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NASA NTRS2016

Solar vs. Fission Surface Power for Mars

A multi-discipline team of experts from the National Aeronautics and Space Administration (NASA) developed Mars surface power system point design solutions for two conceptual missions. The primary goal of this study was to compare the relative merits of solar- versus fission-powered versions of each surface mission. First, the team compared three different solar power options against a fission power system concept for a sub-scale, uncrewed demonstration mission. The 4.5 meter (m) diameter pathfinder lander's primary mission would be to demonstrate Mars entry, descent, and landing techniques. Once on the Martian surface, the lander's In Situ Resource Utilization (ISRU) payload would demonstrate liquid oxygen propellant production using atmospheric resources. For the purpose of this exercise, location was assumed to be at the Martian equator. The three solar concepts considered included a system that only operated during daylight hours (at roughly half the daily propellant production rate of a round-the-clock fission design), a battery-augmented system that operated through the night (matching the fission concept's propellant production rate), and a system that operated only during daylight, but at a higher rate (again, matching the fission concept's propellant production rate). Including 30% mass growth allowance, total payload masses for the three solar concepts ranged from 1,116 to 2,396 kg, versus the 2,686 kg fission power scheme. However, solar power masses are expected to approach or exceed the fission payload mass at landing sites further from the equator, making landing site selection a key driver in the final power system decision. The team also noted that detailed reliability analysis should be performed on daytime-only solar power schemes to assess potential issues with frequent ISRU system on/off cycling. Next, the team developed a solar-powered point design solution for a conceptual four-crew, 500-day surface mission consisting of up to four landers per crewed expedition mission. Unlike the demonstration mission, a lengthy power outage due to the global dust storms that are known to occur on Mars would pose a safety hazard to a crewed mission. A similar fission versus solar power trade study performed by NASA in 2007 concluded that fission power was more reliable-with a much lower mass penalty-than solar power for this application. However, recent advances in solar cell and energy storage technologies and changes in operational assumptions prompted NASA to revisit the analysis. For the purpose of this exercise a particular landing site at Jezero Crater, located at 18o north latitude, was assumed. A fission power system consisting of four each 10 kW Kilopower fission reactors was compared to a distributed network of Orion-derived Ultraflex solar arrays and Lithium ion batteries mounted on every lander. The team found that a solar power system mass of about 9,800 kg would provide the 22 kilowatts (kW) keep-alive power needed to survive a dust storm lasting up to 120-days at average optical depth of 5, and 35 kW peak power for normal operations under clear skies. Although this is less than half the mass estimated during the 2007 work (which assumed latitudes up to 30o) it is still more than the 7,000 kg mass of the fission system which provides full power regardless of dust storm conditions.

Rucker, Michelle A.↗

DOE OSTI2026

Biogas Utilization in Refuse Power Plants (BURP 2 )

The BURP 2 project investigated the technical and financial viability of co firing biogas with waste coal for power generation while using carbon capture and sequestration to achieve net negative emissions. A comparative assessment integrating geospatial mapping, technoeconomic analysis, and life cycle analysis was carried out to evaluate retrofitting an existing coal fired facility in West Virginia, versus developing a new greenfield power plant in Kentucky located near a low quality coal resource. The study found that CO 2 capture rates of 90% or higher, in combination with biogas feedstocks such as animal manure, could significantly reduce global warming potential compared to plants using neither biogas nor CO 2 capture systems. Economic feasibility depended heavily on federal tax credits and proximity to fuel sources. In both greenfield and retrofit scenarios, access to biogas played a key role. Because the retrofit site was located close to existing biogas resources, it represented a feasible option, whereas the greenfield site, being far from pipelines or biogas sources, would require prohibitively expensive biogas transport infrastructure. Overall, the research showed that repurposing waste or low-quality coal with renewable biogas and CO 2 capture systems could provide a viable approach for reducing carbon emissions in power production, if biogas resources are easily accessible and available in sufficient quantities.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2021

