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The growing concern about climate change and the contemporary increase in mobility requirements call for faster, cheaper, safer, and cleaner means of transportation. The retrofitting of fossil-fueled piston engine ultralight aerial vehicles to hydrogen power systems is an option recently proposed in this direction. The goal of this investigation is a comparative analysis of the environmental impact of conventional and hydrogen-based propulsive systems. As a case study, a hybrid electric configuration consisting of a fuel cell with a nominal power of about 30 kW, a 6 kWh LFP battery, and a pressurized hydrogen vessel is proposed to replace a piston prop configuration for an ultralight aerial vehicle. Both power systems are modeled with a backward approach that allows the efficiency of the main components to be evaluated based on the load and altitude at every moment of the flight with a time step of 1 s. A typical 90 min flight mission is considered for the comparative analysis, which is performed in terms of direct and indirect emissions of carbon dioxide, water, and pollutant substances. For the hydrogen-based configuration, two possible strategies are adopted for the use of the battery: charge sustaining and charge depleting. Moreover, the effect of the altitude on the parasitic power of the fuel cell compressor and, consequently, on the net efficiency of the fuel cell system is taken into account. The results showed that even if the use of hydrogen confines the direct environmental impact to the emission of water (in a similar quantity to the fossil fuel case), the indirect emissions associated with the production, transportation, and delivery of hydrogen and electricity compromise the desired achievement of pollutant-free propulsion in terms of equivalent emissions of CO2 and VOCs if hydrogen is obtained from natural gas reforming. However, in the case of green hydrogen from electrolysis with wind energy, the total (direct and indirect) emissions of CO2 can be reduced up to 1/5 of the fossil fuel case. The proposed configuration has the additional advantage of eliminating the problem of lead, which is used as an additive in the AVGAS 100LL. [ABSTRACT FROM AUTHOR]

Featured Application: Repowering of existing vessels with hybrid power system for electricity production and storage with focus on reduced power requirement, increased efficiency, and eliminated greenhouse gas emissions are the applications. As marine traffic is contributing to pollution, and most vessels have predictable routes with repetitive load profiles, to reduce their impact on environment, hybrid systems with proton exchange membrane fuel cells (PEMFC-s) and battery pack are a promising replacement. For this purpose, the new approach takes into consideration an alternative to diesel propulsion with the additional benefit of carbon neutrality and increase of system efficiency. Additionally, in the developed numerical model, control of the PEMFC–battery hybrid energy system with balance of plant is incorporated with repowering existing vessels that have two diesel engines with 300 kWe. The goal of this paper is to develop a numerical model that analyzes and determines an equivalent hybrid ship propulsion system for a known traveling route. The developed numerical model consists of an interconnected system with the PEMFC stack and a battery pack as power sources. The numerical model was developed and optimized to meet the minimal required power demand for a successful route, which has variable loads and sees ships sail daily six times along the same route—in total 54 nautical miles. The results showed that the equivalent hybrid power system consists of a 300 kWe PEMFC stack and battery pack with 424 kWh battery and state of charge varying between 20 and 87%. To power this new hybrid power system, a hydrogen tank of 7200 L holding 284.7 kg at pressure of 700 bar is required, compared to previous system that consumed 1524 kg of diesel and generated 4886 kg of CO2. [ABSTRACT FROM AUTHOR]

Hydrogen is a promising energy carrier in all fields of transportation, including unmanned aerial vehicles (UAVs) and manned vehicles for urban air mobility (UAM). In these applications, one of the biggest challenges is to overcome the limitations of lithium battery technologies, while keeping the advantage of clean energy, at least in terms of direct emissions. For these reasons, there is an ever-increasing interest in the development, simulation, and testing of propulsion systems adopting air-cooled proton exchange membrane fuel cells (PEMFCs). Fuel cells for aerospace must be designed for power-to-weight maximization. For this reason, auxiliary systems are simplified, and the adoption of air-cooling and passive cooling techniques is favored. However, the performance and dynamic behavior of PEMFCs are affected by the operating conditions, which, in applications like UAVs and UAM, are continuously changing due to the variation of speed and altitude during the flight. This investigation analyzes semi-empirical and control-oriented models of fuel cell systems proposed in the scientific literature. The review addresses the whole fuel cell system, inclusive of the balance of the plant, and introduces the transition from dynamic models to digital twins. [ABSTRACT FROM AUTHOR]

Solid Oxide Fuel Cell (SOFC) stacks are one of the most critical modules in industrial SOFC energy conversion systems. Although the detailed multiphysics distribution has been elaborately studied with accurate 3-dimensional (3D) models, development and validation of agile stack model is yet inadequate. Due to slow and tedious meshing and simulation, fast prototyping of stacks remains a challenge. Therefore, a 30-cell stack was tested at varied temperatures and gas flowrates and a real-time transient layer-resolved stack model is established and calibrated using the measured data, which gives a Root-Mean-Square (RMS) prediction error of 2.21% for measured voltages and 1.53 °C for measured temperatures. With layer resolution, the stack model shows the voltage, average temperature, as well as fuel and air flowrates of each cell. Moreover, the stack model reveals the relation of voltage distribution at varied fuel flowrates with temperature distribution. Furthermore, the stack model is potentially applicable to stack scaling effects, or designing Balance of Plant (BoP). [Display omitted] • An accurate layer-resolved stack model for voltage/temperature distributions. • Low computational cost of the model enabling agile and real-time applications. • Explained the role of operating conditions on flowrate inhomogeneity. • Revealed strong impact of temperature on stack voltage distribution. [ABSTRACT FROM AUTHOR]

