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All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Decision-Making Framework to Evaluate Opportunities for Recovery of Rare Earth Elements and Critical Minerals in Produced Water Networks

Oil and gas development activities require a significant amount of water. Given the environmental impacts associated with high consumption and subsequent disposal of this water, there is a need for strategies to support effective reuse of, treatment of, and/or resource recovery from this produced water. These streams can contain appreciable concentrations of rare earth elements (REE) and critical minerals (CM) (e.g., Lithium), which are critical for many important applications in electronics, technology, manufacturing, energy, and medicine [1]. Along with REE/CM present in produced water, other waste streams such as fly ash from coal-fired power plants and acid mine discharge present other potential sources for recovery of REE/CM [2-4]. And with increases in demand for REE/CM, the need for recovery from wastewater streams is becoming even more important. There is a need to develop effective decision-making tools to evaluate the economic and environmental potential for REE/CM recovery from produced water networks while supporting the needs of drilling and hydraulic fracturing activities. In this work, we present our progress in developing a decision-making framework to efficiently design and operate produced water networks for REE/CM recovery. Our approach considers REE/CM recovery from produced water streams alongside other potential wastewater sources. The models consider the location and capacity of storage and decentralized treatment processes as well as the design and operation of pipeline and transportation networks to connect different sources and effectively schedule inventories, reuse, and recovery opportunities. We focus on the evaluation of opportunities for REE/CM recovery with treatment constraints on composition and flow. We demonstrate this framework with an illustrative case study that features diverse production sites, storage facilities, transportation, and treatment sites. This proposed framework will be deployed in an open-source software package that is compatible with the PARETO framework to deliver analysis and decision-making tools that allow stakeholders to quantitatively evaluate potential opportunities for REE/CM recovery in produced water networks.

Pulsipher, Joshua↗
DOE OSTI2020

Value-of-Information Analysis of a Fracture Prediction Method

A core-based fracture prediction method is used to illustrate a Value of Information (VOI) decision-analysis protocol to inform completion decisions in tight-gas sandstones. The ratio of late host-rock cement to available pore volume or degradation index uses petrographic observations of cement distributions in core (including sidewall cores) to predict whether nearby but unsampled fractures (widths > 0.5 to 1 mm) are sealed (non-conductive) or open (conductive). Measurements from four sandstone plays suggest that the index correctly predicts open vs. sealed fractures with an accuracy in excess of 80%. The value added is calculated using Bayesian inference in which accuracy of the index serves as the likelihood of the prior distribution of open fractures to assess the posterior probability that data represent a useful predictor of producibility. VOI of the prediction method is more than three times the cost to acquire the data. VOI is most sensitive to play-specific geologic and cost parameters including cost to drill, expected revenue from a successful well, cost of completion, cost of acquiring data for the index, and fracture probability distributions. The approach provides a way to value acquiring fracture data and points to a need for zone-specific production data in tight-gas sandstones.

02 PETROLEUM↗
DOE OSTI2025

Southwest Regional Partnership on Carbon Sequestration: Phase III (Final Scientific/Technical Report)

