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DOE OSTI2021

Techno-economic-environmental impacts of industrial energy assessment: Sustainable industrial motor systems of small and medium-sized enterprises

Energy assessments can provide an effective way of identifying and implementing energy efficiency measures to save energy costs and avoid emissions throughout manufacturing facilities. Consequently, it generates significant economic and environmental benefits to localities, states, and the nation. Quantifying these benefits requires a systematic techno-economic-environmental framework for capturing the interactions. This article employs methodologies to improve the energy efficiency of small and medium-size industries through their sustainable industrial motor systems. Motor systems offer large opportunities to enhance energy efficiency through adopting advanced technologies and better-informed operations. Case studies presented illuminate the potential savings and impacts from implementing sustainable motor systems and the importance of energy assessments. Here, the integrated macro-economic analysis quantifies the regional sustainability impacts of implementing the industrial energy efficiency offered by an energy auditing program in Ohio over a ten-year period. Results show that implementing all the center’s motor recommendations have directly saved $\$702$ M in energy costs, avoided 2.7 million metric tons of carbon dioxide emissions, and created 3,445 jobs, resulting in a total annual economic impact of $\$788$ M stemming from direct, indirect, and induced regional economic impacts. It provides policy implications for encouraging sustainable industrial motor systems.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2026

Organic Rankine Cycle Integration and Optimization for High Efficiency CHP Genset Systems (Final Technical Report)

This project successfully advanced the integration of Organic Rankine Cycle (ORC) technology with reciprocating engine–based combined heat and power (CHP) systems to improve electrical efficiency, total CHP efficiency, and grid-responsive operation. Over three budget periods, the work progressed from high-temperature ORC component development and thermodynamic model validation to next-generation system design, working fluid transition, and techno-economic analysis. Key technical accomplishments include development and validation of a thermodynamic model capable of accurately predicting ORC performance across an expanded temperature and pressure envelope; successful identification and validation of low-global-warming-potential (GWP) working fluids—most notably R1233zd(E)—as viable replacements for R245fa; and demonstration of scalable ORC architectures suitable for integration with 1–20 MW class reciprocating engines. These advances enable flexible CHP configurations that can increase electrical output while maintaining high overall utilization of available thermal energy. The project also produced a clean-sheet design for a next-generation ORC system targeting substantially higher power output per unit, supported by detailed component selection, heat exchanger evaluation, and system-level modeling. Techno-economic analyses indicate that ORC-enabled flexible CHP systems can meet or exceed Department of Energy (DOE) efficiency targets while providing value to both facility operators and the electric grid.. Late-stage testing of the largest next-generation ORC prototype identified limitations related to pump net positive suction head (NPSH) requirements and condenser flooding under certain operating conditions. Although these issues constrained full validation of that configuration within the project timeframe, they provided clear and actionable design guidance for future system refinements. Importantly, validated modeling, smaller-scale testing, and working fluid evaluations confirmed the technical viability of the overall approach. In aggregate, this project met its core objectives by establishing validated design tools, de-risking key ORC technologies for CHP applications, and defining a credible pathway toward commercialization of flexible, high-efficiency CHP systems. The results form a strong foundation for continued development and deployment beyond the conclusion of the DOE-funded effort.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2024

RESOLVING THE ELECTROCHEMICAL EQUATIONS OF A SOLID OXIDE FUEL CELL FOR USE IN TRANSIENT SIMULATION AND INTEGRATION INTO CYBER-PHYSICAL SYSTEMS

