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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 OSTI2021

Proceedings of the 2021 Airborne Wind Energy Workshop

On March 2-3, 2021, the National Renewable Energy Laboratory (NREL) conducted a virtual workshop to evaluate the status, potential development, and technical viability of AWE systems as a source of energy in the United States. Stakeholder input provided at the workshop will contribute to the report to Congress. This report summarizes key workshop findings, current technology research and development activities in the United States, and opportunities and potential modes of collaboration and coordination for future technology research and development activities. The workshop focused on U.S. stakeholders in AWE, with approximately 100 experts and industry stakeholders from AWE technology developers, operators, engineering firms, consultants, government, national laboratories, and university researchers. The workshop began with an explanation from DOE's Wind Energy Technologies Office (WETO) Technology Manager, Ben Hallissy, of the context and purpose of the workshop, including a request from Congress that the U.S. Department of Energy (DOE) deliver a "report on the potential for, and technical viability of, airborne wind energy systems to provide a significant source of energy in the United States, including a summary of research, development, demonstration, and commercialization needs, including an estimate of Federal funding requirements, to further examine and validate the technical and economic viability of airborne wind energy concepts over the 10-year period." The workshop began with brief introductions from attendees who explained their interest in AWE. Nicolas El Hayek of Planair summarized the proceedings from the AWE workshop held in September 2020 by the International Energy Agency (IEA) Wind Task 11. This was followed by a presentation by Roland Schmehl of TU-Delft summarizing European AWE R&D efforts. Chris Vermillion of North Carolina State University and Jason Jonkman of NREL presented an overview of U.S. R&D efforts. Then five panelists discussed AWE markets, sizes of AWE systems, challenges, and opportunities. Panelists included: Cristina Archer, professor at the College of Earth, Ocean, and Environment and associate director at the Center for Research in Wind (CReW) at the University of Delaware; Stephan Brabeck, chief technology officer at SkySails; Thierry Delahave, innovation and technology development lead at Saipem; Rob Creighton, founder and chief executive officer at WindLift; and David Schaefer, founder and chief executive officer at eWind Solutions. The second day of the workshop began with a brief overview of five key topics that are crucial to enabling AWE in the United States. These topics range from estimates of the U.S. wind resource, technical generation potential, economic analysis, environmental challenges, status of current technology and R&D activities, and needed activities to enable commercialization of AWE. This set the stage for a robust discussion in breakout groups where individuals could offer their opinions on the potential opportunities for AWE in the United States. The following topics were discussed in the breakout groups: resource potential and energy output, technical potential, social and environmental impacts, and permitting, techno-economic analysis and markets, technology assessment and upscaling and demonstration and commercialization needs. The second day concluded with reports by the NREL research team, communicating the key themes and outcomes from each of the breakout group discussions.

17 WIND ENERGY↗

DOE OSTI2023

Collimation Systems for the PSR

This note provides a review of collimator systems being used or considered in high-intensity proton accelerators like SNS, J-PARC, LHC, and PIP-II. These facilities use collimators to remove beam halo, restrict transverse size and momentum in the beam to constrain beam losses around collimators and minimize beam losses downstream, particularly losses arising from particles missing the design location at the stripping foil when injected into the proton storage ring. Collimators are placed either in the transport injection lines (single-pass collimators) or in the rings (multi-pass collimators). Collimators in the transport line are placed around stripping foils in H- accelerators, allowing the beamline optics to get rid of the unstripped protons into well localized absorbers. Rings and proton accelerators mostly rely on tungsten scrapers and collimators in a multi-stage configuration to clean the scattered beam particles mainly responsible for heavy losses at high energies. Placement of the collimators is carefully chosen in terms of the right phase advance to maximize the collimating efficiency, whether the collimation is intended to match an injection stripping foil or a downstream acceptance. Collimation systems are designed with the specific concerns of each facility in mind, although all of them prioritize the minimization of activation due to beam losses to enable hands-on access during maintenance periods. At LANSCE, there are no high-energy collimators, although pairs of horizontal and vertical jaws are routinely used in the LEBT to clean and control the transverse beam profile delivered downstream. This report will help in understanding, together with the beam dynamics simulations, which collimation schemes would be most effective for the PSR upgrade. For example, SNS designed off-momentum collimators to be placed in a 90° arc bend, a high-dispersion region in the beam injection line, very similar to the bend at Line D in LANSCE. This system was very effective at minimizing losses during injection into the SNS accumulator ring and is being re-designed for future operation.

