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DOE OSTI2017

DE-FOA-EE0005502 Advanced Percussive Drilling Technology for Geothermal Exploration and Development Phase II Report.

Percussive hammers are a promising advance in drilling technology for geothermal since they rely upon rock reduction mechanisms that are well-suited for use in the hard, brittle rock characteristic of geothermal formations. The project research approach and work plan includes a critical path to development of a high-temperature (HT) percussive hammer using a two- phase approach. The work completed in Phase I of the project demonstrated the viability of percussive hammers and that solutions to technical challenges in design, material technology, and performance are likely to be resolved. Work completed in Phase II focused on testing the findings from Phase I and evaluating performance of the materials and designs at high- operating temperatures. A high-operating temperature (HOT) drilling facility was designed, built, and used to test the performance of the DTH under extreme conditions. Results from the testing indicate that a high-temperature capable hammer can be developed and is a viable alternative for user in the driller's toolbox.

15 GEOTHERMAL ENERGY↗

DOE OSTI2015

Task Order 20: Supercritical Carbon Dioxide Brayton Cycle Energy Conversion Study

AREVA Inc. developed this study for the US Department of Energy (DOE) office of Nuclear Energy (NE) in accordance with Task Order 20 Statement of Work (SOW) covering research and development activities for the Supercritical Carbon Dioxide (sCO2) Brayton Cycle energy conversion. The study addresses the conversion of sCO2 heat energy to electrical output by use of a Brayton Cycle system and focuses on the potential of a net efficiency increase via cycle recuperation and recompression stages. The study also addresses issues and study needed to advance development and implementation of a 10 MWe sCO2 demonstration project.

03 NATURAL GAS↗

DOE OSTI2017

Final Scientific/Technical Report: Correlations and Fluctuations in Weakly Collisional Plasma

Plasma is a state of matter that exhibits a very rich range of phenomena. To begin with, plasma is both electrical and mechanical - bringing together theories of particle motion and the electromagnetic field. Furthermore, and especially important for this project, a weakly-collisional plasma, such as is found in high-temperature (fusion energy) experiments on earth and the majority of contexts in space and astrophysics, has many moving parts. For example, sitting in earth’s atmosphere we are immersed in a mechanical wave field (sound), a possibly turbulent fluid motion (wind), and an electromagnetic vector wave field with two polarizations (light). This is already enough to produce a rich range of possibilities. In plasma, the electromagnetic field is coupled to the mechanical motion of the medium because it is ionized. Furthermore, a weakly-collisional plasma supports an infinite number of mechanically independent fluids. Thus, plasmas support an infinite number of independent electromechanical waves. Much has been done to describe plasmas with "reduced models" of various kinds. The goal of this project was to both explore the validity of reduced plasma models that are in use, and to propose and validate new models of plasma motion. The primary means to his end was laboratory experiments employing both electrical probes and laser spectroscopy. Laser spectroscopy enables many techniques which can separate the spectrum of independent fluid motions in the ion phase-space. The choice was to focus on low frequency electrostatic waves because the electron motion is relatively simple, the experiments can be on a spatial scale of a few meters, and all the relevant parameters can be measured with a few lasers systems. No study of this kind had previously been undertaken for the study of plasmas. The validation of theories required that the experimental descriptions be compared with theory and simulation in detail. It was found that even multi-fluid theories leave out a large part of the complexity of plasma motion. Reduced descriptions were found to fail under most circumstances. A new technique was developed that enabled a measurement of the phase-space resolved ion correlation function for the first time. The wide range of plasma dynamics possible became clear through this technique. It was found that collisionless (Vlasov) theory has a large field of application even when the plasma is weakly-collisional. A new approach, the kinetic wave expansion, was proposed, tested and found to be very useful for describing electrostatic ion waves. This project demonstrated a new way of looking at the "degrees-of-freedom" of plasmas and provided significant validation tests of fluid and kinetic plasma descriptions.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2017

High Specific Stiffness Shafts and Advanced Bearing Coatings for Gas Turbine Engines Final Report CRADA No. TC-1089-95

