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All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Comprehensive Study of the Potential of Extracting and Processing Critical Minerals from Coal-Based Resources - Phase I

The Phase I report prepared for the Department of Energy addresses U.S. Executive Order 13817 titled A Federal Strategy to Ensure Secure and Reliable Supplies of Critical Minerals, issued on December 20, 2017, that lists 35 critical minerals that are vulnerable to supply disruption. A comprehensive review of each of the minerals was conducted to determine the criticality based primarily on extractability from coal-based resources. Several other factors were also considered such as gaps in supply and demand, use in current technology, and the existence of viable substitutes. It was determined that the critical minerals that show highest potential for extraction from coal-based resources are lithium, rare earth elements (REEs), cobalt, and manganese. All four of the critical minerals listed serve an important role in the technology industry, have few substitutes, and have a heavy import reliance. Most notably are lithium, which is widely used in the electric vehicle industry, and the REEs which can be found in virtually all electronic devices. The research of critical mineral extraction from coal-based resources was completed using a combination of literature review from public sources as well as cooperation from coal mines and power plants across the United States. Samples collected from six different geographical locations across the U.S. were subjected to sample preparation (i.e., pH measurement, moisture content, particle size analysis) and characterization studies using Inductively Coupled Plasma-Mass Spectroscopy (ICP-MS) and Scanning Electron Microscopy, Energy Dispersive X-Ray Spectroscopy (SEM-EDX) instruments. 27 samples of coal waste materials such as refuse, sludge, and fly ash were tested to characterize the rare earth element concentration by total rare earth elements (TREEs), heavy rare earth elements (HREEs), and light rare earth elements (LREEs). Of the 27 samples tested, 22 contained a TREE concentration higher than the threshold of 300 ppm, which is considered a viable feedstock material. 3 samples contained less than 300 ppm of TREEs; however, they were within 20 ppm of the threshold, and could potentially be considered viable sources in the future pending the advancement of more efficient extraction technologies. 2 of the 27 samples had significantly low TREE concentrations, which does not imply any potential for being a source for REEs. For the minerals identified as most critical in the literature review, a conceptual process flow diagram (PFD) was developed for their extraction from different coal-based feedstocks. The process targets selective recovery of one commodity (i.e., rare earths, lithium, cobalt, and manganese) via several hydrometallurgical separation methods. By identifying potentially extractable coal-based critical mineral resources, a study of the current and future market environments for each critical mineral, and a review of current processing methodologies for critical mineral extraction from coal-based resources, the foundation has been laid to further characterize and explore new resources and extraction techniques. As reliance on technologies in industries such as the production of electronic devices, batteries, and alloys containing critical minerals utilizing critical minerals continues to increase, a sound understanding of our nation’s dependence on and even the global criticality of certain critical minerals, will serve as a catalyst for innovation in virtually all fields of science.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2023

Development of an All-Aqueous Thermally Regenerative Redox Flow Battery to Support Fossil Fuel Assets

Low-temperature thermal energy, a largely untapped resource, holds significant promise for large-scale electrical power generation globally. Various stationary sources, including industrial entities and thermal power plants, emit considerable low-temperature heat that currently remains unutilized. This energy is often overlooked because its low temperature renders it unsuitable for efficient power generation using conventional methods. However, current research is exploring diverse technologies capable of converting low-temperature heat into grid-scale power, aiming to enhance grid efficiency, further decarbonization initiatives, and facilitate a shift toward more decentralized power systems. One such innovative technology is the thermally regenerative battery (TRB), noted for its high power and energy densities compared to similar technologies, positioning it as a potential game-changer in power generation. TRBs integrate two scalable and well-established unit operations: a redox flow battery and a distillation column. This integration suggests that once an effective TRB chemistry is established, the pathway to commercialization could be expedited. The copper-based thermally regenerative ammonia battery (Cu aq -TRAB) stands out as the first TRB that circumvents electrodeposition/dissolution reactions, stabilizing Cu(I) and Cu(II) within the electrolyte and maintaining stability of all electroactive species in an aqueous phase. This stabilization has led to improvements in coulombic efficiency, open circuit potential, and copper solubility, thereby enhancing power density, energy density, and overall energy efficiency. Preliminary tests were conducted to determine the effects of various electrolyte species on the performance metrics of the battery, both theoretically and experimentally. These tests revealed that the solubility of copper in the Cu aq -TRAB electrolyte was constrained by the Cu(I)-NH 3 complex. Adjusting the background electrolyte to 5 M NH4Br and the ligand concentration to 4 M NH 3 enabled the copper concentration to reach a maximum of 0.6 M. This modification led to an estimated theoretical maximum energy density of 9.5 Wh L -1 for the Cu aq -TRAB. Additionally, full cell testing indicated a tradeoff between peak power and energy density with varying copper and ammonia concentrations. Increasing the applied current density during discharge linearly raised the average power output, with a minimal reduction in energy density due to a balance between higher ohmic overpotential and reduced time for undesirable ammonia crossover. Furthermore, a comprehensive numerical sensitivity analysis of the complete Cu aq -TRAB system was performed. This analysis aimed to assess how the battery and the distillation column responded to changes in system input parameters, providing insights into optimal research directions for enhancing system performance. The analysis revealed that at room temperature, battery power was significantly more sensitive to ohmic losses than to mass transfer, with reaction rates having minimal impact. This trend continued even at higher temperatures. Also, the thermal energy required for ammonia separation was studied, showing that increased temperatures generally reduced energy requirements, except in low-pressure scenarios above 65 °C. An investigation into membrane performance in the Cu aq -TRAB was undertaken, given the significant impact of ammonia transport control and ohmic losses on system performance. Various membranes were evaluated to identify key performance metrics. Among the tested membranes, Selemion CMVN exhibited the highest performance, with a peak power density of 84 mW cm -2 and average values of 26 ± 6.8 mW cm -2 for power density and 2.9 Wh L -1 for energy density at an applied current density of 50 mA cm -2 . An economic assessment indicated a levelized cost of storage at $410 per MWh under optimal conditions, highlighting the commercial potential of the Cu aq -TRAB when utilizing cost-effective, readily available materials.

