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DOE OSTI2021

Idaho National Laboratory Annual Report for Permit to Construct P-2015.0023 for Calendar Year 2020

The U.S. Department of Energy (DOE) Idaho National Laboratory (INL) Site operates facilities with potential emissions criteria and hazardous air pollutants. This report documents the calendar year 2020 criteria and hazardous air pollutants emissions and has been prepared to comply with permit to construct (PTC) P-2015-0023, Condition 2.9 and Idaho Administrative Procedures Act (IDAPA) 58.01.01.178, Standard Contents of Permits Establishing a Facility Emissions Cap (FEC). IDAPA 58.01.01.178.04 requires that all permits establishing a FEC shall include sufficient reporting to assure compliance with the permit establishing the FEC. Total hazardous air pollutant (HAP) emissions for the year were 0.59 tons in aggregate and the maximum individual HAP was hydrochloric acid at 0.35 tons. Criteria pollutant emissions were 1.23 tons for sulfur dioxide, 40.96 tons for oxides of nitrogen, 11.7 tons of carbon monoxide, 3.01 tons of total particulate matter and 1.98 tons of volatile organic compounds (VOC).

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2025

Redefining Design for Remanufacturing: A Practical Methodology for Prioritizing Remanufacturing Design Rules

Products are often discarded when they fail or no longer meet user needs. These outcomes are frequently shaped by early design decisions. While remanufacturing offers a sustainable alternative by restoring products to like‐new condition, its potential is often limited by designs that do not consider remanufacturing from the outset. This research addresses that challenge by introducing a structured Design for Remanufacturing (DfRem) methodology and a CAD‐integrated tool to support real‐time design decisions. The DfRem framework introduces a new primary design function focused on preserving product functionality across its life cycle. It is supported by a fault tree that identifies failure modes that limit remanufacturing potential and a hierarchy of design principles including Prevent, Minimize, Relocate, Restore, and others. Each principle is linked to actionable design rules that help engineers reduce the need for remanufacturing or improve its efficiency when necessary. To operationalize this framework, we developed CAD plugins for Autodesk Inventor and PTC Creo. These tools use a state machine model to present prioritized design rules based on selected failure modes and user input. By embedding DfRem logic directly into widely used CAD environments, the tool enables engineers to make sustainability‐informed decisions without disrupting existing workflows. Furthermore, this approach highlights the critical role of design in enabling circular and resource‐efficient product development, making remanufacturing a more practical and accessible strategy during the early stages of product design.

CAD↗

DOE OSTI2023

Linker Vacancy Engineering of a Robust ftw–type Zr–MOF for Hexane Isomers Separation

Discrimination of physically similar molecules by porous solids represents an important yet challenging task in industrially relevant chemical separations. Precisely controlled pore dimension and/or tailored pore surface functionality are crucial to achieve high-efficiency separation. Metal-organic frameworks (MOFs) are promising candidates for these challenging separations in light of their structural diversity as well as highly adjustable pore dimension/functionality. We report here a microporous, ftw-type Zr-based MOF structure, HIAM-410 (HIAM=Hoffmann Institute of Advanced Materials), built on hexanuclear Zr 6 cluster and pyrene-1,3,6,8-tetracarboxylate (ptc 4– ). Its crystallographic structure has been determined using continuous rotation electron diffraction (cRED) technique combined with Rietveld refinement against powder X-ray diffraction data, aided by low-dose high-resolution transmission electron microscopy (HRTEM) imaging. The compound features exceptional framework stability that is comparable to the prototype MOF UiO-66. Interestingly, the linker vacancies in the pristine MOF structure could be partially restored by post-synthetic linker insertion. Its separation capability of hexane isomers is enhanced substantially upon the linker vacancy engineering. As a result, the restored structure exhibits efficient splitting of monobranched and dibranched hexane isomers at both room temperature and industrially relevant temperature.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2021

Influence of the concentration ratio on the thermal and economic performance of parabolic trough collectors

