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All sourcesNASA NTRSDOE OSTI
DOE OSTI2013

Titanium Sheet Production from Commercial Powder

Powder metallurgy titanium sheet was produced from hydride dehydride (HDH) powder using a diverse industrial supply chain. Three different processing routes were developed and production protocols were established in each route to provide options for manufacturing sheet. The produced sheet was tested in accordance with American Society for Testing and Materials (ASTM) B265 specifications and found to be equivalent with grade 4 in yield strength and tensile strength and were at grade 2 levels for elongation. The produced sheet was tested in a newly designed flat plate heat exchanger specifically designed for enhanced reverse osmosis desalination. The powder metallurgy sheet was found to be equivalent in performance to commercially available sheet produced by the standard Kroll process. The testing allows for an alternate supply chain for thin gage titanium sheet to be developed that is not based on the often volatile, aerospace supply chain.

Muth, Thomas R.↗
DOE OSTI2013

An interface tracking model for droplet electrocoalescence.

This report describes an Early Career Laboratory Directed Research and Development (LDRD) project to develop an interface tracking model for droplet electrocoalescence. Many fluid-based technologies rely on electrical fields to control the motion of droplets, e.g. microfluidic devices for high-speed droplet sorting, solution separation for chemical detectors, and purification of biodiesel fuel. Precise control over droplets is crucial to these applications. However, electric fields can induce complex and unpredictable fluid dynamics. Recent experiments (Ristenpart et al. 2009) have demonstrated that oppositely charged droplets bounce rather than coalesce in the presence of strong electric fields. A transient aqueous bridge forms between approaching drops prior to pinch-off. This observation applies to many types of fluids, but neither theory nor experiments have been able to offer a satisfactory explanation. Analytic hydrodynamic approximations for interfaces become invalid near coalescence, and therefore detailed numerical simulations are necessary. This is a computationally challenging problem that involves tracking a moving interface and solving complex multi-physics and multi-scale dynamics, which are beyond the capabilities of most state-of-the-art simulations. An interface-tracking model for electro-coalescence can provide a new perspective to a variety of applications in which interfacial physics are coupled with electrodynamics, including electro-osmosis, fabrication of microelectronics, fuel atomization, oil dehydration, nuclear waste reprocessing and solution separation for chemical detectors. We present a conformal decomposition finite element (CDFEM) interface-tracking method for the electrohydrodynamics of two-phase flow to demonstrate electro-coalescence. CDFEM is a sharp interface method that decomposes elements along fluid-fluid boundaries and uses a level set function to represent the interface.

Erickson, Lindsay Crowl↗
DOE OSTI2013

Innovative Water Management Technology to Reduce Environmental Impacts of Produced Water

Clemson University with Chevron as an industry partner developed and applied treatment technology using constructed wetland systems to decrease targeted constituents in simulated and actual produced waters to achieve reuse criteria and discharge limits. Pilot-scale and demonstration constructed wetland treatment system (CWTS) experiments led to design strategies for treating a variety of constituents of concern (COCs) in produced waters including divalent metals, metalloids, oil and grease, and ammonia. Targeted biogeochemical pathways for treatment of COCs in pilot-scale CWTS experiments included divalent metal sulfide precipitation through dissimilatory sulfate reduction, metal precipitation through oxidation, reduction of selenite to insoluble elemental selenium, aerobic biodegradation of oil, nitrification of ammonia to nitrate, denitrification of nitrate to nitrogen gas, separation of oil using an oilwater separator, and sorption of ammonia to zeolite. Treatment performance results indicated that CWTSs can be designed and built to promote specific environmental and geochemical conditions in order for targeted biogeochemical pathways to operate. The demonstration system successfully achieved consistent removal extents even while inflow concentrations of COCs in the produced water differed by orders of magnitude. Design strategies used in the pilot-scale and demonstration CWTSs to promote specific conditions that can be applied to designing full-scale CWTSs include plant and soil selection, water-depth selection, addition of amendments, and hydraulic retention time (HRT). These strategies allow conditions within a CWTS to be modified to achieve ranges necessary for the preferred biogeochemical treatment pathways. In the case of renovating a produced water containing COCs that require different biogeochemical pathways for treatment, a CWTS can be designed with sequential cells that promote different conditions. For example, the pilot-scale CWTS for post-reverse osmosis produced water was designed to promote oxidizing conditions within the first wetland cell for nitrification of ammonia, and the subsequent three cells were designed to promote reducing conditions for denitrification of nitrate. By incorporating multiple wetland cells in a CWTS, the conditions within each cell can be modified for removal of specific COCs. In addition, a CWTS designed with multiple cells allows for convenient sample collection points so that biogeochemical conditions of individual cells can be monitored and performance evaluated. Removal rate coefficients determined from the pilot-scale CWTS experiments and confirmed by the demonstration system can be used to calculate HRTs required to treat COCs in full-scale CWTSs. The calculated HRTs can then be used to determine the surface area or "footprint" of a full-size CWTS for a given inflow rate of produced water.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2014

