Cyber-Informed Engineering Water Booster Pump Station Case Study Slides [Slides]
This document presents an introduction to the twelve CIE principles applied through an engineering case study focused on a water booster pump station.
42 ENGINEERING↗
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Fossil Fuel Transitions Framework: Case Studies of the Decision-Making Process for Energy and Economic Development Pathways
Each community is unique, and transitions must be tailored to local and national contexts, with recognition that access to financing is a key differentiator between wealthy and low-to-middle income countries. This analysis examines six community fossil fuel transitions in two different country contexts to provide insights on inclusive processes and decision-making criteria that bring forth positive outcomes for the communities. In both the United States and Chile, a coordination mechanism is established across government agencies and the importance of stakeholder engagement is recognized. In many cases, the government, local community groups, and electric utility or industry players have a critical role in transition planning and support.
29 ENERGY PLANNING, POLICY, AND ECONOMY↗
Updates to Direct Air Capture Sorbent Case Studies
This poster reports preliminary results from an update to NETL’s 2022 “Direct Air Capture [DAC] Case Studies: Sorbent System” (Rev1).
Patel, Kshitij↗
Case Studies in Leveraging Performance Contracts for Resilience Projects
The resilience of federal facilities has become increasingly important among lawmakers, agency leadership, and the American public as high impact natural hazards occur more frequently over time. Resilience is broadly defined as the ability of a federal facility to withstand, respond to, and recover rapidly from disruptions to maintain critical functions. The Department of Energy (DOE) Federal Energy Management Program (FEMP) was codified to facilitate the strengthening of federal energy and water efficiency and resilience. Performance contracting is one of the mechanisms through which federal agencies can finance projects at their facilities, but resilience improvement measures do not always result in utility cost savings, which are the primary driver behind performance contracts. This report provides example cases where performance contracts, specifically energy savings performance contracts (ESPC) or utility energy service contracts (UESCs), were used to implement a resilience measure at a federal facility.
99 GENERAL AND MISCELLANEOUS↗
Site-specific Design Case Study for Wet Waste Hydrothermal Liquefaction and Biocrude Upgrading to Hydrocarbon Fuels
Hydrothermal liquefaction (HTL) is a thermal process that converts wet biomass to renewable hydrocarbon fuel blendstocks (i.e., renewable naphtha, renewable diesel, and sustainable aviation fuel (SAF)). It can utilize a wide range of pure and blended wet feedstocks, including sewage sludge from water resource recovery facilities (WRRF), food and agriculture wastes, algae, fats, oils and greases (FOG) and blends of dry and wet wastes/feedstocks. Historically, techno-economic analysis (TEA) and annual state of technology (SOT) assessments with standard economic assumptions used by the Bioenergy Technologies Office (BETO) were conducted for the wet waste HTL pathway leveraging experimental data collected from Pacific Northwest National Laboratory’s (PNNL) continuous flow reactor systems. The objective of the SOT assessment has been to guide and track progress of BETO’s HTL research and development (R&D) toward reduced cost and greenhouse gas (GHG) emissions for the pathway. However, gaps exist between BETO’s traditional SOT updates and the needs of key external stakeholders that – if addressed – will accelerate technology adoption. This Business Case Study aims to bridge this gap by providing an updated design, TEA, and LCA based on PNNL’s FY23 R&D with added analyses and information that provide enhanced relevance for stakeholders of the HTL technology. This includes specific siting, regional wet waste resource inventory and transportation cost analyses, fuel market information, sustainable fuel policy impacts, economic metrics of net present value (NPV) and internal rate of return (IRR), greenhouse gas (GHG) emissions analysis, and statistical analysis of cost and technical uncertainties of the HTL plant design. The study focuses on the “Detroit combined statistical area (CSA)” region for siting of a wet waste HTL plant adjacent to the Great Lakes Water Authority (GLWA) facility with guidance from industry participants. Regional resource and siting analyses were conducted to identify feedstock availability, scale, and cost, as well as a beneficial site location. TEA with detailed rigorous capital cost estimation for the specific site application was conducted to evaluate the key economic metrics of most value to industrial partners. These include total capital investment, operating costs, minimum fuel selling price (MFSP) of the biocrude and fuel blendstock, and NPV and internal rate of return IRR with sustainable fuel credits. Life cycle analysis was conducted to evaluate the supply chain greenhouse gas (GHG) emissions for the wet waste HTL process as compared with petroleum derived diesel. This study is also informed by years of R&D and process de-risking learnings and was conducted with a basic engineering HTL plant design and costing that akin to a “first-of-a-kind” plant economics. This differs from our conventional “nth plant ” SOT assessments. Specifically, the HTL process model has been updated with more operationally reliable methods for feed heating and phase separations. Further, we have implemented additional spare equipment for redundancy, a more rigorous installed equipment cost estimation approach, and additional costs associated with feed formatting and delivery, building, piping and site development. An Excel-based cost sheet based on the basic engineering design is also released alongside the report that allows users to conduct customized TEA with their own feed composition and financial assumptions.
