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DOE OSTI2022

Tuscaloosa Marine Shale Laboratory

The Tuscaloosa Marine Shale (TMS) in Louisiana and Mississippi is an Upper Cretaceous source rock formation sandwiched between the sands of the upper and lower Tuscaloosa sections. The TMS is believed to be the source rock for underlying prolific Tuscaloosa sand formation. The TMS has an unproven estimate of 7,000,000,000 bbls of recoverable oil while its current total average production is about 3,000 bbls of oil per day in 2017. In 2013 and 2014, more than 80 wells were drilled horizontally into the TMS that were fractured using multi-stage fracturing technology. The results from this have been mixed, but recent production for several wells show an appealing initial oil production rate of more than 1000 bbl/day. The preliminary core analysis by industry partners and a few literature studies shows that the TMS is one of the most clay-rich and sensitive shales to water. Due to these and other technical problems, there is high risk for the economic development of TMS compared to other shale plays. The experiences of major industrial players in the TMS show the necessity of open and collaborative efforts to better understand the critical gaps in the development of this challenging and potentially highly economic shale play to enable more cost-efficient and environmentally-sound recovery from this unconventional liquid-rich shale play. The overall objective of this project is to form a consortium of science and industry partners to address the following six major objectives using scientific and technical approaches: 1. To improve wellbore integrity by better understanding the sources of the wellbore instability issues, proposing innovative mud and cement design for the TMS. 2. To improve formation evaluation using laboratory techniques for the evaluation of mineralogical composition, organic content, and produced-water chemistry as well as well log and geophysical analysis. 3. To determine the role of geologic discontinuities on fracture growth and shale creep behavior using digital image correlation technique. 4. To investigate the application of stable CO 2 foam and super-hydrophobic proppants for improved reservoir stimulation. 5. To better understand the nature of water/hydrocarbon/CO 2 flow in clay and organic-rich formation and the role of water/fluid interaction on recovery. 6. To prepare better socio-economic environment for TMS development by community engagement. Subsequently, the TMS virtual laboratory conducted testing and analysis of various properties of rock and formation fluids from the TMS, including but not limited to the following: Analyzing reports and logs to better understand the source of wellbore instability in TMS wells; Experiments to design a customized cement based on TMS requirements; Experiments to obtain the mineralogical and geochemical composition of TMS samples; Seismic analysis of TMS geophysical data to better predict total organic carbon (TOC) content and brittleness in TMS; Well log analysis to better estimate the TOC and geo-mechanical properties of TMS; Experiments on formation water to understand the chemistry of produced water; Experiments to determine the role of lamination and natural fractures on fracture propagation or rock deformation using digital image correlation technique in in-direct tensile tests, semi-circular bend test and creep tests Experiments to determine the stability and rheological properties of nanoparticle-stabilized CO 2 foam in TMS rock samples; Experiments to determine fluid dynamics in un-propped TMS fractures and the role of nano-coating of proppants on fluid dynamics in fractures with proppants; Micro-fluidics experiments to enhance the understanding of fluid dynamics in tight liquidrich pores with high clay content; Socio-economic studies to better engage communities in TMS development.

58 GEOSCIENCES↗

DOE OSTI2022

Algal Biomass Conversion to Fuels via Combined Algae Processing (CAP) (2021 State of Technology and Future Research)

The annual State of Technology (SOT) assessment is an essential activity for platform research conducted under the Bioenergy Technologies Office. It allows for the impact of research progress to be quantified in terms of economic improvements in the overall biofuel production process for a particular biomass processing pathway, whether based on terrestrial or algal biomass feedstocks. As such, initial benchmarks can be established for currently demonstrated performance, and progress can be tracked towards out-year goals to ultimately demonstrate economically viable biofuel technologies. NREL's algae state of technology benchmarking efforts focus both on front-end algal biomass production and separately on back-end conversion to fuels through NREL's "combined algae processing" (CAP) pathway. The production model is based on outdoor long-term cultivation data, enabled by comprehensive algal biomass production trials conducted under the Development of Integrated Screening, Cultivar Optimization, and Verification Research consortium (DISCOVR) efforts, driven by data furnished by Arizona State University (ASU) at the Arizona Center for Algae Technology and Innovation (AzCATI) testbed site. The CAP model is based on experimental efforts conducted under NREL research and development projects. This report focuses on back-end conversion of algal biomass through the CAP pathway, highlighting the 2021 updates to minimum fuel selling price (MFSP). This update maintains an important recent inclusion of polyurethane (PU) previously incorporated in the 2020 SOT as a value-added coproduct. Relative to the 2020 SOT case, this indicates a minimal increase of $0.10-$0.14/GGE (roughly 2%) for both the acids and BDO pathways, attributed to minimal increases in upstream algal biomass costs from slightly lower demonstrated cultivation productivities in the 2021 SOT.