The growing concern about climate change and the contemporary increase in mobility requirements call for faster, cheaper, safer, and cleaner means of transportation. The retrofitting of fossil-fueled piston engine ultralight aerial vehicles to hydrogen power systems is an option recently proposed in this direction. The goal of this investigation is a comparative analysis of the environmental impact of conventional and hydrogen-based propulsive systems. As a case study, a hybrid electric configuration consisting of a fuel cell with a nominal power of about 30 kW, a 6 kWh LFP battery, and a pressurized hydrogen vessel is proposed to replace a piston prop configuration for an ultralight aerial vehicle. Both power systems are modeled with a backward approach that allows the efficiency of the main components to be evaluated based on the load and altitude at every moment of the flight with a time step of 1 s. A typical 90 min flight mission is considered for the comparative analysis, which is performed in terms of direct and indirect emissions of carbon dioxide, water, and pollutant substances. For the hydrogen-based configuration, two possible strategies are adopted for the use of the battery: charge sustaining and charge depleting. Moreover, the effect of the altitude on the parasitic power of the fuel cell compressor and, consequently, on the net efficiency of the fuel cell system is taken into account. The results showed that even if the use of hydrogen confines the direct environmental impact to the emission of water (in a similar quantity to the fossil fuel case), the indirect emissions associated with the production, transportation, and delivery of hydrogen and electricity compromise the desired achievement of pollutant-free propulsion in terms of equivalent emissions of CO2 and VOCs if hydrogen is obtained from natural gas reforming. However, in the case of green hydrogen from electrolysis with wind energy, the total (direct and indirect) emissions of CO2 can be reduced up to 1/5 of the fossil fuel case. The proposed configuration has the additional advantage of eliminating the problem of lead, which is used as an additive in the AVGAS 100LL.

The aim of the Modulus (Modular Heat Transfer Station) project is to achieve a cost reduction by standardizing the Balance of Plant (BoP) in the field of solar thermal process heat plants. A consortium of three parabolic trough collector manufacturers, one producer of conventional BoP plants, and two research institutes have joined forces to develop a conceptional approach: First, a worldwide research of existing process heat plants was carried out and the database "ship-plants.info" was evaluated. One partner analyzed in particular the plants that will be added in 2021. In the next step, the components of a BoP plant were listed in the power range from 0.5 to 10 MW, their potential for standardization was investigated and classified. Based on this, a standardized piping and instrumentation diagram (P&ID) was developed. This has already been used as a template for further detailing of the BoP for three process heat plants in Europe, which are presented in the third chapter. Finally, further standardization options for commissioning (functional and safety tests) and performance evaluation are discussed.

In recent years, there has been a growing interest in utilizing hydrogen as an energy carrier across various transportation sectors, including aerospace applications. This interest stems from its unique capability to yield energy without generating direct carbon dioxide emissions. The conversion process is particularly efficient when performed in a fuel cell system. In aerospace applications, two crucial factors come into play: power-to-weight ratio and the simplicity of the powerplant. In fact, the transient behavior and control of the fuel cell are complicated by the continuously changing values of load and altitude during the flight. To meet these criteria, air-cooled open-cathode Proton Exchange Membrane (PEM) fuel cells should be the preferred choice. However, they have limitations regarding the amount of thermal power they can dissipate. Moreover, the performances of fuel cell systems are significantly worsened at high altitude operating conditions because of the lower air density. Consequently, they find suitability primarily in applications such as Unmanned Aerial Vehicles (UAVs) and Urban Air Mobility (UAM). In the case of ultralight and light aviation, liquid-cooled solutions with a separate circuit for compressed air supply are adopted. The goal of this investigation is to identify the correct simulation approach to predict the behavior of such systems under dynamic conditions, typical of their application in aerial vehicles. To this aim, a detailed review of the scientific literature has been performed, with specific reference to semi-empirical and control-oriented models of the whole fuel cell systems including not only the stack but also the complete balance of plant. [ABSTRACT FROM AUTHOR]

For the EU-DEMO Helium-Cooled Pebble Bed (HCPB) concept, an indirect coupled design (ICD) with a molten salt (MS) loop as an intermediate heat transport and storage system (IHTS) is considered for the conceptual design phase. The IHTS with an energy storage decouples the primary heat transport system (PHTS) that undergoes pulse and dwell power cycles from the power conversion system (PCS), and thus can provide stable power to the turbine and grid. However, the maintenance of stable He and MS parameters during transitions from dwell to pulse and vice versa is challenging for the design of the MS loop, and the real performance of the helium–MS heat exchanger (He/MS HX) shall be verified. To investigate such components and conditions, a new R&D infrastructure HELOKA-US (Helium Loop Karlsruhe—Upgrade Storage) is under construction for the validation of prototypical components and the MS loop operation under stationary and transitional conditions. This paper provides the design features of Phase 1a of the project and the simulation results with EBSILON on the power generation phase.

Making fusion power viable both technologically and commercially has been a challenge for decades due to the great complexity of the science and engineering challenges. In recent years, changes in both government policies and the emergence of private fusion companies have ushered a newfound push to accelerate fusion energy development. Kyoto Fusioneering (KF) is a privately funded fusion engineering start-up, founded to accelerate the development of high performance, commercially viable technologies that will be required for a fusion power plant, specifically those associated with heating and current drive systems, power generation, and the tritium fuel cycle. The company is focused on supporting the rapid expansion of the budding fusion industry. This paper provides a high-level description of some of the technical and industrial challenges it is tackling in developing a commercial fusion reactor, in particular in relation to: plasma heating with gyrotrons, tritium handling and breeding, energy conversion, and fusion materials. It provides an overview of KF's activities in finding solutions to challenges in each of these areas, including via its new testing facility now under construction, UNITY (Unique Integrated Testing Facility). KF’s core capabilities and areas of R&D focus are discussed, with reference to how they benefit the development of a new fusion industry as a whole and bring the technology closer to industrialisation, including via UNITY and through collaboration with external partners. The importance of industrialisation and subsequently commercialisation is also discussed, through KF’s assessment of the newly emerging fusion ecosystem, and where KF as a company sits within it. [ABSTRACT FROM AUTHOR]

As marine traffic is contributing to pollution, and most vessels have predictable routes with repetitive load profiles, to reduce their impact on environment, hybrid systems with proton exchange membrane fuel cells (PEMFC-s) and battery pack are a promising replacement. For this purpose, the new approach takes into consideration an alternative to diesel propulsion with the additional benefit of carbon neutrality and increase of system efficiency. Additionally, in the developed numerical model, control of the PEMFC–battery hybrid energy system with balance of plant is incorporated with repowering existing vessels that have two diesel engines with 300 kWe. The goal of this paper is to develop a numerical model that analyzes and determines an equivalent hybrid ship propulsion system for a known traveling route. The developed numerical model consists of an interconnected system with the PEMFC stack and a battery pack as power sources. The numerical model was developed and optimized to meet the minimal required power demand for a successful route, which has variable loads and sees ships sail daily six times along the same route—in total 54 nautical miles. The results showed that the equivalent hybrid power system consists of a 300 kWe PEMFC stack and battery pack with 424 kWh battery and state of charge varying between 20 and 87%. To power this new hybrid power system, a hydrogen tank of 7200 L holding 284.7 kg at pressure of 700 bar is required, compared to previous system that consumed 1524 kg of diesel and generated 4886 kg of CO2.

