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DOE OSTI2017

NetFlow Dynamics

NetFlow Dynamics is a web-accessible analysis environment for simulating dynamic flows of materials on model networks. Performing a simulation requires both the NetFlow Dynamics application and a network model which is a description of the structure of the nodes and edges of a network including the flow capacity of each edge and the storage capacity of each node, and the sources and sinks of the material flowing on the network. NetFlow Dynamics consists of databases for storing network models, algorithms to calculate flows on networks, and a GIS-based graphical interface for performing simulations and viewing simulation results. Simulated flows are dynamic in the sense that flows on each edge of the network and inventories at each node change with time and can be out of equilibrium with boundary conditions. Any number of network models could be simulated using Net Flow Dynamics. To date, the models simulated have been models of petroleum infrastructure. The main model has been the National Transportation Fuels Model (NTFM), a network of U.S. oil fields, transmission pipelines, rail lines, refineries, tank farms, and distribution terminals. NetFlow Dynamics supports two different flow algorithms, the Gradient Flow algorithm and the Inventory Control algorithm, that were developed specifically for the NetFlow Dynamics application. The intent is to add additional algorithms in the future as needed. The ability to select from multiple algorithms is desirable because a single algorithm never covers all analysis needs. The current algorithms use a demand-driven capacity-constrained formulation which means that the algorithms strive to use all available capacity and stored inventory to meet desired flows to sinks, subject to the capacity constraints of each network component. The current flow algorithms are best suited for problems in which a material flows on a capacity-constrained network representing a supply chain in which the material supplied can be stored at each node of the network. In the petroleum models, the flowing materials are crude oil and refined products that can be stored at tank farms, refineries, or terminals (i.e. the nodes of the network). Examples of other network models that could be simulated are currency flowing in a financial network, agricultural products moving to market, or natural gas flowing on a pipeline network.

Corbet Jr., Thomas F↗

DOE OSTI2021

U.S. Industrial and Commercial Motor System Market Assessment Report Volume 1: Characteristics of the Installed Base