MOOSE Framework Meshing Enhancements to Support Reactor Analysis

MOOSE-based physics codes require an input finite element mesh on which the physics solution is calculated, reported, and transferred to other physics codes. The use of difficult-touse, external licensed software is often required to generate high quality meshes for reactor geometries. High-fidelity geometry modeling also requires elaborate tracking of groups of elements for material property assignment and output reporting which can be considerably complex for the user to identify and maintain. Under the U.S. Department of Energy Office of Nuclear Energy Advanced Modeling and Simulation (NEAMS) program, several meshingrelated enhancements have been developed for the MOOSE framework to address user challenges in creating finite element meshes for advanced reactor geometries. MOOSE mesh generators have been developed to mesh hexagonal geometries (pins, ducted assemblies, and cores) commonly found in liquid-metal cooled fast reactor concepts. The mesh generator used for hexagonal pin cells is generic for regular polygons and therefore may also be used for Cartesian pin cells. Hexagonal pin cells can be stitched into ducted assemblies, and assemblies can be stitched together into a core. The user may specify region ids, region names, and other preferences on the mesh. This control is useful for later material mapping in the MOOSE-based physics codes input. A capability was also developed for meshing rotating control drums including determination of material volume fractions in each mesh element as a function of time. Control drum meshes may be stitched to other hexagonal assemblies to create a core configuration. Additional mesh generators were developed that wrap around the hexagonal meshing capabilities and utilize “extra element integer” ID values on each element. In regular Cartesian or hexagonal assemblies or cores, the bookkeeping of element groups for both material assignment and output reporting can now be automated through assignment of pin, assembly, core, axial and depletion id values stored as extra element integers. The extra element tags on the mesh greatly speed the reactor analyst’s efforts to map materials to meshes, track depletion zones, and parse output such as axial pin power distributions. At the highest level, pin, assembly, and core mesh generators (with this reactor terminology) have also been developed to easily generate regular Cartesian and hexagonal cores, including axial extrusion. These reactor geometry builders call upon the previously mentioned capabilities to produce analysis-ready 3D meshes including material assignments. Open source mesh triangulation capabilities were also investigated for integration into the MOOSE framework to address the need for meshing the core periphery region which extends from the irregular outer assembly border to a cylindrical boundary. Options are limited due to licensing constraints, and the recommendation is pursue building a native MOOSE Delaunay triangulator routine with full functionality. Finally, a series of verification problems were performed with NEAMS physics tools. All developed capabilities will be available in the new open-source “Reactor” module of the MOOSE framework, which is accessible to any MOOSE-based NEAMS physics tool.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2025

SPC-71260 Rev 0 MARVEL Heat Extraction Subsystem Secondary Coolant Equipment (SCE) Design/Build

A. The Microreactor Applications Research Validation and Evaluation (MARVEL) reactor will offer experimental capabilities that are not currently available at DOE’s national laboratories. Idaho National Laboratory (INL), operated for the U.S. Department of Energy (DOE) by Battelle Energy Alliance, LLC (BEA) (Contractor hereafter) is procuring services for the design, analysis, fabrication, testing and delivery of a Secondary Coolant Equipment system (SCE). This specification contains the requirements for design, analysis, fabrication, testing and delivery of the SCE as described herein. The MARVEL reactor is a microreactor which uses eutectic sodium-potassium alloy (NaK) as a primary coolant. The primary coolant is circulated through four primary loops by natural convection of the coolant. In each loop is a closed well which will accommodate an intermediate heat exchanger (IHX) for extracting heat from the loop. These wells will be referred to in this specification as the “IHX wells.” It is intended for the IHX containment to also be filled with NaK. The MARVEL design team has determined that a Heat Extraction System (HES) using pumped NaK will be used to extract heat from the IHXs and deliver it to a downstream system for power generation or alternate process heat users. This Heat Extraction System will enable MARVEL operations including the ability to test, demonstrate, and address issues related to installation, startup, and operations. In addition, it will allow down-stream utilization of process heat for various uses. The objective of this specification is to develop the final design for the HES Secondary Coolant Equipment system (SCE) that will be used as the core of the HES. This system provides control of the NaK circulation between the MARVEL reactor and the subsequent process heat utilization systems. It does not include design of the Intermediate Heat Exchangers and piping inside the T-REXc pit in which the reactor is located. B. The MARVEL microreactor will be installed in the Transient Reactor Test Facility (TREAT) building in the Transient Reactor Test (TREAT) Micro-Reactor Experiment Cell (T-REXc) C. An INL Subcontractor has developed a conceptual design for this system per SPC-71145, referred to in that specification as the Process Heat Extraction System. SPC-71260 is based on the pumped NaK loop concept developed under SPC-71145. D. The SCE system design and (as option scope) fabrication shall be provided by the awardee of the subcontract (Subcontractor hereafter) pertaining to this Specification. Prior to shipment, the SCE will be fabricated, assembled, and tested at the Subcontractor’s facility. After successful completion of acceptance testing, the SCE and associated equipment will be shipped to the Materials and Fuels Complex (MFC) at the INL (Contractor’s Facility hereafter) to be installed by others in TREAT/T-REXc.

21 - SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLAN↗

DOE OSTI2022

Evaluation of Performance Variables to Accelerate the Deployment of Sustainable Aviation Fuels at a Regional Scale

An increase in jet fuel consumption and its associated emissions across the world have led to the need for alternative technologies to produce sustainable aviation fuels (SAF). One option to produce SAFs is to utilize waste or biomass-based feedstocks that has the potential to reduce greenhouse gas emissions by 50% or more compared to conventional jet fuel. However, there is a lack of understanding of how the synergistic effects of key performance variables could hinder or help the deployment of aviation fuels on a regional scale. Here, we assess the implications of key variables-including type and quantity of waste/biomass feedstock availability near the airport, cost of SAF production, life cycle greenhouse gas (GHG) emissions, policies, and fuel/infrastructure logistics-on the deployment of SAF at Chicago's O'Hare International Airport. We consider three ASTM International-approved SAF technologies (Hydroprocessed Esters and Fatty Acids, Fischer-Tropsch, and Alcohol to Jet) that can be blended up to 50% with petroleum-based jet fuel. Results from our analysis show that woody biomass-based Fischer-Tropsch technology has the lowest fuel production costs ($2.31-$2.81/gallon gasoline equivalent) of all pathways, and it reduces life cycle GHG emissions by 86% compared to conventional jet fuel despite the higher availability of crop residues compared to either woody biomass or fats, oils, and greases. Also, infrastructure is available at O'Hare International Airport to blend SAF with Jet A fuel through three terminals directly connected to the airport via pipelines. Our sensitivity analysis shows renewable fuel incentives and feedstock price to be key performance variables affecting the production cost and deployment of SAF.