The Southwest Regional Partnership on Carbon Sequestration (SWP) is one of 7 regional partnerships formed in 2003 under the U.S. Department of Energy’s (DOE) Regional Carbon Sequestration Partnerships (RCSPs) initiative. The overall purpose of the initiative was to help determine and implement the technology, infrastructure, and regulations most appropriate to promote carbon storage in different regions of the country. Covering Arizona, Colorado, New Mexico, Oklahoma, Utah, and parts of Texas, Wyoming, and Kansas, the SWP evaluated regional carbon storage and utilization potential and focused on technologies and sites that could complement the region’s strong position in energy production. The project progressed through three phases: • Phase I (2003–2005): Characterized regional geologic formations and CO 2 sources, assessed sequestration potential, and identified pilot test sites. • Phase II (2005–2013): Conducted small-scale field tests to validate sequestration methods, including geologic and terrestrial projects. • Phase III (2008–2022): Demonstrated large-scale CO 2 injection at a commercial oil field to test monitoring, verification, and long-term storage strategies. This report covers Phase III. The final project site, the Farnsworth Unit (FWU) in Texas, provided real-world testing of reservoir characterization, monitoring, and risk evaluation tools and processes that could be used in any commercial scale carbon capture, utilization, and storage (CCUS) project. Extensive data collection and analysis helped refine best practices for reservoir characterization, injection monitoring, and storage verification. The SWP contributed to national databases, DOE best practice manuals, and regional geological assessments to support future sequestration efforts. Key lessons learned include the importance of robust data management, strategic site selection, regulatory navigation, and effective industry collaboration. The project’s findings will inform ongoing and future carbon storage initiatives. Task 1 (Regional Characterization) • The SWP continued to participate in national outreach efforts and NATCARB. • The SWP evaluated multiple potential sites before selecting the FWU as the primary field test location. Task 2 (Public Outreach and Education) • The SWP contributed to national databases, DOE best practice manuals, and regional geological assessments to support future sequestration efforts. Task 3 (Permitting and Regulatory Compliance) • The SWP ensured compliance with federal and state regulations, including National Environmental Policy Act (NEPA) requirements. • The SWP obtained all necessary permits for drilling, injection, and monitoring activities. Task 4 (Site Characterization and Planning) • The SWP developed work plans for four key activities: characterization, simulation, monitoring and verification, and risk evaluation. • The SWP collected and synthesized legacy data from multiple sources to build initial static geological models and dynamic reservoir models demonstrating project feasibility. • The SWP conducted an initial risk evaluation and developed mitigation plans. Task 5 (Field Operations and Data Collection) • The SWP drilled, logged, and cored three characterization wells to gather critical subsurface data. • The SWP conducted multiple geophysical surveys, including 3D seismic, crosswell seismic, and vertical seismic profiling, to improve reservoir characterization. Task 6 (Monitoring and Verification) • The SWP performed extensive geological characterization using data from characterization wells and seismic surveys. • The SWP established a surface monitoring network to track CO 2 flux in soil gas, groundwater chemistry, and near-surface atmospheric CO 2 levels. • The SWP built and refined reservoir models to study the effects of relative permeability on simulation behavior and improve calibration with experimental data. Task 7 (Risk Assessment and Model Refinement) • The SWP conducted multiple studies to evaluate reservoir integrity, predict CO 2 plume behavior and improve predictive modeling capabilities. • The SWP refined geological models and used them to enhance the accuracy of simulation models. • The SWP continued quantitative risk assessment of top-ranked risks and strengthened the link between qualitative and quantitative risk methodologies.

02 PETROLEUM↗
DOE OSTI2023

Development, Monitoring, and Control of Fracture Thermal Energy Storage in Crystalline Rock Formations (DEMO-FTES) [Abstract]

Approximately half of global energy consumption is used for heating and cooling. Because fossil fuels are used to meet most of this demand, heating and cooling of buildings produces a large portion of global greenhouse gas (GHG) emissions. The proposed project seeks to demonstrate the feasibility of a seasonal thermal energy storage concept called fracture thermal energy storage (FTES), which has the potential to dramatically lower energy requirements for heating and cooling and improve the resilience of building energy systems. FTES is a technique for building a highly efficient heat exchanger by creating a carefully designed set of fractures in the ground below a building. This heat exchanger allows thermal energy to be stored over seasonal timeframes—for example, hot thermal energy that is easily captured in the summer or energy from waste heat sources—to meet heating needs during colder months. FTES offers a solution with a relatively small footprint and lower cost compared to currently operating aquifer thermal energy storage (ATES) systems and could be used in the many areas without aquifers suitable for ATES. If commercialized, FTES systems could exceed the 2.5 TWh of energy storage per year from the more than 2,800 ATES systems in operation worldwide, which range from 0.1 MW to 30 MW. The savings in CO2 emissions per year are also expected to match or exceed individual ATES projects, with the largest, a 30 MW system used to provide heating and cooling to the University of Technology in Eindhoven in the Netherlands, estimated to save 13,000 tons of CO2 emissions per year. FTES utilizes mature drilling and fracturing technology and therefore has the potential to be rapidly commercialized once demonstrated. The ability to construct and establish flow through an FTES heat exchanger has been demonstrated by a previous project and the potential for efficient, large-capacity energy storage has been shown using numerical models. However, no experimental validation of these numerical estimates of thermal energy storage has been made. The first crucial need to advance FTES technology is to identify the sensitivity of key metrics such as thermal energy storage and production rates, capacities, and efficiencies to design parameters such as the number of fractures, depth/temperature of fractures, size of fractures, and circulation rates. The second crucial need is experimental testing of achievable thermal performance with optimized system design parameters. The proposed scope of work seeks to systematically address these two critical needs through a highly complementary international collaboration spanning theory, laboratory, and mesoscale field evaluation. The proposed work plan calls for using dimensional analysis and existing state-of-the-art numerical simulators to design carefully scaled laboratory and 10-meter-scale field tests of the thermal efficiency of FTES. The existing advanced laboratory and intermediate-scale field testbeds that will be used for this project will allow for detailed monitoring of the system performance during the test and of how the performance changes across time and length scales. These results will determine the feasibility of full- scale FTES systems. If the thermal performance is consistent with model predictions, the results will provide a strong economic justification for rapid commercialization of FTES technology in a wide range of geographical areas.

