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At least 73 records · Page 4

Williston Basin Resource Study for Commercial-Scale Subsurface Hydrogen Storage

The Energy & Environmental Research Center (EERC), in partnership with the U.S. Department of Energy (DOE) National Energy Technology Laboratory (NETL), the EERC’s State Energy Research Center (SERC), MPLX Operations LLC, and TC Energy Development Holdings Inc. (a subsidiary of TC Energy Corporation), studied the potential for subsurface hydrogen storage and recovery in the Williston Basin of western North Dakota. The project’s goal was to evaluate the feasibility of large-scale, secure geologic H 2 storage to support future hydrogen generation, storage, and use. This work included laboratory testing, H 2 –rock–fluid exposure experiments, literature reviews on H 2 embrittlement, and reservoir modeling and simulations. The study included an assessment of storage potential across three types of storage reservoirs using both reservoir simulation and DOE’s web-based tool SHASTA-HELP (Subsurface Hydrogen Assessment, Storage, and Technology Acceleration – Hydrogen Estimator for Logistical Planning), as well as investigation of potential H 2 production and markets for commercial-scale deployment. Building on prior EERC gas storage research, three storage options were selected for detailed evaluation: the Broom Creek Formation (a clastic saline reservoir), the Dickinson Lodgepole Mounds (DLM) complex (carbonate mud mound structures) of the Lodgepole Formation (an active oil and gas producing reservoir), and the Dunham Salt Interval of the Piper Formation (to be used for engineered salt cavern development). These targets were prioritized based on prior EERC research using datasets related to seal capacity, reservoir quality, mechanical integrity, and injectivity. Exposure tests on Broom Creek and DLM samples showed mineral dissolution and precipitation that increased brine salinity and altered reservoir rock surfaces. Although these results provide useful insight, they are limited by small sample sizes and short-term (30-day) exposure, requiring further study to assess long-term storage integrity. Salt formations were not tested because of their known nonreactivity and established mechanical stability. Results of reservoir simulations performed for a single site demonstrated that the Broom Creek Formation may be capable of receiving up to 42,000 tonnes of injected H 2 over 7 months via one well. H 2 recovery took place over 5 months, resulting in approximately 26,000 tonnes (~62% without cushion gas [CG]). This work suggests water production may be important and subsequent cycles of injection and production may perform more efficiently; however, significant site-specific work in the future is needed to assess actual reservoir performance of injection and withdrawal of H 2 storage. For oil reservoir potential, a multiple-well model was used to simulate injection of approximately 32,000 tonnes of H 2 into a single wellbore while simultaneously producing in place reservoir fluids from four offset wells to maintain reservoir pressure. The simulation results suggested a high recovery (~98%); in addition, cost advantages through existing infrastructure could be realized. Challenges in this reservoir include vi managing gas purity and leakage risks. In both scenarios, production of H 2 takes place in a single-well scenario with 10 cycles (7 months of injection and 5 months of production) over 10 years. Finally, the use of engineered caverns in the Dunhan Salt was evaluated, and the results suggest that while they have a smaller capacity (<1000 tonnes per cavern), they exhibit nearly complete gas recovery (>99%), fast response times, and low purity risk. While caverns in North Dakota may be smaller in capacity, fields can be developed in galleries to accommodate the volumetric needs and rapid turnaround times necessary to meet market demands. Geographic limitations and thin salt intervals in North Dakota may represent less total storage potential than salt domes elsewhere, but significant opportunities exist to expand this market for gas storage in North Dakota. A basinwide assessment was performed to estimate a first-of-its-kind value for H 2 storage on a large scale. DOE’s SHASTA-HELP, combined with EERC simulation work, was used to perform the assessment. Estimated H 2 storage potential varied widely for each formation type. The Broom Creek saline formation was estimated to have a storage potential of approximately 1.7–90.5 million tonnes (MMt). The DLM oil reservoirs were estimated to have 0.07–0.19 MMt of capacity. Notably, each of these estimates relies on significant assumptions regarding reservoir thickness, porosity, permeability, and CG needed for operation. Much research is needed to understand the true site-specific storage resource potential of each formation. Using the Dunham Salt Interval for cavern development may result in as much as 4.79 MMt (up to 2.87 MMt working gas) of H 2 storage potential. An important note for consideration is that the values presented here need significantly more geological characterization and engineering assessments prior to gaining confidence in performance. This will be a focal point for future research and development needs. The basinwide evaluation also indicated that North Dakota has significant H 2 generation potential, with estimates up to a possible 13 MMt annually, suggesting a substantial opportunity for H 2 market development and thus the need for commercial-scale H 2 storage to facilitate growth and resilience. Key Recommendations 1. Conduct detailed site characterization (3D seismic, well logs, core sampling) to reduce geologic uncertainty. 2. Perform techno-economic analyses incorporating market, regulatory, and incentive frameworks. 3. Investigate long-term interactions among H 2 , CGs, well materials, and formations to assess risks. 4. Develop pilot- and field-scale demonstrations to validate models and establish best practices.

