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At least 523 records · Page 29

Coal-based Bricks & Blocks (CBBs): Process Development to Prototype Fabrication Coupled with Techno-Economic Analysis and Market Survey

Coal-based bricks and blocks (CBBs) were formulated using anthracite and thermoplastic binder. Lab scale test composites were formed by hot-press molding and commercial extrusion for test articles and for a full-scale prototype. Formulations and test matrices followed a systematic experimental design to examine the effects of and interactions among three primary independent variables: a) thermoplastic type, b) weight fractions of binder relative to the total anthracite weight, and c) relative proportions of large versus small (milled) anthracite size fractions. Technical performance metrics include compressive strength, modulus, porosity/permeability and density. These DoE studies establish composition-property relations and identify the best combination for any desired property of interest – in particular, strength. Based on CBB composition and fabrication process, validated against technical performance metrics, a techno-economic analysis was constructed which incorporated a process flow model, engineering design (with scaling), and calculated capital plus operating costs. Based on measured property metrics and estimated process economics and a projected price by TEA (techno-economic analysis), building and construction target markets were identified by a market survey assessment. With known cost, price, performance metrics and competitive advantages for CBBs matched with commercial applications/uses, a technical gap analysis was performed to identify further development required for scale-up and commercialization.

01 COAL, LIGNITE, AND PEAT↗

Mitchell FEED Study Summary Report (Unlimited Rights Version) (Rev. D)

Heidelberg Materials (HM), Sargent & Lundy (S&L), and Mitsubishi Heavy Industries (MHI) completed a Front End Engineering Design (FEED) study for deployment of an amine-based CO 2 capture system at the Mitchell Cement Plant in Indiana. The project includes compression of captured CO 2 to a supercritical state for geological sequestration. The flue gases from 7,000 mtpd clinker plant combined with auxiliary boiler flue gases into the capture system. Auxiliary boiler supplies steam for solvent regeneration. The study developed an AACE Class 3 capital cost estimate (+30%/-20%) at approximately 30% design completion to evaluate the technical and economic feasibility of capturing up to 2 million tonnes of CO 2 per year.

42 ENGINEERING↗

TidGen Power System Commercialization Project

ORPC Maine, LLC, a wholly-owned subsidiary of Ocean Renewable Power Company, LLC (collectively ORPC), submits this Final Technical Report for the TidGen® Power System Commercialization Project (Project), partially funded by the U.S. Department of Energy (DE-EE0003647). The Project was built and operated in compliance with the Federal Energy Regulatory Commission (FERC) pilot project license (P-12711) and other permits and approvals needed for the Project. This report documents the methodologies, activities and results of the various phases of the Project, including design, engineering, procurement, assembly, installation, operation, licensing, environmental monitoring, retrieval, maintenance and repair. The Project represents a significant achievement for the renewable energy portfolio of the U.S. in general, and for the U.S. marine hydrokinetic (MHK) industry in particular. The stated Project goal was to advance, demonstrate and accelerate deployment and commercialization of ORPC’s tidal-current based hydrokinetic power generation system, including the energy extraction and conversion technology, associated power electronics, and interconnection equipment capable of reliably delivering electricity to the domestic power grid. ORPC achieved this goal by designing, building and operating the TidGen® Power System in 2012 and becoming the first federally licensed hydrokinetic tidal energy project to deliver electricity to a power grid under a power purchase agreement in North America. Located in Cobscook Bay between Eastport and Lubec, Maine, the TidGen® Power System was connected to the Bangor Hydro Electric utility grid at an on-shore station in North Lubec on September 13, 2012. ORPC obtained a FERC pilot project license for the Project on February 12, 2012 and the first Maine Department of Environmental Protection General Permit issued for a tidal energy project on January 31, 2012. In addition, ORPC entered into a 20-year agreement with Bangor Hydro Electric Company on January 1, 2013 for up to 5 megawatts at a price of $215/MWh, escalating at 2.0% per year.

