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At least 361 records · Page 20

Feasibility Study of Advanced Manufacturing Techniques and Compositions of High Entropy Alloys

In line with the objectives of Department of Energy’s Office of Nuclear Energy Advanced Materials and Manufacturing technologies program (AMMT), this work focuses on new materials development and qualification research and development for next-generation, high-temperature nuclear reactors. While the currently qualified nuclear materials have demonstrated significant irradiation resistance at high temperatures, the community is still interested in materials that can sustain the harsh environments found in nuclear reactors for temperatures up to 1,000°C for nearly 100,000 hours. High entropy alloys (HEAs) have the potential to serve in these extreme environments of next generation nuclear reactors due to their unique phase transformation pathways and nanoscale and mesoscale microstructures. The current work focuses on understanding such nuclear energy relevant HEAs through a detailed literature survey and developing a decision matrix with criteria for identification of HEAs with may have most impact and value for further examination.

36 MATERIALS SCIENCE↗

Preliminary Feasibility of Printing, Microstructure Analysis and Mechanical Performance of a Down Selected Ni Alloy

This report is submitted as completion of a Milestone 3 deliverable under work package ORNL CT-23OR1304051 in support of the Advanced Materials and Manufacturing Technologies (AMMT) program. The AMMT program is aiming at the faster incorporation of new materials and manufacturing technologies into complex nuclear-related systems. An integrated approach, combining advanced characterization, high-throughput and accelerated testing, modeling and simulation including machine learning and artificial intelligence will be employed. While 316H (Fe-16-18Cr-10-14Ni-2-3Mo-0.04-0.1C) has been identified as a key alloy to be integrated into the AMMT accelerated alloy qualification approach due its relevance for many current and future nuclear energy reactors, many other alloys could be considered for the advanced fabrication of innovate high-performance nuclear components. ANL, INL, ORNL and PNNL are collaborating on identifying the most promising alloy candidates relevant for the AMMT program. A selection criteria matrix was established to evaluate the alloys considering their relative importance and technological readiness levels for nuclear energy applications, with a focus on laser powder bed fusion (LPBF). Due to the broad range of potential candidate alloys, ORNL and INL focused on Ni-based alloys, while ANL and PNNL mainly evaluated Fe-based alloys. PNNL previously published materials scorecards reports on several key alloys and this report is providing a broader overview of Ni-based candidate alloys, expending beyond alloys well-known to the nuclear community. Of particular interest are alloys that are currently commercially available in powder form due to the growing demand from other industries that have invested heavily in additive manufacturing. Among these alloys, Haynes 282 (Fe-20Cr-20Co-8Mo) was selected due to its superior strength at high temperature compared to the code-qualified alloy 617 (Ni-20-24Cr-10-15Co-8-10Mo). To assess the integration of this new alloy into the AMMT digital manufacturing framework, we performed the rapid optimization of alloy 282 printing parameters on a Renishaw 250 machine, the fabrication of sufficient materials for extensive characterization and mechanical testing both at ORNL and INL, and added the printing data into the digital platform via the Peregrine software. A detailed analysis of the LPBF 718 alloy was also conducted, with creep specimens being tested at 600-650°C and characterized by advanced electron microscopy. The alloy superior mechanical strength and great printability associated with the extensive database that has already been generated highlight the promising potential of LPBF 718 as a candidate alloy for the AMMT program. INL, ANL and PNNL have generated similar reports and all the information will be compiled into a final M2 milestone report to provide the AMMT leadership team with clear recommendations on the down selection of reactor materials, as well as establish a roadmap for the qualification of these selected alloys.

36 MATERIALS SCIENCE↗

Red Hills Storage Hub Feasibility Study - Summary of Milestone 2 - Conceptual Basis of Plants and Pipeline Infrastructure

This document provides the first conceptual-level design of plants and pipeline infrastructure, including maps showing the project location, the potential footprint of the carbon capture and storage plant, the potential site of the capture and compression unit, and the conceptual pipeline layout for transporting the CO2 product from the capture facility to the future potential injection sites.

