Results for “Equipment Design” — Page 2

DOE OSTI2025

BESS Digital Assurance, Supply Chain Risk Management, and Emerging Regulation Session One

The TADA BESS Supply Chain Workshops are designed to equip participants with the knowledge and tools necessary to address the evolving challenges at the intersection of battery energy storage systems (BESS), cybersecurity, and supply chain vulnerabilities. The workshops emphasize the application of Cyber-Informed Engineering (CIE) principles using INL’s procurement guide and the CIE-BAT tool. Attendees will develop risk-based security strategies and actionable compliance roadmaps tailored to their BESS projects. Additionally, the program fosters a collaborative network of practitioners and provides guidance on navigating emerging regulatory requirements, including FEOC rules under the OBBB framework, to assess and enhance organizational readiness. This is Session 1 of 3. (Full Version)

25 - ENERGY STORAGE↗

DOE OSTI2025

Design and Development of the Handling Frame Assembly Table for the NIF Sustainment Project (Draft)

The Handling Frame Assembly Table is a custom designed piece of equipment developed to support the NIF Sustainment Project. The NIF Sustainment project's goal is to refurbish the National Ignition Facility (NIF), the world’s largest and most energetic laser, so it can continue advancing research in fusion energy, national security, and high energy density physics. A key aspect of this effort involves replacing all 1,728 blast shields on the NIF, which requires specialized equipment such as the Handling Frame Assembly Table to support the production of new blast shields. This project follows a systems engineering approach that guides the design sequence. This report documents the design process from initial concept through final design, including stakeholder analysis, requirements development, conceptual design, design analysis and validation, and final design. Future work will focus on building and commissioning the system.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2026

Design and Development of the Handling Frame Assembly Table for the National Ignition Facility Blast Shields

The Handling Frame Assembly Table is a custom designed piece of equipment developed to support the NIF Sustainment Project. The goal of the NIF Sustainment Project is to refurbish the National Ignition Facility (NIF), the world’s largest and most energetic laser, so it can continue advancing research in fusion energy, national security, and high energy density physics. A key aspect of this effort involves replacing all 1,728 blast shields on the NIF, which requires specialized equipment such as the Handling Frame Assembly Table to support the production of new blast shields. This project follows a systems engineering approach that guides the design sequence. This report documents the design process from initial concept through final design, including stakeholder analysis, requirements development, conceptual design, final design, and design validation. Future work will focus on building and commissioning the system.

42 ENGINEERING↗

DOE OSTI2026

Design and Development of the Handling Frame Assembly Table for the National Ignition Facility Blast Shields

The Handling Frame Assembly Table is a custom designed piece of equipment developed to support the NIF Sustainment Project. The goal of the NIF Sustainment Project is to refurbish the National Ignition Facility (NIF), the world’s largest and most energetic laser, so it can continue advancing research in fusion energy, national security, and high energy density physics. A key aspect of this effort involves replacing all 1,728 blast shields on the NIF, which requires specialized equipment such as the Handling Frame Assembly Table to support the production of new blast shields. This project follows a systems engineering approach that guides the design sequence. This report documents the design process from initial concept through final design, including stakeholder analysis, requirements development, conceptual design, final design, and design validation. Future work will focus on building and commissioning the system.