25 ENERGY STORAGE↗
NASA NTRSDate not supplied

Large Vehicle Lunar Landing Surface Interaction and In-Situ Resource Based Risk Mitigation: Landing & Launch Pads

A key capability required for the exploration of planetary bodies is the ability to land on the surface. Previous work performed by NASA and other institutions has primarily focused on landing small spacecraft on planetary surfaces and the associated small-to-medium thrusters required for the soft landing. In the case of human exploration—particularly the establishment of long duration exploration and habitation outposts—the ability to land large landers, such as the SpaceX Starship, is necessary. These larger landing systems require the use of more powerful engines, with higher engine exhaust temperatures and higher landing loads. Understanding the excavation of material by the engines, as well as the potential for the landing legs to sink into the subsurface, is key in ensuring reliable and safe landings. A further improvement in landing reliability can be achieved by constructing landing / launch pads, especially with in-situ resources. Some material excavation by the plume is inevitable, leaving at least a portion of the surface scoured and uneven under the lander and ejecting regolith particles and rocks at very high velocities. One possible solution would be to robotically build landing / launch pads (ideally autonomously) at the destination using in-situ materials. In this case, the first one or few landers will need to land on unimproved surfaces at higher risk; however, they would bring the required equipment to build the landing pads with mostly local resources, thus increasing the reliability of safe landing for subsequent larger landers. A number of methods to build in-situ landing and launch pads have already been developed. These methods include no, or some, addition of required binder additives to the local regolith material, different processing approaches and result in varying landing pad strengths. A sub-scale rocket engine plume, was used to simulate some of the conditions of a landing on the Moon to assess the effectiveness of various materials for an in-situ built landing pad, The GO2/GCH4rocket engine fired on a 1m2area coupons of representative pad materials. The results will allow continued development towards materials that satisfy the landing pad properties required for the effective risk reduction and increased reliability for landing people and equipment on the lunar surface. This work contained two parts: (1) computer modeling of a large rocket engine plume interacting with regolith on the Moon, using the Granular Gas Flow Solver (GGFS) provided by CFD Research Corporation as well as other computational fluid dynamics codes (CFD) such as Loci/CHEM. (2) Developing landing/launch pad materials that could be used for in-situ construction on the lunar surface in the future, to mitigate the calculated effects of a large vehicle rocket engine landing and launching on the Moon.

Lunar↗
NASA NTRSDate not supplied

Large Vehicle Lunar Landing Surface Interaction and In-Situ Resource Based Risk Mitigation: Landing & Launch Pads

A key capability required for the exploration of planetary bodies is the ability to land on the surface. Previous work performed by NASA and other institutions has primarily focused on landing small spacecraft on planetary surfaces and the associated small-to-medium thrusters required for the soft landing. In the case of human exploration—particularly the establishment of long duration exploration and habitation outposts—the ability to land large landers, such as the SpaceX Starship, is necessary. These larger landing systems require the use of more powerful engines, with higher engine exhaust temperatures and higher landing loads. Understanding the excavation of material by the engines, as well as the potential for the landing legs to sink into the subsurface, is key in ensuring reliable and safe landings. A further improvement in landing reliability can be achieved by constructing landing / launch pads, especially with in-situ resources. Some material excavation by the plume is inevitable, leaving at least a portion of the surface scoured and uneven under the lander and ejecting regolith particles and rocks at very high velocities. One possible solution would be to robotically build landing / launch pads (ideally autonomously) at the destination using in-situ materials. In this case, the first one or few landers will need to land on unimproved surfaces at higher risk; however, they would bring the required equipment to build the landing pads with mostly local resources, thus increasing the reliability of safe landing for subsequent larger landers. A number of methods to build in-situ landing and launch pads have already been developed. These methods include no or some addition of required binder additives to the local regolith material, different processing approaches and result in varying landing pad strengths. A sub-scale rocket engine plume, was used to simulate some of the conditions of a landing on the Moon to assess the effectiveness of various materials for an in-situ built landing pad, The GO2/GCH4 rocket engine fired on 1m2 area coupons of representative pad materials. The results will allow continued development towards materials that satisfy the landing pad properties required for the effective risk reduction and increased reliability for landing people and equipment on the lunar surface. This work contained two parts: (1) computer modeling of a large rocket engine plume interacting with regolith on the Moon, using the Granular Gas Flow Solver (GGFS) provided by CFD Research Corporation as well as other computational fluid dynamics codes (CFD) such as Loci/CHEM. (2) Developing landing/launch pad materials that could be used for in-situ construction on the lunar surface in the future, to mitigate the calculated effects of a large vehicle rocket engine landing and launching on the Moon. The resulting computed values of plume impingement surface temperature, stagnation pressure, gas velocity, shear stress and heat flux were then matched as closely as possible in the Earth’s atmosphere in a sub-scale rocket engine GO2/CH4 test which was provided by Masten Space Systems in Mojave, California. The rocket engine was mounted on a test stand with vertical translation capabilities so that the landing operations of a lander could be simulated (Figure 1).The pad materials test coupons were placed at the surface of a large bin containing simulated lunar basalt regolith and subjected to a test firing as shown in Figure 2. The results of this testing will be presented with related findings, analysis and discussion.

