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All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Techno-Economic Assessment for Opportunities to Integrate Algae Farming with Wastewater Treatment

This report investigates the economic and scalability potential for algal biomass production based on opportunities to couple algae farming with wastewater treatment (WWT). This activity was motivated in part by a recent influx of technology developers who are currently in various stages of planning, construction, and operation of algae facilities for treating municipal wastewater, all making claims of tremendous economic potential for algal WWT relative to other more traditional WWT methods when viewing treated wastewater as the primary product output and algal biomass as a secondary coproduct. In addition to solving for minimum biomass selling price (MBSP) for a farm configured to maximize biomass production while minimizing water footprint (when sourcing makeup water from local groundwater resources at added cost), the algal WWT cases evaluated here also solved for MBSP while assigning a treatment credit as a means to valorize the treated water as a coproduct in the farm model. This enables a consistent comparison against the National Renewable Energy Laboratory’s standard algae farm models.

09 BIOMASS FUELS↗
DOE OSTI2022

Keyhole-mode Microscopy Dataset for Laser Powder-bed Fusion Modeling

Laser powder-bed fusion (LPBF) is an additive manufacturing (AM) technology that uses high-power sintering lasers to precisely construct metal designs. Material is accumulated by selectively sintering regions of a metal powder layer to a growing structure underneath forming a 3D geometry. Certain conditions make fusion in this process to operate in "keyhole-mode," characterized by targeted materials evaporating as plasma. While keyhole-mode operations can produce deeper molten pools than that observed in "conduction-mode", this mode of operation is often undesirable, as its molten regions can collapse on themselves, encapsulating metal vapors and forming cavities. The formation of such cavities negatively affects strength and consistency of the fused materials. To identify and avoid these detrimental effects of keyhole-mode operation, considerable data collection and analysis regarding this mode of operation is needed. Therefore, under the support of the "Open Data Initiative," Lawrence Livermore National Lab is releasing a dataset for analysis of this keyhole effect, and the conditions which transition operation from conduction-mode to keyhole-mode melting. This dataset consists of 600+ micrographs from laser powder-bed single track runs, with differing cross-section angles and input parameters, operating under both normal and keyhole mode operations. This journal documents the collection, organization, and usage of this dataset.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Report on Year-4 of Water NSTF Matrix Testing: Facility Maintenance and Accident Testing

Under support from the Department of Energy (DOE) and the Office of Advanced Reactor Technologies (ART), a large-scale test facility has been constructed at Argonne National Laboratory to generate NQA-1 qualified validation data for passive decay heat removal systems in advanced reactors. The Natural convection Shutdown heat removal Test Facility (NSTF) reflects key features of a ½ scale, water-based, Reactor Cavity Cooling System (RCCS) and is intended to study the behavior, bound performance, and ultimately guide design decisions for passive decay heat removal systems for advanced reactors. In addition to the experimental activities detailed in this report, a supportive computational modeling effort is on-going which has been demonstrated to significantly strengthen the experimental program while also improving accuracy of the computer models. Together these create a mutually beneficial relationship integral to meeting the overall program objective of examining the heat removal performance of the RCCS concept. This report serves as a summary of maintenance and experimental activities during the program’s fourth year of water-based operation. A planned six-month maintenance period began in August 2021, during which major inspections, repairs, cleaning, and installation of new instrumentation and data acquisition hardware were conducted. Most significantly, two heaters that faulted during Year-3 were repaired, allowing the facility to resume use of the full heated section area and full range of available electric power. The remainder of the year consisted of eight months of test operations, during which the facility logged 211 hours of active heating across one bake-out (following the maintenance period) and seven matrix tests; five classifieds as Accepted per NQA-1, one as Trending, and one as Failed. Testing began by performing two repeat cases to confirm expected facility response and behavior during both single- and two-phase flow conditions, ensuring no changes were introduced during the maintenance period that might have altered the thermal-hydraulic characteristics of the facility. In continuation of the power parametric series initiated in previous years, a high-power test case was then performed examining heat removal performance at a decay heat load equivalent to 2.4 MWt, full-scale, a level exceeding maximum design targets. Additional testing then introduced various blockage scenarios along the network piping, examining the effects of partial and complete blockages of the flow paths on the system behavior and heat removal performance. A study of static boiling tests directed at understanding the geysering two-phase instability was also conducted. The loop was filled only to the bottom of the tank outlet, creating an open loop configuration that prevents any natural circulation flow from occurring, and the heaters were powered on until the facility reached saturation conditions. Following, a series of quasi-steady-state conditions were introduced by adjusting the inventory level in the adiabatic chimney piping at decreasingly lower elevations above the heated region. A strong correlation of geysering characteristics and loop level was observed, with flow and temperature excursions decreasing in intensity, but increasing in frequency, as the fill were reduced to lower elevations along the chimney piping. Once the level fell very low in the chimney, at points near the top of the heated section, the system reached a stable state of continuous boiling without any occurrence of geysering eruptions. A final significant testing accomplishment this year was successful completion of an “accident scenario” test, whose operating conditions were based on a prototypic decay heat curve provided by Framatome and scaled for the NSTF. This test began by establishing steady-state, single-phase “normal operation” conditions, before simulating an accident trip where the availability of active cooling systems was lost. Loop temperatures gradually increased until reaching saturation and subsequent two-phase boiling flow. Over the course of an extended operational period along the defined decay heat curve, steam boil-off caused gradual but continued depletion of liquid inventory until reaching a critically low level causing flow stagnation and cessation of natural circulation heat removal. At this point, after nearly 72 hours of continuous operation, a cold refill was performed to replenish the system inventory and allow the facility to re-establish closed loop natural circulation flow and return to a safe operational state.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

