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DOE OSTI2020

Advanced control sequences and FDD technology. Just shiny objects, or ready for scale?

Innovations in commercial building control sequences (ASHRAE guideline 36) and fault detection and diagnostics (FDD) technology have the potential to transform existing building operational efficiency by realizing whole-building level savings on the order of 15% and higher. However, several technical and market barriers related to up-front estimation of achievable savings, verifying implementation, and ensuring persistence are slowing down their adoption as a core offering through diverse owner-funded initiatives and rate-payer funded programs. This paper describes a suite of solutions to overcome these barriers to program delivery of advanced HVAC controls integrated with FDD energy management and information system (EMIS) technology. First, the Guideline 36 conformance test offers an automated method to confirm correct sequence implementation by the manufacturer, before field deployment. A successful test of a controller was conducted using a new manufacturer-independent hardware-in-the-loop testbed demonstrating the viability and scalability of this approach. Second, the Guideline 36 energy savings calculator uses modeling paired with high-level user inputs to estimate building-specific savings potential, target cost effective implementation and minimize uncertainty. Initial results indicate the baseline control sequences significantly impact energy savings, however, as much as 50% savings may be possible for the worst-case baseline scenario. Third, a functional specification provides minimum recommended EMIS-FDD capabilities, and best practices to integrate the technology into organizational practice and ensure that advanced control sequences provide persistent savings.

Pritoni, Marco↗

DOE OSTI2023

Reverse-Bias Resilience of Monolithic Perovskite/Silicon Tandem Solar Cells

Metal halide perovskites have rapidly enabled a range of high-performance photovoltaic technologies. However, catastrophic failure under reverse voltage bias poses a roadblock for their commercialization. In this work, we conduct a series of stress tests to compare the reverse-bias stability of perovskite single-junction, silicon single-junction, and monolithic perovskite/silicon tandem solar cells. We demonstrate that the tested perovskite/silicon tandem devices are considerably more resilient against reverse bias compared with perovskite single-junction devices. The origin of such improved stability stems from the low reverse-bias diode current of the silicon subcell. This translates to dropping most of the voltage over the silicon subcell, where such a favorable voltage distribution protects the perovskite subcell from reverse-bias-induced degradation. These results highlight that, compared with other perovskite technologies, monolithic perovskite/silicon tandems are at a higher technology readiness level in terms of tackling the reverse bias and partial shading challenges, which is a considerable advantage toward commercialization.

halide perovskite↗

DOE OSTI2021

SECARB-USA: Needs Assessment Framework for Storage Complexes (Task 2.1.b)

A team of SECARB storage experts examined 63 formations at 39 sites that were selected to represent the range of diversity of newly assessed, as well as well-advanced, storage prospects in the SECARB region. We inventoried the data needs triggered by the requirements to obtain a Class VI UIC storage permit, the data needs that results from the requirement to create geocellular fluid flow models to support that permit, and by pragmatic and best practice inputs such as public acceptance, regulatory readiness, and pore space leasing. We anchored both the needs inventory and the processes for and cost of meeting the needs with data from 9 sites in in the SECARB area that have advanced far in characterization. Results show that the total cost of characterization prior to obtaining a permit is convergent, because the permit and modeling requirements drive projects to obtain the same types of data for all cases. The high cost data that control cost are 1) drilling, coring, core-testing, logging, sampling and testing a characterization well and 2) collection of a 3-D seismic survey to map reservoir and confining system properties over the area of the plume or the area of elevated pressure. In 5 of our case study sites we determined that one or both of these costs could be avoided because the needs are met by available data.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2025

Reducing Mass of Steel Auto Bodies using Thin Advanced High Strength Steel with Carbon-Fiber Reinforced Epoxy

