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DOE OSTI2024

Value of Nuclear Energy to the Reliability of the North American Power System: Results for Western and Eastern Interconnections

This report documents the fulfillment of a milestone for the United States (U.S.) Department of Energy Office of Nuclear Energy Light Water Reactor Sustainability Program: completing a baseline study of regional impact of nuclear power plants and hydrogen production in maintaining grid services and power quality. Models have been comprehensively demonstrated for the Western Interconnection, or Western Electric Coordinating Council area, and in the Eastern Interconnection for scenarios representative of past extreme events (e.g., drought and heat waves). Understanding the impact on the reliability of the bulk electric system of any reduction in generation capacity from nuclear power, for any reason, is the motivation of this work. Factors that might lead to the premature or unplanned closure of nuclear plants, extended outages, or repurposing of nuclear power include: • Aging infrastructure: Many nuclear power plants in the U.S. are nearing the end of their designed operating lives. Upgrading aging infrastructure can be expensive, and some utilities may choose to retire plants rather than invest in costly upgrades. • Low wholesale electricity prices: The deregulation of the electricity market in many states has led to increased competition and driven down wholesale electricity prices, causing nuclear power operators to seek other revenue sources for their heat and power such as clean hydrogen production. • Renewables growth: The rapid growth of renewable energy sources like solar and wind power is posing a challenge to traditional generation sources like nuclear. While many see renewables as a key part of the clean energy transition, their intermittent nature requires additional grid solutions for reliable power supply. • The potential for regulatory decisions to be in conflict: In its 2021 rulemaking, EPA rule (86 FR 880), the Environmental Protection Agency (EPA) set a compliance date for the ban on processing and distribution in commerce of Decabromodiphenyl Ether (DecaBDE). Since DecaBDE is in many components, particularly wiring, of nuclear power plants which are deemed safety-related or important to safety, three plants would not have been able to restart after their 2023 spring outages, and numerous others would have faced issues in the near future. Fortunately, in this case, the EPA provided relief to the nuclear energy industry. The report provides a summary of the significant role nuclear energy plays in the United States’ power generation mix, supplying around 20% of the nation’s electricity generation, spread across 28 U.S. states. Nuclear power is reliable, mostly unaffected by weather and seasonal changes, and provides a consistent source of baseload power. In terms of capacity, nuclear power plants account for as much as 26% of balancing area power generation capacity. Nuclear power also provides a substantial contribution (e.g., 10% of the inertia in the Eastern Interconnection) of the synchronous spinning mass/inertia that buffers the rate at which frequency changes when a load and generation imbalance occurs (e.g., a large plant trips or a load is suddenly shed due to a transmission outage). This contribution is critical for maintaining grid stability during sudden changes in load or generation.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2025

Develop a Simulation Framework for Understanding Physico-Chemical Processes and Optimization of CHZ' Plastic Thermolyze Technology (CRADA Final Report)

Thermolyzer(TM) technology is a third-generation, multi-reactor, oxygen-free, low pressure, slow pyrolysis process. It has proven to be remarkably versatile in successfully processing all types of hydrocarbon waste. These include all seven types of plastics, tires, auto shredder residue, carpet, electronic waste, and composites. Working with the IACMI, Thermolyzer(TM) technology has recovered the glass and carbon fibers from wind turbine blades for reuse into new applications. Its primary output is a synthesis gas that is rich in H 2 , CH 4 , and small amounts of C 2-4 aliphatic hydrocarbons. Other components are CO and CO 2 . Three unique features set Thermolyzer(TM) apart from other pyrolysis systems: the syngas is clean enough to run in Siemens or Solar gas turbines or IC engines without fouling, clean, salable, byproducts are produced, and CO 2 emissions are lower than natural gas power plants. Research results have been obtained from an operating 7 ton/day facility. A 44 ton/day plant has successfully operated as noted above. The process works because it makes use of the recoverable embodied energy in the feedstock. Surprisingly, a pound of some plastics has the same recoverable energy content as a pound of gasoline. Thus, it is imperative to develop a process that economically converts scrap plastics (including ocean plastics) into energy and thereby conserve the non-renewable fossil fuels for future generations. The Thermolyzer(TM) technology can also be used to create liquid fuels like gasoline and diesel from hydrocarbon wastes. Because of the high hydrogen content of the synthesis gas, hydrogen can be recovered more inexpensively than the current solar or wind energy being used to electrolyze water. That hydrogen can be used for fuel cell powered vehicles or converted into ammonia for agriculture or as a hydrogen storage medium. Extension of this technology to other wastes such as tires, auto shredder residue or wood wastes would expand the circular economy.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Modeling of High Solids Biomass Liquefaction, Techno-economic Assessment and Life Cycle Assessment for Industrial Scale UP

