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DOE OSTI2022

Critical-Element-Free Permanent-Magnet Materials Based on Ce 2 Fe 14 B

Developing a critical-element-free low-cost permanent magnet is an urgent necessity in view of rapidly developing technologies and the associated huge market demand for Nd 2 Fe 14 B-based magnets. Here, inspired by the abundant and low-cost nature of Ce and these high-performance Nd 2 Fe 14 B permanent magnets, we explore whether it is in fact possible to attain a useful performance in alloys based on the sister material Ce 2 Fe 14 B, employing both experimental and theoretical efforts. Experimentally, we study Ce 2 Fe 14 B with Co, La, and Zr substitutions. The Zr substitution is explored in view of Zr’s frequent role in enhancing magnetic anisotropy in permanent magnets, while the Co and La substitutions serve to remedy the too-low Curie point of 433 K in the base alloy. While we find no Zr-related anisotropy enhancement either experimentally or theoretically, the cosubstitution of La and Co indeed improves the Curie temperature as well as the magnetization, M s , with a potential energy product as high as 38 MG Oe. These properties together suggest optimization of the alloy LaCeFe 12.7 Co 1.3 B (with only 7 wt % cobalt) as a critical-element-free permanent magnet. While the substituted elements do not enhance magnetic anisotropy, from theory, we find a substantial increase, to a first anisotropy constant, K1, as high as 4.24 MJ/m 3 , associated with Bi substitution for Ce. In this paper, our experimental and theoretical results demonstrate the great potential of La, Co, and Bi substitutions in developing low-cost and critical-element-free Ce 2 Fe 14 B-based permanent magnets.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Additive Manufacturing Case Study

Geothermal technologies include an extremely wide range of products required for well construction, completion, production, intervention and surface energy conversion activities. Many of these products are geometrically complex, require multi-step and highly specialized fabrication processes, and are expensive due to the low production numbers typically associated with the geothermal market. These challenges along with the high temperature demands of the geothermal environment have also hindered the adoption of many tools routinely used in the oil & gas industry.Recent advancements in Additive Manufacturing (AM) materials of construction, build volumes and part quality have transitioned the technology from primarily cosmetic prototyping applications to the point where AM can be used to make production parts, even for the most demanding applications. These improved AM capabilities along with the inherent ability of AM to produce complex parts and, in some cases, geometries that cannot be manufactured using conventional casting, machining and joining fabrication approaches motivate an exploration of its potential to positively impact geothermal well construction and operations technologies.Sandia National Labs collaborated with Oak Ridge National Laboratory on a case study examining additive manufacturing opportunities for Geothermal applications. The study focused on designing components with improved performance characteristics that cannot be fabricated conventionally. A rotor for a downhole motor was chosen based on the potential for improving its rotational dynamics. Topology optimization was used as a design method to reduce the rotational inertia of the part while preserving sufficient rotational stiffness to transmit the torque required for the drilling application. The optimization resulted in a nearly 50% reduction in polar moment of inertia while maintaining other desired performance characteristics. The design developed using the topology optimization approach was fabricated using additive manufacturing and cannot be fabricated conventionally. This paper will discuss the design approach, performance improvements and manufacturing methods used to produce the part.

Polsky, Yarom↗

DOE OSTI2024

Evaluating Nationwide Supply Chain for Circularity of PET and Olefin Plastics

PET (Polyethylene Terephthalate, #1) and olefin plastics including HDPE (High Density Polyethylene, #2), LDPE/LLDPE (Low Density/Linear Low-Density Polyethylene, #4) and PP (Polypropylene, #5) together comprise nearly 80% of the U.S. plastic market. Due to their high market share and extensive application in packaging these polymers have better potential for circularity than other polymer types. To understand the potential of future scenarios with higher recycling rates, supply chain scenarios for PET and olefin plastic packaging need to be analyzed with increased availability and collection of plastics. Currently there exists a knowledge gap to understand the circular supply chain on a national level. Performing a nationwide analysis introduces certain challenges such as variability in the plastic mix of the recycling stream in different municipalities, lack of collection of some types of plastics, regional differences in cost and estimating a national supply curve based on state level access rate and participation rate. Currently, a limited number of Plastic Reclaimers recycle the nation’s collected plastic involving transportation over long distances surpassing state boundaries. Modeling a nationwide scenario instead of regional/state based scenario will facilitate transportation beyond state boundaries for the development of a circular economy. A Mixed-integer Linear Programming model was developed, to identify the optimal location and capacity of the Material Recovery Facilities (MRFs) nationwide subject to maximizing the profit margin of the industrial entities within the model. We considered three different scenarios including the base case scenario (S1) collecting 2.27 million metric tons/year as well as two additional scenarios with available plastic supply of 1.8 times (S2) and 2.2 times (S3) of the base case scenario. The model identified 166, 275 and 319 counties as potential MRF locations for scenarios S1, S2 and S3 respectively. Compared to the existing number of counties having MRFs in the US, the model results indicated a reduction of 38% of MRFs for S1. For S2 and S3, the number of counties with MRFs increased 3% and 20% respectively compared to counties currently with MRFs. The average profit remains constant between $180-$181/ton regardless of the increased plastic collection.

