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DOE OSTI2015

Jumpstarting commercial-scale CO 2 capture and storage with ethylene production and enhanced oil recovery in the US Gulf

CO 2 capture, utilization, and storage (CCUS) technology has yet to be widely deployed at a commercial scale despite multiple high-profile demonstration projects. We suggest that developing a large-scale, visible, and financially viable CCUS network could potentially overcome many barriers to deployment and jumpstart commercial-scale CCUS. To date, substantial effort has focused on technology development to reduce the costs of CO 2 capture from coal-fired power plants. Here, we propose that near-term investment could focus on implementing CO 2 capture on facilities that produce high-value chemicals/products. These facilities can absorb the expected impact of the marginal increase in the cost of production on the price of their product, due to the addition of CO 2 capture, more than coal-fired power plants. A financially viable demonstration of a large-scale CCUS network requires offsetting the costs of CO 2 capture by using the CO 2 as an input to the production of market-viable products. As a result, we demonstrate this alternative development path with the example of an integrated CCUS system where CO 2 is captured from ethylene producers and used for enhanced oil recovery in the U.S. Gulf Coast region.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2021

Acoustic Exposure to Turbine Operation Quantifies Risk to Bats at Commercial Wind Energy Facilities

ABSTRACT Turbine‐related bat mortality at commercial wind energy facilities may threaten populations of migratory tree‐roosting bat species in North America. Industry stakeholders and regulatory agencies alike are investigating strategies to reduce risk of population‐level consequences as the wind energy industry grows. Bats collide with turbines only when turbine rotors are spinning and curtailing turbine operation at low wind speeds can effectively reduce bat fatality rates. Nonetheless, few quantitative data exist to determine appropriate threshold wind speeds below which turbine operations should be curtailed. Carcass monitoring is labor‐intensive and does not provide information on factors linked to bat fatality rates on any scale finer than nightly. We tested whether acoustic bat data recorded at turbine nacelles could provide a more precise and sensitive measure of fatality risk to bats by analyzing acoustics, weather, turbine operation, and carcass data collected at 2 commercial wind energy facilities in West Virginia over 7 years. Each wind facility implemented several distinct curtailment treatments during our study, allowing us to compare fatality rates and acoustic bat activity across multiple operational strategies. We found that bat passes exposed to turbine operation explained close to 80% of the variation in carcass‐based estimates of bat fatality rates and accounted for significant variation in raw carcass counts per turbine and probability of finding bat carcasses during individual turbine searches. Conversely, bat activity occurring when turbines were not operating had little or no relationship to fatality rates. We also found that patterns in bat activity exposure could be predicted accurately among turbines and years. Our results demonstrate that measuring exposure of acoustic bat activity provides a quantitative basis for designing, evaluating, and adaptively managing curtailment strategies. This is an important advance towards using curtailment to reduce bat fatality rates strategically while allowing for increased generation of renewable energy. © 2021 The Authors. Wildlife Society Bulletin published by Wiley Periodicals LLC on behalf of The Wildlife Society.

17 WIND ENERGY↗

DOE OSTI2017

Accident tolerant FeCrAl fuel cladding: current status towards commercialization

FeCrAl alloys are rapidly becoming a mature concept for accident tolerant fuel applications. The FeCrAl material class has shown excellent oxidation resistance in high-temperature steam environments, a key aspect of any accident tolerant cladding concept, while also being corrosion resistant, stress corrosion cracking (SCC) resistant, irradiation-induced swelling resistant, weldable, and formable. Current research efforts are focused on design, development and commercial scaling of advanced FeCrAl alloys including large-scale thin-walled seamless tube production followed by a broad spectrum of degradation evaluations in both normal and off-normal conditions. Included in this discussion will be theoretical analysis of the alloying principles and rules, alloy composition design, and overview of the most recent empirical database on possible degradation phenomena for FeCrAl alloys. The results are derived from extensive in-pile and out-of-pile experiments and form the basis for near-term deployment of a lead-test rod and/or assembly within a commercially operating nuclear power plant.

