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DOE OSTI2022

Integration of Superconducting Magnetic Energy Storage (SMES) Systems Optimized with Second-Generation, High-Temperature Superconducting (2G-HTS) Technology with a Major Fossil-Fueled Asset

Utility companies and fossil fueled generation assets are seeking combinations of “hybrid energy storage” to allow power to be provided in advance of, and to otherwise complement, peaking natural gas-fired generation. American Maglev Technology of Florida Inc. (AMT) learned during the Phase I program based on interactions with NRG Energy (NRG) that energy storage such as superconducting magnetic energy storage (SMES) can qualify as a Black Start unit in most markets, ensuring orderly re-start of grid operations and fossil fueled power plants and serving as an important asset of hybrid energy storage technology. In conjunction with the University of Houston (UH), AMT and NRG are working together to scale up low-cost, high- efficiency, second-generation high-temperature superconducting (2G-HTS) technology for deployment across several markets, with a primary focus on the commercial development of utility grid-scale SMES (g-SMES) systems. Ultimately the program confirmed that the novel g-SMES design can meet the performance and financial requirements of the fossil power plant industry, while exhibiting continuous grid-voltage regulation; cost-effective, peak-hour energy storage with almost infinite life; increased input/output efficiency; and the capability to undergo millions of charging cycles, without degradation, representing a significant improvement over lithium ion and other conventional storage technologies. We believe wide scale deployment of this technology is feasible and practical when compared to the higher life cycle cost and relatively short lifespan of chemical batteries. Based on these findings, the future for deployment of SMES at many fossil-fueled power plants exceeding 100MW capability is bright. Further de-risking g-SMES technology would pave the way for the construction of a subscale prototype. Eventually, scaled-down versions of SMES are expected to be competitive with the multi-billion-dollar lithium-ion market for a wide range of commercial, industrial, and transportation uses. There is long-term potential for commercialization and widespread deployment of this disruptive technology, which would spawn a new worldwide supply chain and create domestic, high-tech manufacturing jobs in the green industry.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2022

High-Energy Solid-State Lithium Batteries with Organic Cathode Materials (Final Report)

Organic materials made from abundant elements via low-energy processes are emerging as sustainable and low-cost alternatives to transition metal oxides as the electrode materials for high- energy batteries in the wake of supply chain and environmental issues associated with critical materials during the transition to clean energy. Organic insertion materials (OIMs) offer material- level energy comparable to transition metal oxides, but they have durability difficulties owing to dissolving in common liquid electrolytes. Combining ceramic-based solid electrolytes with organic electrode materials is one intriguing solution. The goal of this project is to design and synthesize high-energy OIMs, to understand the chemical dynamics and mechanical properties at the OIM-sulfide interface during electrochemical cycling, and to develop methods for constructing the optimum cathode microstructure, which will lead to improved electrochemical performance. The project team has accomplished the following over the last four years: (a) demonstrating that the mechanical softness of organic electrode materials is uniquely beneficial in suppressing crack formation at the electrode-electrolyte interface during cell operation; (b) understanding the interaction between cathode microstructure and the mechanical properties of individual components; and (c) establishing predictive control of cathode microstructure by tuning the mechanical properties of solid electrolytes and OIMs; (d) determining the chemical combability of sulfide electrolyte with high-energy OIMs and finally (f) laying out a road map toward a specific energy of 500 Wh kg -1 for solid-state lithium batteries. 14 publications resulted from this project.

