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DOE OSTI2015

The Need for Cyber-Informed Engineering Expertise for Nuclear Research Reactors

Engineering disciplines may not currently understand or fully embrace cyber security aspects as they apply towards analysis, design, operation, and maintenance of nuclear research reactors. Research reactors include a wide range of diverse co-located facilities and designs necessary to meet specific operational research objectives. Because of the nature of research reactors (reduced thermal energy and fission product inventory), hazards and risks may not have received the same scrutiny as normally associated with power reactors. Similarly, security may not have been emphasized either. However, the lack of sound cybersecurity defenses may lead to both safety and security impacts. Risk management methodologies may not contain the foundational assumptions required to address the intelligent adversary’s capabilities in malevolent cyber attacks. Although most research reactors are old and may not have the same digital footprint as newer facilities, any digital instrument and control function must be considered as a potential attack platform that can lead to sabotage or theft of nuclear material, especially for some research reactors that store highly enriched uranium. This paper will provide a discussion about the need for cyber-informed engineering practices that include the entire engineering lifecycle. Cyber-informed engineering as referenced in this paper is the inclusion of cybersecurity aspects into the engineering process. A discussion will consider several attributes of this process evaluating the long-term goal of developing additional cyber safety basis analysis and trust principles. With a culture of free information sharing exchanges, and potentially a lack of security expertise, new risk analysis and design methodologies need to be developed to address this rapidly evolving (cyber) threatscape.

CCE↗

DOE OSTI2021

Data-driven optimization of mixed-integer bi-level multi-follower integrated planning and scheduling problems under demand uncertainty

The coordination of interconnected elements across the different layers of the supply chain is essential for all industrial processes and the key to optimal decision-making. Yet, the modeling and optimization of such interdependent systems are still burdensome. Here we address the simultaneous modeling and optimization of medium-term planning and short-term scheduling problems under demand uncertainty using mixed-integer bi-level multi-follower programming and data-driven optimization. Bi-level multi-follower programs model the natural hierarchy between different layers of supply chain management holistically, while scenario analysis and data-driven optimization allow us to retrieve the guaranteed feasible solutions of the integrated formulation under various demand considerations. We address the data-driven optimization of this challenging class of problems using the DOMINO framework, which was initially developed to solve single-leader single-follower bi-level optimization problems to guaranteed feasibility. This framework is extended to solve single-leader multi-follower stochastic formulations and its performance is characterized by well-known single and multi-product process scheduling case studies. Through our data-driven algorithmic approach, we present guaranteed feasible solutions to linear and nonlinear mixed-integer bi-level formulations of simultaneous planning and scheduling problems and further characterize the effects of the scheduling level complexity on the solution performance, which spans over several hundred continuous and binary variables, and thousands of constraints.

42 ENGINEERING↗

DOE OSTI2020

Voluntary Renewable Energy Procurement Programs in Regulated Utility Markets

Multinational corporations are increasingly purchasing renewable energy (RE) to fulfill international commitments, reduce supply chain emissions, limit environmental impact, and secure stable and affordable electricity. The potential scale of global corporate RE purchasing has been estimated to be nearly 100 GW and growing; however, many markets still lack supportive enabling environments for corporations to access RE through on-site project development or private sector transactions. Even where allowed by law, on-site generation may be insufficient due to space and technical constraints, introducing additional challenges. Utility green pricing and utility green tariff programs backed by renewable energy certificates (RECs), referred to as utility green procurement programs (GPPs) in this report, offer powerful market-based solutions to utilities, regulators, and policymakers to provide corporate and other consumers with RE product options while generating revenue to support RE development. As RE markets expand around the globe, GPPs have proven to be effective mechanisms in market regimes, ranging from fully integrated state-owned utilities to broadly liberalized power markets. GPPs utilize RECs, which are a type of energy attribute certificate and closely resemble guarantees of origin, to track and ultimately monetize RE attributes that corporations and other buyers must procure to demonstrate progress against their RE commitments and make public claims of RE use. Time-tested and transparent REC accounting mechanisms provide market confidence, while at the same time offering flexibility to utilities, regulators, and customers for a range of applications. RECs are used in all types of electricity market structures, as indicated in Figure 1, but REC-based program designs and supporting components differ depending on the type of market. Liberalized markets allow for customers to contract directly with generators for electricity and RECs, while traditionally regulated markets with vertically integrated utility structures may have greater restrictions on generation asset ownership and electricity sales. RE markets can be further defined as being either mandatory or voluntary. Mandatory markets require suppliers to deliver specified amounts of RE to grid customers, such as under a renewable portfolio standard (RPS), while voluntary markets involve no legal mandates, but demand is driven by self-imposed customer goals.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