FY23 Report on Water NSTF Testing at Two-Phase Conditions: Off-normal Scenarios

Under support from the Department of Energy (DOE) and the Office of Advanced Reactor Technologies (ART), a large-scale test facility has been constructed at Argonne National Laboratory to generate NQA-1 qualified validation data for passive decay heat removal systems in advanced reactors. The Natural convection Shutdown heat removal Test Facility (NSTF) reflects key features of a ½ scale, water-based, Reactor Cavity Cooling System (RCCS) and is intended to study the behavior, bound performance, and ultimately guide design decisions for passive decay heat removal systems for advanced reactors. In addition to the experimental activities detailed in this report, a supportive computational modeling effort is on-going which has been demonstrated to significantly strengthen the experimental program while also improving accuracy of the computer models. Together these create a mutually beneficial relationship integral to meeting the overall program objective of examining the heat removal performance of the RCCS concept. This report details the experimental activities and upgrades performed during the program’s fifth year of water-based operation. The theme of this year of testing was examining off-normal scenarios. In practice, that meant examining scenarios with blockages or other design basis conditions. From a maintenance and capability standpoint that meant assessing valving options for implementing blockages, assessing drain and refill capabilities, and ensuring in all cases that operators could safely, efficiently, and repeatably bring the facility to an off-normal condition and return it to the normal operating state. In one notable case, no solution existed, nor was a solution commercially available, that met the facility needs for implementing blockages within the two-phase region of the chimney. A valve and feedthrough were custom-designed for NSTF to operate submerged in saturated water while being safely actuated from outside the tank. The fifth year of testing included eight matrix tests consisting of 162 hours of active heating, 9,735 kWh of electrical heating, with seven tests classified as Accepted per NQA-1 and one as Trending. All matrix tests were performed at two-phase flow conditions. The power parametric series from previous years was extended to include another scenario with a decay load equivalent to 1.75 MWt, full scale, further resolving the system flow oscillation response as a function of input power. A depletion test was performed to extend previous work and examine the system’s approach to stagnation and geysering that were not previously observed. This test began at an initial inventory level of 50%, prototypic power of 2.1 MWt, and employed an accelerated drain of 0.75 gpm plus boiloff until stagnation conditions were achieved and multiple geysering events were recorded. Further exploring the geysering phenomenon was a separate effects test examining static boiling in the risers and chimney. This static boiling test was performed at 48 kWe, a higher power than testing in the previous year, and included enhancements to the drain system to remove inventory in a better-controlled and more reliable manner. Two tests were performed, at prototypic conditions of 1.4 MWt and 2.4 MWt, respectively, examining the system response to throttled conditions in the singlephase region of the piping. A ball valve immediately before he riser inlet header was increasingly throttled, progressing the system through a repeatable pattern of two-phase oscillations and stable regimes before ultimately inducing stagnation and geysering. Concluding the year, two tests were performed at baseline conditions of 70% initial inventory level and 2.1 MWt of prototypic decay heat to examine both repeatability and the response to throttling within the two-phase region, at the inventory tank inlet using the custom valve mentioned above. The first such test repeated transient operating conditions and revealed significant sensitivity t

