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DOE OSTI2024

Center for Tokamak Transient Simulations (RPI Unstructured Mesh Developments for FES SciDAC4 Partnerships) (Final Report)

The goal of this project was the development of unstructured mesh technologies for fusion simulation codes” for FES SciDAC partnerships and to integrate those technologies into the simulation workflows of those partnerships. Specific developments were executed in support of the following FES SciDAC4 partnerships: Partnership Center for High‐fidelity Boundary Plasma Simulation (HBPS), Center for Integrated Simulation of Fusion Relevant RF (RF‐SciDAC), Center for Plasma Surface Interactions: Predicting the Performance and Impact of Dynamic PFC Surfaces (PSI2), and Center for Tokamak Transient Simulations (CTTS). The key unstructured mesh development areas addressed in this project include (i) methods to most effectively perform PIC calculations on unstructured meshes; (ii) creating meshes for fusion systems accounting for any desired level of geometric complexity and providing physics aware mesh configurations, (iii) adapting unstructured meshes to control the discretization errors, (iv) executing unstructured mesh calculations on GPU accelerated systems, (v) supporting physics/application‐specific PIC operations including surface/wall interactions of particles, (vi) providing infrastructure tools to support the interactions of solvers with unstructured meshes, and (vii) providing advanced methods for coupling plasma physics codes.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2024

Cost Competitive Process of Battery Grade Oxides Preparation from Aged LIBS

The increasing demand for lithium-ion batteries (LIBs ) is driving development of advanced recycling and refining methods. In this project, new cathode active materials are prepared from recycled lithium battery materials and subsequently electrochemically evaluated in coin cells. In detail, scrap LIBs were mechanically processed into a metal rich black mass, then reductive acid leached into an aqueous metal solution, and finally high-purity metal hydroxide precursor materials were prepared by selective electrochemical flow precipitation. Closed-loop LIB recycling into active electrode materials will enable US manufacturers to break their reliance on foreign sources of critical materials. For example, electroextraction process used here has potential to significantly reduce chemical & water use as compared to traditional metallurgic techniques. To this end, electroextracted materials refined from used batteries were collected and processed to be tested as precursor cathode active material (pCam).During this project ,samples of high-purity recycled NMC hydroxide (~2kg each) were received from Nth Cycle. In the first received batch some impurities like cadmium, calcium, and sodium are present in quantities that would negatively impact battery performance. Nth Cycle indicated that the impurities such as cadmium are present due to poor battery separation and co-shredding of NiCd batteries with with LIB. Cadmium was not present in the two subsequent batches as Nth Cycle processed cadmium free black mass. Thus, effective recycled battery sorting is critical to closed-loop LIB recycling into active electrode materials.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2025

Cost Competitive Process of Battery Grade Oxides Preparation from Aged LIBS

The increasing demand for lithium-ion batteries (LIBs) is driving development of advanced recycling and refining methods. In this project, new cathode active materials are prepared from recycled lithium battery materials and subsequently electrochemically evaluated in coin cells. In detail, scrap LIBs were mechanically processed into a metal rich black mass, then reductive acid leached into an aqueous metal solution, and finally high-purity metal hydroxide precursor materials were prepared by selective electrochemical flow precipitation. Closed-loop LIB recycling into active electrode materials will enable US manufacturers to break their reliance on foreign sources of critical materials. For example, electroextraction process used here has potential to significantly reduce chemical & water use as compared to traditional metallurgic techniques. To this end, electroextracted materials refined from used batteries were collected and processed to be tested as precursor cathode active material (pCam). During this project , samples of high-purity recycled NMC hydroxide (~2 kg each) were received from Nth Cycle. In the first received batch some impurities like cadmium, calcium, and sodium are present in quantities that would negatively impact battery performance. Nth Cycle indicated that the impurities such as cadmium are present due to poor battery separation and co-shredding of NiCd batteries with with LIB. Cadmium was not present in the two subsequent batches as Nth Cycle processed cadmium free black mass. Thus, effective recycled battery sorting is critical to closed-loop LIB recycling into active electrode materials.

