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DOE OSTI2015

Smart Grid Demonstration Project (Final Report)

The National Rural Electric Cooperative Association (NRECA) organized the NRECA-U.S. Department of Energy (DOE) Smart Grid Demonstration Project (DE-OE0000222) to install and study a broad range of advanced smart grid technologies in a demonstration that spanned 23 electric cooperatives in 12 states. More than 205,444 pieces of electronic equipment and more than 100,000 minor items (bracket, labels, mounting hardware, fiber optic cable, etc.) were installed to upgrade and enhance the efficiency, reliability, and resiliency of the power networks at the participating co-ops. The objective of this project was to build a path for other electric utilities, and particularly electrical cooperatives, to adopt emerging smart grid technology when it can improve utility operations, thus advancing the co-ops’ familiarity and comfort with such technology. Specifically, the project executed multiple subprojects employing a range of emerging smart grid technologies to test their cost-effectiveness and, where the technology demonstrated value, provided case studies that will enable other electric utilities—particularly electric cooperatives— to use these technologies. NRECA structured the project according to the following three areas: Demonstration of smart grid technology; Advancement of standards to enable the interoperability of components; and Improvement of grid cyber security. We termed these three areas Technology Deployment Study, Interoperability, and Cyber Security. Although the deployment of technology and studying the demonstration projects at coops accounted for the largest portion of the project budget by far, we see our accomplishments in each of the areas as critical to advancing the smart grid. All project deliverables have been published. Technology Deployment Study: The deliverable was a set of 11 single-topic technical reports in areas related to the listed technologies. Each of these reports has already been submitted to DOE, distributed to co-ops, and posted for universal access at www.nreca.coop/smartgrid. This research is available for widespread distribution to both cooperative members and non-members. These reports are listed in Table 1.2. Interoperability: The deliverable in this area was the advancement of the MultiSpeak™ interoperability standard from version 4.0 to version 5.0, and improvement in the MultiSpeak™ documentation to include more than 100 use cases. This deliverable substantially expanded the scope and usability of MultiSpeak™, the most widely deployed utility interoperability standard, now in use by more than 900 utilities. MultiSpeak™ documentation can be accessed only at www.multispeak.org. Cyber Security: NRECA’s starting point was to develop cyber security tools that incorporated succinct guidance on best practices. The deliverables were: cyber security extensions to MultiSpeak™, which allow more security message exchanges; a Guide to Developing a Cyber Security and Risk Mitigation Plan; a Cyber Security Risk Mitigation Checklist; a Cyber Security Plan Template that co-ops can use to create their own cyber security plans; and Security Questions for Smart Grid Vendors.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2015

Interstate Electrification Improvement Project

The Interstate Electrification Improvement Project, publicly known as the Shorepower Truck Electrification Project (STEP), started in May 2011 and ended in March 2015. The project grant was awarded by the Department of Energy’s Vehicles Technology Office in the amount of $22.2 million. It had three overarching missions: 1. Reduce the idling of Class 8 tractors when parked at truck stops, to reduce diesel fuel consumption and thus U.S. dependence on foreign petroleum; 2. Stimulate job creation and economic activity as part of the American Reinvestment and Recovery Act of 2009; 3. Reduce greenhouse gas emissions (GHG) from diesel combustion and the carbon footprint of the truck transportation industry. The project design was straightforward. First, build fifty Truck Stop Electrification (TSE) facilities in truck stop parking lots across the country so trucks could plug-in to 110V, 220V, or 480VAC, and shut down the engine instead of idling. These facilities were strategically located at fifty truck stops along major U.S. Interstates with heavy truck traffic. Approximately 1,350 connection points were installed, including 150 high-voltage electric standby Transport Refrigeration Unit (eTRU) plugs--eTRUs are capable of plugging in to shore power1 to cool the refrigerated trailer for loads such as produce, meats and ice cream. Second, the project provided financial incentives on idle reduction equipment to 5,000 trucks in the form of rebates, to install equipment compatible with shore power. This equipment enables drivers to shut down the main engine when parked, to heat or cool their cab, charge batteries, or use other household appliances without idling—a common practice that uses approximately 1 gallon of diesel per hour. The rebate recipients were intended to be the first fleets to plug into Shorepower to save diesel fuel and ensure there is significant population of shore power capable trucks. This two part project was designed to complement each other by providing: 1) the infrastructure to plug into and 2) the on-board equipment capable of plugging into the infrastructure. This project generated the largest dataset to date on shore power TSE utilization and use patterns, providing: insight into driver behavior and acceptance; evidence of cost savings; experience with system operations and management; and data for guiding future development of shore power, whether as a private enterprise or a publicly-subsidized service for meeting air quality goals.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2015

