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Status of the Top Plate and Anticryostat for High Field Cable Test Facility at Fermilab

Fermi National Accelerator Laboratory (Fermilab) is currently constructing a new High Field Vertical Magnet Test Facility (HFVMTF) designed for testing High Temperature Superconducting (HTS) cables under high magnetic fields. This facility is expected to offer capabilities similar to those of EDIPO at PSI and FRESCA2 at CERN. The background magnetic field of 15 T will be generated by a magnet supplied by Lawrence Berkeley National Laboratory. The primary function of HFVMTF will be to serve as a superconducting cable test facility, facilitating tests under high magnetic fields and a broad spectrum of cryogenic temperatures. Additionally, the facility will be utilized for testing high-field superconducting magnet models and demonstrators, including hybrid magnets, developed by the US Magnet Development Program (MDP). This paper provides a comprehensive description of the current status of two pivotal components of the facility: the Top/Lambda Plates Assembly and the Anticryostat for the Test Sample Holder. The latter will serve as a principal interface component connecting cable test samples with the facility's cryostat.

43 PARTICLE ACCELERATORS↗

Non-Fouling, Low Cost Electrolytic Coagulation & Disinfection for Treating Flowback and Produced Water for Reuse

Executive Summary This Final Report is composed of two major sections. The first section presents experimental results obtained in the laboratory during Budget Period 1. The second section presents results from the field test conducted during Budget Period 2. Laboratory Results This research investigated a novel electrochemical process for producing a ferric iron coagulant for use in treating flowback and produced water from hydraulic fracturing and oil production operations. The treatment system improves the effectiveness and lowers the cost of coagulation processes using Fe3+ as the coagulant. The electrolytic coagulant generation (ECG) system uses an electrochemical cell to produce acid and base from oilfield brine solutions. The acid is used to dissolve scrap iron to provide a Fe3+ coagulating agent. The base is used to neutralize the treated water. Compared to conventional electrocoagulation (EC), the main advantage of the ECG system is an order of magnitude lower cost for the source of iron. The second advantage over conventional EC is that it can deliver Fe3+ doses greater than 1 mM, since it is not limited by the amount of dissolved oxygen in the water required to oxidize ferrous to ferric iron. The capital costs for conventional EC and the ECG system are similar, but the operational costs for the ECG system are an order of magnitude lower than conventional EC. The combined costs for iron and electrical energy for treating 1 m3 of FPW with 1 mM Fe3+ is estimated to be $0.87 for conventional EC, and $0.087 for the ECG system. The estimated all-in cost for treating FPW with a 2 mM Fe3+ dose is $0.73/m3 ($0.12/bbl). Field Test Results The field test was conducted at the Paul Foster Central Tank Battery (CTB) in Lea County, New Mexico from November 10, 2022 through December 15, 2022. The feed water to the system was produced water from the Tatanka 1H formation. After approximately two weeks of testing, the initial batch of produced water had been treated and no untreated produced water was available. Thus, after this time, the feed water to the system consisted of previously treated water (i.e., recycled water). The recycled water had nearly all colloidal particles removed, and had a much lower alkalinity due to precipitation of carbonate minerals during the first pass through the system. Although the recycled water was not an ideal test solution due to its low particulate concentrations, its lower alkalinity did allow us to identify the main problem with the treatment system. The main problem with the treatment system was caused by the high alkalinity of the initial feed water (5.4 meq/L) that consumed a significant fraction of the electrochemically generated acid. This resulted in pH values exiting the iron contact tank that were too high to dissolve enough iron to effectively treat the produced water. Tests performed with recycled water with lower alkalinity did not have this issue, and dissolved iron concentrations greater than 20 mM could be achieved. One consistent observation was that effluent water from the iron contact tank was always free of particulates, even when fed with circumneutral solutions. This suggests that there is no need to dissolve high concentrations of iron if all the water to be treated is passed through the scrap iron canister. In this case, dissolved O2 and hypochlorous acid can promote sufficient iron corrosion to provide an effective coagulating agent – even in neutral pH water. This solves the problem resulting from highly alkaline produced water. Modifications to the design of the treatment system were made based on the field test results. These modifications will add minimal additional cost, and were tested in bench-scale laboratory experiments. In short-term testing, the modified treatment process was able to remove colloidal FeS particulates to levels below detection. Long-term, steady state testing will be required to determine whether the modified process is suitable for commercial treatment systems.