Plume Surface Interaction↗
DOE OSTI2020

Resilient U.S. Land Ports of Entry

The continued operation of Land Ports of Entry (LPOE), managed by the Customs and Border Protection (CBP) and General Services Administration% is vital to the U.S. economy and security. Border faculties are included in the Department of Homeland Security (DHS) Government Facilities Sector2, one of the 16 critical infrastructures "whose assets, systems, and networks, whether physical or virtual, are considered so vital to the United States that their incapacitation or destruction would have a debilitating effect on security, national economic security, national public health or safety, or any combination thereof.'" Specifically, disruptions to the flow of border crossing traffic, in the form of closures or increased border crossing wait times, impact the economy and security of all countries involved. This paper describes a process for analyzing and improving the resilience of U.S. Land Ports of Entry. For LPOE, the team believes that energy resilience is the primary objective due to the complete reliance on the e-manifest system and the increasing use of Multi-Energy Portals (MEPs). Emanifests are part of CPB's Automated Commercial Environment (ACE). They document several key pieces of information about cargo vehicles wishing to cross the border into the United States and are submitted before arriving at the port. Vehicles can be flagged for more invasive inspection based on the content of the e-manifest. MEPs are a non-intrusive inspection (NII) technology used to scan the contents of the cargo. Together MEPs and ACE serve an important role in aiding CBP with their mission to protect "the public from dangerous people and materials", and "enabling legitimate trade and travel.'" To analyze resilience of a port, the team would need to understand the port's current energy usage, which systems depend on energy and what backup systems exist, and any emergency operation plans that dictate how systems are operated in the event of a power outage. The team would also need to determine the design basis threats (DBTs) for the LPOE which could include natural disasters, manmade events, and accidents. The magnitudes of the DBTs are calculated and are then translated to expected impacts on the infrastructure and systems at the port. With this information gathered, existing LPOE models developed here at Sandia National Laboratories could be extended to support decisions about resilience. Current models are implemented in FlexSim, a 3rd party discrete event simulator. FlexSim provides 3-D visuals of physical layout that can reveal valuable insights, allows input to be variable (e.g. time it takes to interact with the CBP officer at primary inspection can vary) so that a whole range of possibilities can be captured in the results, and can be used to collect user-defined output metrics. Current LPOE models focus on cargo vehicle traffic, and process changes caused by the installation of new drive-through MEPs. Extending them to address resilience questions would require the addition of key pieces of information learned during the resilience analysis including critical systems, failure rates, and process changes for when failures occur. The primary output metric for current models is border crossing wait time. Additional metrics would also be added to the model to gain a more complete understanding of impacts related to resilience, for example, MEP scan rate. Once complete, the model could be used to analyze the effectiveness of mitigation strategies representing some future state.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2025

Distribution System Blackstart and Restoration Using DERs and Dynamically Formed Microgrids

Extreme weather events have led to long-duration outages in the distribution system (DS), necessitating novel approaches to blackstart and restore the system. Existing blackstart solutions utilize blackstart units to establish multiple microgrids (MGs), sequentially energize non-blackstart units, and restore loads. However, these approaches often result in isolated MGs. In DERs-aided blackstart, the continuous operation of these MGs is limited by the finite energy capacity of commonly used blackstart units like battery energy storage (BES)-based gridforming inverters (GFMIs). To address this issue, this article proposes a holistic blackstart and restoration framework that incorporates synchronization between dynamic MGs and the entire DS with the transmission grid (TG). To support synchronization, we leveraged virtual synchronous generator-based control for GFMIs to estimate their frequency response to load pick-up events using only initial/final quasi-steady-state points. Subsequently, a synchronization switching condition is developed to model synchronizing switches, aligning them seamlessly with a linearized branch flow problem. Finally, we designed a bottomup blackstart and restoration framework that considers the switching structure of the DS, energizing/synchronizing switches, DERs with grid-following inverters, and BES-based GFMIs with frequency security constraints. In conclusion, the proposed framework is validated in IEEE-123-bus system, considering cases with two and four GFMIs under various TG recovery instants.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2020

