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DOE OSTI2024

Retrofitting Holcim Ste. Genevieve Cement Plant with CO2 Capture Plant Using Air Liquide Cryocap™ FG Technology

The global cement manufacturing industry is a major contributor to carbon dioxide emissions. The International Energy Agency's "Net Zero Emissions by 2050 Scenario" identifies CCS as a major strategy for meeting that goal. This project is among the first attempts to transfer capture technology developed at coal-fired power plants to the cement industry. The main objective of the project is to execute and complete a front-end engineering and design (FEED) studies for commercial-scale, carbon capture projects that separates 95% of the total CO2 emissions at the Holcim (US) Ste. Genevieve cement manufacturing facility using Air Liquide’s Pressure Swing Adsorption system (PSA) assisted Cryocap™ technology. The Holcim Ste. Genevieve cement plant in Missouri, US, boasts one of the largest single cement production lines in the world, with a capacity of approximately 12,000 t/day. The plant currently uses traditional fuels, namely coal and petcoke. The captured CO2 will be pipeline and geological storage grade. The industrial host site emits approximately 3.0 million tonne CO2/yr. Air Liquide’s Cryocap™ technology has been developed over the last 18+ years for CO2 capture applications. It has been shown to be applicable to a variety of industrial applications (e.g., steel, cement, SMR, Fluidized Catalytic Crackers (FCCs)). Cryocap™ FG consists of a Pressure Swing Adsorption (PSA) unit coupled with a Cryogenic System. The PSA pre-concentrates the CO2 from the flue gas, while the cryogenic unit enables the CO2 purity to be increased to the desired level. The project team is led by the Prairie Research Institute at the University of Illinois at Urbana-Champaign. The tasks include: complete FEED study for retrofitting the industrial facility with a carbon capture system to support developing a detailed cost estimate; business case analysis outlining the anticipated revenue and credits if projects was built and operated; technoeconomic analysis (TEA) outlining how capture system achieves DOE capture goals; and life cycle (LCA) analysis demonstrating zero net carbon emissions. The FEED study was successfully completed. This includes completing the process basis of design; preliminary engineering; outside battery limits (OSBL) detailed engineering including a Zero Liquid Discharge (ZLD) wastewater treatment system; inside battery limits (ISBL) detailed engineering [1]. An overall project capital cost estimate within a -20%/+30% accuracy was developed. The major contributors to the Total Plant Cost (TPC), by system, are the costs associated with the Outside Battery Limit (OSBL) section of the plant which includes a new river water intake structure and a Zero Liquid Discharge (ZLD) system. By cost category, the major contributors to the TPC are equipment and subcontractor costs, followed closely by engineering, construction management, home office and contractor fees. The TEA has been created to reflect the findings of the project. It analyzes the economic performance of the Cryocap™ technology by reviewing the estimated capital costs, operating cost, and revenue. The Cost of Capture (COC) associated with the Cryocap™ technology for 95% CO2 capture, when considering NETL 2018 economic assumptions (42/58 debt/equity ratio, 5.15% interest on debt and 1.42% return on equity in real dollars) and 2022 economic assumptions (42/58 debt/equity ratio, 8.82% interest on debt and 4.90% return on equity in real dollars) was found to be much lower than that for the DOE-NETL’s base-line cases. The highest contributors to the COC are annualized capital expenditures (CAPEX) and electricity consumption which can be offset by using lower cost renewable sources. The LCA was conducted using OpenLCA which is an open-source software that is recommended by NETL. The database utilized for this study was a modified version of TRACI 2.1 (developed by the US. Environmental Protection Agency’s National Risk Management Research Laboratory and modified by NETL). The Cryocap™ FG technology does not consume fuels in significant quantities and does not utilize specialized chemical solvents subject to decomposition, such as those utilized in amine-based carbon capture systems. The Cryocap™ FG technology mainly utilizes electricity as its energy input; hence, its calculated emissions are mainly associated with the generation of electricity offsite and are dependent on the energy matrix of the grid at the time of project implementation. The water consumption impact of the Cryocap™ FG is mostly for makeup of the water lost by evaporation in the cooling tower; however, the carbon capture plant will be equipped with a ZLD system to avoid effluent streams and minimize water consumption. The successful construction and operation of this plant based on this study results will provide a means to demonstrate an economically attractive and transformational capture technology that can be used to retrofit existing plants and be deployed at new plants.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2011