Laboratory Evaporation Testing Of Hanford Waste Treatment Plant Low Activity Waste Off-Gas Condensate Simulant

The Hanford Waste Treatment and Immobilization Plant (WTP) Low Activity Waste (LAW) vitrification facility will generate an aqueous condensate recycle stream, LAW Off-Gas Condensate, from the off-gas system. The baseline plan for disposition of this stream is to send it to the WTP Pretreatment Facility, where it will be blended with LAW, concentrated by evaporation and recycled to the LAW vitrification facility again. Alternate disposition of this stream would eliminate recycling of problematic components, and would enable de-coupled operation of the LAW melter and the Pretreatment Facilities. Eliminating this stream from recycling within WTP would also decrease the LAW vitrification mission duration and quantity of canistered glass waste forms. This LAW Off-Gas Condensate stream contains components that are volatile at melter temperatures and are problematic for the glass waste form. Because this stream recycles within WTP, these components accumulate in the Condensate stream, exacerbating their impact on the number of LAW glass containers that must be produced. Approximately 32% of the sodium in Supplemental LAW comes from glass formers used to make the extra glass to dilute the halides to be within acceptable concentration ranges in the LAW glass. Diverting the stream reduces the halides in the recycled Condensate and is a key outcome of this work. Additionally, under possible scenarios where the LAW vitrification facility commences operation prior to the WTP Pretreatment facility, identifying a disposition path becomes vitally important. This task examines the impact of potential future disposition of this stream in the Hanford tank farms, and investigates auxiliary evaporation to enable another disposition path. Unless an auxiliary evaporator is used, returning the stream to the tank farms would require evaporation in the 242-A evaporator. This stream is expected to be unusual because it will be very high in corrosive species that are volatile in the melter (chloride, fluoride, sulfur), will have high ammonia, and will contain carryover particulates of glass-former chemicals. These species have potential to cause corrosion of tanks and equipment, precipitation of solids, release of ammonia gas vapors, and scale in the tank farm evaporator. Routing this stream to the tank farms does not permanently divert it from recycling into the WTP, only temporarily stores it prior to reprocessing. Testing is normally performed to demonstrate acceptable conditions and limits for these compounds in wastes sent to the tank farms. The primary parameter of this phase of the test program was measuring the formation of solids during evaporation in order to assess the compatibility of the stream with the evaporator and transfer and storage equipment. The origin of this LAW Off-Gas Condensate stream will be the liquids from the Submerged Bed Scrubber (SBS) and the Wet Electrostatic Precipitator (WESP) from the LAW facility melter offgas system. The stream is expected to be a dilute salt solution with near neutral pH, and will likely contain some insoluble solids from melter carryover. The soluble components are expected to be mostly sodium and ammonium salts of nitrate, chloride, and fluoride. This stream has not been generated yet, and, thus, the composition will not be available until the WTP begins operation, but a simulant has been produced based on models, calculations, and comparison with pilot-scale tests. This report discusses results of evaporation testing of the simulant. Two conditions were tested, one with the simulant at near neutral pH, and a second at alkaline pH. The neutral pH test is comparable to the conditions in the Hanford Effluent Treatment Facility (ETF) evaporator, although that evaporator operates at near atmospheric pressure and tests were done under vacuum. For the alkaline test, the target pH was based on the tank farm corrosion control program requirements, and the test protocol and equipment was comparable to that used for routine evaluation of feed compatibility studies for the 242-A evaporator. One of the radionuclides that is volatile in the melter and expected to be in high concentration in this LAW Off-Gas Condensate stream is Technetium-99 (99Tc). Technetium will not be removed from the aqueous waste in the Hanford WTP, and will primarily end up immobilized in the LAW glass by repeated recycle of the off-gas condensate into the LAW melter. Other radionuclides that are also expected to be in appreciable concentrations in the LAW Off-Gas Condensate are 129I, 90Sr, 137Cs, and 241Am. The concentrations of these radionuclides in this stream will be much lower than in the LAW, but they will still be higher than limits for some of the other disposition pathways currently available. At this time, these scoping tests did not evaluate the partitioning of the radionuclides to the evaporator condensate, since ample data are available separately from other experience in the DOE complex. Results from the evaporation testing show that the neutral SBS simulant first forms turbidity at ~7.5X concentration, while the alkaline-adjusted simulant became turbid at ~3X concentration. The major solid in both cases was Kogarkoite, Na3FSO4. Sodium and lithium fluorides were also detected. Minimal solids were formed in the evaporator bottoms until a substantial fraction of liquid was removed, indicating that evaporation could minimize storage volume issues. Achievable concentration factors without significant insoluble solids were 17X at alkaline pH, and 23X at neutral pH. In both runs, significant ammonia carried over and was captured in the condenser with the water condensate. Results also indicate that with low insoluble solids formation in the initial testing at neutral pH, the use of Reverse Osmosis is a potential alternate method for concentrating the solution, although an evaluation is needed to identify equipment that can tolerate insoluble solids. Most of the ammonia remains in the evaporator bottoms during the neutral pH evaporation, but partitions to the condensate during alkaline evaporation. Disposition of both streams needs to consider the management of ammonia vapor and its release. Since this is an initial phase of testing, additional tasks related to evaporation methods are expected to be identified for development. These tasks likely include evaluation and testing of composition variability testing and evaluations, corrosion and erosion testing, slurry storage and immobilization investigations, and evaporator condensate disposition.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2014

