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At least 469 records · Page 26
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Direct Air Capture of CO 2 and Delivery to Photobioreactors for Algal Biofuel Production (Final Report)

A mobile DAC system was designed and constructed to pair with photobioreactors growing algae for biofuel production. The DAC system was designed as a versatile research system, rather than a compact production unit. The system was constructed and mounted on a mobile skid to facilitate transportation to the algae production site. Within the DAC system, CO 2 was captured using amine-loaded monoliths that allow for high CO 2 uptake with low pressure drop. The CO 2 is collected using a Global Thermostat patented temperature/vacuum swing adsorption (TVSA) process. Amine sorbents and process conditions were optimized to produce 10 to >20 g CO 2 .h-1. The stability of the amine sorbents was also studied, with sorbent modifications made to improve stability to degradation by oxidation. An Algenol-developed Spirulina strain (Arthrospira platensis AB2293) was selected as the production cyanobacterial strain. AB2293 cultured was inoculum for outdoor production following PBR installation by Algenol. The PBR system was composed of three independent PBRs, with each PBR composed of four hanging bags internally recirculated by a liquid turnover pump. The PBRs were operated outdoors in Atlanta, GA, and integrated with the DAC system. Algae were grown with similar productivity using DAC-CO 2 as algae grown using pure CO 2 obtained commercially (Airgas). Throughout the experimental duration, no discoloration was observed, and cellular morphology was consistent between the two experimental treatments. An LCA including lifecycle greenhouse gas emissions, full life cycle inventory of the Algenol system and the DAC system and integrated DAC+PBR system was developed. Lifecycle greenhouse gas emissions were calculated for capture of carbon dioxide using input from Global Thermostat and the National Renewable Energy Laboratory. Three scenarios for energy provision were evaluated: a natural gas combined heat and power system sized to meet the electricity requirement, a natural gas combined heat and power system sized to meet the process heat requirements, and a system without on-site power that procures the electricity from the grid. In all three cases, as expected, the major contributor to the emissions is the energy consumption associated with the desorption step of the DAC process. The LCA quantified the reduced potential energy and greenhouse gas emissions of heat and mass integration of DAC and Algenol compared to unintegrated DAC and Algenol systems. A life cycle assessment of the role of sorbent productivity and lifetime was also developed. The development of more robust, oxidation resistant DAC sorbents may enable small reductions in energy requirements and in lifecycle greenhouse gas emissions and other environmental impacts. NREL performed techno-economic analysis (TEA) to identify the integration scenario most likely to achieve a 15% cost reduction target versus the baseline. Heat and mass integration of DAC and the PBR is critical to minimizing the MFSP. The baseline case utilizes no heat and mass integration, and the DAC system provides 100% of the CO 2 required by the photobioreactors (20 tonnes/hr), operating for 12 hours/day capturing 40 tonnes CO 2 /operating hour. The minimum fuel selling price (MFSP) of ethanol calculated from the baseline case was $10.68/gal ethanol. This corresponds with a targeted MFSP of $9.07/gal ethanol (or 15% reduction). This target was achieved by integration Option 2a with the greatest cost reduction of 17.8% (or $8.78/gal) and integration Option 2b with a cost reduction of 16.4% (or $8.93/gal). Reductions in MFSP are attributed to two primary process considerations: (a) CO 2 storage at night reduces the capital expenses associated with DAC (i.e., increasing on-stream time); and (b) distributed DAC scenarios (DAC-PBR integration Options 2a and 2b) make use of boiler and DAC CHP flue gas CO 2 (free). Direct air capture on-stream time was one of the largest contributors to MFSP reduction.