16 TIDAL AND WAVE POWER↗

Evaluating the Effects of Transient Purge Flow on Stator-Rotor Seal Performance

Abstract As modern engine designs target higher efficiencies through increased turbine inlet temperatures, critical turbine components are at increased risk of damage from conditions exceeding material melting temperatures. In particular, improperly designed underplatform hardware components are susceptible to damage when hot main gas path flow is ingested into the stator-rotor cavity. While all turbines inherently experience transients during operation, a majority of publicly available turbine studies have been executed using steady operating conditions or inherently transient “blowdown” rigs. For this reason, routine transient events are not well understood. To address this need, the present study utilized a combined experimental and computational approach. The test article is a continuous-duration, one-stage test turbine operating with true-scale engine hardware and seal geometries at engine-representative flow conditions. The nature of the continuous-duration facility uniquely supports the direct assessment of transient events through its ability to transition between steady-state operating conditions. The effects of a transient purge flow were investigated in this study to identify general trends for transient events in a full-scale engine. Results from multiple measurement techniques in the wheelspace region show an interdependence of transient purge flow with a thermal lag of the underplatform hardware. Through experiments conducted at different coolant-to-main gas path temperature ratios, the use of pressure measurements as an indicator of fully purged behavior was introduced, and a thermally driven influence on rim seal performance was quantified. The computational results show good agreement with experimental pressure measurements and provide insight into the physical mechanisms that drive the relationship between pressure and sealing effectiveness measurements observed for the tested geometry.

Engineering↗

Load Mitigation on Floating Offshore Wind Turbines with Advanced Controls and Tuned Mass Dampers

General Electric, the National Renewable Energy Laboratory (NREL), the University of Massachusetts Amherst (UMass), and Glosten have recently completed a US Department of Energy (DOE)-funded research program to study technologies for mitigating loads on floating offshore wind turbines through the use of advanced turbine controls and tuned mass dampers (TMDs). The analysis was based upon the Glosten PelaStar tension leg platform (TLP) with GE Haliade 150 turbine, a system developed in a previous front end engineering design (FEED) study funded by the Energy Technology Institute (ETI) in the UK. The platform was designed for the WaveHub wave energy research site, with a mean water depth of 59-m. Loads were analyzed by running time-domain simulations in four 50-year return period (50-YRP) ultimate load state (ULS) conditions and 77 fatigue load state (FLS) environmental conditions. In 50-YRP conditions advanced controls are not active. The influence of TMDs on ULS loads have been reported previously (Park et al. [2]). In FLS conditions advanced controls and TMDs afford dramatic reductions in fatigue damage, offering the potential of significant savings in tower structural requirements. Simulations in turbine idling conditions were run in OrcaFlex, and simulations in operating conditions were run in FAST. Simulations were run with a baseline turbine controller, representative of the current state of the art, and an advanced controller developed by NREL to use collective and individual blade pitch control to maintain rotor speed and reduce tower loads. UMass developed a number of TMD types, with varying system configurations, including passive nonlinear dampers and semi-actively controlled dampers with an inverse velocity groundhook control algorithm. Loads and accelerations in FLS conditions were evaluated on the basis of damage equivalent loads (DELs), and fatigue damage was computed by Miner's summations of stress cycles at the tower base. To study sensitivity to water depth, loads were analyzed at both the 59-m WaveHub depth and a more commercially realistic depth of 100 m. TMDs reduce fatigue damage at the tower-column interface flange by up to 52% in 59-m water depth and up to 28% in 100 m water depth. Advanced controls reduce fatigue damage at the tower-column flange by up to 22% in 59-m water depth and up to 40% in 100 m water depth. The most effective load-mitigation strategy is combining advanced controls with TMDs. This strategy affords a 71% reduction in fatigue damage in both 59-m and 100-m water depths.

17 WIND ENERGY↗

Hydrogen adsorption and desorption with 3D silicon nanotube-network and film-network structures: Monte Carlo simulations