At the time of the CRADA, the largest in-service gas-turbine aircraft engines strove for increased thrust and power density to meet the requirements for take-off thrust, given the increase in take-off gross weight (TOGW) associated with longer range transport requirements. The trend in modem turbo shaft engines was toward turbine shafts with higher and higher length-to-diameter ratios, which reduced the shaft critical speed. Using co nventional shaft materials, this lead to shafts that needed to operate near or above sensitive shaft bending critical speeds, therefore requiring multiple bearings and/ or multiple squeeze-film dampers to control the dynamic response. Using new materials and d esign concepts this project demonstrated the use of new shaft materials which could provide increased shaft speed range above existing maximum engine speeds without encountering a critic al speed event and high vector deflections. This increased main shaft speed also resulted in decreased bearing life associated with lower heat dissipation and higher centrifugal forces. Thus, a limited effort was devoted to feasibility of higher performance bearing coatings to mitigate the speed effects.

42 ENGINEERING↗

DOE OSTI2017

Developments of solid materials for UF 6 sampling

This project demonstrated that a device using majority Commercial Off the Shelf (COTS) components could be used to collect uranium hexafluoride samples safely from gaseous or solid sources. The device was based on the successful Cristallini method developed by ABACC over the past 10 years. The system was designed to capture and store the UF 6 as an inert fluoride salt to ease transportation regulations. In addition, the method was considerably faster than traditional cryogenic methods, collected enough material to perform analyses without undue waste, and could be used either inside a facility or in the storage yard.

36 MATERIALS SCIENCE↗

DOE OSTI2018

NREL Topic 1 Final Report: Cohesive Application of Standards-Based Connected Devices to Enable Clean Energy Technologies

This document is the final report of a two-year development, test, and demonstration project entitled 'Cohesive Application of Standards-Based Connected Devices to Enable Clean Energy Technologies.' The project was part of the National Renewable Energy Laboratory's (NREL) Integrated Network Test-bed for Energy Grid Research and Technology (INTEGRATE) initiative. The Electric Power Research Institute (EPRI) and a team of partners were selected by NREL to carry out a project to develop and test how smart, connected consumer devices can act to enable the use of more clean energy technologies on the electric power grid. The project team includes a set of leading companies that produce key products in relation to achieving this vision: thermostats, water heaters, pool pumps, solar inverters, electric vehicle supply equipment, and battery storage systems. A key requirement of the project was open access at the device level - a feature seen as foundational to achieving a future of widespread distributed generation and storage. The internal intelligence, standard functionality and communication interfaces utilized in this project result in the ability to integrate devices at any level, to work collectively at the level of the home/business, microgrid, community, distribution circuit or other. Collectively, the set of products serve as a platform on which a wide range of control strategies may be developed and deployed.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2017

Final Report: Conceptual Design of an Electron Accelerator for Bio-Solid Waste Treatment

Several studies have identified electron beam (EB) irradiation of municipal wastewater and bio-solids as an effective and promising approach to the environmental remediation of the enormous quantities of human waste created by a growing world-wide population and increased urbanization. However, despite the technical success of experimental and pilot programs over the last several decades, the technique is still not in commercial use anywhere in the world. In addition, the report also identifies the need for “Financial and infrastructure participation from a utility for demonstration project” and “Education and awareness of safety of utilizing electron beam technology” as two additional roadblocks preventing technology adoption of EB treatment for bio-solids. In this concept design, we begin to address these barriers by working with Metropolitan Water Reclamation District of Greater Chicago (MWRD) and by the applying the latest accelerator technologies developed at Fermilab and within the DOE Office of Science laboratory complex.

