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DOE OSTI2022

Challenges and Lessons Learned from an Analysis of Three Zero Energy Buildings

Zero energy buildings, or zero energy ready buildings, which are designed and operated by public or private commercial property owners can play an important role in reducing carbon emissions. This paper discusses lessons learned and key takeaways from an in-depth analysis of three zero energy buildings that took an integrated design and construction approach to significantly reduce energy use. Two of these projects are new construction and one is a retrofit to zero energy. Findings are based on project literature review, data analysis, and in-depth interviews with the building design teams and staff who were involved during the design, construction, and operation of the buildings. The paper addresses value proposition and cost data in such a way that other building owners can replicate the strategies and technology solutions in response to regulatory mandates or organizational goals. It also provides details on operational improvements taken at each zero energy building to enhance energy performance and increase the potential for load flexibility, and discusses challenges and lessons gleaned from design teams and building staff. The findings serve as a reference for building owners, designers, engineers, contractors, or others interested in, or involved with, the design, construction, or use of new or existing buildings. The paper also includes recommended pathways for widespread adoption of zero energy strategies that can be applied in various locations.

ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATION↗

DOE OSTI2017

Wind-Load Analysis of a New Linear Fresnel Receiver Assembly Design

Estimate wind load requirements at operational and survival conditions to facilitate the future optimal engineering design.

Parikh, A.↗

DOE OSTI2014

MAN-004 Design Standards Manual

At Sandia National Laboratories in New Mexico (SNL/NM), the design, construction, operation, and maintenance of facilities is guided by industry standards, a graded approach, and the systematic analysis of life cycle benefits received for costs incurred. The design of the physical plant must ensure that the facilities are "fit for use," and provide conditions that effectively, efficiently, and safely support current and future mission needs. In addition, SNL/NM applies sustainable design principles, using an integrated whole-building design approach, from site planning to facility design, construction, and operation to ensure building resource efficiency and the health and productivity of occupants. The safety and health of the workforce and the public, any possible effects on the environment, and compliance with building codes take precedence over project issues, such as performance, cost, and schedule. These design standards generally apply to all disciplines on all SNL/NM projects. Architectural and engineering design must be both functional and cost-effective. Facility design must be tailored to fit its intended function, while emphasizing low-maintenance, energy-efficient, and energy-conscious design. Design facilities that can be maintained easily, with readily accessible equipment areas, low maintenance, and quality systems. To promote an orderly and efficient appearance, architectural features of new facilities must complement and enhance the existing architecture at the site. As an Architectural and Engineering (A/E) professional, you must advise the Project Manager when this approach is prohibitively expensive. You are encouraged to use professional judgment and ingenuity to produce a coordinated interdisciplinary design that is cost-effective, easily contractible or buildable, high-performing, aesthetically pleasing, and compliant with applicable building codes. Close coordination and development of civil, landscape, structural, architectural, fire protection, mechanical, electrical, telecommunications, and security features is expected to ensure compatibility with planned functional equipment and to facilitate constructability. If portions of the design are subcontracted to specialists, delivery of the finished design documents must not be considered complete until the subcontracted portions are also submitted for review. You must, along with support consultants, perform functional analyses and programming in developing design solutions. These solutions must reflect coordination of the competing functional, budgetary, and physical requirements for the project. During design phases, meetings between you and the SNL/NM Project Team to discuss and resolve design issues are required. These meetings are a normal part of the design process. For specific design-review requirements, see the project-specific Design Criteria. In addition to the design requirements described in this manual, instructive information is provided to explain the sustainable building practice goals for design, construction, operation, and maintenance of SNL/NM facilities. Please notify SNL/NM personnel of design best practices not included in this manual, so they can be incorporated in future updates.