09 BIOMASS FUELS↗

DOE OSTI2021

Advanced Downhole Acoustic Sensing for Wellbore Integrity (Final Report)

Borehole cement is used across the range of energy technologies to stabilize casing, to serve as a barrier to behind-casing fluid movement. Cement debonding and other flaws, both at cement interfaces and within the cement itself, can create leakage pathways that can threaten safety to personnel, and wellbore performance, with economic and regulatory consequences. A primary method to assess cement health and wellbore integrity is via acoustic methods. This project was designed with three aims: demonstrate a significant improvement in the interpretation of cement acoustic behavior, both during curing, and in interpreting effects of flaws and evolving interfaces; develop sensor technologies to improve signal-noise ratios and cement acoustic responses; and lastly, provide a borehole demonstration of at least one of these technologies. We have accomplished the first two objectives, and the third, delayed by pandemic health concerns, is proceeding as of this writing via a technology partner with the University of Texas Advanced Energy Consortium.

15 GEOTHERMAL ENERGY↗

DOE OSTI2022

A Multi-Scale Computational Platform for Predictive Modeling of Corrosion in Al-Steel Joints (Final Report)

The research team proposed to develop innovative multi-scale models to predict corrosion and the resulting mechanical performances in aluminum-steel joints. The methods of joining considered are resistance spot welding, self-piercing riveting, and rivet-welding, all suitable for mass production applications. The multi-scale models integrate high throughput first-principle calculations based on density functional theory (DFT), high throughput calculation of phase diagrams (CALPHAD) modeling, and finite element method (FEM) simulations. These models are to be validated through laboratory experiments. Furthermore, the models are available as open source so as to enable scientists and engineers in the community to adapt and contribute to the development and application. The approaches rely on the research team’s extensive experience on the prediction of properties of individual phases at finite temperatures and variable compositions through DFT calculations, and our broad expertise on dissimilar material joining and their corrosion. The proposed computational framework enables high throughput computations for improved predictions of corrosion and the associated mechanical performance in dissimilar material joints, resulting in significant reduction in computational time needed by the current state-of-the-art methods. With the participation of researchers from three universities, an auto manufacturer, two manufacturing technology/equipment suppliers, and a software developer/vendor, the interdisciplinary research team applies the technical development on both phase-based modeling and laboratory experiments into the automobile body joining processes for validation and technology demonstration. The global cost of corrosion was estimated at about 3.4% of the global GDP in 2013. By using available corrosion control practices, it is estimated a saving between 15-35% of the cost of corrosion. In the U.S., more than $276 billion is spent repairing corrosion damage. Prediction of the corrosion and its impact on performance of the dissimilar material joints is critical for reducing the massive number of the current corrosion-based recalls for automobiles. Thus, the project goal is to develop models to enable predictive maintenance and end-of-life planning of multi-metal joints with risk of corrosion under different conditions such as exposure to high temperatures in summer and salt solutions in winter, quantified through its pH. An academia-industry consortium led by the University of Michigan and including Pennsylvania State University, University of Illinois Urbana-Champaign, University of Georgia, General Motors Company, Livermore Software Technology Corporation, and Optimal Process Technologies, LLC. created multi-scale models for prediction of corrosion in aluminum-steel joint structures such of them used in vehicle subassemblies – chassis and transmission systems. Starting from the first principle calculations, the team developed mathematical and data-driven models to predict the metallic components, which are formed during joining of two metals, for example aluminum and steel - a lightweight multilateral system which is currently used in more than 60% car bodies. These models were used for simulating chemical reactions that are happening when the joining metallic components are exposed to high temperatures and different pH values. The team was able to predict how the corrosion installs on the metallic components and how they lead to a sudden failure of components in cars. Newly developed machine learning algorithms combining Science, Technology, Engineering and Math disciplines, advanced finite element simulation and experimental validations have been integrated in a platform for prediction of the corrosion evolution and prediction the failure of joints under mechanical loadings and fatigue. Moreover, based on machine learning and inverse analysis, the team proposed solutions for designing new metallic alloys less susceptible to corrosion when joining multi-material assembles. An average of 4% error compared with experiments was achieved for the most common joints that are used in vehicle subassemblies.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Expanding the composition of polyhydroxyalkanoates produced by an industrial host: CRADA 505 [Abstract only]