alcohol-to-jet↗

DOE OSTI2023

Cost of Fish Exclusion and Passage Technologies for Hydropower

Hydropower represents a reliable source of renewable energy and accounts for approximately 7% of the total electrical generation in the United States. Future expansion of hydropower is likely to be in the form of either smaller new stream development projects or powering existing non-powered dams. For these new projects to be successful, careful analysis of risks, costs, and uncertainty to offset reduced power production as well as ensuring the protection and safe passage of migratory fish to gain public support, will be required. Exclusion and passage are two common approaches to protect fish from entrainment and impingement at hydropower facilities. The thresholds for entrainment risk and requirements for exclusion and passage often differ depending on the species involved, the characteristics of the facility, and the goals of stakeholders. While the costs associated with environmental mitigations represent a large proportion of the total costs required for the licensing of hydropower facilities, little quantitative information is present within the literature regarding the specific costs of fish exclusion and passage. Working with FOA awardee Natel Energy, scientists at Oak Ridge National Laboratory were tasked with assessing the capital construction costs for downstream fish exclusion and passage infrastructure. This report used keyword searches of an existing environmental mitigation cost data set and manual extraction of additional cost data associated with protection, mitigation, and enhancement (PM&E) measures related to positive barrier screening and passage from regulatory licensing documents available in the Federal Energy Regulatory Commission (FERC) eLibrary. This approach yielded a total of 50 PM&E mitigation measures with estimated capital construction costs pertaining to positive barrier screens, 142 pertaining to passage studies, and 26 pertaining to passage-related studies. PM&E measures associated with positive barrier screens represented <10% of the 171 total FERC project dockets available in the data set. These data were highly skewed toward conventional relicensing projects, as <7% were associated with new stream development (NSD) projects. Results from these data indicate highly variable costs associated with fish screening, with flow-normalized costs one to two orders of magnitude higher for screening with the highest exclusion capability (≤0.09 in. spacing) compared with coarser screening (1 to 2 in.). Furthermore, estimated capital costs of passage infrastructure were positively related to the scale of the project based on installed capacity for some, but not all, types of passage. These data provide an initial baseline for estimating exclusion and passage costs for hydropower development and may help developers consider options for more fish-friendly generation technologies, though gaps remain relating to a lack of data, particularly for NSD projects. More data may still be available within the FERC eLibrary, but significant effort will be required to manually identify and extract the data for future analyses.

13 HYDRO ENERGY↗

DOE OSTI2023

Cost‐benefit assessment framework for robotics‐driven inspection of floating offshore wind farms

Abstract Operations and maintenance (O&M) of floating offshore wind farms (FOWFs) poses various challenges in terms of greater distances from the shore, harsher weather conditions, and restricted mobility options. Robotic systems have the potential to automate some parts of the O&M leading to continuous feature‐rich data acquisition, operational efficiency, along with health and safety improvements. There remains a gap in assessing the techno‐economic feasibility of robotics in the FOWF sector. This paper investigates the costs and benefits of incorporating robotics into the O&M of a FOWF. A bottom‐up cost model is used to estimate the costs for a proposed multi‐robot platform (MRP). The MRP houses unmanned aerial vehicle (UAV) and remotely operated vehicle (ROV) to conduct the inspection of specific FOWF components. Emphasis is laid on the most conducive O&M activities for robotization and the associated technical and cost aspects. The simulation is conducted in Windfarm Operations and Maintenance cost‐Benefit Analysis Tool (WOMBAT), where the metrics of incurred operational expenditure (OPEX) and the inspection time are calculated and compared with those of a baseline case consisting of crew transfer vessels, rope‐access technicians, and divers. Results show that the MRP can reduce the inspection time incurred, but this reduction has dependency on the efficacy of the robotic system and the associated parameterization e.g., cost elements and the inspection rates. Conversely, the increased MRP day rate results in a higher annualized OPEX. Residual risk is calculated to assess the net benefit of incorporating the MRP. Furthermore, sensitivity analysis is conducted to find the key parameters influencing the OPEX and the inspection time variation. A key output of this work is a robust and realistic framework which can be used for the cost‐benefit assessment of future MRP systems for specific FOWF activities.