03 NATURAL GAS↗

National Wind Energy Workforce Assessment: Challenges, Opportunities, and Future Needs

The wind workforce gap is defined as the disconnect between employers having difficulty finding qualified candidates while potential wind energy workers report having difficulty finding jobs and educational institutions having difficulty placing students in industry. For this assessment, a system dynamics model - informed by a survey effort completed in 2022 and other anecdotal research - was created to better understand potential scenarios and actions that could be used to help close the workforce gap. The survey was conducted by the National Renewable Energy Laboratory, in collaboration with BW Research Partnership, to understand the perspective of wind industry firms, wind educators, current wind energy industry employees, and current renewable energy students on the workforce pathways into the wind industry. The information gathered through the survey effort was used to help develop workforce estimation scenarios, gain insight into why the workforce gap exists, and evaluate areas of opportunity to reduce barriers of entry into the wind energy industry.

17 WIND ENERGY↗

Phase stability and microstructure of neutron-irradiated substoichiometric yttrium dihydrides

The impact of the neutron-displacement damage on phase stability and microstructure of substoichiometric yttrium dihydrides (YH x , x <2) were investigated to assess their use as solid moderator in high-temperature nuclear reactors. YH x specimens were, thus, subjected to neutron irradiations in the range of 0.1–2 displacements per yttrium atom (dpa-Y) in the temperature range of 536–878°C at the Oak Ridge National Laboratory's (ORNL's) High Flux Isotope Reactor (HFIR). YH x specimens were initially prepared at stoichiometry (H/Y) ratios of 1.69 and 1.83. HFIR-irradiated specimens were characterized by variety of techniques to investigate H retention characteristics including dimensional analysis, optical microscopy, scanning electron microscopy electron back scatter diffraction (EBSD), transmission electron microscopy, thermal desorption spectroscopy (TDS), and high-energy x-ray diffraction (HE-XRD) characterizations. Overall, YH x exhibited notable structural and phase stability under short-term neutron-irradiation, except for the samples with significant silicon carbide (SiC) interaction at high doses and temperatures. Basic dimensional and mass measurements were misleading for accurate assessment of H retention, as confirmed by EBSD phase maps, XRD line profiles, and TDS signals. Thus, it was discussed that a robust H retention metric is needed to assess irradiated hydrides. Further, nanoscale cavities were observed as a result of the neutron irradiation in all samples. Although no clear impact of dose and irradiation temperature was determined, the initial H/Y ratio had an impact on the cavity number density where low H/Y specimens had high-resistance to cavity formation. The Y-vacancy cluster formation at the collision stage of the displacement cascade and their stabilization by H were considered to be the likely underlying mechanisms for the observed cavity microstructure.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Outline for Feasibility Study on a Nuclear Material Accounting and Control System for Measurement of High-Activity Waste at Tokai Reprocessing Plant during Decommissioning

The objective of this collaboration between the DOE/NNSA International Nuclear Security Program (INS) and JAEA is to conduct a feasibility study on nuclear material accounting and control needs and requirements for NDA measurement of high-activity waste at TRP during the decommissioning process. Under this study, both sides will exchange information, perform an assessment of needs and requirements, and develop joint recommendations for development of the A-HMMS.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗

Techno-economic assessment for the production of algal fuels and value-added products: opportunities for high-protein microalgae conversion

Abstract Background Microalgae possess numerous advantages for use as a feedstock in producing renewable fuels and products, with techno-economic analysis (TEA) frequently used to highlight the economic potential and technical challenges of utilizing this biomass in a biorefinery context. However, many historical TEA studies have focused on the conversion of biomass with elevated levels of carbohydrates and lipids and lower levels of protein, incurring substantial burdens on the ability to achieve high cultivation productivity rates relative to nutrient-replete, high-protein biomass. Given a strong dependence of algal biomass production costs on cultivation productivity, further TEA assessment is needed to understand the economic potential for utilizing potentially lower-cost but lower-quality, high-protein microalgae for biorefinery conversion. Results In this work, we conduct rigorous TEA modeling to assess the economic viability of two conceptual technology pathways for processing proteinaceous algae into a suite of fuels and products. One approach, termed mild oxidative treatment and upgrading (MOTU), makes use of a series of thermo-catalytic operations to upgrade solubilized proteins and carbohydrates to hydrocarbon fuels, while another alternative focuses on the biological conversion of those substrates to oxygenated fuels in the form of mixed alcohols (MA). Both pathways rely on the production of polyurethanes from unsaturated fatty acids and valorization of unconverted solids for use as a material for synthesizing bioplastics. The assessment found similar, albeit slightly higher fuel yields and lower costs for the MA pathway, translating to a residual solids selling price of $899/ton for MA versus $1033/ton for MOTU as would be required to support a $2.50/gallon gasoline equivalent (GGE) fuel selling price. A variation of the MA pathway including subsequent upgrading of the mixed alcohols to hydrocarbon fuels (MAU) reflected a required solids selling price of $975/ton. Conclusion The slight advantages observed for the MA pathway are partially attributed to a boundary that stops at oxygenated fuels versus fungible drop-in hydrocarbon fuels through a more complex MOTU configuration, with more comparable results obtained for the MAU scenario. In either case, it was shown that an integrated algal biorefinery can be economical through optimal strategies to utilize and valorize all fractions of the biomass.

09 BIOMASS FUELS↗

Machine learning for ultrasonic nondestructive examination of welding defects: A systematic review

Recent years have seen a substantial increase in the application of machine learning (ML) for automated analysis of nondestructive examination (NDE) data. One of the applications of interest is the use of ML for the analysis of data from in-service inspection of welds in nuclear power and other industries. These types of inspections are performed in accordance with criteria described in the ASME Boiler and Pressure Vessel Code and require the use of reliable NDE techniques. The rapid growth in ML methods and the diversity of possible approaches indicate a need to assess the current capabilities of ML and automated data analysis for NDE and identify any gaps or shortcomings in current ML technologies as applied to the automated analysis of NDE data. In particular, there is a need to determine the impact of ML on the NDE reliability. This paper discusses the findings from a literature survey on the current state of ML for the automated analysis of data from ultrasonic NDE of weld flaws. It discusses an overview of ultrasonic NDE as used for weld inspections in nuclear power and other industries. Herein, data sets and ML models used in the literature are summarized, along with a generally applicable workflow for ML. Findings on the capabilities, limitations and potential gaps in feature selection, data selection, and ML model optimization are discussed. The paper identified several needs for quantifying and validating the performance of ML methods for ultrasonic NDE, including the need for common data sets.

36 MATERIALS SCIENCE↗

Improving Non-Destructive Detection Technology Through SAVY Feature Detection

Surveillance of special nuclear material (SNM) storage containers is required by the DOE to assess their integrity across the Complex. This work aims to improve the task of container inspections by leveraging automation through machine learning (ML) tools to reduce the human-intensive effort and expert-level knowledge needed to assess container status. A field-deployable, non-destructive technology was designed using off-the-shelf components to collect multiple images from different perspectives of containers in storage to detect both spatial features of interest and anomalies of concern. Nine ML models were generated using unique training datasets and parameters. Learned features include SAVY surface regions including the body side wall, collar, lid, filter, and printed/etched information. Average Precision (AP) is used to calculate detection performance when both viewing previously seen environments and previously unseen environments. The application of image transformations and resolution scaling while training greatly improved the detection performance in unseen environments, and significantly increasing the number of computation iterations improved detection performance on previously seen environments. Additional capabilities were developed including the novel detection of procedural non-compliance and the ability to localize anomalies relative to SAVY surface features.