54 ENVIRONMENTAL SCIENCES↗

Field-Scale Testing of a High-Efficiency Membrane Reactor (MR)—Adsorptive Reactor (AR) Process for H2 Generation and Pre-Combustion CO2 Capture

The study objective was to field-validate the technical feasibility of a membrane- and adsorption-enhanced water gas shift reaction process employing a carbon molecular sieve membrane (CMSM)-based membrane reactor (MR) followed by an adsorptive reactor (AR) for pre-combustion CO2 capture. The project was carried out in two different phases. In Phase I, the field-scale experimental MR-AR system was designed and constructed, the membranes, and adsorbents were prepared, and the unit was tested with simulated syngas to validate functionality. In Phase II, the unit was installed at the test site, field-tested using real syngas, and a technoeconomic analysis (TEA) of the technology was completed. All project milestones were met. Specifically, (i) high-performance CMSMs were prepared meeting the target H2 permeance (>1 m3/(m2.hbar) and H2/CO selectivity of >80 at temperatures of up to 300 °C and pressures of up to 25 bar with a <10% performance decline over the testing period; (ii) pelletized adsorbents were prepared for use in relevant conditions (250 °C < T < 450 °C, pressures up to 25 bar) with a working capacity of >2.5 wt.% and an attrition rate of <0.2; (iii) TEA showed that the MR-AR technology met the CO2 capture goals of 95% CO2 purity at a cost of electricity (COE) 30% less than baseline approaches.

42 ENGINEERING↗

Energy performance evaluation of the ASHRAE Guideline 36 control and reinforcement learning–based control using field measurements

This study evaluates the energy performance of ASHRAE Guideline 36–compliant control (ASHRAE 36 control) and reinforcement learning (RL)–based control through experimental field tests and a simulation study. Three field tests were conducted at Oak Ridge National Laboratory’s commercial building test facility in Oak Ridge, Tennessee: a baseline with a baseline conventional control, a test with ASHRAE 36 control, and a test with RL-based control. The selected ASHRAE 36 controls were trim and respond control, as well as variable air volume (VAV) box control. We compared the measured supply air temperature of the rooftop unit, VAV box supply air temperature, and VAV box supply airflow rate across the three test cases. The field data indicated that ASHRAE 36 controls operated as specified by ASHRAE Guideline 36. Based on these data, ASHRAE 36 control achieved a 45 % reduction in hourly averaged HVAC energy consumption compared with the baseline, and RL-based control achieved a 66 % reduction. These potential annual energy savings were confirmed using a calibrated whole-building energy model. Compared with the baseline, ASHRAE 36 control reduced HVAC energy consumption by 42 %, and RL-based control achieved a 54 % reduction. Furthermore, RL-based control reduced total HVAC energy consumption by 21 % more than ASHRAE 36 control.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Distributed Coaxial Cable Sensors for In-Situ Condition Based Monitoring of Coal-Fired Boiler Tubes

The increasing contributions of renewable energy sources present new challenges to the operation and maintenance of the existing coal-fired power plants. One of the major operational risks is the unexpected failure of superheater boiler tubes, leading to the most unplanned power plant outrages. The boiler tube failure is difficult to predict due to the harsh operating environments. Therefore, condition-based monitoring (CBM) with a reliable high temperature sensor becomes necessary to produce a meaningful assessment of the health condition of boiler tubes and their remaining lifetime. In this work, the stainless-steel and quartz coaxial cable sensor (SSQ-CCS) is proposed for in-situ distributed monitoring of the boiler tube temperatures in existing coal-fired power plants. Comprehensive tests have been conducted with an in-house testing facility at Clemson University to study and evaluate the sensors’ performance in the temperature range of 100℃ to 600℃. The results indicated that the measurement resolution of the SSQ-CCS sensor is better than 1℃, and the drift is less than 2% over long-period testing. Meanwhile, multi-physics finite element analysis has been conducted to optimize the design and evaluate the safety of the SSQ-CCS temperature sensor under various operational conditions. Based on the performance obtained in the laboratory-scale testing, a field test has been implemented at a power plant. Four SSQ-CCS temperature sensors were installed for in-situ monitoring of the temperatures of a power plant’s superheat tube assembles. The data acquisition system has been successfully set up and collected sensing signals for more than three months. The sensing signals have been post-processed, and the monitored temperature history through the SSQ-CCS temperature sensor has been validated and compared with the conventional high temperature thermal couple data.