25 ENERGY STORAGE↗
DOE OSTI2023

Computed Tomography Scanning and Petrophysical Measurements of the Lively Grove #1 Well Core

The computed tomography (CT) facilities and the Multi-Sensor Core Logger (MSCL) at the National Energy Technology Laboratory (NETL) in Morgantown, West Virginia were used to characterize core from the Lively Grove #1 Well (API 121892494700), drilled near Marissa, Washington County, Illinois. Core from the well was obtained as part of the Illinois Storage Corridor’s Carbon Storage Assurance Facility Enterprise (CarbonSAFE) project (DE FE0031892). The primary impetus of this work was to capture a detailed digital representation of the core from the Lively Grove #1 Well. The collaboration between the U.S. Department of Energy’s (DOE) NETL and the Illinois State Geological Survey (ISGS) enables other research entities to access information about this potential carbon storage location and Cambro-Ordovician Storage Complex formations of the Illinois Basin. The resultant datasets are presented in this report and can be accessed from NETL’s Energy Data eXchange (EDX) online system. All equipment and techniques used were non-destructive, enabling future examinations and analyses to be performed on these cores. Fractures, discontinuities, and millimeter-scale features were readily detectable with the medical CT scanner-acquired images. Imaging with the NETL medical CT scanner was performed on entire cores. Qualitative analysis of the medical CT images, coupled with X-ray fluorescence (XRF), gamma density, and magnetic susceptibility measurements from the MSCL were useful in identifying zones of interest for potential future analysis. Higher-resolution industrial and micro-CT images were acquired from selected zones along the depth of the core to visualize the structure in higher detail. The ability to quickly identify key areas for more detailed study with higher resolution will save time and resources in future studies. The combination of methods used provides a multi-scale analysis of the core; with the resulting macro- and micro-descriptions relevant to many subsurface energy related examinations traditionally performed at NETL.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

Thermal and Well Flow Performance of Closed-Loop Geothermal in the Wattenberg Area: Preprint

Closed-loop geothermal systems provide an alternative to resource-constrained hydrothermal systems and stimulation-intensive enhanced geothermal systems. In this work, we apply the slender-body theory (SBT) model, to simulate the well flow and heat transfer performance of U-loop well designs drilled in the Wattenberg area of the Denver-Julesburg Basin. Three U-loop well patterns are investigated including a single, double, and multi-lateral design. The subsurface within area is characterized by deep, hot (> 200degreesC) igneous/metamorphic basement rock underlying multiple sedimentary formations. The lateral section(s) of the U-loop lies within a target depth of 6 km where temperatures are estimated to approach 300degreesC. As a base case, conduction-only heat transfer is investigated through simulations with the SBT model within U-loops with open-hole laterals that exchange heat directly with the hot dry rock using water as a working fluid. The utilization of supercritical CO2 as a heat transfer fluid is also considered. For each scenario, the system performance in terms of annual heat production and temperature profile over a 20-year project lifetime are assessed. Also, the levelized costs of heat and electricity (LCOH and LCOE) are determined using a top-down technoeconomic analysis model. The results show that the performance and cost optimized U-loop design is one having an injection-production well spacing of 1,000 meters with ten 50-meter-spaced laterals that traverse a subsurface system with a temperature gradient of 60degreesC/km. By injecting 20 degreesC-water at a rate of 60 kg/s through this loop, an average heat production of 19 MWth can be achieved, resulting in an LCOE and LCOH of $136/MWh and $1.53/GJ, respectively, over a 20-year project life.