Motor systems are an integral part of our industrial and commercial facilities. They provide the motive force behind the fans, pumps, compressors, chillers, and conveyors in these facilities. Given their centrality to any facility’s operations, they are a critical energy end use to understand, particularly when developing technologies and policies to meet sustainability goals, improve productivity, and enhance resilience. In the late 1990s, the U.S. Department of Energy (DOE) conducted two seminal studies to better understand the installed stock and energy savings opportunities of industrial and commercial motor systems. In the industrial sector, The United States Industrial Electric Motor Systems Market Opportunities Assessment used primary data collected through onsite assessments and led to a greater understanding of the installed base of motor systems, their characteristics, and the opportunities for energy savings (U.S. Department of Energy, 2002). Notable findings included the following: Industrial motor systems consumed 679 billion kilowatt-hours (kWh) in 1994, representing 23 percent of U.S. electricity consumption. Cost-effective energy efficiency measures could result in 62-104 billion kWh of energy savings annually. Sixty-two percent of the energy savings potential was from fan, pump, and compressor end use equipment. Nearly half of motor system electricity consumption was attributable to approximately 3,500 facilities, or 1.5 percent of U.S. manufacturing facilities. Opportunities for Energy Savings in the Residential and Commercial Sectors with High Efficiency Electric Motors provided an evaluation of the installed stock of motor driven equipment in U.S. commercial and residential buildings and opportunities for utilization of high efficiency motors and variable speed technologies (Arthur D. Little, 1999). Notable findings included the following: Commercial motor systems consumed 343 billion kWh in 1995, with refrigeration and space conditioning constituting 93 percent of the total. Cost-effective energy efficiency measures could result in 51 billion kWh of energy savings annually. Due in no small part to these seminal studies, motor system technologies and usage characteristics have changed drastically since the late 1990s. Greater awareness of cost-effective strategies for reducing motor system electricity consumption have been developed and deployed. This includes several software tools, literature, and utility and government programs promoting energy efficiency improvements in motor driven systems. Additionally, several rounds of energy efficiency standards have been enacted, resulting in improved installed motor efficiency. The cost of variable speed drives has dropped substantially, and combined with utility rebate programs, has led to their greater adoption. Further, since these results were published, the U.S. manufacturing sector has undergone a massive transformation. Due to global competition, some sectors have relocated operations overseas. Others have brought operations onshore to avail low cost and abundant natural gas. Additionally, automation and robotics have pervaded the entire sector. Consequently, these two reports likely do not represent the current state of motor driven systems in U.S. industrial and commercial facilities. As cited in recent studies, the lack of current information on motor system electricity consumption and use characteristics limits the ability to conduct analysis on energy savings potential, develop technologies to address energy and productivity gaps, and develop programs to promote energy efficiency practices and technologies for motor systems (International Energy Agency, 2007; UNIDO, 2010; McKane and Hasanbeigi, 2011; Waide and Brunner, 2011). Specifically, the lack of information affects a range of stakeholders: Governments must rely on outdated information when setting research agendas, developing policies, and designing energy efficiency programs and offerings. Utilities and energy efficiency programs cannot identify the current market needs or potential impact when designing rebate and energy efficiency programs. Electric grid planners cannot identify motor system usage characteristics when developing plans to support the resilience of the electric grid. Manufacturers of motors, motor driven equipment, and drives are hampered when developing technologies to meet the needs of their market. Motor system end users are limited in their ability to identify energy saving opportunities within their own facilities because they do not have reliable benchmark information. In response to the lack of current information and analysis on industrial and commercial motor systems, the DOE initiated an update to these two studies. Launched in 2016 and led by Lawrence Berkeley National Laboratory (LBNL), the Motor System Market Assessment (MSMA) provides an updated, more comprehensive assessment of the installed stock of motor systems in both the industrial and commercial sectors, a review of the supply chains supporting motor and drives in the U.S., and the performance improvement opportunity available from using best available technologies and maintenance and operation practices. The outcomes of the MSMA are documented in three U.S. Industrial and Commercial Motor System Market Assessment reports, with this report being the first listed: 1. Volume 1: Characteristics of the Installed Base (this report) documents the findings on the installed base of motor systems in the U.S. industrial and commercial sectors. Quantification of energy savings potential is not documented in this report but in Volume 3. 2. Volume 2: Motors and Drives Supply Chain Review reviews the state of supply chains for motors and drives installed in U.S. industrial and commercial facilities, focusing on advanced motor and drive technologies and their constituent materials. 3. Volume 3: Energy Savings Opportunity analyzes the energy performance improvement opportunity for the installed base of U.S. industrial and commercial motor systems. This report has been prepared as a reference for motor system stakeholders. It provides factual information as could be best determined by the assessment results and avoids speculating on any findings.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2025

Tunable electrochemical pathway for high-purity REMs and CMs

This report details a comprehensive research initiative focused on developing a technical research plan for the efficient and sustainable production of rare earth elements (REEs) and critical materials (CMs) from coal-based resources, specifically lignite coal from the Williston Basin in North Dakota. The project’s methodology centers on the design and evaluation of a tunable electrochemical pathway (TEP), an innovative approach aimed at achieving high-purity rare earth oxides (REOs), rare earth salts (RES), and CMs. This research is crucial for addressing the growing demand for these materials in clean energy technologies, electric vehicles, and high-tech applications, while reducing the United States’ reliance on foreign supply chains.

01 COAL, LIGNITE, AND PEAT↗

NASA NTRS2024

Harmonizing Food Systems Emissions Accounting for More Effective Climate Action

Food systems—encompassing activities in food production, land-use change, supply chains and waste management—contribute significantly to climate change. Recent estimates indicate that food systems produce over 30% of annual anthropogenic greenhouse gas (GHG) emissions (about 20% of CO 2 , 50% of CH 4 , and 75% of N 2 O), with the Intergovernmental Panel on Climate Change (IPCC) estimating a notably broad range of 23%–42% of global GHG emissions. This paper synthesizes current research on the contributions of food systems to climate change, highlights challenges in quantifying their impact and proposes a harmonized accounting framework for more effective climate action. We recommend that an expert committee aligned with the IPCC develop guidance for food systems emissions accounting in four key areas, including: (1) defining system boundaries and nomenclature; (2) developing protocols to allocate broader sectoral emissions to food systems; (3) prioritizing critical areas for research into activity data and emissions factors; and (4) developing a balanced framework for evaluating the impact of mitigation interventions in light of other food systems imperatives. The committee should be integrated into two key international policy processes—the United Nations Framework Convention on Climate Change and the United Nations Food Systems Summit—to support coordinated action towards global net-zero goals. Guidance from the committee could significantly improve the ability of governments, companies, and researchers to estimate, report, monitor and ultimately reduce the climate impacts of food systems.