Irvine Smart Grid Demonstration, a Regional Smart Grid Demonstration Project

ISGD was a comprehensive demonstration that spanned the electricity delivery system and extended into customer homes. The project used phasor measurement technology to enable substation-level situational awareness, and demonstrated SCE’s next-generation substation automation system. It extended beyond the substation to evaluate the latest generation of distribution automation technologies, including looped 12-kV distribution circuit topology using URCIs. The project team used DVVC capabilities to demonstrate CVR. In customer homes, the project evaluated HAN devices such as smart appliances, programmable communicating thermostats, and home energy management components. The homes were also equipped with energy storage, solar PV systems, and a number of energy efficiency measures (EEMs). The team used one block of homes to evaluate strategies and technologies for achieving ZNE. A home achieves ZNE when it produces at least as much renewable energy as the amount of energy it consumes annually. The project also assessed the impact of device-specific demand response (DR), as well as load management capabilities involving energy storage devices and plug-in electric vehicle charging equipment. In addition, the ISGD project sought to better understand the impact of ZNE homes on the electric grid. ISGD’s SENet enabled end-to-end interoperability between multiple vendors’ systems and devices, while also providing a level of cybersecurity that is essential to smart grid development and adoption across the nation. The ISGD project includes a series of sub-projects grouped into four logical technology domains: Smart Energy Customer Solutions, Next-Generation Distribution System, Interoperability and Cybersecurity, and Workforce of the Future. Section 2.3 provides a more detailed overview of these domains.

25 ENERGY STORAGE↗
DOE OSTI2015

Utility-Scale Solar 2014. An Empirical Analysis of Project Cost, Performance, and Pricing Trends in the United States

Other than the nine Solar Energy Generation Systems (“SEGS”) parabolic trough projects built in the 1980s, virtually no large-scale or “utility-scale” solar projects – defined here to include any groundmounted photovoltaic (“PV”), concentrating photovoltaic (“CPV”), or concentrating solar thermal power (“CSP”) project larger than 5 MW AC – existed in the United States prior to 2007. By 2012 – just five years later – utility-scale had become the largest sector of the overall PV market in the United States, a distinction that was repeated in both 2013 and 2014 and that is expected to continue for at least the next few years. Over this same short period, CSP also experienced a bit of a renaissance in the United States, with a number of large new parabolic trough and power tower systems – some including thermal storage – achieving commercial operation. With this critical mass of new utility-scale projects now online and in some cases having operated for a number of years (generating not only electricity, but also empirical data that can be mined), the rapidly growing utility-scale sector is ripe for analysis. This report, the third edition in an ongoing annual series, meets this need through in-depth, annually updated, data-driven analysis of not just installed project costs or prices – i.e., the traditional realm of solar economics analyses – but also operating costs, capacity factors, and power purchase agreement (“PPA”) prices from a large sample of utility-scale solar projects in the United States. Given its current dominance in the market, utility-scale PV also dominates much of this report, though data from CPV and CSP projects are presented where appropriate.

14 SOLAR ENERGY↗
DOE OSTI2012

Driftless Area Initiative Biomass Energy Project

The Driftless Area Initiative Biomass Energy Project evaluated the potential for biomass energy production and utilization throughout the Driftless Region of Illinois, Iowa, Minnesota and Wisconsin. The research and demonstration aspect of the project specifically focused on biomass energy feedstock availability and production potential in the region, as well as utilization potential of biomass feedstocks for heat, electrical energy production, or combined heat and power operations. The Driftless Region was evaluated because the topography of the area offers more acres of marginal soils on steep slopes, wooded areas, and riparian corridors than the surrounding “Corn Belt”. These regional land characteristics were identified as potentially providing opportunity for biomass feedstock production that could compete with traditional agriculture commodity crops economically. The project researched establishment methods and costs for growing switchgrass on marginal agricultural lands to determine the economic and quantitative feasibility of switchgrass production for biomass energy purposes. The project was successful in identifying the best management and establishment practices for switchgrass in the Driftless Area, but also demonstrated that simple economic payback versus commodity crops could not be achieved at the time of the research. The project also analyzed the availability of woody biomass and production potential for growing woody biomass for large scale biomass energy production in the Driftless Area. Analysis determined that significant resources exist, but costs to harvest and deliver to the site were roughly 60% greater than that of natural gas at the time of the study. The project contributed significantly to identifying both production potential of biomass energy crops and existing feedstock availability in the Driftless Area. The project also analyzed the economic feasibility of dedicated energy crops in the Driftless Area. High commodity crop prices and land values coupled with low fossil fuel prices, particularly natural gas, hampered the likelihood of widespread production and/or utilization of for large scale heating or electrical generation at the time of the study.