54 - ENVIRONMENTAL SCIENCES/GLOBAL CLIMATE CHANGE ↗

DOE OSTI2020

In-situ and in-operando analysis of voltage losses using sense wires for proton exchange membrane water electrolyzers

Proton exchange membrane water electrolyzer development requires understanding processes at the materials and interface levels to reach the required performance and lifetime targets for increasing market penetration. To achieve the required progress, it is critical to develop advanced in-situ diagnostics that allow observation of the changes that come with the reduction of catalyst loading combined with long-term intermittent operation. This work presents an internal voltage sensing method that enables observing internal voltage drops in an operating electrolyzer cell. It allows the total cell resistance to be separated into anode, CCM, and cathode resistance. The method is demonstrated by operating cells with different anode porous transport layers (PTLs). The changing properties of the PTLs result in significant variations of the resistances. Enhancing the PTL properties with a protective coating reduces the anode resistance significantly. In addition to these observations, the method enables a real-time monitoring of resistance related values that impact performance in water electrolyzers. Long-term experiments with the method allow us to gain insights into processes that occur during operation such as conditioning or degradation. The internal voltage sensing method presented in this study is a novel technique for diagnosing, analyzing, and optimizing water electrolyzers and other energy conversion devices.

42 ENGINEERING↗

DOE OSTI2026

Making Small-Volume Heat Pump Water Heaters Larger: A Design Framework for Integrated Phase Change Material Heat Exchangers

Those that use electricity for water heating, the majority use resistive elements rather than heat pump water heaters (HPWHs), the latter of which use 60-70% less energy than the former. One major barrier to wider HPWH adoption is the added equipment required, which prevents current 50-80-gallon tanks on the market from fitting into smaller utility closets sized for 30-40 gallons, such as those found in manufactured housing. Additionally, these smaller HPWHs tend to underperform relative to their larger counterparts. One solution that addresses both space and performance concerns is thermal energy storage, and in particular, phase change materials (PCMs). PCMs have been studied extensively in building envelope and HVAC systems, but remain a nascent technology in residential water heating. While water itself has a uniquely high energy storage capacity, PCMs have an even higher energy storage density, thus providing the potential to elevate the performance of 40-gallon HPWHs to that of 50-gallon or larger tanks. This research is part of a larger project that seeks to utilize thermal energy storage to enable decarbonized water heating in low-income communities. In this study, we outline the design process used to produce novel PCM heat exchangers for use in small-volume HPWH tanks, including the identification of design constraints and performance targets relevant to real-world applications. In order to ensure optimal PCM utilization and tank storage capacity, we focus here on co-maximizing surface area and PCM volume in the heat exchangers; therefore, this research targets triply periodic minimal surface (TPMS) lattices. TPMS lattices boast enhanced heat transfer capabilities compared to traditional heat exchanger geometries and offer highly tailorable designs; thus, they pair well with the growing field of additive manufacturing, or 3D printing. Starting with a suite of TPMS lattices, we demonstrate a systematic approach for narrowing down feasible designs that comply with identified constraints while meeting PCM performance objectives.