Hydrogen is clean, sustainable, and renewable, thus is viewed as promising energy carrier. However, its industrial utilization is greatly hampered by the lack of effective hydrogen storage and release method. Carbon nanotubes (CNTs) were viewed as one of the potential hydrogen containers, but it has been proved that pure CNTs cannot attain the desired target capacity of hydrogen storage. In this paper, we present a numerical study on the material-driven and structure-driven hydrogen adsorption of 3D silicon networks and propose a deformation-driven hydrogen desorption approach based on molecular simulations. Two types of 3D nanostructures, silicon nanotube-network (Si-NN) and silicon film-network (Si-FN), are first investigated in terms of hydrogen adsorption and desorption capacity with grand canonical Monte Carlo simulations. It is revealed that the hydrogen storage capacity is determined by the lithium doping ratio and geometrical parameters, and the maximum hydrogen uptake can be achieved by a 3D nanostructure with optimal configuration and doping ratio obtained through design optimization technique. For hydrogen desorption, a mechanical-deformation-driven-hydrogen-release approach is proposed. Compared with temperature/pressure change-induced hydrogen desorption method, the proposed approach is so effective that nearly complete hydrogen desorption can be achieved by Si-FN nanostructures under sufficient compression but without structural failure observed. The approach is also reversible since the mechanical deformation in Si-FN nanostructures can be elastically recovered, which suggests a good reusability. This study may shed light on the mechanism of hydrogen adsorption and desorption and thus provide useful guidance toward engineering design of microstructural hydrogen (or other gas) adsorption materials.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

Giant Mechano-Optoelectronic Effect in an Atomically Thin Semiconductor

Transition metal dichalcogenides (TMDs) are particularly sensitive to mechanical strain as they are capable of experiencing high atomic displacements without nucleating defects to release excess energy. Promising for photonic applications, it has been shown that as TMDs are scaled to a thickness of one monolayer, the photoluminescence response is dramatically enhanced due to the emergence of a direct electronic band gap, compared with multi-layer or bulk TMDs which typically exhibit indirect band gaps. Recently, mechanical strain has also been predicted to enable direct excitonic recombination in these materials, where large changes in the photoluminescence response will occur during an indirect-to-direct band gap transition brought on by elastic tensile strain. Here, we demonstrate a two orders of magnitude enhancement in the photoluminescence emission intensity in uniaxially strained single crystalline WSe 2 bilayers. Through a theoretical model which includes experimentally relevant system conditions, we determine this amplification to arise from a significant increase in direct excitonic recombination. Adding confidence to the high levels of elastic strain achieved in this report, we observe strain-independent mode-dependent Grüneisen parameters over the entire range of tensile strain (1– 3.59 %) which were obtained as 1.149±0.027, 0.307±0.061, and 0.357±0.103 for the E 2g , A 1g , and A 2 1g optical phonon modes, respectively. Lastly, these results can inform the predictive strain-engineered design of other atomically thin indirect semiconductors, where a decrease in out-of-plane bonding strength will lead to an increase in the strength of strain-coupled optoelectronic effects.

36 MATERIALS SCIENCE↗

Co-Optimization of Fuels & Engines: FY16 Year in Review

The U.S. Department of Energy's (DOE) Co-Optimization of Fuels & Engines (Co-Optima) initiative is accelerating the introduction of affordable, scalable, and sustainable fuels and high-efficiency, low-emission engines with a first-of-its-kind effort to simultaneously tackle fuel and engine research and development (R&D). This report summarizes accomplishments in the first year of the project. Co-Optima is conducting concurrent research to identify the fuel properties and engine design characteristics needed to maximize vehicle performance and affordability, while deeply cutting emissions. Nine national laboratories - the National Renewable Energy Laboratory and Argonne, Idaho, Lawrence Berkeley, Lawrence Livermore, Los Alamos, Oak Ridge, Pacific Northwest, and Sandia National Laboratories - are collaborating with industry and academia on this groundbreaking research.

