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DOE OSTI2022

Conceptual Design of Pulverized Coal Electricity Generating Units for Flexible Operation

This presentation was given by Marc Turner, NETL Support Contractor, at the International Center for Sustainable Carbon's "The Energy Transition - the Role for Sustainable Carbon" workshop held in Sardinia, Italy on November 16-18, 2022. The presentation addresses the NETL report titled "Conceptual Design of Pulverized Coal Electricity Generating Units for Flexible Operation" published on September 6, 2022. This study presents an independent conceptual assessment of the features, cost, and performance of pulverized coal power plants (without carbon dioxide capture) intended for flexible, rather than baseload, operation. The objective was to leverage the already substantial knowledge base about flexible operation and develop state-of-the-art pulverized coal power plant cases that are designed to accommodate flexible operation within an electric grid having a high level of renewable generation. This is of significant importance in coal-dependent regions of the world as variable renewable energy becomes more prevalent.

Turner, Marc↗

DOE OSTI2023

Synchronous Wind: Evaluating the Grid Impact of Inverterless Grid-Forming Wind Power Plants

Grid-forming (GFM) control of Type-3 and Type-4 wind turbine generators has attracted substantial attention in power systems research; however, the limited over-current capability of power electronics converters continues to deteriorate the grid strength of the evolving power systems. This paper develops the generic model of synchronous wind power generators, also known as Type-5 wind turbines, for power system integration studies. The Type-5 wind turbine interfaces with the electric grid through a synchronous generator; hence, its operation and consequent grid impacts are similar to a conventional power plant. Based on the developed model, a Type-5 wind power plant is integrated into the IEEE 14-bus test bed to evaluate its control and operation with a bulk power system. Finally, the stability properties of Type-5 wind turbine generators are compared with Type-3 wind turbines in GFM control mode through impedance characterization.

grid strength↗

DOE OSTI2022

Field Experience Detecting PV Underperformance in Real Time Using Existing Instrumentation

Maintenance at large-scale photovoltaic plants employs a mix of preventative and corrective maintenance practices. Large outages, such as an inverter tripping offline, are often easy to detect. More subtle sub-inverter faults and failures can accumulate and go unnoticed for months or years. A software-based fault detection method has been developed to analyze commonly measured data from large-scale PV plants for more timely detection of subtle underperformance. The method has been demonstrated on eight datasets from large-scale plants with high accuracy of detection. Results are validated using aerial infrared scanning. String outages are detected with a true positive rate of 73 percent and tracker issues are detected with a true positive rate of 88 percent. The developed method can be uniformly applied to photovoltaic plants across a range of scales and configurations to assess performance, quickly detect underperformance, and determine the source and location of failures. The results inform and improve operations and maintenance at PV plants, ultimately aiding in improved affordability, reliability, availability, and resiliency of solar electricity.

14 SOLAR ENERGY↗

DOE OSTI2020

Pilot testing of CO2 capture from a coal-fired power plant—Part 2: Results from 1-MWe pilot tests

Abstract Using a 1-MWe slipstream pilot plant, solid-sorbent-based post-combustion CO2 capture was tested at a coal-fired power plant. Results from pilot testing were used to develop a preliminary full-scale commercial design. The sorbent selected for pilot-scale evaluation during this project consisted of an ion-exchange resin that incorporated amines covalently bonded to the substrate. A unique temperature-swing-absorption (TSA) process was developed that incorporated a three-stage fluidized-bed adsorber integrated with a single-stage fluidized-bed regenerator. Overall, following start-up and commissioning challenges that are often associated with first-of-a-kind pilots, the pilot plant operated as designed and expected, with a few key exceptions. The two primary exceptions were associated with: (i) handling characteristics of the sorbent, which were sufficiently different at operating temperature than at ambient temperature when design specifications were established with lab-scale testing; and (ii) CO2 adsorption in the transport line between the regenerator and adsorber that preloaded the sorbent with CO2 prior to entering the adsorber. Results from the pilot programme demonstrate that solid-sorbent-based post-combustion capture can be utilized to achieve 90% CO2 capture from coal-fired power plants.