Benchmark for Fuel Shuffling and Depletion for Pebble-Bed Reactors

Pebble bed reactors have specific operational characteristics when their fuel-cycle and fueling operations are considered. They are specifically distinguished by other type of nuclear reactor designs by their online fuel recycling scheme, where the fuel elements that have not yet reached discharge burnup can be reloaded and recycled continuously during normal operation. The fuel in a pebble bed reactor is not stationary and stochastically moves through the core once or several times during its lifetime, which allows them to operate without requiring a large excess reactivity hold for the burnup. However, this characteristic of pebble bed reactors introduces challenges in simulation, as each pebble can take many different trajectories through the core, its composition depends on the details of the irradiation history that is unique to its aggregated path through the core. For predicting the safety performance characteristics, such as source term, maximum fuel temperatures and fuel failure rates, etc., it is important to accurately incorporate the movement of pebbles through the core during their lifetime in a multi-physics simulation together with other phenomena. The equilibrium core analysis for pebble bed reactors are performed with multi-physics tools including fuel depletion in a multi pass reload coupled to the fuel movement. Currently, there are only a few legacy multi-physics simulation tools that can implement the pebble flow characteristics and perform equilibrium core analysis for pebble bed reactors. However, there are development efforts on-going under Department of Energy's Nuclear Energy Advanced Modelling and Simulation program and also in private industry for including these capabilities into their modelling and simulation tools. Any new development in the modelling and simulation tools needs to be validated by using tools such as experiments, analytical solutions or code-to-code benchmarks. In this work, a code-to-code benchmark for the equilibrium core analysis capability of pebble bed reactors was developed. Multiple cases were identified to capture different fuel cycle strategies that can be used in PBRs. The results of each case are presented in terms of overall equilibrium core characteristics: the discharge burnup; spatial burnup distribution; spatial isotopic distributions; axial and radial neutron flux distributions and power history of fuel elements per pass through the core for both a prototypical pebble bed High Temperature Gas-cooled Reactor and a prototypical pebble bed Fluoride-salt cooled High temperature Reactor.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Flow Induced Vibration Studies in Pressurized Helium Gas Cooling Channels

Production of metastable Technetium-99 (Tc-99m), a radioactive tracer that emits gamma rays, is vital to the medical imaging community. Tc-99m is extracted from the decay of Molybdenum-99 (Mo-99) which has a half-life of about 2-3 days. The work presented in this report is part of the NNSA’s mission to produce Mo-99 commercially, within the US, without the use of highly enriched uranium (HEU) in support of nonproliferation and global security. Los Alamos National Laboratory (LANL) is working with NorthStar Medical Radioisotopes (NMR) on their efforts to produce Mo-99 through the irradiation of Mo-100 targets using an electron beam. The NMR target comprises a stack of approximately 60-70 Mo-100 disks with diameter 24 mm and thickness 0.74 mm held in stainless steel laminations, each separated using 0.25 mm thick stainless steel spacers. The symmetric target stack is housed in an Inconel vessel with two Inconel windows on either side. Two electron accelerators are used to produce 40 MeV, 3.16 µA electron beams each that penetrate the Inconel windows and irradiate the Mo-100 disks. Approximately 90% of the total 250 kW beam power is deposited in the NMR target during the irradiation process. During irradiation, pressurized helium gas flows through 0.25 mm thin gaps between the disks cooling the beam window, target disks, disk laminations and spacers. Both NMR and LANL have found during cold testing of the target system (no heat deposition) that the Mo-100 disks undergo significant mass loss and disk breakage due to vibrations induced by the flowing helium gas. The mass loss is not only undesirable due to monetary loss from reduced final quantities of Mo-99, but also due to the hazards associated with radioactive material trapped in the cooling lines and particle filters. The effect of flow rate and target geometry on the flow induced vibrations need to be quantified, and recommendations provided to minimize this mass loss. This work describes LANL’s experimental characterization of the flow induced vibrations and disk mass loss in a reduced scale set-up containing 10 Mo-100 disks. We use high speed imaging, displacement measurements and microphone measurements combined with signal processing to estimate the vibration frequency of each disk. The effect of disk thickness, target fit and duration of testing on the mass loss is described. We find that in the current configuration of NMR targets, the vibrations and mass loss on the first disk are minimized, while those in the adjacent disks are highest. The microphone and high-speed image data show that increased flow rates and increased duration of testing increases vibration frequency and mass loss. The mass loss is due to both disk rotation and back and forth motion. There are visible wear marks on the disks with the highest mass loss. We also note that the current NMR window gap reduces flow induced vibrations compared to the previous smaller gaps. Longer duration testing will provide more data and verification for the findings presented in this report. The work will be continued in FY 24.