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Feasibility Assessment of Using Electrical Impedance Tomography for Damage Localization in Graphite Microreactor Components

Microreactors have great potential to decrease capital costs and construction timelines, reducing the barriers to implementing advanced nuclear reactor technologies. However, the lower power output of these microreactors introduces economic challenges if the operation and maintenance costs cannot be reduced sufficiently. Many microreactor concepts use graphite materials for in-core moderator and structural purposes, which will require periodic inspection or, ideally, in situ structural health monitoring. This work describes an initial evaluation of the feasibility of leveraging graphite’s semiconducting properties to perform electrical impedance tomography (EIT) for defect localization. First, a study was performed to identify the best methods for bonding electrical contacts to minimize the effects of contact resistance that interfere with impedance measurements of the graphite. After determining the best bonding approach, electrodes were attached to multiple graphite components with varying geometries (e.g., simple block and more representative microreactor hexagonal block). In parallel, finite element analysis approaches were developed and implemented to analyze the impact of defects and contact resistances and to inform an iterative inverse model for reconstructing the conductivity distribution. The results of this study show that defect localization in graphite components is possible using EIT if a sufficient number of electrodes (to improve spatial resolution) can be bonded using a technique with very low contact resistance and those contact resistances remain stable during reactor operation. If the reactor core and vessel design do not allow electrodes to be bonded during reactor operation, then it may be possible to detach/reattach electrodes between reactor operation and outages if a suitable mechanical connection that offers repeatable contact resistance can be identified. Alternatively, future work could focus on identifying contacts that can survive the harsh reactor operating environment so that contacts do not need to be removed.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Verdant Power: Thermoplastic Blade Validation at Full Scale

For the first time in history, thermoplastic composite blades, which have the potential to revolutionize the marine energy industry, are being validated on a large-scale tidal power turbine. Thanks to funding from the U.S. Department of Energy's Water Power Technologies Office and a collaboration with Verdant Power, NREL researchers constructed thermoplastic composite turbine blades and are validating their performance on one of Verdant Power's tidal turbines deployed in New York City's East River.

HYDRO ENERGY↗
DOE OSTI2020

Opening the Door to Grid-Interactive Efficient Buildings with Energy Codes

Building codes represent standard design practice in the construction industry and must continually evolve to account for advancing technologies and innovative practices. Energy codes have historically focused on energy efficiency within buildings and across their systems. However, many of tomorrow's technologies go beyond efficiency and target increased flexibility. These demand flexibility (DF) measures can postpone or reduce building electric load based on price or other grid signals, and include smart appliances, connected lighting, and connected mechanical systems. Expanding codes to enable such grid-interactive efficient building (GEB) has the potential to influence their realization at scale, which will support renewable-energy grid-integration and building-sector decarbonization. However, considering DF measures in code development creates a new set of challenges for codes and the practices contained therein. This paper considers the role of building energy codes in enabling GEB. Specifically, it reviews the status of demand flexibility (DF) measures in current commercial building energy code. It examines the national model code development process and identifies components barring the consideration and inclusion of DF measures - including code scope, characterization and analysis of proposed new prescriptive measures, and accounting for time-of-day and geographic differences in their benefits. The paper presents findings from code development analyses that indicate the cost benefit of DF measures and the limitations associated with current code development conventions. To encourage building flexibility and improved energy resilience moving forward, recommendations are made for removing code development barriers and sanctioning DF measure consideration in future model codes.