Bounding the marginal cost of producing potable water including the use of seawater desalinization as a backstop potable water production technology

The analysis presented in this technical report should allow for the creation of high, medium, and low cost potable water prices for GCAM. Seawater reverse osmosis (SWRO) based desalinization should act as a backstop for the cost of producing potable water (i.e., the literature seems clear that SWRO should establish an upper bound for the plant gate cost of producing potable water). Transporting water over significant distances and having to lift water to higher elevations to reach end-users can also have a significant impact on the cost of producing water. The three potable fresh water scenarios describe in this technical report are: low cost water scenario ($0.10/m 3 ); medium water cost scenario ($1.00/m 3 ); and high water cost scenario ($2.50/m 3 ).

costs↗
DOE OSTI2013

Flexible Distributed Energy & Water from Waste for Food and Beverage Industry

Food and beverage plants inherently consume a large quantity of water and generate a high volume of wastewater rich in organic content. On one hand, water discharge regulations are getting more stringent over the time, necessitating the use of different technologies to reduce the amount of wastewater and improve the effluent water quality. On the other hand, growing energy and water costs are driving the plants to extract and reuse valuable energy and water from the wastewater stream. An integrated waste-tovalue system uses a combination of anaerobic digester (AD), reciprocating gas engine/boiler, membrane bioreactor (MBR), and reverse osmosis (RO) to recover valuable energy as heat and/or electricity as well as purify the water for reuse. While individual anaerobic digestion and membrane bioreactors are being used in increasing numbers, there is a growing need to integrate them together in a waste-to-value system for enhanced energy and water recovery. However, currently operation of these systems relies heavily on the plant operator to perform periodic sampling and off-line lab analysis to monitor the system performance, detect any abnormal condition due to variations in the wastewater and decide on appropriate remedial action needed. This leads to a conservative design and operation of these systems to avoid any potential upsets that can destabilize the system.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2015

DOE SBIR 2014 Topic 2.C – Phase I Final Report

Freshwater is a vital resource for human survival as well as a key component of a wide range of industrial and agricultural needs. However, only 0.65% of the world’s water resources are available as freshwater, and the demand on the world’s water reserves continues to increase, with the demand beginning to outpace the supply in many areas. A water-energy nexus is being reached that requires low –cost and –energy solutions for various degrees of treated water. In a 2012 survey, 88% of Americans were concerned about potential water shortages and approximately two-thirds of the world’s population will be suffering a water shortage over the next few years. Seawater and other saline water materials make up around 98% of the available water, representing an almost unlimited supply of water. The energy, cost and maintenance to remove salts and other unwanted compounds is a barrier to widespread implementation of salt-to-freshwater facilities. These facilities most commonly use reverse osmosis (RO) systems. Due to the high required pressures and moving parts these facilities consume much grid energy and require constant maintenance leading to high capital and operational costs. RO also generates highly concentrated brine that is costly to safely return to the ocean. Capacitive desalination (or capacitive deionization [CDI]) has no moving parts (aside from a low pressure pump and valves), operates at low pressure and does not generate brine that is hazardous to marine life. Not only can the capacitive charge/discharge be cycled almost indefinitely but the system uses low energy and capacitive discharge electrical current can be co-generated back to the system. However, CDI has not seen widespread use for large- or small- scale desalination because electrode efficiency limits the extraction rate below what is useful for most applications. Mainstream Engineering Corporation (MEC) has demonstrated an innovative new electrode structure for the high efficiency desalination of brackish water by capacitive deionization. Electrode manufacturing (nanomanufacturing) is a highly scalable and low-cost electrochemical self-assembly method using a templated process that Mainstream has pioneered and leveraged for several energy technologies over the last decade. The primary accomplishment for Phase I is the fabrication and demonstration of CDI electrode structures are: • Demonstrating the linear scalability of templated approach to the fabrication scaling the electrode structure. • Demonstrated the ability to tune the fabrication of the electrode structures to produce electrodes with a highly controllable aligned nanopore diameter and nanopore depth. • Demonstrated the efficient removal of a sodium chloride salt from brackish water with a 60 times improvement in mg-salt removed/g-carbon compared to a commercial system under the same conditions. • Demonstrated good reproducibility and stability of the electrode structure under realistic CDI operating conditions. • Demonstrated charge efficiency as high as 93% with an expected system level energy requirement of 0.7 to 1.5 kWh/m3 of water; significantly lower than the 2.9 to 3.7 kWh/m3 observed for RO systems Based on the performance characteristics of the electrodes, Mainstream was able to propose a modular and scalable capacitive deionization design that can be adapted to a wide range of conditions providing energy efficient desalination of brackish water.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Use of Low-Temperature Geothermal Energy for Desalination in the Western United States