Diversitak, a company based in Detroit, MI, has developed a proprietary, low specific gravity, carbon fiber-reinforced epoxy (CFRE) under U.S. patent number 9,963,58832. Preliminary testing on this new material conducted in collaboration with ArcelorMittal Steel Company proved out the CFRE concept. A thin layer of this CFRE was applied to a stamped sheet of steel with residual stamping oils from a mill, in a time corresponding to automotive processing (e.g., ~15 seconds), and processed following automotive e-coat procedures (phosphating + 175–200°C heating), to complete the curing. No problems with adherence or performance were noted. While the CFRE does add weight to a thin gauge steel panel, it weighs much less than what is displaced by using thicker conventional mild steel gauges. The application of the coating showed a significant increased dent resistance, oil canning resistance, and part stiffness.This current two-year project was designed to mature this new technology to near manufacturing readiness to reduce the weight of a vehicle and lower the cost of weight reduction. The process involves the use of thinner gauge steels than are currently used. The collaborative development team included two industrial manufacturers: Diversitak and ArcelorMittal Steel Company; LightMAT; and two National Laboratories: Oak Ridge National Laboratory (ORNL) and Idaho National Laboratory (INL). The team developed a new manufacturing process to reduce the weight of a vehicle and lower the cost of weight reduction, as well as a better understanding of how to apply the coating so that it will perform to a high standard in-service. The team also performed an in-depth study to determine the long-term durability of the materials manufactured using this technology and well-known automotive industry standard tests.The overall process involved stiffening the thinner gauge steel by applying the CFRE on only one side. To accomplish this goal, the optimal reinforcement fiber length and fiber concentration was first determined. This was followed by measuring the coefficient of thermal expansion (CTE) in all three directions, so it could be fed into manufacturing models and methods for rapidly and inexpensively applying the coating. This was followed by panel level evaluations of the coating and steel combination, and then by full part demonstration of the technology on door panels. The final step was corrosion testing of the parts.ArcelorMittal characterized the advanced high strength steel (AHSS) (e.g., metallurgy-heat treatment for required AHSS properties as a function of the sheet thickness, state of internal stress) and quantified CFRE adhesion to the steel as a function of sheet preparation (e.g., rolling and stamping).ORNL optimized the fiber length, fiber concentration, and coating thickness for best vehicle function and performance at the least cost. Along with the suppliers, ORNL developed a durable CFRE application process (e.g., gun material, design, robotic dispensing process) and identified the adhesion stability of the CFRE during process holding. An approach to ensure that application/curing timing conforms to conventional assembly line speed and plant cycle times was determined. ORNL also determined the CTE of the material in all three directions and performed material scanning electron microscopy (SEM) analyses.INL characterized the corrosion properties of the steel panels coated with CFRE. The panels were investigated for corrosion resistance and stability as replacement materials used in automotive body panels to reduce mass. The coupons tested at INL were supplied by Diversitak after an optimized CFRE formulation was achieved in the already coated form for corrosion testing.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2023