09 BIOMASS FUELS↗
DOE OSTI2019

Water Innovation and R&D Concept Exploration and Preliminary Assessment: Water Scoping Project Report Deliverable

Pacific Northwest National Laboratory and Idaho National Laboratory produced a cursory review and initial framework to support the US Department of Energy’s Water Power Technologies Office (WPTO) in considering options for program development related to water. The laboratories provided a suite of tools – rationales, evaluation criteria, and visual maps – as well as R&D concepts that could be applied at various scales over short- and long-term time horizons. The effort is, by DOE request, largely the result of the authors’ creative efforts and not intended to be a comprehensive or detailed analytical exercise. This report summarizes the work provided to WPTO and is not intended for broad distribution.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

Rosario Strait Tidal Energy plus Energy Storage — Preliminary Economic Assessment

The Orcas Power and Light Co-op (OPALCO) is a non-profit utility that provides energy services to approximately 11,700 customers across 20 islands in San Juan County, Washington. OPALCO is developing a diverse set of local renewable energy resources to reduce dependence on mainland Washington State for energy and to reduce the regional need for fossil-fueled power. OPALCO’s load doubles in winter but solar production is roughly 20% of levels reached in summer periods. Tidal energy is strong year-round, night and day, and is predictable, requiring much less storage to firm it. To assess the technical and economic feasibility of tidal power, working in combination with multiple other distributed energy resources (DERs), Argonne National Laboratory (Argonne) employed an optimization model to evaluate several economic benefits associated with varying scales of tidal power of between 2.4 and 9.6 megawatts (MW) and other DERs. In addition to existing photovoltaic (PV) and battery energy storage system (BESS) resources located on Decatur Island, Argonne also evaluated the addition of a BESS on southern Orcas Island with power and energy capacities ranging from 1-4 MW and 2-4 hours in storage duration.

25 ENERGY STORAGE↗
DOE OSTI2024

ORNL Campus Sustainability and Decarbonization using Waste Heat Recovery from the Oak Ridge Leadership Computing Facility’s High-Performance Computing Data Center

Heat pumps are a clean and efficient technology that can be powered by renewable electricity to transfer heat using a refrigerant from one place to another by different heat sources, making buildings clean and environmentally friendly. With the support of the ORNL Laboratory Modernization Division, this project explored and evaluated an innovative solution that uses water-water cost-effective midtemperature heat pump (MTHP) technology to leverage the low-grade waste heat from ORNL Frontier and the data center to deliver 85°C hot water, which replaces hot steam generated using natural gas combustion boilers for water heating or space heating in the buildings of ORNL campus. Two scenarios were studied. In the first scenario, which considered the 5600-5700-5800 complex only, Carrier’s commercial 1,000 kW MTHP technology achieves more than 6,640 MWh/year energy savings, an emission reduction of 858 TCO2e/year CO2, and a payback time of 4.85 years. In the second scenario, which considered the 5600-5700-5800 complex and Buildings 5100, 5200, and 5300, the CO2 emission reduction is 1,483 TCO2e/year, the operating cost savings are $0.21 million annually, and the payback time is 3.74 years. Additionally, a comprehensive HP ShowCase Tool was developed for evaluating the optimal solution to improve sustainability and decarbonization of the buildings on the ORNL campus. The tool is an Excel-based tool integrated with VBA (Visual Basic for Applications) coding. The tool includes collected ORNL campus building information and an MTHP library, which comprises collected commercial and ORNL-defined MTHPs. The tool was used to evaluate the sustainability and decarbonization of the ORNL campus. The tool can be widely used or referenced for heat pump solutions and building decarbonization renovation strategies to modernize ORNL facilities and energy use–intensive equipment to enable efficient, sustainable, and resilient operations in the future.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Reduction of Methane Leaks through Corrosion Mitigation Pre-treatments for Pipelines with Field Applied Coatings

