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DOE OSTI2023

Life cycle analysis of a hydrogen production system based on solid oxide electrolysis cells integrated with different energy and wastewater sources

Hydrogen production via water electrolysis is a promising and evolving technology. The solid oxide electrolysis cell (SOEC) is one of the several technologies for this purpose. They are alternatives to the traditional hydrogen production from fossil fuels to enhance global energy decarbonization. However, in the bid for sustainability and a green economy, these technologies are not free from causing some environmental burdens. Using life cycle assessment (LCA), the greenhouse gas emission and degree of environmental impacts by these technologies can be identified and measured throughout their lifespan. This study addresses how to quantify these CO 2 emission impacts for an electrolytic system with different energy sources. The LCA of a novel integrated hydrogen production SOEC system with energy from solar photovoltaic and bituminous powerplant is performed using simaPro, the leading global LCA solution software. Measuring the environmental impact of the electrolytic operation in terms of weight, the bituminous powerplant poses damage which is, on average 700% more than solar PV. The thermal-to-hydrogen efficiency of the SOEC system is 56%, and a probable 28% reduction in carbon footprint with heat integration. The steam generation and the manufacturing of the SOEC have a very high environmental impact potential on the system. Here, we recommend LCA and net energy analysis is carried out for every new hydrogen technology and adequate comparison to enhance sustainable and green economy.

08 HYDROGEN↗

DOE OSTI2023

Storm-DEPART (Damage Estimate Prediction and Recovery Tool)

Storm-DEPART (Damage Estimate Prediction and Restoration Tool): Each year hurricanes and tropical storms in the United States damage critical infrastructure assets, disrupt the services they provide, and cause millions to billions of dollars in economic impacts due to extended recovery times. The Storm-DEPART tool and analytical output enable more impactful data-driven decision-making capabilities and strengthen national-level disaster preparedness, response, and recovery. Storm-DEPART, built through multi-month collaboration between Entergy and INL, combines Entergy’s critical infrastructure inventory data with weather forecasts to predict damages to Electric utility’s assets due to natural disasters and the estimated recovery support needed, including time, materials, and resource allocation. In the event of an approaching hurricane, this innovative solution can assess potential damage to power generation capacity, transmission grids, distribution networks, and communications assets from wind bands, storm surge, and flooding. With more effective predictions, Entergy can more efficiently allocate resources to mitigate impacts and optimize recovery for customers. Storm-DEPART also allows Electric utilities the ability to apply a planning scenario and model expected damage to better inform infrastructure restoration needs leading to enhance system resiliency. The technology is fully transferrable to other electric utilities with the same damage estimating challenges. The INL team is working on the evolution of Storm-DEPART to include ice event damage prediction framework.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2023

Storm-DEPART (Damage Estimate Prediction and Recovery Tool)

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2024

Linkages between riverine flooding risk and economic damage over the continental United States

Economic damages from riverine flooding are expected to grow because of climate change. Yet, there are few 7 studies analyzing flooding damages in the U.S. that clearly measure the roles of hazard, exposure, and vulnerability 8 separately and locally. A lack of this knowledge prohibits spatially detailed predictions of future damages. By being 9 able to separate into these three risk factors, we provide all necessary inputs for uncertainty analysis of the flooding-10 damages forecasts that can incorporate new predictive scenarios for each component. To analyze the flooding risk 11 factors of non-coastal counties within the contiguous U.S. between 1999-2018, we gathered information on (1) 12 property and human damages from flooding, (2) maximum annual river discharge, (3) the number of housing units 13 and the years in which they were built, and (4) the incidence of flooding events. We used the method of trimmed 14 least absolute deviated and trimmed least square estimators to obtain the individual impact of hazard, exposure, and 15 vulnerability in the context of censored flooding damages for panel data. The resulting estimates indicate that 16 exposure has been the main driver of flooding risk for most counties in the U.S. Here, we use these estimates to describe 17 the main source of flooding risk for non-coastal counties for the 1999-2018 period.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2023

Evaluation of Power Transmission Lines Hardening Scenarios Using a Machine Learning Approach