Biomass liquefaction improves corn-stover slurry transport within a biorefinery, and reduces challenges associated with solids handling. Slurries, formed with yield stresses (i.e., viscosities) that are low enough to facilitate pumping from one unit operation to the next, and that enable mixing at reasonable power inputs in large fermentation vessels, enable scaling of cellulose fermentations. Three liquefaction methods: enzyme, enzyme mimetic, and a hybrid approach were analyzed by a combination of techno-economic and life-cycle analyses, resulting in an assessment of cost-effectiveness and environmental impact. Of the three scenarios, enzyme-based processes emerged as the most efficient, both in cost and emissions reduction (gCO2-equivalent/kg slurry).

Ramirez, Jorge↗

DOE OSTI2024

Light Water Reactor Sustainability Program: Technical and Economic Considerations for Uprate of Existing Nuclear Reactors with Cogeneration

The United States nuclear reactor fleet consists of 63 pressurized water reactors and 31 boiling water reactors and is a pivotal component in the nation's energy infrastructure, supplying approximately 97 GW e of clean power. With the country's commitment to decarbonization by 2050, these reactors are not only instrumental in decarbonizing the electricity grid but also play a critical role in decarbonizing industrial processes, producing clean fuels, and scaling up CO 2 removal. This report delves into the potential for power uprates in the existing fleet to contribute to these decarbonization efforts, focusing on the expansion of capacity for applications such as hydrogen production and carbon capture and sequestration. Building on previous research, the report explores regional market demands for hydrogen, oxygen, and carbon dioxide, financial implications of oxygen and CO 2 sales from high-temperature steam electrolysis systems, and the potential for direct air capture systems paired with uprated nuclear plants.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2025

Economic Evaluation of Modernization Expenditures for Electric Utility Distribution Systems: A Guide for Utility Regulators

Cost-effectiveness evaluation of potential grid modernization solutions is integral to integrated distribution system planning (IDSP). This report synthesizes and updates prior cost-effectiveness approaches identified by the U.S. Department of Energy for grid modernization investments, incorporating multi-objective decision-making. The structure of the report follows the IDSP process, from identifying objectives and priorities to prioritizing grid solutions. The report details two methods for conducting initial cost-effectiveness screening of individual and interdependent grid components: (1) Lowest Reasonable Cost and (2) Benefit-Cost Analysis. Drawing on solutions that passed the initial cost-effectiveness screen, the utility prioritizes grid solutions based on policy objectives and priorities, regulatory compliance, operational efficiencies, and other factors to develop a portfolio of distribution solutions. The utility uses multi-objective decision-making to assess each proposed expenditure against each objective and respective metric. The utility applies a weighting factor, reflecting the priority ranking of the objective, to the total numerical “score” based on the contribution of the proposed solution to addressing each objective. Ultimately, the utility ranks each expenditure from highest to lowest priority using the final score for each solution as well as its cost. The report includes examples of emerging best practices for states and utilities and a cost-effectiveness process checklist.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2025

Commercialization of Pumped Storage Hydropower Technologies

Argonne National Laboratory and the National Laboratory of the Rockies were tasked by the U.S. Department of Energy’s Water Power Technology Office (WPTO) to conduct the Commercialization of Pumped Storage Hydropower Technologies study to investigate commercialization challenges faced by developers of pumped storage hydropower (PSH) projects and technologies by going beyond literature review to gather direct industry insights, lessons learned and best practices from interviews and webinars with industry specialists to create this report for PSH stakeholders and the general public. Researchers explored key challenges faced by PSH developers and innovators seeking to commercialize new technologies to improve PSH design, siting, construction, and operations. Along with highlighting challenges, the study sought to identify the best practices in developing and deploying new PSH projects and innovations. This report is designed to present insights, lessons learned, and best practices relevant to those with an interest in highlighting, informing, or advancing these PSH commercialization efforts. Along with highlighting challenges and best practices, the study sought to identify avenues by which DOE and national laboratories can help support and streamline PSH commercialization and project development processes.