The thermal and economic performance of parabolic trough collectors (PTCs) and PTCs with double glass envelope (DGE-PTCs) are analyzed in this work. A model including thermal and optical effects is developed to evaluate the efficiency of vacuum and air-filled DGE-PTCs, while an economic model based on two commercial PTCs (SkyTrough and Ultimate Trough collectors) was developed to assess the economic performance. The efficiency and thermal output per unit cost of the proposed DGE-PTCs are analyzed as a function of the concentration ratio and are respectively compared with the thermal and economic performance of traditional and commercial PTCs. The optimum concentration ratio for maximum thermal performance varies from 11.0 to 23.3 for operation temperatures (T HTF ) between 100 degrees C and 400 degrees C, while the optimum concentration ratio for maximum economic performance ranges between 28.9 and 33.2 for the SkyTrough and between 40.0 and 43.8 for the Ultimate Trough collector designs. Finally, the DGE-PTCs present higher thermal and economic performance at high operating temperatures, which presents a valuable opportunity for implementation in new PTC designs pursuing higher operating temperatures to achieve superior thermal cycle efficiencies.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2020

Development of high concentration photovoltaics (HCPV) power plants in the US Southwest: Economic assessment and sensitivity analysis

High concentration photovoltaic (HCPV) technologies offer several advantages over typical PV systems. In this study, a detailed economic assessment and sensitivity analysis of deploying HCPV plants in the US southwest is performed. To do this, a 20 MWdc HCPV power plant is designed using the System Advisor Model (SAM) and is evaluated from both technical and financial aspects. The sensitivity analysis shows that reducing the installed cost per capacity of the HCPV system can significantly improve the economics and reduce the levelized cost of electricity (LCOE) and levelized power purchase agreement (LPPA). Also, providing proper incentives including both investment tax credits (ITC) and production tax credit (PTC), loan debt ratio, and interest rate are among the most influential parameters. The analysis shows that with the 30% ITC, the LCOE, and LPPA of the designed HCPV projects are between $65.4/MWh and $69.3/MWh and between $71.0/MWh and $75.2/MWh, respectively. The estimated LCOE and LPPA values are almost 50% higher than the utility-scale PV projects. If proper funding is provided to continue the support of the HCPV system, they would become more economical and competitive with PV plants. Federal and state government policies must also be established to advocate HCPV systems.

14 SOLAR ENERGY↗

DOE OSTI2024

Enhancing the Carbon Monoxide Oxidation Performance through Surface Defect Enrichment of Ceria-Based Supports for Platinum Catalyst

Effective synthesis and application of single-atom catalysts on supports lacking enough defects remain a significant challenge in environmental catalysis. Herein, we present a universal defect-enrichment strategy to increase the surface defects of CeO 2 -based supports through H 2 reduction pretreatment. The Pt catalysts supported by defective CeO 2 -based supports, including CeO 2 , CeZrO x , and CeO 2 /Al 2 O 3 (CA), exhibit much higher Pt dispersion and CO oxidation activity upon reduction activation compared to their counterpart catalysts without defect enrichment. Specifically, Pt is present as embedded single atoms on the CA support with enriched surface defects (CA-HD) based on which the highly active catalyst showing embedded Pt clusters (Pt C ) with the bottom layer of Pt atoms substituting the Ce cations in the CeO 2 surface lattice can be obtained through reduction activation. Embedded PtC can better facilitate CO adsorption and promote O 2 activation at Pt C –CeO 2 interfaces, thereby contributing to the superior low-temperature CO oxidation activity of the Pt/CA-HD catalyst after activation.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Highly Active Rutile TiO 2 Nanocrystalline Photocatalysts