17 WIND ENERGY↗

DOE OSTI2020

Time-Lapse Vertical Seismic Profiling (VSP) for CO 2 Storage in a Depleted Oil Field in Northern Michigan

The Midwest Regional Carbon Sequestration Partnership (MRCSP) was founded in 2003 as part of the U.S. Department of Energy’s (DOE’s) Regional Carbon Sequestration Partnership initiative. Since its founding, MRCSP has made significant strides toward making CCUS a viable option for states in the region. The public/private consortium, funded through the DOE Regional Carbon Sequestration Initiative, brings together nearly 40 industry partners and 10 states. Battelle, as the project lead, oversees research, development and operations and coordinates activities among the partners. The incremental, phased approach has built a valuable knowledge base for the industry and paved the way for commercial-scale adoption of CCUS technologies. From 2008 to 2020, MRCSP Phase III focused on the development of large-scale injection projects. This report is part of a series of reports prepared under the Midwestern Regional Carbon Sequestration Partnership (MRCSP) Phase III (Development Phase). These reports summarize and detail the findings of the work conducted under the Phase III project. This report describes the Dover 33 VSP study to test the effectiveness of time-lapse Vertical Seismic Profile (VSP) for detecting and delineating a plume of more than 271,000 tonnes of CO2 injected into the Brown Niagaran and A-1 Carbonate formations within the Dover 33 reef between March 2013 and September 2016. Five 2D walkaway VSP (WVSP) source lines were acquired by SIGMA3 in September 2016 to investigate the possible time-lapse response in both P-wave and PS-wave seismic data. The data was compared to the same survey geometry acquired in March 2013 by SR2020. The seismic energy was recorded into an 80-level, three-component geophone array deployed into the Dover 1-33 well and placed just above the reef. P-wave and PS-wave reflection images were produced for each of the three source lines from both the 2013 baseline and 2016 monitor surveys. The images were then compared to look for changes in the reflectivity at and around the injection location that might indicate how the CO 2 has moved over this time period. This technique revealed several localized areas with sizable impedance differences inside the reef where CO 2 would be expected; however, a large number of similar impedance “hotspots” were also detected outside the reef in areas where injected CO 2 would not be expected. Therefore, a second analysis that involved calculating P-wave and S-wave travel time differences between the 2013 and 2016 VSPs was conducted to look for a change that could be caused by the CO 2 plume.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2024

HERO CarbonSAFE Phase 2 Project in the Columbia River Basalt Group

The Hermiston, Oregon Basalt CarbonSAFE Phase II project (HERO CarbonSAFE) seeks to accelerate the deployment of commercial carbon dioxide (CO2) storage projects in basaltic rocks. Basalt CO2 storage has several advantages to conventional saline storage reservoirs including 1. The potential for rapid mineralization of CO2, 2. Associated decreases in pressure and CO2 migration risks, 3. Reduced long-term monitoring requirements with respect to plume tracking, 4. Widespread geographic distribution and, 5. Large storage potential due to thickness, porosity, and CO2 interactions with basalt. And for locations such as the Pacific Northwest, Hawaii, Iceland, India and Japan, basalts may offer the only economically feasible option for local CO2 storage. However, there are limited field-scale assessments of CO2 storage in basalt, and current carbon capture utilization and storage (CCUS) permitting and regulatory frameworks were developed for conventional saline reservoirs. HERO CarbonSAFE is designed to address research gaps and uncertainties associated with basalt storage. Specifically, the project will assess the feasibility of CO2 injection in the deep layered basalts, long-term storage (mineralization), practical approaches for large-scale implementation (50+ million metric tons of CO2 over 30 years), lithology-specific risks, and the technoeconomic potential for CO2 storage in basalts. The HERO CarbonSAFE project will assess feasibility of developing a commercial-scale (50+ million metric tons of CO2) geological storage complex within the Columbia River Basalt Group (CRBG), a layered continental flood basalt complex that underlies Calpine’s natural gas-fired Hermiston Power Project (HPP) in Hermiston, OR (Figure 1). Under this 2-year CarbonSAFE Phase II project, the HERO team will conduct a data acquisition campaign that includes drilling a stratigraphic well to a total depth of ~1,500 m into the thick layered basalts proximal to HPP. A comprehensive well logging and hydrologic testing program will be augmented with new core collected from flow zones and sealing units, and comprehensive laboratory testing to help refine the kinetic rates of mineralization. The newly acquired information will be integrated with existing data from regional wells to correlate basalt injection zone properties to develop storage hub/commercial-scale models. Using these models, the project team will evaluate injection scenarios to define the technical and economic potential for storing a minimum of 50 million metric tons of CO2 over a 30-year period, along with a robust sensitivity analysis on key parameters governing reservoir viability for sustainable injection over a commercial project lifetime. Specific technical objectives of HERO are: (1) assessing the reservoir response of a series of stacked layered reservoir flowtop sequences occurring in this area of the CRBG to commercial-scale injection volumes; (2) extending prior efforts by the project team to characterize the deep layered basalts encountered in regional studies, to leverage prior investments by U.S. Department of Energy’s (DOE) Carbon Storage program; (3) leveraging DOE’s mineralization characterization efforts to advance model parametrization for commercial scale injection of CO2 in basalts; (4) conducting risk assessments associated with scaling up to commercial storage hub injection goals, while validating DOE’s National Risk Assessment Partnership (NRAP) tools, to identify potential constraints that would prevent the CRBG from serving as a commercial-scale storage complex; (5) developing mitigation plans to address identified risks; (6) developing a commercial-scale injection and monitoring, verification and accounting (MVA) strategy; (7) utilizing computational models to define and minimize, if possible, the Area of Review (AoR) under Class VI regulations; and (8) developing a robust CO2 management strategy for CRBG that also considers a regional source/sink approach that is responsive to stakeholder needs and industrial demand. Specific institutional objectives are: (1) identifying and developing plans to mitigate the nontechnical challenges associated with the build-out of a commercial-scale storage complex within the CRBG with integrated CO2 sources; (2) implementing the community outreach plan; (3) conducting regulatory research, including a survey of issues related to pore space ownership, MVA and long-term assurance of mineralization-based storage, to support an eventual application for a UIC Class VI permit; (4) advancing the project’s plan for CO2 liability management; and (5) continuing to refine and update the project’s economic model. The final objective is the preparation of a comprehensive Site Characterization Plan that draws upon the technical and institutional feasibility assessments to prepare the project for future commercialization efforts.

