in air at 800 C for the LSM/Ni0.33Co0.67O/AISI441 assembly. Average mechanical strengths of 6.8 and 5.0 MPa were obtained for the cathode/contact/cathode and interconnect/contact/interconnect structures, respectively. The significantly low ASR was probably due to the dense structure and therefore improved electrical conductivity of the Ni0.33Co0.67O contact and the good bonding of the interfaces between the contact and the cathode, and between the contact and the interconnect.

  15. Characterization of Cr poisoning in a solid oxide fuel cell cathode using a high-energy x-ray microbeam.

    SciTech Connect (OSTI)

    Liu, D. J.; Almer, J.; Cruse, T.

    2010-01-01

    A key feature of planar solid oxide fuel cells (SOFCs) is the feasibility of using metallic interconnects made of high temperature ferritic stainless steels, which reduce system cost while providing excellent electric conductivity. Such interconnects, however, contain high levels of chromium, which has been found to be associated with SOFC cathode performance degradation at SOFC operating temperatures; a phenomenon known as Cr poisoning. Here, we demonstrate an accurate measurement of the phase and concentration distributions of Cr species in a degraded SOFC, as well as related properties including deviatoric strain, integrated porosity, and lattice parameter variation, using high energy microbeam X-ray diffraction and radiography. We unambiguously identify (MnCr){sub 3}O{sub 4} and Cr{sub 2}O{sub 3} as the two main contaminant phases and find that their concentrations correlate strongly with the cathode layer composition. Cr{sub 2}O{sub 3} deposition within the active cathode region reduces porosity and produces compressive residual strains, which hinders the reactant gas percolation and can cause structural breakdown of the SOFC cathode. The information obtained through this study can be used to better understand the Cr-poisoning mechanism and improve SOFC design.

  16. Characterization and Quantification of Electronic and Ionic Ohmic Overpotential and Heat Generation in a Solid Oxide Fuel Cell Anode

    SciTech Connect (OSTI)

    Grew, Kyle N.; Izzo, John R.; Chiu, Wilson K.S.

    2011-08-16

    The development of a solid oxide fuel cell (SOFC) with a higher efficiency and power density requires an improved understanding and treatment of the irreversibilities. Losses due to the electronic and ionic resistances, which are also known as ohmic losses in the form of Joule heating, can hinder the SOFC's performance. Ohmic losses can result from the bulk material resistivities as well as the complexities introduced by the cell's microstructure. In this work, two-dimensional (2D), electronic and ionic transport models are used to develop a method of quantification of the ohmic losses within the SOFC anode microstructure. This quantification is completed as a function of properties determined from a detailed microstructure characterization, namely, the tortuosity of the electronic and ionic phases, phase volume fraction, contiguity, and mean free path. A direct modeling approach at the level of the pore-scale microstructure is achieved through the use of a representative volume element (RVE) method. The correlation of these ohmic losses with the quantification of the SOFC anode microstructure are examined. It is found with this analysis that the contributions of the SOFC anode microstructure on ohmic losses can be correlated with the volume fraction, contiguity, and mean free path.

  17. Three-dimensional microstructural changes in the NiYSZ solid oxide fuel cell anode during operation

    SciTech Connect (OSTI)

    Nelson G. J.; Chu Y.; Grew, K.N.; Izzo Jr. J.R.; Lombardo, J.J.; Harris, W.M.; Faes, A.; Hessler-Wyser, A.; Van herle, J.; Wang, S.; Virkar, A.V.; Chiu, W.K.S.

    2012-04-07

    Microstructural evolution in solid oxide fuel cell (SOFC) cermet anodes has been investigated using X-ray nanotomography along with differential absorption imaging. SOFC anode supports composed of Ni and yttria-stabilized zirconia (YSZ) were subjected to extended operation and selected regions were imaged using a transmission X-ray microscope. X-ray nanotomography provides unique insight into microstructure changes of all three phases (Ni, YSZ, pore) in three spatial dimensions, and its relation to performance degradation. Statistically significant 3D microstructural changes were observed in the anode Ni phase over a range of operational times, including phase size growth and changes in connectivity, interfacial contact area and contiguous triple-phase boundary length. These observations support microstructural evolution correlated to SOFC performance. We find that Ni coarsening is driven by particle curvature as indicated by the dihedral angles between the Ni, YSZ and pore phases, and hypothesize that growth occurs primarily by means of diffusion and particle agglomeration constrained by a pinning mechanism related to the YSZ phase. The decrease in Ni phase size after extended periods of time may be the result of a second process connected to a mobility-induced decrease in the YSZ phase size or non-uniform curvature resulting in a net decrease in Ni phase size.