25 ENERGY STORAGE↗

DOE OSTI2025

Addressing the Split Incentive Challenge for Enhanced Solar Adoption in Multifamily Rental Properties [Abstract]

The split incentive problem is particularly pronounced in rental markets, where landlords prioritize investments that directly increase property value or rental income. Since energy savings from solar photovoltaic (PV) systems primarily benefit tenants, landlords may perceive little return on investment unless mechanisms exist to recapture some of the financial gains. The primary objective of this project is to develop a publicly available, web-based tool to analyze the U.S. Department of Energy’s ResStock database, which models the U.S. residential building stock. The tool allows users to filter buildings by location, type, HVAC system, square footage, and other characteristics, and outputs typical electric load profiles. By leveraging location-specific electric load data, Fram Energy aims to advance business strategies that address the split incentive barrier and promote the adoption of solar PV installations in rental properties. In addition, a machine learning model will be developed to weigh the marginal contribution of building features across the dataset in predicting electricity demand, supporting guided decision making in forecasting electric load profiles. Lastly, based on each building’s location, load profile, and utility’s electricity rate, an optimized solar photovoltaic array and battery energy storage system will be sized to provide energy arbitrage opportunities.

14 SOLAR ENERGY↗

DOE OSTI2022

Novel and effective surface passivation for high efficiency n- and p-type Silicon solar cell

The project objective was to develop a novel Si surface passivation method using chalcogens, sulfur (S) and/or selenium (Se), as passivating elements, to withstand industry-standard high temperature contacting and metallization schemes for p-type Si based passivated emitter and rear contact (p-PERC) solar cells. The back surface passivation of PERC cells has been improved drastically with the invention and successful application of an Al 2 O 3 passivation layer. However, the front n + diffused junction surface is still poorly passivated by the standard amorphous silicon nitride (SiNx) anti-reflection coating (ARC) layer. This project sought to address the passivation challenges of both front n+ emitter and undiffused p-Si back surface. Improved p-PERC solar cell performance with open circuit voltage (V OC ) > 680 mV and efficiency of 22% were targeted to validate superior defect passivation properties as compared to standard SiO 2 / Al 2 O 3 passivation. During this project, we systematically investigated process-structure-properties-performance relationships of this novel advanced defect passivation approach. The S/Se passivation was carried out by reacting industrial Czochralski (Cz) Si wafers in H 2 S and H 2 Se gases in a chemical vapor deposition (CVD) reactor at temperatures up to 700°C. After an exhaustive optimization of the process parameters (temperature, time, and gas concentration), we established an optimized process and demonstrated extremely low surface recombination velocities (SRVs) of 1.5 cm/s and 8 cm/s on n-type and p-type Si, respectively, by S-passivation. In-depth surface and interface characterization were performed using soft x-ray and photoelectron spectroscopies (XPS, UPS, XES), combined with capacitance-voltage-frequency (C-V-f) measurements, to decipher the surface chemical/electronic structure and interface defect state densities. These measurements provided critical understanding of the defect passivation mechanism and elucidated the presence of surface S-Si bonds, a reduction of surface dipoles, and low interface state densities (D it ) < 10 11 cm -2 ev -1 . We also found that the Se-passivation is inferior to the S-passivation (by at least one order of magnitude in SRV). Application of the optimized S-passivation to the n+ diffused emitter surface led to a low surface recombination current density, J0 ≈ 40 fA/cm 2 (~ 1/4 of the industry-standard SiNx-passivation), and high implied V OC (686 mV) in p-PERC solar cell structures. The S-passivation process also was found to improve the bulk quality of the p-type Si, better than the SiO 2 or Al 2 O 3 passivation processes. After successful demonstration of efficient passivation of Si surface defects by S, we extensively studied the air, thermal, and illumination stability of the passivation structure. S-passivation itself degrades in air due to competing reactions with moisture and oxygen to form oxides, which can be eliminated by a SiNx capping layer (also acting as a anti-reflective coating). After SiNx process optimization, we demonstrated illumination and thermally stable S-passivation with SRV < 5 cm/s and J 0 < 80 fA/cm 2 . These enhancements in Si passivation, incorporated into p-PERC cells, achieved an efficiency of 19.93% with V OC = 649 mV, using manufacturing metallization and contacting schemes. The low cell performance (cell V OC is much less than the implied V OC = 686 mV, anticipated from surface passivation) was identified due to degradation of S-passivation during the metal firing step (out-diffusion of S from the Si interface to the SiNx surface). The S-passivation of Si surfaces shows significant promise with excellent passivation quality, essential for high performance (high V OC , high efficiency) solar cells. Integration of this innovative defect passivation into devices, however, demands further development of the capping layer, low temperature (<700°C) metallization process, and/or engineering of advanced device structures. Surface passivation-dominated advanced Si solar cells, such as tunnel oxide passivated contacts and Si heterojunctions, are increasingly of interest due to their high-performance potential and will have a growing photovoltaic market share in the near future.