The Agile BioFoundry (ABF) is a multi-national lab consortium funded by the Department of Energy’s Bioenergy Technologies Office that has developed a biofoundry that enables the rapid deployment of bioproducts into the market. Working with two ABF laboratory members (National Renewable Energy Laboratory (NREL) and Pacific Northwest National Laboratory (PNNL), Danimer will develop bacterial strains to produce PHAs with different compositions aimed at expanding Danimer’s product offerings. This project will enable the ABF to contribute to the development of a high-profile, commercial product that falls squarely in the DOE mission space and has strong potential to have meaningful benefit both to the US economy and the environment.

09 BIOMASS FUELS↗

DOE OSTI2022

Energy Northwest - Horn Rapids Solar and Storage: An Assessment of Battery Technical Performance

Chartered in 1957 as a joint action agency of the state, Energy Northwest (ENW) is a consortium of 27 public utility districts and municipalities across Washington state. ENW takes advantage of economies of scale and shared services to help utilities run their operations more efficiently and at lower cost, to the benefit of more than 1.5 million customers. ENW develops, owns, and operates a diverse mix of electricity generating resources, including hydro, solar, and wind projects – and the Northwest’s only active nuclear energy facility. These projects provide enough reliable, affordable, and environmentally responsible energy to power more than a million homes each year, and that carbon-free electricity is provided at the cost of generation. The agency continually explores new generation projects to meet its members’ needs. In 2017, as part of the second round of funding from the Washington state Clean Energy Fund, the Washington State Department of Commerce granted up to $3 million in matching funds to develop an estimated $6.5 million project that deployed a 4-MW, 20-acre solar generating array of photovoltaic (PV) panels coupled with a 1 MW/5.5 MWh lithium-iron-phosphate battery energy storage system (BESS) in Richland, Washington. The combination of PV and BESS will provide a predictable, renewable generating source and will also serve as a training ground for solar and battery technicians throughout the nation. The City of Richland will purchase the power from the project and utilize the benefits of the energy storage. The project provides Washington state with its first opportunity to integrate a large-scale solar and storage facility into its clean mix of hydro, nuclear, and wind resources. This first-of-its-kind facility combines solar generation with battery storage and technician training. In 2019, Pacific Northwest National Laboratory (PNNL) worked with ENW to assess the integrated PV and BESS in representative use cases that could benefit the City of Richland. Between March and May 2022, extensive testing was conducted, and the results were used to assess the technical performance of the BESS subjected to actual field operations. Both reference performance and use case tests were performed: (A) Reference performance tests assess the general technical capabilities of the BESS, such as energy capacity, round-trip efficiency (RTE), ramp rate, and signal tracking capability. These are the first tests performed (baseline), and they are repeated after use case tests (post cycle). A standardized U.S. Department of Energy (DOE) energy storage performance protocol was used to characterize the BESS, including representative duty cycle profiles, test procedure guidance, and calculation guidance for determining key characteristics. (B) Use case tests examine the performance of the BESS for specific use cases using duty cycles developed by PNNL in collaboration with ENW. Five use cases were selected for testing: 1) demand charge reduction, 2) load shaping, 3) transmission charge reduction, 4) Volt-VAR service, and 5) outage mitigation. The use case duty cycles were developed based on utility and site-specific characteristics in addition to the technical characteristics and physical capabilities of the BESS. Use case tests were performed between the baseline and post cycle tests. This report describes the BESS and its components, presents testing and performance analysis results, and shares key insights and lessons learned from this project. Outcomes of the tests and analyses will help ENW understand the performance of the Horn Rapids BESS in its current state and design appropriate operational strategies for this and other BESSs over the long term.