43 PARTICLE ACCELERATORS↗

DOE OSTI2018

STTR Phase I: Low-Cost, High-Accuracy, Whole-Building Carbon Dioxide Monitoring for Demand Control Ventilation

This STTR Phase I project assessed the feasibility of a new CO 2 sensing system optimized for low-cost, high-accuracy, whole-building monitoring for use in demand control ventilation. The focus was on the development of a wireless networking platform and associated firmware to provide signal conditioning and conversion, fault- and disruptiontolerant networking, and multi-hop routing at building scales to avoid wiring costs. Early exploration of a bridge (or “gateway”) to direct digital control services was also explored. Results of the project contributed to an improved understanding of a new electrochemical sensor for monitoring indoor CO 2 concentrations, as well as the electronics and networking infrastructure required to deploy those sensors at building scales. New knowledge was acquired concerning the sensor’s accuracy, environmental response, and failure modes, and the acquisition electronics required to achieve accuracy over a wide range of CO 2 concentrations. The project demonstrated that the new sensor offers repeatable correspondence with commercial optical sensors, with supporting electronics that offer gain accuracy within 0.5%, and acquisition accuracy within 1.5% across three orders of magnitude variation in generated current. Considering production, installation, and maintenance costs, the technology presents a foundation for achieving whole-building CO 2 sensing at a price point below $0.066 / sq-ft – meeting economic feasibility criteria established by the Department of Energy. The technology developed under this award addresses obstacles on the critical path to enabling whole-building CO 2 sensing and demand control ventilation in commercial retrofits, small commercial buildings, residential complexes, and other highpotential structures that have been slow to adopt these technologies. It presents an opportunity to significantly reduce energy use throughout the United States.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2018

Biofuel Micro-Refineries for Local Sustainability (Final Report)

This project demonstrated the adaptability of commercial off-the-shelf instrumentation and controls designed for continuous flow large-scale refineries to a transportable micro-scale refinery that will enable production of fuel from bio-feedstock by small groups such as a municipality or farmer cooperative.

09 BIOMASS FUELS↗

DOE OSTI2018

Continuous Silicon Consolidation and Reduction

The goal of the Department of Energy’s (DOE’s) Sunshot program is to increase the adaptability of photovoltaic (PV) solar power generation by reducing the cost of power generation. The cost of polysilicon is one of several factors affecting the costs of a solar power module. The National Renewable Energy Laboratory (NREL) assumes module manufacturing costs (all-in vertically integrated module production) of 0.63 (cents)/Wdc (2015 NREL data). If the NREL polysilicon costs are replaced by the SRI International (SRI) polysilicon costs, the module manufacturing costs are reduced to 0.58 (cents)/Wdc (2015 basis) i.e., reduction of 0.05 (cents)/Wdc. The NREL cost model (System Advisor Module, SAM) is based on $20/kg of blended polysilicon silicon cost. The Continuous Silicon Consolidation and Reduction (CoSiRC) process is estimated to produce polysilicon at 8.06 (dollars)/kg. In addition, SRI’s CoSiRC process introduces a commercially viable path to recycle and reclaim kerf loss silicon fines that would otherwise go to a landfill, thereby reducing a precious resource from going to waste. The results of this project demonstrate that SRI’s silicon production process that uses a reduction reaction can be successfully integrated with a kerf loss reclaiming process. The combined process was first demonstrated at lab scale and then fit to a bench-scale process. Leveraging the industrial expertise of the commercial partners, it is feasible to adapt industrial-scale equipment for SRI’s CoSiRC process.

14 SOLAR ENERGY↗

DOE OSTI2019

Electrogenerative Reactors for Process Intensified Cogeneration of Power and Liquid Fuel from Shale Gas