14 SOLAR ENERGY↗

DOE OSTI2022

Dynamic Frequency Regulation Improvement in Hydropower-Hybrid System using Variational Mode Decomposition

Providing frequency response, especially fast frequency response such as Red D in the Pennsylvania-New Jersey-Maryland Interconnection (PJM) market, is challenging for many generation plants to deliver on their own. If they have adequate flexibility, hydropower plants are typically able to provide slower regulation support (e.g., Reg A in PJM), but do not respond fast enough to provide Reg D. The ability to provide Reg D would improve their revenue because this service is typically more valuable. This work presents a control approach to use hydropower, battery, and ultracapacitor systems to provide fast regulation in a way that uses the response contribution of each asset. In particular, the proposed control architecture applies a variational mode decomposition (VMD) technique on the incoming Reg D signal to extract multiple dynamic-regulation components with non-overlapping frequencies. With the response-speed dependent alignment, these regulation components are fed to the hydrogenator and hybrid energy storage system (HESS). The paper evaluates the proposed approach on a direct-current (DC)-coupled active system by computing several performance measures and analyzing sensitivity based on HESS component proportional capacities. The results reveal that the proposed VMD-based signal conditioning performs well and that optimizing the sizing of the battery and ultracapacitor components further enhances performance.

13 HYDRO ENERGY↗

DOE OSTI2020

An experimental and kinetic modeling study of cyclopentane and dimethyl ether blends

Cyclopentane is a suitable naphthene, or cycloalkane, in a palette for multi-component gasoline surrogate fuels due to its presence in market fuels and its relevance to alkyl substituted cyclopentanes also present. However, the previous oxidation studies of cyclopentane have primarily focused on neat mixtures. Blending cyclopentane with dimethyl ether in this work therefore serves to inform our understanding of, and improve predictive models for, multi-component mixtures. Here, the auto-ignition of cyclopentane/dimethyl ether blends was studied in a high-pressure shock tube and in a rapid compression machine. A wide range of temperatures (650 – 1350 K) and elevated pressures of 20 and 40 bar were studied at equivalence ratios of 0.5, 1.0 and 2.0 in air for two blending ratios (30/70 and 70/30 mole% cyclopentane/di-methyl ether mixtures). A detailed kinetic model for cyclopentane was revised to capture the measured ignition delay times and apparent heat release rates in this study. Literature ignition delay time, jet-stirred reactor, and laminar burning velocity measurements of neat cyclopentane were used as additional validation. Improvements to the kinetic model were based on recent literature studies related to sub-models including cyclopentene and cyclopentadiene which allowed the removal of previous local rate-constant optimizations. Low temperature reactivity of cyclopentane was found to be controlled by the branching ratio between concerted elimination of HO͘ 2 and the strained formation of Q&#775OOH radicals in agreement with previous studies. In this study, the low branching ratio of Q&#775OOH formation increases the influence of a competing consumption pathway for cyclopentyl-peroxy (CPTO͘ 2 J) radicals. The sensitivity of the simulated ignition delay times to the formation of cyclopentyl hydroperoxide (CPTO 2 H), from CPTO͘ 2 J and HO͘ 2 , is discussed. The current model is used to analyze the influence of dimethyl ether on the reactivity of cyclopentane in the context of previous literature studies of dimethyl ether binary blends with ethanol and toluene.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2023

