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At least 73 records · Page 4

Simple and Scalable Process for Nanocellulose Production from Residues and Waste (CRADA Final Report)

This project successfully developed an innovative, cost-effective, and scalable method for converting low-cost agricultural waste feedstocks into nanocellulose—a sustainable material with wide-ranging industrial applications. It addressed the critical challenges of high production costs and limited global supply, which have hindered the widespread adoption of nanocellulose in industry. Through this work, significant advancements were made in optimizing resource use, improving process efficiency, and reducing costs. Notable achievements included a 50% reduction in water usage, 30% lower chemical consumption, and 20% energy savings, all while maintaining high-quality product standards. The technical feasibility of the process was further validated at a 10L scale in collaboration with the Advanced Biofuels and Bioproducts Development Unit (ABPDU), demonstrating scalability and replicability. Key challenges in reducing nanocellulose production costs were addressed by utilizing low-cost biomass feedstocks and implementing low-temperature conversion reactions, leading to lower capital and operating expenses. The project also mitigated financial risk by generating critical data on the feasibility, adaptability, and scalability of the conversion technology, paving the way for its commercial implementation. Public benefits include advancing the circular bioeconomy, reducing environmental impact, fostering job creation, and enabling a shift toward biobased materials as sustainable alternatives to fossil-based products. These outcomes align closely with national goals to reduce greenhouse gas emissions and promote sustainable technological innovation.

09 BIOMASS FUELS

Modernizing Fermilab's Accelerator Control Hardware

Modernizing the Fermilab accelerator control system is essential to future operations of the laboratory's accelerator complex. The existing control system has evolved over four decades and uses hardware that is no longer available.The Accelerator Controls Operations Research Network (ACORN) Project will modernize the control system and replace end-of-life power supplies to enable future accelerator complex operations with megawatt particle beams. The ACORN project is planning to replace Fermilab s obsolete CAMAC crate-and-card controls hardware with modern MicroTCA hardware. There are over 2,000 CAMAC cards and over 250 CAMAC crates serving various functions in Fermilab s control system. We will review the existing CAMAC hardware and provide updates on the status of the ACORN project, which includes the conceptual design of the MicroTCA replacement hardware and software tools for supporting the installation of hundreds of MicroTCA crates.

43 PARTICLE ACCELERATORS

Design and implementation of the cosmic ray tagger system for the ICARUS detector at FNAL

The ICARUS-T600 Liquid Argon Time Projection Chamber is operating at Fermilab at shallow depth and thus exposed to a high flux of cosmic rays that can fake neutrino interactions. A cosmic ray tagging (CRT) system (∼ 1100 m 2 ), surrounding the cryostat with two layers of fiber embedded plastic scintillators, was developed to mitigate the cosmic ray induced background. Using nanosecond-level timing information, the CRT can distinguish incoming cosmic rays from outgoing particles from neutrino interactions in the TPC. In this paper an overview of the CRT system, its installation and commissioning at Fermilab, and its performance are discussed.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND

First measurement of the total inelastic cross section of positively charged kaons on argon at energies between 5.0 and 7.5 GeV

ProtoDUNE Single-Phase (ProtoDUNE-SP) is a 770-ton liquid argon time projection chamber that operated in a hadron test beam at the CERN Neutrino Platform in 2018. We present a measurement of the total inelastic cross section of charged kaons on argon as a function of kaon energy using 6 and 7 GeV/𝑐 beam momentum settings. The flux-weighted average of the extracted inelastic cross section at each beam momentum setting was measured to be 380 ± 26 mbarns for the 6 GeV/𝑐 setting and 379 ± 35 mbarns for the 7 GeV/𝑐 setting.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND

Stealth dark matter spectrum using Laplacian Heaviside smearing and irreducible representations

