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DOE OSTI2022

Design Methods, Tools, and Data for Ceramic Solar Receivers Year 1 Continuation Report

This report describes the first year of work on a project to develop the methods, tools, and data required to analyze high temperature ceramic Concentrating Solar Power (CSP) components. This first year focused on developing the methods and data required for a time-independent assessment of potential components, focusing in particular on ceramic solar receivers. The report describes both model development and testing work focused on accomplishing this goal. Our overall conclusion is that high temperature ceramic CSP components are viable and could provide a means to overcome the expected low reliability and short service life for equivalent components constructed from Ni-based superalloys. Based on the results reported here, we recommend the project continue to Phase II which will develop more sophisticated, realistic models for time-dependent failure of ceramics operating in expected CSP component conditions and develop the time-dependent ceramic test data needed to parameterize these models, using commercial SiC as a reference material.

14 SOLAR ENERGY↗

DOE OSTI2024

Design improvements to the SNS ion source and diagnostics

The U.S. Spallation Neutron Source (SNS) is a state-of-the-art neutron scattering facility delivering the world's most intense pulsed-neutron beams to a wide array of instruments which are used to conduct investigations in many fields of science and engineering. The accelerator system is fed by an RF-driven, multicusp, H - ion source which nominally provides pulsed beam currents of 50-60 mA (1ms, 60Hz). This report provides a discussion of ongoing design improvements to the SNS ion source and Low Energy Beam Transport (LEBT) as well as diagnostic upgrades undertaken since the previous ICIS conference. These improvements include (i) simple mechanical modifications to the source outlet aperture which resulted in dramatically increased extracted beam current and comparable or lower emittance at similar beam currents, (ii) design improvements to the LEBT chopper target which will enable full power beam-dumping during physics studies, (iii) refinement of the SNS Allison emittance scanner that has enabled the first reliable LEBT beam measurements at full beam power (65kV, 50-100mA, 1ms, 60Hz) on the SNS ion source test stand and (iv) the implementation of a thermal imaging camera for the monitoring the LEBT electrode temperatures. (v) The design of an advanced Cs system, capable of more efficient Cs utilization with significantly lower Cs losses from the source is also presented. Mechanical details, computational simulations and experimental results are discussed within the context of these improvements.

47 OTHER INSTRUMENTATION↗

DOE OSTI2023

Transactive Energy Communications Interface Standards Landscape

Transactive energy represents distributed, optimal-seeking coordination approaches for managing the operation of large numbers of energy-related devices and systems. The concept assumes intelligent agents interact with other agents on behalf of their owners to balance the supply and demand of energy and coordinate other operation services in an electric system. They do this by exchanging value signals for services in near-term and forward time periods using market mechanisms. The technique is particularly applied to coordination of flexibility in operating distributed energy resources. The integration of large numbers of devices requires that they be able to connect and interoperate easily and reliably. Given the many technologies and solution providers integrating products, communications interfaces based on clear, unambiguous specifications with supporting tests require standardization and adoption by the community of system integrators. This report reviews the state of communications interface standards that show promise for transactive energy approaches to the coordination of distributed energy resources. It reviews promising standards to highlight challenges and gaps. It offers structured comparisons between standards and the features offered by their ecosystems of participants.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2023

The Vela Hotel Program: The AEC's Space-Based Nuclear Detection and Treaty Verification Program [Slides]

Early Interest in "Detection": "I would suggest that the best way to get reliable information in a short time would be to send from the States a man qualified to do the testing of the samples on the spot. This man should be officially a representative of the State Department, and his detecting devices, such as small portable Geiger Counters, could then go into Switzerland in the diplomatic pouch via air from Southern Italy. This man could then contact, through the Embassy, suitable people who could collect the water samples without arousing too much curiosity. A fishing trip in a boat would probably give the best disguise, as the fisherman could carry a water bottle in his lunch basket, and fill it after drinking the original contents. The water should be collected from the center of the river, to get the swiftest flowing water, so that the holdup could be minimized. In the lake, the water should be collected as near to the suspected site as possible, or as near to each of the inlet rivers as can be done. Speed in getting from the collection point to the counting room is of great importance, as you are, no doubt, aware." - Luis Alvarez to Major Furman, May 1944.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2024