  18. Soft X-Ray Spectroscopic Study of Dense Strontium-Doped Lanthanum Manganite Cathodes for Solid Oxide Fuel Cell Applications

    SciTech Connect (OSTI)

    L Piper; A Preston; S Cho; A DeMasi; J Laverock; K Smith; L Miara; J Davis; S Basu; et al.

    2011-12-31

    The evolution of the Mn charge state, chemical composition, and electronic structure of La{sub 0.8}Sr{sub 0.2}MnO{sub 3} (LSMO) cathodes during the catalytic activation of solid oxide fuel cell (SOFC) has been studies using X-ray spectroscopy of as-processed, exposed, and activated dense thin LSMO films. Comparison of O K-edge and Mn L{sub 3,2}-edge X-ray absorption spectra from the different stages of LSMO cathodes revealed that the largest change after the activation occurred in the Mn charge state with little change in the oxygen environment. Core-level X-ray photoemission spectroscopy and Mn L{sub 3} resonant photoemission spectroscopy studies of exposed and as-processed LSMO determined that the SOFC environment (800 C ambient pressure of O{sub 2}) alone results in La deficiency (severest near the surface with Sr doping >0.55) and a stronger Mn{sup 4+} contribution, leading to the increased insulating character of the cathode prior to activation. Meanwhile, O K-edge X-ray absorption measurements support Sr/La enrichment nearer the surface, along with the formation of mixed Sr{sub x}Mn{sub y}O{sub z} and/or passive MnO{sub x} and SrO species.

  19. Characterization and Quantification of Electronic and Ionic Ohmic Overpotential and Heat Generation in a Solid Oxide Fuel Cell Anode

    SciTech Connect (OSTI)

    Grew, Kyle N.; Izzo, Jr., John R.; Chiu, W. K. S.

    2011-01-01

    The development of a solid oxide fuel cell (SOFC) with a higher efficiency and power density requires an improved understanding and treatment of the irreversibilities. Losses due to the electronic and ionic resistances, which are also known as ohmic losses in the form of Joule heating, can hinder the SOFCs performance. Ohmic losses can result from the bulk material resistivities as well as the complexities introduced by the cells microstructure. In this work, two-dimensional (2D), electronic and ionic transport models are used to develop a method of quantification of the ohmic losses within the SOFC anode microstructure. This quantification is completed as a function of properties determined from a detailed microstructure characterization, namely, the tortuosity of the electronic and ionic phases, phase volume fraction, contiguity, and mean free path. A direct modeling approach at the level of the pore-scale microstructure is achieved through the use of a representative volume element (RVE) method. The correlation of these ohmic losses with the quantification of the SOFC anode microstructure are examined. It is found with this analysis that the contributions of the SOFC anode microstructure on ohmic losses can be correlated with the volume fraction, contiguity, and mean free path.

  20. Materials & Fabrication

    Broader source: All U.S. Department of Energy (DOE) Office Webpages (Extended Search)

    Fabrication - Sandia Energy Energy Search Icon Sandia Home Locations Contact Us Employee Locator Energy & Climate Secure & Sustainable Energy Future Stationary Power Energy Conversion Efficiency Solar Energy Wind Energy Water Power Supercritical CO2 Geothermal Natural Gas Safety, Security & Resilience of the Energy Infrastructure Energy Storage Nuclear Power & Engineering Grid Modernization Battery Testing Nuclear Fuel Cycle Defense Waste Management Programs Advanced Nuclear

  1. Study on the mechanism of diametral cladding strain and mixed-oxide fuel element breaching in slow-ramp extended overpower transients

    SciTech Connect (OSTI)