25 ENERGY STORAGE↗

DOE OSTI2022

Prioritizing ICS Beachhead Systems for Cyber Vulnerability Testing

Cyber Testing for Resilient Industrial Control Systems™ (CyTRICS™) is the Department of Energy’s (DOE’s) program for cybersecurity vulnerability testing, digital subcomponent enumeration, and forensic assessment. CyTRICS leverages best-in-class test facilities and analytic capabilities at six DOE National Laboratories and strategic partnerships with key stakeholders including technology developers, manufacturers, asset owners and operators, and interagency partners. During the program’s development, CyTRICS established a unique methodology for prioritizing digital components within operational technology (OT) and industrial control systems (ICS) in the Energy Sector Industrial Base (ESIB) for cyber vulnerability testing. The CyTRICS Prioritization Process leverages multiple characteristics of systems, components, and their contextual deployment to calculate a quantification of individual digital components for CyTRICS testing. The initial version of the CyTRICS Prioritization Process was premised largely upon the impact which could result to an industrial control system if the digital component under testing was compromised, either through malicious means, faulty engineering, or other modes. The worldwide compromise of the SolarWinds Orion platform, first reported in December 2020, through malicious interference with the digital patching cycle was a watershed event in cyber supply chain security. The SolarWinds compromised demonstrated the strategic importance of certain types of ubiquitous software, and the ability to generate widespread cybersecurity effects. To address this challenge and as a part of the Department of Energy’s response to the SolarWinds compromise, DOE’s Office of Cybersecurity, Energy Security, and Emergency Response (CESER) directed the National Laboratories to evolve the CyTRICS Prioritization Process methodology to encompass additional factors related to the strategic importance of digital components. CESER directed CyTRICS researchers to identify, characterize, and append strategic factors to the CyTRICS Prioritization Process to provide additional weight to these characteristics. National Laboratory expert researchers identified functionality, distribution, and platform characteristics for digital components in ICS and OT that they assessed would be likely targeted in strategic initial-access cyber attack. CyTRICS has termed these factors “ICS Beachhead Systems,” leveraging a definition first advanced by Schneider Electric, which is intended as a blanket term to encompass digital components, products, and systems in OT. This paper describes the ICS Beachhead Systems identified and the rationale for inclusion. As a next step in the research and refinement process, the National Laboratories will validate this initial set of characteristics against digital components evaluated by the CyTRICS program and current implementation of the CyTRICS Prioritization Process. After validation, CyTRICS researchers will then develop a scoring methodology to generate a quantitative score to assess the degree to which a digital component is characterized as an ICS Beachhead System. Finally, the National Laboratories will append this scoring to the existing CyTRICS Prioritization Process algorithm.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2022

Wet Waste Hydrothermal Liquefaction and Biocrude Upgrading to Hydrocarbon Fuels: 2021 State of Technology

Each year the U.S. Department of Energy Bioenergy Technologies Office (BETO) assesses progress in their research and development efforts toward sustainable production of renewable fuels (DOE 2016) through the annual state of technology (SOT) assessment. The SOT assessment evaluates the impact of the year’s research progress on the modeled minimum fuel selling price (MFSP) for selected biofuel conversion pathways and measures the current state of the technology relative to defined goal case projections. Supply chain sustainability analysis to track and guide research toward improved greenhouse gas (GHG) emissions, energy usage, water usage and other environmental metrics for the pathway is performed by Argonne National Laboratory (Cai et al. 2018, 2020). Technical and cost targets for a projected goal case set for the year 2022 were previously established for the wet waste hydrothermal liquefaction (HTL) and biocrude upgrading pathway and summarized in a design report (Snowden-Swan et al. 2017). Process performance advancements made for HTL and biocrude hydrotreating have resulted yearly reductions in the modeled MFSP relative to the initial SOT (2018) (Snowden-Swan et al. 2020, 2021). This report summarizes the research and associated techno-economic analysis (TEA) for the pathway 2021 SOT. Methods and economic assumptions for the nth plant analysis used for the TEA are consistent with the design report (Snowden-Swan et al. 2017), with the exception of updates in the modeled cost year (2016) and income tax rate (21%).