58 GEOSCIENCES↗

DOE OSTI2026

Elevating SolTrace's Capabilities for the Next Generation of Concentrating Solar Analysis

SolTrace is an open-source Monte Carlo ray tracing software developed at NREL. SolTrace can characterize concentrating solar thermal (CST) collector optical performance and is CST technology agnostic. Shown in Fig. 1, SolTrace is a foundational tool in NREL's CST system and component modeling suite. SolTrace's generic surface elements can flexibly model novel collector and receiver designs to predict spatial and temporal flux distributions - critical to understand for CST component design, performance prediction, and system integration. Since its initial development, SolTrace has over 1,650 references on Google Scholar, over 9,800 downloads since 2017, and has served the CST research and development community as a benchmark of 3rd party verification. SolTrace provides users with many options for defining surface shape and boundaries. However, SolTrace provides limited documentation which can result in a steep learning curve for new users. Additionally, SolTrace lacks the computational performance required to evaluate optical performance of a CST system over the course of a year and/or iteratively over design parameters in a timely manner. To address this, we are working towards a new release of SolTrace that enables increased computational throughput by implementing ray tracing acceleration structures and enabling GPU parallelization. Additionally, we are working to improve SolTrace's usability, accessibility, and maintainability by (1) automating solar position time-dependent simulation processes, (2) creating general CST collector templates of grouped elements, (3) updating the user interface to better visualize model inputs and outputs, and (4) creating a user support network through forums, "how to" videos, and documentation.

14 SOLAR ENERGY↗

DOE OSTI2020

Spent Nuclear Fuel Storage and Radioactive Waste Disposal in the United States: A Law and Policy Analysis - 20302

While Congress plays political football, spent nuclear fuel continues to sit in de facto interim nuclear waste storage sites throughout the country. This ad hoc approach - if it can even be called an approach - to nuclear waste management is in no one's best interests, because of financial, safety, environmental, and national security concerns with the status quo. Senate leadership had asserted that an up-or-down vote on the Yucca Mountain Project would take place in September or October 2019, but that did not occur. Rather, a conference bill was agreed to, and it provided that, although the nuclear program should receive some funding, funding was not made available for centralized interim storage ('CIS') or the Yucca Mountain Project. The President's FY2021 Budget Request does not contain any proposed funding for the Yucca Mountain Project ('the Project'). This paper will discuss the implications of that process, both for the Project itself and for the U.S. nuclear waste program more generally. In order to provide context for the current situation, this paper will begin by chronicling the history of U.S. nuclear waste management, from the passage of the Nuclear Waste Policy Act of 1982 and to the present day. It will discuss the roles of the U.S. Department of Energy, the Nuclear Regulatory Commission, federal and state political delegations, and the nuclear energy industry. The paper will then identify key themes that can be expected to affect the future of nuclear waste management in the United States. For example, it will consider whether development of additional CIS facilities is a viable short- to medium-term solution. CIS facilities may relieve immediate pressure at decommissioned or soon-to-be-decommissioned nuclear power plants; but with that pressure partially alleviated, support for building a long-term repository may be reduced. It will also discuss opposition by the State of New Mexico and others to the proposed New Mexico CIS project, based not only on siting concerns but also whether it might become a de facto repository, and whether the State of Texas and others may also be opposed, for similar reasons, to the proposed CIS facility in Texas. Additionally, the paper will examine consent-based siting and its implications for Nevada and other states that are potential hosts for spent nuclear fuel storage and disposal facilities. Further, if the Project is not a politically viable solution, the paper will examine whether it is now time for serious consideration of an alternate location for a permanent repository, as well as consideration of other options entirely, such as deep geologic disposal. The paper will conclude by looking ahead to the 2020 elections. It will describe the positions of candidates (particularly Presidential candidates) on spent nuclear fuel storage and disposal options, without advocating for any particular candidate or political party. Perhaps in 2020, we will at least see a start to a solution to the seemingly intractable problem of nuclear waste management in the United States. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2022

Operating Strategies for Dispatchable PEM Electrolyzers that Enable Low-Cost Hydrogen Production