The controllable synthesis of rutile TiO 2 single crystal particles with the preferential orientation of {111} facets still remains a scientific and technological challenge. Here, we developed a facile route for fabrication of rutile TiO 2 nanorod crystals (RTiO 2 NRs) having high ratios of oxidative {111} to reductive {110} surfaces. RTiO 2 NRs were synthesized using a peroxo-titanium complex (PTC) approach, which was controlled by changing the Ti/H 2 O 2 ratio. The thus obtained RTiO 2 NRs revealed a high tendency to agglomerate through orientation-dependent attachment along the {110} facets. This resulted in an increased {111}/{110} surface ratio and led to a markedly improved photocatalytic activity of RTiO 2 NR aggregates. The reported findings illustrate the rich potential of the herein proposed facile and energy-efficient synthesis of nanostructured rutile TiO 2 -based photocatalysts.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2020

Selective inhibition of human translation termination by a drug-like compound

Methods to directly inhibit gene expression using small molecules hold promise for the development of new therapeutics targeting proteins that have evaded previous attempts at drug discovery. Among these, small molecules including the drug-like compound PF-06446846 (PF846) selectively inhibit the synthesis of specific proteins, by stalling translation elongation. These molecules also inhibit translation termination by an unknown mechanism. Using cryo-electron microscopy (cryo-EM) and biochemical approaches, we show that PF846 inhibits translation termination by arresting the nascent chain (NC) in the ribosome exit tunnel. The arrested NC adopts a compact α-helical conformation that induces 28 S rRNA nucleotide rearrangements that suppress the peptidyl transferase center (PTC) catalytic activity stimulated by eukaryotic release factor 1 (eRF1). These data support a mechanism of action for a small molecule targeting translation that suppresses peptidyl-tRNA hydrolysis promoted by eRF1, revealing principles of eukaryotic translation termination and laying the foundation for new therapeutic strategies.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2020

Pressure dependence of antiferromagnetic and superconducting phases in U 2 Rh 1–x Pt x C 2

In this work, we report temperature (T)- and pressure (P)-dependent resistivity measurements on the isostructural compounds U 2 Rh 1–x Pt x C 2 (x = 0, 0.5, and 0.9) from which we construct a T–P–x phase diagram. Compounds with x = 0 and x = 0.5 are antiferromagnets below 22.1 and 9.4 K, respectively, and their Néel temperature (T N ) decreases under applied pressure. For x = 0, the critical pressure P c required to suppress T N to zero temperature is projected to be about 8.8 GPa, but P c for x = 0.5 is between 1.6 and 2.1 GPa. At atmospheric pressure, increasing Pt concentration in U 2 Rh (1–x) Pt x C 2 tunes magnetic transition temperatures to zero at a critical value of x c ≈ 0.7, and, consequently, we surmise the existence of a quantum-phase boundary in the P–x plane at T = 0 K that extends from (P = 0, x = xc) to (P c ≈ 8.8 GPa, x = 0). For x = 0.9, superconductivity appears at T c = 1.09 K , which decreases at a rate of ≈ –1 K/GPa that is nearly twice that found for U 2 PtC 2 whose T c is 1.47 K. Together, these results indicate that domes of magnetism and superconductivity formed with T–P–x variations are detached and that the two broken symmetries are independent of each other. Fluctuations in average composition produce rare regions that play an important role in determining physical properties of materials with noninteger x.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2024

Techno-economic assessment of electricity market potential for co-located hydro-floating PV systems

Abstract—Harnessing renewable energy from diverse sources is paramount for sustainable power systems. Recently, co-located floating PV (FPV) systems present an intriguing prospect in this context. These hybrid systems, blending hydro and solar power, may offer a more consistent electricity output and potential economic advantages. Yet, assessing their actual potential requires a comprehensive techno-economic assessment. In addition, probabilistic price forecasting has recently gained attention in electricity market because decisions based on such predictions can yield significantly higher profits than those made with point forecasts alone. To this end, this paper embarks on a journey to elucidate the electricity market potential of co-located hydro-FPV systems in a probabilistic fashion to investigate the technological merits and economic viability of co-located hydro-FPV under different market structures. Our preliminary findings suggest that LCOE and payback metrics are sensitive not only to different markets but also to different solar incentives. Concurrently, we also observe that the payback period is generally faster with a production tax credit (PTC) than an investment tax credit (ITC). This assessment serves as a cornerstone for understanding the future prospects of co-located hydro-FPV systems in modern electricity markets.