NASA NTRS2013

Moving Technologies from the Test Tube to Commercial Products

Successful technologies include objects, processes, and procedures that share a common theme; they are being used to generate new products that create economic growth. The foundation is the invention, but the invention is a small part of the overall effort. The pathway to success is understanding the competition, proper planning, record keeping, integrating a supply chain, understanding actual costs, intellectual property (IP), benchmarking, and timing. Additionally, there are obstacles that include financing, what to make, buy, and sell, and the division of labor i.e. recognizing who is best at what task. Over the past two decades, NASA Langley Research Center (LaRC) has developed several commercially available technologies. The approach to commercialization of three of these inventions; Langley Research Center-Soluble Imide (LaRC-SI, Imitec Inc.), the Thin Layer Unimorph Driver (THUNDER, FACE International), and the Macrofiber Composite (MFC, Smart Material Corp.) will be described, as well as some of the lessons learned from the process. What makes these three inventions interesting is that one was created in the laboratory; another was built using the previous invention as part of its process, and the last one was created by packaging commercial-off-the-shelf (COTS) materials thereby creating a new component.

Bryant, Robert G.↗

DOE OSTI2023

Evaluation of Nickel Alloys, Manufactured through Powder Bed Fusion, for Application for Advanced Nuclear Reactors

In collaboration with other laboratories, Idaho National Laboratory has investigated additively manufactured alloys for applications in advanced nuclear reactors. The primary focus has been on nickel alloys, as well as “other” alloys, which are alloys not considered steel nor nickel-based alloys, manufactured by laser powder bed fusion. Suitability of investigated alloys were considered against a matrix of properties of interest, developed jointly with the collaborating laboratories. For the nickel alloys, Alloys 282 and 625 are considered promising due to their properties, existing data, and availability of commercial powder feedstock. Haynes 244 is also of interest for its molten salt corrosion resistance, however there is no current feedstock supply chain, and no experience with this alloy as an additively manufactured material. Iron-chrome-aluminum alloys, titanium alloys, zirconium alloys, ceramics, and ceramic inclusions were all considered within the other alloys category. The results and discussions within this report will be compiled with the investigations from the other collaborating laboratories and compiled into a final report later this year (2023).

36 MATERIALS SCIENCE↗

DOE OSTI2023

Gridtrust: Electricity Grid Root-of-Trust Decentralized Supply Chain Cyber-Security (Final Scientific/Technical Report)