A major challenge with complex cyber-physical systems stems from long model computational time that creates a mismatch between the model system and the physical system. The numerical modeling of solid oxide fuel cells (SOFCs) presents particular challenges due to the highly coupled nature of the underlying equations and the multiphysics needed to fully resolve their behavior during a transient event. To this end current approaches revolve around splitting the computational efforts into resolving temperature effects and resolving electrochemical effects. Current methods employed for the transient simulation of an SOFC for implementation in the Hybrid Performance (HyPer) facility cyberphysical plant at the National Energy Technology Laboratory reveal a distinct need for accelerated results with a high degree of stability. To this aim, an investigation into the computational time for the code reveals that the underlying electrochemical algorithm takes an order of magnitude more time than its thermal counterpart and has a tendency to vary in terms of iteration time and as such a rework of the underlying system is proposed. The primary method for accelerated electrochemical algorithm solutions is to employ higher order root finding recipes for the resolution of the highly coupled electrochemical equations. This is done with the intention to reduce the overall number of subiterations necessary for resolving voltage, current density, and species concentration, properties of the fuel cell that are all directly coupled and require nested iterative approaches. The overall objective of this approach is an order of magnitude reduction in calculation time without sacrificing stability and increasing accuracy. Specific approaches involve using both bounded and unbounded techniques, such as the False Position method and the Secant method (or if applicable Newton-Raphson) respectively, the drawbacks being slower convergence for False Position and instability for the Secant or Newton-Raphson methods. Current preliminary results on simplified versions of the parent functions involved for electrochemical calculations indicate a reduction in computational steps by a factor of two for the secant method and a factor of three for Newton-Raphson. When implemented into new modified electrochemical algorithms, the results indicate a possible order of magnitude reduction in calculation time.

Arias, Jesus↗

DOE OSTI2023

National Ignition Facility Opacity Time Resolved Spectrometer Systems Engineering Final Project

The National Ignition Facility (NIF) is the world’s largest and most energetic laser facility. The NIF system is designed to produce high energy density (temperature and pressure) conditions through the application of its 192 laser beams. One of the users of NIF is the opacity platform developed to study the opacities at temperatures and densities relevant to the solar interior and stellar evolution. The platform was developed to study iron (Fe) opacity at temperatures relevant to the solar interior. The opacity campaign uses spectrometers to gather data. Spectrometers utilize crystals to produce x-ray spectra that are recorded on time-integrated and time-resolved detectors. The opacity spectrometer (OpSpec) currently fielded and in use at NIF uses a time integrated film channel to collect data. The opacity spectrometer time resolved (OpSpecTR) will utilize novel hCMOS detectors to capture time resolved images of spectra of interest. The key stakeholders identified for OpSpecTR included the physicists responsible for OpSpec and OpSpecTR, the Target Area Science and Engineering (TASE) department at NIF, the NIF and Photon Science (NIF & PS) Opacity program, the Nevada National Security Site (NNSS) Physics and Engineering program, the Sandia hCMOS manufacturing and testing program, and the Los Alamos National Laboratory (LANL) program sponsor. The Target and Experimental Operations (TEXOPS) was identified as a key stakeholder because the group includes the individuals that will physically interact with the OpSpecTR system as it participates in NIF experiments. The opacity platform collects data in a unique orientation relative to the existing diagnostics fielded at NIF. The existing infrastructure at NIF uses a diagnostic manipulator (DIM) to insert the diagnostic near the target chamber center to collect data during a NIF shot. Existing diagnostics collect data through the center line of the DIM axis and collect relevant data perpendicular to this axis. The opacity platform requires crystals mounted in a specific orientation which requires data collection parallel to the DIM axis. This deviation from standard NIF practices was a key factor in developing requirements.

42 ENGINEERING↗

DOE OSTI2025

Project-specific considerations for retrofitting carbon capture technology to power generating and industrial facilities

The National Energy Technology Laboratory (NETL) has previously reported on learnings from 7 FEED studies examining retrofitting power plants with capture. This presentation builds on this effort by highlighting learnings from 3 additional FEED studies examining retrofitting power plants with capture and 7 FEED and pre-FEED studies examining retrofitting industrial plants with capture. This includes a discussion of the design, performance, and cost implications associated with (1) site-specific considerations such as water availability, land availability, and site accessibility, and (2) host-plant-specific factors such as flue gas specifications, operational mode, and allowable degree of integration between the capture system and host plant.