Corrosion of buried, coated steel pipelines transporting natural gas is a significant source of methane emissions, from pipeline venting required for maintenance and repairs and from pipeline leaks and incidents. Corrosion of steel under field applied coatings is an important safety concern for the pipeline industry. This project investigates the application of a field applied alloy over girth welds to mitigate external corrosion of buried coated steel pipelines. Various metallic coating options were considered, which were required to meet several criteria: (1) it must resist corrosion under open-circuit or mild cathodic protection conditions, (2) it must protect the substrate steel, and (3) it must not negatively affect the adhesion of the field coating. Finite element models and lab testing were performed of alloy coating compositions to identify promising alloy types underneath disbonded coatings. Polarization curves of coating alloys were generated to provide the boundary conditions for the COMSOL model to compute potential and current distributions around coated areas. Sacrificial and corrosion-resistant metal alloy coatings were evaluated and optimized using corrosion modeling and laboratory electrochemical testing, where aluminum alloy 5356 (5% Mg) and steel alloy B9 (9% Cr) were selected. Corrosion test coupons were designed and fabricated using thermal spray aluminum 5356 and welded B9 steel overlays on API 5L grade X42 line pipe steel. The corrosion test coupons, with simulated pipe coating damage, were tested in a laboratory soil box and a field pipeline site in Texas for 3-months. Corrosion test coupons were then tested for 6-months at field pipeline sites in Texas and Tennessee to quantify corrosion rates and performance of the aluminum and steel alloys under polyethylene tape and 2-part epoxy coatings, various coating holidays, and with and without cathodic protection.

03 NATURAL GAS↗
DOE OSTI2026

Performance Validation of Endcap Timing Layer Detector Modules for CMS Phase-2 Upgrade

The High-Luminosity Large Hadron Collider (HL-LHC) will operate up to 200 simultaneous collisions per bunch crossing, which is a significant jump from the current value of about 30 collisions per bunch crossing, producing significant pileup that challenges accurate event reconstruction. To address this, the Compact Muon Solenoid (CMS) experiment is implementing the Endcap Timing Layer (ETL), a precision timing detector designed to provide timing measurements with a resolution of approximately 50 ps per hit and 35 ps per reconstructed track. This project focuses on the characterization and validation of ETL detector modules using laboratory laser test data. ETL performance is evaluated by analyzing key quantities such as Bunch Crossing Identification (BCID), Time-of-Arrival (TOA), Time-over-Threshold (TOT), Noise Stability etc. The resulting analysis provides insight into the timing performance and operational stability of ETL modules, contributing to the quality assurance process req uired before their installation in the CMS experiment and ensure that the modules can meet the long-term reliability requirements of approximately 10 years of operation without replacement.

Chipara, Munashe [Fermilab]↗
DOE OSTI2021

How New Mexico Leveraged a COVID-19 Case Forecasting Model to Preemptively Address the Healthcare Needs of the State: Quantitative Analysis

Prior to the COVID-19 pandemic, US hospitals relied on static projections of future trends for long-term planning and were only beginning to consider forecasting methods for short-term planning of staffing and other resources. With the overwhelming burden imposed by COVID-19 on the health care system, an emergent need exists to accurately forecast hospitalization needs within an actionable timeframe. Our goal was to leverage an existing COVID-19 case and death forecasting tool to generate the expected number of concurrent hospitalizations, occupied intensive care unit (ICU) beds, and in-use ventilators 1 day to 4 weeks in the future for New Mexico and each of its five health regions. We developed a probabilistic model that took as input the number of new COVID-19 cases for New Mexico from Los Alamos National Laboratory’s COVID-19 Forecasts Using Fast Evaluations and Estimation tool, and we used the model to estimate the number of new daily hospital admissions 4 weeks into the future based on current statewide hospitalization rates. The model estimated the number of new admissions that would require an ICU bed or use of a ventilator and then projected the individual lengths of hospital stays based on the resource need. By tracking the lengths of stay through time, we captured the projected simultaneous need for inpatient beds, ICU beds, and ventilators. We used a postprocessing method to adjust the forecasts based on the differences between prior forecasts and the subsequent observed data. Thus, we ensured that our forecasts could reflect a dynamically changing situation on the ground. Forecasts made between September 1 and December 9, 2020, showed variable accuracy across time, health care resource needs, and forecast horizon. Forecasts made in October, when new COVID-19 cases were steadily increasing, had an average accuracy error of 20.0%, while the error in forecasts made in September, a month with low COVID-19 activity, was 39.7%. Across health care use categories, state-level forecasts were more accurate than those at the regional level. Although the accuracy declined as the forecast was projected further into the future, the stated uncertainty of the prediction improved. Forecasts were within 5% of their stated uncertainty at the 50% and 90% prediction intervals at the 3- to 4-week forecast horizon for state-level inpatient and ICU needs. However, uncertainty intervals were too narrow for forecasts of state-level ventilator need and all regional health care resource needs. Real-time forecasting of the burden imposed by a spreading infectious disease is a crucial component of decision support during a public health emergency. Our proposed methodology demonstrated utility in providing near-term forecasts, particularly at the state level. This tool can aid other stakeholders as they face COVID-19 population impacts now and in the future.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2020