We present nonperturbative lattice calculations in the quenched approximation of the low-lying meson and baryon spectrum of the SU(4) gauge theory with fundamental fermion constituents. This theory is one instance of stealth dark matter, a class of strongly coupled theories, where the lowest mass stable baryon is the dark matter candidate. This work constitutes the first milestone in the program to study stealth dark matter self-interactions. Here, we focus on reducing excited state contamination in the single-baryon channel by applying the Laplacian Heaviside method, as well as projecting our baryon operators onto the irreducible representations of the octahedral group. We compare our resulting spectrum to previous work involving Gaussian smeared nonprojected operators and find good agreement with reduced statistical uncertainties. We also present the spectrum of the low-lying odd-parity baryons for the first time.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS

Ducted Fuel Injection and Cooled Spray Technologies for Particulate Control in Heavy-Duty Diesel Engines

Heavy-duty diesel engine manufacturers are continually seeking simple, low-cost technologies to reduce emissions. Ducted Fuel Injection (DFI) and Cooled Spray (CS) technologies have emerged as promising solutions, offering the potential for nearly sootless operation. These innovations could significantly decrease harmful Particulate Matter (PM) emissions while enabling further optimization to reduce Nitrogen Oxides (NOx) and increase efficiency. While initial experiments across various engine types have shown promise, uncertainties remain regarding the ideal geometry, scaling properties, and effectiveness of these technologies across different operating conditions. This project aims to address these knowledge gaps through experiments in both optical and metal single-cylinder engines.

33 ADVANCED PROPULSION SYSTEMS

Reduction of Porosity in Cementitious Waste Forms to Reduce Effective Diffusivity

Although current practices meet regulations for grout waste forms, development of sequestration materials and techniques for contaminants of concern could expand the use of grout waste forms and reduce risk to established processes from future compositional changes. There are contaminants in waste streams that are not permanently and completely sequestered in current grout waste forms under certain conditions. These contaminants include methyl mercury, 129 I, 99 Tc, and nitrate. Each of these species have minor fractions that are not permanently and completely isolated from the environment and therefore potentially contribute to long-term environmental impacts. An approach of interest includes the technique of reducing porosity to result in reduced leachability of all contaminants simultaneously. The current Savannah River Site (SRS) saltstone formulation was used to evaluate the relationship between leachability and porosity reduced waste forms by altering the water-to-binder ratio. Results indicated decreasing the water-to-binder directly reduced porosity and resulted in the waste form’s ability to more effectively immobilize nitrate. This work was funded by the Department of Energy Office of Environmental Management (DOE-EM) Technology Operations Office (TOO) Project # HQ221818.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W

A Complexity Agnostic Clustering Engine for Time Projection Chambers and its Implementation in FPGA

A clustering functional block implemented in field-programable-gate-array (FPGA) for time projection chambers (TPC) operating with predictable time regardless the complexity of the event is described in this paper. The clustering functional block reorganizes input data and the hits data belonging to the same clusters are output together for further process in the later stages. The clustering operation consists of two phases, data filling phase and data outputting phase, and the later uses the same number of clock cycles as the data filling phase. The clustering block can accommodate events with arbitrary number of clusters and number of hits per cluster as long as the total number of hits is within a predesigned limit. The operation time is exactly twice of the data filling time with no residual O(n2) term. The clustering block has been implemented with operating frequency of 200 MHz in a low-cost FPGA evaluation module and test results confirm the expected performance.

Wu, Jinyuan [Fermilab] (ORCID:0000000344329521)

Modernizing to an AI-Ready Control System

The Accelerator Controls Operations Research Network (ACORN) project will modernize the accelerator control system and upgrade power supplies to enable future operations of the Fermilab Accelerator Complex with megawatt proton beams. By focusing on MLOps, ACORN enables full integration of AI into the control system to allow safe and reliable improvements to accelerator beam operations.