09 BIOMASS FUELS↗
DOE OSTI2014

Optimization of Installation, Operation and Maintenance at Offshore Wind Projects in the U.S.: Review and Modeling of Existing and Emerging Approaches

The United States Department of Energy (DOE) awarded a grant to GL Garrad Hassan (GL GH) to investigate the logistics, opportunities, and costs associated with existing and emerging installation and operation and maintenance (O&M) activities at offshore wind projects as part of the DOE’s program to reduce barriers facing offshore wind project development in the United States (U.S.). This report (the Report) forms part of Subtopic 5.3 “Optimized Installation, Operation and Maintenance Strategies Study” which in turn is part of the “Removing Market Barriers in U.S. Offshore Wind” set of projects for the DOE. The purpose of Subtopic 5.3 is to aid and facilitate informed decision-making regarding installation and O&M during the development, installation, and operation of offshore wind projects in order to increase efficiency and reduce the levelized cost of energy (LCoE). Given the large area of U.S. territorial waters, the generally higher mean wind speeds offshore, and the proximity to the coast of many large U.S. cities, offshore wind power has the potential to become a significant contributor of energy to U.S. markets. However, for the U.S. to ensure that the development of offshore wind energy projects is carried out in an efficient and cost-effective manner, it is important to be cognizant of the current and emerging practices in both the domestic and international offshore wind energy industries. The U.S. can harness the experience gained globally and combine this with the skills and assets of an already sizeable onshore wind industry, as well as the resources of a mature offshore oil and gas industry, to develop a strong offshore wind sector. The work detailed in this report is aimed at assisting with that learning curve, particularly in terms of offshore specific installation and O&M activities. This Report and the Installation and O&M LCoE Analysis Tool, which were developed together by GL GH as part of this study, allow readers to identify, model and probe the economic merits and sensitivities of various approaches to construction and O&M practices, using illustrative offshore projects across a wide range of alternative offshore development areas located in U.S. waters. The intention is to assist decision-makers in clearly understanding the relative economic benefits of both conventional and novel construction installation methodologies and maintenance techniques within the critical parameters of a Project’s LCoE.

17 WIND ENERGY↗
DOE OSTI2016

Final DOE-ASR Report for the Project “Advancing our Understanding and the Remote Sensing of Ice Clouds”

This project has evolved during its execution, and what follows are the key project findings. This project has arguably provided the first global view of how cirrus cloud (defined as having cloud base temperature T < 235 K) nucleation physics (evaluated through satellite retrievals of ice particle number concentration Ni, effective diameter De and ice water content IWC) evolves with the seasons for a given temperature, latitude zone and surface type (e.g. ocean vs. land), based on a new satellite remote sensing method developed for this project. The retrieval method is unique in that it is very sensitive to the small ice crystals that govern the number concentration Ni, allowing Ni to be retrieved. The method currently samples single-layer cirrus clouds having visible optical depth ranging from about 0.3 to 3.0, using co-located observations from the Infrared Imaging Radiometer (IIR) and from the CALIOP (Cloud and Aerosol Lidar with Orthogonal Polarization) lidar aboard the CALIPSO (Cloud-Aerosol Lidar and Infrared Pathfinder Satellite Observation) polar orbiting satellite, employing IIR channels at 10.6 μm and 12.05 μm. Retrievals of Ni are primarily used to estimate the cirrus cloud formation mechanism; that is, either homo- or heterogeneous ice nucleation (henceforth hom and het). This is possible since, in general, hom produces more than an order of magnitude more ice crystals than does het. Thus the retrievals provide insight on how these mechanisms change with the seasons for a given latitude zone or region, based on the years 2008 and 2013. Using a conservative criterion for hom cirrus, on average, the sampled cirrus clouds formed through hom occur about 43% of the time in the Arctic and 50% of the time in the Antarctic, and during winter at mid-latitudes in the Northern Hemisphere, hom cirrus occur 37% of the time. Elsewhere (and during other seasons in the Northern Hemisphere mid-latitudes), this hom cirrus fraction is lower, and it is lowest in the tropics. Thus, the microphysical properties of cirrus clouds in the Polar Regions are much different than they are in the tropics; something unknown prior to this study. Moreover, the frequency of cirrus cloud occurrence in the Polar Regions varies strongly with season, peaking during winter in the Arctic and during spring in the Antarctic. Considering these seasonal changes in microphysics and inferred cloud coverage, this leads us to speculate that the buildup of Arctic cirrus during winter may significantly contribute to tropospheric heating in that region, possibly affecting winter jet-stream dynamics and mid-latitude weather patterns through the thermal-wind balance relationship. This cirrus cloud research provides essential guidance for realistically representing cirrus clouds in climate models; guidance previously unavailable. For example, mid-latitude hom cirrus were widespread during winter over or nearby mountainous terrain, evidently due to mountain-induced waves that produce strong updrafts at cirrus cloud levels. The treatment of turbulent mountain stress and gravity waves will likely need to be improved in climate models in order to adequately represent cirrus clouds outside the tropics. Another goal of this project was to develop a ground-based 94-GHz radar retrieval for winter snowstorms, based on (1) an improved analytical framework describing the interaction of radiation from radar with snowfall and (2) the development of a steady-state snow growth model that predicts the height-evolution of the ice particle size distribution through ice particle growth by vapor diffusion, aggregation and riming (i.e. the growth of snow through collisions with supercooled cloud droplets). Although activities (1) and (2) were completed, there was insufficient time to test and finalize the radar retrieval scheme. However, activity (2) provided a new method for relating ice particle mass “m” and projected area “A” to the ice particle maximum dimension “D”. The ice cloud microphysical processes (which determine ice cloud radiative properties) in climate models are parameterized in terms of these m-D and A-D relationships. By improving these relationships, the ice cloud radiative properties in Community Atmosphere Model version 5, or CAM5 (an atmosphere global climate model, or GCM) were improved. Student funding from the University of Nevada, Reno, was combined with funds from this project to conduct some basic research on the mechanism of the North American monsoon, or NAM. Federal research on the NAM has dwindled since 2006, but atmospheric soundings taken during research vessel cruises in the Gulf of California (GC) during the North American Monsoon Experiment (NAME) were used to reveal a likely mechanism that explains the relationship between an intrusion of tropical warm water into the GC during late spring-early summer and the onset of relatively heavy NAM rainfall in northwest Mexico and the southwestern United States. These soundings, combined with reanalysis data, satellite sea surface temperatures and satellite measurements of outgoing longwave radiation were used to develop and provide evidence for a planetary-scale NAM mechanism. As far as we know, no other physical explanation has been offered for the spring-summer evolution of the NAM system.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2016