Final Technical Report

Statement of the problem or situation that is being addressed in your application. The DOE and its national laboratories developed the Home Energy Score™ (HES) to encourage homeowners to improve their energy performance, lower costs and to share energy information through the MLS listing, appraisal, and financing channels. While the HES is an instrumental tool, it is currently underutilized and consists of technical, structural and sector barriers which need to be addressed in order to scale and many energy efficiency contractors are understandably overwhelmed by the added time and effort and lack of incentive to sell and deliver deep retrofit projects while simultaneously meeting the DOE HES program requirements; consequently, contractors may decide to forgo participation. Home Energy Rating System (HERS) Raters have the opportunity to play the critical Assessor role in producing a Home Energy Score (HES); this role has immense potential but currently is unfulfilled. Lastly, while utilities are interested in their customer base achieving greater energy efficiency, especially to help offset growing residential loads in states like California that are accelerating electrification, utilities do not have access to the market actors who are on the front line of influence to homeowners or review and approve their permits: HERS Raters, assessors, contractors and building departments. General statement of how this problem is being addressed: ConSol will integrate the Home Energy Score™ (HES) to its State of California, approved home energy rating services (HERS) platform (CHEERS) to develop a single tool for contractors nationwide to assess, record and install recommended cost, energy, and emissions saving measures to the 140 million single-family homes throughout the U.S. and 14 million homes in California (CHEERS+HES). The CHEERS high fidelity energy code permitting data will be integrated with HES for simple, accurate, easy-to-use home energy estimation and analysis and will directly gain access to the retrofit and renovations markets with the same upgraded platform. This innovative project will assist the utilities in supporting existing homes in their jurisdictions with HES and develop measures to improve energy efficiency and reduce emissions. How is this problem being addressed? What is the overall project approach? In effort to expand the Home Energy Score™ (HES) by increasing the use of aggregable home energy asset data, ConSol proposes to integrate the DOE HES via Application Programming Interface (API) to its State of California approved home energy rating services platform (CHEERS). Once the CHEERS platform and HES are integrated (CHEERS+HES), this enhanced platform will be instantly available and actively deployed via Phase 1 pilot to HERS Raters, assessors and contractors in California to market-test the solution, understand the rate of adoption and identify opportunities for improvement prior to scaling nationally. The CHEERS high fidelity energy code permitting data will be integrated with HES for simple, accurate, easy-to-use home energy estimation and analysis and will directly gain access to the retrofit and renovations markets with the same upgraded platform. This innovative project will assist the building industry and homeowners with an easy-to-use assessment if energy and carbon impacts of existing homes, and assist the utilities in supporting existing homes in their jurisdictions with HES to improve energy efficiency and reduce emissions. What is to be done in Phase I? During Phase I of this proposed project, ConSol will (1) design software architecture that links CHEERS to the Home Energy ScoreTM via API, (2) solicit partnership from one or more California utilities for a regional pilot, (3) test the new software with its HERS Raters and contractor network in the partnership utility jurisdiction, (4) launch a pilot version of the newly developed software with HERS Raters and contractors in the utility territory, and (5) explore California’s GoGreen energy efficiency homeowner lending program in parallel with the pilot. Commercial Applications and Other Benefits. Summarize the future applications or public benefits if the project is carried over into Phase II or Phase III and beyond. The CHEERS+HES commercialized product will be ready for national market scale following a successful Phase 1 performance. The CHEERS+HES adoption is estimated to reach a 5% adoption growth rate versus the 110,000 baseline, starting in Year 1 after Phase I completion, and continuing each year. As a direct benefit to the DOE, CHEERS will set a goal of 100,000 Home Energy Score assessments for existing home alterations within the first 10 years following Phase 1 performance. The technical benefits of this proposed project include the harmonized, automated, and seamless integration of the DOE HES into the widely used and market leading California energy registry, CHEERS. The social benefits include the aggregate energy, cost and GHG savings by allowing the broader public streamlined access to the CHEERS+HES measurement and the energy efficiency recommended measures that may result. Key Words: Home Energy ScoreTM (HES); Application Programming Interface (API); Home Energy Rating Services (HERS); HERS Raters; contractors; assessors; existing homes, energy asset data; cost, energy, and emissions saving measures; energy code (Title 24) compliance; document repository; utilities; pilot; newly developed software; energy efficiency; homeowner. Summary for Members of Congress: The DOE Home Energy Score™ (HES) is a tool to encourage homeowners to improve their energy performance, lower costs and share energy information but is underutilized and consists of barriers which need to be addressed in order to scale. In effort to expand the HES, CHEERS, Inc. will integrate the HES to its State of California, approved home energy rating services (HERS) platform (CHEERS) to develop a single tool for contractors nationwide to assess, record and install recommended cost, energy, and emissions saving measures to the 140 million single-family homes throughout the U.S. and 14 million homes in California.

Application Programming Interface (API)↗

DOE OSTI2022

Perspective on “code qualifying” new graphite grades for use in advanced nuclear reactors*

The American Society of Mechanical Engineers (ASME) publishes the Boiler and Pressure Vessel (BPV) Code, which include guidance for the safe development, construction, and operation of boilers and pressure vessels. ASME BPV Code Section III “Rules for Construction of Nuclear Facility Components” Division 5 focuses on “High Temperature Reactors”. Subsection HH, subpart A lists the different materials properties that are to be measured and how those properties change due to different environmental conditions (oxidation and irradiation damage) for a graphite to be accepted for use in a high temperature reactor core (i.e., “Code Qualified”). Currently there are no nuclear graphite grades that are “Code Qualified” (i.e., a reactor designer can select a graphite grade and build their reactor without any additional testing), which is due in part to development of new graphite grades in the last 20 years and the lack of comprehensive programs needed to produce the data for the code cases. This perspective is going to discuss the requirements, as called out in the ASME BPV Code, that are necessary to “code qualify” a nuclear graphite grade but will primarily focus on the practical and technical challenges associated with irradiation-induced property changes and how to address these to assist with getting graphite ready for use in advanced nuclear reactors. These same technical challenges can be expected to arise for other materials being developed for advanced reactor concepts.