13 HYDRO ENERGY↗

DOE OSTI2025

Investigating the Potential and Limitations of Fast Scanning Calorimetry to Simulate the Laser Power Bed Fusion Coalescence Process

Laser-Based Powder Bed Fusion (PBF-LB) • PBF-LB is part of one of seven additive manufacturing techniques • Layer wise printing that selectively coalesces discrete powder particles into a solid object o Advantages: Low anisotropy, use of engineering grade materials o Weaknesses: lack of method standardization, challenges in controlled post print quality

Blackman, Malik A. [Georgia Inst. of Technology, A↗

DOE OSTI2020

TeraChem Cloud: A High-Performance Computing Service for Scalable Distributed GPU-Accelerated Electronic Structure Calculations

The encapsulation and commoditization of electronic structure arise naturally as interoperability, and the use of nontraditional compute resources (e.g., new hardware accelerators, cloud computing) remains important for the computational chemistry community. Here, we present TERACHEM CLOUD, a high-performance computing service (HPCS) that offers on-demand electronic structure calculations on both traditional HPC clusters and cloud-based hardware. The framework is designed using off-the-shelf web technologies and containerization to be extremely scalable and portable. Within the HPCS model, users can quickly develop new methods and algorithms in an interactive environment on their laptop while allowing TERACHEM CLOUD to distribute ab initio calculations across all available resources. This approach greatly increases the accessibility of hardware accelerators such as graphics processing units (GPUs) and flexibility for the development of new methods as additional electronic structure packages are integrated into the framework as alternative backends. Cost-performance analysis indicates that traditional nodes are the most cost-effective long-term solution, but commercial cloud providers offer cutting-edge hardware with competitive rates for short-term large-scale calculations. We demonstrate the power of the TERACHEM CLOUD framework by carrying out several showcase calculations, including the generation of 300,000 density functional theory energy and gradient evaluations on medium-sized organic molecules and reproducing 300 fs of nonadiabatic dynamics on the B800-B850 antenna complex in LH2, with the latter demonstration using over 50 Tesla V100 GPUs in a commercial cloud environment in 8 h for approximately $1250.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Enabling ITO-free perovskite solar cells through n-doped poly(benzodifurandione) (n-PBDF) electrodes

The burgeoning commercialization of perovskite solar cells (PSCs) is propelled by their exceptional power conversion efficiency (PCE), enhanced stability, and ease of fabrication. However, the rigidity of mainstream transparent conductive oxides (TCOs) limits the adaptability of PSCs to various application scenarios. Although alternative materials such as silver nanowires, carbon nanotubes, graphene, and PEDOT:PSS have been evaluated, the p-type nature confines their device designs to inverted architecture and restricts broader applicability. Here, for the first time, a conducting polymer electrode based on n-doped poly(benzodifurandione) (n-PBDF) was used to replace TCOs in PSCs. The n-PBDF electrodes can be readily fabricated via low-temperature, solution-based processes, indicating substantial potential for reducing manufacturing costs. Furthermore, its integration into PSCs has negligible effect on the phase, morphology, or photophysical properties of the perovskite layer, which is comparable to the typical TCOs. After optimization, the n-PBDF-based device achieves a power conversion efficiency of 12.70 and 11.23%, for rigid and flexible devices, respectively. Our study provides a promising alternative to the widely used TCOs in PSCs, highlighting the advantages of using n-doped conducting polymers in terms of processability and flexibility.

Kumar, Prashant [Purdue University, West Lafayette↗

DOE OSTI2025

Molecular property prediction for very large databases with natural language processing: a case study in ionic liquid design

The prospect of using artificial intelligence (AI) to accurately screen very large databases of compounds for multiple properties has yet to be realized. Here, we explore this possibility using ionic liquids (ILs) which offer unique physicochemical properties and excellent tunability, making them highly versatile solvents for various research applications. Screening millions of potential ILs for the best perfomance for use in specific tasks with experimental methods alone however, is impractical. Further, traditional’ physics-based computational chemistry is hindered by high computational cost. To address this challenge, we leverage a natural language processing (NLP)-based molecular embedding technique with advanced machine learning (ML) models to predict seven key IL properties: viscosity, density, ionic conductivity, surface tension, melting temperature, toxicity, and water solubility. Comprehensive datasets for these properties are obtained, then NLP featurization with Mol2vec is compared with other featurization techniques such as 2D Morgan fingerprints, and 3D quantum chemistry-derived sigma profiles. NLP-based featurization exhibited the best predictive performance, achieving the highest R 2 and lowest RMSE values for all the studied IL properties. Further, we present case studies of how ILs might be screened using combined property criteria for practical cases – lignocellulosic biomass processing, CO 2 capture, and optimal electrolytes for batteries – screening a novel database of ∼10.6 million generated feasible ILs. The results introduce NLP as a powerful tool for engineering many designer solvents with desirable properties for task specific applications.