closed-loop geothermal↗
DOE OSTI2023

Building an EPA Class VI Permit Application

Summary To accelerate the commercialization of carbon capture and storage (CCS), the US Department of Energy (US DOE) is building on decades of characterization efforts and pilot-scale projects through their CarbonSAFE program. Administered through their National Energy Technology Laboratory, this program seeks to bring fully integrated projects to the sector that can store more than 50 million tonnes of CO2 over a 30-year period. The program, which was enacted before the enhancement of Internal Revenue Code Section 45Q, is in the capture assessment, characterization, and permitting phase. The objectives of this paper are to discuss (a) the injection permitting requirements of the CarbonSAFE projects; (b) information gathering in support of the permit; (c) the timelines of field development and permit-related activities; (d) the major technical components of the field development plan; and (e) early feedback from the regulators toward acceptance of the permit. In Mississippi, more than 30,000 acres have been characterized by six deep characterization wells, a deep groundwater well, and 92 line miles of 2D seismic as part of the CarbonSAFE Project ECO2S. During the acquisition of seismic data, all receiver lines were live, which resulted in the generation of a pseudo-3D seismic design. The incorporation of a 3D seismic survey was not included as part of this project due to logistical difficulties presented by the undulating, wooded surface terrain. A suite of openhole geophysical logs was taken from each well, allowing for a detailed interpretation of prospective storage reservoirs and confining intervals to complement the analysis carried out on the 290 ft of a whole core that was cut through the prospective confining zone and storage reservoir. The detailed geologic and reservoir data were assembled and entered into a 3D model to assess the injection capacity and the area of review (AoR). This information fed into the detailed corrective action, monitoring, testing, and postinjection site care (PISC) modeling. The results have been exceptional. The geologic assessment has revealed three primary storage targets, ranging in depth from 3,500 ft to 6,000 ft. These storage reservoirs net 1,300 ft of sandstone, with mean porosity and permeability of 29% and 3.6 darcies, respectively. Together, these reservoirs have storage capacities that may exceed 20 million tonnes per square mile, making this a gigatonne prospect. Forward modeling of the project resulted in an AoR of 16 sq miles, injecting about 8000 t/d, for 30 years, via two deep injection wells. The excellent confining characteristics of the caprock, relatively simple geologic structure, and lack of historical well drilling activity in this area provide excellent containment of the injected CO2. Based on this work, the project has proposed 20 years of PISC. To date, only two US CO2 injection permits have been granted. These projects relied on a singular capture point feeding a singular sequestration point (source to sink), and considerations have not been made to garner CO2 emissions from other industrial sources. The Kemper County Storage Complex is a first-of-its-kind storage hub concept that looks to develop an area capable of storing significant quantities of CO2 from the region. Also, this work will show how characterization efforts, geological and numerical modeling efforts, and plan development were constructed in support of permit and incentives acceptance.

Energy & Fuels↗
DOE OSTI2025

DEEPEN: DErisking Exploration for Geothermal Plays in Magmatic ENvironments: Cooperative Research and Development (Final Report)

High resource risk and high capital costs are key barriers to scaling up geothermal energy development globally. Reducing both resource risk and costs has for a long time been a priority area of both research institutions and industry, particularly when it comes to new types of geothermal resources. The DErisking Exploration for geothermal Plays in magmatic Environments (DEEPEN) project aimed to contribute to this goal through increasing the probability of success when drilling for geothermal fluids in magmatic systems.