Multiscale Porous High-temperature Heat Exchanger Using Ceramic Co-extrusion

In this project, our MIT, Purdue, and GE team aims to design, model, fabricate, and test a novel high temperature, compact, and durable ceramic heat exchanger to be operated under high temperature and pressure conditions for aerospace applications. Our approach is grounded in introducing multiscale porosity, i.e., centimeter-scale channels embedded with micrometer-scale channels, into the ceramic heat exchanger to significantly improve its heat transfer performance and mechanical strength while maintaining minimal pressure losses. We first developed high-fidelity thermal-fluid-mechanical model capable of precisely capturing the heat transfer rate, temperature profile, pressure drop, and mechanical stress throughout the entire heat exchanger design. Guided by our model, we identified the optimal design parameters for the SiC heat exchanger body and manifolds. Then, we established a completed fabrication procedure to create multiscale features in the ceramic heat exchanger, including co-extrusion, lamination, burnout, and sintering. We fabricated multiple heat exchanger bodies consisting of 6 × 6 and 3 × 3 centimeter-scale channels where each individual centimeter-scale channel comprises 625 crack-free microchannels with 90 μm × 90 μm opening. Owing to the multiscale features, our fabricated heat exchanger bodies exhibited desirable mechanical strength with 156 MPa flexural strength under 1300 Celsius degree. Despite the demonstrated highly tailorable microscopic features and superior mechanical strength, we identified delamination due to the complex interaction among ceramic, polymer, and gas species can be a critical challenge to create fully defect-free heat exchanger, which requires further fundamental investigations in future works. To test the heat exchanger performance, we constructed a high-temperature and high-pressure experimental apparatus that can be safely operated under 400 Celsius degree and 4 bar. With insights gained from mechanistic modeling, material development, and detailed characterization, a cost model was finally developed to understand the market potential of the developed technology, where a cost of $43,000 Celsius degree/kW was envisioned. This project developed a transformative approach to high-performance heat exchanger design. The thermal-fluid-mechanical design approach developed in this project can serve as a generic tool to guide the design of various heat-exchangers operated under high-temperature and high-pressure conditions. The material fabrication approach established in this project can be a useful guide for ceramic processing at extreme length scales.

42 ENGINEERING↗

DOE OSTI2024

Assessment of Technoeconomic Opportunities in Automation for Nuclear Microreactors

Achieving full decarbonization of all economic sectors remains a challenge, especially in niche markets. For example, remote communities and industrial or mining activities detached from the main electric grid heavily rely on fossil fuels, similar to urban and industrial microgrids with combined heat and power needs. A combination of renewables and energy storage is often not suitable due to cost, reliability, intermittency, and large storage requirements. Small nuclear reactors with a flexible purpose could serve these applications. Microreactors (MR) are a class of reactors that are compact, factory manufactured, transportable, and self-regulating. Typically, they generate much less power than their large reactor counterparts. The main advantages of microreactors include the versatile nature of the energy produced, the reliability of supply, and freedom from having to transport and store large quantities of fuels on-site, coupled with the absence of dependence on an electrical grid. A strong business case is needed to move from the microreactor prototype to the commercialization phase. In fact, fossil fuels are still relatively inexpensive, and in the near term, carbon credits will be available to virtually compensate for emissions. For microreactors, one of the main costs in operation and maintenance (O&M) is their staffing levels. In this study, we investigate how to optimize the number (and thus the cost) of workers, moving from a traditional, fully manned, on-site personnel approach to an unmanned, remote personnel approach. We examine four different staffing models that can be implemented as the technology matures and evolves. We estimate the staffing needs of each model and build a business case to justify the substitution of on-site personnel with adequate technologies. To do so, we propose a cost model to quantify potential cost reductions from automating O&M activities. The model accounts for both the reduction in cost derived from the reduced number of full-time-equivalent (FTE) employees and the increase in cost derived from the need to buy new control hardware as needed. Applying the cost model that we created to different scenarios, an on-site O&M cost reduction exceeding 80% can be expected. Additionally, we found that it is more impactful to focus on automating routine O&M tasks rather than attempting to automate transient management (shutdowns, restarts, monitoring condition deviations). In fact, transients typically account for less than 1% of the total FTE time spent on the reactors.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2023

Development of a Heavy-Duty Electric Vehicle Integration and Implementation (HEVII) Tool