GridTrust represents a departure from reliance on a single organization or a single person to multiple organizations and therefore multiple people across organizational structures. The motivating idea behind involving multiple organizations is the increase in security due to human factors. More specifically, the requirement that distinct people in different organizations sign off on a change or an update makes a cyberattack much less likely due to the inherent requirement that both organizations be penetrated and fooled. GridTrust focuses on the software update process as the primary exemplar for the research and development work. A novel hardware-based technology referred to as a Physical Unclonable Function (PUF) provides a microchip Root-of-Trust (RoT), i.e., a starting point for verifying that the hardware being communicated with is the hardware the control center believes the hardware to be. As a result, staff at power grid control centers can ensure the accurate and reliable identification of hardware devices from the outset. The GridTrust protocol introduces two key innovations, as detailed in this report. Firstly, the utilization of a PUF as a root-of-trust in the initial phase of a software or firmware update. Secondly, the application of multiple cryptographic signatures from two or more organizations to the update binary. These signatures are verified before implementing the update on a power grid device in the field. In terms of GridTrust hardware design, this report outlines two main components. The first is the GridTrust Native Device, integrating PUF technology intrinsically into the hardware device itself. The second is the GridTrust Interfacing Device, which incorporates PUF technology and multiple cryptographic signatures. These signatures are cross-checked within a separate hardware positioned between the power grid control center and the legacy power grid device, functioning as an intermediary. While the GridTrust Interfacing Device offers the advantage of being applicable to existing power grid equipment, it may have reduced security if the intermediary component is targeted. On the other hand, the GridTrust Native Device boasts increased security due to protocol integration within a unified form factor. The effectiveness of GridTrust technology has been extensively demonstrated, with multiple external red-team attackers unable to breach GridTrust's security measures. This was observed both in controlled laboratory settings during Phase 1 of the project and in real-world conditions within a City of Marietta substation during Phase 2 of the project.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2020

Improved Advanced Biomass Logistics Utilizing Woody and other Feedstocks in the Northeast and Pacific Northwest (Final Report)

Willow and poplar short rotation woody crops (SRWC) have shown promise with regards to environmental benefits and rural development but wide adoption lags due to underdeveloped markets and supply systems. High costs associated with harvesting, handling and transportation (40-60% of delivered cost) have impeded expansion. A better understanding of these systems will create opportunities to improve efficiency, reduce costs, and realize environmental benefits and impacts. The project’s goal was to lower the delivered cost of hybrid poplar in the Northwest and willow in the Northeast by optimizing harvesting and logistics supply systems while maintaining or improving biomass quality along the supply chain. Over 3,400 Mg of biomass and 300 ha of willow and poplar were monitored over a range of crop and field conditions. Feedstock quality as affected by storage and preprocessing were shown to improve or maintain feedstock quality. Modeled harvesting costs ranged from $38–61 Mg -1 dry; when including delivery and preprocessing feedstock costs ranged between $79-83 Mg -1 dry for willow and $106-116 Mg -1 dry for poplar. Costs for willow minimized when hot water extraction and high-moisture densification preprocessing were used. Models also suggest that social and regional factors could further reduce costs. Results will give guidance to feedstock growers, harvesting and logistic operations, biorefinery project developers, and policy makers developing SRWC to support a growing bioeconomy.

, biomass↗

DOE OSTI2024

Synthesizing Highly Crystalline Graphite Powder from Bulk Polyethylene Waste for Lithium-Ion Battery Anodes

Upcycling plastic waste into graphite can potentially be used, in conjunction with other methods, to manage existing waste materials and diversify graphite supply chains. However, synthesizing large quantities of crystalline graphite powder from plastic waste, particularly polyethylene (PE), remains a challenge because PE decomposes into light gases during thermal processing and simple methods do not exist at any appreciable size scale to address this challenge. In this work, a method is developed for air processing bulk forms of PE waste to create stable carbon char that does not readily decompose during high-temperature processing. This method employs solid additives in the form of salts, which are combined with the PE melt during air processing to increase the effective surface area of the melt and improve the oxygen-driven chemistry that stabilizes PE for high-temperature processing. After removal of the solid salt additives from the PE-derived char, it is converted into a highly crystalline bulk graphite powder using an Fe-based catalytic process. The PE-derived graphite anode in a lithium-ion coin cell showed a specific capacity of 345 mAh/g at 0.05C with an initial Coulombic efficiency of 87% and reversible capacity retention of ~100% at different current rates. It also showed a specific capacity of up to 313 mAh/g at 0.5 discharge/charge cycles per hour (0.5C) and Coulombic efficiency of 99.9% after 250 cycles, indicating excellent electrochemical performance as an anode material for lithium-ion batteries. This method illustrates that there are opportunities for upcycling large quantities of PE waste to produce graphite powders suitable for use in LIBs.