42 ENGINEERING↗

DOE OSTI2024

ILAW Container Cost Reduction and Optimization Study

This study, performed on behalf of Washington River Protection Solutions (WRPS), examines the potential for making cost savings for the Immobilized Low Active Waste (ILAW) containers over the mission life of the Waste Treatment and Immobilization Plant (WTP). it builds on earlier study assessments 24590-LAW-RPT-M-01-001 Rev 0 ILAW Product Container Specifications Optimization Study and DOE/ORP-2013-02 Rev 0 Decision Analysis of Low-Active Waste Container Finishing Handling System Alternatives. The WTP design and installed equipment has evolved over an extended period ~20 years. Consequently, some of the existing requirements relating the ILAW containers may no longer be applicable under current mission plans where the glass filled containers are placed into the Integrated Disposal Facility (IDF) rather than stacked in an engineered purpose-built ventilated store as originally envisioned. The study team reviewed available WTP project reference documents to establish the functions the container must perform and assign requirements against each of these functions. With the assumptions that some of the existing WTP contract restrictions would not necessarily apply to the subsequent facility operations contract the container requirements were reviewed to identify those which were ‘hard constraints‘, imposed by regulatory requirements. Initially each of these hard constraints were reviewed, evaluated and documented to see if they precluded the use of an alternate less expensive material of construction, carbon steel, to the existing 304 L stainless steel in the current container specification. That review did not generate any fatal flaws for a change in material of construction to carbon steel allowing the study team to examine the impacts of material cost savings, potential changes to the design and requirements and impacts on interfaces of the containers with the existing WTP process equipment from container receipt, transfers, glass filling, cooling and export. In addition, a change in container target fill level was evaluated and qualitative, and quantitative where feasible, impacts to the container fabrication process assessed. Lastly, additional follow on development or testing activities to support the use of carbon steel were assessed and a recommended path forward with a ROM cost and timescale developed.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2025

Cost analysis of alternative large-scale high-temperature solid oxide electrolysis hydrogen production facilities

We extend our past cost analysis of gigawatt-scale solid oxide electrolysis (SOE) facilities that produce high purity hydrogen gas from water by estimating construction and operating costs for three new alternative design cases: (1) offsite feed steam generation; (2) near-atmospheric pressure (NAP) stack; and (3) onsite electric boiler feed steam generation. Pressure effects on hydrogen electrode-(cathode-)supported SOE cell (SOEC) stack performance are estimated for the same assumed cell and stack construction and used to determine facility-wide stack capital costs for achieving a fixed H2 production at different pressures. Modular balance of plant (BOP) process equipment capital costs are estimated for each new alternative design case using our past equipment sizing, design, and cost data and scaling relationships. Furthermore, we update BOP equipment sizing and design for the NAP case using Aspen®. Vendor quotes for electric boilers are used to estimate costs for the electric boiler design case. Factory and onsite assembly and installation costs for SOEC stacks and BOP equipment are calculated using our past simplified first-principles approach. First-of-a-kind (FOAK) and N th -of-a-kind (NOAK) production maturity cost estimates are included for all results. The case with NAP stacks offers the lowest facility total capital cost (TCC, ~23% lower than base) while use of small electric boilers requires the highest TCC (~3% higher than base). H 2 production prices decrease from the base of ~$\$2.17$ /kgH 2 to ~$\$1.92$/kgH 2 for 1 GW e DC SIP facilities utilizing NAP stacks supplied by offsites steam situated in large modules and blocks for $\$0.030$/kWh e and $0.009/kWh t prices for electricity and thermal energy, respectively. We report all costs in 2021 US dollars.

Balance of plant (BOP) process equipment↗

DOE OSTI2026

High-Accuracy and High-Stability Fiber-Optic Temperature Sensors for Coal Fired Advanced Energy

A research team at Michigan State University, led by Dr. Ming Han, has developed a revolutionary fiber-optic thermometer for use in next-generation coal-fired power plants. Funded by the U.S. Department of Energy, this new sensor is designed to measure extremely high temperatures with unmatched accuracy and long-term stability. Unlike conventional optical sensors that can give false readings due to mechanical strain and often drift out of calibration at high heat, this new technology uses a sealed gas chamber as its core. By measuring the temperature-dependent properties of the gas (air or argon), the sensor’s readings remain absolute and reliable, completely unaffected by the physical stresses on the surrounding equipment. The breakthrough design eliminates the need for complex and costly correction systems. It represents a fundamental shift in sensing technology, paving the way for a primary thermometer that maintains calibration and provides foundational accuracy essential for advanced energy systems.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2025

Rheological Properties of Enzymatically Hydrolyzed Corn Stover Pretreated via Deacetylation and Mechanical Refining