13 HYDRO ENERGY↗

DOE OSTI2020

Spectroscopy of Palladium Nanoparticle Synthesis: Tailoring Nanoparticle Growth Parameters for Hydrogen Storage

Using palladium for hydrogen storage requires palladium (Pd) particles exhibiting specific parameters, including surface area, particle size, and particle shape, with increased interest in palladium nanoparticles (Pd NPs). In order to routinely monitor the synthesis of these particles a spectroscopic method is being developed using infrared (IR), Raman, and UV-Vis spectroscopy. By monitoring the production of Pd NPs, the growth of the NPs can be controlled to ensure quality of the product to match the desired finished particle specifications. For the reaction presented, the conversion of the intermediate tetraamminepalladium(II) chloride (PTC) to diamminepalladium(II) chloride (PDC) can influence the Pd NPs properties. This study is first being developed in lab bench scale quantities to allow ultimate control of the Pd NPs.

08 HYDROGEN↗

DOE OSTI2022

High-Temperature Linear Receiver Enabled by Multicomponent Aerogels

Concentrating solar thermal (CST) technology has significant potential mainly due to its dispatchability and low cost of storage. However, to compete with other sources, including utility-scale solar PV, its final cost (cents/kWh) still needs to be lowered. Cost reduction can be achieved by improving the system level efficiency of the CST plants through the deployment of advanced power cycles, which operate at high temperatures of ~700°C. However, optical, and thermal losses pose a major challenge to the efficiency of such CST systems. The overall aim of this project is to investigate and de-risk a linear solar receiver concept called an Aerogel Insulated Receiver (AIR) that generates high temperatures (up to 700°C) at a low solar concentration ratio (<100) and with a high collection efficiency (optical × receiver). Our prior work has demonstrated the thermal stability1 and optical and heat-insulating properties2,3 of transparent aerogel insulation at a one-inch scale. The focus of this work is on (1) co-optimization of the geometry of the aerogel tile and receiver enclosure to fit a standard parabolic collector (PTC), (2) scale-up of aerogels into 4-inch tiles while preserving key properties, (3) experimental measurement of receiver heat loss (W/m) in a >70-cm test stand and validation of anticipated receiver performance at high temperatures. Regarding (1), appropriate optical and thermal models for a parabolic trough receiver (PTR) are developed and validated. The geometry of the aerogels and the receiver enclosure are co-optimized to maximize the collection efficiency. The model predicts a 54% collection efficiency at 700°C for an AIR design based on flat aerogels. By combining the collection efficiency with the power block efficiency of supercritical CO 2 cycles, we predict >10% improvements in peak plant efficiency relative to existing line-focusing CST systems. The application of curved plasmonic aerogels is predicted to further increase the collection efficiency to 64%. Regarding (2), we demonstrate the successful development of 6-inch-long refractory aerogel tiles with optical, thermal, and stability characteristics consistent with our prior work. This scale-up requires a transition to a larger ALD station and modifying the ALD process variables such as exposure time and the number of precursor doses. Regarding (3), we design and develop an AIR test stand measuring 3 feet in length. Heat loss performance analysis is carried out using the test stand. The results indicate that aerogel insulation can significantly reduce receiver thermal losses at the high operating temperatures required for next-generation PTRs. The experimental results agree with the heat loss performance predicted by our receiver model. Lastly, we conducted preliminary failure mode and effects (FMEA) and techno-economic (TEA) analyses to identify failure mitigation strategies and commercial opportunities, respectively. Overall, this project identifies key opportunities and challenges in deploying aerogel insulating receivers in next-generation line-focusing CST technologies.