09 BIOMASS FUELS↗

DOE OSTI2022

High Yield, Economical and Environmentally Benign Production of Rare Earth Elements from Coal Ash (Phase II Final Summary Report)

Fly ash stored in landfills and ponds across the United States is an attractive, abundant domestic resource for the cost-effective recovery of rare earth elements (REE) and other critical minerals (CM). Physical Sciences Inc. (PSI) and its team members, Winner Water Services (WWS) and University of Kentucky/Center for Applied Energy Research (UK/CAER) successfully executed a multiphase program that developed technologies and their implementation in a pilot plant. We demonstrated plant operations for cost-effective and environmentally-friendly production of rare earth element oxide (REO) concentrates, and the critical minerals scandium and aluminum (in the forms of salts or oxide products), from coal ash. We also constructed and demonstrated a research-scale (0.5 kg/day) micropilot facility to validate the key physical and chemical processing operations, predict yields, and troubleshoot process bottlenecks. The project team then designed, constructed and operated two decoupled pilot plants: (1) an operational pilot plant for physical separation processes with capacity of 0.4 metric tons per day (tpd), where we optimized processes to produce selected ash fractions as the feedstock for chemical processing and as valuable byproducts such as cenospheres, magnetic ash, and secondary fuel carbon, and (2) an operational pilot plant for chemical ash processing with a capacity of 0.5 tpd that developed optimized processes for the production of: (a) REO concentrates, (b) critical minerals (Sc, Al), and (c) beneficiated ash as a valuable byproduct suitable for cement applications. In Phase I, the project team (with Equinox Chemicals in place of WWS) developed and demonstrated the feasibility of the physical and chemical separation processes, developed the design of a pilot plant, and began the development of a preliminary techno-economic model. In the baseline (initial) Phase II program, the project team developed and demonstrated the above pilot scale plant, producing salable REE concentrates, including Y and Sc (REYSc), plus commercially viable byproducts, using environmentally safe and high-yield physical and chemical enrichment processes. The team successfully demonstrated chemical pilot design, construction, shakedown, and operations of the plant. We produced the Phase II deliverable REYSc concentrate ((50 g of >60 wt.% purity REYSc salts on elemental basis), generated the feed for the Phase II follow-on program, identified processing challenges for future optimizations, and refined the techno-economic model. In the Phase II follow-on program, the project team: (1) developed and demonstrated processes to increase the REE amount by 3X (content basis) and convert the Phase II REE salt mixture to an oxide mixture, (2) produced/delivered >38 g of REO mixture with >85 wt.% purity (elemental basis); (3) developed processes to recover critical minerals scandium and aluminum from intermediate streams; (4) produced/delivered > 1 g of scandium salt mixture with >85 wt. % purity (elemental basis); (5) produced/delivered > 100 g of aluminum oxide type material with >70% wt. purity (elemental basis); and (6) updated the techno-economic model from the baseline Phase II program to assess CAPEX and OPEX of a commercial operation. This program has developed extensive databases on process chemistry, unit operations, plant engineering, and techno-economics that will enable further scale-up toward commercial plant design. Specific future developments will be focused on achieving dramatic savings in energy, reagent usage, and operating costs. The combined results will contribute significantly for maturing the technologies of REE recovery from coal byproducts and promote the establishment of domestic REE and CM supply chains.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2022

CO 2 Intermediate Storage (CIS) Concept Overview

The objective of this overview is to provide a comprehensive set of qualitative considerations to inform future quantitative technical and economic CIS analyses. This overview focuses on CO 2 EOR as the end-user for CCUS supply chains that might implement CIS.

42 ENGINEERING↗

DOE OSTI2022

Offshore Wind Market Report: 2022 Edition

The 2022 edition of the Offshore Wind Market Report provides offshore wind policymakers, regulators, developers, researchers, engineers, financiers, supply chain participants, and other stakeholders with up-to-date quantitative information about the offshore wind market, technology, and cost trends in the United States and worldwide. The report covers the global offshore wind industry for the 2021 calendar year and the most significant U.S. domestic industry progress and events from January 1, 2021, through May 31, 2022.