GHG accounting↗

DOE OSTI2021

Electrification FY2020 Annual Progress Report

The Electric Drive Technologies (EDT) program’s mission is to conduct early-stage research and development on transportation electrification technologies that accelerate the development of cost-effective and compact electric traction drive systems that meet or exceed performance and reliability requirements of internal combustion engine (ICE)-based vehicles, thereby enabling electrification across all light-duty vehicle types.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2026

Structural dynamics of the renewable energy economy: A longitudinal input-output insights for a resilient transition

As countries accelerate their energy transitions, understanding how renewable energy (RE) systems structurally integrate into national economies is essential. This study presents a longitudinal economic input-output (EIO) analysis of the renewable energy sector in South Korea from 2016 to 2022. We develop a novel EIO-based framework that disaggregates the RE sector both by energy source (thermal, hydro, nuclear and renewable) and by industrial function (manufacturing, generation, and services), allowing for a detailed assessment of production dynamics, value-added creation, and import dependency. By quantifying backward and forward linkages and induced economic effects, the analysis reveals persistent structural vulnerabilities in renewable manufacturing and increasing sectoral interdependencies. Results reveal that while the renewable energy sector's production and value-added shares have increased, critical segments remain highly import-dependent, particularly in equipment manufacturing. The analysis highlights systemic gaps in domestic supply chain resilience and offers sector-specific insights for reducing vulnerability and enhancing energy security. Although applied to South Korea as a case study, the proposed framework is designed to be transferable to other national contexts where renewable energy planning requires economic structural insights. The findings offer policy-relevant guidance for enhancing domestic energy resilience and aligning industrial strategy with long-term decarbonization goals.

Economic linkage↗

DOE OSTI2022

Storm DEPART(Damage Estimate Prediction And Recovery Tool)

Damage prediction, materials needed, and resource allocation modeling capability in order to support pre-incident planning and preparation by predicting damage to the power generation capacity, transmission grids, distribution networks, and communications assets. The capabilities will be developed by multiple factors to include wind bands, storm surge, and flooding forecasts to participant’s assets which will result in a report of predicted damages. Additional factors to include available participants infrastructure data to include class, age, construction, location, wind rating, and additional information not in the public domain. Based on predicted damages, the output will be a bill of materials (BOM) to support short-term recovery operations. The extensiveness and level of detail for this BOM will depend on the replacement configuration specifications provided for each individual participant asset. Any limiting factors for the model will be applied related supply chain and resource constraints.

Klett, Mary↗

DOE OSTI2024

Techno-economic and life cycle analysis of synthetic natural gas production from low-carbon H 2 and point-source or atmospheric CO 2 in the United States

Synthetic natural gas (SNG) is of great interest in reducing fossil energy consumption while maintaining compatibility with existing NG infrastructure and end-use applications equipment. SNG can be produced using clean H 2 generated from renewable or nuclear energy and CO 2 captured from stationary sources or the atmosphere. In this study, we develop an engineering process model of SNG production using Aspen Plus® and production scales reported by the industry. We examine the levelized cost and life cycle greenhouse gas (GHG) emissions of SNG production under various CO 2 supply scenarios. Considering the higher cost of H 2 transportation compared with CO 2 transportation, we assume that CO 2 feedstock is transported via pipeline to the H 2 production location, which is collocated with the SNG plant. We also evaluate the cost of CO 2 captured from the atmosphere, assuming the direct air capture process can occur near the SNG facility. Depending on the CO 2 supply chain, the levelized cost of SNG is estimated to be in the range of $\$45–76$ per million British thermal units (MMBtu) on a higher heating value (HHV) basis. The SNG production cost may be reduced to $\$27–57$/MMBtu-HHV by applying a tax credit available in the United States for low-carbon H 2 production (45V). With a lower electricity price of 3¢/kWh for water electrolysis and accounting for a 45V tax credit, the SNG cost reaches parity with the cost of fossil NG. Depending on the CO 2 supply chain, SNG can reduce life cycle GHG emissions by 52–88% compared with fossil NG.