97 MATHEMATICS AND COMPUTING↗

Outline for Feasibility Study on Nuclear Material Accounting and Control Technologies for Pu Fuel Cycle Facilities under Decommissioning at Tokai Site [Slides]

DOE/NNSA and JAEA to conduct a feasibility study on nuclear material accounting and control needs and requirements for non-destructive assay (NDA) measurement of material unaccounted for (MUF) in waste streams at JAEA Tokai fuel cycle facilities during the decommissioning process. Under this study, both sides will exchange information, perform an assessment of needs and requirements, and develop joint recommendations for development of NDA systems at select facilities.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Republic of Korea–United States Green Shipping Corridor Prefeasibility Study: Cargo Flows

This prefeasibility study, as a part of the decarbonization efforts through the Mission Innovation Zero Emission Shipping Mission, was conducted to provide a high-level assessment of the opportunities and challenges in planning and implementing green shipping corridors between major commercial seaports in the United States of America (USA) and the Republic of Korea (ROK). For each country, three major ports were included in the scope of this study: Seattle, Tacoma, and Everett (all in Washington State) for the USA and Busan, Ulsan, and Masan for the ROK. This prefeasibility study report focuses on describing operation characteristics of major vessel and cargo flows between the two countries. Vessel shipments directly affect energy use and demand. Therefore, it is critically important to understand which major vessel types and cargo types are operated or transported within the selected scope and to identify potential target segments for green shipping. Furthermore, this prefeasibility study also discusses limitations and additional assessments that need to be further analyzed in the next stage of the feasibility study. The summary findings and observations discussed in this report are not intended to be used to determine the final target corridors, but to guide later, deeper assessments of their potential impacts and challenges. In the following section, the data sources used in this study are discussed. Section 0 shows the overall vessel trades between the USA and ROK, considering all ports in the two countries. Then, a more detailed analysis by vessel type and cargo flow is presented in Sections 3–6 based on only the three-to-three ports between the two countries. Finally, Section 7 summarizes the findings with suggested target segmentations for the vessel types and discusses other limitations to be considered during the later feasibility stage.

42 ENGINEERING↗

Reviewing clinical considerations and guideline recommendations of C1 inhibitor prophylaxis for hereditary angioedema

Abstract Background Hereditary angioedema (HAE), a rare disease that is characterized by painful and recurring non‐allergic swelling episodes, is caused by the deficiency or dysfunction of C1 inhibitor (C1INH) protein. A comprehensive HAE management plan may require long‐term prophylaxis (LTP) in addition to on‐demand treatment to help “normalize” patients' lives so that they may fully engage in work, school, family, and leisure activities. Aim The main objective of this narrative review is to provide an overview of updated guideline recommendations specific to LTP of HAE and discuss clinical considerations and pharmacologic management options, with a focus on C1INH. Materials and Methods The authors reviewed relevant HAE literature for current recommendations regarding LTP and the role of C1NH. Results Acute HAE attacks are treated with on‐demand medication; however, there is a consensus that LTP should routinely be considered for risk reduction and prevention of future episodes. The 2017 World Allergy Organization/European Academy of Allergy and Clinical Immunology guidelines recommend that all patients with HAE be evaluated for LTP routinely and the 2020 HAE Association (HAEA) guidelines emphasize that the decision to use LTP should not be based on rigid criteria, but rather should be based on individual patient needs. Both guidelines recommend C1INH as first‐line/preferred therapy for LTP in a range of patient types including adults, children/adolescents, and pregnant/lactating patients. The HAEA also recommends the kallikrein inhibitor, lanadelumab, as a first‐line option for LTP. HAE pathway‐specific agents for LTP have not been associated with notable safety concerns. Discussion Plasma‐derived C1INH has been available for 40+ years in Europe and impacts multiple targets within the HAE pathway. C1INH has been used for on‐demand treatment and LTP. A subcutaneous formulation of plasma‐derived C1INH is approved for LTP and produces functional C1INH activity levels consistently above the threshold needed for protection from HAE attacks. Other pathway‐specific options for LTP include the plasma kallikrein inhibitors, lanadelumab‐flyo and berotralstat, approved for adults and pediatric patients aged ≥12 years. C1INH is approved for adults and pediatric patients aged ≥6 years. Conclusion Assessing the need for LTP is vital in the ongoing dialogue between clinicians and patients, as both disease‐related factors and patient preferences may change over time. Among available options for LTP, plasma‐derived C1INH is the broadly recommended first‐line option for LTP in patients with HAE, including pregnant/lactating women and pediatric patients (≥6 years).