17 WIND ENERGY↗

DOE OSTI2022

CRADA NO. NFE-22-00001 Between CNS and Northrop Grumman Systems Corporation

Consolidated Nuclear Security, LLC (CNS) and Northrop Grumman Systems Corporation (NGC) have established a partnership through the subject Cooperative Research and Development Agreement (CRADA) in three areas of collaboration: (1) Additive Manufacturing (AM) of manufactured carbon-carbon composite materials, (2) modeling and simulation, and (3) specialized chip and circuit board manufacturing for supply chain assurance.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Michigan Hydrogen and Fuel Cell Electric Vehicle Deployment Plan: H2 FCEV Roadmap 2022

This report describes a roadmap for hydrogen fuel cell electric vehicles in the state of Michigan. This plan provides links to relevant information to assess, plan, and initiate hydrogen and FCEV deployment to help meet the energy, economic, and environmental goals for the State of Michigan. Policies and incentives that support hydrogen and fuel cell technology will increase deployment, thus increasing production and creating jobs throughout the supply chain. As deployment increases, an economy of scale will develop and manufacturing costs will decline, positioning hydrogen and fuel cell technology to compete more effectively in a global market without incentives. Policies and incentives to purchase and support the deployment of FCEVs, FCEBs, and hydrogen refueling can be coordinated regionally to maintain this advanced clean transportation sector as a global exporter for long-term growth and economic development. Overall, the execution of this plan will maintain Michigan's role as a global showcase for regionally manufactured transportation technology while reducing NOx and CO 2 emissions and as new jobs are created for businesses and industry.

08 HYDROGEN↗

DOE OSTI2022

Feedstock Carbon Intensity Calculator (FD-CIC): Users’ Manual and Technical Documentation

The carbon intensities (CIs) of biofuels are determined with the life cycle analysis (LCA) technique, which accounts for the energy/material uses and emissions during the complete supply chain of biofuel including feedstock production and fuel conversion stages. Regulatory agencies such as California Air Resources Board (CARB) adopts LCA to calculate biofuel CIs. The Low Carbon Fuel Standard (LCFS) program developed by CARB allows individual biofuel conversion facilities to submit their own biofuel CIs with their facility input data and incentivizes the reduction in the CI specific to that particular facility compared to a reference fuel’s CI (Liu et al 2020). Such an incentive program has driven innovations in biorefineries to reduce their greenhouse gas (GHG) emissions by linking their revenue directly to its CI score through LCFS credit trading. Besides the biofuel conversion stage, different farming practices for feedstock growth can result in significant CI variations for feedstocks, thus for biofuels. To provide evidence-based research findings, the U.S. Department of Energy’s Advanced Research Projects Agency–Energy (ARPA-E) has supported the Systems Assessment Center of the Energy Systems and Infrastructure Analysis Division at Argonne National Laboratory to examine CI variations of different farming practices to grow agricultural crops for biofuel production. Meanwhile, the ARPA-E has launched the Systems for Monitoring and Analytics for Renewable Transportation Fuels from Agricultural Resources and Management (SMARTFARM) program to develop technologies and data platforms that enable an accurate measurement of key farming parameters that can help robust accounting of the GHG benefits of sustainable, low-carbon agronomic practices at farm level.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2022

Land-Based Wind Market Report: 2022 Edition

Wind power additions in the United States totaled 13.4 gigawatts (GW) in 2021. Recent growth is supported by the industry’s primary federal incentive—the production tax credit (PTC)—as well as a myriad of statelevel policies. Long-term improvements in the cost and performance of wind power technologies have also been key drivers for wind capacity additions, even as supply chain constraints due to increased commodity and transportation costs and COVID-19 restrictions push costs higher.

17 WIND ENERGY↗

DOE OSTI2022

Offshore Wind Market Report: 2022 Edition

17 WIND ENERGY↗

DOE OSTI2022

Circular economy as a climate strategy: current knowledge and calls-to-action

Existing pledges and NDC targets, even if fully achieved, are still not sufficient to meet the Paris climate goals. Considerable additional strategies and actions are urgently needed to close the emission gap. Built environment, transport, food system, and clean energy are the most relevant sectors for circular economy strategies to deliver climate change mitigation benefits. Circular economy strategies can complement decarbonization measures to further reduce GHG emissions from material production, help lower emissions from operational energy use in the built environment and transport, and cut emissions from waste management. The largest potential GHG emissions reductions through circularity come from consumption side measures and product design measures. Circular economy strategies can support a sustainable clean energy transition, by helping relieve the mineral supply pressure, increasing supply chain resilience, preventing new waste challenges, accelerating the adoption of clean energy technologies, as well as maximizing their climate benefits. Furthermore, circular economy strategies can help enhance adaptation to climate change. Nine calls-to-action are put forward, for government, business, and civil society leaders to accelerate circular economy strategies with the highest potential for climate benefits, and for the research community to close critical knowledge gaps.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2022