Field, Kevin G.↗

DOE OSTI2018

Commercialization of Micro-fabrication of Antenna-Coupled Transition Edge Sensor Bolometer Detectors for Studies of the Cosmic Microwave Background

In this work, we report on the development of commercially fabricated multichroic antenna-coupled transition edge sensor (TES) bolometer arrays for cosmic microwave background (CMB) polarimetry experiments. CMB polarimetry experiments have deployed instruments in stages. Additionally, stage II experiments deployed with O(1000) detectors and reported successful detection of B-mode (divergence-free) polarization pattern in the CMB. Stage III experiments have recently started observing with O(10,000) detectors with wider frequency coverage. A concept for a stage IV experiment, CMB-S4, is emerging to make a definitive measurement of CMB polarization from the ground with O(400,000) detectors. The orders of magnitude increase in detector count for CMB-S4 require a new approach in detector fabrication to increase fabrication throughput and reduce the cost. We report on collaborative efforts with two commercial micro-fabrication foundries to fabricate antenna-coupled TES bolometer detectors. The detector design is based on the sinuous antenna-coupled dichroic detector from the POLARBEAR-2 experiment. The TES bolometers showed the expected I–V response, and the RF performance agrees with the simulation. We will discuss the motivation, design consideration, fabrication processes, test results, and how industrial detector fabrication could be a path to fabricate hundreds of detector wafers for future CMB polarimetry experiments.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2020

Commercially Fabricated Antenna-Coupled Transition Edge Sensor Bolometer Detectors for Next-Generation Cosmic Microwave Background Polarimetry Experiment

We report on the development of commercially fabricated multi-chronic antenna-coupled transition edge sensor (TES) bolometer arrays for cosmic microwave background (CMB) polarimetry experiments. The orders of magnitude increase in detector count for next-generation CMB experiments require a new approach in detector wafer production to increase fabrication throughput. Here, we describe collaborative efforts with a commercial superconductor electronics fabrication facility (SeeQC, Inc.) to fabricate antenna-coupled TES bolometer detectors. We have successfully fabricated an operational dual-polarization, dichroic sinuous antenna-coupled TES detector array on a 150-mm-diameter wafer. The fabricated detector arrays have average yield of 95% and excellent uniformity across the wafer. Both RF characteristics and TES bolometer properties are suitable for CMB observations. We successfully fabricated different types of TES bolometers optimized for frequency multiplexing readout, time-domain multiplexing readout, and microwave SQUID multiplexing readout. We also demonstrated high production throughput. We discuss the motivation, design considerations, fabrication processes, test results, and how industrial detector fabrication could be a path to fabricate hundreds of detector wafers for future CMB polarimetry experiments.

47 OTHER INSTRUMENTATION↗

DOE OSTI2015

A performance comparison of commercially available strontium extraction chromatography columns

Extraction chromatographic separations following a nuclear event will require both speed and accuracy. Ideally these separations will be carried out using commercially available products. Because 90Sr is a likely material to be used in a radioactivity dispersal device, commercially available products for the separation of strontium were tested to evaluate differences in their elution profiles that may affect elution procedures. Gravity flow columns show better resolution, but vacuum flow columns allow rapid processing and are still adequate for purification if multiple aqueous conditions can be employed in the elution strategy.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗

DOE OSTI2013

Current Understanding of Cu-Exchanged Chabazite Molecular Sieves for Use as Commercial Diesel Engine DeNOx Catalysts