25 ENERGY STORAGE↗

DOE OSTI2024

Synthesizing Highly Crystalline Graphite Powder from Bulk Polyethylene Waste for Lithium-Ion Battery Anodes

Upcycling plastic waste into graphite can potentially be used, in conjunction with other methods, to manage existing waste materials and diversify graphite supply chains. However, synthesizing large quantities of crystalline graphite powder from plastic waste, particularly polyethylene (PE), remains a challenge because PE decomposes into light gases during thermal processing, and simple methods do not exist at any appreciable size scale to address this challenge. In this work, a method is developed for air processing bulk forms of PE waste to create a stable carbon char that does not readily decompose during high-temperature processing. This method employs solid additives in the form of salts, which are combined with the PE melt during air processing to increase the effective surface area of the melt and improve the oxygen-driven chemistry that stabilizes the PE for high-temperature processing. After removing the solid salt additives from the PE-derived char, it is converted into a highly crystalline bulk graphite powder using a Fe-based low-temperature (<1500 °C) catalytic process. The PE-derived graphite powder showed excellent electrochemical performance as an anode material for lithium-ion batteries (LIBs) with a capacity of up to 302 mAh/g at 0.5 discharge/charge cycles per hour (0.5 C) and capacity retention of 100% after 415 cycles.

Huynh, Ngoc Tien↗

DOE OSTI2024

Synthesizing Highly Crystalline Graphite Powder for Lithium-Ion Battery Anodes from Bulk Polyethylene Waste

Upcycling plastic waste into graphite can potentially be used to manage existing waste materials and diversify graphite supply chains. However, synthesizing large quantities of crystalline graphite powder from plastic waste, particularly polyethylene (PE), remains a challenge because PE decomposes into light gases during thermal processing, and simple methods do not exist at any appreciable size scale to address this challenge. In this work, a method is developed for air processing bulk forms of PE waste to create a stable carbon char, then be converted into a highly crystalline bulk graphite powder using a Fe-based catalytic process. The PE-derived graphite demonstrates excellent electrochemical performance as an anode material for lithium-ion batteries.

Gao, Yuan↗

DOE OSTI2024

Synthesizing Highly Crystalline Graphite Powder from Bulk Polyethylene Waste for Lithium-Ion Battery Anodes

Upcycling plastic waste into graphite can potentially be used, in conjunction with other methods, to manage existing waste materials and diversify graphite supply chains. However, synthesizing large quantities of crystalline graphite powder from plastic waste, particularly polyethylene (PE), remains a challenge because PE decomposes into light gases during thermal processing, and simple methods do not exist at any appreciable size scale to address this challenge. In this work, a method is developed for air processing bulk forms of PE waste to create a stable carbon char that does not readily decompose during high-temperature processing. This method employs solid additives in the form of salts, which are combined with the PE melt during air processing to increase the effective surface area of the melt and improve the oxygen-driven chemistry that stabilizes the PE for high-temperature processing. After removing the solid salt additives from the PE-derived char, it is converted into a highly crystalline bulk graphite powder using a Fe-based low-temperature (<1500 °C) catalytic process. The PE-derived graphite powder showed excellent electrochemical performance as an anode material for lithium-ion batteries (LIBs) with a capacity of up to 302 mAh/g at 0.5 discharge/charge cycles per hour (0.5 C) and capacity retention of 100% after 415 cycles. This method illustrates there are opportunities for upcycling large quantities of PE waste to produce graphite powders.

Huynh, Ngoc Tien [NETL Site Support Contractor, Na↗

DOE OSTI2011

Integrating Materials, Manufacturing, Design and Validation for Sustainability in Future Transport Systems