KOMPASS-II: Compaction of Crushed salt for Safe Containment – Phase 2

Long-term stable sealing elements are a basic component in the safety concept for a possible repository for heat-emitting radioactive waste in rock salt. The sealing elements will be part of the closure concept for drifts and shafts. They will be made from a welldefinied crushed salt in employ a specific manufacturing process. The use of crushed salt as geotechnical barrier as required by the German Site Selection Act from 2017 /STA 17/ represents a paradigm change in the safety function of crushed salt, since this material was formerly only considered as stabilizing backfill for the host rock. The demonstration of the long-term stability and impermeability of crushed salt is crucial for its use as a geotechnical barrier. The KOMPASS-II project, is a follow-up of the KOMPASS-I project and continues the work with focus on improving the understanding of the thermal-hydraulic-mechanical (THM) coupled processes in crushed salt compaction with the objective to enhance the scientific competence for using crushed salt for the long-term isolation of high-level nuclear waste within rock salt repositories. The project strives for an adequate characterization of the compaction process and the essential influencing parameters, as well as a robust and reliable long-term prognosis using validated constitutive models. For this purpose, experimental studies on long-term compaction tests are combined with microstructural investigations and numerical modeling. The long-term compaction tests in this project focused on the effect of mean stress, deviatoric stress and temperature on the compaction behavior of crushed salt. A laboratory benchmark was performed identifying a variability in compaction behavior. Microstructural investigations were executed with the objective to characterize the influence of pre-compaction procedure, humidity content and grain size/grain size distribution on the overall compaction process of crushed salt with respect to the deformation mechanisms. The created database was used for benchmark calculations aiming for improvement and optimization of a large number of constitutive models available for crushed salt. The models were calibrated, and the improvement process was made visible applying the virtual demonstrator.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2024

Does practice make perfect? Lessons learned from full-scale power system incident response exercise

While threats to the energy sector occur daily, few utilities get the opportunity to fully test out their detection and response mechanisms to advanced threats in the real world. With the high demand for reliability, few grid operators would allow execution of simulated cyber-attacks on their live systems. The DOE-funded Liberty Eclipse project offers a unique opportunity for small and large utilities and coops to practice their combined IT/OT responses to a live red team executing attacks against an isolated power system on an island in New York. Both cyber teams and power operations teams must work together to detect and respond to attacks, even restoring the power system against extreme impacts. Lessons learned from these exercises reveal key takeaways for understanding what a real attack against the electric sector will look like, gaps in execution of the best-laid plans when the pressure of a real event is bearing down, and how organizations can better prepare for advanced attacks by optimizing participation in exercises. This presentation will discuss successes and opportunities for improvement both in how utilities can prepare for and respond to events, as well as how full-scale IT/OT exercises can be coordinated.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2023

Simulation, Challenge Testing & Validation of Occupancy Recognition & CO 2 Technologies (Final Project Report)

This final report covers the results of the development of testing methods of occupancy sensor systems connected to HVAC controls. This project focused on the development of test methods to evaluate the performance of HVAC-connected occupancy sensor systems, including occupancy presence, occupancy counting, and CO 2 sensor systems in commercial and residential buildings. This included evaluation of the reliability, ease of commissioning, and energy savings potential of these sensor systems. The results of this work help to standardize the methods used to evaluate performance, to enable the ability to compare sensor system performance following the same methods, to understand which sensor systems perform better or worse compared to others. The U.S. building stock’s energy usage can benefit substantially from having building system operations informed by reliable occupancy recognition and CO 2 measurements, however to date, standard methods have not been in place to ensure that sensor systems’ reported performance is uniformly evaluated. The results of this work support the development of a standard or guideline that outlines the developed methods of testing. This project also included the testing of both off-the-shelf and novel SENSOR team-developed low-cost occupancy sensor systems, using the developed methods of testing. The results of this testing helped to inform further development and improvement of new low-cost sensor systems that will benefit from being used in residential and commercial buildings throughout the country.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2025