This joint project between the National Renewable Energy Laboratory and the Colorado School of Mines has examined the potential of using low-temperature geothermal resources for desalination. The temperature range in question is not well suited for electricity generation, but can be used for direct heating. Accordingly, the best integration approaches use thermal desalination technologies such as multi-effect distillation (MED) or membrane distillation (MD), rather than electric-driven technologies such as reverse osmosis (RO). The examination of different desalination technologies led to the selection of MD for pairing with geothermal energy. MD operates at near-ambient pressure and temperatures less than 100°C with hydrophobic membranes. The technology is modular like RO, but the equipment costs are lower. The thermal energy demands of MD are higher than MED, but this is offset by an ability to run at lower temperatures and a low capital cost. Consequently, a geothermal-MD system could offer a low capital cost and, if paired with low-cost geothermal energy, a low operating cost. The target product water cost is $1.0 to $1.5 per cubic meter depending on system capacity and the cost of thermal energy.

15 GEOTHERMAL ENERGY↗
DOE OSTI2016

Development of Ultrafiltration Membrane-Separation Technology for Energy-Efficient Water Treatment and Desalination Process

The growing scarcity of fresh water is a major political and economic challenge in the 21st century. Compared to thermal-based distillation technique of water production, pressure driven membrane-based water purification process, such as ultrafiltration (UF), nanofiltration (NF) and reverse osmosis (RO), can offer more energy-efficient and environmentally friendly solution to clean water production. Potential applications also include removal of hazardous chemicals (i.e., arsenic, pesticides, organics) from water. Although those membrane-separation technologies have been used to produce drinking water from seawater (desalination) and non-traditional water (i.e., municipal wastewater and brackish groundwater) over the last decades, they still have problems in order to be applied in large-scale operations. Currently, a major huddle of membrane-based water purification technology for large-scale commercialization is membrane fouling and its resulting increases in pressure and energy cost of filtration process. Membrane cleaning methods, which can restore the membrane properties to some degree, usually cause irreversible damage to the membranes. Considering that electricity for creating of pressure constitutes a majority of cost (~50%) in membrane-based water purification process, the development of new nano-porous membranes that are more resistant to degradation and less subject to fouling is highly desired. Styrene-ethylene/butylene-styrene (SEBS) block copolymer is one of the best known block copolymers that induces well defined morphologies. Due to the polarity difference of aromatic styrene unit and saturated ethylene/butylene unit, these two polymer chains self-assemble each other and form different phase-separated morphologies depending on the ratios of two polymer chain lengths. Because the surface of SEBS is hydrophobic which easily causes fouling of membrane, incorporation of ionic group (e,g, sulfonate) to the polymer is necessary to reduces fouling. Recently, sulfonated SEBS became commercially available and has been extensively explored for membrane-mediated water purification technology. The sulfonated block copolymer creates a well developed nano-sale phase-separated morphologies composed of hydrophilic domains (sulfonated polystyrene) and hydrophobic domains (polyethylene/polybutylene). The hydrophilic domains determines transport properties (water transport, salt and/or ion rejection, etc) and the hydrophobic domains provides mechanical stability of the membrane. Unfortunately, a high degree of sulfonation of SEBS induces excessive swelling and deterioration of mechanical stability of the membrane. In an effort to develop robust polymeric membrane materials for water purification technology, phosphonic acid-functionalized SEBS membranes are investigated during this report period. In compare to sulfonated polymers, the corresponding phosphonated polymers are known to swell less because of the formation of extensive hydrogen bonding networks between phosphonates. In addition to the expected better mechanical stability, phosphonated polymers has another advantage over sulfonated polymers for the use water purification membrane; each phosphonate can accommodate two ions while each sulfonate accommodates only one ion. Membrane properties (ion type, ionic density, etc) of new membranes will be studied and their separation performance will be evaluated in water purification and desalination process. Through systematic study of the relationship of chemical structure–surface property–membrane performance, we aim to better understand the nature of membrane fouling and develop more fouling-resistant water purification membranes. The basic understanding of this relationship will lead to the development of advanced membrane materials which can offer a solution to environmentally sustainable production of fresh water.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Status on the Component Models Developed in the Modelica Framework: High-Temperature Steam Electrolysis Plant & Gas Turbine Power Plant