FEED Studies↗

DOE OSTI2024

Robotics for Systems Integration in Buildings - Pilot Study of Viable Approaches to Install Hygrothermal and Rigid Electrical Systems: Preprint

The Industrialized Construction Innovation (ICI) team at the National Renewable Energy Laboratory (NREL) has been exploring the use of robotics to integrate hygrothermal, mechanical, electrical, and plumbing systems in prefabricated building assemblies (offsite construction) and 3D Printed buildings (onsite construction). Such multi-system integration tasks often require specialized robots and custom end-effectors for handling a range of rigid and non-rigid building components. This paper begins with a brief overview of the current state of robotics in construction, followed by a pilot study exploring the use of robotics to integrate a simple prototype multi-trade wall assembly composed of structural studs, hygrothermal layer, wall finishing, and electrical fixtures. The study was funded by the Department of Energy's (DOE) Advanced Materials and Manufacturing Technologies Office (AMMTO). Insights about the implementation of design for manufacturing and assembly (DfMA) principles in designing the prototype wall for robotic assembly, and selection of appropriate robotic end effector hardware for handling these components are included. Detailed comparison of computational toolpath simulations of the robotic assembly process and real-life demonstration of the same is presented. Finally, limitations and lessons learned from this study along with future research recommendations for robotic assembly of more complex multi-trade assemblies, including potential scenarios such as robotic outfitting of facilities in extra-terrestrial environments is included.

advanced manufacturing↗

DOE OSTI2024

The LSU-Argonne conversion electron spectrometer: A new detector for the X-Array and SATURN decay station

In this study, a new conversion electron detector has been commissioned at the ATLAS/ CARIBU facility at Argonne National Laboratory. The LSU-Argonne Conversion Electron Spectrometer (LACES) is a LN 2 -cooled Si(Li) detector system designed to be incorporated into a decay station that comprises the dedicated HPGe clover array with a box geometry (X -Array) and the Scintillator and Tape Using Radioactive Nuclei (SATURN) device. This integration enables simultaneous measurements of conversion electrons and gamma-rays in decay experiments, yielding novel information on transition multipolarities, electric monopole transitions, and isomeric states that decay mostly via conversion electrons. A measurement of the energy resolution of LACES yielded 2.3-keV FWHM at 975 keV for electrons and 1.3-keV FWHM at 75 keV for X-rays. A detailed study of the absolute detection efficiency (at 5 mm from the source) was performed, where this quantity was determined experimentally in the range of electron transition energies between 25.5 keV and 1047.8 keV and subsequently simulated using the GEANT4 code. Measurement and simulations are found to be in excellent agreement. A precise characterization, for this type of detector system, of the absolute detection efficiency for such a wide energy range is reported for the first time.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2022

Demonstration of plasma mirror capability for the OMEGA Extended Performance laser system

A plasma mirror platform was developed for the OMEGA-EP facility to redirect beams, thus enabling more flexible experimental configurations as well as a platform that can be used in the future to improve laser contrast. The plasma mirror reflected a short pulse focusing beam at 22.5° angle of incidence onto a 12.5 μm thick Cu foil, generating Bremsstrahlung and k α x rays, and accelerating ions and relativistic electrons. By measuring these secondary sources, the plasma mirror key performance metrics of integrated reflectivity and optical quality are inferred. It is shown that for a 5 ± 2 ps, 310 J laser pulse, the plasma mirror integrated reflectivity was 62 ± 13% at an operating fluence of 1670 J cm –2 , and that the resultant short pulse driven particle acceleration and x-ray generation indicate that the on target intensity was 3.1 × 10 18 W cm –2 , which is indicative of a good post-plasma mirror interaction beam optical quality. By deriving the plasma mirror performance metrics from the secondary source scalings, it was simultaneously demonstrated that the plasma mirror is ready for adoption in short pulse particle acceleration and high energy photon generation experiments using the OMEGA-EP system.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2026