14 SOLAR ENERGY↗

DOE OSTI2022

Challenge Problem 1: Preliminary Model Development and Assessment of Flexible Heat Transfer Modeling Approaches

This report presents the modeling progress of a university consortium studying flexible modeling for turbulent heat transfer. In the context of advanced nuclear reactor design, where challenges include non-unity Prandtl fluids, free and mixed convection, and transitional flow, computational fluid dynamics methods are underutilized due to low confidence in modeling approaches and high computational cost. This report evaluates the performance of engineering CFD models in diabatic, buoyant turbulent flow. It finds that all turbulence models including several variants of the k-ε and k-ω models struggle to predict accurate turbulent momentum and heat transfer in such flows. The Nusselt numbers have been compared between the models and the DNS data, where calculations have been performed for each case and trends have shown a good agreement between DNS estimated Nusselt numbers and available correlations as well as experimental data. A novel DNS correlation for high Pr cases as they are transitioning from mixed convection to natural convection has been proposed. While Nusselt number errors relative to DNS range from 20% to 50%, the models capture similar trends to DNS with respect to Nusselt suppression and amplification under varying levels of buoyancy effect. This report also highlights model form error as a significant contributor to CFD predictions and proposes a framework for quantifying model error and improving confidence in CFD calculations. To improve the predictive capability of engineering CFD models, data-driven approaches for turbulence models are investigated. Theoretical frameworks based on the invariant tensor / vector basis neural networks for prediction of Reynolds stresses and turbulent heat fluxes are employed. The models are developed using direct numerical simulations data for forced convection flows of different fluids in vertical planar channel domain. The framework is implemented in spectral element solvers Nek5000 / nekRS and has shown a potential for future development and consideration of mixed convection flows.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2022

Bypass Flow Model Implementation for VERA BWR

The Virtual Environment for Reactor Applications (VERA) has been developed by the Consortium for Advanced Simulation of LWRs (CASL) over the past 10 years to address difficult problems facing commercial light-water reactors (LWRs). VERA comprises several high-fidelity physics packages, each of which models a different aspect of the reactor. These individual pieces are then linked to provide a fully coupled multiphysics solution for various LWR analyses.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2021

In-situ Photophysical Monitors and Corrective Algorithms for Photovoltaic Film Deposition and Rapid Thermal Processing in Scalable Roll-to-Roll Manufacturing

This project evaluated three photophysics-based approaches for in situ process monitoring of the scalable deposition of perovskite photovoltaic films. Based on stakeholder input and the results of laboratory trials and literature analysis, two techniques, angle resolved elastic light scattering (ARLS) and time-resolved photoluminescence (TRPL) were prototyped and demonstrated with a mixture of simulation, offline and online tests. Also, a hybrid gas flow and humidity control enclosure was constructed and demonstrated to stabilize the ambient conditions around the slot die deposition process and were demonstrated to meet the target humidity control in situ. Due in part to a delayed start and COVID-related lab restrictions and personnel changes, some of the milestones were not met. In spite of these challenges, however, both techniques were prototyped through several iterations and demonstrated significant promise for rapid in line perovskite characterization within the targeted characterization time windows and these techniques are under further development for use in DE-FOA000235:2357-1586. The TRPL system was fully mounted and demonstrated on the scaled slot die roll to roll and sheet coating systems at the Washington Clean Energy Testbeds (WCET). Motivated by significant internal and stakeholder interest, the successful prototyping achieved here, the ongoing need for in-situ characterization for the scale-up of perovskite manufacturing, and the benefits of in situ photophysical characterization for future funded process development research, we are continuing with the principle aims of the project to develop effect in situ photophysical probes for fast analysis of the optoelectronic and structural quality of sheet based and roll to roll process perovskites. TRPLS and ARLS probes proposed in the project are to be completed with external support from the Washington Research Foundation at the WCET. We are currently actively engaged in the acquisition of components and plan to complete and test the probes within three months. It is our intention that these probes will then be used in ongoing perovskite development with our research and commercialization partners including First Solar and other member of the US MAP consortium in future funded development work.