U.S. Billion-Ton Update: Biomass Supply for a Bioenergy and Bioproducts Industry

The report, Biomass as Feedstock for a Bioenergy and Bioproducts Industry: The Technical Feasibility of a Billion-Ton Annual Supply (generally referred to as the Billion-Ton Study or 2005 BTS), was an estimate of 'potential' biomass based on numerous assumptions about current and future inventory, production capacity, availability, and technology. The analysis was made to determine if conterminous U.S. agriculture and forestry resources had the capability to produce at least one billion dry tons of sustainable biomass annually to displace 30% or more of the nation's present petroleum consumption. An effort was made to use conservative estimates to assure confidence in having sufficient supply to reach the goal. The potential biomass was projected to be reasonably available around mid-century when large-scale biorefineries are likely to exist. The study emphasized primary sources of forest- and agriculture-derived biomass, such as logging residues, fuel treatment thinnings, crop residues, and perennially grown grasses and trees. These primary sources have the greatest potential to supply large, reliable, and sustainable quantities of biomass. While the primary sources were emphasized, estimates of secondary residue and tertiary waste resources of biomass were also provided. The original Billion-Ton Resource Assessment, published in 2005, was divided into two parts-forest-derived resources and agriculture-derived resources. The forest resources included residues produced during the harvesting of merchantable timber, forest residues, and small-diameter trees that could become available through initiatives to reduce fire hazards and improve forest health; forest residues from land conversion; fuelwood extracted from forests; residues generated at primary forest product processing mills; and urban wood wastes, municipal solid wastes (MSW), and construction and demolition (C&D) debris. For these forest resources, only residues, wastes, and small-diameter trees were considered. The 2005 BTS did not attempt to include any wood that would normally be used for higher-valued products (e.g., pulpwood) that could potentially shift to bioenergy applications. This would have required a separate economic analysis, which was not part of the 2005 BTS. The agriculture resources in the 2005 BTS included grains used for biofuels production; crop residues derived primarily from corn, wheat, and small grains; and animal manures and other residues. The cropland resource analysis also included estimates of perennial energy crops (e.g., herbaceous grasses, such as switchgrass, woody crops like hybrid poplar, as well as willow grown under short rotations and more intensive management than conventional plantation forests). Woody crops were included under cropland resources because it was assumed that they would be grown on a combination of cropland and pasture rather than forestland. In the 2005 BTS, current resource availability was estimated at 278 million dry tons annually from forestlands and slightly more than 194 million dry tons annually from croplands. These annual quantities increase to about 370 million dry tons from forestlands and to nearly 1 billion dry tons from croplands under scenario conditions of high-yield growth and large-scale plantings of perennial grasses and woody tree crops. This high-yield scenario reflects a mid-century timescale ({approx}2040-2050). Under conditions of lower-yield growth, estimated resource potential was projected to be about 320 and 580 million dry tons for forest and cropland biomass, respectively. As noted earlier, the 2005 BTS emphasized the primary resources (agricultural and forestry residues and energy crops) because they represent nearly 80% of the long-term resource potential. Since publication of the BTS in April 2005, there have been some rather dramatic changes in energy markets. In fact, just prior to the actual publication of the BTS, world oil prices started to increase as a result of a burgeoning worldwide demand and concerns about long-term supplies. By the end of the summer, oil prices topped $70 per barrel (bbl) and catastrophic hurricanes in the Gulf Coast shut down a significant fraction of U.S. refinery capacity. The following year, oil approached $80 per bbl due to supply concerns, as well as continued political tensions in the Middle East. The Energy Independence and Security Act of 2007 (EISA) was enacted in December of that year. By the end of December 2007, oil prices surpassed $100 per bbl for the first time, and by mid-summer 2008, prices approached $150 per bbl because of supply concerns, speculation, and weakness of the U.S. dollar. As fast as they skyrocketed, oil prices fell, and by the end of 2008, oil prices dropped below $50 per bbl, falling even more a month later due to the global economic recession. In 2009 and 2010, oil prices began to increase again as a result of a weak U.S. dollar and the rebounding of world economies.

09 BIOMASS FUELS↗
DOE OSTI2011

EnergySavers: Tips on Saving Money & Energy at Home (Brochure)

The U.S. Department of Energy's consumer guide to saving money and energy at home and on the road. It consists of the following articles: (1) Save Money and Energy Today - Get started with things you can do now, and use the whole-house approach to ensure that your investments are wisely made to save you money and energy; (2) Your Home's Energy Use - Find out how your home uses energy, and where it's losing the most energy so you can develop a plan to save in the short and long term; (3) Air Leaks and Insulation - Seal air leaks and insulate your home properly so your energy dollars don't seep through the cracks; (4) Heating and Cooling - Use efficient systems to heat and cool your home, and save money and increase comfort by properly maintaining and upgrading equipment; (5) Water Heating - Use the right water heater for your home, insulate it and lower its temperature, and use less water to avoid paying too much; (6) Windows - Enjoy light and views while saving money by installing energy-efficient windows, and use strategies to keep your current windows from losing energy; (7) Lighting - Choose today's energy-efficient lighting for some of the easiest and cheapest ways to reduce your electric bill; (8) Appliances - Use efficient appliances through-out your home, and get greater performance with lower energy bills; (9) Home Office and Electronics - Find out how much energy your electronics use, reduce their out-put when you're not using them, and choose efficient electronics to save money; (10) Renewable Energy - Use renewable energy at home such as solar and wind to save energy dollars while reducing environmental impact; (11) Transportation - Choose efficient transportation options and drive more efficiently to save at the gas pump; and (12) References - Use our reference list to learn more about energy efficiency and renewable energy.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2012

Manufacturing Process Modeling of 100-400 kW e Combined Heat and Power Stationary Fuel Cell Systems

A one year project to examine the processes employed in the manufacture of combined heat and power stationary fuel cells operating in the 100-400kWe range was commissioned in June 2010. The results of this project would be used to inform decision makers in charge of allocating R&D resources by highlighting the most expensive steps in the manufacturing process where processing alternatives might have the greatest potential for high impact cost reduction. Three fuel cell technologies were examined: phosphoric acid (PAFC), molten carbonate (MCFC), and solid oxide (SOFC) fuel cells. Two fuel cell technologies, PAFC and MCFC, are represented by commercially available products within the study boundaries. United Technologies Corporation (UTC) offers the PureCell 400 ® , a 400 kWe combined heat and power PAFC system. FuelCell Energy (FCE) offers the DFC-300 ® , a 375 kWe combined heat and power MCFC. A combined heat and power SOFC within the study boundaries is not available in the marketplace at the time of this study. Process based cost models using 2010 dollars were developed for each fuel cell technology. For all three technologies, model boundaries encompassed all direct and indirect materials; direct and indirect labor; capital, maintenance, tooling, floor space, and energy costs associated with the manufacturing process. Cost estimates were developed with academic and patent literature, industry partners, supplier quotations, Monte Carlo simulation software, and DFMA software. Life cycle and non-manufacturing costs such as sales, administration, R&D, office floor space, and profit were not quantified. Results presented are for assumed annual production volumes of 5, 20, 50, and 500 MWe/yr, and expressed in terms of dollars per kilowatt of electrical energy. A model baseline production volume of 20 MWe/yr (similar to recent production volumes experienced by UTC and FCE) was assumed for all three technologies.