03 NATURAL GAS↗

DOE OSTI2024

Electrodialysis: An effective methodology to purify the leachate of spent Li-ion batteries

The electrification of transportation and the transition of society towards low or net-zero carbon emissions has led to a skyrocketing global demand for Li-ion batteries. After a service life of three to ten years, Li-ion batteries have less than 80 % of their initial capacities and draw near to the end of their lives for practical utilization. Due to potential supply chain shortages and the value embodied in Li-ion batteries, it is imperative to recycle them, to recover the materials, and to improve the circularity and the sustinability of the industry. How to cost-effectively purify spent batteries while reducing time, energy, and waste emissions is a challenge faced by Li-ion battery recyclers. The first electrochemical membrane reactor reported in our group hasa high selectivity towards lower Cu 2+ , Al 3+ and Fe 3+ ions (<5 ppm) and retains >95% of the Ni 2+ , Co 2+ and Mn 2+ ions in the leachate. An advanced electrochemical membrane reactor was developed in this study. Further, not only does the new reactor have the same selectivity as the original reactor, but other advantages including a faster leachate processing rate (up to 10X faster). The advanced reactor can also directly generate acid at the anode side; eliminating the reactor restoration step. The prominent advantages that this electrodialysis technology has over chemical-precipitation methods include: (1) ion recovery efficiencies do not diminish after removing the impurities, Ni 2+ , Co 2+ and Mn 2+ , even at a higher initial Ni 2+ ion concentrations; in comparison, chemical precipitation has Ni 2+ , Co 2+ and Mn 2+ ion recovery efficiencies reduced significantly when the initial Ni 2+ , Co 2+ and Mn 2+ ion concentrations increase. (2) electrodialysis does not change the concentrations of Ni 2+ , Co 2+ and Mn 2+ ions significantly, but chemical precipitation could reduce Ni 2+ and Co 2+ ions to less than half of their initial values. Through electro-dialyzing the leachate, the H 2 evolution reaction mechanism was found to switch from the Volmer-acid Heyrovsky mechanism to the Volmer-alkaline Heyrovsky mechanism at a pH of around 3.7.

25 ENERGY STORAGE↗

DOE OSTI2018

Assessing Alignment Between a Top-Down LCA Model and a Bottom-Up Supply Chain Model for Data Gap Identification and Prioritization

This work presents a method for evaluating the alignment between the results of bottom-up and top-down models and using the evaluation to enhance the bottom-up model and underlying data set. Disaggregation is used to enhance the embodied energy results of top-down models, which are then compared to bottom-up model results. Using the disaggregated top-down results makes it possible to identify specific data gaps and deficiencies within the bottom-up model and its data set. The top-down results will also provide information around which data gaps in the bottom-up model are contributing the most error to the results; in this way, data gaps can be identified as either critical or non-critical, and the effort needed to acquire and add data can be prioritized. Although the proposed method could be applied to any physical quantity or environmental impact that can be quantified with both bottom-up models (typically in physical units) and top-down models (typically in monetary units), embodied energy is the focus of this work. The disaggregated energy baseline is calculated from the throughput vector x, which gives the total economic activity required from each sector to provide a final demand. Using the direct requirements matrix, each element in x is disaggregated into a vector of inputs to the corresponding sector. Energy data from the interventions matrix B is then used to convert the monetary flows of the disaggregated x into physical energy flows. For each energy flow, the origin sector, the destination sector, and the energy carrier type will all be known. These energetic flows are analogous but not identical to direct energy inputs that would appear in a unit process used in life cycle analysis and other bottom-up methods, and thus can be used to evaluate the alignment between the top-down results and the results of a bottom-up model. To demonstrate and further develop the proposed method, embodied energy for chemicals assessed in the 2015 U.S. DOE bandwidth study on energy use within the chemical sector will be calculated using a top-down and a bottom-up model. The Materials Flows through Industry (MFI) modeling tool developed at the National Renewable Energy Laboratory is used as the bottom-up model, and the U.S. EEIO model, recently published by the U.S. Environmental Protection Agency, is used as the top-down model. U.S. EEIO and MFI results will be evaluated to determine how well the model results align. Where the two models are not in good alignment, the disaggregation method described above will be applied to the top-down model to generate a more detailed set of results that will aid in identifying data gaps in the MFI database. Using only MFI, data gaps can be identified in terms of which sectors have few or no unit processes in the database, but no information is available regarding the impact of the missing data on MFI results. The disaggregated top-down results will provide this information on which gaps in the MFI data are critical and have a significant impact on the results, and which are less important.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2015