43 PARTICLE ACCELERATORS↗
NASA NTRS2019

Powering OSCAR

Recycling waste has been an issue on Earth for decades. The OSCAR project seeks to find ways to make sure that it does not become an issue in space. The main focus of OSCAR is the combustion of waste and reclamation of gaseous products in microgravity. The first phase of testing relies on a ground rig that operates both under normal (Earth) gravity and in drop tower tests that briefly simulate a microgravity environment. In the second phase, a test will be performed during a suborbital flight were the experiment will be carried out in microgravity. Throughout the spring term, interns have played an integral part in continuing the progress made by the project. They performed work in upgrading the electrical and mechanical systems that make up OSCAR. They made multiple improvements to the test rig's operating software to improve readability and usability. They prepared and edited documents that were vital to the engineering process. And, they were responsible for performing lab tests and refining the lab operations document and procedure. The interns were a big help in maintaining the rigorous test schedule. OSCAR, which stands for Orbital Syngas Commodity Augmentation Reactor, is to find a way to turn astronaut waste into chemical energy. The two parts of this are important: finding a way to dispose of waste generated in space, and seeing if there is a way to recycle that waste into chemical energy. The importance of the disposal aspect is that there is currently no way to dispose of, or recycle, waste that is created in space other than jettisoning it (which is what the ISS does via empty supply capsules). As manned missions go deeper into space, that method will no longer be viable, as a craft would essentially be littering the space and planets that they visit. Energy reclamation is also important because of the high monetary and spatial costs of sending supplies on space missions. Every little bit extra that can be reused out of what is sent can save room and funds for other supplies. The facet of this problem that the OSCAR project is focusing on is how to combust waste in zero gravity. Combustion in the presence of gravity is one of those things that is taken for granted. When something burns on Earth, the flames rise above the fuel as oxygen flows from underneath. In microgravity, the flames surround the object completely, which restricts the amount of oxygen that can reach the fuel, and retards the combustion. OSCAR uses a vortex reaction chamber to counter this phenomenon. The OSCAR test rig will eventually be tested on a suborbital flight to see if it is an effective solution to the issue in real-world conditions. Currently, there is a prototype test rig that is fully functional. This rig has been previously tested in a 2 second drop test at Glenn Research Center’s (GRC) Zero Gravity Facility (ZGF). (The free-fall conditions of the drop mimic microgravity, if only for a brief period of time). This session’s focus was on upgrading the test rig and software, updating the paperwork, performing additional lab tests, and readying the rig for the five second drop test, again at GRC. II. Upgrades The state of the testing rig at the start of the session was in between its configurations for the two second drop tower and the five second drop tower. The rig needed upgrades to address various insufficiencies that either were discovered during the two second campaign or were a direct result of the differences between the two drop tower setups. The main differences that had to be handled were the increase in shock loads from 30g to 65g, a difference in drop indicating signal (on the falling edge of a pulse instead of a change from high to low), and the ambient pressure of the test apparatus (the two second tower dropped the rig in atmosphere, while the five second tower drops in vacuum).

Cauvel, Thomas↗
NASA NTRS2023

Move That Goo!

On May 5, 1961, Alan B. Shepard became the first American in space (K. Mars); since then, NASA has made leaps and bounds in space exploration and continues to develop new technologies. Through their X-Hab program, NASA has teamed up with the National Space Grant Foundation to fund our student-centered project with one main goal: Move That Goo! Liquid amine absorption is a method by which CO2 is removed from an environment and is intended to be the primary method for CO2 removal for NASA’s sustained human presence on extraterrestrial bodies such as the Moon and Mars. Liquid amines can be highly viscous when absorbing CO2, thus the team needed to produce a design that could move a high viscosity fluid while staying under the power requirement of 1 kW and allowing a few square meters in a closed system. Prompted by NASA and with the support of our faculty mentors, we have been tasked with the research, development, production, and testing of a system able to move a high viscosity liquid amine which requires adequate air exposure to absorb carbon dioxide from a habitat atmosphere in low gravity. The system is split into two main groups, fluids, and materials, with two separate teams of students assigned to their half of the design. The fluids team is responsible for everything in the design that directly touches the fluid. The materials team is responsible for the test stand to which the fluids team’s design is attached to as well as additive manufacturing material selection. In the first semester, the team focused on brainstorming ideas, design selection, budget creation, and CAD modeling. Multiple concepts were generated but the team decided on a design to get the high viscosity fluid to move around a rectangular channel using a screw conveyor mechanism. The liquid must be moved by the turning screw from the thermal chamber going around a rectangular trough back to the thermal chamber. The screw and the trough geometry will be important to allow for the high viscosity fluid to flow, utilizing surface tension to maintain contact to the trough as seen in Figure 1 below.

Olivia Angst↗
DOE OSTI2023

Grand challenges in the design, manufacture, and operation of future wind turbine systems

Abstract. Wind energy is foundational for achieving 100 % renewable electricity production, and significant innovation is required as the grid expands and accommodates hybrid plant systems, energy-intensive products such as fuels, and a transitioning transportation sector. The sizable investments required for wind power plant development and integration make the financial and operational risks of change very high in all applications but especially offshore. Dependence on a high level of modeling and simulation accuracy to mitigate risk and ensure operational performance is essential. Therefore, the modeling chain from the large-scale inflow down to the material microstructure, and all the steps in between, needs to predict how the wind turbine system will respond and perform to allow innovative solutions to enter commercial application. Critical unknowns in the design, manufacturing, and operability of future turbine and plant systems are articulated, and recommendations for research action are laid out. This article focuses on the many unknowns that affect the ability to push the frontiers in the design of turbine and plant systems. Modern turbine rotors operate through the entire atmospheric boundary layer, outside the bounds of historic design assumptions, which requires reassessing design processes and approaches. Traditional aerodynamics and aeroelastic modeling approaches are pressing against the limits of applicability for the size and flexibility of future architectures and flow physics fundamentals. Offshore wind turbines have additional motion and hydrodynamic load drivers that are formidable modeling challenges. Uncertainty in turbine wakes complicates structural loading and energy production estimates, both around a single plant and for downstream plants, which requires innovation in plant operations and flow control to achieve full energy capture and load alleviation potential. Opportunities in co-design can bring controls upstream into design optimization if captured in design-level models of the physical phenomena. It is a research challenge to integrate improved materials into the manufacture of ever-larger components while maintaining quality and reducing cost. High-performance computing used in high-fidelity, physics-resolving simulations offer opportunities to improve design tools through artificial intelligence and machine learning, but even the high-fidelity tools are yet to be fully validated. Finally, key actions needed to continue the progress of wind energy technology toward even lower cost and greater functionality are recommended.