Building Energy Codes and Standards, Grid-Interact↗
DOE OSTI2025

Rare Earth Extraction and Concentration at Pilot-Scale from North Dakota Coal-Related Feedstocks (Final Technical Report)

The objectives of this project were to design, construct, commission, and operate a pilot-scale system utilizing UND's REE extraction technology from lignite, and complete saleability and economic evaluations of products. The process includes a dilute-acid extraction process from low-rank-coals, followed by selective precipitations and further processing to produce mixed rare earth oxide materials. The pilot was successfully constructed to a 1,000 lb/hr nameplate capacity and tested with over 100 tons of >300-ppm lignite-based feedstocks and produced saleable-quality products during operation. The team successfully attained a TRL status of 6 with the completion and testing of the pilot system, and the technology is poised for demonstration at a commercial scale.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2020

Volume I. Introduction to DUNE

The preponderance of matter over antimatter in the early universe, the dynamics of the supernovae that produced the heavy elements necessary for life, and whether protons eventually decay -- these mysteries at the forefront of particle physics and astrophysics are key to understanding the early evolution of our universe, its current state, and its eventual fate. The Deep Underground Neutrino Experiment (DUNE) is an international world-class experiment dedicated to addressing these questions as it searches for leptonic charge-parity symmetry violation, stands ready to capture supernova neutrino bursts, and seeks to observe nucleon decay as a signature of a grand unified theory underlying the standard model. The DUNE far detector technical design report (TDR) describes the DUNE physics program and the technical designs of the single- and dual-phase DUNE liquid argon TPC far detector modules. This TDR is intended to justify the technical choices for the far detector that flow down from the high-level physics goals through requirements at all levels of the Project. Volume I contains an executive summary that introduces the DUNE science program, the far detector and the strategy for its modular designs, and the organization and management of the Project. The remainder of Volume I provides more detail on the science program that drives the choice of detector technologies and on the technologies themselves. It also introduces the designs for the DUNE near detector and the DUNE computing model, for which DUNE is planning design reports. Volume II of this TDR describes DUNE's physics program in detail. Volume III describes the technical coordination required for the far detector design, construction, installation, and integration, and its organizational structure. Volume IV describes the single-phase far detector technology. A planned Volume V will describe the dual-phase technology.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2024

Hydropower Supply Chain Gap Analysis

In 2022, DOE conducted supply chain "deep dives" for renewable energy technologies, including hydropower (Uria-Martinez, Hydropower Industry Supply Chain Deep Dive Assessment 2022). The deep dive identified several challenges in the current hydropower supply chain. In addition, Nguyen et. al (2022) conducted an analogous deep-dive assessment on large (> 100-MW) power transformers (LPTs), a critical component of hydropower installations, and concluded that the LPTs as well as several upstream components and materials also have domestic supply chain challenges. These deep dives were the initial high-level assessments of these supply chains and were focused on identifying the biggest issues. Both recommended further investigation. In the two years since the deep dives were published, the Water Power Technologies Office (WPTO) has focused on improving our understanding of the hydropower supply chain and developing strategies for addressing these challenges. Because the challenges outlined above are most acute for large hydropower systems, most of the report and specifically, this report concentrates on the larger > 100-MW hydropower systems. Early in 2023, DOE's Secretary of Energy asked the Water Power Technologies Office (WPTO) to engage the hydropower community and seek input on strategies to secure and encourage domestic manufacturing. WPTO has established three focus areas for engagement: 1) Define the market for planned rehabilitations and new construction of the domestic fleet, 2) Provide insights for policies, incentives, loan programs, and technology investments to encourage domestic content, and 3) Define the existing and required domestic hydropower manufacturing capabilities and workforce. This report summarizes these efforts and complements the earlier work by further exploring the identified challenges and identifying potential actions to address these challenges. Furthermore, we conducted a detailed gap analysis of the domestic hydropower supply chain, down to the component level. From this analysis, we then make specific, actionable recommendations for closing these gaps. Section 2 of the report summarizes recent (i.e., since 2021) legislation impacting hydropower deployment and/or its supply chain. It then describes the efforts of WPTO to assess and improve the hydropower supply chain since the publication of the deep-dive assessments. In Section 3, the report updates the earlier supply chain and market studies, identifying specific capabilities by company and location. Section 4 outlines the hydropower demand signal for both new builds due to clean energy goals as well as refurbishments and upgrading of the current domestic fleet. Section 5 is a detailed gap analysis while Section 6 provides actionable recommendations for closing the gaps. Section 7 concludes the report by linking the recommendations to the identified gaps and discusses future efforts.