Improved Large Aperture Collector Manufacturing

The parabolic trough is the most established CSP technology and carries a long history of design experimentation dating back to the 1970’s. This has led to relatively standardized collector architectures, a maturing global supply chain, and a fairly uniform cost reduction strategy. Abengoa has deployed more than 1,500MWe of CSP troughs across several countries and has built and tested full-scale prototypes of many R&D concepts. The latest trough R&D efforts involved efforts to internalize non-CSP industry experience including a preliminary DFMA principles review done with Boothroyd Dewhurst, a construction literature review by the Arizona State University School of Construction Management, and two more focused manufacturing engineering subcontracts done by Ricardo Inc. and the nonprofit Edison Welding Institute. The first two studies highlighted strong opportunities in lowering part count, standardizing components and fasteners, developing modular designs to support prefabrication and automation, and devising simple, error-proof manual assembly methods. These principles have delivered major new cost savings in otherwise “mature” products in analogous industries like automotive, truck trailer manufacture, metal building fabrication, and shipbuilding. For this reason, they were core in the design development of the SpaceTube® collector, and arguably key to its early successes. The latter two studies were applied specifically to the first-generation SpaceTube® design and were important in setting the direction of the present SolarMat project. These studies developed a methodology to analyze the costs of manufacture and assembly, and identify new tooling concepts for more efficient manufacture. Among the main opportunities identified in these studies were the automated mirror arm manufacturing concept and the need for a less infrastructure-intensive assembly line, both of which now form central pillars of the SolarMat project strategy. These new designs will be supported by new technology in the area of quality control inspection, in which state of the art photogrammetry and laser CMM inspection methods will be used to qualify parts and assemblies, and in which the recently-developed Absorber Reflection Method will enable in-line quality control inspection of modules produced by the new high-rate production line.