15 GEOTHERMAL ENERGY↗
DOE OSTI2024

NORTH DAKOTA CARBONSAFE PHASE III: SITE CHARACTERIZATION AND PERMITTING OF GEOLOGIC STORAGE OF CARBON DIOXIDE

The Energy & Environmental Research Center (EERC), in partnership with Minnkota Power Cooperative Inc. (Minnkota), SLB, and Computer Modelling Group Ltd. (CMG), supported wide-scale deployment of carbon capture and storage (CCS) as part of the U.S. Department of Energy (DOE) National Energy Technology Laboratory Carbon Storage Assurance Facility Enterprise (CarbonSAFE) Initiative Phase III. This phase included the acquisition, analysis, and development of information to fully characterize two storage complexes to demonstrate viable storage resources for commercial volumes of CO2 (defined by DOE as a minimum of 50 million tonnes [MMt] of CO2 within a 30-year period) (National Energy Technology Laboratory, 2024). Phase III also involved the preparation, submission, and approval of North Dakota underground injection control (UIC) Class VI storage facility permits (SFPs)—required precursors to applications for Class VI injection well permits. The presumed viability of commercial-scale CCS, situated adjacent to Minnkota’s Milton R. Young Station (MRYS), is validated by Minnkota’s continued pursuit of Project Tundra—an initiative to build the world’s largest lignite-based CCS project in central North Dakota (www.projecttundrand.com). Project Tundra comprises two scopes of work, Tundra Capture (installation of postcombustion CO2 capture at MRYS) and Tundra SGS (secure geologic storage). The efforts of North Dakota CarbonSAFE Phase III, Site Characterization and Permitting, supported Tundra SGS. Extensive site-specific characterization activities included a successful multimeasurement geophysical approach and drilling a stratigraphic test well (J-ROC 1, subsequently renamed Liberty-1) adjacent to MRYS. Core collection and analyses, downhole testing and fluid sampling, and geophysical logging were performed on J-ROC 1 and on a nearby stratigraphic test well (known as J-LOC 1), which was drilled, cored, and tested under a complementary project funded by the North Dakota Lignite Research Program. The injection tests performed on J-LOC 1 positively impacted the CarbonSAFE project, resulting in fewer proposed injection wells and significant construction, operations, and monitoring cost savings. The characterization data collected and analyses performed were integrated into geologic models, and successive numerical simulations were run to determine CO2 plume extent and subsurface pressure buildup associated with the planned CO2 injection rate of nearly 4 MMt per year. The latter doubles the CarbonSAFE Initiative goal with an estimated 100 MMt of CO2 stored in 20 years. Application of the U.S. Environmental Protection Agency’s (EPA’s) method for estimating the Class VI Rule area of review (AOR) to the overpressurized Broom Creek Formation inspired an alternative method of calculation, called risk-based AOR delineation. This peer-reviewed method was applied for the first time during the storage facility-permitting process. The two SFP applications submitted in 2021 successfully resulted in North Dakota Industrial Commission (NDIC) orders in 2022 authorizing the creation of the storage facility areas and amalgamation of pore space as well as establishing financial responsibility requirements. After approval of the SFPs, Minnkota filed in 2022 applications for permits to reenter the J-ROC 1 well and to drill two new wells—all with the intended purpose to become Class VI injection wells. To establish eligibility under the Internal Revenue Code for Section 45Q tax incentives, a monitoring, reporting, and verification (MRV) plan was prepared and submitted by Minnkota to EPA in 2022, resulting in the first such plan approved in North Dakota. Also in 2022, under the National Environmental Policy Act (NEPA), Minnkota prepared and submitted an environmental information volume (EIV) describing the proposed CCS project and associated potential environmental impacts. Based on the EIV, DOE determined that the proposed construction project required an environmental assessment, and Minnkota submitted the first draft in 2023 and a revised draft in 2024. Both submissions were followed by a public comment period. Subsequently, DOE issued a finding of no significant impact (FONSI) on September 13, 2024. A successful outreach program, strongly based in the production, presentation, and dissemination of informational material, fostered an environment to aid stakeholders in making informed decisions regarding the planned project. Opportunities for public input were provided at various steps along the way, including at county planning and zoning meetings, before and during the SFP administrative hearing, and during environmental assessment public comment periods. In addition, land/pore space owners and mineral owners had various points of contact, including granting access rights, securing pore space leasing, and mineral owner notifications. Based upon the successful storage facility permitting issued by NDIC, approval of the MRV plan by EPA, and receipt of a FONSI under the NEPA, Minnkota is continuing its pursuit of Project Tundra. In December 2023, the Office of Clean Energy Demonstrations under its Carbon Capture Demonstrations Projects Program announced funding for the capture system (Office of Clean Energy Demonstrations, 2023) and a proposal for CarbonSAFE Phase IV: Construction funding was submitted in March 2024 for the storage project. A go/no-go decision to proceed with construction and operations in the Broom Creek Formation is anticipated in 2024. References National Energy Technology Laboratory, CarbonSafe Initiative, https://netl.doe.gov/carbon-management/carbon-storage/carbonsafe (accessed August 2024). Office of Clean Energy Demonstrations, 2023, OCED selects three projects in CA, ND, and TX to reduce harmful carbon pollution, create new economic opportunities, and advance carbon reducing technologies, December, www.energy.gov/oced/articles/oced-selects-three-projects-ca-nd-and-tx-reduce-harmful-carbon-pollution-create-new (accessed August 2024).

Peck, Wesley↗
DOE OSTI2024

Characterization of Pliocene and Miocene Formations in the Wilmington Graben, Offshore Los Angeles, for Large-Scale Geologic Storage of CO2

The project Characterization of Pliocene and Miocene Formations in the Wilmington Graben, Offshore Los Angeles, for Large-Scale Geologic Storage of CO2 is one of 9 site characterization projects that were implemented as part of ARRA (American Recovery and Reinvestment Act). Data from this project was used to improve resolution of data in NATCARB in the area of study. Data related to this study has already been incorporated in NATCARB Atlas. The Los Angeles Basin presents an opportunity for large-scale geologic CO2 storage. Due to its large population and historical and geologic setting as one of the most prolific oil and gas producing basins in the United States, the region is home to more than 12 major power plants and oil refineries that produce more than 5 million metric tons of fossil fuel-related CO2 emissions each year. GeoMechanics Technologies worked to characterize the Pliocene and Miocene sediments in the Wilmington Graben, offshore of Los Angeles, California, for high-volume CO2 storage. The Graben is located offshore of the Los Angeles and Long Beach Harbor area, making it accessible yet geologically isolated from the nearby Wilmington oilfield and onshore areas. These sediments span more than 5,000 feet of vertical interval with an estimated storage resource of more than 100 million metric tons of CO2. The project team analyzed and interpreted existing geologic data within the region, including detailed exploration well log data and 2-D and 3-D seismic data. New seismic lines were acquired to fill in current data gap areas and two new characterization wells were drilled and logged. This information was integrated with existing geologic interpretations for adjacent onshore areas to help characterize optimal areas for CO2 storage and seals to safely store CO2. Integrated 3-D geologic and geomechanical models for the Wilmington Graben were developed to simulate the fate and transport of injected CO2 in the subsurface and to assess risks. This project contributed to the understanding of injectivity, containment mechanisms, rate of dissolution and mineralization, and storage capacity of the Wilmington Graben and associated analogous basins. This effort also provided greater insight into the potential for offshore geologic formations to safely and permanently store CO2.