Assessment of Light-Duty Plug-in Electric Vehicles in the United States, 2010 – 2021

The number of plug-in electric vehicles (PEVs) sold in the United States has consistently grown since 2010, reaching 4% of the light-duty vehicle market in 2021. This report examines how the characteristics for these PEVs has changed over this decade, evaluating range, energy efficiency, costs, and performance. Given the vehicle characteristics, this report estimates miles driven, electricity consumption, petroleum reduction, and greenhouse gas emissions attributable to electric vehicles. This report also explores vehicle manufacturing and battery production, considering supply chains from battery cells to assembly. Over 2.1 million PEVs have been sold in the United States through December 2021, with 1.3 million of these all fully-electric battery electric vehicles (BEV), and 800,000 plug-in hybrid electric vehicles (PHEV) which have the capability of using gasoline. The sales-weighted average range for BEVs reached 290 miles in 2021 and 28 miles for PHEVs. We estimate that electric vehicles have driven 68 billion miles on electricity since 2010, thereby reducing national gasoline consumption by 0.54% in 2021 and 2.5 billion gallons cumulatively through 2021. In 2021, PEVs used 6.1 terawatt-hours of electricity to drive 19.1 billion miles, offsetting 700 million gallons of gasoline. We find that this fuel switching reduced consumer fuel costs by $1.3 billion in 2021. Since 2010, 65% of PEVs sold in the United States have been assembled domestically, and over 110 gigawatt-hours of lithium-ion batteries have been installed in vehicles to date.

25 ENERGY STORAGE↗

DOE OSTI2022

Innovative Method for Welding in Generation 3 CSP to Enable Reliable Manufacturing of Solar Receivers to withstand Daily Cycling at Temperatures Above 700°C (Final Technical Report)

Inconel® Alloy 740H® (alloy 740H) was the first age-hardenable nickel-based alloy approved by the ASME Boiler & Pressure Vessel Code for use in pressure-boundary applications. Over the past ~20 years the alloy has been optimized for weldability and high-temperature stability, approved for use in different applications. Development of a supply chain combined with the advantageous properties of the alloy (high-temperature creep strength, oxidation and corrosion resistance, etc.) have resulted in the alloy being applied to new high-temperature power cycle demonstration projects, and of particular interest are applications to concentrating solar power (CSP) to enable higher-efficiency Generation 3 CSP systems and the corresponding supercritical CO 2 (sCO 2 ) power cycle components (heat exchangers, piping, etc.). The high allowable stresses of alloy 740H also make it a desirable material for current Generation 2 CSP solar power receivers to improve cyclic capability and/or reduce receiver height. Recent experiences in demonstration projects utilizing alloy 740H identified cracking issues during welding and fabrication. In this project, a detailed study was done to confirm and clarify the Stress Relaxation Cracking (SRxC) mechanism, also known as stress relief cracking or strain-age cracking (SAC), during post-weld heat-treatment (PWHT). This involved detailed microscopy and advanced characterization to understand the root cause(s) of three failures obtained from industry. Based in-part on these findings, a targeted laboratory based SRxC test method was utilized to evaluate variables such as heat-to-heat variations, strain level, PWHT temperature, and starting material condition on three heats of alloy 740H. Industrial shop welding of cold-worked plates was also conducted. The research showed the following: SRxC was confirmed as the cracking mechanism for all field failures; Stress state (from residual stresses, constraint, deformation, and local stress concentrations) was playing a significant role in field failures and laboratory testing confirmed increasing susceptibility for all heats with increasing strain levels. High levels of microstructural strain were identified at crack initiation locations, in some cases leading to local recrystallization; Precipitate free zones (PFZs) at grain boundaries were found at relaxation cracks and crack initiation locations uniquely associated with SRxC in alloy 740H. Laboratory testing reproduced this microstructural feature which had only previously been reported in long-term creep testing of weldments. Advanced nano-scale characterization confirmed the presence of a moving boundary leading to coarsening of precipitates and PFZs where damage accumulated; The research suggested heat-to-heat variations due to local chemistry and processing may influence SRxC susceptibility, but more work is needed to fully clarify these effects. To disseminate the key learnings from this research to the scientific and engineering communities and alloy 740H end users, multiple technical publications and presentations were made, an industrial alloy 740H users meeting was held, and a new industry guideline specification document which can be directly implemented by end-users of alloy 740H was produced.