The power transmission infrastructure is vulnerable to extreme weather events, particularly hurricanes and tropical storms. A recent example is the damage caused by Hurricane Maria (H-Maria) in the archipelago of Puerto Rico in September 2017, where major failures in the transmission infrastructure led to a total blackout. Numerous studies have been conducted to examine strategies to strengthen the transmission system, including burying the power lines underground or increasing the frequency of tree trimming. However, few studies focus on the direct hardening of the transmission towers to accomplish an increase in resiliency. This machine learning-based study fills this need by analyzing three direct hardening scenarios and determining the effectiveness of these changes in the context of H-Maria. A methodology for estimating transmission tower damage is presented here in this study as well as an analysis of impact of replacing structures with a high failure rate with more resilient ones. We found the steel self-support-pole to be the best replacement option for the towers with high failure rate. Furthermore, the third hardening scenario, where all wooden poles were replaced, exhibited a maximum reduction in damaged towers in a single line of 66% while lowering the mean number of damaged towers per line by 10%.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2023

Assessing the Impact of Cybersecurity Attacks on Energy Systems

This paper investigates the cyber resiliency of future power systems with high penetration of distributed energy resources using advanced distributed and (or) hierarchical control architectures. Specifically, we simulate cyberattacks on three prototypical use cases, and we identify attack scenarios that are the most damaging to the overall system performance. We show that these attacks can have a significant impact on grid operation. Results provide additional insights into the robustness of the system to the most common cyberattacks.

buildings↗

DOE OSTI2026

Effect of Oil Viscosity and Impact of Ionic Liquid Additive on Electrically Induced Pitting in Rolling Contact

Electrically induced bearing damage (EIBD) is a growing concern in electric drivetrains, where electrical discharge currents generate localized pitting that accelerates wear and premature failure. While ionic liquids (ILs) have shown promise as lubricant additives due to their natural physical adsorption, strong capabilities of tribofilm formation, and high molecular tunability, their role in mitigating EIBD is little known. This gap is especially evident because lubricant viscosity and film thickness affect discharge behavior, and additive performance in these regimes has not been well explored. In this study, tribological tests were performed using a ball-on-disk pure rolling-contact system under an applied voltage on polyalphaolefin oils of three viscosities (4, 10, and 150 cSt measured at 100 °C), with and without the addition of a phosphonium-phosphate IL. Surface damage was analyzed using scanning electron microscopy (SEM) and stylus profilometry. Damage quantification was based on pit morphology analysis of SEM images. The results provide new insights into how oil viscosity governs the discharge behavior and how an IL additive could influence the pit formation. While viscosity seems to play a significant role, an IL additive shows potential to reduce EIBD and deserves further study.

electrically induced bearing damage (EIBD)↗

DOE OSTI2021

Performance Evaluation of Comparative Vacuum Monitoring and Piezoelectric Sensors for Structural Health Monitoring of Rotorcraft Components