Utility-Scale Solar 2015: An Empirical Analysis of Project Cost, Performance, and Pricing Trends in the United States

The utility-scale solar sector—defined here to include any ground-mounted photovoltaic (“PV”), concentrating photovoltaic (“CPV”), or concentrating solar power (“CSP”) project that is larger than 5 MWAC in capacity—has led the overall U.S. solar market in terms of installed capacity since 2012. It is expected to maintain its market-leading position for at least another five years, driven in part by December 2015’s three-year extension of the 30% federal investment tax credit (“ITC”) through 2019 (coupled with a favorable switch to a “start construction” rather than a “placed in service” eligibility requirement, and a gradual phase down of the credit to 10% by 2022). In fact, in 2016 alone, the utility-scale sector is projected to install more than twice as much new capacity as it ever has previously in a single year. This unprecedented boom makes it difficult, yet more important than ever, to stay abreast of the latest utility-scale market developments and trends. This report—the fourth edition in an ongoing annual series—is intended to help meet this need, by providing in-depth, annually updated, data-driven analysis of the utility-scale solar project fleet in the United States. Drawing on empirical project-level data from a wide range of sources, this report analyzes not just installed project costs or prices—i.e., the traditional realm of most solar economic analyses—but also operating costs, capacity factors, and power purchase agreement (“PPA”) prices from a large sample of utility-scale solar projects throughout the United States. Given its current dominance in the market, utility-scale PV also dominates much of this report, though data from CPV and CSP projects are also presented where appropriate.

14 SOLAR ENERGY↗
DOE OSTI2017

Final Report for Project DE-FG02-05ER15718 Fluoropolymers, Electrolytes, Composites and Electrodes

This report is for a project that was initiated under the title “New Proton-Conducting Fluoropolymer Electrolytes for PEM Fuel Cells”, as part of the DOE program titled “Basic Research for the Hydrogen Fuel Cell Initiative”, Program Notice DE-FG01-04ER04-20. The project received 750,000 dollars in initial funding for a three-year term with a start date of August 15, 2005. Creager was PI and co-PIs were DesMarteau and Smith, all from Clemson. The project was renewed for a second three-year term with a start date of June 15 2008, again for 750,000 dollars, with the new title, “Fluoropolymers, Electrolytes, Composites and Electrodes”. Shortly after the renewal was put in place, co-PI Smith left Clemson to accept a position at the University of Texas at Dallas. After a period of no-cost extension the project was renewed on January 1 2013 for another three-year term, this time for a smaller amount ($525,000) and with Thrasher, a new senior hire at Clemson, as co-PI in place of Smith. DesMarteau had retired from Clemson by this time but was retained as a project advisor. After a final one-year no-cost extension for calendar year 2016, the project ended on December 31, 2016, giving it an active period of eleven and one-half years, from August 15 2005 to December 31 2016. The overall objective of this research project has been to create and understand the behavior of new fluoropolymer-based electrolytes and electrodes suitable for use in electrochemical energy storage and conversion devices. The objective was pursued via research on new fluorinated monomers, new polymers and polyelectrolytes (also known as ionomers), and new electrocatalyst supports that in some cases include chemically grafted electrolytes to promote rapid ion transport to electrocatalytically active sites (usually platinum nanoparticles) on the support. The research involved synthesis and characterization of new materials, and creation and use of new measurement techniques that address key properties of the materials, e.g. mixed electronic / ionic conduction in the absence of liquid electrolyte, that are relevant to their use in energy conversion and storage.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2015