Paving the Way for Net Zero Energy Codes through Performance Based Approaches

The prescriptive path is the most widely used approach for commercial code compliance in the United States. However, to achieve near-term net zero energy performance that many stakeholders in the buildings industry desire, it is clear that energy codes will need to transition from prescriptive to performance-based approaches. However, that transition is not without potential pitfalls. Among the concerns expressed by stakeholders are added complexity and cost, lack of confidence in energy modeling results, gamesmanship on the part of applicants, lack or qualified reviewers, challenges in promoting de-carbonization, and the inequity of trading long lived envelope efficiency for short lived measures such as building controls. This paper will discuss multiple approaches being evaluated and implemented by Pacific Northwest National Laboratory to improve the usability of the performance-based approach for both code compliance and beyond code programs to meet aggressive energy savings targets. A 'system performance' approach provides a simpler approach compared to whole building performance, while keeping tradeoffs limited to specific building systems. A simplified whole-building performance-based approach for small commercial buildings can cost effectively achieve deeper savings for buildings that typically follow the prescriptive compliance approach. Improved reporting and verification processes applied to the traditional performance path can provide greater confidence in simulation results and facilitate adoption of performance-based approaches. Prescriptive packages provide prescriptive solutions while targeting specific performance thresholds. This paper discusses the progress being made with each of these approaches and provides examples of their implementation in energy codes and beyond code programs.

Performance Based Codes, Appendix G, PRM, TSPR, Sy↗
DOE OSTI2023

Lessons Learned From Techno-Economic Analysis of Solar Photovoltaics and Battery Energy Storage at a Vietnam Industrial Park

Through the Clean Energy Investment Accelerator (CEIA), engineers from the United States (U.S.) National Renewable Energy Laboratory (NREL) conducted a case study analysis evaluating the techno-economic feasibility of battery energy storage systems (BESS) at an industrial park in Vietnam. The analysis uses NREL's REopt platform, a distributed energy modeling and optimization tool, to identify the cost-optimal system sizing for BESS, in conjunction with onsite renewables such as solar photovoltaics (PV), to reduce electricity costs, increase onsite renewable energy generation utilization, and improve resilience to grid outages.

batteries↗
DOE OSTI2023

NREL Project CloudZero

The National Renewable Energy Laboratory's (NREL's) CloudZero project is evaluating the ability to reliably and securely manage complex energy systems from the cloud, identifying major technical and regulatory barriers to cloud adoption, suggesting new security controls and best practices for cloud applications, and empowering industry to embrace the cloud, where appropriate.

cloud↗
DOE OSTI2022

Underground sources of drinking water chemistry changes in response to potential CO 2 leakage