Warren, Joshua A.↗
DOE OSTI2014

Economic Impact of Pacific Northwest National Laboratory on the State of Washington in Fiscal Year 2013

Pacific Northwest National Laboratory (PNNL) is a large economic entity, with $1.06 billion in annual funding, $936 million in total spending, and 4,344 employees in fiscal year (FY) 2013. Four thousand, one hundred and one (4,101) employees live in Washington State. The Laboratory directly and indirectly supports almost $1.31 billion in economic output, 6,802 jobs, and $514 million in Washington State wage income from current operations. The state also gains more than $1.21 billion in output, more than 6,400 jobs, and $459 million in income through closely related economic activities, such as visitors, health care spending, spending by resident retirees, and spinoff companies. PNNL affects Washington’s economy through commonly recognized economic channels, including spending on payrolls and other goods and services that support Laboratory operations. Less-commonly recognized channels also have their own impacts and include company-supported spending on health care for its staff members and retirees, spending of its resident retirees, Laboratory visitor spending, and the economic activities in a growing constellation of “spinoff” companies founded on PNNL research, technology, and managerial expertise. PNNL also has a significant impact on science and technology education and community nonprofit organizations. PNNL is an active participant in the future scientific enterprise in Washington with the state’s K-12 schools, colleges, and universities. The Laboratory sends staff members to the classroom and brings hundreds of students to the PNNL campus to help train the next generation of scientists, engineers, mathematicians, and technicians. This investment in human capital, though difficult to measure in terms of current dollars of economic output, is among the important lasting legacies of the Laboratory. Finally, PNNL contributes to the local community with millions of dollars’ worth of cash and in-kind corporate and staff contributions, all of which strengthen the economy. This report quantifies these effects, providing detailed information on PNNL’s revenues and expenditures, as well as the impacts of its activities on the rest of the Washington State economy. This report also describes the impacts of the four closely related activities: health care spending, spinoff companies with roots in PNNL, visitors to the Laboratory, and PNNL retirees.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2012

Evolution of the U.S. Energy Service Company Industry: Market Size and Project Performance from 1990-2008

The U.S. energy service company (ESCO) industry is an example of a private sector business model where energy savings are delivered to customers primarily through the use of performance-based contracts. This study was conceived as a snapshot of the ESCO industry prior to the economic slowdown and the introduction of federal stimulus funding mandated by enactment of the American Recovery and Reinvestment Act of 2009 (ARRA). This study utilizes two parallel analytic approaches to characterize ESCO industry and market trends in the U.S.: (1) a “top-down” approach involving a survey of individual ESCOs to estimate aggregate industry activity and (2) a “bottom-up” analysis of a database of -3,265 projects (representing over $8B in project investment) that reports market trends including installed EE retrofit strategies, project installation costs and savings, project payback times, and benefit-cost ratios over time. Despite the onset of an economic recession, the U.S. ESCO industry managed to grow at about 7% per year between 2006 and 2008. ESCO industry revenues are relatively small compared to total U.S. energy expenditures (about $4.1 billion in 2008), but ESCOs anticipated accelerated growth through 2011 (25% per year). We found that 2,484 ESCO projects in our database generated -$4.0 billion ($2009) in net, direct economic benefits to their customers. We estimate that the ESCO project database includes about 20% of all U.S. ESCO market activity from 1990-2008. Assuming the net benefits per project are comparable for ESCO projects that are not included in the LBNL database, this would suggest that the ESCO industry has generated -$23 billion in net direct economic benefits for customers at projects installed between 1990 and 2008. We found that nearly 85% of all public and institutional projects met or exceeded the guaranteed level of savings. We estimated that a typical ESCO project generated $1.5 dollars of direct benefits for every dollar of customer investment. There is empirical evidence confirming that the industry is responding to customer demand by installing more comprehensive and complex measures—including onsite generation and measures to address deferred maintenance—but this evolution has significant implications for customer project economics, especially at K-12 schools. We found that the median simple payback time has increased from 1.9 to 3.2 years in private sector projects since the early-to-mid 1990s and from 5.2 to 10.5 years in public sector projects for the same time period.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2015

Economic Impact of Pacific Northwest National Laboratory on the State of Washington in Fiscal Year 2014

PNNL is a large economic entity with a total of 4,308 employees, $939 million (M) in total funding, and $1.02 billion (B) in total spending during FY 2014. The number of employees that live in Washington State is 4,026 or 93 percent of the Laboratory staff. he Laboratory directly and indirectly supported $1.45 billion in economic output, 6,832 jobs, and $517 million in Washington State wage income from current operations. The state also gained more than $1.19 billion in output, over 6,200 jobs, and $444 million in income through closely related economic activities such as visitors, health care spending, spending by resident retirees, and spinoff companies. PNNL affects Washington’s economy through commonly recognized economic channels, including spending on payrolls and other goods and services that support Laboratory operations. Less commonly recognized channels also have their own impacts and include company-supported spending on health care for its staff members and retirees, spending of its resident retirees, Laboratory visitor spending, and the economic activities in a growing constellation of “spinoff” companies founded on PNNL research, technology, and managerial expertise. PNNL also has a significant impact on science and technology education and community not-for-profit organizations. PNNL is an active participant in the future scientific enterprise in Washington with the state’s K-12 schools, colleges, and universities. The Laboratory sends staff members to the classroom and brings hundreds of students to the PNNL campus to help train the next generation of scientists, engineers, mathematicians, and technicians. This investment in human capital, though difficult to measure in terms of current dollars of economic output, is among the important lasting legacies of the Laboratory. Finally, PNNL contributes to the local community with millions of dollars’ worth of cash and in-kind corporate and staff contributions, all of which strengthen the economy. The purpose of this report is to quantify these effects, providing detailed information on PNNL’s revenues and expenditures, as well as the impacts of its activities on the rest of the Washington State economy.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2015