Carbon Capture and Storage,CarbonSAFE↗

Demonstrating the Feasibility of Biomass Pyrolysis Liquid, Coal, Plastic Oil Mixtures for Entrained Flow Gasification

There is interest in co-gasifying coal, biomass and plastic. An attractive alternative is to do that in a pressurized entrained-flow gasifier, technology that has been used for coal gasification for decades. The approach taken in this study is to liquefy biomass through fast pyrolysis and to liquefy waste plastic by thermal decomposition. The liquids form the basis of a slurry that also includes coal particles. In this work, several different compositions of coal-bioliquid-plastic oil slurries were prepared and evaluated for viscosity and settling properties. Suitable composition ranges were identified and are highlighted in the presentation.

Hughey, Logan↗

Hydrogen Transportation and Distributed Energy Systems Risk and Feasibility Assessment for Airport Facilities - CRADA 555 (Abstract)

This CRADA presents the strategy that Pacific Northwest National Laboratory (PNNL) and Sandia National Laboratories (SNL) will take to support PDX in performing a risk assessment for several hydrogen deployment scenarios. It is intended that the deployment of hydrogen at PDX could serve several roles, including decarbonizing its bus fleet and building out a distributed energy system which could also be used to facilitate emergency operations. PDX’s initial plans concern replacing their current fleet of 28 busses with FCEBs. To do so, PDX will need to deploy the hydrogen systems needed to support the buses. This includes hydrogen storage, production, delivery, filling, compression, and maintenance. PDX also has long range plans to build a distributed energy system to support normal and resilient operations. This study will investigate the risks of each plan individually, and a combined plan which serves both. Additionally, PDX is in an area with the potential for high seismic activity, as such this work will also include a seismic risk assessment. A detailed risk assessment using PDX as a test case is necessary to ensure the deployment of large-scale hydrogen is successful and to understand the benefits or drawbacks in contrast to electric only technologies. Many technologies have been proposed that claim to utilize hydrogen for both transportation and distributed energy systems; however, these technologies need to be analyzed as they apply to an actual site. The physical infrastructure and hydrogen use cases for PDX will be analyzed, a risk assessment will be performed on the hydrogen infrastructure and distributed energy system. These assessments will be useful for understanding how each of these technologies would perform as applied to a large public facility and public safety. The results of this CRADA, and an impact of the DOE funding, will evaluate hydrogen as a key fuel for PDX and will accelerate by several years availability of hydrogen, fuel cells, and other low-carbon technologies.

08 HYDROGEN↗

Community-Centric Microgrid Feasibility Analysis Framework to Accelerate Resilience of Island Communities

Marine energy offers a reliable energy solution for island and coastal communities, which often lack traditional local generation, to support their transition to energy independence and reduce reliance on externally imported fuels. Successful deployment of new technologies in these isolated locations requires community acceptance and approval from the outset, as these communities typically lack the financial and technical resources to operate and maintain new systems. This report presents a community-centric microgrid planning framework for remote coastal and island communities. Community engagement is integrated as the first step in the planning process, incorporating community profiles and visions into energy development scenarios. A case study was conducted in St. George, Pribilof Islands, Alaska, which relies entirely on diesel yet has significant wind and wave energy potential. Community engagement revealed a unique history and current economic status, with an interest in adopting advanced energy technologies despite past failures. Various microgrid configurations were optimized, considering different technologies to meet current and future energy needs while balancing cost and energy resilience. Wave energy converters (WECs) were a key component, integrated with other energy sources using the Xendee optimization tool. The Marine Energy Microgrid Toolkit, developed as part of this work, uses commercial power system analysis tools to optimize and analyze microgrid scenarios. The developed framework and toolkit can be applied to island and coastal communities to enhance resilience and support microgrid deployments. Future enhancements will include incorporating new marine resources, developing dynamic models, and automating the integration of Xendee and PowerFactory simulations.