43 PARTICLE ACCELERATORS

Helium recovery system at IB3a

The increasing need for optimal and sustainable use of cryogenic resources to support Fermilab’s scientific mission has highlighted the necessity of improving the Laboratory’s helium management practices. An assessment of cryogenic test facilities identified the Technical Division’s Industrial Building 3a (IB3A) as a key site requiring upgrades to integrate a helium recovery system. The IB3A facility is essential for characterizing and testing superconductors, cables, and coils for various R&D projects, including the US High-Luminosity LHC Accelerator Upgrade Project (AUP), Mu2e, and other external collaborations. Currently, the facility relies on 500 L helium Dewars and vents the vaporized helium directly into the atmosphere, leading to significant helium loss. Given the non-renewable nature of helium, recovering and reusing this resource is critical for the sustainability of Fermilab’s operations. To address this challenge, a project has been initiated to connect IB3A to an existing helium purification station and refrigeration system located in another building via a dedicated pipeline pass over the roof of several buildings. This solution will enable the efficient capture of vented helium, its transfer to the purification station, and subsequent liquefaction for reuse in future operations. The project includes a detailed design phase, specifying the pipeline route, flow control mechanisms, and integration with the existing cryogenic infrastructure, followed by phased implementation and commissioning. By implementing this pipeline connection and upgrading IB3A, Fermilab aims to significantly reduce helium waste, lower operational costs, and align with its commitment to sustainability. This initiative provides a model for resource-efficient cryogenic operations and reinforces the Laboratory’s capacity to support its science mission for the long term.

Porwisiak, D. [Fermilab]

Determining Exact RANS Operators with the Macroscopic Forcing Method (Final Report)

This report contains a compilation of key results and findings from the ACT project “Determining Exact RANS Operators with the Macroscopic Forcing Method.” The Macroscopic Forcing Method (MFM), a numerical tool for determining closure operators, is used to measure eddy diffusivity moments in Rayleigh-Taylor (RT) instability. It is first applied to low-Atwood 2D RT instability; that work is then extended to 3D RT at different finite Atwood numbers. It is found that nonlocality is important for modeling the mean scalar transport closure operator in RT mixing. Additionally, work is done to improve the statistical convergence of MFM for chaotic problems like RT mixing.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC

FEED Study of CarbonCapture Inc DAC and CarbonCure Utilization Technologies Using United States Steel’s Gary Works Plant Waste Heat (Final Report)

The University of Illinois at Urbana-Champaign (UIUC) led this project to produce a front-end engineering design (FEED) study of an advanced Direct Air Capture and Utilization System (DACUS) system that can remove a minimum of 5,000 tonnes/yr net of carbon dioxide from air (based on cradle-to-gate LCA) and utilizing the CO 2 to produce low carbon intensity ready mix concrete. The designed system, if built, would be larger than any currently existing Direct Air Capture (DAC) collector in the U.S. Such carbon capture technologies are critical to meeting the goals of the DOE’s program to accelerate climate-critical technology. In addition to the power sector, industrial facilities for the manufacture of steel and cement/concrete are among the major sources of anthropogenic CO 2 . DAC is a promising new technology for reducing CO 2 , a potent greenhouse gas, in the atmosphere but is expensive, in part due to the energy required to adsorb and desorb captured CO 2 during cycles. By integrating CarbonCapture Inc. (CCI) DAC modules at United States Steel's Gary Works (USS) and utilizing the site's waste heat, energy, and location this project evaluates the feasibility of utilizing the captured CO 2 and the logistics of transportation. CarbonCapture Inc. has developed an innovative DAC system using novel adsorbents to cost-effectively capture CO 2 . The captured, liquified gas will be trucked to ready-mix concrete plants within the region, the closest of which is approximately 3.5 miles away, where CarbonCure will inject it into concrete during the mixing process at the facilities. The carbon dioxide reacts with concrete, mineralizing into calcium carbonate (CaCO 3 ), permanently locking the greenhouse gas into the matrix of the building material. This FEED study demonstrated a full CO 2 value chain for DACUS from industrial facilities. It also provided a means for Visage Energy Corp. (Visage) to assess the impact of this holistic approach on job creation, regional economic impact, and environmental justice. The project team also included Sargent & Lundy (S&L) to provide the constructability review and costing of the integration of the DAC with the steel plant. Ecotek Engineering USA, LLC designed the outside battery limit (OSBL) infrastructure to connect the DAC and the plant. Activities performed during the project included: (1) Project Management Plan; (2) Technology Maturation Plan (TMP); (3) Initial Workforce Readiness Plan; (4) Workforce Readiness Plan; (5) Front-End Engineering Design (FEED) Study; (6) Project Design Basis; (7) Hazards and Operability (HAZOP) Study; (8) Constructability Review; (9) Project Cost Assessment; (10) Logistics Analysis of CO 2 Transportation to the Utilization Site; (11) Business Case Analysis; (12) Life Cycle Analysis (LCA); (13) Environmental Health and Safety (EH&S) Analysis; (14) Environmental Justice Analysis; and (15) Economic Revitalization and Job Creation Outcomes Analysis. This report provides a summary of the outcomes and results of the project, which was performed between Oct. 1, 2022, through Sept. 30, 2024.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI

Carbon storage cost modeling for the offshore Gulf of Mexico

Groundbreaking for geologic carbon storage (GCS) projects in the offshore Gulf of Mexico is imminent, and there is great interest in utilizing this region for GCS projects. Offshore saline reservoirs provide a significant and accessible resource for GCS. However, conducting GCS in the offshore environment will pose distinct challenges pertaining to site selection, operations, infrastructure use, and monitoring compared to operating onshore that ultimately affect technoeconomic assessment of offshore GCS projects. Carbon storage and transport costs are critical to project developers looking to deploy carbon storage in the offshore environment. We present CO2_S_COM_Offshore, a model developed by the National Energy Technology Laboratory (NETL) as a screening-level offshore saline GCS cost modeling tool. Based on NETL’s widely used CO2_S_COM cost model for onshore saline CS, CO2_S_COM_Offshore enables technoeconomic analysis of GCS in offshore areas. This model comprehensively incorporates multiple facets of offshore GCS projects, from regional evaluation and site selection to permitting, transport, operations, monitoring, site closure, and decommissioning. In general, the model can explore the cost implications for potential offshore GCS project(s) by enabling the user to change several project operational and financial attribute configurations. Key inputs include offshore storage formation options, CO2 injection rate and duration, infrastructure types, monitoring intensity, project financing, and post-injection site care duration. Supporting cost algorithms within CO2_S_COM_Offshore were compiled utilizing S&P Global’ s QUE$TORTM cost estimation software alongside a variety of open-source scientific literature. In addition to reviewing key model components, we discuss several sensitivity analyses, input variabilities, and results on analysis of break-even CO2 price required by a project based on different regulation/policy and operational scenarios for the offshore Gulf of Mexico. These results indicate the value of modeling offshore GCS specifically, and the potential of offshore GCS within a decarbonization value chain. Presented at the 41st USAEE/IAEE North American Conference, 3-6 November 2024, Baton Rouge, LA, United States.

Mark-Moser, Mackenzie K.

Investigation of the Challenges of Offshore Wind in Ultradeep Water

Floating offshore wind technology allows offshore wind energy systems to be deployed in water depths that are inaccessible with conventional fixed bottom technology. Several floating offshore wind energy pilot projects have demonstrated reliable operation of the technology in water depths between 200 m and 300 m. Building on that experience, commercial-scale projects are being developed in areas out to 1,300 m depths. In some regions there is substantial resource potential for wind energy generation in even deeper waters, however, increasing depths may introduce new challenges for installation, maintenance, and repair. In this report, we consider technical, environmental, and economic challenges for floating offshore wind energy in ultradeep water, defined here as depths between 1,300 m and 3,000 m.