Jiao, Xinyu↗

Brine Availability Test in Salt (BATS) FY24 Update

This report summarizes fiscal year 2024 (FY24) activities centered around a series of field tests in bedded salt at the Waste Isolation Pilot Plant (WIPP) funded by the Office of Spent Fuel and Waste Science and Technology in the Spent Fuel and Waste Disposition (SFWD) program of the US Department of Energy’s Office of Nuclear Energy (DOE-NE). High-level Purpose of Experiments: The Brine Availability Test in Salt (BATS) field tests are revealing both brine occurrence (i.e., where, and how much) and brine migration (i.e., how easily it moves) in the excavation damaged zone (EDZ). This understanding is foundational to develop a safety case for a future heat-generating waste repository in salt, and to starting up a generic repository program in salt to buy down risk. BATS seeks to predict how much brine can flow into both ambient and heated excavations (e.g., boreholes or rooms) in salt. This work is educating and empowering new repository scientists on two fronts: “design and execution of field tests” and “prediction and modeling of coupled processes.” DOE-NE capabilities in salt have grown and been tested through international modeling and benchmarking exercises (e.g., DECOVALEX, RANGERS, KOMPASS, and MEASURES; see Mills et al., 2024). The hands-on expertise we are building is a necessary step towards large-scale disposal demonstrations and eventual implementation.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Time-Sensitive Quantum Key Distribution (TSQKD)

This is the final report for the Time-Sensitive Quantum Key Distribution (TSQKD) project and summarizes the demonstration and longer-term field testing at an electric utility, EPB of Chattanooga, in Chattanooga, TN. The demonstration was held virtually (due to the COVID pandemic) and successfully executed the tests outlined in a prior report, “Task 10: Develop a QKD Time-Sensitive Networking Test Suite” submitted 9/30/2020. The portable test equipment explained in Task 10 and earlier task reports was tested at GE Research remotely connected with Qubitekk’s QKD equipment in San Diego, CA. Then the equipment was shipped to Qubitekk for physical integration with Qubitekk’s Quantum DataLoc™ Key Server 1570nm (http://qubitekk.com/products/qkd-for-industrial-control-systems-ics/). The portable test equipment was shipped from Qubitekk to EPB for demonstration and extended field testing. A summary of the demonstration and test results are described in this report. The demo and extended field test results are enabled by the NETCONF/YANG IEEE P1913 data management model developed as part of this project (Task 5). The NETCONF/YANG IEEE P1913 data management model demonstrated significant practical utility in providing a common means of monitoring and configuring the QKD system. All data in this report comes from the IEEE P1913 data management model.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Status of the Top Plate and Anticryostat for High Field Cable Test Facility at Fermilab

Fermi National Accelerator Laboratory (FNAL) and Lawrence Berkeley National Laboratory (LBNL) are building a new High Field Vertical Magnet Test Facility (HFVMTF) for testing superconducting cables in high magnetic field. This facility will be located at Fermilab and will have a capability similar to EDIPO at PSI and FRESCA2 at CERN. The background magnetic field of 15T in HFVMTF will be produced by a magnet pro-vided by LBNL. The HFVMTF is jointly funded by the US DOE Offices of Science, High Energy Physics, and Fusion Energy Sciences. As a primary use it will be superconducting cable test facility, in high magnetic fields and wide range of temperatures. Complementary, this facility will be used to test high-field super-conducting magnet models and demonstrators, including hybrid magnets, produced by the US Magnet Development Program (MDP). The paper describes the status of Top Plates Assembly and Sample Insert Anticryostat, which will be a main interface component between cable test mode and magnet test mode at this facility.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