Commissioning of the large-scale lead tungstate scintillating calorimeter

Here, we report on the installation and initial commissioning of a large-scale lead tungstate (PbWO4) scintillating crystal calorimeter developed for high-rate photon detection and precise energy measurement. The calorimeter comprises 1596 high-granularity, high-resolution scintillating crystals optimized for electromagnetic-shower detection over a wide energy range. Scintillation light from each crystal is read out by Hamamatsu R4125 photomultiplier tubes equipped with a custom voltage divider and front-end amplifier to ensure stable gain at high rates. All calorimeter modules were fabricated and characterized using a light-emitting diode–based optical test system prior to installation to verify uniformity and photodetector performance. After installation, the electromagnetic calorimeter was fully integrated into the experiment data acquisition and energy-based trigger systems. The optical response of the modules was equalized using the light-monitoring system, cosmic-ray muons, and photons from Compton-scattering events. Commissioning results demonstrate a reliably calibrated optical response and stable detector performance during the first run. These results validate the calorimeter design and commissioning methodology for large-scale scintillator-based photonic instrumentation.

Analog to digital converters↗

DOE OSTI2022

Embedded acoustic sensing and monitoring techniques for small modular reactors

The goal of this project was to study the applicability of specific innovative instrumentation techniques for assessing parameters needed for safe small modular reactor operation and safeguarding of nuclear material. Small modular reactor core designs are currently being developed to provide energy more effectively and efficiently than in the past because they can be built as modules at fabrication sites and then transported to a power-producing facility. However, these modules and/or the final core will often be sealed and not accessible again until disposal. Instead of instruments that access the core directly, during and after operation, to monitor flux/dose and structural integrity, as current power plants use, new sensors need to be designed that can be built into the reactor initially to determine operating history, structural integrity through operation of the system, and nuclear material accountancy after shutdown and before disposition of the core. Embedded sensors already exist that can provide neutron flux, gamma dose, and temperatures, but techniques to expand upon these for assessing structural health and material inventory in the system over time need to be developed. Structural health assessments include the detection and imaging of cracks in the components that could eventually cause radioactive fission products to be released.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

Quantitative risk assessment examples for underground hydrogen storage facilities

Hydrogen energy storage can be used to achieve goals of national energy security, renewable energy integration, and grid resilience. Adapting underground natural gas storage facility (UNGSF) infrastructure for underground hydrogen storage (UHS) is one method of storing large quantities of hydrogen that has already largely been proven to work for natural gas. There are currently some underground salt caverns in the United States that are being used for hydrogen storage by commercial entities, but it is still a fairly new concept in that it has not been widely deployed nor has it been done with other geologic formations like depleted hydrocarbon reservoirs. Assessments of UHS systems can help identify and evaluate risks to people both working within the facility and residing nearby. This report provides example risk assessment methodologies and analyses for generic wellhead and processing facility configurations, specifically in the context of the risks of unintentional hydrogen releases into the air. Assessment of the hydrogen containment in the subsurface is also critically important for a safety assessment for a UHS facility, but those geomechanical assessments are not included in this report.

08 HYDROGEN↗

DOE OSTI2024

Robotics for Systems Integration in Buildings: Pilot Study of Viable Approaches to Install Hygrothermal and Rigid Electrical Systems

The Industrialized Construction Innovation (ICI) team at the National Renewable Energy Laboratory (NREL) has been exploring the use of robotics to integrate hygrothermal, mechanical, electrical, and plumbing systems in prefabricated building assemblies (off-site construction) and 3D-printed buildings (on-site construction). Such multisystem integration tasks often require specialized robots and custom end effectors to handle a range of rigid and nonrigid building components. This paper begins with a brief overview of the current state of robotics in construction, followed by a pilot study exploring the use of robotics to integrate a simple prototype multitrade wall assembly composed of structural studs, hygrothermal layer, wall finishing, and electrical fixtures. The study was funded by the US Department of Energy's (DOE's) Advanced Materials and Manufacturing Technologies Office (AMMTO). Insights about the implementation of design for manufacturing and assembly (DfMA) principles in designing the prototype wall for robotic assembly, and selection of appropriate robotic end-effector hardware to handle these components are included. Detailed comparison of computational toolpath simulations of the robotic assembly process and real-life demonstration of the same are presented. Finally, limitations and lessons learned from this study are included, along with future research recommendations for robotic assembly of more complex multitrade assemblies, including potential scenarios such as robotic outfitting of facilities in extraterrestrial environments.