43 PARTICLE ACCELERATORS↗

DOE OSTI2023

The Port of Los Angeles Zero- and Near-Zero-Emission Freight Facilities "Shore to Store" Project (Final Project Report)

The City of Los Angeles Harbor Department (Harbor Department, POLA) partnered with Equilon Enterprises LLC (d/b/a Shell Oil Products US) (Shell), Toyota Motor North America (Toyota) and Kenworth Truck Company (Kenworth) partnered with the Port of Hueneme (POH), United Parcel Service (UPS), Total Transportation Services Inc. (TTSI), Southern Counties Express (SCE), Toyota Logistics Services (TLS), Air Liquide, National Renewable Energy Laboratory (NREL), Coalition For A Safe Environment, and the South Coast Air Quality Management District (South Coast AQMD) to introduce hydrogen (H 2 ) fuel into the Southern California drayage truck market by demonstrating near-commercial heavy-duty H 2 fuel cell electric trucks at and between freight facilities throughout the region, while continuing to lay the groundwork for battery-electric operations. The "Shore to Store" (S2S) project built on project team experience to help realize our vision of zero-emission freight operations in the future. Ten Kenworth zero-emission Class 8 fuel cell electric trucks, integrated with Toyota's fuel cell drive technology, were operated by UPS, TTSI, SCE, and TLS in revenue service. The demonstration fleet fueled at the S2S hydrogen fueling stations that were built in Ontario, California and Wilmington, California. An additional station at the Port of Long Beach (Portal Station) was available for fueling the fleet. Portal Station was supported by grants from the California Energy Commission (CEC) and South Coast AQMD and used as match funding for the S2S project. POH demonstrated two battery-electric yard tractors, and TLS demonstrated two zero-emission forklifts at their warehouse facility, showcasing elements of the entire supply chain operating on zero-emissions. This project showcased a snapshot of the zero-emission supply chain of the future, providing a model by which freight facilities can support zero-emission operations.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2023

The Port of Los Angeles Zero- and Near-Zero-Emission Freight Facilities Shore to Store Project

The City of Los Angeles Harbor Department (Harbor Department, Port of Los Angeles) partnered with Equilon Enterprises LLC (d/b/a Shell Oil Products US) (Shell), Toyota Motor North America (Toyota), and Kenworth Truck Company (Kenworth) partnered with the Port of Hueneme, United Parcel Service, Total Transportation Services Inc., Southern Counties Express, Toyota Logistics Services, Air Liquide, National Renewable Energy Laboratory, Coalition For A Safe Environment, and the South Coast Air Quality Management District to introduce hydrogen fuel into the Southern California drayage truck market by demonstrating near-commercial heavy-duty hydrogen fuel cell electric trucks at and between freight facilities throughout the region, while continuing to lay the groundwork for battery-electric operations. The Shore to Store project built on project team experience to help realize our vision of zero-emission freight operations in the future. Ten Kenworth zero-emission Class 8 fuel cell electric trucks, integrated with Toyota’s fuel cell drive technology, were operated by United Parcel Service, Total Transportation Services Inc., Southern Counties Express, and Toyota Logistics Services in commercial service. The demonstration fleet fueled at the Shore to Store hydrogen fueling stations that were built in Ontario, California, and Wilmington, California. An additional station at the Port of Long Beach (Portal Station) was available for fueling the fleet. Portal Station was supported by grants from the California Energy Commission and South Coast Air Quality Management District and used as match funding for the Shore to Store project. The Port of Hueneme demonstrated two battery-electric yard tractors, and Toyota Logistics Services demonstrated two zero-emission forklifts at their warehouse facility, showcasing elements of the entire supply chain operating with zero emissions. This project showcased a snapshot of the zero-emission supply chain of the future, providing a model by which freight facilities can support zero-emission operations. The Shore to Store project: Demonstrated the technical feasibility of zero-emission hydrogen fueled Class 8 heavy-duty trucks and electric cargo handling equipment in rigorous goods movement operation throughout the Southern California region. Cumulatively completed 59,212 miles of zero-emission operation, with 21,650 miles driven in-service with the fleets, using hydrogen fuel cell electric Class 8 heavy-duty trucks. Operated zero-emission yard tractors for a total of 2,749.6 hours. Created direct localized emission reductions in designated disadvantaged communities, including those in zip codes 90220, 90247, 90248, 90731, 90744, 90802, and 91761. For the 59,212 miles of zero-emission operation, reduced emissions by an estimated total of 15.5 kg NOX (0.163 g/km), 1.01 kg SOX (0.0106 g/km), and 304.8 metric tonnes of CO2e (3.2 kg/km) compared to diesel baseline vehicles including both tailpipe emissions and the emissions from producing the fuel sources.