09 BIOMASS FUELS↗
Large-Scale CO2 Storage and Reservoir Management Strategies: Case Studies
This poster describes large-scale CO2 storage and reservoir management case studies for presentation at the AGU2024 conference. The analysis in this study provides a wealth of details on the designs and strategies that can lead to an optimal solution for pressure and CO2 plume management under critical constraints. These findings not only promise a reduction in the CO2 storage footprint but also hold the potential to create a more environmentally friendly ecosystem. Furthermore, this research offers valuable insights into the decision-making process when considering multi-project deployment in a shared basin for large-scale and gigatons of CO2 storage, paving the way for a more sustainable future. Poster presented (virtual) at the 2024 AGU Conference, December 9-13, 2024, Washington, D.C.
Liu, Guoxiang [NETL]↗
Electric Vehicle and Charging Infrastructure Assessment in Cold-Weather Climates: A Case Study of Fairbanks, Alaska
The purpose of this report is to determine the effects that extreme cold temperatures have on electric vehicles (EVs) and electric vehicle supply equipment (EVSE). The adoption of EVs in extreme cold weather presents challenges that require careful analysis of efficiency and charging infrastructure. This report, "Electric Vehicle and Charging Infrastructure Assessment in Cold-Weather Climates: A Case Study of Fairbanks, Alaska," explores how EVs and EVSE perform in temperatures as low as -40 degrees C (-40 degrees F), focusing on real-world data from Teslas in Alaskan winter conditions. The findings indicate that EVs can successfully function in extreme cold, though efficiency is significantly affected. Vehicles stored in heated environments outperformed those stored outdoors, with efficiency dropping by up to 69% for outdoor storage. Despite these challenges, none of the vehicles experienced failures that prevented travel. Storing EVs indoors led to benefits such as faster preconditioning and improved efficiency, while charging in extreme cold, though slower, remained functional. Ultimately, the report concludes that with proper precautions and best practices, EVs are viable transportation solutions in cold climates. Investing in enclosed, heated storage is recommended to maximize efficiency and minimize battery strain. As advancements in battery chemistry and thermal management progress, EV adoption in extreme climates is expected to become even more feasible.
33 ADVANCED PROPULSION SYSTEMS↗
Sustainable Materials Selection in Manufactured Products: A Framework for Design-Integrated Life Cycle Thinking with Case Studies
Materials selection can provide a major opportunity to improve the environmental performance of manufactured products. Substitution of conventional materials with eco-friendly options can lower a product's environmental impact while still meeting key application requirements. A prerequisite for sustainability-informed decision-making is that relevant data and information are available for all materials being considered. Here we outline examples of the types and sources of data needed; and we explore key considerations for sustainable materials selection through a series of practical, cross-sectoral case studies.