Synchronous Machine Governor Upgrade

Conventional generation sources play a critical role in the stability and reliability of the electrical grid, particularly as we transition towards more renewable energy sources. To understand and accurately emulate their behavior for optimizing grid operations and ensuring seamless integration with renewable technologies, it is essential to better emulate the grid- and plant-level impacts of conventional generation sources, such as natural gas (NG) driven heat recovery steam generators (HRSGs) and combustion turbines (CTs). Therefore, a governor model is developed in a programmable logic controller (PLC) to investigate the performance of the conventional generator under various dynamic operating conditions and to identify the impact on grid stability in a controlled environment. The governor model aims to enable the hardware-in-the-loop (HIL) based emulation of these conventional generation sources using the existing 2 MVA synchronous machine/generator that is driven by a flexible 2.5 MW variable speed drive. This setup will allow us to replicate the dynamic characteristics and response behaviors of NG-driven HRSGs and CTs. The controls for the emulated conventional plants follow the industry standard and are adjustable, ensuring they accurately reflect the operational capabilities and limitations of real-world systems. These controls include load-following capabilities, ramp rates, startup and shutdown sequences, and emissions characteristics. By incorporating these adjustable controls, we aim to capture the nuanced impacts of conventional generation, such as their ability to provide ancillary services like frequency regulation, voltage support, and spinning reserve. In this report, we simulate two types of dynamic operations: grid-connected and islanding. For each dynamic operation, representative starting sequences are tested, including turbine purge, ignition, speed ramping up, generator excitation and synchronizing, and breaker close. The HIL based tests provides insights for field deployment, specifically the high-fidelity governor model provides results to predict the potential stability and reliability risk and suggest possible integration measures (e.g., generation and load balancing, tuning of governor control parameters). Ultimately, this enhanced emulation capability will be integrated into our Advanced Research on Integrated Energy Systems (ARIES), enabling us to conduct comprehensive studies on the interactions between conventional and renewable energy sources. By better understanding these interactions, we can develop strategies to optimize the overall performance and reliability of the grid. This will support the deployment of advanced grid management techniques, such as demand response, grid-forming inverters, and energy storage systems. The main contributions are summarized as follows: (1) This report introduces a PLC-based governor model for gas turbines. This model accurately simulates the dynamic behavior of conventional generation sources under various operational scenarios; (2) The model is integrated with an HIL testbed that includes a 2.5 MW variable speed drive and a 2 MVA synchronous machine. This setup enables realistic, real-time emulation of conventional power plants, particularly NG driven HRSGs and CTs; (3) The developed model is adaptable to various gas turbine configurations and allows for precise control over parameters such as MW ramp rates. This flexibility makes it a valuable tool for future research and industry collaboration; and (4) By incorporating the model into the National Renewable Energy Laboratory's Advanced Research on Integrated Energy Systems, the report lays the groundwork for future studies on interactions between conventional and renewable energy sources, enhancing the ability to develop advanced grid management strategies.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2024

Open-source electrochemical cell for in situ X-ray absorption spectroscopy in transmission and fluorescence modes

X-ray spectroscopy is a valuable technique for the study of many materials systems. Characterizing reactions in situ and operando can reveal complex reaction kinetics, which is crucial to understanding active site composition and reaction mechanisms. In this project, the design, fabrication and testing of an open-source and easy-to-fabricate electrochemical cell for in situ electrochemistry compatible with X-ray absorption spectroscopy in both transmission and fluorescence modes are accomplished via windows with large opening angles on both the upstream and downstream sides of the cell. Using a hobbyist computer numerical control machine and free 3D CAD software, anyone can make a reliable electrochemical cell using this design. Onion-like carbon nanoparticles, with a 1:3 iron-to-cobalt ratio, were drop-coated onto carbon paper for testing in situ X-ray absorption spectroscopy. Cyclic voltammetry of the carbon paper showed the expected behavior, with no increased ohmic drop, even in sandwiched cells. Chronoamperometry was used to apply 0.4 V versus reversible hydrogen electrode, with and without 15 min of oxygen purging to ensure that the electrochemical cell does not provide any artefacts due to gas purging. The XANES and EXAFS spectra showed no differences with and without oxygen, as expected at 0.4 V, without any artefacts due to gas purging. The development of this open-source electrochemical cell design allows for improved collection of in situ X-ray absorption spectroscopy data and enables researchers to perform both transmission and fluorescence simultaneously. It additionally addresses key practical considerations including gas purging, reduced ionic resistance and leak prevention.

08 HYDROGEN↗

DOE OSTI2023

Comparative Analysis of Imaging and Measurements of Micrometer-Scale Fracture Aperture Fields Within a Heterogeneous Rock Using PET and X-ray CT