Lignocellulosic biomass is a feedstock for fuels and chemicals that does not compete with food resources and has less contaminants than refuse-derived biomass feedstocks. To convert lignocellulosics to biofuels or value-added products, multiple processing steps are typically necessary. One method of producing biofuels from lignocellulosic biomass utilizes a deacetylation and mechanical refining pretreatment and an enzymatic hydrolysis reaction to produce fermentable sugars from cellulose and hemicellulose. The rheological properties of biomass, such as yield stress and plastic viscosity, change during enzymatic hydrolysis and alter the energy requirements for pumping and mixing, an important consideration for the design of processing equipment. The dynamic changes in rheological properties that occur in a corn stover feedstock undergoing enzymatic hydrolysis are characterized in this work, and the influence on pressure losses in piping systems is estimated. Two rheometer geometries were fabricated with stereolithography 3D printing to reduce wall slip and sample ejection. The slurries have complex rheological behaviors that include shear-thinning behavior. Shear stress ramps were performed on samples at 20 and 50 degrees C using the custom geometries, and the Herschel-Bulkley model was fit to the data. The dynamic nature of the rheological properties is correlated with changes in the average fiber length at various extents of reaction, and the influence of solids concentration on the observed rheology and piping pressure losses is discussed.

09 BIOMASS FUELS↗

DOE OSTI2025

Autonomous Fueling System for Heavy-Duty Fuel Cell Electric Trucks

The motivation for this project stemmed from the challenges associated with rapidly refueling heavy-duty hydrogen fuel cell electric trucks (FCETs). Current manual refueling processes for fast refueling involve large, heavy equipment (e.g., hoses three times heavier than standard) and pose ergonomic risks and potential for equipment damage. The goal was to develop and test an autonomous fueling system to improve ergonomics, enhance safety, increase equipment durability through design improvements, and potentially speed up the fueling process. This project aimed to add to the understanding of autonomous systems in the context of heavy-duty hydrogen refueling, evaluating the technical effectiveness of potential concepts. A successfully developed system would benefit the public by facilitating the adoption of zero-emission heavy-duty transport, reducing reliance on manual labor for a physically demanding task, and potentially improving the safety and efficiency of hydrogen refueling infrastructure. The major accomplishment during the project's active period was the completion of the system-level architecture task. This involved establishing a detailed list of system requirements covering interfaces, environmental conditions, regulatory compliance, industry standards, safety, security, performance capabilities, and optional features. Five key use cases for the autonomous system were also identified. However, due to internal restructuring at Nikola, the necessary resources could not be allocated to continue the project. Consequently, Nikola opted to discontinue the project. The award was mutually terminated by Nikola and the DOE.

08 HYDROGEN↗

DOE OSTI2025

Fermilab's controls development with virtual accelerator

Control Systems development is often the last thing considered when designing and building new equipment, e.g. a new detector or superconducting RF LINAC; however when the new equipment is installed, it is the first thing desired to be operational for testing. Due to frequent delays in building new equipment and project deadlines, control system development and testing is often curtailed. A way to alleviate this problem is to simulate the control system, though this will be challenging for complex systems.The Fermilab PIP-II (proton improvement plan - II) project is being constructed at Fermilab to deliver $800\,MeV$ protons of $>1\,MW$ beam power to replace the present LINAC for the remainder of the existing accelerator complex. The new LINAC consists of a warm front end (WFE), 23 superconducting RF cryomodules (of 5 types), and a beam transfer line (BTL) to the existing complex.The accelerator physics group has a parallel project to create a digital twin (DT) of the PIP-II accelerator. We have coupled the EPICS controls to this DT and are developing both the DT and EPICS software in parallel. This will allow us to develop the EPICS software framework, the HMIs, sequences, high level physics applications, and other services for use in a fully functional control system.This presentation will detail the work that we have performed to date and show demonstrations of controlling and monitoring the status of the accelerator, as well as future plans for this work.

Hanlet, Pierrick [Fermilab]↗

DOE OSTI2026

Comparison of juvenile white sturgeon blade strike survival through a conventional and a novel hydropower turbine