36 MATERIALS SCIENCE↗
Techno-economic Tool for Evaluating Direct Air Capture System Performance: A Case Study across U.S. Cities
The presentation provides an overview of the Direct Air Capture (DAC) Siting Tool including regional factors impacting DAC performance and modeling costs for CO2 transport and storage. The presentation shows illustrative results in terms of the cost of CO2 removal ($/tonne) and DAC favorability index for case study sites.
direct air capture (DAC)↗
FY25 Status Update on A709 Code Case Testing at ANL
This report provides an update on the status of the creep rupture testing on the precipitation-treated (PT) Alloy 709 samples fabricated from the first, the second and the third commercial heats, in support of the first, 100,000-hour Alloy 709 Code Case development under the American Society of Mechanical Engineers (ASME) Section III, Division 5 for high-temperature reactor construction. In Fiscal Year (FY) 25, no new tests were initiated, while 5 previously loaded tests were completed. This report presents an overview of the creep-rupture data gathered at Argonne National Laboratory (ANL) since FY21 that totaled 52 completed tests. Metallographic images showing crack morphologies in some representative samples ruptured in FY25 are also included. Key conclusions include: 1) the creep behavior of the three heats of Alloy 709 can be well described by the Larson-Miller relationship; 2) higher temperatures and larger stresses lead to shorter creep life and higher minimum creep rate; 3) Alloy 709 is overall very ductile under creep; 4) the crack morphologies near fracture surfaces are dependent on material’s grain size and test conditions.
22 GENERAL STUDIES OF NUCLEAR REACTORS↗
Understanding Geometry and Microstructure Interactions In LPBF By Linking Lab Scale Studies To Real Part Case Examples
The mechanical properties derived from simple tensile tests are uniquely important in the design and qualification of load bearing metallic components. The tensile properties in standards for wrought metallic materials are generally accessible for design and simulation engineers, but this is not the case for additively manufactured metals. This work investigates the influence of tensile specimen geometry on the mechanical properties of laser powder bed fusion (LPBF) additively manufactured Ti-6Al-4V, particularly in relation to properties measured from specimens excised from an exemplar part. A comprehensive analysis was conducted across various specimen geometries, considering factors such as thermal history, cross-sectional area, shape, and surface roughness. Key findings reveal that sample size, particularly cross-sectional area, significantly affects reported tensile properties, with ASTM E8 flat and round specimens exhibiting differences in elastic modulus (13%), yield strength (17%), ultimate tensile strength (UTS) (14%), and elongation to failure (11%). Additionally, surface roughness was found to have a limited impact on ASTM round geometries, but it becomes critical in thin-walled and small high-throughput samples. The ASTM flat samples closely matched the properties of samples excised from the exemplar part, underscoring the necessity of testing witness samples that accurately represent end-use conditions. Furthermore, mechanical properties of samples built within the stitch zone of the exemplar part demonstrated reduced ductility, highlighting the importance of laser alignment and qualification in multi-laser additive manufacturing processes. Overall, this study emphasizes the need for careful consideration of specimen geometry and testing conditions to ensure accurate reporting of mechanical properties in LPBF Ti-6Al-4V.
36 MATERIALS SCIENCE↗
Combining Long‐Term Observations and Lagrangian Case Studies to Evaluate Stratiform Cloud Precipitation Processes in Climate Models
Final Technical Report for DE‐SC0021983 Combining Long‐Term Observations and Lagrangian Case Studies to Evaluate Stratiform Cloud Precipitation Processes in Climate Models
Russell, Lynn [Univ. of California, San Diego, CA ↗
Driving Economics and Reducing Risks: The Business Case for Security-by-Design in Nuclear Power
This report provides an analysis of the financial, operational, and strategic advantages of incorporating Security-by-Design (SeBD) early in the lifecycle of nuclear power plant projects. By framing security as a foundational design element rather than a late-stage add-on, owners, vendors, and operators can reduce budget overruns, strengthen regulatory compliance, and increase revenue opportunities. The report details key lifecycle phases, highlighting the strategic imperative for organizations (including project developers, investors, vendors, and regulators) to adopt SeBD. Drawing on industry estimates, real-world case studies, and comparative cost analyses, the findings underscore that even a modest upfront investment in SeBD can yield substantial long-term returns by preventing costly retrofit activities, minimizing regulatory delays, and positioning nuclear vendors for the ability to adapt in the evolving security market. By avoiding excessive retrofit expenses and positioning security as a built-in feature rather than an afterthought, nuclear projects can protect their financial performance, enhance public trust, and secure a competitive edge in an increasingly complex global energy market. The authors advocate for SeBD’s strategic implementation, supported by established quality management methodologies, thereby promoting continuous improvement and defect avoidance. Ultimately, early SeBD integration represents a strategic investment, yielding significant returns by preventing costly retrofits and positioning nuclear projects for enhanced competitiveness and public trust.