25 ENERGY STORAGE↗

DOE OSTI2025

Advanced Brine Processing to Enable U.S. Lithium Independence (CRADA Report)

Current production of LiOH, which is needed to make Li-ion battery cathode active materials, utilizes a multistep process including solar evaporation, precipitation with Na 2 CO 3 and then conversion to LiOH using Ca(OH) 2 . This process requires a large amount of land area for solar evaporation, the right weather conditions, and chemicals for the conversion process that result in NaCl and CaCO 3 waste products. The production of Ca(OH) 2 is very energy intensive and evolves significant quantities of CO 2 . An alternative process flow utilizing direct lithium extraction techniques, followed by a chemical free conversion process can have benefits in reducing the needed land requirements and chemicals for traditional brine processing. There are many potential direct lithium extraction technologies that are currently being developed. The direct lithium extraction process from typical brine sources will produce a LiCl solution with some impurities including typically high concentrations of Na. This brine then needs to be converted to LiOH for use in battery cathode production. Ideally this conversion could occur without the use of additional chemicals. Electrochemistry can do this conversion either via electrolysis or bipolar membrane electrodialysis (BPED) to produce LiOH and HCl in solution. BPED utilized bipolar membranes to split water, which has a reduced potential as compared to splitting water at electrodes into hydrogen and oxygen gas. This reduced potential required results in a significant energy savings for BPED over electrolysis methods. This CRADA project aimed to develop such an integrated process using direct lithium extraction followed by BPED to produce a LiOH solution. That solution can then be crystallized into battery grade LiOH. In particular, Albemarle utilized a direct lithium extraction process to produce a concentrated LiCl solution that could be used for the BPED process. The BPED process was first tested using various LiCl solutions with impurity ions added at bench scale to understand the effects of impurities and determine processing parameters. Then testing was performed using the direct lithium extracted brine at the bench scale before scaling the process up. After the process was scaled up a long duration test was carried out to estimate the lifetime of the membranes, which is key to the economics of the BPED process.

25 ENERGY STORAGE↗

DOE OSTI2025

Learning quantum computers' errors using interpretable neural networks

Learning and reducing the errors and noise in quantum computing systems is necessary for achieving quantum computation’s promise. However, rapid advances in experimental quantum computing are making this task increasingly difficult, because state-of-the-art systems now contain hundreds of qubits and many characterization techniques are hard to apply at this scale. Furthermore, complex kinds of errors in these systems, such as crosstalk and non-Markovian effects, must be understood and decreased, but these errors are challenging to study with most existing methods. In this project, we explored using neural networks for scalable characterization of complex errors in quantum computers. We proposed and demonstrated characterizing a quantum computer’s errors with neural networks that have interpretable parameters corresponding to the rates of different kinds of errors, within a sparse Lindbladian parameterization for errors. To enable scaling to many qubit systems, these networks then predict how these errors combine within quantum circuits and impact their outcomes using an efficient approximations. We demonstrated these networks ability to learn coherent crosstalk errors and context-dependent errors in a simulated 4-qubit system.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2025

Evaluating pulse-shaping capabilities of next-generation pulsed power architectures

This project evaluated the pulse shaping capabilities of next-generation pulsed power (NGPP) architectures. NGPP architectures share several common attributes including multiple independent pulse-generation lines, a radial water-insulated impedance transformer, and a central vacuum insulated load region. A multi-module circuit model was developed, incorporating independent pulse-generation lines and a 2-D transmission line mesh of the radial impedance transformer to assess the effects of azimuthal asymmetry in pulse-shaped experiments. Circuit model simulations demonstrated that NGPP architectures are able to produce the the desired current pulse shapes for exemplar NGPP experiments. Additionally, the project explored automated methods for experiment design, including derivative -ree optimization and machine learning. Pulse-shaped experiments require designers to determine machine parameters that reliably produce the desired current pulse at the load, a process that typically relies on expert knowledge and iterative adjustments using the Z circuit model. Given the increased complexity of NGPP systems, this manual approach may be impractical. While the evaluated methods do not eliminate the need for manual iteration, they can reduce the time required for experiment design. Derivative-free optimization automates much of the trial-and-error process, providing a close starting point for manual adjustments or making small modifications to near-final designs. Meanwhile, deep neural network methods can generate a good qualitative match to the desired current pulse in under one second without requiring circuit model simulations.