Pacific Northwest Smart Grid Demonstration Project Technology Performance Report Volume 1: Technology Performance

The Pacific Northwest Smart Grid Demonstration (PNWSGD), a $179 million project that was co-funded by the U.S. Department of Energy (DOE) in late 2009, was one of the largest and most comprehensive demonstrations of electricity grid modernization ever completed. The project was one of 16 regional smart grid demonstrations funded by the American Recovery and Reinvestment Act. It was the only demonstration that included multiple states and cooperation from multiple electric utilities, including rural electric co-ops, investor-owned, municipal, and other public utilities. No fewer than 55 unique instantiations of distinct smart grid systems were demonstrated at the projects’ sites. The local objectives for these systems included improved reliability, energy conservation, improved efficiency, and demand responsiveness. The demonstration developed and deployed an innovative transactive system, unique in the world, that coordinated many of the project’s distributed energy resources and demand-responsive components. With the transactive system, additional regional objectives were also addressed, including the mitigation of renewable energy intermittency and the flattening of system load. Using the transactive system, the project coordinated a regional response across the 11 utilities. This region-wide connection from the transmission system down to individual premises equipment was one of the major successes of the project. The project showed that this can be done and assets at the end points can respond dynamically on a wide scale. In principle, a transactive system of this type might eventually help coordinate electricity supply, transmission, distribution, and end uses by distributing mostly automated control responsibilities among the many distributed smart grid domain members and their smart devices.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2019

AOI2 - Initial Engineering, Testing, and Design of a Commercial-Scale Postcombustion CO 2 Capture System on an Existing Coal-Fired Generating Unit (Project Carbon)