The purpose of this study was to quantify changes to underground sources of drinking water (USDW) quality in response to potential CO 2 leakage from geologic CO 2 sequestration (GCS) reservoirs. Here, the developed a framework of combined laboratory experiments and reactive transport simulations and used this framework to evaluate the Ogallala aquifer overlying the Farnsworth Unit (FWU), an active GCS site, as a case study. Using chemical reaction parameters obtained from laboratory experiments and numerical simulations, site-specific mechanisms of CO 2 -water-sediment interactions at the USDW aquifer were interpreted. Long-term risks of potential CO 2 leakage were then evaluated with field-scale numerical models using the regional hydrogeological characteristics and reaction parameters obtained from our experiments and simulations. Results suggest that carbonate mineral impurity and cation exchange are key mechanisms for interactions between CO 2 and the aquifer sediment. Additionally, for a large leakage rate of 0.1 % injection from one leaky well, the leakage plume might impact an area of 300 m in diameter and significantly affect the local water quality by changing pH and cation concentrations (e.g., Zn, Ba and Sr). After leakage ceases, the zone of impacted fluids would not migrate significantly in subsequent decades due to a low regional groundwater flowrate (for this case study). The relatively small area of impact might not be detected in a monitoring well given the broader spacing in a typical field scenario. Effective early leakage detection may require additional tools, e.g., borehole CO 2 movement, four-dimensional seismicity, CO 2 soil flux, samples from deeper aquifers, etc., to ensure effective leakage detection and long-term safety of GCS projects.

58 GEOSCIENCES↗
DOE OSTI2026

Connecting ambient toxicity testing with community-level responses of benthic macroinvertebrates in an impacted stream in East Tennessee, USA

Single-species laboratory toxicity tests are a standard tool for evaluating potential impairment of freshwater systems; however, it remains uncertain how well they reflect community-level impacts in natural environments. This study presents a multi-decadal dataset (2005-2025) pairing ambient toxicity testing with macroinvertebrate surveys along Bear Creek on the Oak Ridge Reservation (Tennessee, USA) downstream of an industrial complex to assess the ability of laboratory tests using stream water to track community-level effects. Biannual three-brood Ceriodaphnia dubia tests from 2005 to 2025 often showed reduced reproduction at select sites. Integrating water quality data showed strong positive correlations between sublethal toxicity and specific conductance. Macroinvertebrate diversity metrics, family-level occurrence, and densities were also associated with conductance and contemporaneous C. dubia responses. Laboratory-measured sublethal toxicity was a stronger indicator of macroinvertebrate change than conductance alone, although responses varied among sites and seasons. At the site with the highest diversity, densities and richness of Ephemeroptera, Plecoptera, Trichoptera (EPT) and non-EPT taxa were significantly related to C. dubia reproduction, with greater toxicity corresponding to lower diversity. At the family level, some pollution-tolerant taxa were more prevalent and at higher densities during periods of sublethal toxicity, while some sensitive families were absent or reduced. These patterns may reflect site-specific mixtures of acute and chronic stressors, with laboratory toxicity tests more effectively capturing short-term impacts. Overall, these multi-decadal observations suggest that laboratory toxicity tests can help track water-quality changes linked to shifts in aquatic community diversity, despite variable responses reflecting the complexity of dynamic stressors in this impacted freshwater system.