13 HYDRO ENERGY↗
DOE OSTI2023

High-throughput genetic engineering of nonmodel and undomesticated bacteria via iterative site-specific genome integration

Efficient genome engineering is critical to understand and use microbial functions. Despite recent development of tools such as CRISPR-Cas gene editing, efficient integration of exogenous DNA with well-characterized functions remains limited to model bacteria. Here, we describe serine recombinase–assisted genome engineering, or SAGE, an easy-to-use, highly efficient, and extensible technology that enables selection marker–free, site-specific genome integration of up to 10 DNA constructs, often with efficiency on par with or superior to replicating plasmids. SAGE uses no replicating plasmids and thus lacks the host range limitations of other genome engineering technologies. We demonstrate the value of SAGE by characterizing genome integration efficiency in five bacteria that span multiple taxonomy groups and biotechnology applications and by identifying more than 95 heterologous promoters in each host with consistent transcription across environmental and genetic contexts. We anticipate that SAGE will rapidly expand the number of industrial and environmental bacteria compatible with high-throughput genetics and synthetic biology.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2021

Construction, characterization and crystal structure of a fluorescent single-chain Fv chimera

In vitro display technologies based on phage and yeast have a successful history of selecting single-chain variable fragment (scFv) antibodies against various targets. However, single-chain antibodies are often unstable and poorly expressed in Escherichia coli. Here, we explore the feasibility of converting scFv antibodies to an intrinsically fluorescent format by inserting the monomeric, stable fluorescent protein named thermal green, between the light- and heavy-chain variable regions. Our results show that the scTGP format maintains the affinity and specificity of the antibodies, improves expression levels, allows one-step fluorescent assay for detection of binding and is a suitable reagent for epitope binning. We also report the crystal structure of an scTGP construct that recognizes phosphorylated tyrosine on FcεR1 receptor of the allergy pathway.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2021

Economic risk analysis for the capture of a distributed energy resource using modular chemical process intensification

Recent advances in the chemical process industry have allowed for the intensification of reactors and unit operations, by enhancing heat and mass transfer or combining multiple unit operations. Process intensification can enable chemical plants to be constructed in a more compact, modular fashion, offering improvements over conventional on-site approaches to capital construction, operations and maintenance. This modular chemical process intensification (MCPI) offers several benefits over conventional stick-built (CSB) plant construction in terms of reduced footprint, reduced energy consumption, lower cost, less waste and improved safety and quality control. However, acceptance of MCPI over CSB construction practices within the chemical industry can be impeded by the uncertain risks associated with investing in new technology. Furthermore, the work here documents a case study during the development of a modular chemical plant for capturing distributed energy resources within chemical production. This MCPI approach to plant construction is contrasted with a CSB approach for producing the same chemical product. Data collection tools were developed, based on a literature review, and data was collected from the technology developer to understand the process technology. Sensitivity analysis was then conducted to analyze the business rationale for the application of MCPI over CSB across several market scenarios. It was found that MCPI would be better suited for capacities up to 150 000 metric tons per year, but that improvement in payback period was needed. Additionally, for MCPI approach to achieve acceptable payback periods, efforts are needed to reduce the cost of capital equipment and compress the schedule for ramping up modular production.

42 ENGINEERING↗
DOE OSTI2022

U.S. Building Stock Characterization Study: A National Typology for Decarbonizing U.S. Buildings