14 SOLAR ENERGY↗

DOE OSTI2022

Automated Vulnerability Detection (AVUD) for Compiled Smart Grid Software

This project developed and implemented a system for conducting cybersecurity vulnerability detection of smart grid components and systems by performing static analysis of compiled software (“firmware”). The resulting system for automated vulnerability detection (AVUD) was implemented as part of Oak Ridge National Laboratory’s existing test bed for smart meters, the Sustainable Campus Initiative. The work consisted of two phases: the first phase implemented the necessary software and computational models to perform the analysis, and the second phase demonstrated the system on example firmware in partnership with smart meter manufacturer Sensus USA, Inc. The resulting system won an R&D 100 award and has been successfully commercialized, winning a National Laboratory Consortium Commercialization Award.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2022

Roadmap to Advance Heliostat Technologies for Concentrating Solar-Thermal Power

Heliostat-based concentrating solar-thermal power (CSP) systems can offer immense potential to provide low-cost, dispatchable renewable thermal and electrical energy to help achieve 100% decarbonized energy infrastructure in the United States. Heliostats are a major capital cost technology and a performance-dominating component of state-of-the-art commercial molten salt towers and Generation 3 CSP systems. In 2021, the U.S. Department of Energy (DOE) Solar Energy Technologies Office (SETO) launched the Heliostat Consortium (HelioCon), a five-year initiative to advance heliostat technologies. The HelioCon mission is threefold: (1) establish strategic core testing and modeling capabilities and infrastructure at national labs; (2) support heliostat technology development in relevant industries; and (3) serve as a central repository to integrate industry, academia, and other stakeholders for heliostat technology research, development, validation, and deployment. In this report, HelioCon presents a roadmapping study on advancing heliostat technologies, intended as a central reference for the whole CSP community.

14 SOLAR ENERGY↗

DOE OSTI2022

What's in a Test Site? Past & Future Lunar Analog Testing at the NNSS

Presentation for the Fall Meeting of Johns Hopkins' Lunar Surface Innovation Consortium (LSIC). Additional details at this link: https://lsic.jhuapl.edu/Events/Agenda/index.php?id=350 Nicholas Downs will be the presenter of these slides. Conference Location: University of Texas El Paso Conference Dates: 11/1/22-11/3/22

58 GEOSCIENCES↗

DOE OSTI2022

Summary: SEE4GEO

The seismoelectric effects technique (SEE) is a new and innovative approach for geothermal subsurface imaging and monitoring at reservoir scale. The objective of this project is to assess SEE in terms of data acquisition, cost and quality, and to determine its capability in comparison with classical imaging and monitoring techniques, particularly decoupled seismic and electromagnetic methods. This will be achieved by (1) development of a fast, true 3D numerical package, handling SEE imaging and subsurface properties characterization, including resistivity and permeability, (2) laboratory experiments performed in a controlled environment to define optimal deployment design, data quality, and inform field deployment, and (3) field surveys to ultimately test and draw lessons for practical use of SEE technology. There is a relatively extensive body of work in the literature on SEE, and members of this consortium have been involved in theoretical and numerical development of SEE modeling as well as laboratory experiments. Nevertheless, to our knowledge few, if any, documented efforts have been specifically targeting the use of SEE for geothermal subsurface imaging and monitoring. The strength and originality of our proposal rely on an integrated approach leveraging numerical, laboratory and field experiments, to properly document the practical use of SEE. Through this process, SEE in-hand technology for the geothermal industry will be able to progress from a TRL 1 to TRL 3.