Knowledge of the spatial distribution of fracture apertures is essential for reliable characterization of flow and transport processes in fractured systems and for better understanding of physicochemical matrix–fracture interactions. Here, we propose and test two image-based methods, thereby extending the current experimental capabilities to characterize aperture size distribution in structurally heterogeneous geologic porous media noninvasively. The first approach utilizes an inversion method based on the dataset acquired from positron emission tomography (PET) and the second approach considers an extension of the classic missing attenuation technique that relies on clinical X-ray computed tomography (X-ray CT). Independent sets of imaging experiments are conducted on a fractured basalt core with heterogeneous matrix properties and aperture distributions to compare the two methodologies. A repeat of each experiment is conducted to verify the proposed workflows. The performance of these two imaging techniques is systematically evaluated through the analysis of signal-to-noise ratio, minimum fracture size detectability, and measurement errors. While both approaches provide a reliable estimation of fracture aperture distributions, PET yields a signal-to-noise ratio that is substantially higher than the corresponding X-ray CT measurements. Furthermore, uncertainties of the aperture values for PET are considerably lower ($\bar {\sigma}_{\text {d}} = 15\%$) compared to those obtained from X-ray CT ($\bar {\sigma}_{\text {d}} = 29\%$), allowing for the detection of minimum aperture sizes of 20 $\mu$m with 70% confidence level. Finally, these approaches provide key experimental tools for better understanding dynamic hydromechanical fracture properties in geologic systems.

58 GEOSCIENCES↗

DOE OSTI2024

Developments for Novel Module Architecture for Lower CapEx and Improved Recyclability for c-Si PV Modules

Photovoltaic (PV) energy production is currently increasing at a significant rate. A novel module architecture has been demonstrated that has potential for reducing manufacturing cost while improving module reliability and recycling for c-Si PV which utilizes an edge-seal. Referred to as Edge Sealed Module (ESM), this architecture eliminates the vacuum lamination process and cross-linked encapsulants on the interior of the module. Functioning prototypes of c-Si have been fabricated for stress testing in collaboration with National Renewable Energy Laboratories (NREL). These modules are being tested and compared to traditionally manufactured modules. Based on preliminary results, this module architecture is a potentially viable solution for improving the manufacturing cost and recyclability of PV modules while enhancing module performance.

costs↗

DOE OSTI2025

Feeding from the sun—Successes and prospects in bioengineering photosynthesis for food security

There is an urgent need for increased crop productivity to reduce food insecurity and improve sustainability. Photosynthesis converts sunlight energy into carbohydrates, providing the source of nearly all of humanity’s food. Photosynthesis is a key target for improvement, owing to inherent inefficiencies in the biochemical process. Over the last decade of advancements in bioengineering, strategies to increase the efficiency of photosynthesis were tested with proven enhancements to crop yields in field trials. Simple strategies like increasing the content of photosynthetic proteins have reliably increased photosynthesis and productivity in crops, as have more complex strategies such as bypassing photorespiration. While insertion of carbon-concentrating mechanisms into C3 plants remains an engineering challenge, modeling suggests that achieving that would have the greatest gain for crop improvement. This review discusses the many successes in improving photosynthesis achieved over the past decade and quantifies the potential for future engineering targets to increase crop productivity.

Long, Stephen P. [University of Illinois, Urbana, ↗

DOE OSTI2026

Thermal property characterization of phase change materials in building applications: A systematic review of fundamentals, recent progress, and future directions

Phase change materials (PCMs) can reduce building peak loads and enable demand-responsive thermal energy storage (TES), but their deployment depends on reliable measurement and interpretation of thermal properties across laboratory, intermediate, and application scales. Here, this review systematically examines characterization methods, testing protocols, and recent advances for neat PCMs and PCM composites, emphasizing thermal conductivity, enthalpy-related properties (phase change temperature, latent heat, specific heat), and cycling stability. For thermal conductivity, we compare steady-state and transient techniques and note limitations when phase transition and contact resistance affect measurements. For enthalpy–temperature characterization, we discuss differential scanning calorimetry together with intermediate- and bulk-scale methods, including T-history, heat flow meter testing, and three-layer calorimetry (3LC), to generate application-relevant enthalpy–temperature profiles. Cycling stability is organized into four experimental families: thermoelectric–air, fully thermoelectric, water-bath, and in situ chamber approaches, with attention to separating reversible supercooling from true degradation such as phase segregation. We highlight emerging noncontact diagnostics, including infrared thermography and embedded sensing, for spatially resolved validation and multiscale interpretation. Finally, we review the growing use of AI and machine learning for property prediction, inverse characterization from experimental signals, and real-time state estimation in building-integrated TES. Key needs include harmonized protocols, interlaboratory benchmarking, uncertainty reporting, and metadata-rich datasets to accelerate reproducible PCM qualification for grid-flexible buildings.