42 ENGINEERING↗

DOE OSTI2026

Cost Competitive Process of Battery Grade Oxides Preparation from Aged LIBs

The increasing demand for lithium-ion batteries (LIBs) is driving development of advanced recycling and refining methods. In this project, new cathode active materials are prepared from recycled lithium battery materials and subsequently electrochemically evaluated in coin cells. In detail, scrap LIBs were mechanically processed into a metal rich black mass, then reductive acid leached into an aqueous metal solution, and finally high-purity metal hydroxide precursor materials were prepared by selective electrochemical flow precipitation. Closed-loop LIB recycling into active electrode materials will enable US manufacturers to break their reliance on foreign sources of critical materials. For example, electroextraction process used here has potential to significantly reduce chemical & water use as well as waste production as compared to traditional metallurgic techniques. To this end, electroextracted materials refined from used batteries were collected and processed to be tested as precursor cathode active material (pCAM). For this project, two samples of high purity recycled NMC hydroxide (~1 kg each) were received from N th Cycle’s Ohio demonstration facility. The NMC compositions of the two materials are similar, and the levels of impurities have been confirmed. Indeed, impurities like copper, boron and sodium are present in quantities that could negatively impact battery performance. However, some studies have demonstrated that the control of the quantity of elements like copper or boron may improve the electrochemistry properties of Lithium-NMC batteries. The principal objective is to determine the electrochemical performance of these 2 NMC hydroxide batches and clearly determine the effect of the impurities on the performance.

25 ENERGY STORAGE↗

DOE OSTI2025

Neutrino Induced Charged Current Coherent Pion Production for Constraining the Muon Neutrino Flux at DUNE

We study neutrino induced charge current coherent pion production (νμ CC-Coh π) as a tool for constraining the neutrino flux at the Deep Underground Neutrino Experiment (DUNE). The neutrino energy and flavor in the process can be directly reconstructed from the outgoing particles, making it especially useful to specifically constrain the muon neutrino component of the total flux. The cross section of this process can be obtained using the Adler relation with the π-Ar elastic scattering cross section, taken either from external data or, as we explore, from a simultaneous measurement in the DUNE near detector. We develop a procedure that leverages νμ CC-Coh π events to fit for the neutrino flux while simultaneously accounting for relevant effects in the cross section. We project that this method has the statistical power to constrain the uncertainty on the normalization of the flux at its peak to a few percent. This study demonstrates the potential utility of aνμ CC-Coh π flux constraint, though further work will be needed to determine the range of validity and precision of the Adler relation upon which it relies, as well as to measure the π-Ar elastic scattering cross section to the requisite precision. We discuss the experimental and phenomenological developments necessary to unlock the νμ CC-Coh π process as a "standard candle'' for neutrino experiments.

Putnam, Gray [Fermilab]↗

DOE OSTI2026

PRACtical LLM Evaluation using Performance, Response, and Context

This project produced practical methods for evaluating Large Language Models (LLMs) based only on characteristics of LLM responses and without ground truth. Further development of these methods will enable the ability to rapidly identify and mitigate different failure types and supports the appropriate use of LLMs in mission applications.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2020

Multi-beam resin curing system and method for whole-volume additive manufacturing

A multi-beam volumetric resin curing system and method for whole-volume additive manufacturing of an object includes a bath containing a photosensitive resin, a light source for producing a light beam, and a spatial light modulator which produces a phase- or intensity-modulated light beam by impressing a phase profile or intensity profile of an image onto a light beam received from the light source. The system and method also include projection optics which then produces multiple sub-image beams from the modulated light beam which are projected to intersect each other in the photosensitive resin to cure select volumetric regions of the resin in a whole-volume three-dimensional pattern representing the object.