advanced manufacturing↗

DOE OSTI2021

Model predictive control for integrated control of air-conditioning and mechanical ventilation, lighting and shading systems

Modern buildings are increasingly automated and often equipped with multiple building services (e.g., air-conditioning and mechanical ventilation (ACMV), dynamic shading, dimmable lighting). These systems are conventionally controlled individually without considering their interactions, affecting the building’s overall energy inefficiency and occupant comfort. A model predictive control (MPC) system that features a multi-objective MPC scheme to enable coordinated control of multiple building services for overall optimized energy efficiency, indoor thermal and visual comfort, as well as a hybrid model for predicting indoor visual comfort and lighting power is proposed. The MPC system was implemented in a test facility having two identical, side-by-side experimental cells to facilitate comparison with a building management system (BMS) employing conventional reactive feedback control. The MPC system coordinated the control of the ACMV, dynamic façade and automated dimmable lighting systems in one cell while the BMS controlled the building services in the other cell in a conventional manner. The MPC side achieved 15.1–20.7% electricity consumption reduction, as compared to the BMS side. Simultaneously, the MPC system improved indoor thermal comfort by maintaining the room within the comfortable range (-0.5 < predicted mean vote < 0.5) for 98.3% of the time, up from 91.8% of the time on the BMS side. Visual comfort, measured by indoor daylight glare probability (DGP) and horizontal illuminance level at work plane height, was maintained for the entire test period on the MPC side, improving from having visual comfort for 94.5% and 85.7% of the time, respectively, on the BMS side.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

Colorado State University (CSU) X-Band Precipitation Radar Plan Position Indicator Data Processed with Corrected Moments in Antenna Coordinates (CMAC) Value-Added Product Report

In 2010 the U.S. Department of Energy (DOE) Atmospheric Radiation Measurement (ARM) user facility procured 3- and 5-cm wavelength radars for documenting the macrophysical, microphysical, and dynamical structure of precipitating systems. To maximize the scientific impact, ARM supported the development of an application chain to correct for various phenomena in order to retrieve the “point” values of moments of the radar spectrum and polarimetric measurements. We have now used the lessons learned from the processing of the 3- and 5-cm wavelength radars obtained by ARM to help process X-band radar data from the Surface Atmospheric Integrated Field Laboratory (SAIL) field campaign. This report details the motivation, science, and progress to date as well as charting a path forward.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2025

Low Carbon Intensity Formic Acid Chemical Synthesis from Direct Air Captured CO 2 Utilizing Chemical Plant Waste Heat - Final Technical Report

The primary objective of Low Carbon Intensity Formic Acid Chemical Synthesis from Direct Air Captured CO 2 Utilizing Chemical Plant Waste Heat (ChemFADAC) is to execute and complete a FEED study for an integrated direct air capture (DAC) and carbon conversion system (together, the DACUS system) co-located at a Nutrien nitric acid production facility in Kennewick, WA capable of capturing and converting a minimum of 5,000 MT/year net atmospheric CO 2 to low carbon intensity formic acid (FA) using industrial waste heat and renewable electricity. The goal will be achieved through the completion of four objectives using a collaborative approach with community stakeholders. Objective 1. Conduct a FEED study and Class 3 project cost estimate for the proposed DACUS system that maximizes use of thermal energy from the Nutrien KFO host site to produce low carbon intensity FA from atmospheric CO 2 . Objective 2. Perform a cradle-to-gate life-cycle analysis of the DACUS system to determine the environmental sustainability and carbon intensity (CI) of the proposed project and product from the results of the FEED study. Objective 3. Perform a business case analysis from results of the LCA, FEED study and cost estimate to justify investment to build the DACUS project at the Nutrien KFO site. Objective 4. Quantify how deployment of the proposed technology will promote and prepare a ready workforce for clean energy and manufacturing jobs and coordinate with community stakeholders to perform an environmental justice and a preliminary economic revitalization and job creation outcomes analysis.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2022