Stevenson, Louise [ORNL] (ORCID:0000000349679897)↗
DOE OSTI2020

Nuclear Data Sheets for A=233

The present evaluation of the known A=233 nuclides ( 233 Fr, 233 Ra, 233 Ac, 233 Th, 233 Pa, 233 U, 233 Np, 233 Pu, 233 Am, 233 Cm) and 233 Bk represents an update and revision, after 15 years of the previous evaluation of A=233 published by B. Singh and J.K. Tuli (2005Si15). Laboratory identification of 233 Bk nuclide is still considered as tentative. Various decay and reaction data are evaluated and compared. Adopted data, levels, gammas, level half-lives, spins, parities, and configuration assignments are provided. For 233 Fr, 233 Ra, 233 Ac, 233 Pu, 233 Am and 233 Cm, information is available for the respective ground states only. The decay schemes from β - decays of 233 Fr and 233 Ra, and from ε decay of 233 Am and 233 Cm are unknown, while those from β - decay of 233 Ac, and from ε decay of 233 Np are considered incomplete. The α decay of 237 Np to 233 Pa has been studied in detail by many investigators, yet the decay scheme is considered incomplete as several very low-energy transitions are involved, without the knowledge of their intensities, resulting in mismatch of directly measured α feedings and those deduced from γ-transition intensity balances. The decay schemes from α decays of 237 Am, 237 Cm and 237 Cf to respective A=233 daughters are considered incomplete. Particle-transfer and high-spin data are available for 233 Th, 233 Pa and 233 U nuclei, which remain the most extensively studied in this mass chain. However, data for half-lives for the excited states are available only for one level in 233 Pa, and for five levels in 233 U, thus limiting the knowledge of reduced transition probabilities in this mass chain.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2024

Effect of Anoxic Iron Corrosion on WIPP Brine Geochemistry FY23 Final Report (U)

A 280-day study was completed to evaluate the effect of zero-valent iron (Fe 0 ) on the Waste Isolation Pilot Plant (WIPP) brine geochemistry under anticipated reducing conditions. Hydrogen (H 2 ) gas is expected to be present in the repository after closure due to the anoxic corrosion of a vast quantity of iron contained in the waste forms disposed at WIPP; therefore, a background argon atmosphere containing H 2 was chosen for this study. WIPP groundwater brine pH and E h will impact the mobility and fate of plutonium within the repository. Modeling and laboratory results for Castile WIPP brine indicate that equilibrium fa values relative to the standard hydrogen electrode (SHE) are 40 mV more reducing (i.e., more negative) than those for Salado WIPP brine (-480 mV vs. -440 mV, respectively) because of the higher pH of the Castile brine (pH 9 .3 for Castile vs. pH 8.8 for Salado). The E h and pH data were corrected for the effects of high ionic strength. The experimental results for both brines are consistent with thermodynamic predictions using OLI Systems' Mixed Solvent Electrolyte chemical equilibrium model. The measured and corrected pH and E h data from this study are provided in Table ES-I and Table ES-2, respectively. The experimental study, with four test conditions in triplicate, was performed in a dual glovebox with a nominally 3 vol.% H 2 in argon atmosphere (target H 2 range: 3 ± I vol.%). Simulants containing MgO only ( experimental control) and MgO+Fe 0 (WIPP base case) were prepared for both the Salado and Castile brines. MgO was included in all simulants to account for the use of bulk magnesium oxide in the WIPP repository. Fe 0 was included in some simulants to incorporate the effects of the anoxic corrosion of iron and in-situ hydrogen generation in the study. The brine compositions were developed by Sandia National Laboratory (SNL; Xiong, 2008) and have been used in previous WIPP evaluations. The test method (agitation, etc.) is partially based on ASTM D3987-12. Twelve rounds of periodic measurements of pH and E h were performed over the course of the study. Chemical analysis results for liquids and solids (ICP-MS, ICP-ES, IC Anion, TIC, SEM-EDX) are consistent with the pH, E h , and thermodynamic modeling results. This study included the following conditions that deviate from anticipated post-closure conditions following brine intrusion, but were selected to facilitate bench-scale testing to validate modeling of pH and E h for the post-closure WIP P repository: an anoxic glove box atmosphere containing ≤ 4 vol. % H 2 vs. substantially higher H 2 gas concentrations assumed in the WIPP Performance Assessment (PA); a significantly higher liquid-to-solid test ratio compared to the much lower phase ratio anticipated in the WIP P repository; agitation of the simulant bottles to maximize mass transfer; and finally the use of Fe 0 reagents having a much greater surface area than expected in the WIP P repository. Non-representative conditions were chosen for various reasons such as: to provide bounding conservative results, to provide a margin of safety for testing, or to facilitate simulant sub-sampling and analysis. In a parallel effort, aqueous electrolyte thermodynamic models were developed for the synthetic Salado and Castile brines to inform the experimental design, facilitate laboratory data interpretation, and allow extension of evaluations beyond the parameters tested. Thermodynamic modeling simulations including the MgO and Fe 0 additives that are directly relevant to the experimental measurements (e.g., pH calibration curve, ORP corrections) are included in this report. The measured fa of the simulants was close to the OLI model predictions for both brines and was largely controlled by the background H 2 partial pressure in the vapor phase as well as H 2 generated in situ in the aqueous phase by the Fe 0 corrosion. The H 2 gas-phase concentration tested and thermodynamically evaluated was much lower than is assumed in the WIPP PA; however, H 2 (g) concentrations significantly below this level are still predicted to result in very reducing conditions. In conclusion: • The experimental results are consistent with thermodynamic model predictions for fa, pH, and the effects of high ionic strength. • Evidence to date suggests that the H2 concentration in the glovebox atmosphere ultimately determined the final E h values of the simulants and resulted in highly reducing conditions. As a result, little difference was observed between the control simulants containing only MgO and the WIPP base-case simulants that contained MgO and Fe 0 . • This test methodology is recommended for future studies evaluating WIPP repository conditions. The methodology includes: (1) background H 2 in argon with agitation ( or could alternatively include in-situ-generated H 2 in sealed bottles); (2) carefully measured and corrected ORP data ( with much effort focused on allowing the probes to fully stabilize); and (3) ionic-strength-corrected pH data. Other best practices, such as simulant sparging/handling, ORP probe replacement, etc., should also be considered. • The coupling of experimental studies and thermodynamic modeling is also highly recommended because these methods inform and direct one another leading to greater confidence in and understanding of the results.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2022