    Tomoyuki Uwaba; Seiichiro Maeda; Tomoyasu Mizuno; Melissa C. Teague

    2012-10-01

    Cladding strain caused by fuel/cladding mechanical interaction (FCMI) was evaluated for mixed-oxide fuel elements subjected to 7090% slow-ramp extended overpower transient tests in the experimental breeder reactor II. Calculated transient-induced cladding strains were correlated with cumulative damage fractions (CDFs) using cladding strength correlations. In a breached high-smeared density solid fuel element with low strength cladding, cladding thermal creep strain was significantly increased to approximately half the transient-induced cladding strain that was considered to be caused by the tertiary creep when the CDF was close to the breach criterion (=1.0), with the remaining strain due to instantaneous plastic deformation. In low-smeared density annular fuel elements, FCMI load was significantly mitigated and resulted in little cladding strain. The CDFs of the annular fuel elements were lower than 0.01 at the end of the overpower transient, indicating a substantial margin to breach. A substantial margin to breach was also maintained in a high-smeared density fuel element with high strength cladding.

  2. Update on Fabrication of Extrusions for TREAT Trade Study

    SciTech Connect (OSTI)

    Luther, Erik Paul; Leckie, Rafael M.; Dombrowski, David E.; Papin, Pallas A.

    2014-03-05

    This supplemental report describes fuel fabrication efforts conducted for the Idaho National Laboratory Trade Study for the TREAT Conversion project that is exploring the replacement of the HEU (Highly Enriched Uranium) fuel core of the TREAT reactor with LEU (Low Enriched Uranium) fuel. Previous reports have documented fabrication of fuel by the upgrade process developed at Los Alamos National Laboratory. These experiments supplement an earlier report that describes efforts to increase the graphite content of extruded fuel and minimize cracking.

  3. Solar Thermochemical Fuels Production: Solar Thermochemical Fuel Production via a Novel Lowe Pressure, Magnetically Stabilized, Non-volatile Iron Oxide Looping Process

    SciTech Connect (OSTI)

    2011-12-19

    HEATS Project: The University of Florida is developing a windowless high-temperature chemical reactor that converts concentrated solar thermal energy to syngas, which can be used to produce gasoline. The overarching project goal is lowering the cost of the solar thermochemical production of syngas for clean and synthetic hydrocarbon fuels like petroleum. The team will develop processes that rely on water and recycled CO2 as the sole feed-stock, and concentrated solar radiation as the sole energy source, to power the reactor to produce fuel efficiently. Successful large-scale deployment of this solar thermochemical fuel production could substantially improve our national and economic security by replacing imported oil with domestically produced solar fuels.

  4. Doped Yttrium Chromite-Ceria Composite as a Redox-Stable and Sulfur-Tolerant Anode for Solid Oxide Fuel Cells

    SciTech Connect (OSTI)

    Yoon, Kyung J.; Coyle, Christopher A.; Marina, Olga A.

    2011-12-11

    A Ca- and Co-doped yttrium chromite (YCCC) - samaria-doped ceria (SDC) composite was studied in relation to a potential use as a solid oxide fuel cell (SOFC) anode material. Tests performed using the yttria-stabilized zirconia (YSZ) electrolyte-supported cells revealed that the electrocatalytic activity of the YCCC-SDC anode towards hydrogen oxidation at 800 C was comparable to that of the Ni-YSZ anode. In addition, the YCCC-SDC anode exhibited superior sulfur tolerant characteristics showing less than 10% increase in a polarization resistance, fully reversible, upon exposure to 20 ppm H2S at 800 C. No performance degradation was observed during multiple reduction-oxidation (redox) cycles when the anode was intentionally exposed to the air environment followed by the reduction in hydrogen. The redox tolerance of the YCCC-SDC anode was attributed to the dimensional and chemical stability of the YCCC exhibiting minimal isothermal chemical expansion upon redox cycling.

  5. Materials & Fabrication

    Broader source: All U.S. Department of Energy (DOE) Office Webpages (Extended Search)

    Safety, Security & Resilience of the Energy Infrastructure Energy Storage Nuclear Power & Engineering Grid Modernization Battery Testing Nuclear Fuel Cycle Defense Waste Management ...

  6. LLNL MOX fuel lead assemblies data report for the surplus plutonium disposition environmental impact statement

    SciTech Connect (OSTI)

    O`Connor, D.G.; Fisher, S.E.; Holdaway, R.