State Approaches to Demand Reduction Induced Price Effects: Examining How Energy Efficiency Can Lower Prices for All

Effects (DRIPE) as a real, quantifiable benefit of energy efficiency and demand response programs. DRIPE is a measurement of the value of demand reductions in terms of the decrease in wholesale energy prices, resulting in lower total expenditures on electricity or natural gas across a given grid. Crucially for policymakers and consumer advocates, DRIPE savings accrue not only to the subset of customers who consume less, but to all consumers. Rate-paying customers realize DRIPE savings when price reductions across an electricity or natural gas system are passed on to all retail customers as lower rates (depending upon regulation and market structure, residual savings may be wholly or partially retained by utilities). DRIPE savings, though seemingly small in terms of percent price reductions or dollars per household, can amount to hundreds of millions of dollars per year across entire states or grids. Therefore, accurately assessing DRIPE benefits can help to ensure appropriate programs are designed and implemented for energy efficiency measures. This paper reviews the existing knowledge and experience from select U.S. states regarding DRIPE (including New York and Ohio), and the potential for expanded application of the concept of DRIPE by regulators. Policymakers and public utility commissions have a critical role to play in setting the methodology for determining DRIPE, encouraging its capture by utilities, and allocating DRIPE benefits among utilities, various groups of customers, and/or society at large. While the methodologies for estimating DRIPE benefits are still being perfected, policymakers can follow the examples of states such as Maryland and Vermont in including conservative DRIPE estimates in their resource planning.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
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 OSTI2017

A New Remote Communications Link to Reduce Residential PV Solar Costs

Monitoring of PV/DER site production is expensive to install and unreliable. Among third party systems providers, lost communications links are a growing concern. Nearly 20% of links are failing, provisioning is complex, recovery is expensive, production data is lost, and access is fragmented. FleetLink is a new concept in DER system communications, purpose built for lowering the cost of maintaining active contact with residential end user sites and ensuring that production data is reliably available to third party systems providers. Systems providers require accurate, secure system monitoring and reporting of production data and system faults while driving down overall costs to compete effectively. This plug and play, independently operating communications solution lowers the cost of fleet contact from typically .08 dollars-$.12/W down to .02 dollars -.03/W including installation and maintenance expenses. FleetLink establishes a breakthrough in simplicity that facilitates rapid expansion of residential solar by reducing initial capital outlay and lowering installation labor time and skill levels. The solution also facilitates higher DER installation growth rates by driving down maintenance costs and eliminating communications trouble calls. This is accomplished by the FleetLink’s unique network technology that enables dynamic network configuration for fast changes, and active, self-healing DER site contact for uptime assurance. Using an open source network framework with proprietary, application specific enhancements, FleetLink independently manages connectivity, security, recovery, grid control communications, and fleet expansion while presenting a compliant SunSpec interface to the third party operations centers. The net system cost savings of at least .05 dollars/W supports the SunShot cost goals and the flexibility and scalability of the solution accelerates the velocity and ubiquitous adoption of solar.

14 SOLAR ENERGY↗
DOE OSTI2017

Coeur d’Alene Tribe Benewah Market Energy Efficiency Project Final Technical Report

The Coeur d’Alene Reservation has been the home of the Coeur d’Alene Tribe since time immemorial and it is fitting that the Tribe’s name in the Coeur d’Alene language is schitsu’umsh, “the ones who were found here.” The Reservation is located in northern Idaho, is approximately 345,000 acres and is comprised of forest land, agricultural land, several streams, Coeur d’Alene Lake and the St. Joe River and a small amount of developed land. The project area was conducted within the boundaries of the Coeur d’Alene Reservation. The population of the Reservation is 6,760 (2010 Census). Currently, there are approximately 2,463 enrolled Coeur d’Alene Tribal members (Coeur d’Alene Tribe Enrollment 2016). The Benewah Market is a Tribally-owned and operated facility located at 1111 B St. Plummer, ID 83851. The Benewah Market is an approximately 23,500 square foot single-story structure. The majority of the building is occupied by a grocery store with a full meat department, deli, and bakery. Approximately 20% of the floor area at the northeast corner is occupied by an Ace Hardware retailer. The largest part of the building is approximately 17,000 square feet, is separately metered and houses the grocery store which was constructed in 1984. The market is the largest full service market serving the Coeur d’Alene Reservation and is the only full service market in a 35-mile radius. The Tribe has benefited greatly from the Benewah Market Energy Efficiency Project and will continue to do so for many years: The health and safety of the food has been improved greatly now that the refrigeration and freezer cases are at a constant and safe temperature on a monitoring and alarm system. There is no longer a thaw and freeze cycle that allows fluctuations in temperature. If the power goes out, there is an immediate alarm and contact so that time may be tracked and food kept safe during an outage. The overall annual energy use in the Benewah Market has dropped by 22.9% -Energy costs for the Market decreased by an estimated 11,620 dollars in one year due to this project. The Tribe has seen an increase in the cost of energy from Plummer Power and this was offset by the reduction in energy consumed. This estimate assumes that the Tribe would have consumed the same amount of energy as the prior year. -Maintenance costs are estimated to have decreased by $10,000 in just the one year since installation in contract repair and maintenance. The Tribe estimates that it has saved 24,000 dollars over a one-year time period in labor costs to maintain the older system. Due to having a more efficient store, with safer, more attractive display of food and lower energy and maintenance costs, the store is able to be more viable economically. The store has increased its sales and has been able to pass along operations and maintenance savings to its customers and employees. The Tribe hosted a ribbon-cutting ceremony on February 28, 2017 at the Benewah Market with Chris Deschene, then Office of Indian Energy Director, as well as representatives from the Coeur d’Alene Tribe and Bonneville Power Administration. While the ribbon-cutting ceremony was going on, the Tribe’s media outlets covered the ceremony and placed information about the project on the Tribe’s Facebook page on two separate occasions. The Coeur d’Alene Tribe’s Natural Resources Department and the Tribe’s Development Corporation are thankful for the opportunity that the Benewah Market Energy Efficiency Project has afforded the Coeur d’Alene Tribal community. Without the U.S. Department of Energy’s Indian Energy Program funding and its dedicated staff, this project would not have been completed. This has been a lot of work for all parties involved but has provided benefits to thousands of people for many years to come.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2017