Selective catalytic reduction (SCR) of NOx with ammonia using metal-exchanged molecular sieves with a chabazite (CHA) structure has recently been commercialized on diesel vehicles. One of the commercialized catalysts, i.e., Cu-SSZ-13, has received much attention for both practical and fundamental studies. For the latter, the particularly well-defined structure of this zeolite is allowing long-standing issues of the catalytically active site for SCR in metal-exchanged zeolites to be addressed. In this review, recent progress is summarized with a focus on two areas. First, the technical significance of Cu-SSZ-13 as compared to other Cu-ion exchanged zeolites (e.g., Cu-ZSM-5 and Cu-beta) is highlighted. Specifically, the much enhanced hydrothermal stability for Cu-SSZ-13 compared to other zeolite catalysts is addressed via performance measurements and catalyst characterization using several techniques. The enhanced stability of Cu-SSZ-13 is rationalized in terms of the unique small pore structure of this zeolite catalyst. Second, the fundamentals of the catalytically active center; i.e., the chemical nature and locations within the SSZ-13 framework are presented with an emphasis on understanding structure-function relationships. For the SCR reaction, traditional kinetic studies are complicated by intra-particle diffusion limitations. However, a major side reaction, nonselective ammonia oxidation by oxygen, does not suffer from mass-transfer limitations at relatively low temperatures due to significantly lower reaction rates. This allows structure-function relationships that are rather well understood in terms of Cu ion locations and redox properties. Finally, some aspects of the SCR reaction mechanism are addressed on the basis of in-situ spectroscopic studies.

chabazite zeolite catalyst↗

DOE OSTI2018

Mechanical Behavior of Commercially Pure Titanium Weldments at Lower Temperatures

Commercially pure titanium is used for low-temperature applications due to good toughness attributed to single-phase microstructure (α). Electron beam welding (EBW) and gas tungsten arc welding (GTAW) processes have been used for welding two grades of commercially pure titanium (Grade 2 and Grade 4). Martensitic microstructure is found to be finer in the case of EBW joint as compared to GTAW joint due to faster rate of cooling in the former process. Weldments have been characterized to study the mechanical behavior at ambient (298 K) and cryogenic temperatures (20 and 77 K). Strength of weldments increases with the decrease in temperature, which is found to be more prominent in case of Grade 4 titanium as compared to Grade 2. Weld efficiency of Grade 4 is found to be higher at all the temperatures (ambient, 77 and 20 K). However, ultimate tensile strength/yield strength ratio is higher for Grade 2 as compared to Grade 4. % Elongation is found to increase/retained at cryogenic temperatures for Grade 2, and it is found to decrease for Grade 4. Electron backscattered diffraction analysis and transmission electron microscopy of deformed samples confirmed the presence of extensive twinning in Grade 2 and the presence of finer martensitic structure in Grade 4. Fractography analysis of tested specimens revealed the presence of cleavage facets in Grade 4 and dimples in specimens of Grade 2. Higher strength in Grade 4 is attributed to higher oxygen restricting the twin-assisted slip, which is otherwise prominent in Grade 2 titanium.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Low-Pressure Diffusion Bonding of Vanadium to Commercially Pure Titanium and Ti-6Al-4V

Modern technology increasingly requires components to be made from specific high-performance materials. To support complex multi-metal structures, a variety of techniques are required to join dissimilar metal parts with precise shapes. This study evaluates vacuum diffusion bonding as a method for joining titanium and vanadium, focusing on both pure titanium and the common alloy Ti-6Al-4V. We employ modest pressure provided by a weight and simple surface preparation to simulate the most commercially applicable process. Here, we show that Ti-6Al-4V alloy bonds readily to V, forming a continuous, clearly defined interdiffusion layer with predictable kinetics. Conversely, commercially pure Ti forms a crack-prone bond with V that fails to improve at higher bonding temperatures or longer times. We attribute this failure to the concentration of stress caused by the ß-to-α phase transformation in Ti. The contrasting bonding efficacy between pure Ti and the alloy provides insight into the crystallographic interactions that occur at the interface during bonding and cooling. These results provide surprising insight into a new method for bonding Ti alloys to V and possibly other metals that share the body-centered cubic crystal structure.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Impact of Parcel Size, Field Shape, Crop Yield, Storage Location, and Collection Equipment on the Performance of Single-Pass Cut-and-Chip Harvest System in Commercial Shrub Willow Fields