17 WIND ENERGY↗
NASA NTRS1944

An Experimental Investigation of the Flow of Air in a Flat Broadening Channel

The wide use of diffusers, in various fields of technology, has resulted in several experimental projects to study the action and design of diffusers. Most of the projects dealt with steam (steam turbine nozzles). But diffusers have other applications - that is, ventilators, smoke ducts, air coolers, refrigeration, drying, and so forth. At present there is another application for diffusers in wind-tunnel design. Because of higher requirements and increased power of such installations more attention must be paid to the correctness of work and the decrease in losses due to every section of the tunnel. A diffuser, being one of the component parts of a tunnel , can in the event of faulty construction introduce considerable losses. Therefore, in the design of the new CAHI wind tunnel, it was suggested that an experimental study of diffusers be made, with a view to applying the results to wind tunnels. The experiments conducted by K. K. Baulin in the laboratories of CAHI upon models of diffusers of different cross sections, lengths, and angles of divergence, were a valuable source of experimental data. They were of no help, however, in reaching any conclusion regarding the optimum shape because of the complexity and diversity of the factors which all appeared simultaneously, thereby precluding the.study of the effects of any one factor separately. On the suggestion of the director of the CAHI,Prof. B. N. Ureff, it was decided to experiment on a two-dimensional diffuser model and determine the effect, of the angle of divergence. The author is acquainted with two experimental projects of like nature: the first was conducted with water, the other with air. The first of these works, although containing a wealth of experimental data, does not indicate the nature of flow or its relation to the angle of divergence. The second work is limited to four angles - that is, 12 deg, 24 deg, 45 deg, 90 deg. The study of this diffuser did not supply any information about the effect of smaller angles which, because of their advantages, are more commonly used, The author was able to acquaint himself with the second work only after the experiments were started. For these reasons, as well as because on the basis of those works no conclusion can be reached regarding the nature of flow distribution, of eddies, and so forth, experimental work was continued. The need for determining flow patterns follows from the fact that from them are determined methods of measurement - that is, the determination of velocities by means of the pitot tube, which, as is well known, gives correct indications only when placed with its axis parallel to the axis of flow. The data contained in this report were obtained from experiments conducted by the Aerodynamical Laboratories of the CAHI. The solutions to some. of the mathematical problems connected with the experiments are due to Prof. S. A, Chapligin.

Vedernikoff, A. N.↗
DOE OSTI2022

Effect of Moisture and Feedstock Variability on the Rheological Behavior of Corn Stover Particles

Continuous feeding, processing, and handling of biomass powders is pivotal to the economic viability of integrated biorefineries. However, current challenges associated with the operational reliability of bulk solids handling and transport greatly impact the process economics and ultimately the widespread commercialization of integrated biorefineries. In this work, we examine the effect of moisture and feedstock variability on the flow behavior of corn stover biomass particles. The total flow energy, compressibility, shear properties, and wall friction angles were measured for corn stover samples A and B containing 0%, 15%, 25%, 50%, and 75% (mass fraction) moisture contents using a FT4 powder rheometer. In general, the flowability of both A and B was reduced when moisture was present as indicated by the stability and variable flow rate, compressibility, and shear tests. The 15% moisture sample had the highest flow energy, revealing the interplay between the increased surface tension and looser packing both of which were caused by liquid bridging. The 75% moisture sample had the highest compressibility and the lowest flowability factor (ff c ). The trend in wall friction angle was found to be dependent upon the surface hydrophobicity of the wall material. The wall friction angle on the hydrophilic, stainless-steel surface increased with moisture and therefore poses additional handling challenges. On the other hand, the wall friction angle on the hydrophobic polymer surfaces were the lowest for samples with intermediate moisture contents. Sample B had greater bulk density, smaller compressibility, and greater flowability than the sample A , as suggested by the compressibility and shear tests. The wall friction angle of sample B was higher than or equal to that of sample A depending on both the type and the surface roughness of the wall material.