The costs associated with the increasing maintenance and surveillance needs of aging structures are rising at an unexpected rate. Multi-site fatigue damage, hidden cracks in hard-to-reach locations, disbonded joints, erosion, impact, and corrosion are among the major flaws encountered in today’s extensive fleet of aging aircraft and space vehicles. Aircraft maintenance and repairs represent about a quarter of a commercial fleet’s operating costs. The application of Structural Health Monitoring (SHM) systems using distributed sensor networks can reduce these costs by facilitating rapid and global assessments of structural integrity. The use of in-situ sensors for real-time health monitoring can overcome inspection impediments stemming from accessibility limitations, complex geometries, and the location and depth of hidden damage. Reliable, structural health monitoring systems can automatically process data, assess structural condition, and signal the need for human intervention. The ease of monitoring an entire on-board network of distributed sensors means that structural health assessments can occur more often, allowing operators to be even more vigilant with respect to flaw onset. SHM systems also allow for condition-based maintenance practices to be substituted for the current time-based or cycle-based maintenance approach thus optimizing maintenance labor. The Federal Aviation Administration has conducted a series of SHM validation and certification programs intended to comprehensively support the evolution and adoption of SHM practices into routine aircraft maintenance practices. This report presents one of those programs involving a Sandia Labs-aviation industry effort to move SHM into routine use for aircraft maintenance. The Airworthiness Assurance NDI Validation Center (AANC) at Sandia Labs, in conjunction with Sikorsky, Structural Monitoring Systems Ltd., Anodyne Electronics Manufacturing Corp., Acellent Technologies Inc., and the Federal Aviation Administration (FAA) carried out a trial validation and certification program to evaluate Comparative Vacuum Monitoring (CVM) and Piezoelectric Transducers (PZT) as a structural health monitoring solution to specific rotorcraft applications. Validation tasks were designed to address the SHM equipment, the health monitoring task, the resolution required, the sensor interrogation procedures, the conditions under which the monitoring will occur, the potential inspector population, adoption of CVM and PZT systems into rotorcraft maintenance programs and the document revisions necessary to allow for their routine use as an alternate means of performing periodic structural inspections. This program addressed formal SHM technology validation and certification issues so that the full spectrum of concerns, including design, deployment, performance and certification were appropriately considered. Sandia Labs designed, implemented, and analyzed the results from a focused and statistically relevant experimental effort to quantify the reliability of a CVM system applied to Sikorsky S-92 fuselage frame application and a PZT system applied to an S-92 main gearbox mount beam application. The applications included both local and global damage detection assessments. All factors that affect SHM sensitivity were included in this program: flaw size, shape, orientation and location relative to the sensors, as well as operational and environmental variables. Statistical methods were applied to performance data to derive Probability of Detection (POD) values for SHM sensors in a manner that agrees with current nondestructive inspection (NDI) validation requirements and is acceptable to both the aviation industry and regulatory bodies. The validation work completed in this program demonstrated the ability of both CVM and PZT SHM systems to detect cracks in rotorcraft components. It proved the ability to use final system response parameters to provide a Green Light/Red Light (“GO” – “NO GO”) decision on the presence of damage. In additional to quantifying the performance of each SHM system for the trial applications on the S-92 platform, this study also identified specific methods that can be used to optimize damage detection, guidance on deployment scenarios that can affect performance and considerations that must be made to properly apply CVM and PZT sensors. These results support the main goal of safely integrating SHM sensors into rotorcraft maintenance programs. Additional benefits from deploying rotorcraft Health and Usage Monitoring Systems (HUMS) may be realized when structural assessment data, collected by an SHM system, is also used to detect structural damage to compliment the operational environment monitoring. The use of in-situ sensors for health monitoring of rotorcraft structures can be a viable option for both flaw detection and maintenance planning activities. This formal SHM validation will allow aircraft manufacturers and airlines to confidently make informed decisions about the proper utilization of CVM and PZT technology. It will also streamline future regulatory actions and formal certification measures needed to assure the safe application of SHM solutions.

42 ENGINEERING↗

DOE OSTI2023

Low-damage electron beam lithography for nanostructures on Bi 2 Te 3 -class topological insulator thin films

Nanostructured topological insulators (TIs) have the potential to impact a wide array of condensed matter physics topics, ranging from Majorana physics to spintronics. However, the most common TI materials, the Bi 2 Se 3 family, are easily damaged during nanofabrication of devices. In this paper, we show that electron beam lithography performed with a 30 or 50 kV accelerating voltage—common for nanopatterning in academic facilities—damages both nonmagnetic TIs and their magnetically doped counterparts at unacceptable levels. We additionally demonstrate that electron beam lithography with a 10 kV accelerating voltage produces minimal damage detectable through low-temperature electronic transport. In conclusion, although reduced accelerating voltages present challenges in creating fine features, we show that with careful choice of processing parameters, particularly the resist, 100 nm features are reliably achievable.

42 ENGINEERING↗

DOE OSTI2022

Simulating Impacts of Extreme Events on Grids with High Penetrations of Wind Power Resources

As extreme weather events become more frequent and intense, the demand for connecting grid operation and infrastructure planning with extreme event models will increase as well. We present a methodology for creating damage contingencies and scenarios for electric transmission grids during a hurricane strike. Using WIND Toolkit meteorological data in conjunction with fragility curves for various electric grid elements, we generate stochastic damage scenarios that can be used for short- and long-term planning problems, e.g., emergency asset management. Included is an example case study: Hurricane Dolly damaging a synthetic 2000-bus test system during its landing in Southern Texas. We perform statistical analysis of damages and discuss topological effects on the example synthetic grid. Also, we include a cursory evaluation of impacts using simplified operational models. Finally, we discuss how our method can be extended to use even higher-fidelity meteorological data sets and suggest directions for future work.