Hydrogen is a promising energy carrier in all fields of transportation, including unmanned aerial vehicles (UAVs) and manned vehicles for urban air mobility (UAM). In these applications, one of the biggest challenges is to overcome the limitations of lithium battery technologies, while keeping the advantage of clean energy, at least in terms of direct emissions. For these reasons, there is an ever-increasing interest in the development, simulation, and testing of propulsion systems adopting air-cooled proton exchange membrane fuel cells (PEMFCs). Fuel cells for aerospace must be designed for power-to-weight maximization. For this reason, auxiliary systems are simplified, and the adoption of air-cooling and passive cooling techniques is favored. However, the performance and dynamic behavior of PEMFCs are affected by the operating conditions, which, in applications like UAVs and UAM, are continuously changing due to the variation of speed and altitude during the flight. This investigation analyzes semi-empirical and control-oriented models of fuel cell systems proposed in the scientific literature. The review addresses the whole fuel cell system, inclusive of the balance of the plant, and introduces the transition from dynamic models to digital twins.

EUROFUSION DEMO is a Fusion Power Plant concept under assessment, based on Tokamak technology. Regarding the Balance of Plant definition, particular effort has been posed to the design of the Power Conversion System (PCS), thermally coupled to the Primary Heat Transport System. Several architectures of the PCS have been assessed, and the present work is focused on the PCS, based on the Rankine Cycle technology and equipped with a Small Energy Storage System (ESS) operated with Molten Salt. A new Energy Map has been released in 2021, revealing uncertainties on the thermal power deposited on the different in-Vacuum Vessel components (i.e. Breeding Blanket, Divertor, Limiters and Vacuum Vessel) and rejected to the coolant of related cooling circuits. This fact leads to several (12) possible operating scenarios. The following treatment will be analyzed the 2022 PCS Small ESS concept design review, performed by the industry with the main aim to align the new layout with the updated thermal inputs and its comparison with the preliminary design developed in 2018. Design novelties will be highlighted, especially those that dealt with improving the cycle control, robustness, safety of the operation and efficiency. The outcomes of the transient analysis will be shown and compared, to verify the mechanical and thermal stress during the DEMO period (pulse/dwell). Finally, a performance and efficiency analysis of the 2022 PCS layout is also presented and compared to 2018 configuration.

In recent years, there has been a growing interest in utilizing hydrogen as an energy carrier across various transportation sectors, including aerospace applications. This interest stems from its unique capability to yield energy without generating direct carbon dioxide emissions. The conversion process is particularly efficient when performed in a fuel cell system. In aerospace applications, two crucial factors come into play: power-to-weight ratio and the simplicity of the powerplant. In fact, the transient behavior and control of the fuel cell are complicated by the continuously changing values of load and altitude during the flight. To meet these criteria, air-cooled open-cathode Proton Exchange Membrane (PEM) fuel cells should be the preferred choice. However, they have limitations regarding the amount of thermal power they can dissipate. Moreover, the performances of fuel cell systems are significantly worsened at high altitude operating conditions because of the lower air density. Consequently, they find suitability primarily in applications such as Unmanned Aerial Vehicles (UAVs) and Urban Air Mobility (UAM). In the case of ultralight and light aviation, liquid-cooled solutions with a separate circuit for compressed air supply are adopted. The goal of this investigation is to identify the correct simulation approach to predict the behavior of such systems under dynamic conditions, typical of their application in aerial vehicles. To this aim, a detailed review of the scientific literature has been performed, with specific reference to semi-empirical and control-oriented models of the whole fuel cell systems including not only the stack but also the complete balance of plant.

For the EU-DEMO Helium-Cooled Pebble Bed (HCPB) concept, an indirect coupled design (ICD) with a molten salt (MS) loop as an intermediate heat transport and storage system (IHTS) is considered for the conceptual design phase. The IHTS with an energy storage decouples the primary heat transport system (PHTS) that undergoes pulse and dwell power cycles from the power conversion system (PCS), and thus can provide stable power to the turbine and grid. However, the maintenance of stable He and MS parameters during transitions from dwell to pulse and vice versa is challenging for the design of the MS loop, and the real performance of the helium–MS heat exchanger (He/MS HX) shall be verified. To investigate such components and conditions, a new R&D infrastructure HELOKA-US (Helium Loop Karlsruhe—Upgrade Storage) is under construction for the validation of prototypical components and the MS loop operation under stationary and transitional conditions. This paper provides the design features of Phase 1a of the project and the simulation results with EBSILON on the power generation phase. [ABSTRACT FROM AUTHOR]

2‐Propanol/acetone is a promising liquid organic hydrogen carrier system for fuel cell reactions. Herein, six different concepts for a 2‐propanol/acetone fuel cell system are evaluated in MATLAB simulation with respect to their thermodynamic integration and technical feasibility. Four of the concepts use a direct 2‐propanol fuel cell while the other two first release molecular hydrogen from 2‐propanol and subsequently use a hydrogen fuel cell. The presented liquid phase 2‐propanol fuel cell concept is thermodynamically feasible but cannot be realized technically using commercial Nafion membranes, due to membrane dissolution by the 2‐propanol/acetone/water fuel mixture. Gaseous 2‐propanol fuel cells imply a high heating requirement for the evaporation of the fuel. A direct high‐temperature fuel cell using 2‐propanol is thermodynamically feasible because there is less water in the overall system but is not technically feasible because of the esterification of phosphoric acid. A very interesting option is the conversion of gaseous 2‐propanol to pressurized hydrogen in an electrochemical pumping step followed by a hydrogen fuel cell, because here the waste heat of a sufficiently hot hydrogen fuel cell can drive the 2‐propanol evaporation. [ABSTRACT FROM AUTHOR]

Zero-dimensional two-stage SOFC stacks dynamic model was developed to investigate the effect of operating parameters on stacks performance. The model resolves spatially thermal and thermo-electrochemical behaviour for electrochemical reactions, Catalytic Partial Oxidation and Steam Reforming processes. Design variables and thermo-electrochemical properties were obtained from in-house-fabricated SOFCs carried out by project partners. The completed SOFCs based Combined Heat and Power, CHP, system model was validated by data18 and numerical results obtained at steady-state mode showing its high-fidelity. A parametric study with respect to key operating parameters including changes in fuel utilization, lambda number and current density values was conducted. The global CHP system dynamic response, in term of the current/voltage delivered by two-stage SOFC stacks, under a fixed fuel utilization, has been determined resulting in greater variations in the voltage of a single cell in the first stack in comparison to the corresponding values in the second stack.