In this paper, an integrated system of harvesting, collecting, and transporting willow biomass crop to a storage site was modeled and evaluated using the IBSAL simulation model. A scenario analysis was used to quantify the impacts of five major input parameters on the performance of the integrated system. These parameters include parcel size, field shape, willow yield, distance to the storage site, and type of the collection equipment. Multiple performance indicators were identified to quantify the impacts on the system such as size of the equipment fleet, effective material and field capacity of the harvester, operating costs, and waiting times. The input data were collected from 36 commercial, short-rotation, shrub willow fields in northern New York State. The simulation results indicated that crop yield and type of collection equipment have the highest impact on operating costs and the equipment fleet size. As the size of equipment fleet increases in the system, variability in the system performance tends to increase. Field shape has the least impact on the overall system performance compared to the other four input parameters. The simulation results suggest that a combination of performance indicators need to be considered to evaluate the overall performance of the dynamic and complex system of harvesting, collection and transportation in commercial willow fields. The developed IBSAL model and scenario analysis approach can assist in planning this system based on the characteristics of field, crop, and logistical equipment to reach a high system performance.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2025

Effect of CO on alcohol oxidation over commercial oxidation catalysts for control of emissions from lean-burn engines

For commercialization, alcohol-based net-zero carbon fuels in diesel-driven internal combustion engines must meet emissions standards set by the U.S. Environmental Protection Agency. Here, a series of aged commercial oxidation catalysts, Pt diesel oxidation catalyst (DOC), Pd+Pt DOC, and Pt oxidation catalyst (Pt OC), were studied using an automated flow reactor and in situ DRIFTS techniques to investigate the impact of CO on alcohol oxidation. Surface formate and acetate intermediates were formed due to partial oxidation of methanol and ethanol, respectively. Sequential introduction of alcohol and CO experiments using in situ DRIFTS on all three catalysts showed that CO inhibited low temperature methanol oxidation. Mutual inhibition effects between CO and ethanol were observed during co-oxidation. Acetate species shifted CO oxidation to higher temperatures on Pt DOC and Pt OC, whereas CO pre-exposure inhibited acetate formation. CO oxidation occurred at lower temperatures during ethanol and CO co-oxidation on Pd+Pt DOC.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2017

Electric load shape benchmarking for small- and medium-sized commercial buildings

Small- and medium-sized commercial buildings owners and utility managers often look for opportunities for energy cost savings through energy efficiency and energy waste minimization. However, they currently lack easy access to low-cost tools that help interpret the massive amount of data needed to improve understanding of their energy use behaviors. Benchmarking is one of the techniques used in energy audits to identify which buildings are priorities for an energy analysis. Traditional energy performance indicators, such as the energy use intensity (annual energy per unit of floor area), consider only the total annual energy consumption, lacking consideration of the fluctuation of energy use behavior over time, which reveals the time of use information and represents distinct energy use behaviors during different time spans. To fill the gap, this study developed a general statistical method using 24-hour electric load shape benchmarking to compare a building or business/tenant space against peers. Specifically, the study developed new forms of benchmarking metrics and data analysis methods to infer the energy performance of a building based on its load shape. We first performed a data experiment with collected smart meter data using over 2,000 small- and medium-sized businesses in California. We then conducted a cluster analysis of the source data, and determined and interpreted the load shape features and parameters with peer group analysis. Finally, we implemented the load shape benchmarking feature in an open-access web-based toolkit (the Commercial Building Energy Saver) to provide straightforward and practical recommendations to users. The analysis techniques were generic and flexible for future datasets of other building types and in other utility territories.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2019

Reactivity of novel high-performance fuels on commercial three-way catalysts for control of emissions from spark-ignition engines