The continued long-term use of North Dakota lignite is likely dependent on creating a business case for carbon capture, utilization, and storage (CCUS) that also addresses society’s desire to reduce carbon emissions. CCUS coupled with enhanced oil recovery appears to be the most feasible option for utilities to sustain and grow the lignite industry. Establishing a market where lignite-powered utilities provide carbon dioxide (CO 2 ) to oil producers depends upon having a cost-effective method to capture CO 2 . The application of CO 2 capture technology to lignite-fired flue gas has challenges in addition to the cost of capture, including the effects of the buildup of heat-stable salts, aerosol formation, degradation of solvents or solid sorbents, or subsequent solvent loss. Lignite, especially North Dakota lignite, presents its own set of challenges that include the combination of high sodium, sulfur, and ash contents; NO x reduction; and footprint limitations. Project Carbon was designed to address these technical barriers and provide pre-FEED (preliminary front-end engineering and design) information necessary for additional commercial demonstrations to move forward. A long-term pilot-scale evaluation of Mitsubishi Heavy Industries’ (MHI’s) KS-1™ solvent at Minnkota Power Cooperative’s lignite-fired Milton R. Young Station Unit 2 (MRY2) was a major objective of the project. The purpose of the test was to demonstrate the technology’s compatibility with MRY2’s flue gas over an extended period of time. During the long-term test, aerosol sampling and measurement were performed, and a pilot-scale baghouse was tested to determine the effect of bag material and operation on aerosol concentrations in the flue gas. Project engineering and design work were performed to support the other major project objective: a pre-FEED study of CO 2 capture at MRY2. Finally, a techno-economic assessment (TEA) of the application of CO 2 capture to MRY2 was performed. This project was performed over a period of 28 months, with a total budget of $12,700,000. The U.S. Department of Energy’s (DOE’s) National Energy Technology Laboratory, through the Energy & Environmental Research Center’s (EERC’s) Cooperative Agreement, the North Dakota Industrial Commission, and industry partners ALLETE and Minnkota Power Cooperative, funded the project. The pilot-scale test system at MRY2 performed very well for the continuous test period of 83 days. The CO 2 capture plant achieved stable operation while utilizing MHI’s KS-1™ solvent and the MHI amine emission reduction unit. No major concerns were encountered when capturing CO 2 from lignite-fired flue gas. Challenges were encountered because the cooling water temperature was warmer than needed for the capture system to operate efficiently. This affected the ability of the solvent to capture CO 2 and promoted solvent loss through solvent entrainment caused by high CO 2 gas temperature within a cyclone separator. The KS-1™ solvent and the lignite-derived flue gas were analyzed during the long-term test. Analysis of the solvent indicates that, although some metals and heat-stable salts increased over the course of the long-term test, they were at levels that can be treated with filtration and reclaiming and do not pose a concern for effective solvent operation. Fourier transform infrared (FTIR) spectrometry was successfully used to determine the composition of the lignite-derived flue gas as well as concentrations of select components of the flue gas at various locations within the EERC’s CO 2 capture system. The formation of aerosols during the capture process is of interest, as are approaches for their reduction, especially in a baghouse. Testing of aerosol removal was performed using the EERC’s portable baghouse. It was found that both Ryton and polytetrafluoroethylene (PTFE) membrane bags were effective at reducing the level of aerosols during steady-state operation. During backpulse events, however, the amount of aerosols passing through the bags was an order of magnitude lower for the Ryton bags than the PTFE membrane bags. The testing showed that proper design of the baghouse air-to-cloth ratio as well as minimization of backpulsing can dramatically reduce the amount of aerosols that pass through the bags and remain in the flue gas stream exiting a baghouse system. A technology maturation plan (TMP) was performed to enable successful development of the Kansai Mitsubishi Carbon Dioxide Recovery® (KM CDR®) Process for application to a combustion flue gas for which the process has not yet been demonstrated. In the TMP, new challenges to the MHI CO 2 capture technology during its application to MRY2 were identified. These challenges included capture from lignite-fired (as opposed to subbituminous coal-fired) flue gas, a larger scope than previous applications of the technology, and implementation in a colder climate that could affect process and equipment operability. Because MRY2 is located where stack icing in the winter could be problematic, a rime icing study was performed. Rime icing modeling indicated that, under both 100% and 50% operating loads, there is a potential for many icing events during any given part of the year in which below-freezing weather conditions exist. The models showed that a critical amount of rime ice could be formed at the stack top during two or more events per year. CO 2 capture plant stack height and location will need to be determined in order to minimize the formation of rime ice. It was found that the integration of the MHI CO 2 capture process into the normal operation of the MRY2 steam turbine is a viable alternative to a cogeneration facility to provide steam and power for the carbon capture facility. The research performed under this project showed that CO 2 capture at a lignite-fired power plant can successfully be performed. No known fatal flaws that would prevent the continued development of the MRY2 CO 2 capture facility were identified during the pre-FEED study. A TEA performed following DOE methodology shows that applying capture technology to MRY2 may not only meet but exceed the DOE-recognized state-of-the-art baseline.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2017

Data Analytics: Project-level Cost Estimates

Sandia National Laboratories is interested in understanding how data analytics can be applied to business problems, in particular financial management. This project examines how a combination of qualitative and analytical tools can be used to increase the accuracy of cost estimates at the project level. Although the initial scope of the project was to perform analyses on lab- or portfolio- level projections and forecasts, we examined project-level cost estimates for three reasons. First, qualitative and quantitative data were feasible to obtain within the 8-week project time frame. Second, we could develop a thorough enough understanding at this level to provide meaningful recommendations. Third, the results of our project would still be relevant despite undefined changes caused by the Financial Simplification. We performed external research on other companies in industry and on other national labs, internal research at Sandia, and data analysis using ARC and Excel. In total, we conducted twelve interviews, researched three other companies, and applied four analytical techniques.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2021

2020 Mitigation and Monitoring Report for the Arroyo Las Positas Management Project

This report describes maintenance, monitoring, and mitigation conducted in 2020 as part of the Arroyo Las Positas Management Project (the project) at Lawrence Livermore National Laboratory’s (LLNL’s) Livermore Site. The purpose of this project is to enhance habitat value for the California red-legged frog (Rana draytonii) within the LLNL reach of Arroyo Las Positas and protect LLNL facilities from flooding. The project description, in addition to the monitoring and mitigation requirements for this project are described in the October 2015 Revised Mitigation and Monitoring Plan for the Arroyo Las Positas Management Project (MMP) and the Formal Consultation on the Proposed Arroyo Maintenance Project on Arroyo Las Positas at Lawrence Livermore National Laboratory (biological opinion; Service File Numbers 1-1-97-F-173 and 1-1-98-I-1562).