advanced nuclear reactors↗

DOE OSTI2021

Development of a Modular, Crushed-Rock Thermal Energy Storage Pilot Design

The goal of this project, primarily funded by the U.S. Department of Energy, is to design a next-step pilot to advance near-term energy storage integrated with a fossil plant to provide a facility capable of being viable and effective in a market with growing penetration of variable renewable energy (VRE). Thermal energy storage (TES) represents an ideal technology for this purpose. The current effort will complete a feasibility study to prepare for the Phase II pre-front end engineering design (pre-FEED) for implementing a crushed-rock TES system integrated with a natural gas combined cycle (NGCC) plant. The crushed rock storage technology, which is being developed by Brenmiller Energy, is a modular TES system termed bGen™, which can accommodate both thermal and electrical inputs and output steam, hot water, or hot air. For this application, the estimated efficiency is 80% thermal to thermal. The TES technology is being designed to operate on a slipstream from NYPA’s Eugene W. Zeltmann Power Project (Zeltmann) natural gas combined cycle (NGCC) plant. The projected size of the system will be up to 4 MWe with at least 4 hours of storage duration, or 16 MWh-e total. Final sizing is being determined during the ongoing feasibility study. The next-step pilot being designed as part of the current project will represent a 5-fold increase in scale for this TES technology, and will be used to validate the technology’s ability to provide effective and economical energy storage. This pilot would represent the next-to-last demonstration scale before the technology could be commercial ready at GWh-e scales in the 2030 timeframe. This project is expected to design the critical next-step pilot, which will be undertaken in real-world operating conditions to better determine the crushed rock TES technology’s ability to be integrated with an NGCC plant and assess degradation over transient cycling at rates befitting various marketplaces. The crushed-rock TES pilot design is a technically feasible next step in the development of the technology and is built upon years of prior testing and demonstration. The proposed TES technology was developed by Brenmiller over the last 8 years and has been tested in 3 generations of demonstration units at various sites, globally. During this field testing, different characteristics and performance of the technology were validated, including the following key features: energy storage capacity, energy storage charge/discharge rate, energy storage loses, energy storage mechanical testing. This presentation will provide an update on the results of the conceptual design study for the modular crushed-rock TES system, integrated with a NGCC power plant.

03 NATURAL GAS↗

DOE OSTI2026

FY26 Mid-Year Report Self-Diagnostic Capabilities for Neutron Instruments

This year we will transfer the latest version of INCC6 with last year’s self-diagnostic features to the IAEA. In FY25 we completed the development of three automated self diagnostic features into INNC6. The completion of these features marked the final stable version of INCC 6.0 ready for release to the IAEA and other users. In the first half of the Fiscal Year 2026 we have worked with LANL’s Feynman Center and Export Control office to attain a license for exporting INCC6 to the IAEA. We have successfully attained the export license for INCC6, and contacts at the IAEA have been granted permission to receive INCC6. We are in the final stage of writing the version 6 user manual. Once this is complete, we will deliver INCC6 to the IAEA for testing.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2020

Improving PCM Waste Management Through New Approaches to Screening for LLW Treatment and Disposal - 20145

A major step forward in the management of Plutonium Contaminated Material (PCM) Waste has been taken at the Sellafield site with the introduction of new capabilities to enable wastes previously conservatively designated as PCM Intermediate Level Waste (ILW) to be re-classified for treatment as Low Level Waste (LLW). The Sellafield site, located in the North West of England, within the United Kingdom (UK), has operated plutonium processing plants and waste facilities for almost 70 years. During this time management of the raw PCM waste produced has presented a variety of challenges. The waste is currently processed by high force waste compaction in the Waste Treatment Complex (WTC). The WTC converts 200 litre drums of raw PCM waste into a compacted, grout encapsulated monolith form within stainless steel containment, ready for emplacement within the UK's Geological Disposal Facility (GDF) when it becomes available. To help progress some of the wastes waiting for treatment, recent improvements have been made with the introduction of new waste assay instrumentation which enables the identification of a 'candidate' waste potentially suitable for disposal via the LLW treatment route. Opening a new LLW route for previously designated PCM has been a major advance in PCM waste management policy. It has required a range of technical assessment arrangements to be developed, tested and commissioned and involved the engagement of a wide range of stakeholders. In particular, very detailed technical analysis methods have been developed to ensure that there is a robust and conservative approach to the final sentencing of waste. Following completion of commissioning tests, the first 86 m{sup 3} of previously designated PCM waste was successfully treated through the LLW route and consigned to LLW disposal in June 2019. The direct benefit of sentencing waste to the correct waste route (LLW) is the significant cost savings across the complete range of waste management activities. This work is also strategically important for demonstrating to a range of stakeholders including workforce and regulators, that waste previously designated as PCM can be re-classified in a systematic and justifiable way without increasing risk to personnel or the wider environment. By ensuring that waste is being managed appropriately it will be possible to carry out more remediation work safely, in less time, and at a lower cost. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2021