As demand for consumer electric vehicles (EVs) has drastically increased in recent years, manufacturers have been working to bring heavy-duty EVs to market to compete with Class 6-8 diesel-powered trucks. Many high-profile companies have committed to begin electrifying their fleet operations, but have yet to implement EVs at scale due to their limited range, long charging times, sparse charging infrastructure, and lack of data from in-use operation. Thus far, EVs have been disproportionately implemented by larger fleets with more resources. To aid fleet operators, it is imperative to develop tools to evaluate the electrification potential of heavy-duty fleets. However, commercially available tools, designed mostly for light-duty vehicles, are inadequate for making electrification recommendations tailored to a fleet of heavy-duty vehicles. The main challenge is that light-duty tools do not estimate real-time vehicle mass, a factor that has a disproportionate impact on the energy consumption of large commercial vehicles. The Heavy-Duty Electric Vehicle Integration and Implementation (HEVII) tool advances the state of the art in evaluating electrification potential and infrastructure requirements for fleets of commercial vehicles. In this work, the HEVII tool is demonstrated with non-uniformly sampled telematics data from an existing fleet to assess the suitability for electrification of each individual vehicle, determine optimal locations for charging infrastructure to support a fleet of EVs and analyze associated costs. Payload mass is predicted using sparse ground-truth data for all input drive cycles and an initial data analysis is conducted to assess the characteristics driving behaviors and energy consumption of the fleet using an adaptable vehicle model. Battery size requirements are determined by applying a novel charger placement algorithm to maximize routes that are viable for EVs and balance time delays with infrastructure development costs. This work details and demonstrates the different aspects of the HEVII tool, presenting preliminary results from an example use case.

ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2022

Minimizing Fraud in the Carbon Offset Market Using Blockchain Technologies

Fraud in the Environmental Benefit Credit (EBC) markets is pervasive. To make matters worse, the cost of creating EBCs is often higher than the market price. Consequently, a method to create, validate, and verify EBCs and their relevance is needed to mitigate fraud. The EBC market has focused on geologic (fossil fuel) CO 2 sequestration projects that are often over budget and behind schedule and has failed to capture the "lowest hanging fruit" EBCs - terrestrial sequestration via the agricultural industry. This project reviews a methodology to attain possibly the least costly EBCs by tracking the reduction of inputs required to grow crops. The use of bio- stimulant products, such as humate, allows a farmer to use less nitrogen without adversely affecting crop yield. Using less nitrogen qualifies for EBCs by reducing nitrous oxide emissions and nitrate runoff from a farmer's field. A blockchain that tracks the bio-stimulant material from source to application provides a link between a tangible (bio-stimulant commodity) and the associated intangible (EBCs) assets. Covert insertion of taggants in the bio-stimulant products creates a unique barcode that allows a product to be digitally tracked from beginning to end. This process (blockchain technology) is so robust, logical, and transparent that it will enhance the value of the associated EBCs by mitigating fraud. It provides a real time method for monetizing the benefits of the material. Substantial amounts of energy are required to produce, transport, and distribute agricultural inputs including fertilizer and water. Intelligent optimization of the use of agricultural inputs can drive meaningful cost savings. Tagging and verification of product application provides a valuable understanding of the dynamics in the water/food energy nexus, a major food security and sustainability issue. As technology in agriculture evolves so to must methods to verify the Enterprise Resource Planning (ERP) potential of innovative solutions. The technology reviewed provides the ability to combine blockchain and taggants ("taggant blockchains") as the engine by which to (1) mitigate fraudulent carbon credits; (2) improve food chain security, and (3) monitor and manage sustainability. The verification of product quality and application is a requirement to validate benefits. Recent upgrades to humic and fulvic quality protocols known as ISO CD 19822 TC134 offers an analytical procedure. This work has been assisted by the Humic Products Trade Association and International Humic Substance Society. In addition, providing proof of application of these products and verification of the correct application of prescriptive humic and bio-stimulant products is required. Individual sources of humate have unique and verifiable characteristics. Additionally, methods for prescription of site- specific agricultural inputs in agricultural fields are available. (See US Patents 734867B2, US 90658633B2.) Finally, a method to assure application rate is required through the use of taggants. Sensors using organic solid to liquid phase change nanoparticles of various types and melting temperatures added to the naturally occurring materials provide a barcode. Over 100 types of nanoparticles exist ensuring numerous possible barcodes to reduce industry fraud. Taggant materials can be collected from soil samples of plant material to validate a blockchain of humic, fulvic and other soil amendment products. Other non-organic materials are also available as taggants; however, the organic tags are biodegradable and safe in the environment allowing for use during differing application timeliness.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2022