Innovative Patient Room Lighting System with Integrated Spectrally Adaptive Control

In December of 2013, the U.S. Department of Energy’s SSL R&D Program released a Funding Opportunity Announcement (FOA), that for the first time, contained opportunities for comprehensive application-specific system development. The FOA included opportunities for two applications, one of which was a Patient Room. Philips Lighting Research North America, submitted a proposal for the Patient Room application, and was selected for the complete project award. The award amount was for $497,127, with a Philips Research co-funding commitment 165,709 dollars. The total project value was 662,836 dollars. This project sought to redefine lighting for the patient room application. The goal was to deliver an innovative LED patient suite (patient room and bathroom) lighting system solution that was 40% more energy-efficient than traditional fluorescent incumbent technologies, and would meet all the visual and non-visual needs of patients, caregivers and visitors, and improve the patient experience. State-of-the-art multichannel LED platforms and control technologies that would provide spectral tuning and become part of an intelligent, connected lighting system drove the solution. The project was scoped into four main task areas that included a) System Concept Creation, b) Identification of the Luminaire Portfolio, c) Development of the Connected Lighting Infrastructure, and d) System Performance Validation. Each of the four main tasks were completed and validated extensively over the course the 2 ½ year project. The system concept was created by first developing a lighting design that demonstrated best practices for patient room lighting – illuminance and uniformity for task performance, reduced glare, and convenient controls, in addition to giving patients control over the lighting in their environment. A framework was defined to deliver circadian support via software behaviors. Through that process luminaires were identified from the Philips portfolio that were adaptable – by their form, dimensions, and optical materials – to mix multicolor LED platforms uniformly and deliver target design lumen levels. The Blue Sky luminaire was selected for the patient bed area to give the illusion of skylight while providing white light on the patient bed. Luminaires used existing 2-channel tunable white LED boards, and newly developed 4-channel LED boards. Red-Orange, Blue, Green, and Blue-shifted Yellow LED chips were selected based on spectral characteristics and their ability to produce high quality white light. 4-channel Power over Ethernet (PoE) drivers were developed and firmware written so they would communicate with both 2- and 4-channel boards. These components formed the backbone of the connected lighting infrastructure. Software, flexible and nuanced in its complexity, was written to set behaviors for myriad lighting scenes in the room throughout the 24 hour day – and all could be overridden by manual controls. This included a dynamic tunable white program, three color changing automatic programs that simulated degrees of sunrise to sunset palettes, and an amber night lighting system that offered visual cues for postural stability to minimize the risk of falls. All programs were carefully designed to provide visual comfort for all occupants, support critical task performance for staff, and to support the patient’s 24hr rhythms. A full scale mockup room was constructed in the Philips Cambridge Lab. The lighting system was installed, tested and functionality demonstrated to ensure smooth operation of system components – luminaires, drivers, PoE switches, wall controls, patient remote, and daylight and occupancy sensors. How did the system perform? It met visual criteria, confirmed by calculations, simulations and measurements in the field. It met non-visual criteria, confirmed by setting circadian stimulus (CS) targets and performing calculations using the calculator developed by the Lighting Research Center. Finally, human factors validation studies were conducted to gain insight from real end users in the healthcare profession; surveys were administered, data analyzed, and audio comments captured. The general consensus was positive, with requests to pilot the system in their hospitals. The importance of the research completed under this grant is that it allowed the exploration and development of a unique lighting system, one that would deliver a blend of visual and non-visual criteria in patient room design for today’s healthcare environment. The research investigated the area of multichannel LED technology, multichannel Power over Ethernet (PoE) drivers and their integration with automatic and manual controls as a system – uncovering and meeting challenges along the way. It married visual needs of patients and staff with support for 24 hour rhythms, placing value on the wellbeing of the patient – while successfully saving energy over incumbent technologies. Indications are that the market is ready and willing to invest – multiple healthcare facilities are in line to pilot this system, recognizing its value beyond energy to patient and staff well-being. Its value to the public can best be expressed by a patient support coordinator who, after spending several hours in the room being immersed in the lighting, analyzing all its features, commented: “This re-writes lighting for healthcare”.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2018

An Integrated Supercritical System for Efficient Produced Water Treatment and Power Generation