    1998-08-01

    The purpose of this document is to support the US Department of Energy (DOE) Fissile Materials Disposition Program`s preparation of the draft surplus plutonium disposition environmental impact statement. This is one of several responses to data call requests for background information on activities associated with the operation of the lead assembly (LA) mixed-oxide (MOX) fuel fabrication facility. The DOE Office of Fissile Materials Disposition (DOE-MD) has developed a dual-path strategy for disposition of surplus weapons-grade plutonium. One of the paths is to disposition surplus plutonium through irradiation of MOX fuel in commercial nuclear reactors. MOX fuel consists of plutonium and uranium oxides (PuO{sub 2} and UO{sub 2}), typically containing 95% or more UO{sub 2}. DOE-MD requested that the DOE Site Operations Offices nominate DOE sites that meet established minimum requirements that could produce MOX LAs. LLNL has proposed an LA MOX fuel fabrication approach that would be done entirely inside an S and S Category 1 area. This includes receipt and storage of PuO{sub 2} powder, fabrication of MOX fuel pellets, assembly of fuel rods and bundles, and shipping of the packaged fuel to a commercial reactor site. Support activities will take place within a Category 1 area. Building 332 will be used to receive and store the bulk PuO{sub 2} powder, fabricate MOX fuel pellets, and assemble fuel rods. Building 334 will be used to assemble, store, and ship fuel bundles. Only minor modifications would be required of Building 332. Uncontaminated glove boxes would need to be removed, petition walls would need to be removed, and minor modifications to the ventilation system would be required.

  7. Fast Reactor Fuel Type and Reactor Safety Performance

    SciTech Connect (OSTI)

    R. Wigeland; J. Cahalan

    2009-09-01

    Fast Reactor Fuel Type and Reactor Safety Performance R. Wigeland , Idaho National Laboratory J. Cahalan, Argonne National Laboratory The sodium-cooled fast neutron reactor is currently being evaluated for the efficient transmutation of the highly-hazardous, long-lived, transuranic elements that are present in spent nuclear fuel. One of the fundamental choices that will be made is the selection of the fuel type for the fast reactor, whether oxide, metal, carbide, nitride, etc. It is likely that a decision on the fuel type will need to be made before many of the related technologies and facilities can be selected, from fuel fabrication to spent fuel reprocessing. A decision on fuel type should consider all impacts on the fast reactor system, including safety. Past work has demonstrated that the choice of fuel type may have a significant impact on the severity of consequences arising from accidents, especially for severe accidents of low probability. In this paper, the response of sodium-cooled fast reactors is discussed for both oxide and metal fuel types, highlighting the similarities and differences in reactor response and accident consequences. Any fast reactor facility must be designed to be able to successfully prevent, mitigate, or accommodate all consequences of potential events, including accidents. This is typically accomplished by using multiple barriers to the release of radiation, including the cladding on the fuel, the intact primary cooling system, and most visibly the reactor containment building. More recently, this has also included the use of inherent safety concepts to reduce or eliminate the potential for serious damage in some cases. Past experience with oxide and metal fuel has demonstrated that both fuel types are suitable for use as fuel in a sodium-cooled fast reactor. However, safety analyses for these two fuel types have also shown that there can be substantial differences in accident consequences due to the neutronic and thermophysical properties of the fuel and their compatibility with the reactor coolant, with corresponding differences in the challenges presented to the reactor developers. Accident phenomena are discussed for the sodium-cooled fast reactor based on the mechanistic progression of conditions from accident initiation to accident termination, whether a benign state is achieved or more severe consequences are expected. General principles connecting accident phenomena and fuel properties are developed from the oxide and metal fuel safety analyses, providing guidelines that can be used as part of the evaluation for selection of fuel type for the sodium-cooled fast reactor.

  8. Sodium fast reactor fuels and materials : research needs.

    SciTech Connect (OSTI)

    Denman, Matthew R.; Porter, Douglas; Wright, Art; Lambert, John; Hayes, Steven; Natesan, Ken; Ott, Larry J.; Garner, Frank; Walters, Leon; Yacout, Abdellatif

    2011-09-01

    An expert panel was assembled to identify gaps in fuels and materials research prior to licensing sodium cooled fast reactor (SFR) design. The expert panel considered both metal and oxide fuels, various cladding and duct materials, structural materials, fuel performance codes, fabrication capability and records, and transient behavior of fuel types. A methodology was developed to rate the relative importance of phenomena and properties both as to importance to a regulatory body and the maturity of the technology base. The technology base for fuels and cladding was divided into three regimes: information of high maturity under conservative operating conditions, information of low maturity under more aggressive operating conditions, and future design expectations where meager data exist.