Sjostrom, Sharon↗

DOE OSTI2023

Synchronous Wind: Evaluating the Grid Impact of Inverterless Grid-Forming Wind Power Plants: Preprint

Grid-forming (GFM) control of Type-3 and Type-4 wind turbine generators have attracted substantial attention in power system research. However, the limited over-current capability of power electronics converters continues to deteriorate the grid strength of the evolving power systems. This paper developed the generic model of synchronous wind power generators, also known as Type-5 wind turbines, for the power system integration studies. The Type-5 wind turbine interface to the grid through a synchronous generator; hence, its operation and consequent grid impacts are similar to a conventional power plant. Based on the developed model, a Type-5 wind power plant is integrated into IEEE 14-bus testbed to evaluate its control and operation with a bulk power system. Finally, the stability properties of Type-5 wind turbine generators are compared with Type-3 wind turbines in GFM control mode through impedance characterization.

grid strength↗

DOE OSTI2020

Data Collection and Analysis Challenges and Mitigation Strategies for Quantitative Human Factors Research Studies in Nuclear Power Plant Modernization

The United States (U.S.) Department of Energy (DOE) Light Water Reactor Sustainability (LWRS) program Plant Modernization Pathway is conducting targeted research and development (R&D) to address aging and reliability concerns with the legacy instrumentation and control and related information systems of the U.S. LWR fleet. In this effort, the application of human factors engineering (HFE) provides an important role in ensuring new digital plant technologies enable broad innovation and business improvement with continued operational safety. Evaluation is a key activity in HFE, which often occurs iteratively through the system design lifecycle. While qualitative methods are important in collecting information of how users perform tasks through observations, quantitative methods are equally important in assessing system design based on performance. In collecting and analyzing this quantitative data, there are notable challenges in the nuclear HFE domain that may threaten the validity and reliability of the inferences made in these studies. Notable challenges include small sample size and limited resources, large error variance and small effect size, an “adding test features to losing degrees of freedom” dilemma, non-normal distribution, and heterogeneity of variance. The results in control room usability studies are often statistically non-significant, which makes it hard to interpret. This work discusses these challenges across different scientific viewpoints and provides real-world examples of these challenges in practice. Collectively, the objective of this work is to position these challenges to the larger data science community as a means of identifying future opportunities to address these issues.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2024

Non-destructive, whole-plant phenotyping reveals dynamic changes in water use efficiency, photosynthesis, and rhizosphere acidification of sorghum accessions under osmotic stress

Noninvasive phenotyping can quantify dynamic plant growth processes at higher temporal resolution than destructive phenotyping and can reveal phenomena that would be missed by end-point analysis alone. Additionally, whole-plant phenotyping can identify growth conditions that are optimal for both above- and below-ground tissues. However, noninvasive, whole-plant phenotyping approaches available today are generally expensive, complex, and non-modular. We developed a low-cost and versatile approach to noninvasively measure whole-plant physiology over time by growing plants in isolated hydroponic chambers. We demonstrate the versatility of our approach by measuring whole-plant biomass accumulation, water use, and water use efficiency every two days on unstressed and osmotically stressed sorghum accessions. We identified relationships between root zone acidification and photosynthesis on whole-plant water use efficiency over time. Our system can be implemented using cheap, basic components, requires no specific technical expertise, and should be suitable for any non-aquatic vascular plant species.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2023

High Temperature Electrochemical Sensors for In-Situ Corrosion Monitoring in Coal-Based Power Generation Boilers

In this project, we successfully achieved the goals we proposed: 1. optimization and development of electrochemical sensor, 2. sensor construction and package, 3. sensor testing @Longview Power Plant and data analysis, 4. lab-scale sensor optimization and corrosion database development, 5. electrochemical and corrosion monitoring validation and 6. TEA.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2025

XFEM Development for Modeling Crack Growth in Prototypical Welded Components

Nuclear power plant components are subjected to harsh operating environments that can lead to multiple degradation mechanisms in which fracture can play a prominent role. Predicting crack growth is important for assessing the integrity of welded components. The extended finite element method (XFEM) is an important tool for modeling such crack growth, and XFEM capabilities have been developed within the MOOSE framework. This report documents work in the MOOSE XFEM module to model fractures in three-dimensional representations of components using a topologically two-dimensional mesh to define cutting planes. Crack growth algorithms have been implemented to evolve the cutting mesh based on equations for stress corrosion cracking. Additionally, several usability and robustness improvements have been developed to enable three-dimensional fracture simulations. The cutting algorithms were demonstrated on a three-dimensional model of a prototypical reactor component undergoing stress corrosion cracking driven by idealized weld residual stresses. This is an incremental step toward using this capability to model more complex components with residual stresses computed through welding process simulations.