14 SOLAR ENERGY↗

DOE OSTI2015

Utilization of CO2 in High Performance Building and Infrastructure Products

The overall objective of DE-FE0004222 was to demonstrate that calcium silicate phases, in the form of either naturally-occuring minerals or synthetic compounds, could replace Portland cement in concrete manufacturing. The calcium silicate phases would be reacted with gaseous CO2 to create a carbonated concrete end-product. If successful, the project would offer a pathway to a significant reduction in the carbon footprint associated with the manufacture of cement and its use in concrete (approximately 816 kg of CO2 is emitted in the production of one tonne of Portland cement). In the initial phases of the Technical Evaluation, Rutgers University teamed with Solidia Technologies to demonstrate that natural wollastonite (CaSiO3), milled to a particle size distribution consistent with that of Portland cement, could indeed fit this bill. The use of mineral wollastonite as a cementitious material would potentially eliminate the CO2 emitted during cement production altogether, and store an additional 250 kg of CO2 during concrete curing. However, it was recognized that mineral wollastonite was not available in volumes that could meaningfully impact the carbon footprint associated with the cement and concrete industries. At this crucial juncture, DE-FE0004222 was redirected to use a synthetic version of wollastonite, hereafter referred to as Solidia Cement™, which could be manufactured in conventional cement making facilities. This approach enables the new cementitious material to be made using existing cement industry raw material supply chains, capital equipment, and distribution channels. It would also offer faster and more complete access to the concrete marketplace. The latter phases of the Technical Evaluation, conducted with Solidia Cement made in research rotary kilns, would demonstrate that industrially viable CO2-curing practices were possible. Prototypes of full-scale precast concrete products such as pavers, concrete masonry units, railroad ties, hollow-core slabs, and aerated concrete were produced to verify the utility of the CO2-curing process. These products exhibited a range of part dimensions and densities that were representative of the precast concrete industry. In the subsequent Demonstration of Commercial Development phase, the characteristics and performance of Solidia Cement made at a LafargeHolcim cement plant were established. This Solidia Cement was then used to demonstrate the CO2-curing process within operating concrete plants. Pavers, concrete masonry units and roofing tiles were produced according to ASTM and manufacturer specifications. A number of attractive manufacturing economies were recognized when Solidia Cement-based concrete parts were compared to their Portland cement based counterparts. These include reduced raw materials waste, reduced dependence on admixtures to control efflorescence, shorter curing time to full concrete strength, faster equipment clean-up, reduced equipment maintenance, and improved inventory management. These economies make the adoption of the Solidia Cement / CO2-curing process attractive even in the absence of environmental incentives. The culminating activity of the Demonstration of Commercial Development phase was the conversion of 10% of the manufacturing capacity at a concrete paver and block company from Portland cement-based products to Solidia Cement-based products. The successful completion of the Demonstration of Commercial Development phase clearly illustrated the environmental benefits associated with Solidia Cement and Solidia Concrete technologies. The industrial production of Solidia Cement, as a low-lime alternative to traditional Portland cement, reduces CO2 emissions at the cement kiln from 816 kg of CO2 per tonne of Portland cement clinker to 570 kg per tonne of Solidia Cement clinker. Industrial scale CO2-curing of Solidia Concrete sequestered a net of 183 kg of CO2 per tonne of Solidia Cement used in concrete pavers. Taken together, these two effects reduced the CO2 footprint associated with the production and use of cement in concrete products by over 50% (a reduction of 430 kg of CO2 per tonne of cement). Applied at the first commercial Solidia Concrete manufacturing site, the two effects will combine to reduce the CO2 footprint associated with the production and use of cement by over 10,000 tonnes per year. When applied across the precast concrete industry in the U.S., it is estimated that the CO2 footprint will be reduced by 8.6 million tonnes per year (20 million tonnes of cement used in precast concrete x 430 kg of CO2 per tonne of cement). Applied across the entire concrete industry in the U.S., it is expected that 43 million tonnes of CO2 will be avoided per year (100 million tonnes of cement used in all concrete x 430 kg of CO2 per tonne of cement).

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRSDate not supplied

Microbes Share Rides Too: Updating Encapsulated Bioburden Estimate Values in Electronic Parts Common to Class D Missions

As NASA develops more planetary protection missions that are Category III and in the Class D/rideshare mission platform, there is an increasing reliance on estimation of prelaunch bioburden to understand needs for burn up and breakup analyses or other methods to meet pre-launch bioburden levels. Current levels estimated for the encapsulated bioburden of semiconductor parts cited by NASA have been based on estimates of semiconductor manufacturing approaches from the 1970s that do not incorporate the evolving cleanliness of semiconductor manufacturing since that time. This investigation will focus on direct sampling of semiconductor parts for encapsulated bioburden values, drawing upon Goddard’s strength in EEE parts, supply chain management, destructive parts analysis and existing local planetary protection lab facilities to prepare and measure encapsulated bioburden at a statistically significant level for standard electronics parts common to known Class D/rideshare platforms.

planetary protection↗

DOE OSTI2011

RTSTEP Regional Transportation Simulation Tool for Evacuation Planning: Transportation Research and Analysis Computing Center (Final Report)