DEVELOPMENT OF A 25 MWTH FLAMELESS PRESSURIZED OXY-COMBUSTION PILOT

The Flameless Pressurized Oxy-Combustion (FPO) cycle, a novel flexible fuel technology, is being developed into a large pilot. This effort seeks to complete the preliminary engineering and planning of a 25 MWth Pilot Plant that will demonstrate the technology for scale-up to a commercial unit. The technology, pioneered by ITEA at the 5 MWth scale, must be brought to a higher technology readiness level (TRL) to be viable at the commercial scale. The 25 MWth pilot cycle was optimized for cost and technology development and demonstration. Preliminary drawings, layouts, and plans were defined. Process flow diagrams were used to describe the pilot configuration in greater detail. A heat and mass balance with stream data was created. A master equipment list specified the operating conditions for major pieces of equipment within the pilot using this heat and mass balance. The 25 MWth FPO pilot is assessed for environmental performance. A test campaign is developed to assess the type of test and number of hours required for pilot demonstration. The environmental performance is compared against projected performance at the commercial scale. This project builds upon extensive evaluation of the techno-economic performance of the FPO technology already performed by ITEA. This includes system improvements, such as the addition of a turbo-expander to the flue gas stream. Some of the performance-enhancing components are not as well defined as others. The primary goal of this effort was to bring all of the core cycle components to the same level of design maturity. A techno-economic assessment (TEA) evaluated the FPO technology at the commercial scale in comparison to the NETL baseline cases. The reference plants were used in combination with proprietary equipment estimates to build a plant capital cost and cost of electricity evaluation. FPO performed better than the sub-bituminous post-combustion capture cases. Further preliminary estimates of improvements to the FPO cycle show even further gains when compared to conventional carbon capture methods.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2021

Advanced Ultra-Supercritical Component Test (ComTest) Project for 760*C Steam Conditions

ComTest is a $27M Department of Energy-funded project. Phase I, which began in November 2015, served to identify the technology gaps, as well as the scope and cost of required testing. Phase II, which was awarded in December 2018, includes an advanced manufacturing effort to complete U.S. based supply chain development for full commercial scale (800-850 MWe) AUSC components made of nickel-based alloys, components operating at up to 760°C. Completion of Phase II scheduled for September 30, 2021. Strategic Objectives of U.S. AUSC Project include: Power Plant Efficiency Improvements –Develop cost-effective, reliable technologies to improve the efficiency of new and existing high-temperature advanced generation power plants. Close gaps to achieve readiness for commercial scale demonstration of Advanced Ultra-Supercritical (AUSC) technology. Fabricate full-scale versions of key nickel-based alloy components. Validate capabilities of US supply chain for cost certainty. Support cross-cutting high-temperature generation technologies. Obtain ASME Code approval for new materials, components and processes. Increase power plant steam temperatures for higher cycle efficiency (Note: Average efficiency of US coal-fired fleet = 33% HHV; A-USC plant efficiency over 47% HHV at 1,400°F (760°C) steam temperature).

fireside corrosion↗

DOE OSTI2025

The 200 Gbps Challenge: Imagining HL-LHC analysis facilities

The IRIS-HEP software institute, as a contributor to the broader HEP Python ecosystem, is developing scalable analysis infrastructure and software tools to address the upcoming HL-LHC computing challenges with new approaches and paradigms, driven by our vision of what HL-LHC analysis will require. The institute uses a "Grand Challenge" format, constructing a series of increasingly large, complex, and realistic exercises to show the vision of HL-LHC analysis. Recently, the focus has been demonstrating the IRIS-HEP analysis infrastructure at scale and evaluating technology readiness for production. As a part of the Analysis Grand Challenge activities, the institute executed a "200 Gbps Challenge", aiming to show sustained data rates into the event processing of multiple analysis pipelines. The challenge integrated teams internal and external to the institute, including operations and facilities, analysis software tools, innovative data delivery and management services, and scalable analysis infrastructure. The challenge showcases the prototypes - including software, services, and facilities - built to process around 200 TB of data in both the CMS NanoAOD and ATLAS PHYSLITE data formats with test pipelines. The teams were able to sustain the 200 Gbps target across multiple pipelines. The pipelines focusing on event rate were able to process at over 30 MHz. These target rates are demanding; the activity revealed considerations for future testing at this scale and changes necessary for physicists to work at this scale in the future. The 200 Gbps Challenge has established a baseline on today's facilities, setting the stage for the next exercise at twice the scale.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2024