Status of the High Field Cable Test Facility at Fermilab

Fermi National Accelerator Laboratory (FNAL) and Lawrence Berkeley National Laboratory (LBNL) are building a new High Field Vertical Magnet Test Facility (HFVMTF) for testing superconducting cables in high magnetic field. The background magnetic field of 15 T in the HFVMTF will be produced by a magnet provided by LBNL. The HFVMTF is jointly funded by the US DOE Offices of Science, High Energy Physics (HEP), and Fusion Energy Sciences (FES), and will serve as a superconducting cable test facility in high magnetic fields and a wide range of temperatures for HEP and FES communities. This facility will also be used to test high-field superconducting magnet models and demonstrators, including hybrid magnets, produced by the US Magnet Development Program (MDP). The paper describes the status of the facility, including construction, cryostat designs, top and lambda plates, and systems for powering, and quench protection and monitoring.

43 PARTICLE ACCELERATORS↗

Current Status of the High Field Cable Test Facility at Fermilab

Fermi National Accelerator Laboratory (FNAL) and Lawrence Berkeley National Laboratory (LBNL) are collaborating to construct a new High Field Vertical Magnet Test Facility (HFVMTF) designed for testing superconducting cables in high magnetic fields. This state-of-the-art facility will be situated at Fermilab and will provide capabilities comparable to EDIPO at PSI and FRESCA2 at CERN. The HFVMTF’s background magnetic field, reaching 15 T, will be generated by a magnet supplied by LBNL. The HFVMTF is a collaborative effort supported by the US DOE Offices of Science, High Energy Physics, and Fusion Energy Sciences. It will serve as a vital testbed for superconducting HTS cables, subjecting them to high magnetic fields and a wide range of temperatures, benefiting both scientific communities. Additionally, this facility will play a key role in testing high-field superconducting magnet models and demonstrators, including hybrid magnets, developed by the US Magnet Development Pro gram (MDP). These hybrid magnets, utilizing both LTS and HTS superconductors, are significant advancements toward achieving 18+ T dipoles for future hadron-hadron colliders. The presentation outlines the current status of the facility, covering aspects such as construction progress, cryostat designs, top and lambda plates, and systems for powering, quench protection, and monitoring.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

Development of a Pre-Combustion CO 2 Capture Process Using High-Temperature PBI Hollow-Fiber Membranes

The overall objective of this project was to evaluate the advantages of transformational polybenzimidazole (PBI) polymer hollow-fiber membrane (HFM)-based, carbon dioxide (CO 2 ) capture and purification technology at bench-scale using an actual coal-derived syngas stream from a coal gasification facility. The project was carried out over two budget periods. The technical objectives in Budget Period 1 (BP1) included preparing HFs and modules and upgrading the available skid for field testing. The technical objectives for BP2 were to field-test the skid unit with actual coal-derived syngas from an oxygen-blown gasifier to obtain performance data, update the Techno-Economic Analysis (TEA) that would assist with future process scale-up, and provide information on the design of a small pilot-scale test unit. The goal was to advance the PBI-HFM CO 2 capture and gas separation system for pre-combustion applications beyond second-generation economic performance predictions and make progress toward meeting overall fossil energy performance goals of CO 2 capture with 95% CO 2 purity at a cost of electricity (COE) 30% less than baseline capture approaches. The research program was designed with progressive technical tasks leading to both dynamic and steady-state testing of the PBI-HFM skid with actual coal-derived syngas. The work plan was to: (1) fabricate sufficient Generation-2 (GEN-2) fibers for module fabrication; (2) upgrade the fiber skid to accommodate large fiber modules for bench-scale field testing; (3) conduct dynamic and steady-state testing with coal-derived syngas from an oxygen-blown gasifier and obtain system performance data; (4) perform a TEA and environmental, health, and safety (EH&S) assessment; (5) update the State-Point Data Table, Technology Gap Analysis (TGA), and Technology Maturation Plan (TMP); (6) uninstall and return the test skid to the Recipient’s facilities; and (7) submit a Final Report that describes the results and analysis of the project research effort.