This report has been prepared as part of an effort to design and build a modeling and simulation (M&S) framework to assess the economic viability of a nuclear-renewable hybrid energy system (N-R HES). In order to facilitate dynamic M&S of such an integrated system, research groups in multiple national laboratories have been developing various subsystems as dynamic physics-based components using the Modelica programming language. In fiscal year (FY) 2015, Idaho National Laboratory (INL) performed a dynamic analysis of two region-specific N-R HES configurations, including the gas-to-liquid (natural gas to Fischer-Tropsch synthetic fuel) and brackish water reverse osmosis desalination plants as industrial processes. In FY 2016, INL has developed two additional subsystems in the Modelica framework: a high-temperature steam electrolysis (HTSE) plant and a gas turbine power plant (GTPP). HTSE has been proposed as a high priority industrial process to be integrated with a light water reactor (LWR) in an N-R HES. This integrated energy system would be capable of dynamically apportioning thermal and electrical energy (1) to provide responsive generation to the power grid and (2) to produce alternative industrial products (i.e., hydrogen and oxygen) without generating any greenhouse gases. A dynamic performance analysis of the LWR/HTSE integration case was carried out to evaluate the technical feasibility (load-following capability) and safety of such a system operating under highly variable conditions requiring flexible output. To support the dynamic analysis, the detailed dynamic model and control design of the HTSE process, which employs solid oxide electrolysis cells, have been developed to predict the process behavior over a large range of operating conditions. As first-generation N-R HES technology will be based on LWRs, which provide thermal energy at a relatively low temperature, complementary temperature-boosting technology was suggested for integration with the HTSE process that requires higher temperature input. Simulation results involving several case studies show that the suggested control scheme could maintain the controlled variables (including the steam utilization factor, cathode stream inlet composition, and temperatures of the process streams at various locations) within desired limits under various plant operating conditions. The results also indicate that the proposed HTSE plant could provide operational flexibility to participate in energy management at the utility scale by dynamically optimizing the use of excess plant capacity within an N-R HES. A natural-gas fired GTPP has been proposed as a secondary energy supply to be included in an N-R HES. This auxiliary generator could be used to cover rapid dynamics in grid demand that cannot be met by the remainder of the N-R HES. To evaluate the operability and controllability of the proposed process during transients between load (demand) levels, the dynamic model and control design were developed. Special attention was given to the design of feedback controllers to regulate the power frequency, and exhaust gas and turbine firing temperatures. Several case studies were performed to investigate the system responses to the major disturbance (power load demand) in such a control system. The simulation results show that the performance of the proposed control strategies was satisfactory under each test when the GTPP experienced high rapid variations in the load.

08 HYDROGEN↗
DOE OSTI2017

Final Scientific/Technical Report for Program Title: Solar Powered Dewvaporation Desalination System

Desalination technologies have been used increasingly throughout the world to produce the drinking water from the brackish ground and sea water for the past few decades. Among the commercially available desalination technologies, reverse osmosis (RO) and multi-stage flash distillation are the most widely used technologies globally. However, these technologies are difficult to be directly integrated with green energies without converting them to electricity. Dewvaporation, a desalination process, uses saturated steam as a carrier-gas to evaporate water from saline feeds and form pure condensate. It has the major technical benefit of reusing energy, released from vapor condensation, multiple times. The current proposal has been planned to address this issue. In Phase I, we have successfully demonstrated the feasibility of a new plasmonic nanoparticle based approach through fabrication and evaluation of a solar powered water vapor generation module. The water vapor generation module allows generation of high temperature plasmon on a fiber bundle end, where strong water and plasmon interaction occurs generating water vapor. Plasmon enhanced water evaporation has been realized on plasmonic nanoparticle immobilized substrate with an energy conversion efficiency of over 50%.

14 SOLAR ENERGY↗
DOE OSTI2017

Status Report on the High-Temperature Steam Electrolysis Plant Model Developed in the Modelica Framework (FY17)

This report has been prepared as part of an effort to design and build a modeling and simulation (M&S) framework to assess the economic viability of a nuclear-renewable hybrid energy system (N-R HES). In order to facilitate dynamic M&S of such an integrated system, research groups in multiple national laboratories have been developing various subsystems as dynamic physics-based components using the Modelica programming language. In fiscal year 2015 (FY15), Idaho National Laboratory (INL) performed a dynamic analysis of two region-specific N-R HES configurations, including the gas-to-liquid (natural gas to Fischer-Tropsch synthetic fuel) and brackish water reverse osmosis desalination plants as industrial processes. In FY16, INL developed two additional subsystems in the Modelica framework: (1) a high-temperature steam electrolysis (HTSE) plant as a high priority industrial plant to be integrated with a light water reactor (LWR) within an N-R HES and (2) a gas turbine power plant as a secondary energy supply. In FY17, five new components (i.e., a feedwater pump, a multi-stage compression system, a sweep-gas turbine, flow control valves, and pressure control valves) have been incorporated into the HTSE system proposed in FY16, aiming to better realistically characterize all key components of concern. Special attention has been given to the controller settings based on process models (i.e., direct synthesis method), aiming to improve process dynamics and controllability. A dynamic performance analysis of the improved LWR/HTSE integration case was carried out to evaluate the technical feasibility (load-following capability) and safety of such a system operating under highly variable conditions requiring flexible output. The analysis (evaluated in terms of the step response) clearly shows that the FY17 model resulted in superior output responses with much smaller settling times and less oscillatory behavior in response to disturbances in the electric load than those observed with the FY16 model. Simulation results involving several case studies show that the suggested control scheme could maintain the controlled variables (including the steam utilization factor, cathode stream inlet composition, and temperatures and pressures of the process streams at various locations) within desired limits under various plant operating conditions. The results also indicate that the proposed HTSE plant could provide operational flexibility to participate in energy management at the utility scale by dynamically optimizing the use of excess plant capacity within an N-R HES.