09 BIOMASS FUELS↗
DOE OSTI2025

Modernizing the Nuclear Industry and New Ways of Working

Nuclear energy is recognized as the most feasible energy source towards achieving nation-wide net-zero goals (COP 208, MIT). Additionally, the demand for reliable, consistent energy supply is soaring with the construction of energy hungry data centers and AI tools. This means the construction of new nuclear and the continuation of current nuclear are a high national priority. However, this leaves the nuclear industry with a workforce challenge. The rising demand for nuclear power is threatened by an underpopulated workforce. There exist a few contributors to the decreased workforce such as skewed workforce demographics resulting in large-scale workforce retirement. Also, some plants have observed difficulty hiring and retaining skill sets that typically comprise the nuclear power workforce – specifically skilled craftsman. Those who are graduating with desirable skills are seeking employment in sectors that are more modern and culturally more aligned with younger generational values. Lastly, within the nuclear sector, skilled employees will be a competitive commodity as advanced plants come online offering work environments that incorporate modern technologies, skill sets, and opportunities for career advancement. These factors emphasize the need for legacy plants to modernize with a focus on the workplace environment and culture that meets younger generations’ skills, cultural expectations, and desire for advancement opportunities. Nuclear plants are actively engaged in deploying advancements that improve the management of systems, structures, and components as well as process improvements and technologies that can reduce the costs of operation and maintenance. However, the advancements must also be analyzed, reviewed and deployed in a manner that considers the impact on how people within the organization collaborate, communicate, make decisions, and solve problems. Neglecting to consider the cultural impact of modernization risks poor adoption, unrealized opportunities, or insignificant change toward helping attract new employees. The traditional way of working is not necessarily the way new generations want to engage with their employer. For instance, in a survey performed by North American Young Generation in Nuclear the top three reasons for younger nuclear employees to seek other job opportunities was seeking better work-life balance, a lack of advancement opportunities, and work culture and leadership style differences (Smyth et al. 2022). Integrated Operations for Nuclear (ION) is an approach for the nuclear industry to create long-term strategic modernization plans and analyze each advancement for the impact on people and processes and measure how those impacts flow up to support high-level, long-term plant goals and requirements. One principle of ION is to replace the current labor-centric operation style in legacy nuclear plants with data-centric collaborative operation styles. This paper will explain how transitioning operations to leverage centralized skills and responsibility, multi-skilled teams, and collaborative decision making can flatten the hierarchical structure in plants, enable greater individual efficacy while also offering more experiences and advancement opportunities to staff. Adopting the ION way of working shifts the industry mind-set towards more networked, collaborative, and modern way of working that will attract skilled, next-generation workers to operate the legacy nuclear fleet.

99 - GENERAL AND MISCELLANEOUS↗
DOE OSTI2025

Vulcan Test Platform: Demonstrating the Data Center as a Flexible Grid Asset

Explosive data center demand is outpacing grid infrastructure development. AI workloads and hyperscale cloud growth are creating unprecedented power requirements, while traditional grid expansion faces multi-year development timelines, regulatory hurdles, and decarbonization challenges. Sidewalk Infrastructure Partners recognized this impending crisis years ago and founded Verrus to develop an innovative solution: data centers that function as grid assets rather than passive loads. The Verrus approach integrates proprietary grid-aware controls with battery energy storage systems (BESS) in a medium-voltage architecture that delivers three critical capabilities: Fast-responding demand flexibility that can service requests from the utility within 10 seconds, Uninterrupted transition to islanded operation during grid disturbances, Continuous uptime assurance while maintaining all customer service level commitments Through Verrus' strategic partnership with the National Renewable Energy Laboratory (NREL), we validated these capabilities on Vulcan, a 70 MW utility-scale test platform powered by NREL's ARIES Virtual Emulation Environment. This deployment-ready technology has successfully demonstrated that Verrus data centers can deliver meaningful grid services while maintaining mission-critical reliability. This technical report outlines the design, methodology, and results of this emulated deployment, demonstrating that data centers can play a pivotal role in enhancing grid flexibility and reliability, without sacrificing service level guarantees.

24 POWER TRANSMISSION AND DISTRIBUTION↗
NASA NTRS2003

Mixed Conducting Electrodes for Better AMTEC Cells

Electrode materials that exhibit mixed conductivity (that is, both electronic and ionic conductivity) have been investigated in a continuing effort to improve the performance of the alkali metal thermal-to-electric converter (AMTEC). These electrode materials are intended primarily for use on the cathode side of the sodium-ion-conducting solid electrolyte of a sodium-based AMTEC cell. They may also prove useful in sodium-sulfur batteries, which are under study for use in electric vehicles. An understanding of the roles played by the two types of conduction in the cathode of a sodium-based AMTEC cell is prerequisite to understanding the advantages afforded by these materials. In a sodium-based AMTEC cell, the anode face of an anode/solid-electrolyte/cathode sandwich is exposed to Na vapor at a suitable pressure. Upon making contact with the solid electrolyte on the anode side, Na atoms oxidize to form Na+ ions and electrons. Na+ ions then travel through the electrolyte to the cathode. Na+ ions leave the electrolyte at the cathode/electrolyte interface and are reduced by electrons that have been conducted through an external electrical load from the anode to the cathode. Once the Na+ ions have been reduced to Na atoms, they travel through the cathode to vaporize into a volume where the Na vapor pressure is much lower than it is on the anode side. Thus, the cathode design is subject to competing requirements to be thin enough to allow transport of sodium to the low-pressure side, yet thick enough to afford adequate electronic conductivity. The concept underlying the development of the present mixed conducting electrode materials is the following: The constraint on the thickness of the cathode can be eased by incorporating Na+ -ionconducting material to facilitate transport of sodium through the cathode in ionic form. At the same time, by virtue of the electronically conducting material mixed with the ionically conducting material, reduction of Na+ ions to Na atoms can take place throughout the thickness of the cathode. The net effect is to reduce the diffusion and flow resistance to sodium through the electrode while reducing the electronic resistance by providing shorter conduction paths for electrons. Reduced resistance to both sodium transport and electronic conductivity results in an increase in electric power output.