14 SOLAR ENERGY↗

DOE OSTI2022

Production of Fischer-Tropsch Synfuels at Nuclear Plants

A case study analysis was performed to evaluate nuclear-powered synthetic fuel production in the midwestern United States (U.S.). A Fischer-Tropsch (FT) fuel synthesis plant design was used as the basis for the analysis. The FT plant design was configured to produce a product slate consisting of diesel fuel, jet fuel, and motor gasoline blend stocks from carbon dioxide (CO 2 ) and hydrogen (H 2 ) feedstocks. The CO 2 feedstock for the FT plant was assumed to be sourced from biorefineries in the region around a Midwest light water reactor (LWR) nuclear power plant (NPP). The analysis specifies that power from the LWR is used to produce H 2 via high-temperature steam electrolysis and to operate the FT synfuel production plant. Capital costs were estimated for the FT plant while capital costs for the electrolysis plant were based on previous Idaho National Laboratory (INL) studies. In addition to labor and maintenance costs for the FT and electrolysis plants, operating costs also include the costs for CO 2 feedstock transport. An analysis was performed to determine the cost of transporting CO 2 from the distributed biorefinery sources to the centralized fuel synthesis plant as a function of the synfuel plant capacity and corresponding CO 2 demand. The primary revenue streams are associated with sales of the synthetic fuel products. The synthetic fuel products will likely follow the same market trends as the conventional fuel products. The synfuel price data was thus based on projections made by the U.S. Energy Information Administration (EIA) 2021 Annual Energy Outlook (AEO) for conventional fuel products minus federal and state taxes, as well as marketing and distribution costs. The economic analysis also considered cases that included and excluded revenues from the 2022 Inflation Reduction Act (IRA) clean hydrogen production tax credit (PTC) of $\$ $3.00/kg for the first ten years of operation. The economic analysis calculated the net present value (NPV) for cases involving steady-state synfuel production for comparison with the NPV for a business-as-usual case in which NPP continues to sell only electric power to the grid. A synfuel production “Reference Case” was considered in addition to sensitivity cases in which the plant capacity, electricity price, and synthetic fuel product prices were perturbed. The synfuel production Reference Case considered a scenario in which the electrolysis and synfuel plants utilized a combined electrical load of 1000 megawatt electrical (MWe) from the LWR with the balance of the LWR power output being sold to the electric grid. The economic analysis suggests that the synfuel production Reference Case evaluated in this analysis would lead to considerable economic potential for near-term deployment of a nuclear-based synfuel production plant. Specifically, the economic analysis suggests that the deployment of a 1000 megawatt (MW) nuclear-powered synfuel plant could result in a NPV increase of approximately $\$ $1.7 billion for a case with no clean synfuel price premium relative to conventional petroleum fuels when accounting for the additional revenues from the 2022 IRA clean hydrogen PTCs of $\$ $3/kg. Sensitivity analysis was performed to evaluate the effect of perturbation of selected model input parameters on the NPV for the synfuel production Reference Case. The sensitivity analysis indicates that the plant capacity has the largest impact on the differential NPV, with a smaller synfuel production capacity resulting in a decrease in revenue when a larger fraction of the power from the NPP is sold to the grid and a smaller fraction of the power is used to produce synthetic fuel products. The synfuel product pricing has the next largest impact on the differential NPV, with lower synfuel prices resulting in decreased NPV from decreased synfuel sales revenue while higher synfuel prices result in increased NPV from increased synfuel sales revenue. Electricity pricing has a smaller effect on the NPV than the fuel sales price since, in the Reference Case, most of the energy from the NPP is used for synfuel production and a smaller amount of the system revenues are associated with electrical power sales. However, the electricity price sensitivity does indicate that the Synfuel Integrated Energy System (IES) would have a greater NPV than the business-as-usual case (e.g., grid power sales only) when electricity market prices are low, suggesting that synfuel production could provide a strategy for decreasing the economic risks to NPPs posed by a loss of revenues attributed to falling electricity market prices.