Anderson, John↗

RadResponder Nationwide Drill 2020: FRMAC participation After Action Report

On February 11th, 2020 FRMAC participated in the 2020 RadResponder nationwide drill involving survey data review and approval. During this drill, dozens of organizations from across the country participated in uploading simulated survey results to their own RadResponder event and reviewing those data given some "best-practice" guidelines. FRMAC participated in this drill to learn how this process is carried out in RadResponder and to determine some areas of improvement that will make FRMACs use of RadResponder more effective and efficient. As drill participants, the four FRMAC staff each set up their own RadResponder events so they could work independently to work through each step. Each were given an import file with 60 survey measurements to import and review. At the end of the drill a hotwash was held where users were able to ask questions and receive feedback from Chainbridge and FRMAC participants. In summary, several areas for improvement have been identified and will be categorized as items that need immediate attention (Bugs), areas for improvement in the near-term (change requests), and ideas on how the overall process can be improved (feature requests). The items presented in this report by no means reflect all the required changes FRMAC Monitoring and Sampling and Assessment will need to carry out their procedures in RadResponder but do represent a step in the right direction. A full review and exercise of the FRMAC process will need to be conducted with more subject matter experts to discover all the required features FRMAC needs to carry out their mission.

97 MATHEMATICS AND COMPUTING↗

Impacts of climate change on subannual hydropower generation: a multi-model assessment of the United States federal hydropower plant

Abstract Hydropower is a low-carbon emission renewable energy source that provides competitive and flexible electricity generation and is essential to the evolving power grid in the context of decarbonization. Assessing hydropower availability in a changing climate is technically challenging because there is a lack of consensus in the modeling representation of key dynamics across scales and processes. Focusing on 132 US federal hydropower plants, in this study we evaluate the compounded impact of climate and reservoir-hydropower models’ structural uncertainties on monthly hydropower projections. In particular, instead of relying on one single regression-based hydropower model, we introduce another conceptual reservoir operations-hydropower model in the assessment framework. This multi-model assessment approach allows us to partition uncertainties associated with both climate and hydropower models for better clarity. Results suggest that while at least 70% of the uncertainties at the annual scale and 50% at the seasonal scale can be attributed to the choice of climate models, up to 50% of seasonal variability can be attributed to the choice of hydropower models, particularly in regions over the western US where the reservoir storage is substantial. The analysis identifies regions where multi-model assessments are needed and presents a novel approach to partition uncertainties in hydropower projections. Another outcome includes an updated evaluation of Coupled Model Intercomparison Project Phase 5 (CMIP5)-based federal hydropower projection, at the monthly scale and with a larger ensemble, which can provide a baseline for understanding future assessments based on CMIP6 and beyond.

54 ENVIRONMENTAL SCIENCES↗

Robust evaluation of ENSO in climate models: How many ensemble members are needed?