The Department of Energy “Co-Optimization of Fuels and Engines” initiative aims to simultaneously develop novel high-performance fuels with advanced engine designs to reduce petroleum consumption. To achieve commercialization, advanced engines running on alternative fuels still must meet emissions regulations. Warm three-way catalysts (TWC) are very effective at meeting the stringent emissions regulations on pollutants such as nitrogen oxides (NOx), non-methane organic gases (NMOG) and carbon monoxide (CO) from gasoline-fueled spark-ignition (SI) engines operating under stoichiometric conditions; thus, most SI engine emissions occur during cold-start, when the TWC has not yet achieved light-off. In the current study, the light-off behavior of novel high-performance fuel candidates has been investigated on a hydrothermally-aged commercial TWC using a synthetic engine-exhaust flow reactor system according to industry guidelines. Over 30 potential fuel components were examined in this study, including alkanes, alkenes, alcohols, ketones, esters, aromatic ethers, and non-oxygenated aromatic hydrocarbons. Short-chain acyclic oxygenates, including alcohols, ketones, and esters, tended to light off at relatively low temperatures, while alkenes, aromatics, and cyclic oxygenates tended to light off at relatively high temperatures. The light-off behavior of alkanes and alkenes depended strongly on their size and structure. In terms of the influence on CO light-off on the TWC, the fuels fell into two distinct categories: (i) non-inhibiting species including C 2 -C 3 alcohols, alkanes, acyclic ketones, and esters; and (ii) inhibiting species including alkenes, aromatic hydrocarbons, cyclic oxygenates, and C 4 alcohols.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2020

Data-driven evaluation of HVAC operation and savings in commercial buildings

Commercial buildings consumed 36% of electricity, or 1.35 trillion kWh, in the United States in 2017, and almost 30% of this energy was wasted. Much of this loss can be attributed to inefficient heating ventilation and air conditioning (HVAC) systems. By improving the operational conditions of HVAC, significant savings can be achieved. However, most buildings and building equipment do not use costly sub-meters to monitor and address performance issues, and on-site auditing can be expensive and insufficient. Alternatively in this study, we propose a data-driven method to identify savings opportunities using only whole building meter data and without setting foot in the building. For this purpose, we introduced two algorithms that virtually quantify the value of a thermostat setpoint setback and HVAC rescheduling. Additionally, we developed novel methods for detecting occupancy patterns and quantifying the baseload of the HVAC operation. Using a clustering algorithm, we identified those buildings for which HVAC savings was significant and further categorized the buildings based on their potential for savings. A population study of over 432 commercial buildings demonstrated a median percentage energy savings of 1.6% from a baseload reduction and 2.1% from HVAC rescheduling. Additionally, results indicate that retail buildings have the highest potential for savings among the building types studied.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2021

An assessment of the harvesting and fuel performance of a single-pass cut-and-chip harvester in commercial-scale short-rotation poplar crops as influenced by crop and weather conditions

There is a need for data on commercial-scale harvesting operations in hybrid poplar short rotation crops to better understand costs and logistics, especially for modeling large scale biorefineries. An investigation was conducted on the in-field performance of a single-pass cut-and-chip harvester operating in commercial fields for over 370 individual wagon loads representing a range of crop and field conditions. Mean material capacity peaked at 70 Mg h -1 in dry conditions in lower biomass (<60 Mg ha -1 ), but was only 28 Mg h -1 during wet conditions and often higher standing biomass. Wet ground conditions require the harvester to divert additional power to maintaining forward movement, which results in decreased material capacity and increased fuel consumption. Crops with higher standing biomass had taller trees that do not always feed as smoothly into the harvester, slowing forward progress and lowering material capacity. Mean crop specific fuel consumption, L of fuel per Mg of biomass processed, generally decreased as standing biomass increased. When standing biomass was above 40 Mg ha -1 mean crop specific fuel consumption (FCC) was 1.69 L Mg -1 in dry conditions and 3.98 L Mg -1 in wet conditions, but when standing biomass was below 40 Mg ha-1 FCC increased drastically (as high as 5 L Mg -1 ) because the harvester is putting more effort into forward speed instead of material processing. Developing relationships between material capacity and fuel consumption based on standing biomass and ground conditions at representative scales are essential for conducting environmental and economic analyses of these systems.