Hydrogen is a pathway to enabling decarbonization across multiple economic sectors that cannot be directly decarbonized with electricity including heat for industrial operations, medium- and heavy-duty transportation applications, long-duration energy storage, and as a feedstock for chemical synthesis. Producing hydrogen at low costs and carbon footprint is likely essential to economically decarbonize these otherwise "hard to decarbonize" sectors. Low-temperature polymer electrolyte membrane (PEM) electrolysis produces hydrogen from water and electricity and is a rapidly developing pathway towards making hydrogen at the scales required for decarbonization applications. The levelized cost of electrolytic hydrogen is dependent on the capital cost, efficiency, and durability of the electrolyzer system as well as the price of electricity supplied to the electrolyzer and the annual utilization of the electrolyzer (capacity factor). Electricity price and capacity factor depend on the source of energy that the system uses and impact other economic factors. Electricity price and capacity factor and the connections between other aspects of hydrogen production via PEM electrolyzers are the focus of this work. PEM electrolyzers have conventionally been operated at high capacity factors using electricity purchased from utilities with a constant price throughout the year. To achieve lower effective electricity prices, recent work has investigated opportunities for electrolyzers to purchase electricity in wholesale markets, where the cost of electricity varies hourly. This option can lead to lower electricity costs when the electrolyzer is a controllable load that ramps up and down rapidly and turns on and off frequently. This configuration and operating strategy capitalizes on times of low wholesale electricity prices and results in lower hydrogen levelized costs than constant operation due to reduced electricity costs even though the reduced capacity factor increases the cost of recovering the capital investment. Cycling on and off frequently also has implications for electrolyzer durability. An electrolyzer configuration where it is directly connected to renewable generation such as wind or solar, only running when the generator is producing energy, has similar implications on operating strategy, hydrogen levelized cost, capacity factor, and durability. This work provides insight into the relationships between dispatchable electrolyzer operating strategies and the cost of producing hydrogen from these systems, outlining strategies and opportunities to minimize production costs while minimizing operations that are likely to negatively impact system durability and efficiency. We find strategies that minimize electrolyzer cycling and the resulting durability impacts while increasing the hydrogen levelized cost only slightly above the minimum. We also find opportunities for batteries to minimize the number of cycles in systems directly connected to renewable generation. These findings outline key opportunities for future electrolyzer deployments and the synergistic benefits between electrolyzers and increased deployment of renewable energy generation like wind and solar. They also inform research and development that is reducing electrolyzer capital cost while managing durability impacts.

electricity markets↗

DOE OSTI2023

Structure and Electronic Properties of Mesopores in Si PV Devices with PLEO Contacts

All current state-of-the-art silicon photovoltaic (PV) devices employ some flavor of passivating contact structure to minimize detrimental recombination while providing good conductivity. These properties are most often provided by a dielectric layer (SiNx, Al2O3, or SiOx) that is in contact with the crystalline silicon (c-Si) substrate. The effectiveness of these layers is heavily dependent on the nanoscale structure of both the dielectric layers and the crystalline silicon interface. As an example, the tunneling probability for charge carriers across thin SiOx layers, a process that is critical to maintain high conductivity, is extremely sensitive to the SiOx thickness. SiOx with a thickness below 2 nm readily allows charge carrier tunneling, whereas it is impeded for greater thicknesses. In the latter case it has been shown that modifications to the thermal processing schedule can induce disruptions, or pinholes, in thick SiOx layers that allow transport of charge carriers while maintaining excellent passivation. However, this requires higher temperatures processes that may inhibit widespread adoption by industry. Recently, another option has been presented that may circumvent the necessity for high temperature processing, namely metal assisted chemical etching (MACE). MACE relies on deposition of Ag nanoparticles onto the SiOx layers with subsequent electroless etching to form mesopores in the SiOx layers that are analogous to the pinholes created with high temperature processing. The size and density can be controlled based on the Ag nanoparticle deposition conditions. The resulting contact structure is known as polysilicon on locally etched oxide (PLEO) contacts. The nanoscale structure of the mesopores in PLEO contacts define the device level observables such as recombination current (Jo) and junction resistance. In this work we present atomic resolution transmission electron microscopy (TEM) analysis of mesopores in PLEO contacts formed with a different processing conditions to connect provide insight into how the nanoscale structure of the SiOx layer influences PV device properties. Additionally, we have previously used electron beam induced current (EBIC) to probe local transport properties in Si PV devices with a SiOx layer containing pinholes due to high temperature processing. Using EBIC we were able to directly show the enhance charge carrier transport through the pinholes. Here we also employ EBIC to study non-uniformities in charge carrier recombination and transport associated with mesopores in PLEO contacts and compare these results with our previous work on devices with pinholes in the SiOx formed through high temperature processes. The products of this work provide critical information that is required to both further optimize performance of Si PV devices with PLEO contact and to drive future adoption of this technology by industry.