Shusteff, Maxim↗

DOE OSTI2021

Separations Consortium: Counter Current Chromatography

In support of the Bioenergy Technologies Office in recovering coproducts in biorefineries this project evaluates the use of Counter Current Chromatography (CCC) in recovering co-products from Reductive Catalytic Fractionation (RCF) oil, Alkaline Pretreatment Liquor (APL), aqueous phase Hydrothermal Liquefaction (HTL) oil, and Catalytic Fast Pyrolysis (CFP) oil. The project addresses three technology barriers in developing the bioeconomy; (1) Cost of production (2) Selective separation of organic acid species, and (3) Advanced bioprocess development. CCC is a unique, scalable, chromatographic technology that operates with two immiscible liquid phases moving counter current to one another. Unlike Simulated Moving Bed (SMB) technology, CCC is a true moving bed and because it uses liquids as both the stationary and mobile phase it can handle solids directly in the feed. This aspect of CCC allows it to skip the expensive filtration step needed prior to traditional SMB, furthermore the liquid phases are composed on relatively inexpensive organics (e.g. hexane and ethyl acetate). This project develops CCC methods for direct isolation of co-products from RCF oil, APL, HTL aqueous, and CFP oil. TechnoEconomic Analysis and process modeling is presented to compare CCC to SMB and assess its applicability in a holistic biorefinery. Initial results indicate approximately 4x reductions in solvent demand and 2x reduction in energy consumption compared to SMB.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2023

Multi-beam resin curing system and method for whole-volume additive manufacturing

Shusteff, Maxim↗

DOE OSTI2021

Analysis methods for quantifying Xe-127 samples from the UNESE project

In the Underground Nuclear Explosions Signatures Experiment (UNESE) radioactive 37 Ar and 127 Xe were used as tracers in subsurface migration experiments. As part of the experiment, methods were developed to quantify 127 Xe via β-γ coincidence spectroscopy. Later examination of the results highlighted a weakness of this analysis method in samples with no 127 Xe present, so a reanalysis of samples was performed to identify those which were falsely identified as having 127 Xe present. Ongoing work to develop a new analysis method with targeted regions of interest is also described. Measurements were also performed to quantify the concentration of 127 Xe and 37 Ar which were injected as part of UNESE Phase 2. A best value for the concentration of 37 Ar and 127 Xe was determined and reported here for use in future analyses of the UNESE Phase 2 results.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2020

Non-autoregressive time-series methods for stable parametric reduced-order models

Advection-dominated dynamical systems, characterized by partial differential equations, are found in applications ranging from weather forecasting to engineering design where accuracy and robustness are crucial. There has been significant interest in the use of techniques borrowed from machine learning to reduce the computational expense and/or improve the accuracy of predictions for these systems. These rely on the identification of a basis that reduces the dimensionality of the problem and the subsequent use of time series and sequential learning methods to forecast the evolution of the reduced state. Often, however, machine-learned predictions after reduced-basis projection are plagued by issues of stability stemming from incomplete capture of multiscale processes as well as due to error growth for long forecast durations. To address these issues, we have developed a non-autoregressive time series approach for predicting linear reduced-basis time histories of forward models. In particular, we demonstrate that non-autoregressive counterparts of sequential learning methods such as long short-term memory (LSTM) considerably improve the stability of machine-learned reduced-order models. Further, we evaluate our approach on the inviscid shallow water equations and show that a non-autoregressive variant of the standard LSTM approach that is bidirectional in the principal component directions obtains the best accuracy for recreating the nonlinear dynamics of partial observations. Moreover-and critical for many applications of these surrogates-inference times are reduced by three orders of magnitude using our approach, compared with both the equation-based Galerkin projection method and the standard LSTM approach.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2022

Design Methods, Tools, and Data for Ceramic Solar Receivers Year 1 Continuation Report

This report describes the first year of work on a project to develop the methods, tools, and data required to analyze high temperature ceramic Concentrating Solar Power (CSP) components. This first year focused on developing the methods and data required for a time-independent assessment of potential components, focusing in particular on ceramic solar receivers. The report describes both model development and testing work focused on accomplishing this goal. Our overall conclusion is that high temperature ceramic CSP components are viable and could provide a means to overcome the expected low reliability and short service life for equivalent components constructed from Ni-based superalloys. Based on the results reported here, we recommend the project continue to Phase II which will develop more sophisticated, realistic models for time-dependent failure of ceramics operating in expected CSP component conditions and develop the time-dependent ceramic test data needed to parameterize these models, using commercial SiC as a reference material.