08 HYDROGEN↗

DOE OSTI2021

Usability Evaluation of the Innovation Portal and Integrated Capability Analysis Platform

The usability evaluation of the ICAP and IP tools was conducted as part of the United States (U.S.) Department of Energy (DOE) Light Water Reactor Sustainability (LWRS) ION effort with two evaluators for the Idaho National Laboratory. Many nuclear operations in the United States are facing challenges of increased business, operations, and maintenance costs due to subsidized renewables and natural gas. The commercial NPP industry has looked to other industries to develop methods such as Integrated Operations (IO) to use available technologies to reduce operating costs. One concept for reducing costs that has been developed is the Integrated Operations for Nuclear (ION). A capability Stack model was developed as part of the ION effort to break down information related to People, Technology, Processes, and Governance (PTPG). The Innovation Portal (IP) and Integrated Capability Analysis Platform (ICAP) were created from the Capability Stack model as part of the ION effort to help utilities reduce O&M costs by identifying work reduction opportunities. Two heuristic evaluations and a cognitive walkthrough of the ICAP and IP tools were completed to identify usability issues to further develop the tools for use in the ION effort. Usability issues identified were rated by priority levels and across both tools. The priority levels identified were high (5), medium (11), and low (10). Recommendation were made to help reduce usability issues of the systems and help increase the user response rate of using the systems once they are implemented for utilities. Future work on designs for the IP tool and additional heuristic evaluations and external testing are being developed to continue refinement of the ICAP and IP tools for the ION effort.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2025

Application of Advanced Materials Processing to Enable Direct Production of Fast Reactor Fuel Alloys

Argonne National Laboratory (the Contractor), located in Lemont, IL, and Oklo, Inc. (the Participant), headquartered in Sunnyvale, CA, entered into a Cooperative Research and Development Agreement (CRADA) to integrate advanced electrorefining co-deposition and molten-salt monitoring technologies to produce a uranium-transuranic (U/TRU) alloy within a controlled composition range that can be used as fast reactor fuel for Oklo, Inc.’s advanced reactor technology. Argonne performed the integration of electrorefining and process monitoring technologies, determined operating parameters for producing U/TRU alloys, and developed optimized design and operating parameters for co-deposition of U/TRU alloys. Oklo, Inc. worked with Argonne and the Nuclear Regulatory Commission (NRC) to provide the necessary process documentation to begin implementing pyroprocessing technology in the fast reactor fuel production process. Outcomes of this project included a pilot-scale co-deposition cathode design and technical basis for the operation of the co-deposition electrorefiner to produce U/TRU alloys with controlled composition.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2020

Moving the Mission Forward with Renewable Energy

Presentation gives an overview of proven examples of renewable energy technologies. Learn how to properly utilize renewable energy technologies; research, select, fund, and deploy renewable technologies; best operate and maintain the federal government’s fleet of on-site solar photovoltaic (PV) systems; and learn best practices to detect and address performance issues with a PV system.

distributed energy↗

DOE OSTI2024

Microchannel reactive distillation for the conversion of aqueous ethanol to ethylene