14 SOLAR ENERGY↗

DOE OSTI2022

Closing the Gap: A Global Perspective [Slides]

Against the backdrop of negotiations at COP26, a group of internationally recognised research and technology organisations launched a collaboration, with the intention to identify the national and international technology-led opportunities to decarbonise fossil fuel basins globally. This study will evidence the opportunities available to players across the entire energy ecosystem. Governments and funders will be able to spread costs and investment risk, energy companies will develop a greater understanding of the global transition and possible opportunities to develop pilot projects worldwide, and there will be greater incentive to the supply chain once they are aware of the global applicability of certain technologies and technology solutions. Through the analysis and comparison of national energy systems, a number of Net Zero Deployment Strategies and Technology Priorities have been identified, that are shaping the direction of the construction of net zero integrated energy systems globally. These have been considered to design Recommendations for International Collaboration to accelerate the global energy transition.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2023

Artificial Intelligence for Isotopes: Report on the 2022 Workshop on Artificial Intelligence for Isotope R&D and Production

The Department of Energy Isotope Program (DOE IP) hosted a virtual workshop on Artificial Intelligence (AI) for Isotope R&D and Production on March 17 and April 14, 2022. The purpose of the workshop was for DOE IP to further its understanding of the potential roles for and subsequent opportunities to incorporate AI into its activities. The workshop brought over 80 participants together from both the AI and isotope science communities. Participants contributed ideas through plenary talks, lightning talks, and breakout discussion sessions. The primary focus of all discussions was related to isotope production and processing. However, isotope enrichment, workforce development, and supply chain management were also discussed. This report documents the information presented and discussed at the workshop.

07 ISOTOPE AND RADIATION SOURCES↗

DOE OSTI2022

Artificial Intelligence for Accelerating Nuclear Applications, Science, and Technology

Artificial intelligence (AI) and machine learning (ML) methods have had significant impacts in science and technology in recent years. These methods for generating models from datasets or logic-based algorithms that emulate aspects of human performance can similarly accelerate the fields of nuclear applications, science, and technology toward the IAEA goals of contributing to peace, health, and prosperity. In order to accomplish advances with AI in general and ML in particular across these fields, IAEA can play a significant role by establishing, hosting and curating centralised resources, including databases, adhering to FAIR (findable, accessible, interoperable and reusable) principles and Open Science best practices, providing stewardship of data sharing, supporting training efforts and development of relevant workforces, as well as enabling connections among the scientific, technology, mathematics, AI and ethics communities. Many areas can benefit from the use of AI in the realm of nuclear applications. In human health, these areas include clinical research, epidemiology, nutrition, medical imaging, radiotherapy and education of health professionals. AI-based tools are also being used to facilitate different clinical tasks in imaging, computer-assisted diagnosis in mammography and lung cancer screening programmes, and dose prediction in nuclear medicine procedures. ML methods in particular may also increase the efficiency and accuracy of the analysis of computerised tomography and dual-energy absorptiometry scans for body composition and bone analysis. The application of AI methods to nuclear and related technologies in food and agriculture can lead to significant advances and improved efficiency in the optimisation of agricultural production, food product development, management of supply chains, food safety and food authenticity control. In the water and environmental sector, AI can help inform policies to mitigate the world’s water problems. The application of AI techniques to hydrology and environmental sciences is expected to improve patterns identification and enable model predictions under a changing climate.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