ENGINEERING,SOLAR ENERGY↗

DOE OSTI2020

Codisposal Waste Package Loading Options for DOE SNF and HLW PPT

The U.S. Department of Energy (DOE) is responsible for managing spent nuclear fuel (SNF) that is currently in, or will in the future come into, its possession. DOE must continue to safely store that SNF, transport it to an interim storage site or a repository, and dispose of it. These fuels come from a wide range of reactor types with various cladding materials and enrichments. Many of these reactors, now decommissioned, had unique design features, such as core configuration, fuel element and assembly geometry, moderator and coolant materials, operational characteristics, and neutron spatial and spectral properties, resulting in a large diversity of reactor and fuel designs. Because of the wide variety and conditions of SNF, a robust DOE Standard Canister was proposed that would confine radionuclides and preclude moderator. The DOE Standard Canister had four variations: 3.05-meter (10-foot) or 4.57-meter (15-foot) length, and 45.7-cm (18-inch) or 61.0-cm (24-inch) diameter. For ultimate disposal in the Yucca Mountain Repository, these canisters were to be grouped with 61.0-cm (24-inch) diameter high level waste (HLW) canisters in a 2.13-meter (84-inch) diameter co-disposal waste package. The smaller 45.7-cm (18-inch) diameter DOE Standard Canister could be placed in the middle of five HLW canisters. The larger 61.0-cm (24-inch) diameter DOE Standard Canister would take the place of one of the five HLW canisters on the outer ring in the co-disposal waste package. No DOE Standard Canisters have been loaded. A preliminary evaluation has estimated the number of elements of a fuel type that can fit into the different sizes of the DOE Standard Canister, but no definitive loading configuration has been selected. Changing the loading configuration could impact the number of loadable DOE Standard Canisters and the number of co-disposal waste packages needed for eventual disposition. This paper conveys the ranges of DOE Standard Canisters and HLW canisters that may be produced under certain conditions. It also examines the differences in the estimated number of co-disposal waste packages produced for eventual disposal when using different loading strategies in the DOE Standard Canister for Advanced Test Reactor (ATR), Peach Bottom, and High Flux Isotope Reactor (HFIR) SNF. Changing the loading configurations of ATR, Peach Bottom, and HFIR SNF slightly impacted the number of co-disposal waste packages that may be needed for ultimate disposal. The change in loading configuration was more impactful when a different canister was used, as opposed to varying the number of elements that could fit inside the same size canister. In one case, a reduction of co-disposal waste packages could be achieved by allowing mixing of short HLW canisters with long DOE Standard Canisters. The main conclusion from this analysis is that the ratio between HLW canisters and DOE Standard Canisters will drive the total number of co-disposal waste packages. If too many HLW canisters (i.e., more than five times the number of 18-inch DOE standard canisters) or DOE Standard Canisters are produced, some co-disposal waste packages may not have all positions filled. A co-disposal waste package may be filled with all HLW with no DOE Standard Canister, or a co-disposal waste package could be filled with a single DOE Standard Canister. A ratio that does not closely align to optimum could allow for the design of waste packages that hold just HLW canisters or just DOE SNF canisters.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2020

Co-Disposal Waste Package Loading Options for DOE SNF and HLW - 20331

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2024

Investigation of precooling unit design options in hydrogen refueling station for heavy-duty fuel-cell electric vehicles

Precooling gaseous hydrogen fuel to a cold temperature before refueling a heavy-duty (HD) hydrogen fuel cell electric vehicle (HFCEV) is essential to avoid overheating the vehicle tank, as well as achieving a high state of charge (SOC). Because a large volume of hydrogen is dispensed during each fill, the need for a shorter fill time amplifies the need to precool each load for refueling a HFCEV. Thus, the design and operation of a precooling unit (PCU), as well as the associated capital and operating costs, plays a pivotal role in any plans for heavy-duty hydrogen refueling stations. Here, in this paper, we present a thermodynamic and technoeconomic analysis of a PCU in a gaseous hydrogen refueling station (HRS) for HD HFCEVs. By employing Argonne National Laboratory's hydrogen station cost optimization and performance evaluation (H2SCOPE) model, the refueling of 50 kg of hydrogen on-board type IV tank at ambient temperatures of 15–45 °C and varying fill rates is simulated. The required degree of precooling temperature to obtain either 100% or the maximum possible SOC is obtained from the simulation. Additionally, the simulation results demonstrate that the average flow rate of hydrogen is approximately 40% lower than the maximum flow rate during a typical fill; which motivates further evaluation of the instantaneous hydrogen mass flow rate profile and suggests the scope of improving precooling unit design. Accordingly, a hybrid strategy of precooling hydrogen has been proposed to address the cooling load by sizing the refrigeration unit for the average flow rate of hydrogen, while supplementing the above average peak hydrogen flow cooling load through thermal buffering. The combined technique enables the downsizing of the original PCU capacity by 25–40% and demonstrates a potential cost reduction of the PCU by approximately 30%, which translates to an installed cost reduction of ∼$125,000 per dispenser.