42 ENGINEERING↗

DOE OSTI2016

The New S-RAM Air Variable Compressor/Expander for Heat Pump and Waste Heat to Power Application

S-RAM Dynamics (S-RAM) has designed an innovative heat pump system targeted for commercial and industrial applications. This new heat pump system is more efficient than anything currently on the market and utilizes air as the refrigerant instead of hydrofluorocarbon (HFC) refrigerants, leading to lower operating costs, minimal environmental costs or concerns, and lower maintenance costs. The heat pumps will be manufactured in the United States. This project was aimed at determining the feasibility of utilizing additive manufacturing to make the heat exchanger device for the new heat pump system. ORNL and S-RAM Dynamics collaborated on determining the prototype performance and subsequently printing of the prototype using additive manufacturing. Complex heat exchanger designs were fabricated using the Arcam electron beam melting (EBM) powder bed technology using Ti-6Al-4V material. An ultrasonic welding system was utilized in order to remove the powder from the small openings of the heat exchanger. The majority of powder in the small chambers was removed, however, the amount of powder remaining in the heat exchanger was a function of geometry. Therefore, only certain geometries of heat exchangers could be fabricated. SRAM Dynamics evaluated a preliminary heat exchanger design. Although the results of the additive manufacturing of the heat exchanger were not optimum, a less complex geometry was demonstrated. A sleeve valve was used as a demonstration piece, as engine designs from S-RAM Dynamics require the engine to have a very high density. Preliminary designs of this geometry were successfully fabricated using the EBM technology.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2019

Making Coal Relevant for Small Scale Applications: Modular Gasification for Syngas/Engine CHP Applications in Challenging Environments

This Front-End Engineering Design (FEED) study is funded by the US Department of Energy (DOE), and managed by the National Energy Technology Laboratory (NETL) through a Cooperative Agreement awarded to the University of Alaska Fairbanks (UAF) to perform a technical and cost study for the design and installation of a Hamilton-Maurer International (HMI) gasifier for generating a clean syngas for firing in reciprocating engines. An existing diesel engine generator (DEG) and a commercially available spark ignition engine are used to generate electricity with the low-Btu syngas. Other than the HMI gasifier, only commercially available technologies were assumed for this study. An important objective of this design study was to estimate capital and operating costs of small modular coal and coal/biomass fired generating units to provide wind regulation services. Although this study is based on retrofitting an existing coal fired power plant with the HMI gasifier, sufficient data was developed to characterize greenfield units. The original concept was to provide clean syngas and tars/oils from the gasification process to the existing Colt-Pielstick PC2.6B diesel engine generator (9.6 MWe) installed at the UAF Atkinson Power Plant. The intent was to convert the diesel engine to operate in a dual fuel mode, firing both syngas and tars/oils. As the project progressed, Fairbanks Morse Engine (FME), current licensee for the Colt-Pielstick engine line, was not able to develop a modification package for the engine to allow for syngas firing. Although this type of modification is available for firing natural gas, the capability does not extend to syngas. Western Energy Systems, distributor for Innio Jenbacher, was able to offer the Jenbacher Model JMS620 engine. After review of available options, the project team selected a design configuration using two Jenbacher engines rated at 1965 kWe each to fire the syngas, with the oils/tars directed to the Colt Pielstick diesel to be blended with ultra-low sulfur diesel oil (ULSD). The Jenbacher engines are expected to operate at continuous base load, with some load-following ability, while the existing diesel engine will operate in grid support service, with loads varying from a nominal 25% to 100%. An annual capacity factor for the diesel engine is projected to be between 50% and 60%. The overall gasifier and gas clean-up system is sized to produce enough syngas to adequately fuel three Jenbacher Engines for a nominal power output of 5.9 MWe, but this study assumes that only two Jenbacher engines will be installed due to space constraints in the Atkinson Power Plant, and because of expected air emission permit limitations. There is still potential that the excess syngas capacity equivalent to about 2 MWe could be used as supplemental fuel for the DEG. The exhaust from the Jenbacher engines is passed through heat recovery units to generate low pressure steam, thereby providing a significant portion of the steam required for operating the gasifier. The overall performance of the HMI gasifier/engine configuration is summarized as follows: 1) Overall electric efficiency, Jenbacher and diesel engines, based on gasifier fuel production (syngas and pyrolysis liquids) is 35.2% LHV, 2) Overall cogenerating efficiency (electricity plus steam), based on gasifier fuel production (syngas and pyrolysis liquids) is 54.8% LHV, 3) Overall electric efficiency, Jenbacher and diesel engines, based on coal input, is 29.6% LHV, and 4) Overall cogenerating efficiency, electricity plus steam, based on coal input is 46.0%. This project is estimated to have a Bare Erected Cost (BEC) of $\$$ 33.4 million and a Total Plant Cost (TPC) of $\$$ 45.7 million. Based on the original scope, sending both the clean syngas and the oils and tars to the existing diesel engine, the BEC and TPC values would have been $\$$ 23.3 million and $\$$ 32.1 million, respectively. A variable Cost of Electricity (COE) is calculated to reflect only those costs that will be incurred by incremental operation of the system for the HMI gasifier/Jenbacher engine combination. Operation of the diesel engine is determined separately. The variable COE values are: Case 1: 100% Usibelli Coal: (a) HMI gasifier/Jenbacher Engines -- 8.3 cents/kWh; (b) Diesel Engine -- 20.2 cents/kWh, and Case 2: 80% Usibelli Coal + 20% wood chips (proportion based on Btu input, LHV basis): (a) HMI Gasifier/Jenbacher -- 13.7 cents/kWh; (b) Diesel Engine -- 20.2 cents/kWh. The incremental cost of operating the gasifier/Jenbacher system increases with co-firing of wood chips due to the high cost of this material, over five times as costly as Usibelli coal delivered to the Atkinson Power building. The diesel cost is constant as the oils and tars are priced at the same value as the ULSD for the purposes of fueling the diesel engine. Section 8 of this report provides details of the O&M costs. The overall power system is configured to be modular and scalable to provide a wide range of generating capacity using the same components. This allows for reduction in cost, risk, schedule time to engineer and construct, and provides some degree of repeatability for air permitting.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2015