17 WIND ENERGY

MICROREACTOR APPLICATIONS, RESEARCH, VALIDATION, AND EVALUATION (MARVEL) REACTOR ? STATUS, CONSTRUCTION, AND TESTING

The paper presents the current status of the Microreactor Applications, Research, Validation, and Evaluation (MARVEL) microreactor design, qualification testing, fabrication, and high-level construction schedule. An overview of initial criticality, low power physics testing, and start-up testing is included, as well as an overview of the envisioned processes in which end-users can engage the project for access to operational data or specific demonstrations. Designed by the Idaho National Laboratory (INL) under the auspices of the US Department of Energy’s Microreactor Program for construction and operation at the INL, MARVEL is a small, fully functional advanced reactor with UZrH fuel and thermal output of 85 kW. It offers a unique opportunity for scaled demonstrations that can dramatically accelerate the design, licensing, and deployment of commercial microreactors for power production or process heat applications. MARVEL’s objective is to build a small liquid-metal thermal reactor at the INL to demonstrate design and operating processes for microreactors, microgrid integration, and process heat applications. MARVEL finished 90%-final-design in September 2023 and completed an independent project assessment in early 2024. Fabrication of long-lead components and fuel, safety analysis review, and procurement for construction are underway. MARVEL assembly and construction will start in 2025 and fuel loading is expected in mid- 2027. Initial criticality will be performed in a dry condition in late 2027, followed by loading of NaK coolant and start-up testing. Approximately six months later, release for unrestricted operations will enable subsequent testing of microreactor characteristics, microgrid integration and select heat extraction applications.

22 GENERAL STUDIES OF NUCLEAR REACTORS

Guideline for Characterizing and Evaluating a Candidate Project Site for Solar Thermal Applications

This document presents a structured procedure for characterizing and evaluating candidate project sites for concentrating solar power (CSP) and solar heat for industrial processes (SHIP) applications. The objective is to provide project developers, researchers, and other stakeholders with a consistent, technology-agnostic framework for early-stage site assessment, enabling informed decision-making prior to significant investment in project development. Site selection is a critical factor in project success or failure for both CSP and SHIP projects. Key factors such as solar resource availability, land characteristics, environmental and regulatory constraints, infrastructure availability, and community context are determined by the choice of project site and can materially impact project performance, cost, schedule, and overall viability. This procedure is designed to systematically evaluate these factors, identify potential fatal flaws, and prioritize the most favorable candidate sites for further development. The process begins with rapid screening-level evaluation, using publicly available data to assess solar resource, land availability and suitability, zoning and land-use compatibility, and exclusion zones such as protected lands or sensitive habitats. Sites that meet the minimum screening criteria advance to a more detailed characterization. Subsequent sections of this report provide guidance for a next-level assessment of the most important technical and environmental parameters, including: 1) Solar resource quality, variability, and uncertainty using multiyear datasets and, where appropriate, on-site measurement campaigns; 2) Meteorological conditions such as wind, temperature, extreme weather events, and soiling impacts; 3) Land characteristics including slope, shading, and geotechnical conditions; and 4) Environmental and regulatory considerations, including permitting processes, endangered species, cultural resources, and visual impacts. The procedure also addresses infrastructure and integration considerations, including: 1) Grid interconnection requirements for CSP power generation projects; 2) Electrical and operational integration for SHIP facilities; 3) Water availability, quality, and permitting constraints, which are particularly critical for CSP in arid regions; and 4) Site access, construction logistics, and availability of workforce and supporting services. Recognizing the importance of social and economic context, the procedure includes evaluation of community engagement factors, such as stakeholder sentiment, proximity to sensitive visual receptors, workforce development opportunities, and local economic incentives. The outputs of these assessments are synthesized in a cost and risk evaluation, translating site characteristics into expected impacts on capital cost, operating cost, schedule, and technical risk. This is complemented by screening-level performance modeling, including 8760 simulations and long-term projections, to quantify expected energy or thermal output, assess variability thereof, and support comparison between candidate sites. Finally, the procedure provides high-level guidance on a structured go/no-go decision framework, categorizing sites based on identified risks and constraints, and outlining a clear path forward to feasibility studies and front-end engineering design for viable projects. By standardizing the site characterization process across both CSP and SHIP applications, this guideline aims to: 1) Improve consistency and transparency in early-stage project evaluation; 2) Reduce development risk and avoid investment in nonviable project sites; 3) Support collaboration between developers, researchers, and public agencies; and 4) Accelerate successful deployment of concentrating solar technologies for both power generation and industrial process heat.