• The present study reports on the current (2023) thermal system design of DEMO HCPB ICD BOP for 12 operational states defined by the DEMO Design Central Team (DCT) in 2021. • It was shown that the PCS is able to accommodate all of the 12 operational points defined based on the uncertainties of the energy map, provided that an additional bypass line at the outlet of the Divertor Cassettes (DIV-CAS) Heat Exchanger (HX) towards the low-pressure part of the feedwater line (to the condenser in this investigation) is installed in the system. • This bypass line is activated only in the cases, where the feedwater flow to the low temperature DEMO sources HXs is needed to be higher than that necessary to remove BB power at the Steam Generator (SG). In all the other cases, the bypass line remains unused. • Additionally, perspective improvements of DEMO HCPB BOP regarding thermal ESS, as well as PCS are discussed. An option for the Intermediate Coupling Design (ICD) of the European Demonstration Fusion Reactor (DEMO) Balance of Plant (BOP) configuration for Helium-Cooled Pebble Bed (HCPB) Breeding Blanket (BB) concept consists of the Primary Heat Transport System (PHTS), the Intermediate Heat Transfer System (IHTS), using HITEC salt as coolant, equipped with a thermal Energy Storage System (ESS), and the Power Conversion System (PCS). The aforementioned BOP configuration is capable of producing electricity continuously during the pulse time (2 h) and dwell time (10 min) of DEMO plant operation. The present study reports on the current (2023) thermal system design of DEMO HCPB ICD BOP for 12 operational states defined by the DEMO Design Central Team (DCT) in 2021. It was shown that the PCS is able to accommodate all of the 12 operational points defined based on the uncertainties of the energy map, provided that an additional bypass line at the outlet of the Divertor Cassettes (DIV-CAS) Heat Exchanger (HX) towards the low-pressure part of the feedwater line (to the condenser in this investigation) is installed in the system. This line is activated only in the cases, where the feedwater flow to the low temperature DEMO heat sources HXs is needed to be higher than that necessary to remove BB power at the Steam Generators (SGs). In all the other cases, the bypass line remains unused. Additionally, perspective improvements of DEMO HCPB BOP regarding thermal ESS, as well as PCS are discussed. [ABSTRACT FROM AUTHOR]

Two once-through steam generators and a combination of a steam generator and a gas preheater for supplying feed gases to solid-oxide electrolysis stacks were evaluated for their carryover characteristics of contaminants from the feed-water into the steam phase. The concentrations of various trace impurities in the steam were determined by sampling the steam condensates and screening them with inductively coupled plasma–mass spectrometry for 19 elements and liquid ion chromatography and continuous flow analysis for chloride and ammonium. Steam-soluble species such as boric acid undergo complete volatilization and transfer into the steam phase. During unstable evaporation in the steam generators an extensive physical carryover of alloying metal species was observed. At realistic operation conditions for steam electrolysis, the gas preheater caused a considerable release of silicon into the steam phase. Two stack experiments were performed with common preheater temperatures and showed largely increased cell voltage degradation at higher operation temperatures. The post-test chemical analysis of cell samples revealed significant concentrations of silicon in the samples that are regarded as primary cause for increased degradation. These findings could partially explain the wide spread of degradation rates reported for solid-oxide steam electrolysis experiments. [ABSTRACT FROM AUTHOR]

Electrochemical ammonia generation allows direct, low pressure synthesis of ammonia as an alternative to the established Haber-Bosch process. The increasing need to drive industry with renewable electricity central to decarbonisation and electrochemical ammonia synthesis offers a possible efficient and low emission route for this increasingly important chemical. It also provides a potential route for more distributed and small-scale ammonia synthesis with a reduced production footprint. Electrochemical ammonia synthesis is still early stage but has seen recent acceleration in fundamental understanding. In this work, two different ammonia electrolysis systems are considered. Balance of plant (BOP) requirements are presented and modelled to compare performance and determine trade-offs. The first option (water fed cell) uses direct ammonia synthesis from water and air. The second (hydrogen-fed cell), involves a two-step electrolysis approach firstly producing hydrogen followed by electrochemical ammonia generation. Results indicate that the water fed approach shows the most promise in achieving low energy demand for direct electrochemical ammonia generation. Breaking the reaction into two steps for the hydrogen fed approach introduces a source of inefficiency which is not overcome by reduced BOP energy demands, and will only be an attractive pathway for reactors which promise both high efficiency and increased ammonia formation rate compared to water fed cells. The most optimised scenario investigated here with 90% faradaic efficiency (FE) and 1.5 V cell potential (75% nitrogen utilisation) gives a power to ammonia value of 15 kWh/kg NH3 for a water fed cell. For the best hydrogen fed arrangement, the requirement is 19 kWh/kg NH3. This is achieved with 0.5 V cell potential and 75% utilisation of both hydrogen and nitrogen (90% FE). Modelling demonstrated that balance of plant requirements for electrochemical ammonia are significant. Electrochemical energy inputs dominate energy requirements at low FE, however in cases of high FE the BOP accounts for approximately 50% of the total energy demand, mostly from ammonia separation requirements. In the hydrogen fed cell arrangement, it was also demonstrated that recycle of unconverted hydrogen is essential for efficient operation, even in the case where this increases BOP energy inputs.