A method to select human-system interfaces for nuclear power plants

The new generation of nuclear power plants (NPPs) will likely make use of state-of-the-art technologies in many areas of the plant. The analysis, design, and selection of advanced human–system interfaces (HSIs) constitute an important part of power plant engineering. Designers need to consider the new capabilities afforded by these technologies in the context of current regulations and new operational concepts, which is why they need a more rigorous method by which to plan the introduction of advanced HSIs in NPP work areas. Much of current human factors research stops at the user interface and fails to provide a definitive process for integration of end user devices with instrumentation and control (I&C) and operational concepts. The current lack of a clear definition of HSI technology, including the process for integration, makes characterization and implementation of new and advanced HSIs difficult. This paper describes how new design concepts in the nuclear industry can be analyzed and how HSI technologies associated with new industrial processes might be considered. Furthermore, it also describes a basis for an understanding of human as well as technology characteristics that could be incorporated into a prioritization scheme for technology selection and deployment plans.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2014

Sandia National Laboratories Facilities Management and Operations Center Design Standards Manual

42 ENGINEERING↗

DOE OSTI2014

Performance evaluation approach for the supercritical helium cold circulators of ITER

The ITER project design foresees Supercritical Helium (SHe) forced flow cooling for the main cryogenic components, namely, the superconducting (SC) magnets and cryopumps (CP). Therefore, cold circulators have been selected to provide the required SHe mass flow rate to cope with specific operating conditions and technical requirements. Considering the availability impacts of such machines, it has been decided to perform evaluation tests of the cold circulators at operating conditions prior to the series production in order to minimize the project technical risks. A proposal has been conceptualized, evaluated and simulated to perform representative tests of the full scale SHe cold circulators. The objectives of the performance tests include the validation of normal operating condition, transient and off-design operating modes as well as the efficiency measurement. A suitable process and instrumentation diagram of the test valve box (TVB) has been developed to implement the tests at the required thermodynamic conditions. The conceptual engineering design of the TVB has been developed along with the required thermal analysis for the normal operating conditions to support the performance evaluation of the SHe cold circulator.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2020

Spawn [SWR-SWR-20-10]

Spawn is a next generation building simulation engine designed to build on the strengths of NREL's venerable EnergyPlus engine, and add new advanced HVAC and controls modeling capability by incorporating the Modelica equation based modeling language. In effect, Spawn is a hybrid of the existing EnergyPlus and Modelica software products, with some new software to provide glue between the components in order to provide a seamless end user experience.