09 BIOMASS FUELS↗

Advanced Hydrogen Fueling Station Supply: Tube Trailers

Air Products and Chemicals, Inc. (Air Products) is reporting on the results of a DOE-funded program to develop and validate Advanced Hydrogen Fueling Station hydrogen tube trailers to support hydrogen and fuel cell market applications. The project involved the engineering design and development of a new composite over-wrapped pressure vessel to increase the pressure capability of tube trailers to deliver hydrogen to greater than 8500 psi (586 bar). The new composite over-wrapped pressure vessel tube trailer was expected to provide improved delivery technology and reduce the cost of transporting hydrogen from central hydrogen production sources. The project aimed to meet or exceed DOE’s 2020 delivery targets for tube trailer hydrogen distribution. A gated approach was taken for the project, with early project Go/No-Go decision points. Specific goals for this four-stage product development project included: Preliminary Study, Modeling, and Analysis: Complete a preliminary design analysis and cost viability of a >8500 psi (586 bar) hydrogen storage vessel with an appropriate frame and chassis configuration for a complete trailer to US DOT requirements; Develop New Tube Size for >8500 psi (586 bar) Vessel: Fabricate tubes for test units, perform testing, and submit test results for a DOT Special Permit; Design, fabricate, and test a delivery trailer unit; Deploy the delivery trailer to hydrogen stations and collect data. Work conducted under DE-EE0006524 established costs for US DOT Type III vessels at 8500 psi (586 bar), 12500 psi (862 bar), and 14000 psi (965 bar) with manufactured water volumes up to 375 liters. Trailer module designs were established for the maximum US DOT design limits and for Air Products’ design limit of a 40-foot trailer length that addresses California hydrogen fueling station ingress and egress operating constraints. Conceptual trailer designs were not capable of achieving the DOE 2020 capacity and cost targets, but they did exceed the DOE pressure target of 500 bar. Based on new trailer cost and simulated operating performance, the 8500 psi (586 bar) new trailer design is not feasible in comparison to Air Products’ DOT-approved 7500 psi (520 bar) trailer design in operation today. Also, the project was expected to incur significantly higher product development costs associated with new US DOT vessel development and approval. Alternative trailer design concepts were explored that included 700 bar compression-less mobile fueling that could be promising for early-market hydrogen infrastructure fueling station placement and development and niche military applications. Due to the economic and budget challenges identified in the feasibility phase of the program, Air Products, in agreement with the Department of Energy, decided to terminate this development program.

08 HYDROGEN↗

FULL ACCEPTANCE INTERACTION REGION DESIGN OF JLEIC

Nuclear physics experiments envisioned at a proposed future Electron-Ion Collider (EIC) require high luminosity of 10^33-10^34 cm^-2s^-1 and a full-acceptance detector capable of reconstruction of a whole electron-ion collision event. Due to a large asymmetry in the electron and ion momenta in an EIC, the particles associated with the initial ion tend to go at very small angles and have small rigidity offsets with respect to the initial ion beam. They are detected after they pass through the apertures of the final focusing quadrupoles. Therefore, the apertures must be sufficiently large to provide the acceptance required by experiments. In addition, to maximize the luminosity, the final focusing quadrupoles must be placed as close to the interaction point as possible. A combination of these requirements presents serious detection, optics and engineering design challenges. We present a design of a full-acceptance interaction region of Jefferson Lab Electron-Ion Collider (JLEIC). The paper presents how this design addresses the above requirements up to an ion momentum of 200 GeV/c. We summarize the magnet parameters, which are kept consistent with the Nb-Ti superconducting magnet technology.

Morozov, V.S.↗

High Performance Solvent for NGCC Flue Gas CO 2 Capture (Final Technical Report)

Amine-based solvent absorption is the most mature and reliable technology for large scale CO 2 capture, dating back to the 1930s when monoethanolamine (MEA) was used to treat acid gases from oil refineries. However, while strategic advancements have optimized the CO2 capture process, the cost of capture remains high, where current estimates suggest that CO 2 capture costs are around $\$$72/tonne of CO 2 . To address this, solvent development and optimization have become a focus of current research. This project sought to develop a high-performance solvent to reduce the overall cost of CO 2 capture from NGCC flue gas. Here, solvent optimization focused on: (1) reducing the energy required for CO 2 desorption in a reboiler, (2) improving CO 2 absorption and desorption reaction kinetics, (3) improving solvent stability, and (4) reducing environmental impacts. Susteon has developed and evaluated a promoted solvent, Sustenol™, for NGCC flue gas CO 2 capture. The optimized Sustenol™ also shows a higher dynamic CO 2 absorption capacity of ~0.5 mol CO2 /mol amine compared to 0.25 mol CO2 /mol amine for 30 wt% MEA. Additionally, the solvent is oxidatively, thermally and hydrothermally stable, which leads to lower solvent loss and emissions. These advancements have resulted in a solvent regeneration energy of 2.16 GJ/tonne of CO 2 which is >30% lower than current state-of-the-art commercial and emerging solvents. Combined with empirical data from the bench and pilot scale testing, this preliminary TEA study indicated the cost of CO 2 capture by Sustenol™ for 97% CO 2 removal at $\$$54/tonne and for 90% removal at $\$$49/tonne, with a pathway to achieve $\$$45/tonne of CO 2 with continued process and solvent advancements. Susteon has developed a technology roadmap to reduce the cost of CO 2 capture to <$\$$45/tonne for NGCC flue gas. Susteon plans to derisk this technology for commercial deployment through comprehensive solvent degradation testing, long-term testing in a pilot plant at 5 tonne CO2 /day and demonstration scale testing at 100 tonne CO2 /day with NGCC flue gas and engineering design studies to qualify Sustenol™ as a drop-in replacement solvent.