.las↗
DOE OSTI2022

Interlaboratory Reproducibility of Contour Method Data in a High Strength Aluminum Alloy

The contour method for residual stress measurement has seen significant development, but an experimental reproducibility study utilizing physical samples has not been published. A double-blind reproducibly study is reported, having scope beginning with EDM cutting and ending with residual stress calculation. A reinforced I-beam sample geometry is identified for its unique residual stress profile when extracted from residual stress bearing quenched aluminum bar (7050-T74). Contour measurements are prescribed on a midplane of symmetry with dimensions 24.0 mm by 50.0 mm. Fourteen identically prepared samples are fabricated from a single long bar with well characterized and uniform residual stress. Five samples throughout the bar are identified for planning measurements to validate sample uniformity and overall suitability of the residual stress field. The planning measurements employ a range of techniques: contour method, neutron diffraction, and hole-drilling. Eight samples are distributed to an international group of participants to execute their standard measurement practice. A double-blind process is followed to provide anonymity. Results are provided by eight participants: six being self-similar and two being quite different, the latter set aside as outliers. An average residual stress field is established from non-outlying results and the spatial distribution of reproducibility standard deviation is determined. The average stress field ranges from -60 to 70 MPa and the reproducibility standard deviation averages 8.1 MPa on the measurement plane. The average reproducibility standard deviation is about 3 × larger for points within 1.0 mm of plane boundaries (17.6 MPa) than for the remaining points (6.1 MPa). Reproducibility standard deviation (among different labs) for contour method residual stress measurement is found to be very similar to repeatability standard deviation (in a single lab) reported in prior work. The reproducibility observed here, for the entire measurement process, is also similar to that found in a prior reproducibility study limited to contour method data analysis.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Macro-level mechanical interlocking: A rapid joining approach for additively manufactured compression molded composite panels

Composite joining typically involves multiple steps, such as drilling and surface treatment, as part of the manufacturing process, which leads to low throughput and long cycle times. In the present study, we demonstrated a macro-level mechanical interlocking (MI) based, rapid joining technique to assemble additively manufactured compression molded (AMCM) panels, enabling the production of parts larger than the mold dimensions. Composite panels made of 20 wt% short carbon fiber reinforced acrylonitrile butadiene styrene (CF/ABS) were joined using MI features of various geometries, namely tree (TR), dovetail (Dov), rectangle 2 (Rect2), and rectangle 1 (Rect1), and their in-plane strength was evaluated. The resultant strength of the tested MI joints reached up to 74 % of the baseline tensile strength (i.e., the ‘no joint’ case). Observations from optical and scanning electron microscopy revealed inadequate polymer diffusion between the adherends, indicating that the joint strength was primarily derived from mechanical interlocking. Additionally, the fracture surfaces exhibited stress-whitening marks, which were characterized using differential scanning calorimetry (DSC). The increase in melting enthalpy suggested local stretching of polymer chains due to MI. Finite element analysis (FEA) indicated that the Rect1 MI feature, which generated the lowest stress concentration, outperformed the others in terms of joint strength, achieving 42 MPa. As a demonstration of the MI joining method, a battery box tray measuring 108 cm × 34 cm using a mold with an effective dimension of 36 cm × 34 cm successfully manufactured, resulting in a part with an area three times larger than the mold. In conclusion, this study presents a promising approach to improving composite joining techniques while minimizing production complexities.