New policies and strict emission limits in the transports sector result in a gradual switch towards alternative fuels and hydrogen is getting attention: fuel cell systems are considered ideal energy converters of the next future. As the interest is rising in Proton Exchange Membrane Fuel Cells (PEMFC), there is a need for experimental research and dedicated laboratories on systems designed with Balance of Plant. In this context, the HI-SEA Laboratory (240-kW PEMFC by Nuvera FC, a joint between the University of Genoa-Fincantieri) was born. In this paper, the tuning of the laboratory to simulate a ship-likely environment is addressed, looking at the main problematics and resolutions, related to the cathodic line and the cooling control. Some guidelines are defined to install a PEMFC system onboard a ship exploiting the existing infrastructure. Thanks to the experimental campaign, a stack voltage model previously validated is employed to evaluate the performance of the system. • Tuning of 240 kW PEMFC integrated system and lesson-learned. • Balance of Plant of FC system simulates shipping environment. • Identification and resolution of cooling and cathodic lines issues. • Performance evaluation of experimental data through PEMFC model application. • Identification of management procedure for performance optimization. [ABSTRACT FROM AUTHOR]

• STEAM will experimentally validate the DEMO WCLL BoP water coolant systems. • STEAM is an experimental facility equipped with air coolers operating as heat sink. • The steady-state characterization of STEAM was performed by RELAP5/Mod3.3. • Critical aspects of the air coolers operation were investigated and discussed. • Preliminary control systems were tested for some of the main STEAM components. DEMO power station aims to demonstrate the generation of hundred MWs of electrical power from fusion reactions, then transmitted from the Tokamak reactor to the grid through the Balance of Plant (BoP). The design approach for the Water Cooled Lithium Lead (WCLL) Breeding Blanket (BB) Primary Heat Transfer Systems (PHTSs) leverages nuclear industry expertise but faces challenges due to DEMO pulsed operation and low-load periods. To assess the feasibility of these components, ENEA Experimental Engineering Division at Brasimone R.C. is designing STEAM, a facility investigating water technologies applied to the DEMO BB and BoP systems and components. STEAM is mainly composed of a primary system reproducing the DEMO WCLL BB PHTS thermodynamic conditions (15.5 MPa, 328–295 °C) and a secondary two-phase (liquid/steam) loop reproducing the DEMO power conversion system conditions (6.4 MPa, 238–300 °C). Experimental validation will reproduce steady-state and transient operation under DEMO-relevant conditions, including dedicated tests on the DEMO once through steam generator mock-up. STEAM objectives and description are presented in this paper, together with the RELAP5/Mod3.3 nodalization of the facility. The latter is used to, thermal-hydraulically characterize the facility behaviour. The outcomes of the steady-state qualification supported the optimization of the system layout appraising the performances of key components under the specified operating conditions. [ABSTRACT FROM AUTHOR]

• STEAM will experimentally characterize the EU-DEMO Steam Generator mock-up. • DEMO pulsed operation arises challenges requiring thermal hydraulic characterization. • A complete RELAP5/Mod3.3 model of the experimental facility was developed. • STEAM low power pre-test analyses were performed by using the developed model. • RELAP5 analysis provided feedbacks on the facility design and operative procedures. While nuclear fusion reactors hold promise, their realization faces significant complexities, not only in the construction but also in managing the auxiliary systems required for safely operating plasmas. Pulsed plasma regime, integral to reactor normal operations, determines atypical operative conditions that can cause high thermal stresses on the components and generate instabilities. R&D activities are therefore required to characterize the components behavior in the extremely severe conditions of pressure and temperatures associated with fusion, especially during sudden power transitions. ENEA, as part of the EUROfusion consortium, is planning the construction of STEAM, an experimental facility aimed at qualifying the DEMO Steam Generator during pulse-dwell-pulse transitions within the W-HYDRA platform. Dedicated experimental campaigns will reproduce the low-power phase associated with the only material activation (dwell), the full-power phase (pulse) and the corresponding power transitions. This paper focuses on the low-power phase, presenting the performed RELAP5/Mod3.3 simulations, investigating the thermal-hydraulic performances of the system at 1 %, 5 % and 10 % of the nominal power, hence in conditions considerably different from fission standard practices. The simulation results are essential for defining regulation strategies for the SG test section and ensuring the correct operation of the entire system. [ABSTRACT FROM AUTHOR]

The objective of the study was to develop a steady-state system model in Aspen TECH using user-defined subroutines to predict the SOFC electrochemical performance. In order to achieve high overall fuel utilization and thus high electrical efficiency, a concept of Combined Heat and Power system with two-stage SOFC stacks of different number of cells was analyzed. The concept of two-stage SOFC stacks based system was developed in the framework of the FP7 EU-funded project STAGE-SOFC. The model was validated against data gathered during the operation of the proof-of-concept showing good agreement with the comparative simulation data. Following model validation, further simulations were performed for different values of fuel utilization to analyze its influence on system electrical performance. Simulation results showed that the concept of two-stage SOFC stacks configuration was viable and reliable. The model can be useful for development the optimal control strategy for system under safe conditions.

A state-of-the-art review of the optimization of electrical cables in offshore wind farms (OWFs) is presented in this paper. One of the main contributions of this paper is to propose a general classification of this problem, framed in the general context of the OWFs design and optimization (OWiFDO). The classification encompasses two complementary aspects. First, the optimum sizing of electrical cables, with the three main approaches used nowadays, static-rated sizing, dynamic load cycle profile, and dynamic full time series, is conceptually analyzed and compared. The latest techniques and advances are described, along with the presentation of potential research areas not thoroughly addressed today, such as dynamic cable rating, and cable's lifetime estimation under time-varying conditions. Second, the network optimization of large OWFs is thoroughly presented, dividing the problem with a bottom-top approach: cable layout of the collection system, wind turbines (WTs) allocation to offshore substations (OSSs), number and location of OSSs, and interconnection between OSSs and onshore connection points (OCPs). A comparison among different methods is performed, taking into consideration the main engineering constraints. Global optimization, specifically, binary programming (BIP) or mixed-integer linear programming (MILP), is envisaged as the best way to tackle this topic. The full combinatorial problem is found to be better addressed following a top-bottom approach, combining exact formulations with high-level heuristics, or holistically with evolutionary algorithms.