contingencies↗

DOE OSTI2025

Assessing Simulations of Forest Hurricane Disturbance and Recovery in Puerto Rico by ELM-FATES Using Field Measurements

In the past three decades, Puerto Rico (PR) experienced five hurricanes that met or exceeded category three, and they caused severe forest structural damage and elevated tree mortality. To improve our mechanistic understanding of hurricane impacts on tropical forests and assess hurricane-affected forest dynamics in Earth system models, we use in situ forest measurements at the Bisley Experimental Watersheds in Northeast PR to evaluate the Functionally Assembled Terrestrial Ecosystem Simulator coupled with the Energy Exascale Earth System Model Land Model (ELM-FATES). The observations show that before Hurricane Hugo, 77.3% of the aboveground biomass (AGB) is from the shade-tolerant plant function type (PFT). The Hugo-induced mortality rates are over ~50%, and they induce a ~39% AGB reduction, which recovers to a level like the pre-Hugo condition in 2014, following a second, lower intensity hurricane, Georges. We perform numerical experiments that simulate damage from Hugo and Georges on the forests, including defoliation, sapwood and structural biomass damage, and hurricane-induced mortality. ELM-FATES can reasonably represent coexistence between the two PFTs–light-demanding and shade-tolerant–for both the pre-Hugo and post-Hugo conditions. The model represents a reasonable size distribution of mid-and large-sized trees although it underestimates AGB, likely due to the overestimated nonhurricane mortality. ELM-FATES temporarily stimulated leaf biomass and diameter increment after Georges, an effect that should be tested with observations of future hurricane defoliation events. This research indicates that addressing model-data mismatches in tree mortality and understory dynamics are essential to simulation of more extreme hurricane effects under climate change.

58 GEOSCIENCES↗

DOE OSTI2020

Shock recompaction of spall damage

Spall fracture is a high strain-rate damage phenomenon associated with shock or impulsive loading events. When a material that has been subjected to shock compression is allowed to release, rarefaction waves propagate into the sample and reduce the internal stress to zero. If multiple rarefaction waves intersect, they generate tension which, if sufficient, can nucleate voids in the material. It has been observed in several works investigating spall fracture that although the shock-wave profiles suggested spall occurred, imaging of the recovered sample revealed no voids or cracks. In this study, we aim to determine whether a second shock event could recompact existing spall damage, and if so, what form does the microstructure at the recompaction interface have? Through a series of gas-gun flyer-plate impact experiments, we demonstrate that modest shock stresses of 2 GPa–3 GPa are enough to both fully compact a damaged copper target back to a state of zero porosity and, furthermore, drive recrystallization of the interface such that there is a new bond formed where the free surfaces were brought together.

42 ENGINEERING↗

DOE OSTI2019

Hydromechanical modelling to evaluate impact of fault structure on CO 2 migration in stacked storage system

Faulting processes produce a complex fault damage zone (FDZ) having permeability variations over several orders of magnitude within a very short distance. In this study we use an example normal fault system from a depleted oil field in southern Louisiana with multiple stacked sand beds along the fault structure. Geostatistical techniques are used to introduce heterogeneities of several orders of magnitude over very short distances that honor the across- and along-fault architecture of the system. A total of 15 cases are simulated to account for the impact of a fragmented core, an intact core and a naturally fractured core on inter-sand leakage rates. The presented results show the complex nature of CO 2 migration within the fault structure, where an interplay between overcoming the fault core’s high capillary entry pressure and stress propagation in the vertical direction dictates the leakage direction and rates. It is observed that hydromechanical evolution of fracture flow properties may result in significant leakage from the storage zone. In one case with small caprock thickness, a loss of 18% of the total injected mass is observed. The results presented highlight some unique features of representative fault related leakage in stacked sand systems and thus will be beneficial for storage integrity analysis in these systems.