With the abundance of natural gas and its primary components of methane, ethane and propane, there is the opportunity to convert these light alkanes to higher-value products. The growth in natural gas supply in the U.S. has increased substantially since the mid-2000s due to advances in horizontal drilling and hydraulic fracturing. As petroleum prices are volatile, natural gas resources are progressively attractive as alternative fuel sources. However, many of these shale gas wells are in regions of the U.S. that are remote and costly to transport to petrochemical and refining centers. In addition, much of this shale gas is “wet gas” that contains condensable amounts of ethane. While dedicated ethane gas pipelines have been built to get a small fraction of this gas to market, they are very capital intensive and compete for existing land use. As a result of this Phase I project, we developed a process to convert ethane to a transportable liquid fuel. This was achieved by implementing process intensification for this gas-to-liquids approach; we use novel eletrogenerative reactors in a two-step process rather than multi-step well-known technologies such as Fisher-Tropsch synthesis. These reactors borrow on well proven solid oxide fuel cell technology. Therefore, when produced in mass will be a very low-cost modular chemical reactor. This project demonstrated that EcoCatlaytic’s catalysts are highly selective towards ethylene and are compatible with anode materials. These integrated catalysts with the anode were able to maintain stable activity under ethane. Process simulations demonstrate an energy savings while producing gasoline and electricity for a modular system that produces 1,000 bbl/day gasoline. The system, not only produces gasoline, but also generates electricity which is a very valuable commodity in the remote shale gas facilities. This process could potentially allow remote natural gas producers to upgrade their feedstock to valuable gasoline on-site rather than flaring.

03 NATURAL GAS↗

DOE OSTI2019

A platform for quantum information and large-scale entanglement with Rydberg atoms in programmable optical potentials

Large-scale quantum systems with controllable interactions are important for understanding complex phenomena in nature, and are the basis for advanced quantum technologies. Realizing a controllable platform for controlling, understanding, and ultimately harnessing the entanglement is an outstanding challenge in quantum science. This project demonstrated reconfigurable arrays of individually-trapped ultracold atoms, thus realizing a platform that could demonstrate large-scale quantum entanglement with the addition of strong inter-atomic interactions. Arrays of more than 50 trap sites were formed via digital holography and a high-numerical aperture imaging system that featured in-situ trap diagnostics and single-atom imaging resolution. We further discovered a new implementation of a controlled-phase gate that utilized coherent excitation to Rydberg states. This method will enable robust entanglement protocols in many-atom systems such as the one developed here.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2019

Used Fuel Storage Monitoring Using Helium-4 Scintillation Fast Neutron Detectors and Neutron Spectral Analysis

This project aimed to address the technology gap in the reliable methods to verify contents of sealed dry storage casks for spent nuclear fuel. Helium-4 gas scintillation neutron detectors was proposed to be developed into a neutron spectroscopy and imaging system for nuclear security and safeguards applications. 4 He gas is significantly more available than 3 He gas and it has unique advantages such as low gamma interaction probability and direct detection of fast neutrons. Due to the sheer amount of fissile materials in a single dry cask, there is a significant neutron fluence emitted whose energies range from thermal to uncollided high-energy neutrons suitable for the detection capability of the 4 He detectors. Our project demonstrated the first ever neutron spectroscopic capabilities using 4 He detectors, explored novel detector design and performed detector characterization. It further qualified the detectors for use in various applications including high-flux environments with significant gamma-fluence. Computer simulations were used to test various large cask measurement system designs and tests, beyond the compact prototype system and laboratory measurements exploring the feasibility of the neutron spectroscopic approach. Although some cask-characterization methods proved unfeasible, alternative characterization methods using the He-4 detectors were explored and generated promising results.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2019

Analysis of Gas Samples Taken from the High Burnup Demonstration Cask

The High Burn-Up Demonstration Project was recently initiated by the Department of Energy (DOE) to evaluate the effects of fuel drying and long term dry storage on high burn-up spent nuclear fuel. As part of the project, samples of the He backfill gas were collected 5 hours, 5 days, and 12 days after completion of drying. The samples provide information on the state of the fuel at closure, and on the environment within the cask. At Sandia National Laboratories, the samples were analyzed by gamma-ray spectroscopy to quantify fission product gases and by gas mass spectrometry to quantify bulk and trace gases; water content was measured via humidity probe. Gamma-ray spectroscopy results indicated no detectible 85 Kr, indicating no failed fuel rods were present after drying. Mass spectrometry indicated build-up of CO 2 to 930 ppmv over two weeks, attributed to oxidation of organic compounds (possibly vacuum grease or vacuum pump oil) within the cask. H 2 , generated by either radiolysis or metal corrosion, also increased up to —500 ppmv. Water contents in the cask were higher than anticipated, increasing to —17,400 ppmv ±10% after 12 days. Measuring water content proved challenging, and possible improvements to the method for future analyses are proposed.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2018