03 NATURAL GAS↗

BENCH-SCALE DEVELOPMENT OF A TRANSFORMATIVE MEMBRANE PROCESS FOR PRE-COMBUSTION CO 2 CAPTURE

This final technical report describes work conducted by Membrane Technology and Research, Inc. (MTR) for the Department of Energy, National Energy Technology Laboratory (DOE NETL) on development of the second generation (Gen-2) Proteus™ membrane modules and a pre-combustion membrane process for carbon dioxide (CO 2 ) capture from an Integrated Gasification Combined Cycle (IGCC) plant for power generation (award number DE-FE0031632). The work was conducted from October 1, 2018 through March 30, 2022. The overall goal of this project was to bring a Gen-2 version of the H2-selective Proteus membrane to bench-scale module (component) testing with real syngas. MTR was assisted in this project by Susteon, a technology development company with extensive experience in gasification processes, and the University of North Dakota Energy & Environmental Research Center (EERC), who provided the host site for the slipstream field testing. This report details the work conducted to optimize the Gen-2 Proteus membrane and develop modules capable of operation at 200°C; demonstrate membrane module performance processing coal-derived syngas during a field test at EERC; and optimize integration of a dual-membrane process into an IGCC with carbon capture. Work for this project included membrane optimization and scale-up, module component screening and fabrication of high-temperature lab- and bench-scale modules, design and fabrication of a bench-scale field test membrane skid, operation of the field test skid processing coal-derived syngas at EERC, and a detailed techno-economic analysis (TEA) of the MTR dual-membrane process for IGCC power plant pre-combustion CO 2 capture. This project validated recent membrane technology advancements, mitigates risk in future scale-up activities, and moved the membrane pre-combustion capture technology from TRL-4 to TRL-5. Key results for each major task are discussed in the report.

10 SYNTHETIC FUELS↗

Current Progress on the High-Field Cable Testing Facility at Fermilab

Fermi National Accelerator Laboratory (Fermilab) is constructing a new High Field Vertical Magnet Test Facility (HFVMTF) with capabilities comparable to the European facilities EDIPO and FRESCA2. The facility, located at Fermilab, will feature a background magnetic field of 15 T, generated by a magnet provided by Lawrence Berkeley National Laboratory (LBNL). The HFVMTF will support two U.S. national programs under the DOE Office of Science: the U.S. Fusion Energy Science (FES) program and the Magnet Development Program (MDP). It will enable the testing of HTS samples in high magnetic fields across a wide range of temperatures and facilitate the development of hybrid magnets combining LTS and HTS superconductors. This paper presents an overview of the current progress in constructing the facility, including updates on the test cryostat, power supplies, and systems for quench protection and monitoring.

Velev, G. [Fermilab]↗

Durability Research Is Pivotal for Perovskite Photovoltaics

Metal halide perovskite solar cells have shown promising power conversion efficiencies, but commercialization requires that decent durability is also demonstrated. Under normal operation, solar cells are subject to a complex combination of stressors, such as visible light, ultraviolet light, heat, humidity, mechanical stress and electric potential, which complicates the understanding of failure mechanisms. Existing stress tests do not act as a time machine. In new materials systems such as perovskite photovoltaics, the tests have no known relationship to field service. In this Perspective we recommend following a durability learning cycle that interleaves photovoltaic module engineering with field testing; accelerated testing; and preconditioning and performance engineering. We advocate for field testing to demonstrate real-world performance and identify field-relevant failure modes, and urge the community to develop accelerated and qualification tests that account for device metastability, variations in material composition and different/various processing methods. In conclusion, these practices are more difficult, but more important, than the simple pursuit of higher initial efficiencies.

14 SOLAR ENERGY↗

Comparative study of the effects of prenatal sevoflurane exposure at different cortical stages on forebrain development and maturation in offspring