Large ensembles of model simulations require considerable resources, and thus defining an appropriate ensemble size for a particular application is an important experimental design criterion. We estimate the ensemble size (N) needed to assess a model's ability to capture observed El Niño-Southern Oscillation (ENSO) behavior by utilizing the recently developed International CLIVAR ENSO Metrics Package (Planton et al., 2021). Using the larger ensembles available from CMIP6 and the US CLIVAR Large Ensemble Working Group, we find that larger ensembles are needed to robustly capture baseline ENSO characteristics (N > 50) and physical processes (N > 50) than the background climatology (N ≥ 12) and remote ENSO teleconnections (N ≥ 6). While these results vary somewhat across metrics and models, our study quantifies how larger ensembles are required to robustly evaluate simulated ENSO behavior, thereby providing some guidance for the design of model ensembles.

54 ENVIRONMENTAL SCIENCES↗

Camp Lejeune Federal Fleet Tiger Team EVSE Site Assessment

The National Renewable Energy Laboratory (NREL) was contracted by the Department of Defense (DOD) Environmental Security Technology Certification Program (ESTCP) and the Department of Energy (DOE) Federal Energy Management Program (FEMP) to develop a web tool and complete pilot assessments for the installation of Electric Vehicle Supply Equipment (EVSE). NREL has deployed Tiger Teams comprising engineers and fleet experts to support DOD and DOE on several EVSE site assessments since 2015. However, the advancements developed in support of this report, including a cost-estimation tool and geospatial mapping tool, will enable a user-driven path to assess EVSE needs. This report details the site design recommendations for Camp Lejeune, North Carolina.

ADVANCED PROPULSION SYSTEMS,ENERGY PLANNING, POLIC↗

Safety and Security Defense-in-Depth for Nuclear Power Plants

This report describes the risk-informed technical elements that will contribute to a defense-in-depth assessment for cybersecurity. Risk-informed cybersecurity must leverage the technical elements of a risk-informed approach appropriately in order to evaluate cybersecurity risk insights. HAZCADS and HAZOP+ are suitable methodologies to model the connection between digital harm and process hazards. Risk assessment modeling needs to be expanded beyond HAZCADS and HAZOP+ to consider the sequence of events that lead to plant consequences. Leveraging current practices in PRA can lead to categorization of digital assets and prioritizing digital assets commensurate with the risk. Ultimately, the culmination of cyber hazard methodologies, event sequence modeling, and digital asset categorization will facilitate a defense-in-depth assessment of cybersecurity.

97 MATHEMATICS AND COMPUTING↗

Typological representation of the offshore oceanographic environment along the Alaskan North Slope

Erosion and flooding impacts to Arctic coastal environments are intensifying with nearshore oceanographic conditions acting as a key environmental driver. Robust and comprehensive assessment of the nearshore oceanographic conditions require knowledge of the following boundary conditions: incident wave energy, water level, incident wind energy, ocean temperature and salinity, bathymetry, and shoreline orientation. The number of offshore oceanographic boundary conditions can be large, requiring a significant computational investment to reproduce nearshore conditions. This present study develops location-independent typologies to reduce the number of boundary conditions needed to assess nearshore oceanographic environments in both a Historical (2007–2019) and Future (2020–2040) timespan along the Alaskan North Slope. We used WAVEWATCH III® and Delft3D Flexible Mesh model output from six oceanographic sites located along a constant ~50 m bathymetric line spanning the Chukchi to Beaufort Seas. K-means clustering was applied to the energy-weighted joint-probability distribution of significant wave height (H s ) and peak period (T p ). Distributions of wave and wind direction, wind speed, and water level associated with location-independent centroids were assigned single values to describe a reduced order, typological rendition of offshore oceanographic conditions. Reanalysis data (e.g., ASRv2, ERA5, and GOFS) grounded the historical simulations while projected conditions were obtained from downscaled GFDL-CM3 forced under RCP8.5 conditions. Location-dependence for each site is established through the occurrence joint-probability distribution in the form of unique scaling factors representing the fraction of time that the typology would occupy over a representative year. As anticipated, these typologies show increasingly energetic ocean conditions in the future. They also enable computationally efficient simulation of the nearshore oceanographic environment along the North Slope of Alaska for better characterization of coastal processes (e.g., erosion, flooding, or sediment transport).