To support the U.S. Department of Energy's (DOE's) Advanced Building Construction (ABC) Collaborative, the National Renewable Energy Laboratory (NREL) has been tasked with characterizing the U.S. building stock and developing a national typology of buildings. The potential use cases of such a typology are flexible and evolving, but in this initial phase, the primary intention is to help identify technology requirements and engineering solutions for moving the U.S. building stock toward a zero-carbon future by mid-century. This typology will also support the development of appropriate ABC research goals for existing buildings, such as cost targets for new technology development, and in a later phase, the typology can be used to support the implementation of ABC solutions by informing market aggregation and business model development. The ABC Initiative invests in new technologies that enable high building performance, can be deployed quickly with minimal onsite construction time, and are affordable and appealing to building owners, investors, and occupants. Funding awardees use many innovations, including new building materials, 3D printing, offsite manufacturing, robotics, and digital art-to-part. Although the goals of ABC cover a broad range of objectives around energy, comfort, and health, the primary ABC-related application of this national building characterization study is the development of retrofit packages that can be applied to reduce thermal loads in buildings. Retrofit packages will be determined collaboratively by the DOE and the ABC Collaborative. We anticipate a range of upgrade measures covering envelope-, HVAC-, and water-heating-related loads.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

Molten Salt Loop Testing of Sensors and Off-Gas Components: FY23 progress

The Liquid Salt Test Loop (LSTL) at the US Department of Energy’s (DOE’s) Oak Ridge National Laboratory (ORNL) was developed to demonstrate technology for high-temperature fluoride salt systems (Figure 1). The LSTL is primarily constructed using Inconel 600 alloy and operates at temperatures of up to 700°C. The facility is loaded with 165 kg of LiF-NaF-KF salt (FLiNaK). This salt provides a relevant test environment for de-risking technology while avoiding the costs and hazards associated with beryllium-based or uranium-bearing salts. FLiNaK is also an advantageous salt for the secondary side of molten salt reactors. The facility’s major components include a centrifugal pump for salt circulation, an air-based heat exchanger to reject heat, a suite of instrumentation, and trace heating to prevent salt freezing. Additional heating is available through an induction heater rated at 200 kW. The relatively large heating and cooling capability enables the formation of a temperature gradient across the loop (i.e., a hot and a cold side), which is important for chemistry and corrosion studies. The LSTL is a unique US capability for high-temperature molten halide salt testing. Although some efforts are underway at universities, the LSTL’s scale, co-located purification system, and relatively large power differentiates it from other testing systems. Furthermore, unlike efforts within industry, access to the DOE-supported facility and communication of results, which are generally disseminated publicly, result in a broad significance in the molten salt reactor community.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

Stellarator Simplification using Permanent Magnets (PM4Stell)

This Report describes the design and prototyping of an array of rare-Earth permanent magnets to form a stellarator. This effort was motivated by the hypothesis that the usage of permanent magnets, rather than electromagnetic coils with complex geometry, could reduce the cost of stellarator construction and thereby make increase the feasibility of the stellarator as a technology for a fusion-based power plant. In this project, we have developed novel methods for specifying the positions, shapes, and polarizations of the magnets in the array, and have developed designs for mounting structures and tooling for assembly. We have also performed detailed finite-element modeling to qualify the accuracy of the magnetic field produced by the magnet array as designed, and to confirm that the structure can withstand the forces between the magnets. We have also developed techniques for measuring the magnetic field produced by the array once constructed, as well as for correcting errors in the field arising from misalignments and offsets within the tolerances for mounting and fabrication. Finally, we have constructed a tabletop prototype of a section of the array to qualify the concept for assembling and mounting magnets within the array.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Development of Low-Cost, High-Performance, Easy-To-Apply, Non-Flammable, Inorganic Phase Change Material (PCM) Technology (Project Final Report)