08 HYDROGEN↗
DOE OSTI2018

High Ion-Accessible Surface Area CNT-Ultracapacitors for Groundwater Desalination

Fresh water is a vital resource for human survival, as well as a key component for a wide range of industrial and agricultural needs. However, only 0.65% of the world’s water resources are available as fresh water, and the demand on the world’s water reserves continues to rise, with the demand already beginning to outpace the supply in many areas. A water-energy nexus is being reached that requires low -cost and -energy solutions for various degrees of treated water. Public awareness of the problem has also risen, such that in a 2012 survey, 88% of Americans reported concerns about potential water shortages. Approximately two-thirds of the world’s population could suffer water shortages over the next few years. Seawater and other saline water supplies make up around 98% of the world’s accessible water. Properly treated to reduce the levels of salinity, this represents an almost unlimited supply of fresh water. The high energy requirements, capital costs, and maintenance requirements to remove salts and other unwanted compounds, however, are barriers to widespread implementation of salt-to-freshwater facilities. These facilities most commonly use reverse osmosis (RO) systems that suffer from high required pressures and failures of moving parts; additionally, these facilities consume much grid energy and require constant maintenance, leading to high capital and operational costs. The RO process also generates large volumes of highly concentrated bio-hazardous brine that is costly to safely return to the ocean. In contrast to RO, capacitive desalination or capacitive deionization (CDI) has fewer moving parts (a low-pressure pump and several valves), operates at low pressure, and does not generate large quantities of brine that are hazardous to marine life. The capacitive charge/discharge of a CDI system can be cycled almost indefinitely, and the system has low energy requirements because the capacitive discharge electrical current can be co-generated back to the system. RO must remove the water from the salt while CDI removes the salt from the water. This represents a significant difference in the number of molecules which must be moved and energy required to desalinate water. However, CDI has not seen widespread use for large- or small-scale desalination because electrode efficiency has limited the extraction rate below what is useful for most applications. Mainstream demonstrated the following successes during this SBIR program: Performance - We developed an innovative new electrode structure for the high-efficiency removal of ions from salt-contaminated water samples by CDI. Based on prototype electrochemical tests, our CDI consumes as low as 0.71 kW/m 3 of treated water (compared to 2.9 to 3.7 kW/m 3 for RO). Scalability – During Phase II, we increased the electrode size from 3.8 cm 2 single-sided electrodes to 180 cm 2 double-sided electrodes. Using larger acid baths and CVD furnace, we increased electrode fabrication capacity increased by 315 times. Scalable electrochemical CDI stack design and balance of plant – During Phase II, we demonstrated at scalable low-pressure drop stack design and balance of plant for the continuous removal of ions. Corrosion Resistance – Based on accelerated corrosion testing data, our high-quality graphitic electrodes have a significantly improved corrosion resistance. This was 20 times better corrosion resistance than our Phase I electrodes and significantly higher than typical CDI system electrodes. Flexibility –By tuning the pore size of the electrode materials, we demonstrated the removal of key target ionic contaminants, such as sodium chloride, nitrate, and phosphate salts. These ionic contaminants are common in agricultural and industrial wastewater runoff and are difficult to remove by conventional methods, which require excessive use of reagents.