Li, Yanfei↗

DOE OSTI2020

BioSTEAMDevelopmentGroup/thermosteam

BioSTEAM is a fast and flexible package for the design, simulation, and techno-economic analysis of biorefineries under uncertainty. BioSTEAM’s framework is built to streamline and automate early-stage technology evaluations and to enable rigorous sensitivity and uncertainty analyses. Complete biorefinery configurations are available at the Bioindustrial-Park GitHub repository, BioSTEAM’s premier repository for biorefinery models and results. The long-term growth and maintenance of BioSTEAM is supported through both community-led development and the research institutions invested in BioSTEAM. Through the open-source and community-lead platform, BioSTEAM aims to foster communication and transparency within the biorefinery research community for an integrated effort to expedite the evaluation of candidate biofuels and bioproducts. Additionally, an agile life cycle assessment (LCA) platform has been designed to interface with BioSTEAM, BioSTEAM-LCA. This open-source, installable package allows users to perform streamlined LCAs of biorefineries. The focus of BioSTEAM-LCA is to streamline and automate early-stage environmental impact analyses of processes and technologies, and to enable rigorous sensitivity and uncertainty analyses linking process design, performance, economics, and environmental impacts. ThermoSTEAM is a standalone thermodynamic engine capable of estimating mixture properties, solving thermodynamic phase equilibria, and modeling stoichiometric reactions. ThermoSTEAM builds upon chemicals, the chemical properties component of the Chemical Engineering Design Library, with a robust and flexible framework that facilitates the creation of property packages. The Biorefinery Simulation and Techno-Economic Analysis Modules (BioSTEAM) is dependent on ThermoSTEAM for the simulation of unit operations.

Cortes-Peña, Yoel↗

DOE OSTI2024

CW copper injector for SRF industrial cryomodules

Compact SRF industrial linacs can provide unique parameters of the beam (>1 MW and >1-10 MeV) hardly achievable by normal conducting linacs within limited space. SRF technology was prohibitively expensive until the development of conduction cooling which opened the way for compact stand alone SRF systems suitable for industrial and research applications. Limited cooling capacity puts strict requirements on the beam parameters with zero losses of the beam on the SRF cavity walls. This implies strict requirements on the beam energy to be accepted by the cryomodule and most importantly the beam bunching with zero particles in between. We designed a CW normal conducting RF injector which consists of a gridded RF gun integrated with a first cell of a copper booster cavity to satisfy these requirements. Here we present a complete design of a booster cavity including beam dynamics, RF, thermomechanical and engineering design.

43 PARTICLE ACCELERATORS↗

DOE OSTI2020

Achieving Diesel-Like Efficiency in a High Stroke-to-Bore Ratio DISI Engine under Stoichiometric Operation

This work explores pathways to achieve diesel-like, high-efficiency combustion with stoichiometric 3-way catalyst compatible spark ignition (SI). A high stroke-to-bore engine design (1.5:1) with cooled exhaust gas recirculation (EGR) and high compression ratio (r c ) was used to improve engine efficiency by up to 30% compared with a production turbocharged gasoline direct injection spark ignition engine. To achieve efficiency improvements, engine experiments were coupled with computational fluid dynamics simulations to guide and explain experimental trends between the original engine and the high stroke-to-bore ratio design (1.5:1). The effects of EGR and late intake valve closing (IVC) and fuel characteristics are investigated through their effects on knock mitigation. Direct injection of 91 RON E10 gasoline, 99 RON E0 gasoline, and liquified petroleum gas (i.e., propane/autogas) were evaluated with geometric rc ranging from 13.3:1 to 16.8:1. Finally, engine experiments demonstrated 47% gross thermal efficiency, and 45% net thermal efficiency at stoichiometric engine operation, at up to 17 bar IMEP and 2000 r/min with 16.8:1 rc.