Hydropower is a globally important renewable energy source with profound impacts on aquatic organisms, including direct injury and mortality to fish that move through hydropower facilities. While it is expected that the characteristics of turbine design and operation influence the type, frequency, and magnitude of injuries suffered by entrained fish, few direct comparisons exist to illustrate differences in fish survival outcomes for conventional and novel turbine designs. This study evaluated blade strike-associated injury and mortality rates for juvenile white sturgeon (Acipenser transmontanus) passed through a model-scale turbine equipped with a runner having conventional blade profiles (thin, straight leading edges) and the same turbine equipped with a runner designed for improved fish survival (thick, slanted leading edges). In both trials, head and turbine runner rotational speeds were matched to produce five blade peripheral speeds between 15.0 and 27.6 m/s. High-speed video was captured for all turbine passage events. Fish were assessed for injuries following passage, and mortalities were assessed immediately after passage and after 48 h. Conventional runner passage resulted in 42% to 78% survival after 48 h, with approximately one-third of all tested fish killed by severing. Under the same test conditions, immediate and 48 h survival rates through the novel runner were 100% except at the highest speed condition (95.6% survival at 48 h). These results clearly indicate that turbine design has a profound effect on fish survival, and suggest that thoughtful redesign of hydropower equipment could significantly ameliorate the risks of blade strike mortality.

13 HYDRO ENERGY↗

DOE OSTI2026

Manufactured Home Equipment Sizing and Selection Tool

This tool is for use for manufactured homes built to the HUD Code (thermal provisions of the Manufactured Housing Construction and Safety Standards, Subpart F, Section §3280), including manufactured homes certified as ENERGY STAR® and DOE Efficient New Homes. It provides a simple look-up procedure to assist equipment specifiers, HVAC contractors, home installers, retailers, manufacturers, and electric utility staff. For new manufactured homes, it guides in selection of single speed heat pumps and air conditioners. For existing homes, it determines design conditions and nominal equipment size. The guidelines provide a simple but accurate procedure that reduces oversizing and its associated problems.

Source record↗

DOE OSTI2026

An Online Tool for Preliminary Design and Techno-Economic Analysis of District Geothermal Heating and Cooling Systems

District geothermal heating and cooling systems (DGHCS) have significant benefits for reducing energy consumption as well as building- and grid-level peak electric demand. Currently, no publicly available tools are available to effectively design and conduct techno-economic analysis of DGHCS. GeoWISE was originally developed for preliminary design and techno-economic analysis of geothermal heating and cooling systems in an individual commercial or residential building. This paper introduces recent upgrades of GeoWISE that allow users to design and conduct techno-economic analysis of DGHCS. Several new features are implemented in GeoWISE to allow selection and specification of multiple new or existing buildings. A database of information for over 125 million existing U.S. buildings was used in GeoWISE that allows users easily locate existing buildings of interest based on street addresses, and optionally edit information of the buildings (e.g., footprint, vintage, principal functions, number of floors, window-to-wall ratio). Unique energy simulation models of the selected buildings are then automatically created using the Automatic Building Energy Modeling (AutoBEM) and EnergyPlus simulations are performed to predict thermal loads of the buildings. A simplified DGHCS is then designed and simulated to predict its energy use. A central borehole heat exchanger (BHE) of the DGHCS is sized using the RowWise algorithm of GHEDesigner to meet the thermal loads within user-specified land areas for installing BHE. The upgraded GeoWISE reports the needed capacity of heating and cooling equipment in each building, design of the central BHE, energy consumption reduction, and energy cost saving resulting from using DGHCS compared with conventional HVAC systems. A case study is showcased using the upgraded GeoWISE to design and conduct techno-economic analysis of a simplified DGHCS.

Prem Anand Jayaprabha, Jyothis Anand [ORNL] (ORCID↗

DOE OSTI2025

Reducing the Energy Consumption of Magnetic Resonance Imaging and Computed Tomography Scanners: Integrating Ecodesign and Sustainable Operations

This review aims to provide valuable insights into how energy consumption in magnetic resonance imaging (MRI) and computed tomography (CT) scanners can be effectively monitored, managed, and reduced, thereby contributing to more sustainable medical imaging practices. Demand for advanced imaging technologies such as MRI and CT scanners continues to increase, and understanding the resultant impact on greenhouse gas emissions requires a thorough evaluation of their energy consumption. Here, this review examines the energy monitoring and consumption characteristics of MRI and CT scanners, highlighting potential approaches for energy savings. An overview of MRI and CT principles, hardware components, and their associated energy consumption is provided. After addressing the technical aspects, the hardware and software requirements essential for accurate energy metering are detailed. Baseline measurements of energy consumption data are then provided as a foundation to understand current usage patterns and identify areas for improvement. Ongoing efforts to reduce energy consumption are categorized into 3 main strategies: operations, scanner design enhancements, and active scanning techniques, including accelerated MRI protocols. Ultimately, we emphasize that achieving sustainability in medical imaging requires collaboration across disciplines. By incorporating eco-friendly design in new imaging equipment, we can reduce the environmental impact, promote sustainability, and set a health care industry standard for a healthier planet.