The predictive methods currently used for material specification, component design and the development of manufacturing processes, need to evolve beyond the current 'metal centric' state of the art, if advanced composites are to realise their potential in delivering sustainable transport solutions. There are however, significant technical challenges associated with this process. Deteriorating environmental, political, economic and social conditions across the globe have resulted in unprecedented pressures to improve the operational efficiency of the manufacturing sector generally and to change perceptions regarding the environmental credentials of transport systems in particular. There is a need to apply new technologies and develop new capabilities to ensure commercial sustainability in the face of twenty first century economic and climatic conditions as well as transport market demands. A major technology gap exists between design, analysis and manufacturing processes in both the OEMs, and the smaller companies that make up the SME based supply chain. As regulatory requirements align with environmental needs, manufacturers are increasingly responsible for the broader lifecycle aspects of vehicle performance. These include not only manufacture and supply but disposal and re-use or re-cycling. In order to make advances in the reduction of emissions coupled with improved economic efficiency through the provision of advanced lightweight vehicles, four key challenges are identified as follows: Material systems, Manufacturing systems, Integrated design methods using digital manufacturing tools and Validation systems. This paper presents a project which has been designed to address these four key issues, using at its core, a digital framework for the creation and management of key parameters related to the lifecycle performance of thermoplastic composite parts and structures. It aims to provide capability for the proposition, definition, evaluation and demonstration of advanced lightweight structures for new generation vehicles in the context of whole life performance parameters.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2024

A synthetic co-culture for bioproduction of ammonia from methane and air

Abstract Fixed nitrogen fertilizers feed 50% of the global population, but most fixed nitrogen production occurs using energy-intensive Haber–Bosch-based chemistry combining nitrogen (N2) from air with gaseous hydrogen (H2) from methane (CH4) at high temperatures and pressures in large-scale facilities sensitive to supply chain disruptions. This work demonstrates the biological transformation of atmospheric N2 into ammonia (NH3) using CH4 as the sole carbon and energy source in a single vessel at ambient pressure and temperature, representing a biological “room-pressure and room-temperature” route to NH3 that could ultimately be developed to support compact, remote, NH3 production facilities amenable to distributed biomanufacturing. The synthetic microbial co-culture of engineered methanotroph Methylomicrobium buryatense (now Methylotuvimicrobium buryatense) and diazotroph Azotobacter vinelandii converted three CH4 molecules to l-lactate (C3H6O3) and powered gaseous N2 conversion to NH3. The design used division of labor and mutualistic metabolism strategies to address the oxygen sensitivity of nitrogenase and maximize CH4 oxidation efficiency. Media pH and salinity were central variables supporting co-cultivation. Carbon concentration heavily influenced NH3 production. Smaller-scale NH3 production near dispersed, abundant, and renewable CH4 sources could reduce disruption risks and capitalize on untapped energy resources. One-Sentence Summary Co-culture of engineered microorganisms Methylomicrobium buryatense and Azotobacter vinelandii facilitated the use of methane gas as a sole carbon feedstock to produce ammonia in an ambient temperature, atmospheric pressure, single-vessel system.

Biotechnology & Applied Microbiology↗

DOE OSTI2017

Biomass Blending and Densification: Impacts on Feedstock Supply and Biochemical Conversion Performance

The success of lignocellulosic biofuels and biochemical industries depends on an economic and reliable supply of high-quality biomass. Many research and development efforts, however, have been historically focused on the utilization of agriculturally derived cellulosic feedstocks, without considerations of their low energy density, high variations in compositions and potential supply risks in terms of availability and affordability. This book chapter demonstrated a strategy of feedstock blending and densification to address the supply chain challenges. Blending takes advantage of low cost feedstock to avoid the prohibitive costs incurred through reliance on a single feedstock resource while densification produces feedstocks with increased bulk density and desirable feed handling properties as well as reduced transportation cost. We also review recent research on the blending and densification dealing with various types of feedstocks with a focus on the impacts of these preprocessing steps on biochemical conversion, i.e., various thermochemical pretreatment chemistries and enzymatic hydrolysis, into fermentable sugars for biofuel production.

09 BIOMASS FUELS↗

DOE OSTI2022

Co-Development of Oscillating Water Column (OWC) and Offshore Power Station

The project proposed an Oscillating Water Column (OWC) at a low power rating (1-5kW); to build a prototype and perform field testing within 1–3 years and achieving a commercial version of the OWC 3–5 years. We selected the OWC off-the-shelf components to secure the supply-chain sources and to warrant stable and minimum pricing. We want to curtail the capital cost by reducing the weight and volume of the overall system structure at the design level by designing a high-speed turbine generator and optimizing the airspeed amplification. We want to minimize the operational and maintenance (O&M) costs through simplified architecture, minimal parts, modular/plug-and-play, and easy access designs.