Distributed Generation Valuation and Compensation

This white paper can help guide a state as it considers issues associated with distributed generation valuation and compensation. States may address a common set of questions and issues in the valuation process, but differences in market expectations, policy priorities, and regulations result in different responses. Key issues include: Context is important. Valuations and compensation strategies will vary based on goals and objectives they are being designed to achieve. Goals and objectives should be made clear up front and will drive the perspective used in performing valuations and how outcomes are applied. Utilities and stakeholders can have different interpretations of how value elements should be calculated. In some states, the objective of standardized calculators and methods is to reduce ambiguity and inconsistencies in how valuations are performed. Certain value elements are difficult or impossible to quantify and most efforts to establish workable value of solar or value of distributed energy resource tariffs are emerging and nascent. Assessing locational and temporal value of distributed generation and applying that in compensation schemes is a new and emerging field of study, being explored by a handful of research organizations and advanced states and utilities. The most advanced states, such as California, are using demonstration projects to test valuation and compensation methodologies or are applying valuation and compensation strategies to a subset of customer projects, such as for community solar projects (e.g., Oregon and New York) before rolling out programs to the full customer base. A variety of states are moving away from full net metering, in many cases substituting avoided cost rates (sometimes with an adder) in lieu of full retail rate compensation, instead of pursuing valuation of distributed energy resource approaches. For example, in Indiana a 25% adder is applied to average wholesale electricity prices and in Mississippi a 2.5 cents/kWh adder is applied to avoided cost rates. These adders appear to have been established through policy directives rather than a comprehensive cost of service valuations.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2018

Permanent Magnet Synchronous Motors for Commercial Refrigeration (Final Report)