In-plane joining↗
DOE OSTI2022

Deep drilling in the time domain with DECam: survey characterization

ABSTRACT This paper presents a new optical imaging survey of four deep drilling fields (DDFs), two Galactic and two extragalactic, with the Dark Energy Camera (DECam) on the 4-m Blanco telescope at the Cerro Tololo Inter-American Observatory (CTIO). During the first year of observations in 2021, >4000 images covering 21 deg2 (seven DECam pointings), with ∼40 epochs (nights) per field and 5 to 6 images per night per filter in g, r, i, and/or z have become publicly available (the proprietary period for this program is waived). We describe the real-time difference-image pipeline and how alerts are distributed to brokers via the same distribution system as the Zwicky Transient Facility (ZTF). In this paper, we focus on the two extragalactic deep fields (COSMOS and ELAIS-S1) characterizing the detected sources, and demonstrating that the survey design is effective for probing the discovery space of faint and fast variable and transient sources. We describe and make publicly available 4413 calibrated light curves based on difference-image detection photometry of transients and variables in the extragalactic fields. We also present preliminary scientific analysis regarding the Solar system small bodies, stellar flares and variables, Galactic anomaly detection, fast-rising transients and variables, supernovae, and active Galactic nuclei.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2020

Aquifer Hydraulic Testing and Characterization Plan for the Ringold Formation Unit A in the Hanford 200-ZP-1 Groundwater Operable Unit and Vicinity

This document presents a plan for testing and characterizing the hydraulic properties of the Ringold Formation, member of Wooded Island – unit A (Rwia) in the 200-ZP groundwater operable unit. The testing approach includes multiple field methods and associated analyses designed to investigate and understand aquifer hydraulic properties over a range of scales. Testing was designed to achieve specific testing objectives identified previously in the 200 ZP-1 Groundwater Operable Unit Ringold Formation Unit A Characterization Sampling and Analysis Plan (Ringold A SAP). The test plan provides necessary technical and operational detail for writing subsequent field test instruction documents specific to each testing location. Hydraulic characterization activities will proceed in a phased manner focusing on areas identified to have knowledge gaps and also critical for remedy modifications and/or selection. These activities are designed to minimize impact to pump-and-treat (P&T) operations and to use existing P&T injection and extraction wells as stress wells, and include use of the new Rwia monitoring wells installed for Ringold A SAP activities. ZP-1 hydraulic testing will include slug testing in new Rwia wells, shutdown-recovery tests in multiple Rwia and composite Ringold Formation member of Wooded Island – unit E (Rwie)-Rwia aquifer test locations, installation of new Automated Water Level Network stations in Rwia monitoring wells, characterization of P&T and barometric responses, identifying the vertical distribution of hydraulic conductivity in the Rwia and Rwie units using electromagnetic borehole flowmeter tests, and single-well tracer testing in select Rwia monitoring wells. Slug testing to be conducted during drilling is described under the Ringold A SAP. The remaining testing activities are to be conducted after well drilling and completion and are described in this test plan.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2021

Evaluating Offshore Infrastructure Integrity

Drilling in the offshore environment involves a complex network of infrastructure including pipelines, platforms, rigs, subsea installations, ports, and terminals. Government and industry partners have developed this network over many decades and it remains a critical part of the United States (U.S.) energy portfolio. Many of the major components of this system have been designed with a 20- to 30-year lifespan, yet consistent and growing energy demands support the need to extend the design life of existing infrastructure or repurpose it for secondary needs (i.e. enhanced oil recovery, carbon storage, and new wells). As a result, a growing portion of the offshore infrastructure in the U.S. is approaching or has exceeded its original design life. A critical step in ensuring the continued safe and effective operation of offshore infrastructure is developing a comprehensive understanding of the state of offshore infrastructure and the factors that effect it. The purpose of this project is to assess the current state of existing infrastructure and identify the factors involved in infrastructure degradation through the development and application of big data analytics, machine learning, and advanced spatio-temporal analysis. The project leverages existing data at NETL and combines it with new information on offshore oil and gas structures and the ambient offshore environment in an effort to identify patterns associated with infrastructure integrity. Building on the identified trends and patterns, this project incorporates exploratory analytics and spatial analysis tools in conjunction with machine learning and statistical models to characterize the condition of existing platforms in the offshore environment and predict their risk of failure.