  9. Reformulated diesel fuel

    DOE Patents [OSTI]

    McAdams, Hiramie T [Carrollton, IL; Crawford, Robert W [Tucson, AZ; Hadder, Gerald R [Oak Ridge, TN; McNutt, Barry D [Arlington, VA

    2006-03-28

    Reformulated diesel fuels for automotive diesel engines which meet the requirements of ASTM 975-02 and provide significantly reduced emissions of nitrogen oxides (NO.sub.x) and particulate matter (PM) relative to commercially available diesel fuels.

  10. Studies on phase formation, microstructure development and elastic properties of reduced NiO-8YSZ anode supported bi-layer half-cell structures of solid oxide fuel cells

    SciTech Connect (OSTI)

    Nithyanantham, T.; Biswas, S.; Thangavel, S.N.; Bandopadhyay, S.

    2012-03-15

    Highlights: Black-Right-Pointing-Pointer Detailed study on the development of microstructure and phase in NiO-8YSZ anodes. Black-Right-Pointing-Pointer Detailed study on elastic properties at high temperatures in air/reducing atmosphere. Black-Right-Pointing-Pointer Effects of initial porosity, composition and other issues are evaluated in detail. -- Abstract: Half-cell structures of solid oxide fuel cells (SOFCs) with a thin and dense electrolyte layer of 8YSZ supported by a thick and porous NiO-8YSZ anode precursor structure were reduced in a gas mixture of 5% H{sub 2}-95% Ar at 800 Degree-Sign C for selected time periods in order to fabricate cermets with desired microstructure and composition, and to study their effects on the elastic properties at ambient and reactive atmospheres. It appears that 2 h of exposure to the reducing conditions is enough to reduce {approx}80% of NiO with an enhanced porosity value of 35%. The Ni-8YSZ cermet phase formation in the anode was analyzed with X-ray diffraction (XRD) in correlation with its microstructure. The elastic properties were determined after the reduction, at room and elevated temperatures using the impulse excitation technique. At room temperature the decrease in the Young's modulus was about 44% (after 8 h of reduction) and can be attributed mainly to the changes in the microstructure, particularly the increase in porosity from {approx}12% to 37%. Young's moduli of the as-received precursor and reduced anodes were evaluated as a function of temperature in air and reducing atmosphere. The results were explained in correlation to the initial porosity, composition and oxidation of Ni at the elevated temperatures.

  11. Fuel cells and fuel cell catalysts

    DOE Patents [OSTI]

    Masel, Richard I.; Rice, Cynthia A.; Waszczuk, Piotr; Wieckowski, Andrzej

    2006-11-07

    A direct organic fuel cell includes a formic acid fuel solution having between about 10% and about 95% formic acid. The formic acid is oxidized at an anode. The anode may include a Pt/Pd catalyst that promotes the direct oxidation of the formic acid via a direct reaction path that does not include formation of a CO intermediate.

  12. Effects of Fuel Dilution with Biodiesel on Lubricant Acidity...

    Office of Energy Efficiency and Renewable Energy (EERE) Indexed Site

    Effects of Fuel Dilution with Biodiesel on Lubricant Acidity, Oxidation and Corrosion Effects of Fuel Dilution with Biodiesel on Lubricant Acidity, Oxidation and Corrosion ...

  13. Investigation into the effects of trace coal syn gas species on the performance of solid oxide fuel cell anodes, PhD. thesis, Russ College of Engineering and Technology of Ohio University

    SciTech Connect (OSTI)

    Trembly, J. P.