Cox, Dr. Philip↗
DOE OSTI2018

Case Study: Nuclear-Renewable-Water Integration in Arizona

This document reports the application of the N-R HES software framework to a case study for Arizona Public Service (APS); the manager and part owner of the Palo Verde (PV) nuclear power plant. The case study is a work in progress of which this report presents a detailed description of the current model input data, assumptions and the corresponding results produced by the developed software framework. The goal of the report is, that with this information APS (together with INL) should be able to identify where more detailed data and more accurate model assumptions are necessary to reproduce all driving physical and economic phenomena in order to capture enough complexity of the reality to allow APS to use the results for their strategic decisions. The N-R HES software framework started being developed at INL two years ago [ref]. The framework has reached some level of maturity so that it can be applied to more than simple demonstration cases, e.g. real industry problems. Nevertheless, more capabilities are constantly added to accommodate the special needs of these challenging real life problems. The N-R HES framework is built on top of the RAVEN code [ref] and uses it as driver and workflow manager for all calculations. The framework has specifically been developed for the economic assessment of N-R HES systems. There are four main cornerstones of the N-R HES simulation framework: 1) generation of stochastic time series, 2) a probabilistic analysis and optimization set of algorithms available in RAVEN, 3) a set of models for representation of the physical behavior of N-R HES, and 4) a RAVEN plug-in that maps physical performance into economic performance called CashFlow. Within this framework, a broad spectrum of questions related to N-R HES can be addressed. One of the challenges currently of high interest is that the increasing penetration of variable renewables is altering the profile of the net demand (demand after removing all non curtailable renewable energy sources), with which the other generators on the grid have to cope. The N-R HES software framework is capable to analyze the potential feasibility of mitigating the resultant volatility in the net electricity demand. One possible solution to that problem currently intensively studied by the energy industry is adding stabilizing loads to the grid. These loads can be external industrial processes that are able to ramp production up and down quickly or adding variable internal loads that will lift the base load of the power plant. The latter is a possible solution currently studied by APS. APS if currently anticipating several challenges that will likely arise in the near future. One of them is, as mentioned, coping with the rapid growth of variable renewable energy (VRE) sources put on the grid. Although APS can sell its electricity for a fixed retail price to cover the local demand first, it also sells electricity in excess of the local demand at the Palo Verde energy hub. Due to the growing VRE penetration, the Palo Verde hub electricity spot price is negative more and more frequently. To mitigate this price volatility, APS is seeking to add more base load, so that the quantity of excess energy to be sold for prices potentially less than the internal retail price or even negative prices at the hub is reduced. A second challenge APS is facing is that their cooling water acquisition contract with the Sub Regional Operating Group (SROG) will expire soon and a renewal can only be done for a significantly higher price of the water. Therefore, APS is also seeking for alternative sources for their cooling water. An opportunity currently under investigation is to pump a limited quantity of brackish water from the regional ground water. Although much cheaper than the water from the new SROG contract, the salinity of the brackish water is so high that a blend of brackish and SROG water would need additional treatment to improve its quality for use in the cooling towers. An on-site reverse osmosis (RO) desalination plant is envisaged to reduce the salinity to an acceptable level. This report investigates the economic impact of such an RO plant. As one can see, the RO plant would help with both problems APS is facing: First, it would rise the APS base load helping to mitigate VRE induced hub price volatility. From this perspective, the RO plant can be seen as a stabilizing load on the grid as would be any other industrial process. Second, the RO’s goods, e.g. the clean water produced can be used by APS itself for a (hopefully) lower cost than 100% SROG water would be. The report will first describe the APS water procurement strategy in detail and lay out the possible alternative scenarios studied in this document. This is covered in Chapter 2. Next, in Chapter 3, the APS case model developed within the N-R HES software framework is described. This chapter includes also a description of the needed framework developments to accommodate the APS study.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2019

Novel Membrane and Systems for Industrial and Municipal Water Purification and Reuse

Over the last five years, GE Global Research, University of Colorado-Boulder and the National Institute of Standards and Technology (NIST) teamed to develop nano-engineered, high permeance membrane materials that outperform conventional RO membranes. The team explored liquid and gas-phase molecular layer by layer synthesis (mLbLS) strategies and manufacturing processes for cost effective production of the novel materials. The objective of this project was to decrease the energy consumption of reverse osmosis (RO) membrane separation processes by 50%, while also decreasing the environmental impact and cost of water. The team was successful in identify two promising approaches to achieve that end goal.

36 MATERIALS SCIENCE↗
DOE OSTI2021

CO2 Capture Strategies via Mineralization with Industrial Waste Brines

Large coal-fired power plants (>500 MW) account for 30% of global CO2 emissions, and long-term management of this CO2 to is urgently needed mitigate global temperature increases. Sequestration of CO2 within stable mineral carbonates (e.g., CaCO3) represents an attractive emission reduction strategy because it offers a leakage-free alternative to geological storage of CO2 in an environmentally friendly form. We have previously described a mineralization process in which divalent cations are sourced from various waste streams (e.g., produced water and brackish water) and alkalinity is induced via regenerable ion-exchange materials (Bustillos et. al. Frontiers in Energy Research. 2020, 8, 352). In our process, aqueous carbonate-bearing streams with pH > 8 are produced by contacting fresh water and carbon dioxide with various ion-exchange materials (e.g., Na form zeolites or ion exchange resins). These streams are mixed with produced water containing varying concentrations (~0.01 – 1.0 M) of Ca2+ leading to the precipitation of solid calcium carbonate (PCC). This process has the advantages of using regenerable solids in a simple and continuous process to increase the pH of water by ion exchange instead of relying on the consumption of costly and unsustainable sources of alkalinity (e.g., sodium hydroxide). While once-through column experiments showed the above benefits, the same were yet to established in a steady-state process with recycle streams. In this work, we set up a process simulation to quantify the energy requirements and CO2 emissions associated with the process and seek optimal produced water compositions and CO2 concentrations (5 – 20 vol%). The process simulation was set up in ASPEN Plus using eRNTL as the thermodynamic property method and sequential modular strategy. Ion exchange alkaline solution was simulated using sodium hydroxide and validated against the experimental data obtained from once-through kinetic experiments. Nanofiltration and reverse osmosis membrane steps were also implemented for the separation of divalent cations and production of fresh water and a regeneration stream following mineralization. Sensitivity analysis was carried out using a range of produced water compositions (0.01 – 1.0 M Ca2+, 0.001 – 0.15 M Mg2+, 0.5 – 3.5 M Na+ and 0.0004 – 0.002 M Fe2+) according to the United States Geological Survey (USGS) database. Calcium carbonate yields increased with increasing CO2 concentrations and were maximized using produced water compositions with larger Ca2+ concentrations. Maximum calcium carbonate yields produced at 5 vol%, 12 vol% and 20 vol% CO2 were 2.3 mmol/L, 5.5 mmol/L, and 9.3 mmol/L, respectively, with the formation of brucite (a magnesium hydroxide phase, Mg(OH)2) and goethite (an iron hydroxide phase, FeOOH) as the primary contaminant phases (99% calcite, 0.6% brucite, 0.4% goethite), which agree with phases detected by XRD experimentally. These results indicate high purity calcium carbonate can be precipitated using industrial waste streams. Consequentially, energy consumption and net CO2 emissions were minimized where precipitated calcium carbonate was maximized for all produced water compositions and CO2 concentrations. Minimum energy consumptions were 0.21 kWh/ton CO2 processed, with 98% of the energy input required coming from the membrane filtration steps. Produced water compositions with large Na+ concentrations (> 0.5 M) were effective at reducing energy consumptions due to faster regeneration time of ion exchange materials. Additionally, calculated net CO2 emissions were negative for the process and ranged from -0.02 kg/ton CO2 to -0.15 kg/ton CO2 processed, indicating a low emission process. We will also present techno-economic assessment showing the economic benefits of the current process as an alternative to the addition of stoichiometric bases to induce alkalinity for the precipitation of CaCO3.