Innovative Method for Welding in Generation 3 CSP to Enable Reliable Manufacturing of Solar Receivers to withstand Daily Cycling at Temperatures Above 700°C (Final Technical Report)

Inconel® Alloy 740H® (alloy 740H) was the first age-hardenable nickel-based alloy approved by the ASME Boiler & Pressure Vessel Code for use in pressure-boundary applications. Over the past ~20 years the alloy has been optimized for weldability and high-temperature stability, approved for use in different applications. Development of a supply chain combined with the advantageous properties of the alloy (high-temperature creep strength, oxidation and corrosion resistance, etc.) have resulted in the alloy being applied to new high-temperature power cycle demonstration projects, and of particular interest are applications to concentrating solar power (CSP) to enable higher-efficiency Generation 3 CSP systems and the corresponding supercritical CO 2 (sCO 2 ) power cycle components (heat exchangers, piping, etc.). The high allowable stresses of alloy 740H also make it a desirable material for current Generation 2 CSP solar power receivers to improve cyclic capability and/or reduce receiver height. Recent experiences in demonstration projects utilizing alloy 740H identified cracking issues during welding and fabrication. In this project, a detailed study was done to confirm and clarify the Stress Relaxation Cracking (SRxC) mechanism, also known as stress relief cracking or strain-age cracking (SAC), during post-weld heat-treatment (PWHT). This involved detailed microscopy and advanced characterization to understand the root cause(s) of three failures obtained from industry. Based in-part on these findings, a targeted laboratory based SRxC test method was utilized to evaluate variables such as heat-to-heat variations, strain level, PWHT temperature, and starting material condition on three heats of alloy 740H. Industrial shop welding of cold-worked plates was also conducted. The research showed the following: SRxC was confirmed as the cracking mechanism for all field failures; Stress state (from residual stresses, constraint, deformation, and local stress concentrations) was playing a significant role in field failures and laboratory testing confirmed increasing susceptibility for all heats with increasing strain levels. High levels of microstructural strain were identified at crack initiation locations, in some cases leading to local recrystallization; Precipitate free zones (PFZs) at grain boundaries were found at relaxation cracks and crack initiation locations uniquely associated with SRxC in alloy 740H. Laboratory testing reproduced this microstructural feature which had only previously been reported in long-term creep testing of weldments. Advanced nano-scale characterization confirmed the presence of a moving boundary leading to coarsening of precipitates and PFZs where damage accumulated; The research suggested heat-to-heat variations due to local chemistry and processing may influence SRxC susceptibility, but more work is needed to fully clarify these effects. To disseminate the key learnings from this research to the scientific and engineering communities and alloy 740H end users, multiple technical publications and presentations were made, an industrial alloy 740H users meeting was held, and a new industry guideline specification document which can be directly implemented by end-users of alloy 740H was produced.