    2007-06-01

    Coal is the United States’ most widely used fossil fuel for the production of electric power. Coal’s availability and cost dictates that it will be used for many years to come in the United States for power production. As a result of the environmental impact of burning coal for power production more efficient and environmentally benign power production processes using coal are sought. Solid oxide fuel cells (SOFCs) combined with gasification technologies represent a potential methodology to produce electric power using coal in a much more efficient and cleaner manner. It has been shown in the past that trace species contained in coal, such as sulfur, severely degrade the performance of solid oxide fuel cells rendering them useless. Coal derived syngas cleanup technologies have been developed that efficiently remove sulfur to levels that do not cause any performance losses in solid oxide fuel cells. The ability of these systems to clean other trace species contained in syngas is not known nor is the effect of these trace species on the performance of solid oxide fuel cells. This works presents the thermodynamic and diffusion transport simulations that were combined with experimental testing to evaluate the effects of the trace species on the performance of solid oxide fuel cells. The results show that some trace species contained in coal will interact with the SOFC anode. In addition to the transport and thermodynamic simulations that were completed experimental tests were completed investigating the effect of HCl and AsH3 on the performance of SOFCs.

  14. Performance of Ni-Fe/gadolinium-doped CeO{sub2} anode supported tubular solid oxide fuel cells using steam reforming of methane

    SciTech Connect (OSTI)

    Liang, B.; Suzuki, T.; Hamamoto, K.; Yamaguchi, T.; Sumi, H.; Fujishiro, Y.; Ingram, B. J.; Carter, J. D.

    2012-03-15

    Iron nanoparticles (Fe{sub 2}O{sub 3}) were added to NiO/gadolinium-doped CeO{sub 2} (GDC) anode supported solid oxide fuel cell (SOFC) for the direct methane-water fuel operation. The cell was co-sintered at 1400 C, and the anode porosity is 31.8%. The main size corresponding to peak volume is around 1.5 {mu}m. When steam and methane directly fed to the cell, the power density is about 0.57 W cm{sup -2} at 650 C. It is the familiar performance for H{sub 2} operation (4 times of flow rate) with same fuel utilization. Compare with the testing temperature of 600 and 650 C, there is almost no carbon fiber deposition at 700 C with steam/methane (S/C) of 5. At the same time, fuel operation of high value of S/C (=3.3) resulted in fiber-like deposition and degradation of power performance based on loading test results.

  15. INTEGRATED GASIFICATION COMBINED CYCLE PROJECT 2 MW FUEL CELL DEMONSTRATION

    SciTech Connect (OSTI)

    FuelCell Energy

    2005-05-16

    With about 50% of power generation in the United States derived from coal and projections indicating that coal will continue to be the primary fuel for power generation in the next two decades, the Department of Energy (DOE) Clean Coal Technology Demonstration Program (CCTDP) has been conducted since 1985 to develop innovative, environmentally friendly processes for the world energy market place. The 2 MW Fuel Cell Demonstration was part of the Kentucky Pioneer Energy (KPE) Integrated Gasification Combined Cycle (IGCC) project selected by DOE under Round Five of the Clean Coal Technology Demonstration Program. The participant in the CCTDP V Project was Kentucky Pioneer Energy for the IGCC plant. FuelCell Energy, Inc. (FCE), under subcontract to KPE, was responsible for the design, construction and operation of the 2 MW fuel cell power plant. Duke Fluor Daniel provided engineering design and procurement support for the balance-of-plant skids. Colt Engineering Corporation provided engineering design, fabrication and procurement of the syngas processing skids. Jacobs Applied Technology provided the fabrication of the fuel cell module vessels. Wabash River Energy Ltd (WREL) provided the test site. The 2 MW fuel cell power plant utilizes FuelCell Energy's Direct Fuel Cell (DFC) technology, which is based on the internally reforming carbonate fuel cell. This plant is capable of operating on coal-derived syngas as well as natural gas. Prior testing (1992) of a subscale 20 kW carbonate fuel cell stack at the Louisiana Gasification Technology Inc. (LGTI) site using the Dow/Destec gasification plant indicated that operation on coal derived gas provided normal performance and stable operation. Duke Fluor Daniel and FuelCell Energy developed a commercial plant design for the 2 MW fuel cell. The plant was designed to be modular, factory assembled and truck shippable to the site. Five balance-of-plant skids incorporating fuel processing, anode gas oxidation, heat recovery, water treatment/instrument air, and power conditioning/controls were built and shipped to the site. The two fuel cell modules, each rated at 1 MW on natural gas, were fabricated by FuelCell Energy in its Torrington, CT manufacturing facility. The fuel cell modules were conditioned and tested at FuelCell Energy in Danbury and shipped to the site. Installation of the power plant and connection to all required utilities and syngas was completed. Pre-operation checkout of the entire power plant was conducted and the plant was ready to operate in July 2004. However, fuel gas (natural gas or syngas) was not available at the WREL site due to technical difficulties with the gasifier and other issues. The fuel cell power plant was therefore not operated, and subsequently removed by October of 2005. The WREL fuel cell site was restored to the satisfaction of WREL. FuelCell Energy continues to market carbonate fuel cells for natural gas and digester gas applications. A fuel cell/turbine hybrid is being developed and tested that provides higher efficiency with potential to reach the DOE goal of 60% HHV on coal gas. A system study was conducted for a 40 MW direct fuel cell/turbine hybrid (DFC/T) with potential for future coal gas applications. In addition, FCE is developing Solid Oxide Fuel Cell (SOFC) power plants with Versa Power Systems (VPS) as part of the Solid State Energy Conversion Alliance (SECA) program and has an on-going program for co-production of hydrogen. Future development in these technologies can lead to future coal gas fuel cell applications.