The realization of the Divertor Tokamak Test (DTT) facility is one of the key milestones of the European Roadmap, aiming to explore alternative power exhaust solutions for DEMO, the first nuclear-fusion power plant that will be connected to the European grid. For the actual implementation of the DTT and DEMO plants, it is necessary to define the structure of the internal electric power distribution system, able to supply unconventional loads with a sufficient level of reliability. The present paper reports the preliminary studies for the feasibility and realization of the electrical power systems of DTT, describing the methodology adopted to obtain a first distribution configuration and providing some simulation results. In particular, the first stage of the study deals with the survey and characterization of the electrical loads, which allows defining a general layout of the facility and size the main electrical components. To verify the correctness of the assumptions, simulation models of the grid were implemented in the DIgSILENT PowerFactory software in order to carry out power flow and fault analyses. [ABSTRACT FROM AUTHOR]

A model of an alkaline electrolysis plant is proposed in this paper, including both stack and balance of plant, with the objective of analyzing the performance of a complete electrolysis system. For this purpose, Aspen Plus has been used in this work due to its great potential and flexibility. Since this software does not include codes for modelling the electrolysis cells, a custom model for the stack has been integrated as a subroutine, using a tool called Aspen Custom Modeler. This stack model is based on semi-empirical equations which describe the voltage cell, Faraday efficiency and gas purity as a function of the current. The rest of the components in the electrolysis plant have been modelled with standard operation units included in Aspen Plus. Simulations have been carried out in order to evaluate and optimize the balance of the plant of an alkaline electrolysis system for hydrogen production. Also, a parametric study has been conducted. The results show that increasing the operation temperature and reducing the pressure can improve the overall performance of the system. The proposed model in this work for the alkaline electrolyzer can be used in the future to develop a useful tool to carry out techno-economic studies of alkaline electrolysis systems integrated with other process. • A model of an alkaline electrolysis (AEL) plant has been developed using Aspen Plus. • A custom cell stack model has been integrated in Aspen Plus as a subroutine. • Simulations have been conducted to analyze the performance of an AEL plant. • The proposed model constitutes a useful tool to carry out system optimization. [ABSTRACT FROM AUTHOR]

The European DEMO is considered the nearest-term fusion reactor with the aim to generate several hundred MWs of net electricity, operate with a closed tritium fuel-cycle (achieving the tritium self-sufficiency) and qualify technological solutions for a Fusion Power Plant. Two Breeding Blanket (BB) concepts - relying on different cooling and breeding technologies - are considered for the baseline design: the Helium Cooled Pebble Bed (HCPB) BB and the Water Cooled Lithium Lead (WCLL) BB. The selection of the BB type has a strong impact on the whole DEMO plant design and, in particular, on the Balance of Plant (BoP). The aim of the present work is to investigate a possible concept design of the BoP accommodating two different BB. A flexible tool made with Matlab® was developed to study this configuration and allows to propose several uses of the heat fluxes. [ABSTRACT FROM AUTHOR]

• STEAM will host the mock-up of the EU-DEMO Steam Generators. • STEAM primary loop has been investigated with RELAP5/Mod3.3 system code. • DEMO normal operations have been studied including pulse-dwell transitions. • Different primary loop management strategies have been numerically simulated. • Setting the primary average temperature minimizes the loop operative fluctuations. The Water Cooled Lithium Lead Breeding Blanket (WCLL BB) is a key candidate for the driver blanket of the European DEMO reactor, progressing toward its Conceptual phase by the end of 2027. To assess different water and lithium-lead technologies for the WCLL BB and Balance of Plant (BoP) systems, the Water-thermal-HYDRAulic (W-HYDRA) experimental platform is under development at the ENEA Brasimone Research Centre. Among the facilities constituting the new W-HYDRA multipurpose infrastructure, STEAM is going to experimentally investigate the DEMO WCLL BoP thermal-hydraulics, focusing on the Steam Generator (SG) of the Primary Heat Transfer Systems (PHTS), to qualify its performances and suitability under its unconventional operation. The paper aims at supporting the thermal-hydraulic characterization of the Steam Generator mock-up during the sudden power variations typical of a pulsed fusion reactor. The analyzed selected scenario is the operational transient dwell-pulse-dwell, which determines high thermal cycling and correspondent high thermo-mechanical stresses on the primary side components. Two control logics with their relative drawbacks have been analyzed with a RELAP5/Mod3.3 1-D model, the first regulating the primary side average temperature, the second monitoring the minimum one. The comparison of the two systems highlighted that neither approach leads to hazardous conditions for the facility. However, while the average temperature controller is characterized by reduced thermal stresses on the components, the minimum temperature controller is characterized by higher thermal gradients for the primary loop. Both methodologies will be tested in the dedicated experimental campaign, aiming at yielding insights and evaluations concerning control strategies applicable to the DEMO reactor. [ABSTRACT FROM AUTHOR]

[Display omitted] • Optimal electrode configuration for industrial alkaline water electrolyzer. • Balance of Plant system design with full automatic running function. • Achieved 4.3kWh/m3H 2 @4000 A/m2 based on the optimized configuration. • Provided reference and guidance for electrode parameter selection and system design. • This study contributes to the deployment of more efficient industrial electrolyzer. The production of green hydrogen by water electrolysis is an effective way to realize the utilization of renewable energy and decarbonization, efficient water electrolysis equipment is of great significance to reduce energy consumption and accelerate the deployment of hydrogen production infrastructure. This paper reports the optimal electrode configuration adapted to actual industrial conditions. The aim of this paper is to study the electrode structure effect and system design of compactly-assembled industrial electrolyzer under the actual operating conditions, so as to find out more suitable electrolyzer configuration parameters. Firstly, the principle and structural parameter design of industrial electrolyzer are carried out, and compactly-assembled industrial alkaline water electrolyzer (22 cells) was manufactured. Secondly, a balance of plant (BOP) system was built and the fully automatic operation process was designed. Finally, a system-level alkaline water electrolysis (AWE) hydrogen production system (including compactly-assembled electrolyzer and BOP) was established. The effect of different expanded meshes and woven meshes on the energy consumption of AWE equipment was tested, and the system component cost was analyzed. Industrial system-level test results show that the electrode dominant parameters affecting AWE performance are different under varying current densities. From the perspective of industrial application, it is more suitable for the strand width and pore width of the woven mesh to be about 0.2 mm, it achieved 4.3kWh/m3H 2 @4000 A/m2 based on the optimized configuration parameters. This study is helpful to the selection of electrode parameters and optimal configuration for industrial AWE equipment, at the same time, it provides a reference for the design of electrolyzer, BOP and system control process. [ABSTRACT FROM AUTHOR]

When progressing from the International Thermonuclear Experimental Reactor (ITER) to the Demonstration Fusion Reactor (DEMO), a system for transferring plasma heat exhaust to a power conversion system is necessary for the so-called Balance of Plant (BOP). During the preconceptual phase of the EU-DEMO project, different BOP concepts were investigated in order to identify the main requirements and feasible architectures to achieve that goal in the most efficient way. This paper comprises the investigations performed during the DEMO preconceptual design phase (p-CDP) and compares the different variants. The main aspect was focused on the helium-cooled pebble bed (HCPB) breeding blanket (BB) concept. After all assessments were performed, the indirect coupled design (ICD) was chosen as the reference configuration for the DEMO HCPB BOP for further development and optimization. The ICD provides decoupling using a molten salt storage loop, which accumulates thermal power during plasma pulses that are released during dwell periods. The work is supported by simulations using design codes EBSILON and MATLAB/SIMULINK, providing the basis for the next design phase.