14 SOLAR ENERGY↗
DOE OSTI2020

Energy Efficiency Package for Tenant Fit-Out: Laboratory Testing and Validation of Energy Savings and Indoor Environmental Quality

Approximately 40% of the total U.S. office floor space of 1.5 billion sq.m (16 billion sq.ft.) is leased space occupied by tenants. Tenant fit-out presents a key opportunity to incorporate energy efficiency within the real estate business cycle. We designed a package of energy efficiency measures tailored to the scope of a tenant fit-out. This tenant fit-out package (TFP) includes advanced lighting and heating, ventilating and air-conditioning (HVAC) controls as core measures, with ceiling fans, automated shading, and plug load controls as additional optional measures. We conducted laboratory testing of six configurations of the package to evaluate energy savings, indoor environmental quality, and identify installation, commissioning, and operational issues. Combined savings for HVAC, lighting, and plug loads ranged from 33–40%. Lighting savings ranged from 69–83%, and HVAC savings from 20–40%. The laboratory testing also revealed some minor but tractable challenges with installation and commissioning of HVAC controls. Overall, the results demonstrate that significant savings can be realized in existing office buildings by incorporating relatively low-risk, proven measures at the time of a tenant fit-out.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Corrosion Testing Of Additively Manufactured Stainless Steel 316H In Molten Salt Environments

The development of a new ASTM standard for evaluating the corrosion resistance of additive manufactured (AM) stainless steel (SS) 316H in chloride molten salts is critical for the use of these materials in extreme environments such as molten salt reactors (MSRs). This report pertains to a work package of the Advaned Materials and Manufacturing Technologies (AMMT) developing a systematic methodology to link changes in AM fabrication parameters, namely surface finishing, porosity, microstructure, and chemical heterogeneity, to corrosion performance in NaCl-MgCl2 salt, a proposed secondary coolant for MSRs. During Fiscal Year 2024, Idaho National Laboratory investigators in the AMMT program, utilized SS316H bars, fabricated with laser bed powder fusion at Los Alamos National Laboratory, to establish and optimize the workflow for evaluating these process-to-performance relationships. Standard practices for specimen preparation were established using these specimens, with particular focus on descaling and sectioning methods that align with ASTM guidelines. A comprehensive experimental design for static corrosion testing was developed, with pre- and post-exposure analysis utilizing optical microscopy and scanning electron microscopy. So far standard descaling techniques were optimized, one static corrosion test was conducted on the LANL AM SS316H specimens, and pre- and post-corrosion practices were established. In addition, the work package yielded a review paper on corrosion testing gaps for AM materials in nuclear applications and submitted a proposal for a rapid-turnaround experiment to the Nuclear Science User Facilities Program to investigate the combined effects of proton irradiation and corrosion on AM SS316H. This work package establishes a foundation for evaluating processing-to-performance relationships for AM SS316H in harsh conditions, contributing to the safe and efficient design of components for next-generation nuclear reactors. The creation of a standardized methodology and the generation of relevant publications and future research pathways represent significant strides towards integrating AM materials into critical applications where corrosion resistance is paramount.

36 MATERIALS SCIENCE↗