42 ENGINEERING↗

DOE OSTI2020

Conceptual Fuel Element Design Candidates for Conversion of High Flux Isotope Reactor with Low-Enriched Uranium Silicide Dispersion Fuel

Engineering design studies are underway to assess the feasibility of converting the High Flux Isotope Reactor (HFIR) to operate with low-enriched uranium (LEU) silicide dispersion (U3Si2-Al) fuel. These studies are supported by the U.S. Department of Energy National Nuclear Security Administration’s Office of Material Management and Minimization. A systematic approach employing neutronic and thermal-hydraulic analyses have been performed with the ORNL Shift and HFIR Steady State Heat Transfer Code tools, respectively, to predict reactor performance and thermal safety margins for proposed LEU3Si2-Al fuel designs. The design process was initiated by generating an optimized design with fabrication features identified from previous studies that result in excellent performance and safety metrics. The approach continued by substituting a single fabrication feature anticipated to be difficult to manufacture with another feature expected to perform an analogous function to that of the removed feature. Four conceptual fuel element design candidates, with various fabrication features, for conversion of HFIR with 4.8 gU/cm3 LEU3Si2-Al fuel have been generated and shown to meet pre-defined performance and safety metrics. Results to date indicate that HFIR could convert with the subject fuel system and meet performance and safety requirements if, among other considerations, fabrication of the specific design features are demonstrated and qualification of the fuel is complete under HFIR-specific conditions.

Chandler, David↗

DOE OSTI2022

Preliminary Reversible Solid Oxide System Specification

This report presents the preliminary documentation of a 10 MWe DC reversible solid oxide cell (rSOC) system designed to use both electrical and thermal energy from a nuclear power plant (NPP). The system is designed to consume 10 MWe DC in electrolysis mode while producing hydrogen from demineralized feedwater. In fuel cell mode, the same stacks produce 2.37 MWe DC of electricity by reacting hydrogen and oxygen, while generating water as a byproduct which is recycled to be used later in the electrolysis mode. The system detailed in this specification is a high-temperature steam electrolysis (HTSE) system when operated in the electrolysis mode. HTSE systems have the benefit of producing hydrogen at a higher efficiency than conventional low-temperature electrolysis (LTE) systems. In this report it is assumed that some of the heat required for HTSE operation comes from an NPP. Heat extraction from an NPP for use in electrolysis mode of the rSOC system allows preheating and vaporization of feedwater before recuperators and trim heaters raise the feed temperature to the approximately 800 °C before entering the solid oxide stacks. The purpose of an rSOC system in a utility company setting is to employ energy arbitrage with a dispatchable demand load which can consume excess electricity generation during times of low grid demand / high generation and can produce electricity for the grid during times of high grid demand / low generation. There is a wide range of energy storage technologies that could be used for utility-scale energy arbitrage (utility-scale battery storage is considered the baseline technology), the object of this work is not to compare and contrast rSOC technology with any of these other technologies, but only to present this preliminary design for consideration and for use in future conceptual or front end engineering design (FEED) work. This document is not meant to be a final specification or definitive description of the rSOC system, but it is meant to showcase preliminary process modeling results, provide boundary conditions and interface requirements such as input feed and utility stream flowrates, temperatures, and pressures as well as thermal and electrical energy requirements, and output conditions in both electrolysis mode and fuel cell mode. These results are intended to inform the future development of a conceptual demonstration-scale study to assess the technical and economic feasibility of a future demonstration of an rSOC integrated project at an NPP.

08 HYDROGEN↗

DOE OSTI2026

Persistent Elevated Soot Emissions Induced by Clustered Stochastic Preignition Events