The realization of the Divertor Tokamak Test (DTT) facility is one of the key milestones of the European Roadmap, aiming to explore alternative power exhaust solutions for DEMO, the first nuclear-fusion power plant that will be connected to the European grid. For the actual implementation of the DTT and DEMO plants, it is necessary to define the structure of the internal electric power distribution system, able to supply unconventional loads with a sufficient level of reliability. The present paper reports the preliminary studies for the feasibility and realization of the electrical power systems of DTT, describing the methodology adopted to obtain a first distribution configuration and providing some simulation results. In particular, the first stage of the study deals with the survey and characterization of the electrical loads, which allows defining a general layout of the facility and size the main electrical components. To verify the correctness of the assumptions, simulation models of the grid were implemented in the DIgSILENT PowerFactory software in order to carry out power flow and fault analyses.

• The progresses of the Primary Heat Transfer System of the HCPB Breeding Blanket for the DEMO reactor are outlined. • The main components of Ex-Vessel PHTS has been sized to be compliant with the new In-Vessel requirements. • Results highlights that the 2017 HCPB BB PHTS has reached improved thermal-hydraulic and safety characteristics. • Further efforts are still needed to reduce PHTS pressure drops and volumes as well as to improve IHXs performance. In the frame of the activities promoted and encouraged by the EURO-fusion Power Plant Physics and Technology (PPPT) department aimed at developing the EU-DEMO fusion reactor, strong emphasis has been recently posed to the whole Balance of Plant (BoP) which represents the set of systems devoted to convert the plasma generated thermal power into electricity and to deliver it to the grid. Among these systems, a very important role is played by the Breeding Blanket (BB) Primary Heat Transfer System (PHTS) as it is responsible to extract more than 80% of the fusion plasma power. In this framework, University of Palermo, Ansaldo Nucleare and CREATE have focused their work to improve thermal-hydraulic, safety and integration features of the Ex-Vessel PHTS for the Helium-Cooled Pebble Bed (HCPB) BB concept of DEMO. Starting from the outcomes obtained in 2016 that have allowed to highlight some criticalities which needed design changes, the paper describes progress and developments of the 2017 HCPB PHTS as well as the goals which have been achieved. The results of the research activity carried out show, in fact, i) an increase of the thermal-hydraulic performances, since a reduction in both total coolant inventory and total pressure drop has been respectively reached, ii) a potential improvement of the overall safety characteristics of the system. Nevertheless a critical assessment of these key parameters reveals that some issues are still open in terms of design integration and feasibility of the whole DEMO BoP for the helium-cooled blanket option, indicating that additional efforts are required to make this technology more attractive. [ABSTRACT FROM AUTHOR]

The EU Demonstration Fusion Reactor (DEMO) Balance of Plant (BoP) configuration studied consists of the Primary Heat Transfer System (PHTS), the Intermediate Heat Transfer System (IHTS), using HITEC salt as coolant, equipped with a thermal Energy Storage System (ESS), and the Power Conversion System (PCS). This configuration is capable of producing electricity continuously through the pulse time (2 h), as well as dwell time (10 min) of the plant operation. The DEMO BoP development process was supported by industrial partners: Siemens Power and Gas Division and Kraftanlagen Heidelberg (KAH). The efficiency of the proposed Rankine cycle of the PCS is obtained to be not less than 39%. While elaborating the improved DEMO BoP design, KIT developed a plant model using the industrial code EBSILON®. [ABSTRACT FROM AUTHOR]

• An overview of few main design issues of DEMO reactor is outlined. • The possible solution for each of those issues has been briefly discussed. • The importance to develop in a homogeneous way the main systems of DEMO has been pointed in order to find an optimal solution to the issue. • The need of integration of design, safety in view of the nuclear license and the operation of the DEMO plant have been outlined. The EU DEMO preliminary safety and operating design requirements are being defined aiming at obtaining the nuclear license. The DEMO design approach is being organized, by taking into account the Nuclear Power Plant, ITER and Generation IV lessons learnt. Outstanding challenges remain in areas exhibiting large gaps beyond ITER. Those require a pragmatic approach, especially to evaluate and improve the readiness of technical solutions through dedicated physics and technology R&D. Therefore, a system engineering approach is adopted based on an integral plant design analysis which follows clear defined goals as safety, availability and power provision to the grid. This ensures not only the identification of critical interfaces but also the margin of possible solutions and, moreover, the definition of target parameters for technical systems to be met in order to arrive at an optimal DEMO design. The overall DEMO plant design has to be strongly safety and operation-balance of plant (BoP) oriented. The paper describes a set of important aspects of safety and BoP that require early attention and a continuous reanalysis at any significant design change. This includes: (i) plasma instability and mitigation actions; (ii) radioactive inventory minimization and control; (iii) energy inventory control and mitigation; (iv) power conversion system challenges and possible simplification; (v) huge and complex electrical loads; (vi) layout of the tokamak building versus plant and safety criteria. Any effort to reduce the complexity of a Fusion Power Reactor through simplification and rationalization of the design of the main systems translates into a more robust plant configuration enlarging safety margins and operational thresholds. [ABSTRACT FROM AUTHOR]

The solar thermal performance of a 102 kW rated thermal capacity linear Fresnel reflector system was evaluated experimentally under fixed and variable airflow rate through the oil-air heat exchanger. The solar thermal system consisted of 240 mirrors (linear Fresnel solar reflectors), each of 1485 by 625 mm size to heat the thermal oil, which was used to heat the air using the oil to air heat exchanger (AFfE). The results show that the actual maximum efficiency of the solar collector lies in the range of 0.28 to 0.34, whereas the calculated one is about 0.54 for the variable airflow rates. However, for a fixed airflow rate, the actual maximum efficiency is between 0.26 and 0.30. It implies that the actual solar collector efficiency is much lower than the calculated values. One of the major factors, which is not accounted for in the theoretical efficiency calculation, is the effect of dust on the primary and secondary mirrors. The investigated site is observing considerable sand movement, which is affecting the thermal output of the solar collector. The maximum heat exchanger effectiveness, e, obtained for variable and fixed airflow conditions is 0.9 and 0.8, respectively. [ABSTRACT FROM AUTHOR]