Mohan, Mood [Oak Ridge National Laboratory (ORNL),↗

DOE OSTI2025

In-Field Testing of Components for Feedback and Control of the ITER Disruption Mitigation System

Here, the shattered pellet injection (SPI) method has been chosen as the disruption mitigation system (DMS) for ITER. To protect the device from plasma disruptions that cause damaging heat and electromagnetic loads, SPI is used to inject high-Z material into the plasma. The process of SPI utilizes cryogenic cooling to form solid pellets. Pellets are accelerated down a barrel and into an angled surface, causing the pellet to shatter prior to entering the tokamak chamber. For the DMS to function reliably, the 27 separate shattered pellet injectors planned for ITER must rely on many components to provide accurate feedback data and for control functions. Each component in the DMS is exposed to an elevated background magnetic field depending on its placement and proximity to the plasma chamber. A Helmholtz coil test stand that is operated at Oak Ridge National Laboratory was utilized to test the components in relevant background field levels to assess component performance. This paper details the test design and results for in-field component operation for a variety of components. This list includes the following components: two different network switches for camera connectivity, a VAT fast shutter valve intended to reduce the flow of SPI propellant gas into the torus, a solenoid control valve intended for use in the pellet formation process, pressure/vacuum switches to be used for feedback and control, a printed circuit board piezo pressure sensor to be used to measure breech pressure, and various relays for the high-voltage pulsed power supply used to drive the SPI propellant valve.

Disruption mitigation↗

DOE OSTI2025

Catalysis Driven by Confined Hot Carriers at the Liquid/Metal/Zeolite Interface

In chemical industry controlling the activity and selectivity of a chemical conversion process is of immense importance. Traditionally, dissipation of thermal energy drives transformation of reactants, which may lead to formation of a variety of products; it remains a key challenge to design a process that dissociation and formation of specific chemical bonds can be triggered to form certain desirable products with very high selectivity, preferably at low temperatures. Introduction of light-sensitive solid materials into catalysis provides a powerful, alternate strategy for this purpose.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2026

Study on Application of Distributed Network of Sensors with List Mode for NMAC Literature Review

Nuclear material accounting and control (NMAC) for nuclear security detects, deters, and resolves questions related to unauthorized removal (i.e. theft) or misuse of nuclear material. NMAC also serves as a key insider threat mitigation measure and aids in recovery of nuclear material that is missing. Effective nuclear security depends on NMAC for timely and accurate information about nuclear material types, quantities, and locations. Bulk nuclear material processing facilities, however, present unique challenges for effective NMAC due to the presence of large quantities of material in-process and the accumulation of residual material holdup within process equipment. These holdup accumulations can obscure accurate physical inventory taking and complicate efforts to resolve NMAC irregularities at the facility level. Bulk material monitoring systems often rely on material balance calculations and indirect measurement techniques, which may mask protracted theft of smaller amounts of nuclear material. These monitoring limitations have generated increased interest in continuous monitoring technologies, including distributed non-destructive assay (NDA) sensor networks capable of providing real-time or near-real-time measurement of material movement and accumulation within bulk processing environments. Recent advancements in distributed networks of NDA radiation detectors and sensing technologies provide an opportunity to address these limitations. Although such distributed sensor networks have been implemented in select facilities for IAEA Safeguards applications, their potential for supporting NMAC functions specifically tailored to nuclear security objectives remains largely unexplored. Furthermore, emerging list-mode data acquisition technologies have reached high technology readiness levels, enabling time-correlated detection of nuclear events across multiple temporal scales. These capabilities provide enhanced opportunities for accurate holdup measurement, continuous process monitoring, and improved detection of material theft or misuse over time. The increasing global expansion of civil nuclear power and development of related bulk material processing facilities, including those supporting high-assay low-enriched uranium (HALEU) and other advanced reactor fuel fabrication, further increases the need for advanced measurement and monitoring strategies for NMAC.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2025

sdt (Solar Data Tools) [SWR-25-130]

Solar Data Tools (sdt) is an open-source Python library for analyzing PV power (and irradiance) time-series data. It was developed to enable analysis of unlabeled PV data, i.e. with no model, no meteorological data, and no performance index required, by taking a statistical signal processing approach in the algorithms used in the package’s main data processing pipeline. Solar Data Tools empowers PV system fleet owners or operators to analyze system performance a hundred times faster even when they only have access to the most basic data stream—power output of the system.