02 PETROLEUM↗

Exploring the Feasibility of INCONEL® ALLOY 740H® for Power Plant Headers: Integrating Machine Learning with Computational Fluid Dynamics (CFD)

This keynote presentation explores the behavior of headers—essential components of pipeline systems—using ANSYS simulation software and machine learning techniques. The study aims to predict the thermal and mechanical performance of headers under diverse conditions through both steady-state and transient simulations. We investigate critical parameters such as heat transfer coefficient, fluid velocity, and temperature to optimize header design. Conducted as part of a DOE project led by NCAT in collaboration with UNC Charlotte, this research encompasses multiple key topics. The initial section focuses on the behavior of header systems under steady-state conditions using ANSYS simulation. It underscores the importance of headers in industrial infrastructure, especially in the energy sector, and examines the implications of material selection and flow direction on heat transfer dynamics. Methodologically, we employ Computational Fluid Dynamics (CFD) analysis through ANSYS, detailing the development of models, material properties, geometry specifications, boundary conditions, and meshing strategies. Our simulations explore various operational parameters, including temperature and mass flow rates, crucial for predicting heat transfer coefficients and enhancing header design. Results from the study include parametric investigations into mesh sensitivity, viscosity model evaluations, and the effects of heat transfer locations, all validated against theoretical calculations. We conclude with insights on mesh optimization, the suitability of viscosity models, and recommendations for future research aimed at improving header system efficiency and sustainability in industrial applications.

20 FOSSIL-FUELED POWER PLANTS↗

Orbiting Lunar Ground Penetrating Radar SAR Feasibility

This report aims to answer the question: “Will ground penetrating radar (GPR) be able to measure lunar subsurface resources from a 10km or above orbit?” Similarly, “Could a reasonable satellite-based system achieve the radar parameters required for lunar orbital GPR?” This report is not proposing a system but exploring if one is possible.

47 OTHER INSTRUMENTATION↗

Ascorbic Acid Stability and pH Testing to Support RWM-018 Pilot Scale Wellhead Treatment System Feasibility Determination

A multitude of groundwater remediation techniques for chlorinated volatile organic compounds (cVOCs) have been conducted at the A/M-Areas of the Savannah River Site (SRS). Historical in-situ chemical oxidation (ISCO) injections of potassium permanganate and sodium persulfate conducted in 2018 and 2020, have left residual oxidant concentrations in the A/M-Area groundwater system. ISCO events targeted dense non-aqueous phase liquids (DNAPLs) through the injection of strong oxidants within plume zones upgradient of current groundwater recovery wells RWM-008 and RWM-018. These residual oxidants could significantly impede the operation of the mercury removal system needed to meet National Pollutant Discharge Elimination System (NPDES) permit requirements for the ongoing pump-and-treat system that hydraulically controls potions of the A/M-Area plume. Effluent treated groundwater from this system is discharged to surface water at the receiving outfall of the M-1 Air Stripper. To prevent interference of the M-1 Air Stripper system by residual oxidants, groundwater recovery has been ceased at well RWM-018. Modeling of oxidant transport in A/M-Area from ISCO estimated that the potential oxidant load contributed by RWM-018 could be as high as 120 mg/L. It is also possible that oxidants may be contributed via pumping at well RWM-008 in the near future as residual oxidants within the aquifer migrate toward its zone of influence. Savannah River National Laboratory (SRNL) has conducted research to investigate potential pre-treatment chemicals to neutralize these residual oxidants, before reaching the M-1 Air Stripper, to allow for resumed groundwater recovery at RWM-018 and continued pumping at RWM-008. Deployment of ascorbic acid for neutralization of residual oxidants at RWM-018 (and possibly RWM-008) is recommended based on results from previous reductant testing (SRNL, 2021). For a maximum estimated oxidant load at RWM-0018, a well-head treatment system would need to dose about 400 gallons of ascorbic acid each month to ensure complete neutralization. A second system with additional reagent should also be considered for deployment at RWM-008.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

On the Feasibility of Geophysical Methods for CO 2 Monitoring in the North Dakota CarbonSAFE Project

Conference presentation at American Institute of Chemical Engineers (AIChE) Annual Meeting, Phoenix, AZ, November 13–18, 2022. An analysis of rock physics crossplots and diagnostic models suggests that the baseline seismic data may be sensitive to changes in lithology and porosity of the Broom Creek Formation and that these changes may be detectable by prestack seismic inversion.