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

Keystone Solar Future Project (KSFP)

The Keystone Solar Future Project (KSFP, also referred to as “Keystone Project” in the report) implements a cost-effective, secure, reliable, and safe technology platform that paves the way for future interconnected distributed energy resources (DER), creates a framework that enables high penetration of DER, and transforms the DER interconnection process. The project is important and necessary in a few aspects. First, the industry definition of Distributed Energy Resource Management System (DERMS) is not yet validated against field deployments and mostly implemented in small pilots relying on third party integration. Keystone project implements a direct plug and play communication to inverter based DER systems. Secondly, most interconnection application portal is not yet fully integrated with back-end system, thus lacks the capability to drive a complete and accurate modeling of DER assets into the planning and operational systems. Keystone project rolled out a fully integrated modeling process of DERs from interconnection to operational management. Lastly, customers were given an opportunity to learn about the advanced functions of the inverters and take full advantages of their benefits through participation in the pilot program. During the project, the technical effectiveness and economic feasibility of DER management were investigated and demonstrated in real life events and simulation studies. The project highlighted the importance of coordinated DER interconnection, installation and management with the rest of the distribution system.

14 SOLAR ENERGY↗
DOE OSTI2022

Techno-Economic Wind Blade Manufacturing Model to Identify Opportunities for Cost Improvements Phase II IACMI Project 4.6/4.8

In IACMI Project 4.6 and IACMI Project 4.8, an Excel-based Techno-Economic Model (TEM) of the manufacturing process for composite wind turbine blades and a DELMIA Factory Flow Simulation of a generic wind blade manufacturing facility was developed. Together, these two tools provide a combined economic modeling capability that accounts for the material, labor, overhead and full-lifecycle operating costs associated with wind blade manufacturing as well as the impact of process flow and factory layout on overall manufacturing efficiency. The tools provide a novel means of detailed comparative analysis of the economic feasibility of proposed technologies and process changes for blade manufacturing. The modeling tools were developed with close support from members of industry and visits to multiple blade manufacturing facilities. With industry oversight, a detailed generalized manufacturing process plan and facility layout were developed with manufacturing parameters, material costs and economic factors based on historical data. Dassault Systèmes and the University of Texas at Dallas (UTD) contributed to the development of the Techno-Economic Model by providing macros to enable the generation of Bill of Material (BOM) data from a 3D blade design in either CATIA or NuMAD format, respectively. The TEM was built with the capability to directly import a Bill of Materials for economic analysis, and with the addition of the macros provided by Dassault and UTD, the TEM can directly import blade designs from both CATIA and NuMAD file formats. The modeling tools developed in Project 4.6 were used to investigate four wind blade manufacturing concepts in detail and select one to explore with laboratory-scale experimentation in Project 4.8. The four manufacturing concepts that were investigated were down-selected by the full project team from a larger list of concepts. The selections were made based on a number of criteria ranking viability and level of interest for each concept. The ‘One-Step Close’ manufacturing concept was ultimately selected for investigation in Project 4.8 and the demonstration was performed at the NREL CoMET facility. The TPI advanced manufacturing facility in Warren, RI contributed the production of several prototype components, the designs for which were developed by Janicki Industries. The demonstration project provided clear indication of the viability of the One-Step Close manufacturing concept for blade manufacturing and good validation of the Techno-Economic Model’s prediction of its economic impact.

17 WIND ENERGY↗
DOE OSTI2014

Geologic Modeling and Simulation Report for the Aquistore Project

The Plains CO 2 Reduction (PCOR) Partnership, through the Energy & Environmental Research Center (EERC), is collaborating with the Petroleum Technology Research Centre (PTRC) on site characterization; modeling and simulation; risk assessment; public outreach; and monitoring, verification, and accounting (MVA) activities for the Aquistore project. The Aquistore project is a carbon capture, utilization, and storage (CCUS) project situated near the town of Estevan, Saskatchewan, Canada, and the U.S.–Canada border. This project is managed by PTRC and will serve as buffer storage of carbon dioxide (CO 2 ) from the SaskPower Boundary Dam CCUS project, the world’s first commercial-scale postcombustion CCUS project from a coal-fired electric generating facility. To date, an injection well and an observation research well (~500 ft apart) have been drilled and completed at the Aquistore site, with injection anticipated to begin in 2014. Using a combination of site characterization data provided by PTRC and independently acquired information, the PCOR Partnership has constructed a static geologic model to assess the potential storage capacity of the Aquistore site and provide the foundation for dynamic simulation. The geologic model and the results of the predictive simulations will be used in the risk assessment process to help define an overall monitoring plan for the project and to assure stakeholders that the injected CO 2 will remain safely stored at the Aquistore site.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2023

Front-End Engineering and Design: Project Tundra Carbon Capture System (Final Report)