58 GEOSCIENCES↗

DOE OSTI2022

Seismoelectric Effects for Geothermal Resources Assessment and Monitoring (SEE4GEO)

58 GEOSCIENCES↗

DOE OSTI2022

The Net Zero World Initiative’s Preliminary Analysis of Decarbonization Pathways for Five Countries. Executive Summary

Under the Net Zero World Initiative, the United States is marshalling the forces of nine U.S. government agencies, led by the U.S. Department of Energy, to partner with philanthropies and multiple countries to cocreate and implement tailored technical and investment pathways to accelerate the decarbonization of global energy systems. In addition, 10 of the DOE national laboratories have built a consortium housed in the Net Zero World Action Center to implement this vision by providing the deep analysis and modeling required to carry out the vision.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2022

Electricity Costs and Carbon Implications for CO 2 -to-Fuels in Selected Locations in 2030

With the growing interest in converting carbon dioxide (CO 2 ) to fuels and products to reduce overall greenhouse gas emissions and extend carbon from biogenic and other sources, the development of carbon capture and utilization (CO2U) technologies and industry is crucial. The Markets, Resources, and Environmental and Energy Justice of CO 2 -to-Fuels Technologies (short title: MarkeRs & EEJ) project supports this goal by assessing the resource and market potential and infrastructure requirements for mid-term (-2030) and long-term (-2050) deployment of CO2U technologies. The overall project analyzes CO2U economic and resource requirements as well as sustainability and environmental and energy justice (EEJ) metrics. This report focuses on short-term (-2030) aspects of the project. It identifies three CO2U locations in the Midwestern United States and quantifies the costs for potential electricity resources and marginal emissions for each site in the near term (e.g., 2030). We focus on four electricity purchase options, including retail rate, physical power purchase agreement (PPA), financial PPA, and real-time pricing (RTP), for each of the three sites and consider potential policies such as production tax credits (PTCs). We also assess time-dependent hourly marginal electricity costs and the marginal emission rates using modeled scenarios from Cambium (Gagnon et al. 2021).The results of the analysis are expected to inform other projects within the U.S. Department of Energy's CO 2 -to-Fuels Consortium, especially the Economics and Sustainability of CO 2 Utilization Technologies with Techno-Economic Analysis and Life Cycle Analysis (TEA/LCA) project, led by Michael Wang of Argonne National Laboratory and Ling Tao of the National Renewable Energy Laboratory. The project results are also expected to inform the investment and technology communities and policymakers at the U.S. Department of Energy, state, and regional levels and guide investment by government and industry in research and development portfolios.

09 BIOMASS FUELS↗

DOE OSTI2022

Designing Resilient Communities: Hardware demonstration of resilience nodes concept

As part of the project “Designing Resilient Communities (DRC): A Consequence-Based Approach for Grid Investment,” funded by the United States (US) Department of Energy’s (DOE) Grid Modernization Laboratory Consortium (GMLC), Sandia National Laboratories (Sandia) is partnering with a variety of government, industry, and university participants to develop and test a framework for community resilience planning focused on modernization of the electric grid. This report provides a summary of the section of the project focused on hardware demonstration of “resilience nodes” concept.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2022

State of Common Grid Services Definitions

This document is prepared as part of the Department of Energy’s Grid Modernization Laboratory Consortium (GMLC) 2.5.2 project, whose goal is to develop and socialize a common set of grid service definitions relevant to grid-related interactions with distributed energy resources (DER: responsive generation, storage, and loads), and to advance the concept and requirements of the Energy Services Interface (ESI) to the point of launching related interface standards and guides that can be implemented in communication protocols and business process definitions. The notion of “grid services” is integral to the definition of an ESI because a key principle of the ESI is that it permits coordination between grid operators and DER facilities in a way that is service-oriented, with an understanding of performance expectations. This document reviews the current state of grid service definitions, including those actively used in the market today as well as new services that have been proposed for future implementation. The document describes grid services used in transmission as well as distribution systems. In defining grid services, this document also distinguishes between two fundamental concepts: an “operational objective” and a “grid service,” which describes a generator’s or customer’s expected physical performance in delivering power to or consuming power from the grid.

24 POWER TRANSMISSION AND DISTRIBUTION↗