20 FOSSIL-FUELED POWER PLANTS↗

Technical Feasibility of Recovering Critical Minerals from Oil and Gas Industry Produced Water

Economic recovery of critical minerals from solid and liquid streams produced from natural resource extraction operations including Oil and Gas production, Mining, geothermal, and other industries can help alleviate shortage of the minerals important to industry. It is important to develop techniques for extraction that can be utilized at large scale to be economically viable, and to minimize waste products that require special disposal procedures. NETL and Participant will collaborate to develop and evaluate at the lab-scale, a process to recover and concentrate critical minerals from oil and gas industry produced water using a combination of physical and chemical methods, so that it may be converted into a valuable product. This effort promotes a circular economy by converting a waste stream into marketable products.

02 PETROLEUM↗

Microwave-Assisted Dehydroaromatization of Flare Gas: Reactor Modeling, Plant-Wide Simulation and Economic Feasibility Analysis

Flaring is widely practiced in the oil, gas, and petrochemical sectors to ensure safety during upsets and maintenance but emits large amounts of GHGs, causing energy and economic losses. In the U.S., about one-third of Bakken gas (~250 MMSCFD) and ~100 MMSCFD from Eagle Ford are flared. Recovering this gas is essential for sustainability. Existing recovery methods—compression and reinjection (EOR), conversion to NGL, LNG/CNG, GTL, and GTW—are often limited by flowrate, composition, and variability, especially in unconventional wells. This study develops a microwave-assisted dehydroaromatization (DHA) process to convert flare gas into benzene, toluene, ethylene, and naphthalene. A laboratory reactor model is scaled up into a modular plant-wide system. Techno-economic (TEA) and life-cycle (LCA) analyses evaluate performance and sustainability, with sensitivity studies on plant capacity, electricity cost, and catalyst price confirming strong economic potential.

dehydroaromatization↗

Feasibility Analyses for the Microgrid of the Mountain in the Cordillera Central Region of Puerto Rico

Distributed energy resource (DER) development can benefit communities through improvement of access to reliable electricity and a resilient energy system. Many place-specific considerations must be accounted for when designing electrical systems with co-located generation and loads. This paper presents an overview of four studies focusing on different aspects for regional DER development in the Cordillera Central region of Puerto Rico, including a grid and load stability study with the introduction of solar energy generation, microgrid design based on the solar resource in the area, resilience considerations during power outage scenarios, and qualitative risk aspects for components in the microgrid. Additionally, a conceptual substation microgrid analysis is conducted using the Microgrid Design Toolkit (MDT) to evaluate trade-offs between cost and energy availability, providing insights into optimal design strategies. A microgrid resilience assessment is performed using the Resilient Nodal Cluster Analysis Tool (ReNCAT) to identify critical loads and evaluates their accessibility during outages, emphasizing the importance of community needs. Finally, a qualitative risk assessment utilizing Hazard and Operability Analysis (HAZOP) methods highlights potential hazards and mitigations for microgrid components, ensuring robust system design and operation.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Feasibility of Enhanced Geothermal Systems (EGS) Development at Bradys Hot Springs, Nevada

The Bradys EGS project focused on utilizing EGS technology to improve permeability in an existing non-productive well (15-12 ST1, located on BLM land) at Ormat’s Bradys geothermal facility in Churchill County, Nevada. The Bradys geothermal field is located within the Hot Springs Mountains, approximately 50 miles northeast of Reno, NV, along the western boundary of a very large intermontane basin known as the Carson Sink. It is one of several producing geothermal areas in the region; the Desert Peak, Stillwater, Soda Lake, and Salt Wells geothermal projects also lie within the Carson Sink, which is a region of high heat flow characterized by prominent NNE-striking faults that have formed in response to regional extension within the Basin and Range geologic province.