54 ENVIRONMENTAL SCIENCES↗

Preliminary Assessment of Alternate Chlorination Process

Recent advancements towards low-temperature chlorination with disulfur dichloride and thionyl chloride of Al-clad used nuclear fuel (UNF) have been summarized for work control technical expertise development at the Savannah River National Laboratory (SRNL). This technique aims to provide a more effective method for separating U from cladding or alloying elements. A preliminary assessment determined needs for unit operation developments in regard to reaction kinetics and reagent quality. Furthermore, an analysis of an Uruguay fuel plate (U-Al x fuel meat), with low-enriched uranium (LEU) and located at SRNL, was a potential candidate for future experiments with lightly irradiated (0.08% burnup) fuel to test for chlorination. Future proposed work would involve kinetic studies, reagent quality assessments, and the machining of the fuel plate down to an appropriate bench-scale size and testing the effectiveness of low-temperature chlorination on the fuel plate.

Chlorination↗

Optimized Carbon Fiber Composites in Wind Turbine Blade Design: Follow-On Studies

This project has identified opportunities to bring further reductions in the mass and cost of modern wind turbine blades through the use of alternative material systems and manufacturing processes. The fiber reinforced polymer material systems currently used by the wind industry have stagnated as the technology continues to mature and as a means to reduce risk while introducing new products with continually increasing blade lengths. However, as blade lengths continue to increase, the challenge of controlling blade mass becomes even more critical to enabling the associated levelized cost of energy reductions. Stiffer and stronger reinforcement fibers can help to resolve the challenges of meeting the loading demands while limiting the increase in weight, but these materials are substantially more expensive than the traditional E-glass fiber systems. One goal of this project and associated work is to identify pathways that improve the cost-effectiveness of carbon fiber such that it is the reinforcement of choice in the primary structural elements of wind blades. The use of heavy-tow textile carbon fiber material systems has been shown to reduce the blade mass by 30-31% when used in the spar cap and by up to 7% when used in edgewise reinforcement. A pultrusion cost model was developed to enable a material cost comparison that includes an accurate estimate of the intermediate manufacturing step of pultrusion for the carbon fiber composite. Material cost reductions were revealed in most cases for the heavy-tow textile carbon fiber compared to infused fiberglass. The use of carbon fiber in the edgewise reinforcement produced the most notable material cost reduction of 33% for the heavy-tow textile carbon fiber. The mass and cost savings observed when using carbon fiber in edgewise reinforcement demonstrate a clear opportunity of this design approach. A carbon fiber conversion cost model was expanded to include a characterization of manufacturing costs when using advanced conversion processes with atmospheric plasma oxidation. This manufacturing approach was estimated to reduce the cost of carbon fiber material systems by greater than 10% and can be used with textile carbon systems or traditional carbon fiber precursors. The pultrusion cost model was also used to assess the opportunity for using pultruded fiberglass in wind blades, studying conventional E-glass fiber reinforcement. When using pultruded fiberglass as the spar cap material for two design classifications, the blade weight was reduced by 6% and 9% compared to infused fiberglass. However, due to the relatively large share of the pultrusion manufacturing cost compared to fiber cost, the spar cap material cost increased by 12% and 7%. When considering the system benefits of reduced blade mass and potentially lower blade manufacturing costs for pultruded composites, there may be opportunity for pultruded E-glass in wind blade spar caps, but further studies are needed. There is a clearer outcome for using pultruded fiberglass in the edgewise reinforcement where it resulted in a blade mass reduction of 2% and associated reinforcement material cost reduction of 1% compared to infused E-glass. The use of higher performing glass fibers, such as S-glass and H-glass systems, will produce greater mass savings but a study is needed to assess the cost implications for these more expensive systems. The most likely opportunity for these high-performance glass fibers is in the edgewise reinforcement, where the increased strength will reduce the damage accumulation of this fatigue-driven component. The blade design assessments in this project characterize the controlling material properties for the primary structural components in the flapwise and edgewise directions for modern wind blades. The observed trends with low and high wind speed turbine classifications for carbon and glass fiber reinforced polymer systems help to identify where cost reductions are needed, and where improvements in mechanical properties would help to reduce the material demands.

17 WIND ENERGY↗