16 TIDAL AND WAVE POWER↗

DOE OSTI2021

Deactivation and Cathode-Healing™ to support the Low-Cost US Supply Chain

Lithium-ion recycling is challenged by cost and safety related to reactivity of lithium and electrolytes. OnTo’s deactivation eliminates flammability and residual reactivity enabling a roadmap for safe, low-cost end-of-life battery services essential to the industry. Deactivation coupled with Cathode-healing provides safety and efficiency in material recycling that can be applied all along the manufacturing value chain. Dr. Sloop will present recent developments in application and scale of these innovative technologies.

25 ENERGY STORAGE↗

DOE OSTI2022

Economic and Environmental Analysis to Evaluate the Potential Value of Co-Optima Diesel Bioblendstocks to Petroleum Refiners

The U.S. petroleum refining sector is undergoing a period of historic transformation, catalyzed by the decarbonization of the U.S. economy. Diesel-boiling-range bioblendstocks have gained traction, owing to their superior fuel properties and environmental performance as compared to traditional petroleum fuels. This work couples refinery linear programming models with life cycle assessment to quantify the potential economic and environmental benefits, and trade-offs, of blending diesel-boiling-range bioblendstocks at petroleum refineries. Linear programming models were developed in Aspen Process Industry Modeling Systems (PIMS) for three representative petroleum refinery configurations of differing complexity. Seven diesel-boiling-range bioblendstocks: 4-butoxyheptane, 5-ethyl-4-propylnonane, soy biodiesel, sludge hydrothermal liquefaction diesel, polyoxymethylene ethers, renewable diesel, and hexyl hexanoate, were investigated to identify key fuel properties that influence refineries' economics and to track the effect of adding bioblendstocks on refinery-wide cradle-to-gate greenhouse gases (GHG) emissions. These analyses considered blending levels from 10 to 30 vol% and fuel demand projections over the period 2040 to 2050. This analysis determines that bioblendstock sulfur content and cetane number are the primary fuel attributes with the potential to provide value to refiners. Life cycle assessment results indicate that the use of diesel-boiling-range bioblendstocks can reduce cradle-to-gate refinery GHG emissions by up to ~ 40 % relative to conventional refinery operations when considering carbon uptake in the supply chain of the bioblendstock. Refinery-wide marginal GHG abatement costs range from 120 to 3,600 USD2016/metric tons carbon dioxide equivalent avoided across the scenarios evaluated. Reducing the price of bioblendstocks is identified as a key to their adoption.

ADVANCED PROPULSION SYSTEMS,BIOMASS FUELS,ENERGY P↗

DOE OSTI2011

Biofuel impacts on water.

Sandia National Laboratories and General Motors Global Energy Systems team conducted a joint biofuels systems analysis project from March to November 2008. The purpose of this study was to assess the feasibility, implications, limitations, and enablers of large-scale production of biofuels. 90 billion gallons of ethanol (the energy equivalent of approximately 60 billion gallons of gasoline) per year by 2030 was chosen as the book-end target to understand an aggressive deployment. Since previous studies have addressed the potential of biomass but not the supply chain rollout needed to achieve large production targets, the focus of this study was on a comprehensive systems understanding the evolution of the full supply chain and key interdependencies over time. The supply chain components examined in this study included agricultural land use changes, production of biomass feedstocks, storage and transportation of these feedstocks, construction of conversion plants, conversion of feedstocks to ethanol at these plants, transportation of ethanol and blending with gasoline, and distribution to retail outlets. To support this analysis, we developed a 'Seed to Station' system dynamics model (Biofuels Deployment Model - BDM) to explore the feasibility of meeting specified ethanol production targets. The focus of this report is water and its linkage to broad scale biofuel deployment.

02 PETROLEUM↗