25 ENERGY STORAGE↗

DOE OSTI2022

Performance and Total Cost of Ownership of a Fuel Cell Hybrid Mining Truck

The main objective of this work was to investigate the potential of hydrogen and fuel cells replacing diesel and internal combustion engines in the ultraclass haul trucks deployed in the mining sector. Performance, range, durability, and cost are the main criteria considered for comparing the two fuels and engine options. Fuel cell system (FCS) performance is characterized in terms of heat rejection, efficiency, and fuel consumption for a hybrid platform equivalent to a 3500 hp diesel engine operating on a representative open pit mining duty cycle. A hybrid platform was chosen because the heat rejection, with a constrained radiator frontal area, limits the maximum fuel cell-rated power by about 50% compared to that of the diesel truck. The hybrid powertrain was 81–88% more efficient than the diesel powertrain on the truck duty cycle. A liquid hydrogen storage system is required for an equal range or time between refilling, but the packaging remains a challenge. Fuel cell and battery durability were evaluated for their performance degradation and lifetime. Achieving a fuel cell lifetime comparable to the time between major overhauls for diesel trucks necessitates the oversizing of the membrane-active area, catalyst overloading, and voltage clipping. For an equal lifetime, the battery must be oversized to control its depth of discharge and charge/discharge rates. A total cost of ownership (TCO) analysis considering the initial capital expenditures, as well as the lifetime cost of fuel, operation, and maintenance, indicates that fuel cells and hydrogen can compete with diesel. A breakeven fuel cost for TCO parity is obtained if H2 is available at USD 5.79–6.85/kg vs. diesel at USD 3.25/gal and the FCS-specific cost is USD 323/kW e relative to USD 250/kW for a diesel genset. Volume manufacturing is required for FCS cost reduction. High volume is possible through the standardization, modularity, and proliferation of class 8 long-haul truck systems across different heavy-duty applications.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2021

Advanced Fuels Campaign Execution Plan

The Advanced Fuels Campaign (AFC) Execution Plan outlines the strategy, mission, scope, near-term and long-term goals, structure, and organization associated with nuclear fuels and materials research, development, and demonstration activities within the Department of Energy’s (DOE) Nuclear Fuel Cycle and Supply Chain (NFCSC) program. NFCSC has been given responsibility to identify and mature advanced fuel technologies for the DOE using a science-based approach, focused on developing a fundamental understanding of nuclear fuels and materials to drive development of integrated nuclear fuel and materials technology. This science-based approach combines theory, experiments, and multiscale modeling and simulation to achieve a predictive understanding of relevant behaviors ranging from fuel fabrication processes (and their resulting fuel microstructures) through fuel/cladding performance under irradiation (in contrast to more empirical, observation-based approaches frequently used in fuel performance modeling and fuel qualification). The traditional scope of AFC includes the evaluation and development of multiple fuel forms to support two fuel cycle options: once-through and full recycle. The word “fuel” is used generically to include conventional fuels, transmutation targets, and any associated cladding or duct materials. The once-through fuel cycle addresses advanced light water reactor fuels with enhanced performance, extended burnup, and reduced waste generation. In fiscal year (FY) 2012, AFC’s scope expanded to include research, development, and demonstration (RD&D) for light water reactor (LWR) fuels with enhanced accident tolerance. Fuel fabrication activities include the development of innovative methods to enhance process efficiencies, reduce waste, and improve control over as-fabricated fuel microstructural properties to achieve desired in-reactor performance. Using modern modeling and simulation approaches, the objective is to predict fresh fuel properties given the feedstock characteristics and fabrication process parameters. The performance-related activities include small-scale, in-reactor, and out-of-reactor phenomenological testing (distinct from, but synergistic with, integral prototypic testing) and extensive, quantitative characterization (focusing on characterization of fuel and cladding materials at the scale of microstructure) both before and after testing. Larger-scale, prototypic experiments are conducted in concert with phenomenological testing to drive a Fuel Development and Qualification program, incorporating a fundamental understanding of fuel behavior performance characteristics. Then, using the tools developed under the productive science-based approach, fuels will be optimized to meet specific performance requirements, thereby minimizing the need to repeatedly perform large-scale, integral experiments over a wide parametric range as a means of experimental exploration. Two significant initiatives are underway within AFC. First, a gap analysis completed in early FY 2019 identified critical irradiation testing needs that are lacking within the national light water reactor (LWR) fuels testbed since the shutdown of the Halden Reactor in 2018. The identified gaps are for instrumented, prototypic testing of LWR fuels, especially under boiling water reactor conditions, ramp conditions, and conditions leading to fuel failure; these needs exist for supporting current LWR fuels and their possible extension to higher burnups, but are especially urgent relative to near-term development and qualification of accident-tolerant fuels. Recommendations that resulted from the Halden Gap Analysis focused on enhancements at Advanced Test Reactor (ATR) and Transient Reactor Test Facility (TREAT) to fill gaps in testing capabilities relative to these needs. Second, a concerted effort to develop and demonstrate a systematic approach to accelerating the development, testing, and qualification of new fuel systems has been initiated. This is highlighted by a test strategy that combines the considerable advances in multiscale, mechanistic fuel modeling of recent years with a MiniFuel separate effects test program in the High Flux Isotope Reactor (HFIR) and a Fission Accelerated Steady-state Testing (FAST) semi-integral accelerated test program in ATR. This approach is being tested/demonstrated using the metallic fuel system, but if successful it is expected to be extensible to multiple fuel types and diverse applications. This document includes an overview of the NFCSC program, a definition of science-based development of nuclear fuels, near-term goals for Advanced LWR fuels (ALFs), and longer-term goals for Advanced Reactor Fuels (ARFs) RD&D. This includes the activities that will be conducted to achieve success toward the grand challenge, as well as the goals and milestones to be achieved over the next few decades of research and development. Long-term goals are based on the DOE Office of Nuclear Energ

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