10 SYNTHETIC FUELS↗

DOE OSTI2022

Land-Based Wind Market Report: 2022 Edition

Wind power additions in the United States totaled 13.4 gigawatts (GW) in 2021. Recent growth is supported by the industry’s primary federal incentive—the production tax credit (PTC)—as well as a myriad of statelevel policies. Long-term improvements in the cost and performance of wind power technologies have also been key drivers for wind capacity additions, even as supply chain constraints due to increased commodity and transportation costs and COVID-19 restrictions push costs higher.

17 WIND ENERGY↗

DOE OSTI2020

High-Temperature Heat Transfer Fluid Circulator for Concentrating Solar Power Systems

A high temperature Heat Transfer Fluid circulator compressor with wide turn down ratio aerodynamic performance was designed, fabricated and tested for application with high pressure super Critical CO2 fluid capable of temperatures and pressures to >750°C and 25 MPa respectively. The modular system decoupled the drive motor system from an independent compressor shaft to provide thermal isolation between the high temperature compressor shaft and the lower temperature capable motor elements. While the thermal management approach appears to be viable there are potential losses in the secondary cooling flows that need to be taken into account and fine-tuned during operation in order to achieve desired overall system efficiencies. The system was also shown to be viable and dynamically stable throughout the entire operating speed range, thereby validating the overall system configuration and structural design approach used. Finally, while it was not possible to achieve specific PTC-10 test points, the compressor performance tests provide sufficient data to indicate that the compressor has the ability to achieve the required performance in practice. The two key factors affecting compressor design and cost are the maximum expected temperature and pressure. The maximum allowable temperatures for current state-of-the-art (SOA) motor driven compressor technology is limited to of approximately 150-200°C, but inlet temperatures >750 °C may be encountered. While the optimal efficiency of compression is in the transcritical region, some concepts require inlet pressures to 225 bar.

14 SOLAR ENERGY↗

DOE OSTI2021

High-Temperature Heat Transfer Fluid Circulator for Concentrating Solar Power Systems How Mohawk and Velo3Dare Printing the Future of Energy

14 SOLAR ENERGY↗

DOE OSTI2024

Land-Based Wind Market Report: 2024 Edition

Wind power additions in the United States totaled 6.5 gigawatts (GW) of capacity in 2023. 1 Wind power growth has historically been supported by the industry’s primary federal incentive—the production tax credit (PTC)—as well as numerous state-level policies. Long-term improvements in the cost and performance of wind power technologies have also been key drivers for wind additions, yielding low-priced wind energy for utility, corporate, and other power purchasers. Nonetheless, 2023 was a slow year in terms of new wind deployment, the lowest since 2014. Elevated interest rates played a role in slowing deployment, as did interconnection and siting challenges.

17 WIND ENERGY↗

DOE OSTI2025

Advanced Diagnosis and Accelerated Testing of Balance of System Components for Utility Scale PV Installations: October 1, 2022-September 30, 2024

A study of the durability of PV Balance of System components was performed. Specifically, wire cable jackets and cable connectors were examined within the direct current (DC) PV Power Transmission Chain (PTC). Degraded and failed samples have been obtained from utility PV installations to provide feedback on the degradation modes and the related damage-enabling considerations in today's PV systems. An industry interface group (including system owners, system inspectors, component manufacturers, and test labs) was used to help identify and obtain field-failed samples, for feedback (including samples and experimental design), and to facilitate the subsequent dissemination of the results of this study. Samples were empirically studied using accelerated stress testing with steady-state conditions (cable jackets) in addition to combined-accelerated stress testing (cable jackets, connectors and uncapped connectors). Steady-state accelerated testing has been performed using at least one applied stressor (e.g. UV light) to aid understanding of jacket durability relative to its application. Component- and material-focused failure analysis was conducted to develop an understanding and advise the PV industry. In-depth characterization will be applied selectively to field- and artificially aged-samples, to gain scientific understanding of the structural, chemical, electrical, mechanical, and thermal properties enabling degradation.

24 POWER TRANSMISSION AND DISTRIBUTION↗