14 SOLAR ENERGY

EVs-at-RISC: A Secure and Resilient Interoperable SCM Control System Architecture for Electric Vehicle’s-at-Scale (Final Technical Report)

The EVs-at-RISC project was a five-year research, development, and demonstration initiative to create foundational tools for utility-scale fleet aggregation and Smart Charge Management (SCM) of Electric Vehicles (EV), Electric Vehicle Charging Infrastructure (EVCI), and related Distributed Energy Resources (DER). Rather than seeking to develop and demonstrate highly perfected SCM algorithms and control strategies, this project instead focused on creating foundational software solutions that enable unprecedented digital interoperability across the communications technologies and vendor platforms used to manage EV , EVCI, and DER, as well as existing energy management infrastructure operated by utilities, grid operators, and aggregators. This project then extends these novel interoperability capabilities to develop and deploy powerful middleware abstractions across grid edge networks and EVCI/DER fleet aggregations incorporating modern software tools and best practices, such as CI/CD, to bring the immense capabilities of infrastructure-as-code and policy-as-code to modern grid edge network environments. This addresses the foremost systemic issues preventing realization of any net operational benefits from scaled deployment of behind-the-meter EV, EVCI, and DER assets in electric power grids and markets today. The results of this approach and project unlock massive potential for new SCM capabilities to be easily prototyped, evaluated, and deployed at-scale within the existing grid edge network infrastructure and EVCI/DER technology ecosystem. The EVs-at-RISC project achieves this by extending Open Field Message Bus (OpenFMB), a conceptual model for digital interoperability and distributed intelligence in traditional front-of-meter utility SCADA networks, validating our hypothesis that OpenFMB could be similarly used to solve systemic digital interoperability issues in behind-the-meter environments and unlock real-world utility-scale SCM capabilities without requiring any new proprietary vendor solutions or significant infrastructure reconfiguration.

24 POWER TRANSMISSION AND DISTRIBUTION

A Comparison of Pre‐Construction and Operational Wake Loss Estimates for Land‐Based Wind Plants

The overall bias between pre‐construction energy yield assessment (EYA) estimates of wind plant energy production and the achieved operational production is improving in the wind industry, but uncertainty remains high for individual wind plants. Wake effects within wind plants are one of the largest sources of energy loss considered in the EYA process, and previous work shows wake loss estimates to be a major source of disagreement among wind energy consultants who perform EYAs. To better understand the accuracy of wake loss predictions, we compare overall operational wake loss estimates based on supervisory control and data acquisition data to pre‐construction estimates provided by six wind energy consultants for five land‐based wind plants in North America. By augmenting existing approaches for quantifying operational wake losses, we estimate wake losses during the period of record for which operational data are available as well as the expected long‐term wake losses, based on historical reanalysis weather data, to which the EYA estimates are compared. To account for power variations at different turbine locations caused by terrain‐induced wind resource heterogeneity, we correct the operational wake loss estimates using predicted freestream wind speed variations from the Wind Systems Engineering Reynolds‐averaged Navier–Stokes (RANS) tool. We identify long‐term corrected operational wake losses between 1.9% and 6.4% for the five plants, with a mean loss of 4%. For the project deemed most acceptable for operational wake loss assessment, which is located in the simplest terrain and isolated from neighboring plants, the mean EYA wake loss estimate is within 0.7 percentage points of the operational value of 6.4%. For most of the remaining plants, results suggest that wake losses are generally overpredicted by 2.6–6.3 percentage points. However, operational wake losses may be underestimated for many of these projects because of spatial wind resource variations not captured by the RANS model, external wake effects that are unaccounted for in the estimation process, and wind plant blockage effects. To better understand factors that contribute to the observed wake losses, we investigate operational wake losses as a function of wind direction and wind speed. As expected, wake losses are generally concentrated near wind directions that are aligned with rows of closely spaced turbines and at below‐rated wind speeds; however, for some projects, the energy produced by the wind plant exceeds the estimated potential energy of the plant without wake interactions for certain wind directions and wind speeds, suggesting inaccurate assumptions in the wake loss estimation method for those plants. Lastly, we compare predicted and operational wake losses for individual wind turbines, finding that even when overall wake losses are predicted accurately, large uncertainty exists at the turbine level.

17 WIND ENERGY