As the next phase of Project Tundra, Minnkota Power Cooperative (MPC) completed a front-end engineering and design (FEED) study to install a post-combustion CO 2 capture system (CCS) at the MPC operated (Square Butte Electric Cooperative-owned) Milton R. Young Station (MRYS) Unit 2 (MRY2), a 477-MW power plant fueled by North Dakota lignite. The project team completed the FEED with Fluor’s Econamine FG Plus℠ (EFG+) technology and is taking the next steps leading up to start of construction. Team members included FEED technical lead Fluor Enterprises (Fluor); owner’s engineer and balance of plant (BOP) engineer Burns & McDonnell (BMcD); leading carbon capture consultants (David Greeson Consulting, Hunt International Energy Services); environmental consultants (AECOM, Agora Environmental), other BOP engineering consultants (Golder Associates, Nels); cost-share funding agency, the North Dakota Industrial Commission (NDIC); and the Energy & Environmental Research Center (EERC). Project Tundra’s goal is to implement carbon capture, utilization, and storage (CCUS) in North Dakota, while preserving the use of lignite. Future options could lead to revitalizing legacy oil fields and creating a new CO 2 enhanced oil recovery (EOR) industry. The topic of this report is the FEED study for the carbon dioxide capture portion of Project Tundra. Building on the findings of a pre-FEED study for MRY2, the key deliverables contained in this FEED study are: a) design, costing, and performance data needed to commence project financing activities; b) engineering and material balances required to file for all project permits; and c) a final project schedule. Based on the results of the previous pre-FEED study, MPC and its team evaluated two options to provide the large amount of steam needed to operate the CCS: 1) installation of new natural gas package boilers and a new pipeline to supply natural gas to the facility and 2) extraction of steam from the existing MRYS steam turbine generator. The FEED study was performed using the package boilers option, as it was deemed to have the lowest technical risk, overall cost, and cost uncertainty. A key feature of the design, however, was the mixing the natural gas boilers’ flue gas with the MRY2 flue gas. This increased the size of the CCS system. This design also enabled the tie-in of Unit 1 flue gas for times when Unit 2 is offline. The CCS was designed to capture a combined 12,978 short tons per day (STPD) of CO 2 from the flue gases produced by the existing MRY Unit 2 along with flue gas produced by the new boiler package within the CCS. The 12,978 STPD CO 2 capture is achieved by normally processing 100% of the total available MRY Unit 2 flue gas (considering full load operation) and 100% of the boiler package flue gas, then removing 90% of the CO 2 available from the processed flue gas streams.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2023

Maritime Fuel Cell Generator Project: 2018 – 2023

This report summarizes activity in the Maritime Fuel Cell (MarFC) Generator Project from 2018 – 2023. FY 2018 saw the implementation of upgrades and repairs, making the unit more reliable and operator friendly. In FY2019 the team engaged the Scripps Institution of Oceanography (SIO) to use the MarFC to provide zero-emission shore power to the research vessel R/V Robert Gordon Sproul while in port at the Nimitz Marine Facility in San Diego, CA. In FY2020, the MarFC unit was shipped to San Diego, CA. A fueling contract with IGX was established to support MarFC operations at SIO, with renewable hydrogen provided by the California State University Los Angeles (CSULA) hydrogen station. The project team (Sandia, Cummins/Hydrogenics) provided training to SIO staff on the technical details of the MarFC, the safe use of hydrogen in general and the MarFC in particular. The first fueling of the unit at the SIO pier was successfully completed by IGX. The first powering of a vessel with fuel-cell shore power was conducted with the R/V Robert Gordon Sproul. While the mechanical systems (lights, AC, ventilation, hydraulics, pumps and cranes) were powered without incident, problems arose when powering the computer systems. Inspections carried out in FY2021 revealed the MarFC needed routine maintenance. Maintenance was performed and the unit was upgraded. The MarFC was turned on after the year pause, and initial test data on power levels and stability were collected. FY2022 was a year spent repairing, upgrading and testing the MarFC unit. Spikes in power and voltage were observed above 60 kW that could potentially extend below 60 kW with time. Such spikes could cause problems with the Sproul electrical systems. These age-related problems, the extended time for the Sproul spent in dry dock for scheduled upgrades, and the associated need to reschedule the vessel’s high-priority science missions made it no longer possible to deploy the unit at SIO. After due consideration, the decision was made by DOE, MARAD and the project team to cease the deployment, remove the MarFC from SIO, and not pursue further deployment activities. On December 2, 2022, the MarFC unit was removed from the Scripps Nimitz Marine Facility and shipped to Fridley, Michigan. The Cummins/Hydrogenics plan for the unit is to assess the condition of the MarFC subcomponents, and then use it as a training/learning system for technical employees new to hydrogen fuel-cell technology. After summarizing project activity from 2018 – 2023, this report provides a review of lessons learned. This report provides next steps in contemplating a follow-on project that would further advance the use of fuel-cell-based shore power in a marine setting. A comparison is made of the project results to the original objectives. This report ends with an accounting of presentations stemming from the project, and a list of references.

08 HYDROGEN↗