The Modeling of the Synfuel Production Process: Process models of Fischer-Tropsch production with electricity and hydrogen provided by various scales of nuclear plants

Synthetic fuels (synfuels), also known as electro-fuels (E-fuels), are hydrocarbon fuels produced from waste CO2 streams and water electrolysis, with electricity as the primary source of energy. To achieve substantial reductions in greenhouse gas (GHG) emissions, electricity sources must release zero carbon or near-zero carbon, as is the case with solar, wind, hydro, and nuclear power. Nuclear power is one of the largest and steadiest domestic sources of clean energy in the United States. Moreover, nuclear power has the potential to produce hydrogen economically for less than $2/kg, reaching the DOE near-term target price. Thus, using nuclear power to produce synfuels has the unique potential to significantly reduce the GHG emissions of hydrocarbon fuels production and end-use applications. Fisher-Tropsch or FT fuel (a mixture of naphtha, jet fuel, and diesel) is of great interest because it is a drop-in fuel that can be blended with conventional petroleum counterparts and is compatible with existing infrastructure. By using the ASPEN Plus model, this report develops FT fuel production models on three scales, corresponding to nuclear plants with capacities of 1000 MWe, 437 Mwe, and 100 MWe, respectively. The FT model case with energy from a 437-MWe nuclear plant is used as a baseline case. This report summarizes the baseline ASPEN Plus model results with a detailed mass and energy analysis. Our modeled facility produces 507 MT/day (185,000 gal/day) of FT fuel by converting 255 MT/day of hydrogen and 1,580 MT/day of CO2. The FT fuel production energy efficiency from hydrogen and electricity energy inputs is 70% (lowerheating-value or LHV-based). Including the high-temperature electrolyzer in the system boundary, the FT fuel production LHV efficiency from electricity and thermal energy inputs is 51%, considering 39.8 kWh/kg of electricity and 6.86 kWh/kg of thermal energy use from a nuclear plant for hydrogen production. The FT production efficiency can potentially be increased by further integrating the heat exchange between nuclear plant and FT process, and this study is underway. The carbon conversion ratio in the baseline case is 99%, with process CO2 capture and recirculation and oxy-combustion using the oxygen by-product from water electrolysis. The hydrogen consumption is 1.38 kg/gal-FT fuel and the CO2 consumption is 8.56 kg/gal-FT fuel in the baseline case. With different FT production scales determined by the nuclear plant capacity, the FT model was scaled using the same operating parameters, which led to the same conversion efficiency regardless of scale. However, the different FT plant scales will impact the economics of FT fuel production; this impact will be examined in the next phase of this study.

Zang, Guiyan↗

DOE OSTI2023

Advanced Structured Adsorbent Architectures for Transformative Carbon Dioxide Capture Performance (Final Report)