42 - ENGINEERING↗

DOE OSTI2023

Grid-Forming PV Inverter: Technology Development and Microgrid Applications

Presently, excluding residential backup power applications, grid-forming (GFM) inverters are commercially available for battery energy storage system (BESS) and some PV plus battery systems but not yet for stand-alone PV. This tech update investigates the control design for GFM PV inverter, especially the control required to provide active power reserve and to stabilize the dc link voltage. Subsequently, the use cases of GFM PV plants in utility-level microgrids are discussed considering fully inverter-based microgrids (i.e., with PV and BESS) as well as mixed-source microgrids (i.e., with PV and diesel generator). Scenarios where active power up-reserve from GFM PV plants is beneficial are illustrated. Moreover, requirements and specifications for GFM PV plant, especially for its active power reserve function are developed. In addition, stability of an example utility-level microgrid with two GFM PV plants and a diesel generator is analyzed to shed light on the potential unstable interaction between multiple GFM resources and the countermeasures. This research aims to advance GFM PV technology to offer more flexibility in microgrid design. With GFM PV available, depending on the level of reliability required, cost-benefit analysis, etc., the GFM BESS or diesel generator may be sized smaller while leveraging the full potential of PV generation inside the microgrid.

14 SOLAR ENERGY↗

DOE OSTI2026

Hydropower Infrastructure - LAkes, Reservoirs, and RIvers (HILARRI), v4

HILARRI is a database of links between major datasets of operational hydropower dams and powerplants, and inland water bodies. These connections are critical for conducting large-scale analysis of hydropower infrastructure and their associated natural and engineered water systems. Features include: – Dams from the National Inventory of Dams (2025) and the Global Reservoir and Dam Database (GRanD v1.3) – Hydropower plants from the Existing Hydropower Assets dataset (EHA 2025) – Power plants that are listed in the 2025 U.S. Hydropower Development Pipeline Data or were listed in previous versions of the dataset These hydropower infrastructure features are linked to several major datasets that provide hydrologic and hydraulic information relevant for analysis of hydropower systems that includes the integral water resources. That information comes from: – Products from the National Hydrography Dataset (NHD) – NHDPlusV2 Medium Resolution river network flowlines, – NHD waterbodies (limited to lakes and reservoirs), – NHD Watershed Boundary Dataset (HUC12-level for the Conterminous United States (CONUS)) – NHD High Resolution waterbodies – HydroLAKES water bodies (lakes and reservoirs) – LAGOS-US lakes and reservoirs – EPA National Lakes Assessment (2007, 2012, 2017, and 2022) – The Reservoir Sedimentation Database (RESSED) – EPA SuRGE sampling locations Unique identifiers are used to facilitate joining to the original full datasets. For example, characteristics of NHD flowlines such as estimated average flow rate can be joined from the NHDPlusV2 dataset to a dam or power plant listed in HILARRI based on the ID field, “COMID”, that is common to both datasets. HILARRI only includes basic information about identifiers, location, and data quality or usage notes. It does not contain the attributes or time series data associated with these sites. The HILARRI dataset incorporates information from several datasets to facilitate more effective and accurate analysis of hydropower infrastructure and their associated waterbodies. For example, dams were checked against the most recent American Rivers Dam Removal Database to identify and flag facilities that may no longer exist. Additionally, dams that are listed multiple times in the NID are identified and flagged to avoid double-counting when analyzing and summarizing information. Other quality flags include certainty of operational hydropower (i.e., if one or more datasets indicates hydropower at a particular location), whether an associated water body is accurate or composed of multiple polygons, or whether there is a known issue with reported characteristics in one of the underlying datasets. These additional data flags are designed to increase confidence in data usage for individual to large-scale analyses.

Hansen, Carly [ORNL] (ORCID:0000000193280838)↗

DOE OSTI2025

Enabling The Next Generation of Smart Sensors in Coal Fired Power Plants using Cellular 5G Technology

Ohio University (OHIO), West Virginia University (WVU), and American Electric Power (AEP) proposed to study and report on the benefits of 5G wireless cellular technologies for coal-fired power plants. The significant advantages, cost savings, and potential of 5G wireless data communications based sensors promised to usher in a new era of reliable, inexpensive, and powerful embedded systems that had not previously been available for coal-fired power plants. The team built upon existing experience with cellular-based systems, power plant water quality sensing, and high temperature sensors developed during past projects. Principal Investigator Wilhelm had been developing cellular-based sensor data systems with a commercial partner for 10 years, pioneering innovative solar-powered devices that began with 2G technology. The lessons and knowledge gained served as a foundation to demonstrate innovations and potential impacts specific to coal fired power plants enabled by 5G technology, along with integration with existing sensors and systems.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2022

Transmission Alternatives for California North Coast Offshore Wind, Volume 4: Cost-Benefit Analysis Report