Large-scale evacuations from major cities during no-notice events - such as chemical or radiological attacks, hazardous material spills, or earthquakes - have an obvious impact on large regions rather than on just the directly affected area. The scope of impact includes the accommodation of emergency evacuation traffic throughout a very large area; the planning of resources to respond appropriately to the needs of the affected population; the placement of medical supplies and decontamination equipment; and the assessment and determination of primary escape routes, as well as routes for incoming emergency responders. Compared to events with advance notice, such as evacuations based on hurricanes approaching an affected area, the response to no-notice events relies exclusively on pre-planning and general regional emergency preparedness. Another unique issue is the lack of a full and immediate understanding of the underlying threats to the population, making it even more essential to gain extensive knowledge of the available resources, the chain of command, and established procedures. Given the size of the area affected, an advanced understanding of the regional transportation systems is essential to help with the planning for such events. The objectives of the work described here (carried out by Argonne National Laboratory) is the development of a multi-modal regional transportation model that allows for the analysis of different evacuation scenarios and emergency response strategies to build a wealth of knowledge that can be used to develop appropriate regional emergency response plans. The focus of this work is on the effects of no-notice evacuations on the regional transportation network, as well as the response of the transportation network to the sudden and unusual demand. The effects are dynamic in nature, with scenarios changing potentially from minute to minute. The response to a radiological or chemical hazard will be based on the time-delayed dispersion of such materials over a large area, with responders trying to mitigate the immediate danger to the population in a variety of ways that may change over time (e.g., in-place evacuation, staged evacuations, and declarations of growing evacuation zones over time). In addition, available resources will be marshaled in unusual ways, such as the repurposing of transit vehicles to support mass evacuations. Thus, any simulation strategy will need to be able to address highly dynamic effects and will need to be able to handle any mode of ground transportation. Depending on the urgency and timeline of the event, emergency responders may also direct evacuees to leave largely on foot, keeping roadways as clear as possible for emergency responders, logistics, mass transport, and law enforcement. This RTSTEP project developed a regional emergency evacuation modeling tool for the Chicago Metropolitan Area that emergency responders can use to pre-plan evacuation strategies and compare different response strategies on the basis of a rather realistic model of the underlying complex transportation system. This approach is a significant improvement over existing response strategies that are largely based on experience gained from small-scale events, anecdotal evidence, and extrapolation to the scale of the assumed emergency. The new tool will thus add to the toolbox available to emergency response planners to help them design appropriate generalized procedures and strategies that lead to an improved outcome when used during an actual event.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2024

Ensemble Manufacturing Techniques for Steam Turbine Components Across Length Scales

Faster design to manufacturing requirements were sought for steam turbine components to meet the changing demands of today’s power grid of improved efficiency through operating temperature increases and enhanced operational flexibility from baseload to cyclic operations. Advances in multiple advanced manufacturing (AM) process enabled redesign of turbine components for extreme environments with the potential to reduce cost. AM is of particular interest to improve component functionality, higher temperature capability, and superior durability in large scale steam turbine applications. AM methods have an immense potential to open-up the design space by working directly with the 3D model to produce near-net shapes, enable fast design-manufacturing iterations, thereby significantly reducing product cost and lead-time up to 25 % from current baseline. However, these benefits cannot be fully realized due to the potential for unknown AM processing defects and their resultant effect upon component performance in service. Siemens is partnering with Oak Ridge National Laboratory (ORNL), Electric Power Research Institute (EPRI), and Connecticut Center for Advanced Technology (CCAT) to advance the knowledge of complex process-material interactions for desired microstructures and properties that are closely interlinked to component geometries across different length scales. The proposed program utilized an ensemble of multidisciplinary technologies to accelerate the development of materials, high-throughput experiments for their qualification, and design flexibility/topology optimization for repair/redesign of components to address critical failure mechanisms for improved performance and increased reliability of existing power plant components. The proposed activities, if successfully demonstrated for identified components, will enable paradigm shift in customized manufacturing and accelerated qualification/certification towards increased steam turbine component durability, increased turbine efficiency, and reduced CO 2 emissions in load-following environments compared to today’s technology. Technology maturation is built into the project as successful research will include customized process-component down-selection enabling AM methodologies to be incorporated directly into the existing supply chain. The specific activities of the proposed effort are: 1. Topology optimization of down-selected steam turbine parts that are amenable to additive and hybrid manufacturing for cost/performance improvement. 2. Process-structure-property relationships for five AM processes for steam turbine materials of interest to compare with conventional materials. 3. Perform part/assembly build process using advanced additive/hybrid machine tools followed by quality inspection of the built components for insight into qualification for production scale-up. Steam turbine rig testing of printed components under targeted, well monitored and characterized environmental conditions of for performance comparison of baseline and redesigned components.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Characterization Inform Sustainable Recovery of Critical Minerals from Fossil Energy Waste Feedstocks