Introduction Brain development involves several critical stages, such as proliferation, neuronal migration, axonal pathfinding, and connection formation. Sevoflurane, a γ -aminobutyric acid (GABA) receptor agonist, is widely used as an inhaled general anesthetic. However, its impact on brain development has raised increasing concerns, particularly regarding prenatal exposure. This study aims to investigate the effects of prenatal sevoflurane exposure (PSE) at different cortical stages, focusing on its impact on the migration of glutamatergic and GABAergic neurons and neuronal behavior in offspring. Methods PSE was administered at two critical prenatal stages: embryonic day (E) 12.5 and E18.5. Double in situ hybridization was used to identify the coexpression of GABA receptors in Pax6- and Mash1-positive cells in the forebrain. The radial migration of glutamatergic neurons and the tangential migration of GABAergic neurons were analyzed. Behavioral tests, including the open-field test, elevated plus-maze test, forced swim test, tail suspension test, sucrose preference test, and Morris water maze, were performed on offspring to assess anxiety-like behaviors, depression, and learning and memory impairments. Results PSE inhibits the radial migration of glutamatergic neurons and promotes the tangential migration of GABAergic neurons. Specifically, early exposure (E12.5) inhibited the expression of the Pax6–Tbr2–Tbr1 cascade and the radial migration of Tbr1 in the ventral prefrontal cortex (PFC), whereas late exposure (E18.5) inhibited this process on the dorsal side. In addition, offspring mice with PSE exhibited increased anxiety-like behaviors, rather than depression, as demonstrated by reduced time spent in the center of the open-field test and in the open arms of the elevated plus-maze test. No significant differences were observed in the forced swim test, tail suspension test, or sucrose preference test. Furthermore, learning and memory impairments were observed in the Morris water maze. Conclusion Our results indicate that PSE at E12.5 and E18.5 leads to abnormalities in the migration of glutamatergic and GABAergic neurons, affecting long-term anxiety-like behaviors and causing learning and memory impairments in offspring mice.

Wang, Tianyuan↗

Scale-up Testing of Advanced Polaris Membrane in CO2 Capture Technology

This final technical report describes work conducted by Membrane Technology and Research, Inc. (MTR) for the U.S. Department of Energy (DOE), National Energy Technology Lab (NETL) on the scale-up and testing of advanced Polaris™ membrane CO2 capture technology at the Technology Centre Mongstad (TCM) under award number DE-FE0031591. The work was performed from August 1, 2018 through January 31, 2023. The overall goal of this project was to design, build and operate an advanced Polaris membrane CO2 capture system at TCM. MTR was assisted in this project by Trimeric Corporation (Trimeric), an engineering design services company, the Carbon Capture Simulation for Industry Impact (CCSI2), a partnership among national laboratories, industry, and academic institutions, and the Technology Centre Mongstad (TCM), who provided the host site for the slipstream field test. This report details the work conducted to scale-up MTR’s second-generation (Gen-2) Polaris membrane and advanced planar membrane modules to a final form factor optimized for commercial use; validate their performance in an engineering-scale field test at TCM; and to show the potential of the MTR process to meet DOE CO2 capture targets from large source point emitters. Work for this project included membrane optimization and scale-up, advanced planar module design and fabrication, design and fabrication of an engineering-scale field test membrane skid, operation of the field test skid processing Residue Fluid Catalytic Cracker (RFCC) industrial flue gas at TCM, and a detailed techno-economic analysis (TEA) of the MTR membrane post-combustion process for CO2 capture. This project validated recent membrane technology advancements at the engineering-scale, moves the MTR advanced post-combustion capture technology to TRL-6, and mitigates risk in future Large Pilot or Demonstration scale-up activities.

20 FOSSIL-FUELED POWER PLANTS↗

Distributed Optical Fiber Sensor Systems: Application to Natural Gas Pipeline Monitoring

Distributed fiber optic sensing is a cutting-edge technology that has found extensive applications in the monitoring of pipelines. Considering the low backscattering level of standard single-mode fiber as fiber under test, a Rayleigh enhanced optical fiber embedded within the tight-buffered cable is demonstrated in field testing. We analyzed the increased backscattering fiber cable's vibration performance to the conventional single-mode telecom fiber using a custom-built Φ-OTDR interrogator system. Thereafter, using a 4-inch steel pipeline with a flow rate of 5, 10, 15, and 20 ft/s and a fixed pressure level of 1000 psi, we field-tested the sensor system for monitoring natural gas pipeline acoustic vibrations. We also field tested Brillouin optical time domain analysis (BOTDA) system for pipeline hoop strain monitoring under various pressure conditions. The pilot-scale testing results presented in this study suggested that pipeline operators can accurately perform flow monitoring, leak detection, and pressure monitoring for pipeline integrity monitoring.

Lalam, Nageswara↗