Energy Technology Proving Ground Program Plan

New methods of energy production and distribution are required to meet clean energy goals and demands across all U.S. energy sectors. Idaho National Laboratory’s (INL) Integrated Energy Systems (IES) initiative is enabling clean energy research, development, and demonstration (RD&D) activities. To date, IES demonstration programs have been limited by distributed infrastructure and a lack of large-scale facilities to accommodate industry-scale research of Technical Readiness Level (TRL) 6-8 technologies. The IES initiative plans to eliminate these constraints by establishing a new research complex at INL known as the Energy Technology Proving Ground (Proving Ground) to be led by the Energy and Environment Science and Technology Directorate. The Energy and Environment Science and Technology (EES&T) directorate, one of five Idaho National Laboratory (INL) RD&D organizations, focuses on clean energy technologies that anchor the industry-enabling research of the Proving Ground. The Proving Ground will combine diverse clean energy systems into lean integrated test bed of independent multiscale capabilities available to the government and commercial industries to perform research; and will enable INL’s goal of becoming a Net-Zero entity by 2031. This program encompasses existing and new research space at both the in-town Research and Education Campus (REC) and the Arco desert site (the Site). The Proving Ground will support the maturation of IES technologies from TRL 1 through 8 by providing the infrastructure and capabilities needed to sustain a continuum of RD&D from basic science to industry-scale. To establish The Proving Ground and meet INL’s net-zero goals by 2031, nine research program areas have been identified within the IES initiative that require expanded and new capital infrastructure. This program plan provides guidance for establishing the Proving Ground at the Site for plug-and-play pilot testing and proofing of integrated energy system functionality including fission and renewable energy sources for industry driven application platforms.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2025

Energy Technology Proving Ground FY-2026 Program Plan (Rev.1)

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2022

Transformational Solid Oxide Fuel Cell (SOFC) Technology

This project was conducted under the Co-operative Agreement No. DE-FE0027584 with the US Department Energy to developed advanced Solid Oxide Fuel Cell (SOFC) Technologies. The overall objective of this project was to advance SOFC technology at the cell and stack level to enhance cell robustness and durability, increase performance, and reduce balance-of-plant (BOP) requirements. By reducing system complexity combined with the increases in power density and efficiency, the ultimate goal of the project was to increased reliability and to reduce capital and operating costs of installed systems. The project was focused on pathways that will reduce the cost of the SOFC cell and stack, including the following areas: Robust, redox tolerant cell technology Lower cost cell manufacturing through advances in cell design, which will reduce the amount of material, energy and time used in the fabrication of SOFCs High performance, low temperature electrolyte based on improvement of established materials Innovative SOFC stack architecture which truly integrates Balance of Plant functionality into the stack level design Thermal management of the fuel cell stack for increased durability and expanded window of operation Novel stack design amenable for use in sub-MW to multi-MW-scale power plants and having low replacement cost The incorporation of balance-of-plant (BOP) equipment into the stack platform increased the economic viability of smaller scale systems. The project objectives were met by a multi-prong approach, including new cell design complemented with modifications to existing cell technology, as well as a new stack design incorporating components typically included in the BOP, such as heat exchangers, oxidizer, fuel reformers, and recycle systems. The project culminated with demonstration of a stack test validating the viability of the cell and stack improvements. A cost model was also developed to estimate costs for the advanced stack technology at high volume manufacturing levels. The net outcome of the project is SOFC cell and stack technology with costs significantly below current DOE targets without compromising and, in some cases, improving on the performance and degradation rate demonstrated with the current state-of-the-art stack design. The results of this project advanced the reliability, robustness, and endurance of low-cost SOFC technology that ultimately are ready to be deployed in coal power systems with greater than 60 percent efficiency (based on higher heating value of fuel) and the capability for ≥97% CO 2 capture at a cost-of-electricity that is approximately 40 percent below presently available Integrated Gasification Combined Cycle systems.