Rare earth elements (REE) and other critical minerals (CM, e.g., Co, Ni, Li) have important uses in green energy and modern technologies, yet are vulnerable to potential supply chain disruptions. One potential domestic CM source is fossil energy wastes, such as acid mine drainage (AMD) and treatment solids (AMD solids), coal combustion ash, and Oil and Gas (O&G) drilling wastes (drill cuttings and produced waters). While they can contain lower CM concentrations then traditional ore, the quantity and fast availability as waste feedstock makes them a promising CM resource. To explore their promise, researchers at DOE’s National Energy Technology Laboratory (NETL) have collected and analyzed CM data for aforementioned fossil energy wastes, and utilized advanced geochemical characterization (e.g., synchrotron microprobe and sequential extraction) to identify the CM speciation and binding environments, and developed sustainable and targeted CM recovery. Successful examples include: (1) the discovery of easily mobile REE phases in Ca-rich coal combustion ash and developing a patented REE recovery process from Ca-rich Powder River Basin coal ash; (2) the successful identification of REE/Co/Ni/Zn hosting phases in acid mine drainage treatment solids (AMD solids) with diverse chemical composition (Al, Mn, or Fe-rich) informing the sequential recovery of different REE/CMs from AMD solids; (3) the recovery potential of Li and other CMs in O&G produced waters and drill cuttings. The innovations driven by characterization have the potential to offset the cost of waste management and wastewater treatments while reducing the cost and environmental footprint of CM extraction.

Stuckman, Mengling↗

DOE OSTI2026

MSD CoP Webinar: Modeling the Operations of Reservoir Systems with LLMs and Inverse Reinforcement Learning

Context: This panel featured three presentations centered on the common theme of applying LLMs and inverse reinforcement learning (IRL) to capture the complex human-environment interactions that are central to the operation of reservoir systems. Dr. Wyatt Arnold will kick off the webinar with a talk on how analyzing LLM chain-of-thought reasoning reveals sophisticated quantitative justification and risk awareness, showing promise as a bridge between quantitative models and value-driven water management decisions. Next, Dr. Matteo Giuliani will build on this with a discussion demonstrating that AI- and IRL-driven approaches can infer the trade-offs between flood control and water supply using historical observations. Finally, Dr. Rohan Singh Wilkho will close the webinar with a talk establishing IRL as a generalizable diagnostic tool for decoding decision-making in managed hydrologic and human-infrastructure systems. Across the three presentations, the application of LLMs and IRL opens new possibilities for the development of adaptive, transparent, and human-aware models supporting water management in an increasingly uncertain future. Presenters: Wyatt Arnold (Politecnico di Milano); Matteo Giuliani (Politecnico di Milano); Rohan Singh Wilkho (Cornell University) Moderator: Patrick M. Reed (MSD CoP Facilitation Team); Stefano Galelli (MSD CoP AI Working Group Co-Chair); David Gold (MSD CoP AI Working Group Co-Chair) This webinar was held on: June 23rd, 2026 from 12-1 PM EST.

Arnold, Wyatt [Politecnico di Milano]↗

DOE OSTI2025

4.3.1.1 TCF: Recovery of Lithium from Geothermal Brine with Lithium-Aluminum Layered Double Hydroxide Chloride Sorbents

Lithium has gained importance as a near-critical element for various energy storage applications, and efforts are ongoing to develop simple and cost-effective methods for lithium recovery. For instance, in a typical 50 MW geothermal power plant in the Salton Sea, United States, approximately 15,000 metric tons of Li 2 CO 3 or LiOH salts can be produced annually by recovering and converting LiCl from geothermal plant waste solutions. Currently, approximately 390 MW of geothermal power is generated in the Salton Sea Known Geothermal Resource Area, which corresponds to potential Li 2 CO 3 production of approximately 120,000 metric tons per year. This makes lithium recovery from geothermal brines a promising, potentially low-cost source of lithium, contributing significantly to the global supply chain.

15 GEOTHERMAL ENERGY↗