Simonetti, Dante↗
DOE OSTI2021

Santa Barbara Desalination Digital Twin Technical Report

A digital twin is a computer model that has sufficient breadth and fidelity to enable diagnostic and predictive analyses for outputs of interest. We have constructed a digital twin of the SB desal plant using the ProteusLib software developed for NAWI under task 4.2.2, and specifically the ProteusLib models of pumps, filters, mixers, splitters, and reverse osmosis units and a seawater property model. The steps needed to configure this digital twin with the real conditions of the SB desal plant are: (1) Data reconciliation, which is gathering the data and plant connectivity and ensure that all relevant values are present and in the correct units and validating the data using material and energy balances, and correct for errors, gaps, or deviations; (2) Parameter estimation, which is matching model parameters with data from previous step, filling missing parameters with initial estimates, then iteratively refining estimated values. Once we completed the digital twin, we used the optimization capabilities of ProteusLib to compute outputs of interest over a chosen range of inputs. The primary output of interest to the owners of the plant is its specific energy consumption (kWh/acre-foot). The remainder of this report will provide more detail on the data reconciliation, parameter estimation, and analyses we performed.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

Improving the Economic Viability of Biological Utilization of Coal Power Plant CO 2 by Improved Algae Productivity and Integration with Wastewater Treatment

The overall goal of this project was to improve the cost-effectiveness of systems using algae to capture and beneficially utilize CO 2 from the flue gas of coal-fired power plants. Algal biomass cultivation is an attractive alternative for carbon capture and utilization because it can uptake more CO 2 per land area than any other photosynthetic crop. Also, the resulting biomass can be used to make valuable large-market commodity products, such as biofuels and animal feed. However, the use of algal carbon capture has been limited by several factors including: (1) high costs for growing algae (>$\$1,300$/ton), (2) large land requirements for algae cultivation, and (3) environmental concerns about the large amount of water and nutrient inputs needed for growing algae. This project has taken direct aim at resolving these key limitations and demonstrated several viable approaches to improve the economic and environmental feasibility of algal carbon capture. In particular, this project demonstrated a significant increase in average annual algal productivity from baseline values of 8 g/m 2 -day to above 20 g/m 2 -day. This supports a much lower projected cost of algae production (<$\$500$/ton) and reduces land requirements by more than 50%. Additionally, this project confirmed the ability to grow multiple algae species with wastewater nutrients, which facilitates the potential for substantial new revenue streams for algae cultivation based on tipping fees for nutrient laden wastewater. This study highlighted that there is more potential value in wastewater nutrient treatment credits than in the primary commodity products made from algae. The use of wastewater inputs also mitigates the concerns associated with the large amount of water needed for growing algae. The algal biomass grown for this project using wastewater and simulated flue gas inputs were characterized for potential use as an animal feed ingredient. The algae had a protein content in the range of 35-40%, which is between some common commodity animal feed products— distiller’s grains (~25-30% protein) and soybean meal (45-50% protein). In-vitro digestion tests using cattle rumen fluids, showed that this algae biomass was best suited for use as “bypass protein”, which is digested in the animal intestine. Based on the protein content and amino acid profile of the algae grown in this study, it was estimated to have market value in the range of $\$190$-$\$280$/ton. There is potential for higher value feed products if the algae content of omega-3 fatty acids or antioxidants is accounted for. This project also did small scale demonstration of forward osmosis algae dewatering and nanofiltration of hydrothermal liquefaction aqueous products, which were shown to improve the cost and energy balance for producing algal products. When all the improvements demonstrated in this study were included in techno-economic analysis, it showed there was a viable pathway to profitable algal CO 2 utilization with a payback period in the range of six to ten years.

01 COAL, LIGNITE, AND PEAT↗