Here we demonstrate the proof-of-concept for microchannel reactive distillation for alcohol-to-jet application: combining ethanol/water separation and ethanol dehydration in one unit operation. Ethanol is first distilled into the vapor phase, converted to ethylene and water, and then the water co-product is condensed to shift the reaction equilibrium. Process intensification is achieved through rapid mass transfer—ethanol stripping from thin wicks using novel microchannel architectures—leading to lower residence time and improved separation efficiency. Energy savings are realized with integration of unit operations. For example, heat of condensing water can offset vaporizing ethanol. Furthermore, the dehydration reaction equilibrium shifts towards completion by immediate removal of the water byproduct upon formation while maintaining aqueous feedstock in the condensed phase. For aqueous ethanol feedstock (40% w ), 71% ethanol conversion with 91% selectivity to ethylene was demonstrated at 220 °C, 600 psig, and 0.28 h -1 wt hour space velocity. 2.7 stages of separation were also demonstrated, under these conditions, using a device length of 8.3 cm. This provides a height equivalent of a theoretical plate (HETP), a measure of separation efficiency, of ~3.3 cm. By comparison, conventional distillation packing provides an HETP of ~30 cm. Thus, 9.1× reduction in HETP was demonstrated over conventional technology, providing a means for significant energy savings and an example of process intensification. Finally, preliminary process economic analysis indicates that by using microchannel reactive distillation technology, the operating and capital costs for the ethanol separation and dehydration portion of an envisioned alcohol-to-jet process could be reduced by at least 35% and 55%, respectively, relative to the incumbent technology, provided future improvements to microchannel reactive distillation design and operability are made.

10 SYNTHETIC FUELS↗

DOE OSTI2020

Management of Risk and Uncertainty Through Optimized Co-Operation of Transmission Systems and Microgrids with Responsive Loads (Final Report)

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2020

Management of Risk and Uncertainty Through Optimized Co-Operation of Transmission Systems and Microgrids With Responsive Loads (Final Report)

The evolution of the power system to the reliable, efficient and sustainable system of the future will involve development of both demand- and supply-side technology and operations. Ambitious national and state-level goals around the decarbonization of electricity relies on the integration of very high levels of renewable resources, most of which are variable and intermittent. The use of demand response is an ideal approach to counterbalance the intermittency of renewable generation and brings the consumer into the spotlight. Though individual consumers are interconnected at the low-voltage distribution system, these resources are typically modeled as variables at the transmission network level. Demand-side participation cannot be leveraged effectively without explicitly including the distribution system dynamics in the optimization-based wholesale market operations. This project grew from a vision for co-optimized interaction of distribution systems, or microgrids, with the high-voltage transmission system. In this framework, microgrids encompass consumers, distributed renewables and storage. The energy management system of the lower voltage system (distribution or microgrid) can also sell (buy) excess (necessary) energy from the transmission system. Until recently, very little research had been conducted on the co-optimization of these two systems due to computational limitations. However, advances in computational capabilities, and the judicious use of decomposition methods and innovative approximation methods for high-dimension dynamic programming made this goal a viable objective for this project, leading to a fundamental shift in the ability to integrate and fully utilize demand-side resources. To this end, the modeling framework developed introduces a novel co-optimization framework, to include the operations of both the transmission and distribution systems (or microgrids) in operational decision making. This framework was used to analyze renewable and distributed generation along with responsive demand and to compare the capability of co-optimized systems to perform with higher levels of variable renewables. An ideal microgrid is defined as an electric entity capable of operating in both interconnected (with the high-voltage grid) and islanded mode. As such, the microgrid should incorporate generating units (traditional units and intermittent) and if needed, exchange power with the high-voltage grid. The interplay between the microgrid and high-voltage grid motivated the development of the co-optimization approach to ensure efficient performance of the interconnected network. Results show that the use of a bi-level optimization approach is an appropriate structure, capable of co-optimizing a transmission system with multiple distribution systems and microgrids. While increasing the number of connected systems provides increasing flexibility for renewables integration this can also the economic benefits to the low-voltage subsystems with each additional system connected. Comparison of a traditional single-level decision structure with the co-optimization approach illustrates a reduction in overall system cost under co-optimization, while specific cost allocations to transmission and distribution systems are changed.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2026