Ryan, Margaret↗
NASA NTRS1958

Hypersonic Flight and the Re-Entry Problem: The Twenty-First Wright Brothers Lecture

Up to this point the discussion of the problems of rocket vehicles has been confined to the effects of phenomena which have in the past been important ones for lower speed aircraft and will continue to be important for aircraft of all speeds. Now with considerable extension of both speed and altitude, other phenomena also become important. The nature of some problems will be altered, as a result, and new problems, of course, will be encountered. First, it is well to note that our interest in bluff bodies for ballistic vehicles in particular, and in rounded-nosed bodies generally, has changed our emphasis in aerodynamics. The detached bow waves which occur with such bodies at high supersonic speeds complicate the calculations of the flow-field characteristics. In the present period, much attention is being given to such studies. In addition, at the very high altitudes attained by most of the rocket-craft, the mean free path of air molecules can be of the same order, or long, compared to the dimensions of the vehicles. Thus, slip-flow and free-molecule-flow studies are of interest, particularly for satellite vehicles." The aerodynatnicist must deal with air having unfamiliar states and properties. Second, at hypersonic speeds where, for example, air is greatly decelerated, it may undergo considerable change in composition, the degree of change depending upon many factors. Dissociation of oxygen and nitrogen molecules can occur and, in addition, thermal ionization of many of the constituents. It is naturally to be expected that the convective heat transfer will, as a result, be altered from what it was for the "perfect" gas, and this has been the subject of much recent research effort. Moreover, the decelerated gas becomes capable of radiating energy and the radiative heat transfer must generally be considered for hypersonic vehicles, particularly for long-range ballistic rockets. It is not only the aerodynamic heating problems that are affected. The fact that at very high air temperature the gas becomes electrically conductive introduces new problems in radio wave transmission and reception. In addition, a conducting gas flow can, of course, be influenced by a magnetic field. The study of such flows, which has been termed "magneto gas dynamics," is still in too primitive a state to indicate how important a role it can play, but many interesting possibilities suggest themselves. Third, our experience with airplanes powered by air-breathing engines has naturally been restricted to the stratosphere, or lower. Our ignorance increases with altitude. For rockets, literally, "the sky's the limit," and it is not surprising that a great emphasis has now been placed on obtaining a more thorough understanding of the whole atmosphere. These studies are not aimed at an understanding of the chemical and physical characteristics alone, but also of the occurrence of high-energy particles, from meteors to cosmic rays, and the nature of the problems they will promote.

Wright Brother↗
DOE OSTI2025

High-temperature seals for supercritical carbon-dioxide (sCO 2 ) turbines (Final Report)

This is the final report for project DE-FE0031924 titled “High-temperature seals for supercritical carbon-dioxide (sCO 2 ) turbines.” The report provides a summary of the entire project efforts from October 2020 through December 2024 including the high-temperature commercial dry gas seal (DGS) tests and thermal modeling of Task 2, as well as the high-temperature, large-diameter seal design and high-temperature tests of large-diameter seals in Task 3. A key outcome of Task 2 was the testing completion of specially instrumented commercial DGS in the GE-SwRI Apollo sCO 2 compressor (27,000 rpm). Test data from the DGS showed elevated temperatures upwards of 350 o F, which are close to the higher operating temperature limit of the DGS. The temperature measurements provide insight into the expected thermal loads on DGS operating in high-speed sCO 2 compressor and provided test data for validation of an in-house thermal model of the compressor/seal. Under Task 2.0, this report also presents the development of a steady-state conjugate heat-transfer model of the DGS operating in the sCO 2 compressor – a first of its kind model for modeling heat transfer of sCO 2 in an actual operating compressor. The findings of the thermal model show a reasonable match between temperature predictions of the model and the measured temperature data, also pointing out the validity of the approach and assumptions made in modeling the flows, heat transfer coefficients and windage modeling in the rig. Under Task 3.0, this report presents the preliminary design of a large-diameter hybrid face seal (14 inch and 26-inch diameter) for field testing in a land-based GE turbine. The preliminary seal design effort presented in this report under project DE-FE0031924 builds on the development and successful laboratory testing for such large diameter hybrid face seal under the prior DE-FE0024007 project. Key aspects of seal fluid analyses with CFD, mechanical design considerations and assembly considerations in a land-based turbine are presented. Finally, under Task 3.0, this report also presents the continued high-temperature testing of the 14-inch diameter hybrid face seal developed previously under the DE-FE0024007 program. Specifically, test data demonstrating successful non-contact seal operation and seal effective leakage of 0.001-inch with seal inlet temperatures above 700 o F are presented in this report. Successful hybrid seal operation in a laboratory environment for a large diameter (14-inch) seal at temperatures above 700 o F is a major technological milestone for this technology.

01 COAL, LIGNITE, AND PEAT↗