This report describes a 45-months long research program focused on the development of novel, easy-to-apply, non-flammable, and high-performance inorganic phase change materials (PCMs) for building and industrial applications. The University of Massachusetts Lowell (UML) formed a world-class team consisting of researchers form InsolCorp (only N. American manufacturer of inorganic PCM systems for building applications), and a group of industrial advisors, to develop a universal/multipurpose, simple-to-manufacture and cost-effective PCM technology. The project team expects that the results of this work will spur in the future the adoption of thermal storage materials – a key building energy saving technology as identified by DOE BTO – for a variety of building envelope applications. The main goal of this project was to demonstrate a suite of low-cost, multipurpose, and durable inorganic PCM formulations with phase transition temperatures encompassing typical building applications (between +5 o C and +55 o C). The first objective was to design, fabricate, and experimentally validate a performance of inexpensive, durable, highly efficient, non-flammable, and easy to manufacture PCMs. To allow a variety of building applications, the project team focused on formulations that exhibit repeatable phase transitions between +5 o C and +55 o C. To follow the DOE BTO cost efficiency target without compromising thermal performance, our work was based on inorganic compounds (mostly salt hydrates) and their blends, which represent a fraction of the cost of most of organic PCMs with about twice as high density as well as significantly higher thermal conductivity and phase change enthalpy. The second objective was to develop easy-to-manufacture and -install packaging/encapsulation designs that are 1) a superior barrier to current state-of-the-art macro-packaging, which significantly reduces the risk of loss of hydration water and PCM leak, and 2) optimal in enhancing the heat exchange rates with the surroundings and within the PCM core to ensure complete charging/discharging of the entire PCM within the product. Finally, the project’s intend was to scale-up the fabrication process to demonstrate installation on system-scale applications, and to validate the performance under field conditions. This work aimed at developing low-cost, high-energy storage, and reliable latent heat storage technology for building applications. This development was realized by formulating and integrating the following two technology components: 1) inorganic salt hydrate based PCMs that have high latent enthalpies and are low-cost and durable, and 2) PCM encapsulation (packaging) technology that maximizes PCM concentration and enhances heat transport characteristics in the product and with the external environment/materials. High thermal storage capacity, low cost and fire resistance are key to the building market entry for PCM technology. Therefore, the project’s focus was on salt-hydrate-based formulations which satisfy all these criteria. Packaging and/or encapsulation of PCM is a key processing step. The project team recognized that a low-cost and simple-to-manufacture salt hydrate-based PCM technology holds the best chance to be successful in the building construction market, a market which is traditionally extremely sensitive to cost and where commodity thermal insulations are the benchmark for envelope-related energy saving measures. That is why, in this project, the main intention was to minimize the production cost and maximize the product energy storage density without sacrificing the PCM performance. It was achieved through: 1. Minimizing the non-PCM components (plastics, additives, packaging/encapsulation materials, etc.) because they are significantly more expensive than salt hydrates, 2. Using highly thermally conductive and lightweight PCM carrier (packaging material) to facilitate more complete phase cycling, and 3. Optimizing the thickness and minimizing air spaces in product design (such as in pouched PCM). For this purpose, our approach was to enable an easy system design, including selection of the PCM operating temperatures, optimizing the necessary heat storage capacity (by stacking together several layers of PCM products), and if needed, a synchronized usage of PCM products of different temperatures. A specially designed, robust, highly thermally conducting and highly impermeable packaging (to retain salt hydrate water during phase transition cycles) was designed and tested to increase the overall system thermal performance and durability. All PCM products developed during this project were tested in both lab scale and in full scale field conditions. It is expected that, after further developments and commercialization, the developed PCM technologies may be also applied in space conditioning, energy storage technologies, and heat transfer applications.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Hybrid data-driven cement-stabilized soil design: An integration of machine learning, multi-objective optimization, and life cycle assessment

Soil stabilization is crucial in geotechnical engineering, yet conventional methods are often time-consuming, resource-intensive, and environmentally unsustainable. Despite growing interest in Machine Learning (ML) and optimization tools for mix design, few studies integrate these methods with decision-making techniques and environmental assessment to support practical implementation. This study proposes a hybrid data-driven framework for predicting strength, optimizing mix compositions, and evaluating environmental impacts via life cycle assessment of cement-stabilized soft soils. Six ML models were evaluated, and the top-performing eXtreme Gradient Boosting (XGB) model was further improved using the Grey Wolf Optimizer (GWO). The optimized XGB-GWO model, integrated with a polynomial cost function, served as the objective function in a multi-objective optimization problem solved via the Non-Dominated Sorting Genetic Algorithm II (NSGA-II), with final mix selection guided by the entropy-weighted TOPSIS method. Validation through a case study produced mix designs offering superior strength-cost trade-offs, with the optimal mix achieving 2243.2 kPa unconfined compressive strength and a 16.07 % reduction in carbon emissions compared to the highest-cost design. In conclusion, this study offers a sustainable, scalable approach to soil stabilization and supports informed decision-making in construction.

Life cycle assessment↗