Reliability and Integrity Management Program Implementation Approach

Nuclear energy is the most reliable and environmentally sustainable energy source available today. In the United States, nuclear-generated power accounts for approximately 20% of total electricity and over 55% of clean energy. New advanced reactors have enormous potential to help further decarbonize the energy market, enhance grid resiliency, create new jobs, and build a stronger economy. More than 50 new reactors are being developed in the United States, and the federal government realizes an urgent need to deploy nuclear technologies to meet the country’s energy, environmental, and national security goals. As such, the U.S. Department of Energy launched multiple programs to support advanced reactor deployment. The research described in this paper explores implementation strategies for the Reliability and Integrity Management Program that directly supports the U.S. Department of Energy goal to enable the near-term deployment of the advanced reactor technologies. The project is conducted under the Regulatory Development Program for advanced reactors sponsored by the U.S. Department of Energy.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2022

Pathway to Zero Energy Windows: Advancing Technologies and Market Adoption

As of 2021, buildings account for 39.1% of total U.S. primary energy use and 75% of total U.S. electricity use. Much of this energy is used to maintain a comfortable indoor environment. The building envelope consists of transparent and opaque elements that serve as a controllable barrier to help maintain the indoor environment regardless of external conditions. The envelope also allows the exchange of light and air, as well as other transfers with the external environment when it is beneficial for the building occupants. By leveraging desirable external environmental conditions (e.g., fresh air and natural light) and mitigating the influence of undesirable conditions (e.g., moisture, hot or cold temperatures, wind), the building envelope can reduce the need for space conditioning and electric light, and thus reduce energy use associated with lighting and heating, cooling, and ventilation equipment. In turn, high-performance building envelopes can reduce the substantial CO 2 emissions associated with energy use to satisfy heating, cooling, and lighting needs in buildings. The U.S. Department of Energy (DOE) Building Technologies Office's (BTO's) Emerging Technologies program supports R&D for technologies, systems, and software tools that can contribute to reductions in building energy use. Emerging Technologies funding is distributed competitively through solicitations (e.g., Funding Opportunity Announcements and National Lab Calls, which in general are open to applications from industry, academia, national laboratories, and other entities) and other mechanisms. This document focuses on R&D for windows and window system technologies and will provide guidance for BTO's investments in developing the next generation of high-performance, affordable, cost competitive windows, as well as integrated daylighting and shading technologies in partnership with industry and researchers. This document also addresses areas where DOE invests in software and design tools that translate sophisticated and complex physics into easy-to-use energy performance and optimization methods used by industry and other stakeholders for implementation.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2026

Biomanufacturing and Scale-Up: Pathways to Biochemicals, Biofuels, and Biomaterials

Advancing the bioeconomy requires the development of large-scale microbial bioprocesses capable of converting waste carbon streams into biofuels, biochemicals, and biomaterials at industrially relevant scales. While biomanufacturing has been successfully demonstrated at the laboratory scale for a wide range of chemicals, only a few have reached industrial-scale production. This is partly due to the inherent complexity of microbial systems, which rely on living cells with intricate metabolic pathways that are highly sensitive to environmental changes, making large-scale production difficult to optimize and predict. As a result, scaling-up bioprocesses remains a high-stakes challenge that requires deeper exploration. This involves integrating feedstock and microbial selection, upstream and downstream processes, and computational modelling, among other research efforts. Bulk and specialty chemicals derived from biological processes also face competition from fossil-based production routes, which have been refined through decades of technological advancements. While biologically derived molecules may offer more environmentally friendly production pathways than traditional chemical manufacturing, their widespread adoption depends on achieving cost parity-or superiority-relative to fossil-based methods. This emphasizes the importance of holistic research, including techno-economic analyses and life cycle assessments, to ensure both economic viability and environmental sustainability. This editorial and special issue explores state-of-the-art strategies for converting waste carbon sources into valuable products. It discusses how enzymes, single microbes (e.g., extremophiles), and microbiomes (e.g., through division of labor) can be integrated with upstream and downstream process innovations-such as consolidated bioprocessing and in situ product recovery-to improve the efficiency and scalability of biomanufacturing. The editorial further highlights the role of computational modelling in understanding, predicting, and controlling bioprocess performance across scales, and concludes by emphasizing the importance of techno-economic modelling to identify technologies that can move to market.