  16. 2007 Fuel Cell Technologies Market Report | Department of Energy

    Office of Energy Efficiency and Renewable Energy (EERE) Indexed Site

    power, and transportation -- including data on the range of fuel cell technologies -- polymer electrolyte membrane fuel cell (PEMFC), solid oxide fuel cell (SOFC), alkaline...

  17. Conditioning effects on La1-xSrxMnO3-Yttria stabilized Zirconia electrodes for thin-film solid oxide fuel cells

    SciTech Connect (OSTI)

    Lee, You-Kee; Kim, Jung-Yeul; Lee, Young-Ki; Kim, Insoo; Moon, Hee-Soo; Park, Jong-Wan; Jacobson, Craig P.; Visco, Steven J.

    2002-12-06

    Composite cathodes of 50/50 vol percent LSM-YSZ (La1-xSrxMnO3-yttria stabilized zirconia) were deposited onto dense YSZ electrolytes by a colloidal deposition technique. The cathode characteristics were then examined by scanning electron microscopy (SEM) and studied by an impedance spectroscopy (IS). Conditioning effects of the LSM-YSZ cathodes were seen, and remedies for these effects were proposed for improving the performance of a solid oxide fuel cell (SOFC). LSM surface contamination and modification, cathode bonding to the YSZ electrolyte, changing Pt electrode and bonding paste, and curvature of sintered YSZ electrolytes led to some changes in microstructure and variability in cell performances.

  18. Microbial fuel cell treatment of fuel process wastewater (Patent) |

    Office of Scientific and Technical Information (OSTI)

    DOEPatents Microbial fuel cell treatment of fuel process wastewater Title: Microbial fuel cell treatment of fuel process wastewater The present invention is directed to a method for cleansing fuel processing effluent containing carbonaceous compounds and inorganic salts, the method comprising contacting the fuel processing effluent with an anode of a microbial fuel ell, the anode containing microbes thereon which oxidatively degrade one or more of the carbonaceous compounds while producing

  19. Bonded polyimide fuel cell package

    SciTech Connect (OSTI)

    Morse, Jeffrey D.; Jankowski, Alan; Graff, Robert T.; Bettencourt, Kerry

    2010-06-08

    Described herein are processes for fabricating microfluidic fuel cell systems with embedded components in which micron-scale features are formed by bonding layers of DuPont Kapton.TM. polyimide laminate. A microfluidic fuel cell system fabricated using this process is also described.

  20. Solid oxide fuel cell power plant having a fixed contact oxidation catalyzed section of a multi-section cathode air heat exchanger

    DOE Patents [OSTI]

    Saito, Kazuo; Lin, Yao

    2015-02-17

    The multi-section cathode air heat exchanger (102) includes at least a first heat exchanger section (104), and a fixed contact oxidation catalyzed section (126) secured adjacent each other in a stack association. Cool cathode inlet air flows through cool air channels (110) of the at least first (104) and oxidation catalyzed sections (126). Hot anode exhaust flows through hot air channels (124) of the oxidation catalyzed section (126) and is combusted therein. The combusted anode exhaust then flows through hot air channels (112) of the first section (104) of the cathode air heat exchanger (102). The cool and hot air channels (110, 112) are secured in direct heat exchange relationship with each other so that temperatures of the heat exchanger (102) do not exceed 800.degree. C. to minimize requirements for using expensive, high-temperature alloys.