The main goal of this project was to evaluate the feasibility of an integrated supercritical (SC) water desalination and power generation system for treatment of produced waters from CO 2 sequestration, oil production, and coal-bed methane recovery. This system may offer a transformative approach to generating power from coal or natural gas (NG) and purifying saline water or produced water with high total dissolved solids (TDS) in a zero-liquid discharge plant. The closed-loop steam cycle of conventional power plants was replaced with an open-loop steam cycle that heated the pretreated produced water above the SC point of water (374 °C and 221 bar) to precipitate and separate the salts dissolved in the water. After separation of the precipitated salt, the SC steam required further treatment to reduce the salt content from ~100 mg/L (ppm) to <1 ppm to make it suitable for use in turbines for power generation. A SC membrane distillation unit was used to polish the SC steam, which could be sent through a series of turbines for power generation, and the steam exiting the low-pressure turbine could be condensed by cooling water to produce pure water. Project tasks included a process simulation and a techno-economic evaluation of the integrated system; design and assembly of SC salt precipitation and membrane distillation systems; development and characterization of advanced carbon membranes for SC membrane distillation; and pretreatment, desalination, and purification of different produced water samples with salt concentrations of 30,000–200,000 ppm to a high-purity (<1 ppm) level. Process simulations were performed for 550 MW SC coal-fired or NG baseline cases and various scenarios for the proposed integrated SC system using produced water as the water source and coal or NG as the fuel source. Simulation results indicated that the net plant efficiency loss of the proposed SC cogeneration process would be in the range of <1% to ~4%, in which NG and lower TDS produced water cases would have higher efficiencies. The proposed process for coal-fired cases could provide all water needs for the power generation process and generate additional pure water for beneficial use. A techno-economic analysis was performed to estimate the cost of produced water treatment (dollars /kgal of treated water) by conventional treatment processes compared with the proposed cogeneration process. The cost estimation for the proposed cogeneration system included the cost of pretreatment, the cost of power loss to integrate the water desalination process into the power generation system, and the cost of plant modification or retrofitting. The cost of produced water treatment was calculated by assuming three different scenarios in which converting a baseline power plant to the proposed cogeneration plant would increase the cost of the boiler and feed water system by 10%, 50%, and 100%. Results indicated that the cost of produced water treatment, even with a 100% cost increase, was in the range of $8.6–11.6 dollars per kgal, which is about half of the treatment cost by conventional methods. The cost of produced water treatment by the proposed cogeneration system could be further reduced or a considerable income could be generated if the values of saltwater and freshwater products are considered. Overall, the techno-economic analysis results indicated that the proposed integrated SC system could potentially treat produced water at a cost significantly lower than the cost of produced water treatment by conventional technologies. To evaluate the feasibility of the proposed treatment system at a laboratory scale, a SC salt precipitation and membrane distillation system was designed and fabricated to treat a simulated brine or pretreated produced water by precipitating salts and further polishing the SC steam containing ~100 ppm salts to a high-purity steam. Through baseline tests with NaCl solutions, with concentrations ranging from 30,000 to 200,000 ppm, it was demonstrated that concentrated feed solutions could be treated by precipitating salt at SC conditions to a TDS level of 130 ppm. Produced water samples were collected from a potential CO 2 sequestration site, a coal-bed methane site, and an oilfield in Illinois. Representative samples were characterized for various water quality parameters, including pH; turbidity; conductivity; and concentrations of selected anions, cations, alkalinity, dissolved organic carbon, total suspended solids, TDS, and total petroleum hydrocarbons. The produced water samples were first treated by conventional pretreatment methods to remove residual oil, dissolved organic matter, and scale-forming species. Pretreatment methods included coagulation, sedimentation, filtration, activated carbon adsorption, and ion-exchange adsorption. Pretreated produced waters were treated at SC conditions in which salts were precipitated. Analysis of treated samples revealed that the concentration of Na (the main cation) in produced waters was reduced dramatically from 14,000–47,400 ppm in the feed to 21–80 ppm in treated waters. Concentrations of other main cations (Ca, Mg, Sr, K) also decreased significantly from initial values of ~1,000–22,000 ppm to ~1 ppm or less. However, a significant increase in the concentrations of Fe, Ni, Cu, and Co was observed, mainly caused by leaching of these elements from the system (vessels, filters, tubing), which is manufactured from alloys containing Fe, Ni, Cu, and Co. To polish the SC steam containing a salt content of ~100 ppm to a high-purity level of <1 ppm, a SC membrane distillation treatment using carbon membranes was employed. Different types of self-standing or supported carbon membranes were developed from graphite, graphene, carbon nanotubes, carbon nanofibers, and pyrolytic carbon. Screening tests revealed that only a limited number of developed carbon membranes were suitable for the purification of steam at SC conditions. Membranes that were either fragile and lacked mechanical strength or had large pores and showed limited salt rejection (<20%) were found to be unsuitable for the purification of SC steam. Promising carbon membranes that were successfully tested for purifying SC steam included two graphite membranes (i.e., AF-5, a porous graphite material, and FGS, a flexible graphite sheet) and a carbon nanotube membrane grown on a Hastelloy substrate and then further modified using a proprietary method (i.e., membrane C). The AF-5 membrane exhibited a stable water flux of ~50 kg/m 2 ∙h and ~40% salt rejection. The FGS membrane had a high salt rejection of 95%–98% but a lower water flux of ~15 kg/m 2 ∙h. Membrane C showed an extremely high flux of 200-800 kg/m 2 ∙h, which is one order of magnitude higher than the water flux of conventional membranes. Membrane C also exhibited 87%–93% salt rejection. Overall, a two-stage or multistage polishing treatment by these membranes could lower the salt content of the SC steam from initial values of ~100–200 ppm to the steam quality of <1 ppm or to parts per billion levels required for the power cycle.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2018

A Modular and Flexible High-Frequency-Link Transformer with a Reduced Device Count and Zero High-Side Devices