58 GEOSCIENCES↗

DOE OSTI2024

Limitations of Hydrogen Detection After 150 Years of Research on Hydrogen Embrittlement

Hydrogen's significance in contemporary society lies in its remarkable energy density, yet its integration into the worldwide energy grid presents a substantial challenge. Exposing materials to hydrogen environments leads to degradation of mechanical properties, damage, and failure. While the current approach for assessing hydrogen's impact on materials involves mainly multiscale modeling and mechanical testing, there exists a significant deficiency in detecting the intricate interactions between hydrogen and materials at the nanoatomic scales and under in situ conditions. This perspective review highlights the experimental endeavors aimed at bridging this gap, pointing toward the imminent need for new experimental techniques that can detect and map hydrogen in materials’ microstructures and their site‐specific dependencies.

Tunes, Matheus A.↗

DOE OSTI2024

Emerging Rare Earth Element Separation Technologies

Rare earth elements are essential for numerous clean energy applications, yet their mining, separation, and processing pose significant environmental challenges. Traditional separation processes often result in ecological damage, highlighting the critical need for innovative techniques that reduce environmental impacts. This article reviews recent advancements in rare earth separation technologies, with a particular focus on the role of neutral organic compounds. It explores how these compounds change selectivity across the rare earth series, offering promising strategies for designing more effective rare earth element separation systems. Furthermore, the article points out research areas requiring additional investigation to improve the sustainability of these critical processes.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2024

An approach to combine neutron and ion irradiation data to accelerate material qualification for nuclear reactors

Next-generation nuclear power plants are generally characterized by higher operating temperatures, increased neutron fluences and energies, and distinct corrosive coolant environments versus the existing light water reactor fleet. Whether using existing materials in new environments, newly developed materials tailored for these environments, or new manufacturing methods, the traditional decades-long approach for materials qualification does not facilitate rapid deployment. Ion irradiation has demonstrated success in reproducing material microstructure and select property evolution resulting from neutron irradiation with three to four orders of magnitude reduction in time and cost, making it an ideal candidate for accelerated irradiation testing. Because microstructure has a large impact on bulk material properties, limited neutron irradiation data at lower damage levels can in principle be combined with accelerated ion testing results and modeling and simulation to form an accurate prediction of microstructure evolution and select properties under different neutron irradiation conditions and at higher damage levels. The objective of this work is to present a conceptual framework of specific steps to fulfill several technical challenges associated with qualifying materials for performance in radiation environments on an accelerated time frame. A brief review of the regulatory landscape for materials in nuclear environments is presented, followed by additional overviews to understand the current state of the art for correlation of materials properties across radiation environments using experimental and computational methodologies. Finally, the roles of academia, national laboratories, and industry in the advancement of this accelerated materials qualification framework are discussed as a path forward, with possible case studies presented.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2021

Toward an Electromagnetic Event Resilient Grid

The motivation for writing this article is that the threat of a large-scale electromagnetic event having a negative impact on the electric grid is real. Whether human-caused, via the detonation of a nuclear device, or natural, via a high-intensity burst of solar radiation, our historic experience with these phenomena indicates that as a global community, we should be prepared for such events and know how to mitigate their impacts. Current studies and related discussions provide a wide range of damage assessments for these events. We recommend continuing current technical investigations and research as well as strengthening collaboration between stakeholders and experts. This would ensure future threats are addressed in a timely and effective manner.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2025

Report on Preliminary Detailed Experimental Plan for Neutron Irradiation of A709 at ATR and HFIR

Advanced nuclear power technologies will use higher temperatures as a means to extract energy at a higher efficiency than current plants and therefore put a larger demand on the structural materials. Improved performance of structural materials could enable greater safety margins, longer plant lifetimes, and reduce maintenance costs. Alloy 709 is championed as the next generation of austenitic alloys for advanced nuclear reactors. In parallel to the ASME code case pursued, the AMMT program is initiating a neutron irradiation campaign to provide first-of-a-kind engineering data to establish operational design parameters and how the mechanical response is modified by environmental factors. This document refines the AMMT neutron irradiation campaign to a 4 year program to support the generation of creep knockdown factors for Alloy 709 and welded Alloy 709. The campaign is divided among two national laboratories, Oak Ridge National Laboratory and Idaho National Laboratory, to use the strengths of each laboratory. Through a cooperative plan, time-independent properties and time-dependent properties will be obtained across a large temperature window, nominally 300°C to 800°C, damage levels up to 10 dpa, and with and without the impacts of transmutation produced helium.

99 GENERAL AND MISCELLANEOUS↗