62 RADIOLOGY AND NUCLEAR MEDICINE↗

DOE OSTI2024

LBNF Target Complex Remote Handling

The Long Baseline Neutrino Facility (LBNF) near site at the Fermilab campus in Illinois, USA includes a target complex which houses a 1.5 – 1.8m long graphite neutrino production target, a pre-target baffle, three neutrino focusing horns (A,B,C), and a decay pipe 200m in length leading to an energy absorber / beam dump housed in an adjacent absorber building. The prompt dose rates are such that the Target Hall must be unoccupied while beam is on target. During maintenance periods, the Target Hall can be occupied by trained personnel. However, residual dose rates of activated components necessitate certain operations, such as the annual replacement of the target, be executed remotely by personnel located in a shielded room within the Target Hall. This presentation covers details designed into the infrastructure, equipment, and procedures to allow for successful execution of remote handling operations.

43 PARTICLE ACCELERATORS↗

DOE OSTI2026

What Makes a Bifurcase? Insights from a NADH-Dependent Reduced Ferredoxin: NADP+ Oxidoreductase (Nfn) and Homologs

NADH-dependent ferredoxin:NADP+ oxidoreductases (Nfn) is an enzyme family that engage in flavin-based electron bifurcation (FBEB), a mode of energy conservation utilized by life. The protein comprises one large (NfnL) and one small (NfnS) subunits. Thermoanaerobacterium sacchaloryticum (Tsac) is an anaerobic thermophilic bacterium that - with known involvement of Tsac Nfn - can produce ethanol in high, commercially viable concentrations. We sought to investigate the activity and energetic landscape of Tsac Nfn to determine how the enzyme effectuates FBEB. Tsac NfnS, NfnL, and the partner ferredoxin (Tsac Fd) were recombinantly expressed, purified, and reconstituted with iron-sulfur cluster and FAD cofactors. Electron paramagnetic resonance (EPR) was utilized for all proteins. Spectroelectrochemistry was performed with NfnL. Square-wave voltammetry was conducted on NfnL and Fd. Spectrophotometric activity was assayed for NfnL with or without NfnS. Our group continues to investigate the Nfn from Pyrococcus furiosus (Pf Nfn). Unlike Pf NfnS, Tsac NfnS can be stably expressed, purified, and reconstituted in the absence of its partner NfnL, allowing for this subunit to be characterized separately. The energetic profile of FBEB in Tsac Nfn is overall similar to that of Pf NfnL, with some differences: (1) the proximal cluster is at a lower potential (-780 mV vs -711), (2) the bifurcating FAD is at a higher potential (-406 mV vs -436 mV), and (3) Tsac Fd has two [4Fe-4S] clusters at -550 and -410 mV, unlike Pf Fd with a single cluster at approximately 400 mV. Activity assays indicate that the two enzymes perform FBEB in a similar way. Our work continues to build upon the new field of FBEB by demonstrating that the energetic landscape between distantly related archael (Pf) and bacterial (Tsac Nfn) are largely similar. This equips us to understand design principles for FBEB, allowing us to modulate the process in vivo for specific metabolic outcomes.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2024

Simulations, Modeling and Data Analysis of Parity Violating Electron Scattering Experiments