Graphical abstract Highlights • Layout optimization was performed using a genetic algorithm in MATLAB. • The balance of plant pipework costs in (Christopher W Lapp and Golay, 1997) are 14,914. • Optimization reduced the objective function to 9279 for locating modules on two sides. • The objective function for modules in a standardized grid was reduced to 8036. • Opportunity to reduce materials, build time, save design time and increase safety. Abstract The Small Modular Reactor (SMR) concept is designed such that it will solve some of the construction problems of large reactors. SMRs are designed to be "shop fabricated and then transported as modules to the sites for installation" (IAEA, 2018). As a consequence they theoretically have shorter build schedules and require less capital investment (Locatelli et al., 2014). Factory built modules can also increase safety and productivity, due to higher quality tools and inspection available. A literature review has highlighted substantial work has been undertaken in the research, development and construction of different types of reactors and reactor modules but the design of balance of plant modules has not been extensively researched (Wrigley et al., 2018). The focus of this paper is a case study for balance of plant modules in a light water reactor which also could have applications to other reactor types. Modules that are designed for factory build and transport may be built in a standardized module approach. By maximizing module size for transport, this maximizes work offsite, to achieve the cost and schedule savings associated. A design method needs to be developed to help support this approach. To enable this, a three step method is proposed: group components into modules, layout the modules and arrange components inside the modules. The Shearon Harris nuclear power plant was chosen for its publically available data. A previous study on this plant used matrix reordering techniques to group components and heuristically assign them to large modules, built for construction in an assembly area on site, highlighting a potential capital cost savings of 15%. This paper utilizes the same allocation of components to modules as the previous study but aims to undertake the challenge of how balance of plant modules should be arranged. The literature review highlighted that although the facility and plant layout problem has been extensively researched, mathematical layout optimization has not been applied to nuclear power plants. Many techniques for layout optimization have been developed for facilities and process plants however. The work in this paper develops an optimization model using a genetic algorithm for module layout and allocation within a nuclear power plant. This paper analysed two configurations of modules, where balance of plant modules are located on either one or two sides of the nuclear island. The objective function was to minimise pipe length. In the original research, where the plant was configured for assembly on site, the balance of plant modules are located around three sides of the nuclear island. The objective function was calculated at 14,914. As the distances are calculated rectilinearly, this number would be higher in reality as pipework has to be routed around containment. The optimization reduced the objective function by 33.9% and 37.8% for the three and four floor layouts respectively when balance of plant modules are located on two sides of the nuclear island. Furthermore, when modules are located on one side of the nuclear island, the objective function was reduced by 45.4% and 46.1% for three and four floor layouts respectively. This will reduce materials used, reduce build time and hence reduce the cost of a nuclear power plant. This method will also save design time when developing the layout of modules around the plant. [ABSTRACT FROM AUTHOR]

The Breeding Blanket (BB) is one of the key components of the European Demonstration (EU-DEMO) fusion reactor. Its main subsystems, the Breeder Zone (BZ) and the First Wall (FW), are cooled by two independent cooling circuits, called Primary Heat Transfer Systems (PHTS). Evaluating the BB PHTS performances in anticipated transient and accident conditions is a relevant issue for the design of these cooling systems. Within the framework of the EUROfusion Work Package Breeding Blanket, it was performed a thermal-hydraulic analysis of the PHTS during transient conditions belonging to the category of “Decrease in Coolant System Flow Rate”, by using Reactor Excursion Leak Analysis Program (RELAP5) Mod3.3. The BB, the PHTS circuits, the BZ Once Through Steam Generators and the FW Heat Exchangers were included in the study. Selected transients consist in partial and complete Loss of Flow Accident (LOFA) involving either the BZ or the FW PHTS Main Coolant Pumps (MCPs). The influence of the loss of off-site power, combined with the accident occurrence, was also investigated. The transient analysis was performed with the aim of design improvement. The current practice of a standard Pressurized Water Reactor (PWR) was adopted to propose and study actuation logics related to each accidental scenario. The appropriateness of the current PHTS design was demonstrated by simulation outcomes.

The air supply system of the proton exchange membrane fuel cell stack in fuel cell electric vehicles should be included as one of the components of the balance of plant. However, the air supply system consists of a centrifugal air compressor, driven by an ultra-high-speed motor. Therefore, there occurs a large amount of thermal energy from losses and the temperature of the air supply system should be considered. Accordingly, this study suggests the temperature estimation process for an air supply system based on a lumped parameter thermal network (LPTN). First, performance modeling is introduced using not only the empirical approach but also electromagnetic finite element analysis (FEA). Subsequently, thermal modeling based on the LPTN is presented. For this procedure, optimization techniques, screening, and surrogate model-based optimization are used. Finally, the results of LPTN construction are investigated. Furthermore, an additional experiment is conducted, and the result of this study is verified. • Performance modeling methodology of the air supply system is introduced. • Application of the lumped parameter thermal modeling concept to the overall compressor system is presented. • Determination process of the uncertain coefficients of lumped parameter thermal network is suggested. • Temperature estimation result through the suggested process is experimentally verified. [ABSTRACT FROM AUTHOR]

EU-DEMO is a European project, having the ambitious goal to be the first demonstrative power plant based on nuclear fusion. The electrical power that is expected to be produced is in the order of 700–800 MW, to be delivered via a connection to the European High Voltage electrical grid. The initiation and control of fusion processes, besides the problems related to the nuclear physics, need very complex electrical systems. Moreover, also the conversion of the output power is not trivial, especially because of the inherent discontinuity in the EU-DEMO operations. The present article concerns preliminary studies for the feasibility and realization of the nuclear fusion power plant EU-DEMO, with a special focus on the power electrical systems. In particular, the first stage of the study deals with the survey and analysis of the electrical loads, starting from the steady-state loads. Their impact is so relevant that could jeopardy the efficiency and the convenience of the plant itself. Afterwards, the loads are inserted into a preliminary internal distribution grid, sizing the main electrical components to carry out the power flow analysis, which is based on simulation models implemented in the DIgSILENT PowerFactory software.