In general, large power transformers (LPTs) are not interchangeable with each other and their high costs prohibit extensive spare inventories more so considering that on an average only 1.3 LPTs are manufactured for individual design. The latter pose a further challenge since given that the several existing LPTs are reaching their end of service lives, loss of plurality of such LPTs, that form the backbone of U.S. power grid, will clearly run into the problem of energy security related to the non-availability of sufficient spares (and extended lead time) exacerbated further by the fact that these spares are not interchangeable for installations at different locations. Conventional LPT cost millions of dollars and weighs significantly between approximately 100 and 400 tons. Two raw materials—copper and electrical steel—account for over 50 percent of the total cost of an LPT. In recent years, the price volatility of these two commodities in the global market has affected the manufacturing conditions and procurement strategy for LPTs. Transportation is also an important element of the total LPT cost, because an LPT can weigh significantly and often requires long-distance transport. Transporting an LPT is challenging—its large dimensions and heavy weight pose unique requirements to ensure safe and efficient transportation. Current road, rail, and port conditions are such that transportation is taking more time and becoming more expensive. Conventional low-frequency LPTs typically follow a monolithic approach to design due to historical reasons that need to transition to more modular and flexible (e.g., in voltage, impedance, and power flow) designs with ability to seamlessly/near-seamlessly scale. They should also have the ability to incorporate new technologies without in all cases redoing a LPT design from scratch. Given that the cost of raw materials has continued to increase, next-generation LPTs need to pursue avenues for reducing these costs. An added necessity is to reduce the transportability cost, which is significant in conventional LPTs. Further, given that LPTs are for the long term, they need to be durable, efficient, and fault tolerant with overloading capability. Given this backdrop, the objective and accomplishment of this one-year DOE (SPONSOR) R&D project, led by small business NextWatt LLC (PRIME, Lead PI: Dr. Sudip K. Mazumder) and University of Arkansas at Fayetteville (SUBAWARDEE, PI: Dr. Juan Balda) were to explore the design of a (8 – 20 kHz) high-frequency-link (HFL) based 100-MVA LPT with nominal voltage of 115/69 kV, with $15 - $22 dollars US per kVA when manufactured in “moderate” volume, with 99% energy-conversion efficiency, with 300% reduction in both volume and weight compared to a conventional LPT with the same electrical ratings, with impedance variation greater than 5%, with direct AC/AC power conversion capability, with very-high energy-conversion efficiency (using wide-bandgap SiC based field effect MOSFET devices) over a wide operating temperature, with reduction in both volume and weight with regard to conventional low frequency LPT, and with significant reduction in number of devices compared to state of the art solid state transformer topology.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2015

Cost and Performance Baseline for Fossil Energy Plants Supplement: Sensitivity to CO 2 Capture Rate in Coal-Fired Power Plants

The cost and performance of various plants designed to meet a range of carbon dioxide (CO 2 ) emissions are evaluated in this report by varying the CO 2 capture rate. The base cases for these designs are the supercritical (SC) pulverized coal (PC) plant from the National Energy Technology Laboratory’s (NETL) report “Cost and Performance Baseline for Fossil Energy Plants, Volume 1a: Bituminous Coal (PC) and Natural Gas to Electricity, Revision 3” and the General Electric Energy (GEE) integrated gasification combined cycle (IGCC) plant in NETL’s report, “Cost and Performance Baseline for Fossil Energy Plants, Volume 1b: Bituminous Coal (IGCC) to Electricity, Revision 2 – Year Dollar Update.” The chosen SC PC plants were based on the Case B12B, differing only in the addition of a bypass flow path that allows for an appropriate portion of the flue gas stream exiting the desulfurization step to be directed towards the stack, which reduces the amount CO 2 captured in the Cansolv process. The chosen IGCC plants were based on the Case B5B, differing by bypassing (either partially or entirely) the water gas shift reactors and thereby reducing the amount of CO 2 captured in the Selexol process. The major components of the underlying CO 2 capture technology in the plants were preserved with minimal modifications to the overall processes. The SC PC cases include up-to-date cost and performance information from recent vendor quotes whereas the IGCC performance and cost are based upon the older quotes used for the Revision 2 report, with standard adjustments made to update the costs to 2011 dollars.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2019

Demonstration of High-Temperature Calcium-Based Thermochemical Energy Storage System for use with Concentrating Solar Power Facilities