02 PETROLEUM↗
DOE OSTI2025

Basin & Range Investigation for Developing Geothermal Energy

Hidden geothermal systems represent a potentially prolific energy resource that could support critical U.S. public and government energy priorities. Basin and Range Investigations for Developing Geothermal Energy (BRIDGE) addressed some the challenges associated with hidden system exploration by prioritizing cost-effective exploration early on through strategic workflow and informed decision-making that mitigates early risk and shifts resources to later exploration stages (e.g., drilling). Sandia National Laboratories partnered with U.S. Navy Geothermal Office, Geologic Geothermal Group, and independent consultants, with additional collaboration with U.S. Geological Survey and private industry. The primary tool of the BRIDGE project was to deploy a regional-scale airborne electromagnetic method to investigate the shallow resistivity structure in areas with high prospectivity. This was followed up at several prospects by a multidisciplinary exploration approach, including additional geologic, geophysical and geochemical studies. A central tenet to the BRIDGE methodology is that zones of low resistivity frequently occur over geothermal systems in the Basin and Range, and when paired with other data constraints, imaging these zones can enable discovery of these systems. In addition to exploring greenfield areas (i.e., Grover Point), the BRIDGE project also flew HTEM resistivity surveys over known geothermal systems including those with established power plants (Don A. Campbell and Salt Wells) and prospects that are known to the literature but remain undeveloped, at least in part, due to a lack of understanding on the location of their producible reservoirs. BRIDGE produced a comprehensive set of data from prospects identified in the Nevada Play Fairway Analysis along with conceptual models for top ranking prospects, wherein all of the observations are used to inform an interpreted model of the system. These models present a range of possible system parameters such as temperature and size, and they are further informed by system analogues in the Basin and Range province and elsewhere. The results of this work leave space for further exploration that may now occur at prospects ‘down the list’ rather than distribution exploration resources evenly across all prospects.

15 GEOTHERMAL ENERGY↗
DOE OSTI2020

Deterministic Discrete Fracture Network (DFN) Model for the EGS Collab Project on the 4850 Level of the Sanford Underground Research Facility (SURF)

The EGS Collab is conducting hydraulic fracture stimulation and fluid circulation experiments in the Sanford Underground Research Facility (SURF) located in Lead, South Dakota. A total of eight ~60m-long subhorizontal boreholes were drilled from the 4850 Level (~1.5 km below the ground surface) into the crystalline rock of this former mine. Six of these holes are used for geophysical monitoring, one is used for hydraulic fracture stimulation, and the remaining hole was designed as a production borehole that receives water from the injection well via the induced and natural fracture system. The primary goal of creating the discrete fracture network model is to show that these modeling methods are critical for the development of enhanced geothermal systems (EGS). This includes the prediction of rock behavior during fracturing and during an extended period of water flow between the parallel injection and production boreholes. Understanding the results from the induced fracturing and flow is complicated by the presence of significant natural fractures that interact with the stimulation and/or flow pathways. The delineation and characterization of natural fractures is thus an important part of the project, and therefore a model of the Discrete Fracture Network (DFN) was developed on a deterministic basis. The DFN was populated using observations and interpretations integrated from drift (horizontal passageways that allow access in the underground) fracture mapping, analysis of core recovered from the eight boreholes, borehole televiewer logs and videos, and observations of flow between and within boreholes and in the drift. The natural fracture system is dominated by a pervasive northwest-trending, steeply dipping shear system that is identifiable in the drifts and the core. Hydraulic fracture stimulation, flow/tracer circulation tests, and geophysical monitoring revealed that the behavior of the injected water, and perhaps the growth of induced fractures, has been significantly influenced by the existing fractures identified in the DFN.

40 EE - Geothermal Technologies Office (EE-4G)↗
DOE OSTI2020

Deterministic and Statistical Modeling of a New Thermal Breakout Technology for Measuring the Maximum Horizontal In-Situ Stress

The current state-of-the-art technology for in-situ stress measurements involves an integrated approach that combines borehole breakout observations, drilling-induced tensile fractures, and hydraulic fracturing tests (i.e., “mini-fracs”). This methodology has achieved wide application in the oil and gas industry but has several limitations that often prevent successful in-situ stress measurements. One major limitation is that breakouts do not appear in all boreholes and are generally only a natural occurrence that cannot easily be controlled. Because borehole breakouts are used to directly measure the maximum horizontal in-situ stress magnitude, the absence of borehole breakouts presents a major data gap for in-situ stress measurements. In response to this data gap, a new US Department of Energy (US DOE)-sponsored thermal breakout technology that will provide a method for thermally inducing borehole breakouts and allow the consistent measurement of the maximum horizontal stress magnitude is currently in development. This thermal breakout technology involves heating the borehole and increasing the thermoelastic compressive stress in the rock until a breakout develops, which can be directly correlated to the maximum horizontal stress magnitude. The first step in this project was an analytical modeling study of the thermal breakout process. Based on the Kirsch solution (Kirsch 1898), a deterministic and statistical analysis was performed on the pertinent parameters that influence the maximum horizontal stress calculation. As a result of the analysis, the findings indicate that the thermal breakout technology is feasible and provides improved accuracy and/or an enhanced ability to measure the maximum horizontal stress. Future work as part of this US DOE-sponsored project includes additional validation through more detailed numerical modeling, laboratory testing, and field testing of the thermal breakout technology.

58 GEOSCIENCES↗