The purpose of this report is to compare the costs and benefits of installing offshore wind power plants with capacities up to 500 megawatts (MW) in the Humboldt Wind Energy Area offshore California, focusing on identifying the costs related to transmission upgrades and possible alternatives such as energy storage. We identify several options that result in lower costs than upgrading transmission to provide full deliverability. Our estimates of the levelized cost of energy (LCOE) assuming full deliverability range from $80/MWh for a 144-MW plant to $73/MWh for a 480-MW plant with a 2030 commercial operation date; however, the additional cost of transmission upgrades increases these values to between $86/MWh and $98/MWh. Based on curtailment and revenue estimates developed using a production cost model, the LCOEs for plant capacities of 144 MW and 168 MW with Energy Only deliverability are lower than the combined cost of energy and transmission upgrades for full deliverability. The addition of a 4-hour, 15-MW battery energy storage system increases revenue for both plant sizes, with the 144 MW + storage scenario producing the most revenue relative to LCOE.

17 WIND ENERGY↗

DOE OSTI2022

Analysis of HolosGen Sub-Scale Simulator with Plant Dynamics Code

The Subcritical Power Module Sub-scale Simulator (SPM-SS) has been designed and constructed by HolosGen LLC under the ARPA-E MEITNER program to simulate the thermal-hydraulic and heat transfer behavior of the full-scale Holos-Quad Subcritical Power Modules (SPMs). Four coupled SPMs, each rated at 5.5MW, form the Holos-Quad gas-cooled microreactor design. The SPM-SS represents a substantially scaled-down system with a power rating less than 40 kW, equipped with an electrically heated fuel cartridge heat exchanger, an electrically heated compressor heat exchanger, and a valve actuated turbine heat exchanger, in addition to a recuperator and a cooler heat exchanger. The fuel cartridge represents a portion of the full-scale SPM core, the compressor heat exchanger mimics the temperature changes resulting from the compressor’s turbomachinery inefficiencies, the turbine heat exchanger mimics the expansion process normally occurring through the turbine, while the recuperator and cooler heat exchangers complete the subscale simulator loop. The heaters equipping the fuel cartridge and the compressor heat exchangers are electronically controlled to simulate normal and off-normal SPM operating conditions. The full-scale Holos-Quad SPM design eliminates the traditional balance of plant and executes thermal-to-electric energy conversion by means of an intercooled Brayton cycle with decoupled compressor-turbine turbomachinery. The Holos-Quad full-scale design is equipped with a multi-stage axial Low- and High-Pressure compressor, and a multistage axial turbine. The SPM-SS is designed for testing and validation of selected components which are instead coupled by a traditional balance of plant. The SPMSS is not equipped with turbo-machinery (compressor and turbine) as the development of these components were excluded from the scope of work under the ARPA-E MEITNER funding program. The SPM-SS balance of plant enables modifications, replacement and testing of individual components with different working fluids and is designed to include the turbo-machinery components that will be developed in future research . The SPM-SS can be operated with different gases, variable mass-flow-rates, pressures, and temperatures to obtain test data for selected components, whose performance can be scaled to validate the computer model of the full-scale SPM at various conditions (e.g., start-up, transients conditions). The SPM-SS can operate at the maximum Holos-Quad design pressure of 7 MPa, and a maximum temperature limited to 650 °C by the electrical heaters. Several SPM-SS tests have been conducted and analyzed with the Plant Dynamics Code (PDC) developed at the Argonne National Laboratory (ANL). These tests aimed at validating the PDC modeled predictions of the full-scale Holos-Quad design with data from selected SPM-SS components. In order to address SPM-SS specific characteristics, such as components heat losses and absence of turbomachinery components, some modifications to the PDC have been implemented to factor the design differences from the full-scale Holos-Quad SPM to the SPM-SS. As the PDC offers capabilities to analyze systems with different working fluids, air, nitrogen, and helium were utilized as the SPM-SS working fluids. Air was utilized to fine-tune the SPM-SS Systems Structures and Components (SSCs), nitrogen was utilized to pressure test the SPM-SS loop at the SPMs design maximum pressure of 7MPa. Helium was utilized as the working fluid circulating through the SPM-SS SSCs for specific tests to validate the PDC predictions of the fuel cartridge heat exchanger. SPM-SS tests data were also analyzed with both the steady-state and transient analysis capabilities offered by the PDC. This report describes the PDC analysis of the SPM-SS tests data, including the necessary code modifications and comparison of the code results with the experimental data. Based on the results, a discussion is presented on how the analysis supports design and transient calculations of the full-scale Holos-Quad microreactor. Also based on the results of this work, recommendations are made for future optimizations of the SPM-SS components and PDC model development needs.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2025

Cost and Performance Baseline for Fossil Energy Plants Volume 1: Bituminous Coal and Natural Gas to Electricity