This report provides background information on various fractional-horsepower electric motor technologies used for evaporator fan applications in commercial refrigeration and summarizes data from a DOE-sponsored evaporator fan motor laboratory and field demonstration project. This report also extrapolates that data to project the potential economic and environmental benefits resulting from upgrading the current installed base of commercial refrigeration evaporator fan motors to permanent magnet synchronous (PMS) motors.Evaporator fan motors used in commercial refrigeration applications are fractional horsepower in size, responsible for moving air across the evaporator coil, and typically run at one speed. Historically, shaded-pole induction motors have been the most commonly used evaporator fan motors in commercial refrigeration equipment and beverage vending machines. These are the simplest and least expensive type of fractional-horsepower motor, with an efficiency of approximately 20%. Electronically commutated (EC) permanent magnet motors, also known as brushless DC motors, were initially commercialized in the late 1980s, and their use in commercial refrigeration applications has increased within the last 10 to 15 years because of economic incentives and regulatory requirements. State-of-the-art EC motors are approximately 66% efficient. Another induction motor type, the permanent split capacitor (PSC) motor, offers a mid-point between shaded-pole and EC motor price and efficiency levels. PSC motors are typically about 29% efficient.A permanent magnet synchronous (PMS) AC motor that can directly use grid-supplied AC current without the need to rectify to DC has recently been commercialized. This new motor exhibits a peak efficiency of 75% and has the potential to significantly reduce the energy consumption of evaporator fan motors in commercial refrigeration equipment. Laboratory evaluation of evaporator fan motor technologies was performed to quantify and compare the performance of shaded-pole, PSC, EC, and PMS evaporator fan motors in a controlled environment, so as to minimize the influence of external factors and anomalies. The laboratory evaluation included dynamometer testing of the fan motors and airflow testing of the motor/fan assemblies. It was found that the 6–12 W PMS motor exhibited a peak efficiency of 75% with a power factor of approximately 0.9 at a power output of 11 W. It was also found that a 38–50 W PMS motor exhibited a peak efficiency of 82% with a power factor of approximately 0.9 at a power output of 35 W.Airflow testing of shaded-pole, PSC, EC, and PMS motor/fan assemblies was performed using an airflow test chamber, which was designed in accordance with ANSI/AMCA Standard 210-16/ASHRAE Standard 51-16, to measure the performance of the subject motor/fan assembly and to determine the incumbent display case system impedance (AMCA 2016). A family of fan curves (static pressure vs airflow rate and electrical power input vs airflow rate) was generated for the 6–12 W PMS motor/fan assemblies with 8-inch fan blades pitched from 17 to 32 degrees. A similar set of curves was generated for the 38–50 W motors paired with 10 and 12-inch blades. Various incumbent motor/fan assemblies were also tested in the laboratory airflow test chamber and their fan curves were generated.Field evaluation of refrigerated display case evaporator fan motors was accomplished by performing side-by-side comparisons of 6–12 W PMS motors to 6–12 W shaded-pole and EC evaporator fan motors. It was found that, on average, a PMS motor consumes 79% less power and draws 82% less current than a shaded pole motor, and on average, 34% less power and 49% less current than an EC motor. In addition, the PMS motor exhibits an average power factor of approximately 0.82, which is on average 40% greater than that of existing evaporator fan motors.Two field test sites were selected to evaluate the performance of the larger 38 to 50 W PMS evaporator fan motors in walk-in cooler/freezer applications. At each supermarket, two walk-in units were selected for investigation: one walk-in dairy cooler and one walk-in freezer. A 61% decrease in fan motor power was measured when retrofitting existing evaporator fan motors with PMS motors in the walk-in cooler. In addition, a 48% decrease in fan motor power was measured when retrofitting existing evaporator fan motors with PMS motors in the walk-in freezer.The culmination of the field evaluation of fan motor technologies was a whole-store retrofit conducted at a supermarket. Pre- and post-retrofit measurement of evaporator fan motor power in medium- and low-temperature refrigerated display cases and walk-in coolers/freezers was performed. Overall for the whole-store retrofit, the current supplied to all monitored evaporator fan motors was reduced by 52%, the real power was reduced by 46% and the apparent power was reduced by 51% following the retrofit of the 262 evaporator fan motors that w

42 ENGINEERING↗

DOE OSTI2019

Conceptual Design of an Electron Accelerator for Bio-Solid Waste Treatment.

43 PARTICLE ACCELERATORS↗

DOE OSTI2019

Initial DOE SNF Standardized Canister Storage Configuration Alternatives Study

This study looks at storage configuration alternatives for United States Department of Energy (DOE) Spent Nuclear Fuel (SNF) Standardized Canisters loaded with DOE-owned SNF. The focus of the study is for the DOE SNF Standardized Canisters that would be packaged in the Idaho Nuclear Technology and Engineering Center (INTEC) area at Idaho National Laboratory (INL), but its general findings are useful across the DOE Complex. The study considered storage in existing facilities, modified existing facilities, new facilities, and new modular systems. The existing INTEC facilities considered in the study include the CPP-603 Irradiated Fuel Storage Facility (IFSF), the CPP-749 Underground Fuel Storage Facility (UFSF), the CPP-666 SNF Wet Storage Basin Facility, CPP-1774 Three Mile Island (TMI) Independent Spent Fuel Storage Facility (ISFSF), and the CPP-2707 Cask Pad Facility. The new facilities considered in the study include the Foster Wheeler designed Idaho Spent Fuel (ISF) Independent Spent Fuel Storage Installation (ISFSI) and some conceptual designs. The new modular systems considered in the study include Holtec International’s HI-STAR/HI-STORM, NAC International’s MAGNASTOR/UMS/MPC and Orano TN’s MATRIX/NUHOMS. Based on considerations of various factors, including but not limited to capacity, impact to facility operations, capital costs, expenditure rate, licensing issues, agreements with the State of Idaho, and road ready conditions, new modular storage systems from commercial vendors may have clear advantages over other storage alternatives. This is further supported by recent experience with West Valley Demonstration Project (WVDP) storage project for High Level Waste Glass canisters.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