09 BIOMASS FUELS↗

DOE OSTI2020

Integrated Risk-Informed Condition Based Maintenance Capability and Automated Platform: Technical Report 1

Due to continuing global energy market trends, driven heavily by the abundant preserves of natural gas, there is an immediate need to reduce costs associated with operation and maintenance (O&M) for the current domestic nuclear power industry and for future reactor developments. This is to ensure that nuclear power generation remains an economically competitive and viable option in the energy market. O&M costs include labor-intensive preventive maintenance (PM) programs, which involve manually-performed inspection, calibration, testing, and maintenance of plant assets at periodic frequency and time-based replacement of assets, irrespective of their condition. This has resulted in an expensive, labor-centric business model to achieve high capacity factors. Fortunately, there are technologies (advanced sensors, data analytics, and risk assessment methodologies) that can enable the transition from a labor-centric business model to a technology-centric business model. The technology-centric business model will result in a significant reduction of PM activities, laying the foundation for real-time condition assessment of plant assets, reducing overall labor and part costs. To enable this transition, PKMJ Technical Services LLC is partnering with the U.S. Department of Energy’s Idaho National Laboratory (operated by the Battelle Energy Alliance, LLC) and the Public Services Enterprise Group (PSEG) Nuclear, LLC in the Integrated Risk-Informed Condition-Based Maintenance Capability and Automated Platform Project. In this report, the configuration of a digital cloud platform using Microsoft Azure is discussed, data from the PSEG Salem Nuclear Generating Station Units 1 & 2 are imported into a digital cloud platform, and the data is used for an evaluation of several key areas: cost impact analysis, risk-informed model development, and preventive maintenance strategy optimization. First, the cost impact analysis reviews which plant assets are potential good candidates for condition-based monitoring. Next, INL utilized the data in their local environment to develop the risk-informed model; which provides estimates of failure rates and probability of failures of assets based upon their past performance. The developed model is performed on assets selected from the cost impact analysis. Lastly, engineers assess the preventive maintenance strategy for the selected assets at PSEG against maintenance strategies in the nuclear industry for similar assets to potentially identify acceptable justification for the extension of current maintenance frequencies.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2024

A Multidisciplinary Approach to Integrated Energy Systems: Advanced Nuclear Plants with Thermal Storage for Dynamic and Flexible Operation in Diverse Markets

Energy supply, distribution, and demand are continuously evolving in accordance with the integration of new power generation sources. In the United States, there is a progressive shift toward incorporating fluctuating energy sources such as wind and solar into the energy mix, alongside the distributed generation. Simultaneously, we are seeing a revolution in consumer technologies such as electric vehicles, energy devices for both residential and commercial use, and industrial processes—all contributing to a fundamental change in energy consumption dynamics. These scenarios have led to huge demand for enhanced flexibility from nuclear power plants (NPPs), requiring them to operate with unprecedented adaptability. Furthermore, advanced NPPs (A-NPPs) could potentially apply to scenarios in which power generation flexibility is prioritized over its current and conventional baseload generation capacity for traditional demand patterns. The present work covers several configurations for coupling nuclear energy production with thermal energy storage (TES). Previous work evaluated systems entailing a simple nuclear-TES configuration that used steam as a heat source for the TES of three different advanced reactors (ARs), but its heat diversion ratio (HDR) for charging was limited. The present work proposes a new configuration that features full decoupling of the nuclear reactor and the power cycle, using reactor coolant (i.e., gas) as a heat source for the TES and offering a theoretically unlimited HDR. This configuration is, however, more complex, as both high- and low-temperature TES (HT-TES and LT-TES) systems are required in order to cover the extended temperature range. Although this configuration imposes certain limitations on the discharge system configuration, it also presents the opportunity to design a more efficient system. For this case in particular, a steam reheat cycle is advantageous. Conventional TES systems take advantage of nominal efficiency when discharging, whereas the reheat cycle in the fully decoupled TES system affords a significant efficiency increase over conventional cases. Material selection, component/equipment sizing, and costing analyses were performed, followed by economic dispatch and size optimization. Dynamic models were developed for the decoupled system in order to generate insights into aspects of off design operation (e.g., drops in cycle efficiency), and these models enable exploration of potential mitigation strategies for addressing such drops. The models also highlight the need to design fail-safes that ensure continuous operational stability and minimize the impact of power ramping on the reactor parameters.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