14 SOLAR ENERGY↗

DOE OSTI2022

Identifying Modular Construction Worker Tasks Using Computer Vision

Modular construction is increasingly being seen as an attractive method for delivering building projects due to advantages in safety, quality, and lead-time. Despite these benefits, this method still relies heavily on human labor, which causes variability in factory assembly-line performance that can erode performance benefits of modular construction. Continuous improvement methods can alleviate some of these issues, but they also require continuous monitoring of human workers' performance. Due to limitations of manual time study and automated sensor-based monitoring methods, recently computer vision-based methods have gained momentum in identifying the activities of construction workers from the videos of onsite construction. Therefore, this paper explores the use of computer vision-based human activity recognition techniques to identify and classify worker activities in modular construction videos. Computer vision-based tracking method has been used to track the human workers in each frame, and Resnet-50 network has been used to classify the activity of tracked workers. Evaluation of this framework has achieved higher than 90% accuracy and recall in testing.

computer vision↗

DOE OSTI2020

Rapid data-driven model reduction of nonlinear dynamical systems including chemical reaction networks using ℓ 1 -regularization

We develop a new data-driven paradigm for efficient model reduction of a broad class of nonlinear dynamical systems. Our model reduction method directly enables the interpretation of key components of the dynamical system, unlike traditional projection-based model reduction methods that focus on reducing computational complexity more than interpretability. Our method is not application specific and is simple to implement on nonlinear dynamical systems arising from a variety of different fields. It requires minimal parameterization using a single parameter to trade-off between model complexity and estimation error. We use a data-driven paradigm to formulate model reduction as an efficient convex optimization problem that scales polynomially in the original size of the complex system, enabling systems with as many as thousands of components to be reduced in a matter of minutes.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2020

Multi-Model and Multi-Scale Global Sensitivity Analysis for Identifying Controlling Processes of Complex Systems

An environmental model consists of multiple process level sub-models, and each sub-model represents a process that is key to the operation of the simulated system. Global sensitivity analysis methods have been widely used to identify important processes for system model development and improvement. The existing methods of global sensitivity analysis only consider parametric uncertainty, and are not capable of handling model uncertainty caused by multiple process models that arise from competing hypotheses about one or more processes. To address this problem, this project develops a new method to probe model output sensitivity to competing process models by integrating model averaging methods with variance-based global sensitivity analysis to address uncertainty in process models and parameters. The new method yields three process sensitivity indices. The first one is called first-order process sensitivity index, and it is derived as a single summary measure of relative process importance. Evaluating the index is computationally expensive, because it relies in a Monte Carlo scheme that requires thousands and even millions of model executions. To reduce computational cost, this project develops a computationally efficient, quasi Monte Carlo method, and this method is presented in Chapter 2 of this report with and a numerical example for demonstration. The numerical example shows that the results of the quasi Monte Carlo method are substantially close to those of the full Monte Carlo method, but the computational cost of the quasi Monte Carlo method is only 0.7% of that of the full Monte Carlo method. The second index is called total-effect process sensitivity index, and it measures interactions between different processes. Therefore, this sensitivity index includes the first-order process sensitivity index, and can be used to identify influential processes. On the other hand, the total-effect process sensitivity index can also be used to screen non-influential processes. This is demonstrated by two numerical examples using the Sobol-G* functions and groundwater flow models that consider recharge process, geological process, and snowmelt process. The numerical examples shows that the total-effect process sensitivity index is more informative than the first-order process sensitivity. The derivation of the process sensitivity index and the numerical examples are discussed in Chapter 3. Chapter 4 presents two computationally efficient methods for screening non-influential processes to exclude them from further investigation. The two methods are the multi-model difference-based sensitivity (MMDS) analysis method, which can be implemented using the Latin Hypercube Sampling. The second one is the implementation of MMDS method using a binning method. The numerical example for the Sobol-G* function indicates the two methods are capable of identifying non-influential models, and the numerical examples for the groundwater flow and reactive transport show that the two methods are effective for groundwater problems. However, it should be noted that the two methods are numerical approximations, and they can only be used for screening non-influential processes, not for ranking importance of system processes. All the sensitivity analysis methods are implemented by developing python codes, and the codes are in a software called SAMMPY: a python package for process sensitivity analysis under multiple models. The SAMMPY design and structure are discussed in Chapter 5, and the package is released to the public for free download.

54 ENVIRONMENTAL SCIENCES↗