09 BIOMASS FUELS↗

DOE OSTI2019

Rethinking HVAC temperature setpoints in commercial buildings: The potential for zero-cost energy savings and comfort improvement in different climates, Building and Environment

Heating, Ventilation, and Air Conditioning (HVAC) systems are responsible for a significant share of the energy consumed in commercial buildings. While energy system retrofits have been found to reduce buildings' carbon footprint substantially, these measures are often hindered by financial, regulatory or design constraints. Recent research sheds light on energy management approaches to energy conservation such as energy-efficient settings of HVAC temperature setpoints. While existing case studies confirm the significant energy saving potential of efficient HVAC operation, there is scarcity of studies quantifying energy savings from optimal HVAC temperature setpoints comprehensively, while controlling for important factors, such as guaranteeing tenant thermal comfort levels and the impact of different climate conditions on the results. In this work, we apply simulation-based multi-objective optimization to fine-tune heating and cooling setpoints of large “typical” office buildings with respect to energy consumption and occupant thermal comfort. We apply the framework in seven climate zones across the US in an effort to examine spatial variations in the energy savings potential due to different climate conditions and propose targeted energy-saving strategies and policies. We show that locations with mild climates, such as San Francisco, CA, can realize up to 60% of annual HVAC-related energy savings without compromising the occupants' thermal comfort. This untapped potential to simultaneously improve building performance and occupants’ comfort drives the discussion on revisiting HVAC setpoint configuration standards in commercial buildings, either as part of individual building retrofit planning or as part of energy policy regulations.

Papadopoulos, Sokratis↗

DOE OSTI2024

Reactivity of net-zero carbon alcohol fuels and their corresponding aldehyde intermediates on PGM-based commercial oxidation catalysts for lean-burn emissions control

Alcohol net-zero carbon fuels will play a significant role in decarbonization of the hard-to-electrify transportation sectors. However, the combustion process in alcohol-fueled engines generate toxic aldehydes. For commercialization of net-zero carbon fuels on engines, compliance with the stringent U.S. EPA regulations is necessary. Here, this contribution focuses on reactivity of alcohols and aldehydes on commercial diesel oxidation catalysts (DOC) to inform selection of future net-zero carbon fuels. Alcohol (and aldehyde) light-off temperatures were measured on aged DOCs under full synthetic engine-exhaust conditions. Methanol was the most reactive, while ethanol completely oxidized at higher temperatures. Alcohols typically formed less reactive aldehyde intermediates. DRIFTS revealed strongly adsorbing surface formates and acetates during methanol and ethanol oxidation, respectively, resulting in inhibition effects. Preliminary alcohol oxidation mechanisms combining flow reactor and DRIFTS observations are presented. Aldehydes inhibited CO oxidation. Minimal N 2 O formation was observed for the alcohols investigated.

Alcohol oxidation↗

DOE OSTI2026

Functionalized benzylamines from commercial kraft lignin

Benzylamines are key intermediates in pharmaceuticals, agrochemicals, and polymers, but their conventional production relies on benzyl chloride - a petroleum-derived compound with high toxicity and energy demands. Lignin, accounting for up to 30% of plant biomass, is the largest renewable source of aromatic carbon on Earth. However, its highly complex and recalcitrant structure poses a major barrier to efficient conversion into high-value chemicals. Here, in this study, we developed a catalytic approach to convert commercial kraft lignin into phenolic benzylamines through selective depolymerization and subsequent functionalization. We systematically evaluated the effects of three alcohol solvents, formic acid (FA), and a ruthenium-on‑carbon (Ru/C) catalyst on monophenol yield and selectivity. Up to 6.5 wt% monophenol yield was achieved using methanol (MeOH), FA, and Ru/C at 300 °C for 2 h. Quantum thermodynamic simulations based on the COSMO-RS model confirmed the superior solvation and reactivity of the MeOH + FA system, rationalizing observed product yield. The purified monophenolic products, primarily guaiacol and alkyl guaiacols, were then converted into functionalized benzylamines with >90% yield via a multicomponent Mannich reaction under mild conditions. Techno economic analysis (TEA) and life cycle assessment (LCA) underscore the importance of improving lignin depolymerization yields and expanding biorefinery scale. Solvent-only configurations outperform other options in both cost and emissions, with the methanol-only case performing the best ($\$$105 /kg and 26 kg CO 2e /kg) at a large-scale facility. This study establishes a scalable, bio-based pathway for producing benzylamines from commercial kraft lignin, advancing lignin valorization and offering a sustainable alternative to produce petrochemical-based benzylamines.

Catalytic reduction↗