Stochastic Preignition (SPI) is an abnormal combustion phenomenon that can occur in spark-ignition engines particularly under high-load operation. SPI is characterized by uncontrolled initiation of combustion prior to spark discharge, an abnormal combustion process that can lead to severe knock events and significant engine damage. SPI has been associated with fuel properties, lubricant composition, and engine design and operation. Here, in this work, a single-cylinder test engine with a dry-sump oil system was utilized to study the SPI response of E10 and E25 fuels with a range of Reid Vapor Pressure (RVP). An automated test procedure was employed, consisting of ten square-waved load profile segments, with each segment composed of 5 min of low-load operation followed by 25 min of sustained high-load operation. These tests were replicated across multiple days of testing including a lubricant triple flush between tests, and an online Fuel in Oil diagnostic measurement. Exhaust particulate emissions were continuously measured by an AVL microsoot sensor (MSS). Elevated particulate matter emissions were observed to occur concurrently with SPI events as blooms of soot. Particularly after clustered events (i.e., multiple SPI cycles occurring within 10 consecutive engine cycles), high soot emissions were observed to persist over several days of sequential operation despite daily lubricant changes, a complete warm-up procedure, and sustained low-load operation between test segments. This result implies that the particulate emissions trends may be dominated by deposit-based effects, where higher load operation is needed to alter deposition and formation processes. The observed soot blooms were also found to correspond to a reduction in the engine fueling and the fuel engine oil dilution rate despite the engine exhaust remaining at stoichiometric exhaust operation. These observations suggest that post-SPI events, pathways for lubricant migration and consumption into the combustion chamber may occur until these pathways are closed from deposit formation or ring dynamics during extended operation. These observed sooting propensity persisted with all fuels tests, but a linear correlation was observed between the summation of soot and particulate matter index (PMI) value for each fuel as well as SPI events, proving that PMI is a crucial fuel property for reducing SPI.

Splitter, Derek [Oak Ridge National Laboratory (OR↗

DOE OSTI2019

A Tool for Evaluating Youth Engagement in an Informal STEM Setting: The WGG Observation Protocol

This paper discusses findings from the use of the Wise Guys and Gals (WGG) Observation of WGG Youth Protocol in a blended learning environment. The protocol was used to assess youth engagement when completing blended engineering design challenges at two Boys and Girls Clubs. WGG is a project funded through a grant from the National Science Foundation and which brings blended learning design challenges to middle school aged learners in informal STEM (science, technology, engineering, and mathematics) settings. This paper explores the feasibility of using the observation protocol to collect data about youth engagement, and the potential use of the protocol in other informal STEM settings.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2019

AOI2 - Initial Engineering, Testing, and Design of a Commercial-Scale Postcombustion CO 2 Capture System on an Existing Coal-Fired Generating Unit (Project Carbon)