03 NATURAL GAS↗

DOE OSTI2022

Tree hydrodynamic modelling of the soil–plant–atmosphere continuum using FETCH3

Modelling the water transport along the soil–plant–atmosphere continuum is fundamental to estimating and predicting transpiration fluxes. A Finite-difference Ecosystem-scale Tree Crown Hydrodynamics model (FETCH3) for the water fluxes across the soil–plant–atmosphere continuum is presented here. The model combines the water transport pathways into one vertical dimension, and assumes that the water flow through the soil, roots, and above-ground xylem can be approximated as flow in porous media. This results in a system of three partial differential equations, resembling the Richardson–Richards equation, describing the transport of water through the plant system and with additional terms representing sinks and sources for the transfer of water from the soil to the roots and from the leaves to the atmosphere. The numerical scheme, developed in Python 3, was tested against exact analytical solutions for steady state and transient conditions using simplified but realistic model parameterizations. The model was also used to simulate a previously published case study, where observed transpiration rates were available, to evaluate model performance. With the same model setup as the published case study, FETCH3 results were in agreement with observations. Through a rigorous coupling of soil, root xylem, and stem xylem, FETCH3 can account for variable water capacitance, while conserving mass and the continuity of the water potential between these three layers. FETCH3 provides a ready-to-use open access numerical model for the simulation of water fluxes across the soil–plant–atmosphere continuum.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2021

Smart Monitoring and Diagnostic System (SMDS) for Packaged Air Conditioners and Heat Pumps for Small/Medium Commercial Buildings: Preparation for Commercialization: CRADA 478 [Abstract only]

This project will enable Pacific Northwest National Laboratory (PNNL) and industry partner, mCloud Technologies, to work collaboratively to ready the Smart Monitoring and Diagnostic System (SMDS) for commercial deployment and validate its performance under real-world conditions at field sites. This project will specifically focus on 1) implementing the SMDS algorithms in a scalable cloud-based software architecture, 2) designing new, innovative, complimentary commercial services based on the SMDS, 3) enhancing the SMDS energy and cost impact algorithms to reduce uncertainty in estimates, 4) determining the lower limits on SMDS performance degradation detection, 5) validating algorithm performance and default values of adjustable thresholds with existing data from controlled physical testing and from customer packaged air conditioners and heat pumps (commonly referred to as rooftop units or RTUs), 6) field testing to validate the system on multiple customer buildings in diverse environments, and 7) expanding field deployment to a larger set of mCloud’s customer buildings. Project results by validating, enhancing, and quantifying the performance of the SMDS will position mCloud, and potential future licensees, to implement the SMDS in commercial offerings that encourage and enable use of condition-based and predictive maintenance, leading to significant reductions in energy use and greenhouse gas emissions associated with space conditioning by RTUs. Furthermore, these enhancements will increase the value of the SMDS for users and increase the potential market for its use and impacts.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2023

Coal as Value-Added for Lithium Battery Anodes (Final Report)

Graphite is a basic material used for energy storage in lithium-ion (Li-ion) batteries. More than 70% of worldwide graphite production and nearly 50% of the annual graphite supply for the United States comes from China. Potential economic and national security concerns exist because Li-ion batteries are used not only for the fast-growing electrical vehicle market (15.6% compound annual growth rate [CAGR] from 2018 to 2028 in North America), but also for defense applications including unmanned aerial and ground vehicles. Development of an alternative formulation for Li-ion batteries is key. Building upon previous research confirming the ability of silicon alloys to improve the energy density of anodes, Semplastics developed a novel material based on our X-MAT® polymer-derived ceramic (PDC) technology. The X-MAT anode material is a composite of chemically tailored silicon oxycarbide (SiOC) and domestically sourced coal powder, designed to be a drop-in replacement for graphite within Li-ion battery anodes. Preliminary tests of this material showed more than twice the reversible capacity of graphite anodes (1,000 mAh/g vs. 372 mAh/g), with excellent stability and capacity retention, almost 100% coulombic efficiency, low voltage potential, and low thermal expansion. At full adoption in 2024, we expect the coal utilization to reach 27,300 tons. Through this project, Semplastics proposed to complete development and begin commercialization of this material. The objective was to determine the best formulation for technical performance and economic viability. At the end of the project, the X-MAT anode material is ready for implementation into existing battery manufacturing processes and can have a significant impact on the utilization of coal, with positive effects for the mining sector and the mitigation of carbon dioxide (CO 2 ) emissions.

01 COAL, LIGNITE, AND PEAT↗