Meyers-Im, Bennet [National Laboratory of the Rock↗

DOE OSTI2025

Part distortion monitoring in additive manufacturing using machining

In additive manufacturing, accumulation of residual stresses can result in severe part distortion from the desired preform shape. Current methods for in-situ part distortion monitoring in additive manufacturing typically require expensive sensors, or capital equipment, and require time-consuming post-processing to understand the shape deviation. This paper presents an in-situ method, in the context of hybrid manufacturing, for part distortion detection using machining of additively manufactured parts. As a surrogate, three test artifacts were used to represent different distorted geometries. The tool axis positions from the machine tool controller and the cutting power were monitored during a facing operation. Cutting power data was used to detect the tool entry and exit in the workpiece using a novel approach with power standard deviation metric. The workpiece geometry and distorted configuration was subsequently predicted for positional and rotational deviations to within 2 mm accuracy using synchronized tool position data with cutting power. The proposed method can be used in a hybrid (additive and subtractive) machine tool to periodically check part distortion in the additive build. The method is applicable for any additive process and is low-cost and computationally inexpensive.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Deep Reinforcement Learning-Based Control of Energy Storage for Interarea Oscillation Damping

With the increasing electricity consumption and lack of transmission investment, today's power systems are operated much closer to their limits, raising concerns of inter-area oscillations that deteriorate the system stability. Here, this article presents a novel energy storage placement and control approach for enhanced damping of interarea oscillations. Combining the residual analysis and dominant mode analysis, we are able to identify the advantageous locations for placing energy storage that achieve improved damping performance. To overcome the challenges, such as fixed control parameters and insufficient damping, we propose to use a deep reinforcement learning-based approach for energy storage control. A state-of-the-art guided surrogate-gradient-based evolutionary strategy is used to train a learning agent in a robust, efficient, and reproducible manner. Parallel computing is also adopted to speed up the training process. The proposed strategy has been tested on both medium and large-scale systems. The proposed methods have demonstrated their effectiveness in mitigating various interarea oscillations within a timeframe of 20 s, thereby averting system collapse and enhancing power grid stability effectively.

25 ENERGY STORAGE↗

DOE OSTI2025

Industrial Electrification Technologies Booklet

Electrification refers to transitioning from fuel-powered systems to electrically-powered alternatives. In an industrial context, this primarily refers to the electrification of process heat, but there are also widespread opportunities to electrify space heating and cooling as well as onsite transportation (e.g., forklifts). Electrification does not refer to one particular technology, but a wide range of technologies that use different methods to transfer electrical energy into a usable form – usually heat.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2020

Hybrid Ceramic-CMC Vane with EBC for Future Coal Derived Syngas Fired 65% Efficient Turbine Combined Cycle

The efficiency of both simple cycle and combined cycle power generation systems scale with the peak temperature at which the gas exits the combustor to drive the turbine. In conventional systems, a substantial fraction of the total turbine core flow exiting the compressor is diverted downstream to cool metallic turbine hardware rather than power the turbine, much of which is used to cool the first-stage turbine vane. The use of coal derived syngas fuels provides an additional challenge to the lifetime of materials utilized in the turbine, as particulate byproducts created in the coal gasification process melt in the combustion gas, and can subsequently deposit and interact with the turbine hardware. The development of durable hot-section materials capable of operating at temperature well above that of single crystal superalloy airfoil/zirconia based thermal barrier coatings is critical to realizing 65% efficient coal derived syngas fired gas turbine based power systems. To enable higher turbine inlet temperatures while lowering cooling air requirements, United Technologies Research Center (UTRC), the central R&D laboratory supporting UT Pratt & Whitney, led the conceptual design of a new type of ceramic composite turbine hot section materials system. The design focused on a novel hybrid monolithic ceramic-fiber reinforced ceramic matrix composite (CMC) first stage turbine vane having an environmental barrier coating. By utilizing ceramic construction in the turbine hot-section, the core flow normally used to cool metallic components will be substantially reduced, increasing efficiency and reducing emissions. To provide the framework for future demonstration testing, UTRC partnered with University of North Dakota Energy and Environmental Research Center (UNDEERC) to provide a conceptual design for a gasified coal fed high-pressure turbine combustor system designed to mimic the conditions expected in a future 65% fuel to busbar efficient syngas fueled gas turbine based combined cycle. The UNDEERC and UTRC collaborated on characterizing dusts from coal gasifier filtration systems.

10 SYNTHETIC FUELS↗