22 GENERAL STUDIES OF NUCLEAR REACTORS↗
Analyzing Case Histories of Process Plant Disasters to Understand Chemical Process Cybersecurity
This presentation reviews worst case plant disasters and map a cyberattack scenario that would have a similar outcome.
42 ENGINEERING↗
Applying Social Science Methods to Assess and Improve Program Outcomes: A Case Study on the Gap Region Outreach Project
This paper outlines a replicable framework for assessing gaps, reach, and the impact of technical assistance (TA) programs, using the Energy to Communities (E2C) Gap Region Outreach Project as a case study. By applying qualitative social science methods, this framework provides tools for effectively engaging with underrepresented regions, identifying barriers to participation, and tailoring solutions to local needs. The study highlights the importance of leveraging stakeholder insights to address disparities in program engagement and participation, offering actionable recommendations to enhance program responsiveness and optimize resource allocation. This approach serves as a guide for practitioners seeking to expand the reach and effectiveness of federally funded TA programs while ensuring alignment with community priorities and capacity needs.
99 GENERAL AND MISCELLANEOUS↗
Typical Use Cases for Energy Storage in Rural Areas
Public power utilities and cooperatives play a crucial role in delivering reliable and affordable electricity to remote and sparsely populated regions. Unlike their urban counterparts, these utilities often face a unique set of challenges that can complicate their operations and service delivery. One of the primary challenges is the vast geographical area they must cover, which often results in higher transmission and distribution costs per customer. Additionally, public power utilities in rural areas often cannot afford the investments required to maintain and upgrade aging grid infrastructure to provide reliable and resilient power or withstand the impacts of recurring, severe weather events, which can cause extended outages and disrupt service delivery. Energy storage has emerged as a promising tool to help public power utilities meet these challenges. By enabling the storage of excess energy during low demand periods and providing a source of backup electricity during outages, energy storage systems can help utilities balance supply and demand more effectively. Additionally, they can help integrate a portfolio of various energy sources, reduce the need for expensive peak power purchases and provide ancillary services that stabilize the grid. This white paper describes potential use cases for energy storage in rural areas as well as documents a set of relevant example projects by project types.
24 POWER TRANSMISSION AND DISTRIBUTION↗
Financing Storage as a Transmission Asset: Initial Considerations for an Emerging Use Case
Deploying energy storage as an electric transmission system asset is a unique use case that, despite a body of policy and regulatory support, has received little attention or investment in the United States. The benefits of using storage on the transmission system—and the remaining barriers to that use—have been explored elsewhere. This paper complements that body of research by exploring the finance implications of using energy storage as a transmission asset (SATA). Because transmission infrastructure in the U.S. is generally subject to rate-of-return regulation, in which asset owners receive both a return of their invested capital and a return on that capital, storage assets deployed for that use are not subject to market volatility and have a much lower risk profile overall. That lower risk profile would, in theory, correspond to lower interest rates and other more favorable financing terms relative to a storage project deployed in a market setting. This paper draws from corollaries in other markets to estimate the expected finance impacts of SATA projects.
24 POWER TRANSMISSION AND DISTRIBUTION↗
White Paper on Case Study of Safe Installation of Second-Life Energy Storage System
This technical report provides for a case study for the safe installation of a second-life, or repurposed, battery, that has been reconfigured for use as a stationary energy storage systems (ESS). Driven by legislative requirements such as California Senate Bill 615 and projections that retired EV batteries could meet a substantial portion of U.S. grid ESS needs beginning in 2035, the repurposing of EV batteries is anticipated to grow significantly. However, safety concerns arise from the effects of aging, unknown prior usage history, and changes in thermal runaway behavior, which may increase failure risks compared to new batteries. NFPA 855, the predominant U.S. standard for ESS installation, mandates that second-life batteries meet all requirements for new batteries, with repurposers complying with UL 1974 in addition to obtaining UL 9540 and UL 1973 listings. These are certifications that few repurposers have achieved and represent a regulatory barrier to entry for the market as a whole.
47 OTHER INSTRUMENTATION↗