15 GEOTHERMAL ENERGY↗

Feasibility of Passive MOSFET Paralleling for Photovoltaic Current-Voltage Curves

Current-voltage curves are an important method of characterizing Photovoltaic (PV) Modules. NREL has developed several low-cost MOSFET-based devices that can characterize PV cells and modules. The size of PV modules that can be measured is limited by the power limitations of a single MOSFET. By using multiple MOSFET devices, each can operate at a lower current, paralleled on resistance is also decreased allowing for higher power loads. Operating multiple devices in parallel can cause an imbalance in current, thus causing some devices to conduct more, pushing them into a thermal runaway condition. To investigate this, an active feedback circuit was tested with paralleled devices using a PV module load. The efficacy, limitations, and design considerations of using parallel MOSFET loads for PV characterization are explored. This work is not new, but the implementation of a paralleled architecture in a low cost characterization tool is novel.

14 SOLAR ENERGY↗

Techno-Economic, Feasibility, and Life Cycle Analysis of Renewable Propane: 2025 Update

To clarify the current and future landscape for renewable propane (RP) production, this work evaluates the value proposition of recovering RP from existing and planned hydroprocessed esters and fatty acids (HEFA) biorefineries and surveys emerging technologies under development or deployment. HEFA biorefineries co-produce a propane-rich fuel gas stream, normally used to meet HEFA process heat requirements, from which propane can be recovered and sold to create an additional revenue stream alongside liquid transportation fuels such as renewable diesel (RD) and sustainable aviation fuel (SAF). This report updates and extends a 2022 analysis of RP recovery from HEFA facilities by escalating capital and operating costs to 2024 prices, incorporating recent policy developments (including the Section 45Z Clean Fuel Production Credit), evaluating RP recovery for both RD- and SAF-focused HEFA facilities at two scales (3,000 and 75,000 barrels per day of feedstock), and quantifying the impact of RP recovery on HEFA liquid-fuel carbon intensity (CI) and associated tax credits using the 45ZCF-GREET model. For a 3,000 BPD RD-focused HEFA facility, approximately 3.5 million gallons per year (MGPY) of RP can be recovered; in this base case, the estimated payback period is 18 months based on the total installed cost of the RP recovery equipment and 36 months based on the total capital investment for the entire RP recovery project. The payback period is slightly shorter for the analogous SAF-focused configuration (approximately 4.3 MGPY RP). Sensitivity analysis shows that CAPEX magnitude, RP recovery plant scale, and CI-driven tax credit valuations are the dominant determinants of project viability. RP recovery may increase the CI of HEFA liquid fuels, which can reduce liquid-fuel tax credits (a key revenue stream for the HEFA biorefinery) and lengthen payback periods. However, RP recovery generally remains economically favorable across a wide range of plausible scenarios and market conditions. The report also summarizes emerging pathways that could expand future RP supply.

09 BIOMASS FUELS↗

Feasibility of Multi-Use Ocean Thermal Energy Conversion (OTEC) Platforms

Tropical islands and coastal communities in the United States and internationally suffer from high energy costs, unreliable electrical supplies, poverty, and underemployment, which are all being exacerbated by climate change. Multi-use Ocean Thermal Energy Conversion (OTEC) systems could align with the goals and values of these underserved and remote communities as scalable platforms that can provide baseload power, freshwater, and food, as well as potentially support new industries. The cold, nutrient-rich deep seawater needed for OTEC’s power cycles has many promising byproduct applications such as seawater air conditioning (SWAC) for residential and industrial cooling, enhancing aquaculture farms (e.g., cooling and nutrients for seaweed, shellfish, finfish), producing freshwater through desalination, and generating efuels such as ammonia and hydrogen.

16 TIDAL AND WAVE POWER↗