Hazard Analysis to Support Fusion Systems Safety Assessments

Reliability, safety, and performance are vital aspects of any nuclear operation. Fusion technology continues to grow in public, private, and research interest, and coupled with rapidly growing energy needs, fusion technology research is poised for fast progress. The development of a Fusion Nuclear Science Facility (FNSF) is seen as stepping stone for demonstrating long-cycle fusion. Naturally, such operation requires systems that are available, reliable, and safe. This work provides a novel demonstration of systems theory coupled with traditional hazard analysis to provide insights into the risk priority of components and systems found within the FNSF. The results of this work are a set of identified hazards that should be considered for the risk-informed design and development of the FNSF.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2020

Sensor Placement Optimization Software Applied to Site-Scale Methane-Emissions Monitoring

Advances in sensor technology have increased our ability to monitor a wide range of environments. However, even as the cost of sensors decline, only a limited number of sensors can be installed at any given site. The physical placement of sensors, along with the sensor technology and operating conditions, can have a large impact on our ability to adequately monitor environmental change. This paper introduces a new open-source Python package, called Chama, that determines optimal sensor placement and technology to improve a sensor network’s detection capabilities. Additionally, the methods are demonstrated using site-specific methane emission scenarios that capture uncertainty in wind conditions and emission characteristics. Mixed-integer linear programming formulations are used to determine sensor locations and detection thresholds that maximize detection of the emission scenarios. The optimized sensor networks consistently increase the ability to detect leaks, as compared to sensors placed near each potential emission source or along the perimeter of the site.

47 OTHER INSTRUMENTATION↗

DOE OSTI2020

Evaluation of smart charging for electric vehicle-to-building integration: A case study

Higher electric vehicle (EV) adoption will stress the importance of demand flexibility to achieve more economic, efficient, and reliable grid operation. Charging technologies will be paramount in shifting temporally to better fit the variable generation of wind and solar. As such, analysis is warranted on the benefits of EV charge scheduling with respect to installation cost, operation cost, difficulty of implementation, and grid flexibility. We tackle this by analyzing the cost savings of implementing an EV charge scheduling infrastructure to reduce demand charges and installation costs. In this paper, we analyze a case study for operation of 16 level 2 chargers and 1 fast charger for two different building types. We then evaluate various test phases for controlling building and charging loads using an adaptive charging network (ACN) algorithm to characterize the ACN’s potential to reduce overall project cost.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2022

The value of in-reservoir energy storage for flexible dispatch of geothermal power

Geothermal systems making use of advanced drilling and well stimulation techniques have the potential to provide tens to hundreds of gigawatts of clean electricity generation in the United States by 2050. With near-zero variable costs, geothermal plants have traditionally been envisioned as providing “baseload” power, generating at their maximum rated output at all times. However, as variable renewable energy sources (VREs) see greater deployment in energy markets, baseload power is becoming increasingly less competitive relative to flexible, dispatchable generation and energy storage. Herein we conduct an analysis of the potential for future geothermal plants to provide both of these services, taking advantage of the natural properties of confined, engineered geothermal reservoirs to store energy in the form of accumulated, pressurized geofluid and provide flexible load-following generation. We develop a linear optimization model based on multi-physics reservoir simulations that captures the transient pressure and flow behaviors within a confined, engineered geothermal reservoir. We then optimize the investment decisions and hourly operations of a power plant exploiting such a reservoir against a set of historical and modeled future electricity price series. Further, we find that operational flexibility and in-reservoir energy storage can significantly enhance the value of geothermal plants in markets with high VRE penetration, with energy value improvements of up to 60% relative to conventional baseload plants operating under identical conditions. Across a range of realistic subsurface and operational conditions, our modeling demonstrates that confined, engineered geothermal reservoirs can provide large and effectively free energy storage capacity, with round-trip storage efficiencies comparable to those of leading grid-scale energy storage technologies. Optimized operational strategies indicate that flexible geothermal plants can provide both short- and long-duration energy storage, prioritizing output during periods of high electricity prices. Sensitivity analysis assesses the variation in outcomes across a range of subsurface conditions and cost scenarios.