This report presents an independent assessment of the cost and performance of select fossil energy power systems—pulverized coal (PC) and natural gas combined cycle (NGCC) plants—using a systematic, transparent, technical, and economic approach. This is Volume 1 of the baseline series: Bituminous Coal and Natural Gas to Electricity. The cost and performance of fossil fuel‐based generation technologies represented in this report are important inputs to assessments and determinations of technology combinations to be utilized to meet the projected demands of future power markets. From a research and development perspective, this report is used to assess goals and metrics and to provide a consistent basis for comparing developing technologies. The main report consists of fifteen power plant configurations, six PC cases (with and without carbon capture) nine NGCC cases (with and without carbon capture) and few additional cases of higher capture rate, for both PC and NGCC plants in the appendix. In addition to the report, an interactive tool was developed that allows users to manipulate six key study parameters simultaneously for each case and visualize the impact on three metrics: 1) levelized cost of electricity (LCOE), 2) cost of CO 2 capture (CCC), and 3) cost of CO 2 avoided (CCA). Following is the link to the interactive tool: https://netl.doe.gov/NETLVol1BaselineTool

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2021

Analytics-at-scale of Sensor Data for Digital Monitoring in Nuclear Plants: 2nd Annual Report

For economic reasons, the nuclear industry is witnessing premature closure of nuclear power plants, despite excellent safety records. Operations and Maintenance (O&M) activities are some of the largest costs in operating legacy light-water plants. By reducing O&M costs, nuclear energy can become more economically competitive with other energy sources. This can be achieved by leveraging machine-learning and artificial intelligence technologies to develop data-driven algorithms to better diagnose potential faults within the system. Improved accuracy of the models can lead to a reduction in unnecessary maintenance, thus reducing costs associated with parts, labor, and unnecessary planned, forced, or extended outages. To address these challenges, the goal of this project is to perform research and development in the area of digital monitoring, i.e., the application of advanced sensor technologies (particularly wireless sensor technologies) and data science based analytic capabilities, to advance online monitoring and predictive maintenance in nuclear plants and improve plant performance (efficiency gain and economic competitiveness). This report summarizes the fiscal year 2020 research progress encompassing (1) different wireless vibration sensor and data indicators used to assess the health of a plant asset; (2) development of diagnostic models for fault detection; and (3) development of prognostic models for estimating the health of the system up to 7 days ahead.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2023

Optimal Sizing and Dispatch of Solar Power with Storage

Designers of utility-scale solar plants with storage, seeking to maximize some aspect of plant performance, face multiple challenges. In many geographic locations, there is significant penetration of photovoltaic generation, which depresses energy prices during the hours of solar availability. An energy storage system affords the opportunity to dispatch during higher-priced time periods, but complicates plant design and dispatch decisions. Solar resource variability compounds these challenges, because determining optimal system sizes requires simultaneously considering how the plant will be operated under the imposed market and weather conditions. We develop an approach to analyze the economic performance of hybrid and single-technology solar power plants, which incorporates optimal dispatch, and considers the expected electricity market and weather conditions. We utilize the System Advisor Model software package to simulate the operation of multiple renewable generation and energy storage technologies, in conjunction with hourly-fidelity generation decisions determined by a revenue-maximizing, mixed-integer linear program. We show that, under our assumed market and weather conditions, the lifetime benefit-to-cost ratio can be improved by 6 to 19 percent, relative to a baseline design without optimizing, and that a concentrating solar power with thermal energy storage design produces significantly more energy per year, but is less profitable under our cost assumptions.

black-box optimization↗

DOE OSTI2020

Synchronverter-based Control of Multi-Port Autonomous Reconfigurable Solar Plants (MARS)

Control of integrated photovoltaic (PV) plants with energy storage systems (ESSs) has become an important research and development topic in recent times. In this context, a Multi-port Autonomous Reconfigurable Solar (MARS) plant that integrates PV and ESS to alternating current transmission grid and high-voltage direct current (HVdc) link is studied in this paper. With penetration of power electronic based resources in the grid, the grid’s capability to recover from frequency or voltage disturbances are reduced. Therefore, one of the vital objectives of any new grid integrated power electronic resource is to provide advanced control functions like voltage and frequency support to the grid during disturbances. In this research work, a detailed implementation of a synchronverter-based control algorithm of MARS is presented. The proposed control algorithm and the MARS control architecture are evaluated through simulations on PSCAD/EMTDC simulation platform to showcase the performance in different operating conditions. In addition, they are evaluated in Opal-RT offline simulation models which can also be used to perform control-hardware-in-the-loop (cHIL) tests.

Marthi, Phani Ratna Vanamali↗