03 NATURAL GAS↗

Co-Optimization of Internal Combustion Engines and Biofuels

The development of advanced engines has significant potential advantages in reduced aftertreatment costs for air pollutant emission control, and just as importantly for efficiency improvements and associated greenhouse gas emission reductions. There are significant opportunities to leverage fuel properties to create more optimal engine designs for both advanced spark-ignition and compression-ignition combustion strategies. The fact that biofuel blendstocks offer a potentially low-carbon approach to fuel production, leads to the idea of optimizing the entire fuel production-utilization value chain as a system from the standpoint of life cycle greenhouse gas emissions. This is a difficult challenge that has yet to be realized. This presentation will discuss the relationship between chemical structure and critical fuel properties for more efficient combustion, survey the properties of a range of biofuels that may be produced in the future, and describe the ongoing challenges of fuel-engine co-optimization.

09 BIOMASS FUELS↗

Spatiotemporal Adaptive Passive Direct Air Capture

Carbon Collect Inc., along with Arizona State University, the Electric Power Research Institute (EPRI), PM Group, and Trimeric Corporation, completed an initial design of a commercial-scale, passive direct air capture (DAC) system termed “carbon trees” that will capture, separate, and store at least 100,000 tonnes/year of carbon dioxide (CO2) from air (net basis). Passive DAC is unique among DAC technologies in that passive air delivery by wind avoids the energy penalty of forced convection. Carbon Collect Inc.’s sorbent-agnostic approach offers the flexibility to choose sorbents for a wide range of climates. A combination of steam, low-grade heat, and vacuum releases the CO2 from the sorbent, which is extracted from the chamber and purified and compressed for geological storage. A commercial carbon tree forest combines the output of several thousand trees for compression and purification with high heat and energy integration. The project team prepared an initial engineering design package for each of three geographically diverse host sites throughout the United States to better understand the effect of local/regional ambient conditions on DAC system performance and project costs. A techno-economic analysis, life cycle analysis, business case analysis, and an environmental, health, and safety risks assessment were also completed for each of the three geographically diverse host sites.

14 SOLAR ENERGY↗

A Concept of a Convection–Cloud Chamber to Study Aerosol–Cloud–Drizzle Interactions

Understanding and quantifying the full chain of processes from aerosol activation to drizzle formation, and the associated feedbacks to the aerosol chemical and physical properties, all within a turbulent cloud are some of the toughest challenges in atmospheric chemistry and physics and are keys to the cloud–precipitation puzzle. This paper describes a concept for a new type of research facility consisting of a cloud chamber plus associated instrumentation and computational models, to explore aerosol–cloud interactions and processing, cloud optical properties, entrainment–cloud interactions, and quantitative assessment of drizzle onset. The envisioned design is for a 3 m × 3 m × 9 m chamber, such that the height is sufficient to achieve long lifetimes for aerosol processing and for significant drizzle growth by collision and coalescence. A suite of computational tools for simulating microphysical properties in the chamber provides a digital twin for designing the chamber and a range of example experiments. Theory and test results from novel remote sensing systems for exploring chemical and physical interactions and evolution of aerosols, cloud droplets, and drizzle within turbulent clouds are described. Testing of technology needed for the operation of a large-volume chamber, including aerosol generation methods and novel materials for water vapor boundary conditions, is described. Simulations suggest that spatially uniform turbulence and microphysical properties can be sustained in a steady state, with reasonable aerosol and water vapor fluxes, and that substantial drizzle can be produced through collision and coalescence of cloud droplets. Remaining challenges for more detailed engineering design and a discussion of possible first-light experiments are described.