In the Standard Model (SM) of nuclear and particle physics, parity violation is incorporated through the representation of the weak interaction as a chiral gauge interaction. Only the left-handed components of particles and right-handed components of antiparticles participate in weak interactions in the Standard Model. This implies that parity is asymmetric for the weak interaction. Parity violating electron scattering (PVES) experiments are designed to probe the physics parameters related to the SM, with the possibility to discover physics beyond the SM (BSM) by measuring the parity violating asymmetry ¿¿¿ of longitudinally polarized electrons scattered off unpolarized targets with high precision. This dissertation will be focused on two PVES experiments, the next 208Pb Lead Radius Experiment (PREX-II), and the Measurement of a Lepton-Lepton Electroweak Reaction (MOLLER) experiment, as well as in some small sections, the Calcium Radius Experiment (CREX) and P2 experiment which are also PVES experiments). PREX-II and CREX experiments, performed in Hall A at the Thomas Jefferson National Accelerator Facility (Jefferson Lab), measured ¿¿¿ in the elastic scattering of longitudinally polarized electrons from 208Pb and 48Ca targets to provide a precise model independent determination of the neutron skin thickness of 208Pb and 48Ca nuclei, respectively. The MOLLER experiment, proposed to start in 2027 and also to be performed in Hall A at Jefferson Lab, is to measure ¿¿¿ of longitudinally polarized electrons scattered off unpolarized electrons (Møller scattering) to determine the weak charge of electrons ¿¿¿ and the weak mixing angle ¿¿ with high precision. As for the P2 experiment, which will be performed at the upcoming MESA accelerator in Mainz Germany, it is to measure the weak charge of proton ¿¿¿ using ¿¿¿ in the elastic electron-proton scattering of polarized electrons off unpolarized protons. The final results from the PREX-II experiment are presented as ¿¿¿=550±16 (¿¿¿¿)±8 (¿¿¿¿) parts-per-billion (ppb). Combining the PREX-I and PREX-II results, the neutron skin thickness from PREX experiments is determined as ¿¿-¿¿=0.283±0.071 ¿¿ in 208Pb. This thesis lists the software and computational contribution of the author to these PVES experiments, including writing scripts and software to help with the PREX-II/CREX experiments, analyzing data to provide useful information and systematic uncertainty for the PREX-II experiment, modeling and simulations for the MOLLER, and providing an alternative design of an electronic equipment for the P2 experiment.

Chen, Yufan↗

DOE OSTI2024

Simulations, Modeling and Data Analysis of Parity Violating Electron Scattering Experiments

In the Standard Model (SM) of nuclear and particle physics, parity violation is incorporated through the representation of the weak interaction as a chiral gauge interaction. Only the left-handed components of particles and right-handed components of antiparticles participate in weak interactions in the Standard Model. This implies that parity is asymmetric for the weak interaction. Parity violating electron scattering (PVES) experiments are designed to probe the physics parameters related to the SM, with the possibility to discover physics beyond the SM (BSM) by measuring the parity violating asymmetry ¿¿¿ of longitudinally polarized electrons scattered off unpolarized targets with high precision. This dissertation will be focused on two PVES experiments, the next 208Pb Lead Radius Experiment (PREX-II), and the Measurement of a Lepton-Lepton Electroweak Reaction (MOLLER) experiment, as well as in some small sections, the Calcium Radius Experiment (CREX) and P2 experiment which are also PVES experiments). PREX-II and CREX experiments, performed in Hall A at the Thomas Jefferson National Accelerator Facility (Jefferson Lab), measured ¿¿¿ in the elastic scattering of longitudinally polarized electrons from 208Pb and 48Ca targets to provide a precise model independent determination of the neutron skin thickness of 208Pb and 48Ca nuclei, respectively. The MOLLER experiment, proposed to start in 2027 and also to be performed in Hall A at Jefferson Lab, is to measure ¿¿¿ of longitudinally polarized electrons scattered off unpolarized electrons (Møller scattering) to determine the weak charge of electrons ¿¿¿ and the weak mixing angle ¿¿ with high precision. As for the P2 experiment, which will be performed at the upcoming MESA accelerator in Mainz Germany, it is to measure the weak charge of proton ¿¿¿ using ¿¿¿ in the elastic electron-proton scattering of polarized electrons off unpolarized protons. The final results from the PREX-II experiment are presented as ¿¿¿=550±16 (¿¿¿¿)±8 (¿¿¿¿) parts-per-billion (ppb). Combining the PREX-I and PREX-II results, the neutron skin thickness from PREX experiments is determined as ¿¿-¿¿=0.283±0.071 ¿¿ in 208Pb. This thesis lists the software and computational contribution of the author to these PVES experiments, including writing scripts and software to help with the PREX-II/CREX experiments, analyzing data to provide useful information and systematic uncertainty for the PREX-II experiment, modeling and simulations for the MOLLER, and providing an alternative design of an electronic equipment for the P2 experiment.

Chen, Yufan↗