AI↗

DOE OSTI2021

Linear solvers for power grid optimization problems: A review of GPU-accelerated linear solvers

The linear equations that arise in interior methods for constrained optimization are sparse symmetric indefinite, and they become extremely ill-conditioned as the interior method converges. These linear systems present a challenge for existing solver frameworks based on sparse LU or LDL T decompositions. Here, we benchmark five well known direct linear solver packages on CPU- and GPU-based hardware, using matrices extracted from power grid optimization problems. The achieved solution accuracy varies greatly among the packages. None of the tested packages delivers significant GPU acceleration for our test cases. For completeness of the comparison we include results for MA57, which is one of the most efficient and reliable CPU solvers for this class of problem.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2021

DIRT/3D: 3D root phenotyping for field-grown maize ( Zea mays )

The development of crops with deeper roots holds substantial promise to mitigate the consequences of climate change. Deeper roots are an essential factor to improve water uptake as a way to enhance crop resilience to drought, to increase nitrogen capture, to reduce fertilizer inputs, and to increase carbon sequestration from the atmosphere to improve soil organic fertility. A major bottleneck to achieving these improvements is high-throughput phenotyping to quantify root phenotypes of field-grown roots. We address this bottleneck with Digital Imaging of Root Traits (DIRT)/3D, an image-based 3D root phenotyping platform, which measures 18 architecture traits from mature field-grown maize (Zea mays) root crowns (RCs) excavated with the Shovelomics technique. DIRT/3D reliably computed all 18 traits, including distance between whorls and the number, angles, and diameters of nodal roots, on a test panel of 12 contrasting maize genotypes. The computed results were validated through comparison with manual measurements. Overall, we observed a coefficient of determination of r 2 > 0.84 and a high broad-sense heritability of H$_{mean}^{2}$ < 0.6 for all but one trait. The average values of the 18 traits and a developed descriptor to characterize complete root architecture distinguished all genotypes. DIRT/3D is a step toward automated quantification of highly occluded maize RCs. Therefore, DIRT/3D supports breeders and root biologists in improving carbon sequestration and food security in the face of the adverse effects of climate change.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2022

Air-to-Liquid Heat Exchanger Fabricated Using Deposition-Based Additive Manufacturing Processes

Abstract This work describes the use of deposition-based additive manufacturing (AM) techniques to fabricate air-cooled, two-fluid heat exchangers. The project focused on a Heating, Ventilation and Air Conditioning application and used an industry-standard copper/aluminum heat exchanger manufactured with conventional technology as the basis for assessing performance. The manufacturing constraints associated with using deposition-based AM technology for this application include the need for a continuous tool path within each build layer that allows uninterrupted extrusion and therefore defect-free water channel walls that correspond to a reliably leak-tight heat exchanger. A geometry that respects these constraints was developed, simulated, optimized and finally manufactured and tested. The material used was a composite of polymer filled with conductive flakes in order to provide high conductivity in the direction that heat must flow in this heat exchanger, across the wall separating the fluids. The measured performance for several test coupons matched the predicted performance and the test coupons exhibited performance that approach and in some cases exceeds conventional technology

Engineering↗

DOE OSTI2022

Large Scale Metal Additive Manufacturing for Stamping Dies

Oak Ridge National Laboratory (ORNL) worked with Dienamic Tooling Systems (DTS) in a follow-on Phase 2 effort to develop and demonstrate additively manufactured conformal cooling for hot stamping dies, providing a new industry capability that did not previously exist. Current approaches to die cooling are nonoptimal and based on what can be machined with traditional technologies. The printed approach to hot stamping cooling channels allows an analytical needs-based size and placement approach to cooling. Cooling is optimized and parts count is reduced producing a simpler more reliable faster to manufacture stamping tool. An additively manufactured hot stamping die with conformal cooling channels was manufactured and successfully tested in a real-world environment.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Analyses Supporting Heat Pipe Experiments

This internship report presents thermal analysis support aiding the development efforts of advanced reactor systems as a part of the Department of Energy Microreactor Program. The heat pipe microreactor (HPMR) is one such reactor concept where the heat from the reactor core is removed via passively operating heat pipes. Heat pipes have found numerous applications in many fields due to their simplicity, effectiveness, and reliability. The present work includes a review of heat pipe experiments and experimental techniques, ideation on experiments using the SPHERE test bed, identification of heat pipe phenomena of interest, and suggestions for future directions on heat pipe experiments. Hence, it directly supports the development of heat pipe microreactors (HPMRs).

22 GENERAL STUDIES OF NUCLEAR REACTORS↗