Svante is a world leader at using solid sorbents for low-cost Carbon Dioxide (CO 2 ) capture, a technology which is recognized as critical in meeting the dual mandates of energy security/reliability and the mitigation of man-made CO 2 emissions. Svante has been developing proprietary adsorbent material compositions, forming them into structured laminates, developing and optimizing process cycles, and system design for efficient capture of CO 2 from post-combustion flue gases of thermal power plants and industrial facilities. The deployment of first-generation CO 2 capture technology has been significantly hampered by high costs and energy penalties, among other barriers. Second generation CO 2 capture technologies (including the Mark I variant of Svante’s Veloxotherm™ adsorption-based technology), utilizing single adsorbent architecture, show promise for reducing the barriers to deploying CO 2 capture plants in commercially meaningful numbers. The objective of this project was to evaluate the Recipient’s transformational (Mark-II) VeloxoTherm™ Technology via the development and bench-scale testing of an advanced structured adsorbent, including novel Bi-layer, laminated adsorbent structures and segmented beds. Svante selected, synthesized, and characterized tailored solid adsorbents for computational modeling, advanced structured adsorbent development, process simulations, and dynamic bench scale (~1-10 kg/day CO 2 captured) testing using an existing single-bed VeloxoTherm™ Station (VTS) coupled with a natural gas-fired boiler. Segmented beds used the in-house, multi-bed Process Demonstration Unit (PDU) to demonstrate key performance indicators (KPIs), such as recovery, product purity, regeneration energy, and the integrated system's productivity in lifetime analysis. Segmented beds were used at a 1 tonne per day (TPD) unit at an industrial site to provide bench-scale validation of performance in an industrial setting. Svante was developing and optimizing the post-combustion CO 2 adsorption technology architectures, including the Bi-layer and segmented laminated adsorbent structure design, integrated rapid cycle temperature swing adsorption (RC-TSA) cycle, flow path architecture, and adsorbent bed construction and packaging (including gas porting) to progress towards achievement of DOE’s Transformational CO 2 Capture goals of 95% CO 2 purity and a cost of electricity at least 30% lower than a supercritical Pulverized Coal (PC) power plant with CO 2 capture, or approximately $30 per tonne of CO 2 captured ready for demonstration by 2030. The main requirements to reach the DOE target cost of carbon capture below $30/MT using Rapid-Cycling Temperature Swing Adsorption (RC-TSA) are as follows: (1) Increased capacity at different CO 2 concentrations, (2) Increased sorbents cycle life, (3) Increased O 2 resistance, and (4) Decreased steam requirement to extract 1 kg of CO 2 .

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2022

Real-Time Drilling Optimization System for Improved Overall Rate of Penetration and Reduced Cost Per Foot in Geothermal Drilling

The key to success in geothermal drilling is economic feasibility, and a major cost in the development of geothermal resources is the actual drilling of the wells. In this project, a real-time drilling optimization system for geothermal drilling was developed. The system couples three individual components while drilling. The first component is a drill stem vibration analysis model, the second is Mechanical Specific Energy (MSE) analyses, and the third is a detailed PDC Rate of Penetration (ROP) drill bit model for optimum RPM and WOB combinations. The benefit of the coupled system is that the range of WOB and RPM could be selected to avoid drill stem vibrations. Secondly, MSE is used as an efficiency measure and the detailed PDC drill bit model ensures the drill bit does not endure temperatures that exceed the temperature at which the PDC cutters experience accelerated wear. The new detailed PDC bit model is based on rock/bit interaction that physically tracks the PDC cutter wear flats as the bit drills ahead giving the capability to calculate the temperature being generated underneath the worn cutters to better advise on operational parameters to avoid accelerated cutter wear and failure and to ensure that operational parameters are applied so that overall ROP is maximized. By combining the drill stem vibrations and the detailed PDC bit cutter wear and “safe” non-accelerated cutter wear temperature and optimum ranges of operating parameters, it results in higher ROP and lower cost drilling. Single cutter PDC testing performed in different lithologies at Sandia was utilized to verify the PDC cutter forces and depth of cut for new and worn cutters. Based on single cutter PDC temperature modeling, verification using single cutter data from the testing done by National Oilwell Varco (NOV) was performed. Sandia’s Hard-Rock Drilling Facility (HRDF) was utilized to test different drill bit configurations with different cutter designs and wear status with different induced modes of vibration to obtain the critical bit RPM/WOB ranges resulting in ineffective drilling and low ROP. The collected test data were further used to verify and calibrate the full hole PDC ROP model that was developed based on single cutter interaction data. A full coupled drill stem vibration model was formulated and verified with geothermal field data from the Chocolate Mountain Aerial Gunnery Range (CMAGR). A graphical user interface (GUI) was developed using Tkinter library in the computer programming language Python, which integrates all the developed models in one system. The developed system consists mainly of the PDC ROP model, PDC bit wear model, PDC cutter temperature model, Mechanical Specific Energy (MSE) model, and drillstring vibration model integrated into one system. The developed system can be used for both, post well analysis and real-time optimization using different criteria such as ROP maximization or MSE minimization. The software uses Differential Evolution Algorithm (DEA) to find optimum values for operational parameters based on last foot drilled while avoiding the drillstring vibration and cutter temperature critical operating parameters.

15 GEOTHERMAL ENERGY↗