15 GEOTHERMAL ENERGY↗

DOE OSTI2023

Physical Sciences Vistas: Perspectives on Simultaneous Excellence (Issue 1, 2023)

The issue begins with an article highlighting Physics Division’s involvement in diagnostic development that led to the measurement of ignition at the National Ignition Facility at Lawrence Livermore National Laboratory. Subsequent articles transition to some of the materials development occurring in Sigma, Materials Science and Technology, and Materials Physics and Applications divisions. This is inclusive of the development of next generation moderator materials as an enabling technology of small modular reactors. These materials will most likely be qualified at a facility at Idaho National Laboratory. The issue also highlights development of novel, additively manufactured foams for next generation weapons. This work is being done in close collaboration with the Kansas City National Security Campus to enable transition of materials development to production in a more agile way. Finally, an article describes Accelerator Operations and Technology Division’s hard work to replace the legacy remote instrumentation and control equipment at the Los Alamos Neutron Science Center (LANSCE) with a modern control system. The story discusses how that engineering success will lead to improved sustainability of the beam during operation and thus a better experience for all of our collaborators and partners in the LANSCE user program.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Sequence Impedance Modeling of Grid-Forming Converters: Preprint

Grid-forming control of inverter-based resources (IBRs) has been identified as a critical technology for operating power systems with high levels of inverter-based resources. This paper presents sequence impedance modeling of grid-forming inverters to evaluate its small-signal stability properties. Droop based grid-forming control with full consideration of the multiloop structure is studied, and the impact of individual controller on the inverter impedance characteristics is discussed. The developed sequence impedance model is compared with that of the grid-following inverter. It is found from the developed sequence impedance models that grid-forming inverters are less prone to harmonic resonance problems during operation with weaker grids. The developed models are validated using PSCAD simulations.

41 EE - Solar Energy Technologies Office (EE-4S)↗

DOE OSTI2020

Study of Additive Manufacturing Application to Geothermal Technologies

Geothermal reservoir characterization, field construction, and reservoir operations are very technology intensive activities that contribute significantly to the cost of delivering electricity produced from geothermal resources. Many geothermal technologies, such as downhole tools and drilling equipment, have unusual material, design, and manufacturing considerations dictated by the harsh geothermal environment and extreme aspect ratios required for deployment in a borehole. An additional challenge that faces geothermal applications is the low tool production volume needed to support the industry. Whereas tens of thousands of Oil & Gas wells are drilled and completed in the U.S. annually, there are typically only tens of geothermal wells that are drilled and completed. If a tool typically used in Oil & Gas applications cannot be directly used for geothermal, then the cost associated with making the tool suitable for geothermal is often prohibitive. There is therefore a much smaller inventory of technologies available to geothermal as compared to Oil & Gas and the level of efficiency and sophistication associated with field practice suffers accordingly. A number of advanced manufacturing methods, such as additive manufacturing, have received increased R&D as well as commercial attention in recent years because of their ability to rapidly prototype complex parts. Additive manufacturing in particular provides an opportunity to increase the technology available to the geothermal industry by either reducing fabrication costs associated with complex components or enabling economic production of low volume parts where specialized tooling is often required. Additional potential benefits of additive manufacturing include increased design freedom to make higher performing parts that cannot be made conventionally, the ability to integrate components into assemblies without joining operations, and the ability to economically fabricate variations on design in cases, such as casting molds, where there are large up-front costs associated with tooling. We have recently completed a study that investigated technology needs, representative use cases, manufacturability, and a techno-economic framework for comparing conventional to additive manufacturing methods for geothermal applications. This paper will provide an overview of this recent effort, describe the different elements of the assessment, and summarize the key takeaways related to both the feasibility of using additive manufacturing for geothermal technology applications as well as the potential benefits and impacts.

Polsky, Yarom↗