54 ENVIRONMENTAL SCIENCES↗

Mechanical Characterization of Woven Composites at Different Temperatures

This work is to characterize the mechanical properties of the selected composites along both on- and off- fiber axes at the ambient loading condition (+25°C), as well as at the cold (-54°C), and high temperatures (+71°C). A series of tensile experiments were conducted at different material orientations of 0°, 22.5°, 45°, 67.5°, 90° to measure the ultimate strength and strain $σ_{f}, ϵ_{f}$, and material engineering constants, including Young's modulus Ε and Poisson's ratio ν. The composite materials in this study were one carbon composite carbon (AS4C/UF3662) and one E-galss (E-glass/UF3662) composite. They both had the same resin of UF 3362, but with different fibers of carbon AS4C and E-glass. The mechanical loading in this study was limited to the quasi-static loading of 2 mm/min (1.3x10 ^(-3) in/s), which was equivalent to 5x10 (-4) strain rate. These experimental data of the mechanical properties of composites at different loading directions and temperatures were summarized and compared. These experimental results provided database for design engineers to optimize structures through ply angle modifications and for analysts to better predict the component performance.

36 MATERIALS SCIENCE↗

2024 International Conference on Microbiome Engineering (ICME)

The 2024 International Conference on Microbiome Engineering (ICME) took place November 12-14 at Tufts University in Medford, MA. ICME connects experts from academia and industry to share the most recent developments in the field of microbiome engineering. This includes genetically engineered organisms that function within microbiomes, control of microbiomes through environmental/nutrient modifications, and inference of engineering principles from analysis of synthetic and natural microbiomes. The conference is unique and distinct from other microbiome conferences in that it specifically highlights the integration of engineering design principles with microbiome research (others are more focused on basic biological principles). The conference thus integrates synthetic biology, systems biology, microbial ecology, and bioinformatics across a range of application spaces from the environment to manufacturing, food, and human health. This project utilized support from the Department of Energy’s (DOE) Office of Biological and Environmental Research (BER) to help trainees and early career faculty attend ICME.

60 APPLIED LIFE SCIENCES↗

An agent-based framework for fuel cycle simulation with recycling

Simulation of the nuclear fuel cycle is an established field with multiple players. Prior development work has utilized techniques such as system dynamics to provide a solution structure for the matching of supply and demand in these simulations. In general, however, simulation infrastructure development has occurred in relatively closed circles, each effort having unique considerations as to the cases which are desired to be modeled. Accordingly, individual simulators tend to have their design decisions driven by specific use cases. Presented in this work is a proposed supply and demand matching algorithm that leverages the techniques of the well-studied field of mathematical programming. A generic approach is achieved by treating facilities as individual entities and actors in the supply-demand market which denote preferences amongst commodities. Using such a framework allows for varying levels of interaction fidelity, ranging from low-fidelity, quick solutions to high-fidelity solutions that model individual transactions (e.g. at the fuel-assembly level). The power of the technique is that it allows such flexibility while still treating the problem in a generic manner, encapsulating simulation engine design decisions in such a way that future simulation requirements can be relatively easily added when needed. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Status of the CBETA splitter common magnet design

The two common dipole magnets in each of the two CBETA splitter sections serve to direct the beams of 42, 78, 114 and 150 MeV from the linac or FFAG return loop exit into the separate splitter lines for path length adjustment and to direct the beams from the splitter into the linac or FFAG return loop entrance. Here we report the results of design and tracking studies based on the Opera V18R2 software. The choice of the H-magnet design included consideration of using the coil design developed for the internal splitter H-dipoles by Elytt Energy. Considerations of transverse space constraints and the bend angle of about 30 degrees for the 42-MeV beam led to the adoption of a T-shape for the pole. The XYZ magnet dimensions are 34 × 42 × 16 cm. The central field value is 3.6-3.9 kG, but the magnet can operate as high as 4.9 kG, allowing for tests of a beam energy as high as 54 MeV in the S1 splitter line. We include results of tracking studies showing optimal placement of the magnets based on bend angle uniformity for the four beam energies. The project now proceeds to the full engineering design and fabrication to be performed by Elytt Energy.

43 PARTICLE ACCELERATORS↗