Thermochemical energy storage (TCES) systems offer several advantages over sensible heat storage via molten salts for concentrating solar power (CSP) including: energy density, cost, indefinite storage time, and no risk of freezing. SR’s TCES system utilizes a CaO-based carbonation reaction at high temperature in a fixed bed heat exchanger reactor. The SunShot APOLLO project focuses on the validation of the calcium oxide sorbent for capacity, durability, system economics, and demonstration of the system at a small pilot scale, including system control and operation in simulated on-sun conditions, discharging at 720°C. Under phase I SR completed evaluation of the sorbent loaded in a single-channel heat exchanger reactor. The major accomplishments of phase II are: Design, fabrication and commissioning of a 4 kWhth pilot plant (50x capacity increase from previous bench scale) with a closed-loop CO 2 system, and a commercially relevant heat exchange reactor. The heat exchange reactor has been designed with state-of-the-art modeling tools to ensure 1) sufficient lifetime of the Incoloy body and 2) performance of the packed bed reactor will be adequate to meet the milestones. The rest of the pilot system has been designed with off-the shelf components to maximize reliability and cost effectiveness. The system is highly instrumented and capable of time resolved, independent measurements of the heat and mass balances respectively. Major developments in the technoeconomic analysis (TEA) include 1) reduction of the cost of membrane gas storage for the near-term and future systems and 2) integration with liquid metal receivers and particle receivers for higher decarbonation temperatures and pressures which reduced the cost of gas compression and increased system efficiency. The result are three scenarios with costs bases of 21.9 dollars, 14.3 dollars, and 10.9 dollars/kWh th corresponding to a real LCOE of 59, 57, 56 dollars/MW he , respectively. The basic operations of the energy storage system were demonstrated for carbonation (discharging) and decarbonation (charging) over short time periods. Excellent control of the CO 2 mass balance across the reactor was achieved with mass flow controllers and the basic operation of the level control of the CO 2 gas bladder was achieved. The system was apparently free from leaks and operated continuously for 18 days with no mechanical failures, thus meeting milestone 2.5.5. The major shortcomings of the system had to do with the controls which prevented us from deep cycling and or reaching high cycles. We were unable to decarbonate (charge) the system for more than a few minutes at a time, which was much shorter than the design target of 10 hrs. This issue could not be resolved due to facility availability and contract closure. One major finding is that CaO-based TCES is most cost efficient when charged with HTF (heat transfer fluid) temperatures >850°C to reach the round-trip exergy efficiency and system cost targets which are higher temperatures than those considered for Gen 3 CSP. Many of the balance of plant components do not exist today, however we are encouraged by our findings that in general with more work we are able to reduce the capital cost, for example with the membrane gas storage, which is an innovative component in itself. The CaO-based TCES system has potential to meet the latest SunShot 2030 goals of LCOE at 50 $/MW he with capital costs of <11/kWh th .

14 SOLAR ENERGY↗
DOE OSTI2018

Chippewa Cree Residential Solar Deployment Project

The overall project goal was to install clean energy systems in order to achieve the Chippewa Cree Tribe’s long-term goal of energy self-sufficiency, environmental protection, and better lives for our tribal members and community. This would be the first solar deployment project on the Rocky Boy’s Reservation. With 50% of the funding provided by the Office of Indian Energy, the Chippewa Cree Tribe teamed up with GRID Alternatives to install six grid-tied, solar electric systems for low-income single-family homes. The systems installed were estimated to provide 4,400 kWh annually with an estimated $451 dollar savings per household. After monitoring the systems for a year, we were almost able to obtain our goal with an average of 3,971 kWh and a $419 dollar average savings per household. We would have exceeded our goal but one of the units was without power for the majority of the year bringing down the average significantly. Another major component to the grant was workforce development. GRID Alternatives supplied training for students from Stone Child College on the installation process. With the collaboration and planning efforts from all of the departments, the installations were completed in October of 2016. Throughout the report you will see the six installations are diverse, and each needs to be considered in the context of the individual family structure, size, and energy consumption habits.

14 SOLAR ENERGY↗
DOE OSTI2019

Demonstration of High-Temperature Calcium-Based Thermochemical Energy Storage System for use with Concentrating Solar Power Facilities

Thermochemical energy storage (TCES) systems offer several advantages over sensible heat storage via molten salts for concentrating solar power (CSP) including: energy density, cost, indefinite storage time, and no risk of freezing. SR’s TCES system utilizes a CaO-based carbonation reaction at high temperature in a fixed bed heat exchanger reactor. The SunShot APOLLO project focuses on the validation of the calcium oxide sorbent for capacity, durability, system economics, and demonstration of the system at a small pilot scale, including system control and operation in simulated on-sun conditions, discharging at 720°C. Under phase I SR completed evaluation of the sorbent loaded in a single-channel heat exchanger reactor. The major accomplishments of phase II are: Design, fabrication and commissioning of a 4 kWhth pilot plant (50x capacity increase from previous bench scale) with a closed-loop CO 2 system, and a commercially relevant heat exchange reactor. The heat exchange reactor has been designed with state-of-the-art modeling tools to ensure 1) sufficient lifetime of the Incoloy body and 2) performance of the packed bed reactor will be adequate to meet the milestones. The rest of the pilot system has been designed with off-the shelf components to maximize reliability and cost effectiveness. The system is highly instrumented and capable of time resolved, independent measurements of the heat and mass balances respectively. Major developments in the technoeconomic analysis (TEA) include 1) reduction of the cost of membrane gas storage for the near-term and future systems and 2) integration with liquid metal receivers and particle receivers for higher decarbonation temperatures and pressures which reduced the cost of gas compression and increased system efficiency. The result are three scenarios with costs bases of 21.9 dollars, 14.3 dollars, and 10.9 dollars/kWhth corresponding to a real LCOE of 59, 57, 56 dollars/MWhe, respectively. The basic operations of the energy storage system were demonstrated for carbonation (discharging) and decarbonation (charging) over short time periods. Excellent control of the CO 2 mass balance across the reactor was achieved with mass flow controllers and the basic operation of the level control of the CO 2 gas bladder was achieved. The system was apparently free from leaks and operated continuously for 18 days with no mechanical failures, thus meeting milestone 2.5.5. The major shortcomings of the system had to do with the controls which prevented us from deep cycling and or reaching high cycles. We were unable to decarbonate (charge) the system for more than a few minutes at a time, which was much shorter than the design target of 10 hrs. This issue could not be resolved due to facility availability and contract closure. One major finding is that CaO-based TCES is most cost efficient when charged with HTF (heat transfer fluid) temperatures >850°C to reach the round-trip exergy efficiency and system cost targets which are higher temperatures than those considered for Gen 3 CSP. Many of the balance of plant components do not exist today, however we are encouraged by our findings that in general with more work we are able to reduce the capital cost, for example with the membrane gas storage, which is an innovative component in itself. The CaO-based TCES system has potential to meet the latest SunShot 2030 goals of LCOE at 50 dollars/MWhe with capital costs of <11/kWhth.

14 SOLAR ENERGY↗