The continued long-term use of North Dakota lignite is likely dependent on creating a business case for carbon capture, utilization, and storage (CCUS) that also addresses society’s desire to reduce carbon emissions. CCUS coupled with enhanced oil recovery appears to be the most feasible option for utilities to sustain and grow the lignite industry. Establishing a market where lignite-powered utilities provide carbon dioxide (CO 2 ) to oil producers depends upon having a cost-effective method to capture CO 2 . The application of CO 2 capture technology to lignite-fired flue gas has challenges in addition to the cost of capture, including the effects of the buildup of heat-stable salts, aerosol formation, degradation of solvents or solid sorbents, or subsequent solvent loss. Lignite, especially North Dakota lignite, presents its own set of challenges that include the combination of high sodium, sulfur, and ash contents; NO x reduction; and footprint limitations. Project Carbon was designed to address these technical barriers and provide pre-FEED (preliminary front-end engineering and design) information necessary for additional commercial demonstrations to move forward. A long-term pilot-scale evaluation of Mitsubishi Heavy Industries’ (MHI’s) KS-1™ solvent at Minnkota Power Cooperative’s lignite-fired Milton R. Young Station Unit 2 (MRY2) was a major objective of the project. The purpose of the test was to demonstrate the technology’s compatibility with MRY2’s flue gas over an extended period of time. During the long-term test, aerosol sampling and measurement were performed, and a pilot-scale baghouse was tested to determine the effect of bag material and operation on aerosol concentrations in the flue gas. Project engineering and design work were performed to support the other major project objective: a pre-FEED study of CO 2 capture at MRY2. Finally, a techno-economic assessment (TEA) of the application of CO 2 capture to MRY2 was performed. This project was performed over a period of 28 months, with a total budget of $12,700,000. The U.S. Department of Energy’s (DOE’s) National Energy Technology Laboratory, through the Energy & Environmental Research Center’s (EERC’s) Cooperative Agreement, the North Dakota Industrial Commission, and industry partners ALLETE and Minnkota Power Cooperative, funded the project. The pilot-scale test system at MRY2 performed very well for the continuous test period of 83 days. The CO 2 capture plant achieved stable operation while utilizing MHI’s KS-1™ solvent and the MHI amine emission reduction unit. No major concerns were encountered when capturing CO 2 from lignite-fired flue gas. Challenges were encountered because the cooling water temperature was warmer than needed for the capture system to operate efficiently. This affected the ability of the solvent to capture CO 2 and promoted solvent loss through solvent entrainment caused by high CO 2 gas temperature within a cyclone separator. The KS-1™ solvent and the lignite-derived flue gas were analyzed during the long-term test. Analysis of the solvent indicates that, although some metals and heat-stable salts increased over the course of the long-term test, they were at levels that can be treated with filtration and reclaiming and do not pose a concern for effective solvent operation. Fourier transform infrared (FTIR) spectrometry was successfully used to determine the composition of the lignite-derived flue gas as well as concentrations of select components of the flue gas at various locations within the EERC’s CO 2 capture system. The formation of aerosols during the capture process is of interest, as are approaches for their reduction, especially in a baghouse. Testing of aerosol removal was performed using the EERC’s portable baghouse. It was found that both Ryton and polytetrafluoroethylene (PTFE) membrane bags were effective at reducing the level of aerosols during steady-state operation. During backpulse events, however, the amount of aerosols passing through the bags was an order of magnitude lower for the Ryton bags than the PTFE membrane bags. The testing showed that proper design of the baghouse air-to-cloth ratio as well as minimization of backpulsing can dramatically reduce the amount of aerosols that pass through the bags and remain in the flue gas stream exiting a baghouse system. A technology maturation plan (TMP) was performed to enable successful development of the Kansai Mitsubishi Carbon Dioxide Recovery® (KM CDR®) Process for application to a combustion flue gas for which the process has not yet been demonstrated. In the TMP, new challenges to the MHI CO 2 capture technology during its application to MRY2 were identified. These challenges included capture from lignite-fired (as opposed to subbituminous coal-fired) flue gas, a larger scope than previous applications of the technology, and implementation in a colder climate that could affect process and equipment operability. Because MRY2 is located where stack icing in the winter could be problematic, a rime icing study was performed. Rime icing modeling indicated that, under both 100% and 50% operating loads, there is a potential for many icing events during any given part of the year in which below-freezing weather conditions exist. The models showed that a critical amount of rime ice could be formed at the stack top during two or more events per year. CO 2 capture plant stack height and location will need to be determined in order to minimize the formation of rime ice. It was found that the integration of the MHI CO 2 capture process into the normal operation of the MRY2 steam turbine is a viable alternative to a cogeneration facility to provide steam and power for the carbon capture facility. The research performed under this project showed that CO 2 capture at a lignite-fired power plant can successfully be performed. No known fatal flaws that would prevent the continued development of the MRY2 CO 2 capture facility were identified during the pre-FEED study. A TEA performed following DOE methodology shows that applying capture technology to MRY2 may not only meet but exceed the DOE-recognized state-of-the-art baseline.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2014

Classifier-guided sampling for discrete variable, discontinuous design space exploration: Convergence and computational performance

A classifier-guided sampling (CGS) method is introduced for solving engineering design optimization problems with discrete and/or continuous variables and continuous and/or discontinuous responses. The method merges concepts from metamodel-guided sampling and population-based optimization algorithms. The CGS method uses a Bayesian network classifier for predicting the performance of new designs based on a set of known observations or training points. Unlike most metamodeling techniques, however, the classifier assigns a categorical class label to a new design, rather than predicting the resulting response in continuous space, and thereby accommodates nondifferentiable and discontinuous functions of discrete or categorical variables. The CGS method uses these classifiers to guide a population-based sampling process towards combinations of discrete and/or continuous variable values with a high probability of yielding preferred performance. Accordingly, the CGS method is appropriate for discrete/discontinuous design problems that are ill-suited for conventional metamodeling techniques and too computationally expensive to be solved by population-based algorithms alone. In addition, the rates of convergence and computational properties of the CGS method are investigated when applied to a set of discrete variable optimization problems. Results show that the CGS method significantly improves the rate of convergence towards known global optima, on average, when compared to genetic algorithms.

42 ENGINEERING↗