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At least 847 records · Page 47

Conceptual Design of Pulverized Coal Electricity Generating Units for Flexible Operation

This National Energy Technology Laboratory (NETL) study addresses the conceptual design of greenfield pulverized coal (PC) plants intended for flexible rather than high capacity factor baseload operation. The United States has plentiful, low-cost natural gas resources - studies of aggressive decarbonization scenarios of the US energy sector suggest that the variability of carbon-free power can be economically addressed using dispatchable natural gas-fueled generation. Globally, natural gas resources are not as plentiful or low cost; consequently, some regions of the world are anticipated to continue to rely upon coal generation, even as they pursue decarbonization efforts. To support the increased utilization of variable renewable generation in these coal-dependent regions, plant designs must target low-capacity factor coal plants with increased emphasis on flexibility attributes such as start-up times, ramp rates, minimum load, and part-load heat rates. While much work has been performed on the improvement of the flexibility for existing coal plants originally designed for baseload service, little public literature exists on clean sheet design for flexible operation. This conceptual design study aims to define the features, performance characteristics, and costs for greenfield coal plants intended for flexible operation. Quantifying these characteristics provides critical information required by utility owners, grid planners, energy market modelers, and energy policy decision makers in coal-dependent regions of the world to better understand how coal-fired power plants can support a transition to low carbon generation.

20 FOSSIL-FUELED POWER PLANTS↗

Operations, maintenance, and cost considerations for PV+Storage in the United States

Battery storage systems are increasingly being installed at photovoltaic (PV) sites to address supply-demand balancing needs. Although there is some understanding of costs associated with PV operations and maintenance (O&M), costs associated with emerging technologies such as PV plus storage lack details about the specific systems and/or activities that contribute to the cost values. This study aims to address this gap by exploring the specific factors and drivers contributing to utility-scale PV plus storage systems (UPVS) O&M activities costs, including how technology selection, data collection, and related and ongoing challenges. Specifically, we used semi-structured interviews and questionnaires to collect information and insights from utility-scale owners and operators. Data was collected from 14 semi-structured interviews and questionnaires representing 51.1 MW with 64.1 MWh of installed battery storage capacity within the United States (U.S.). Differences in degradation rate, expected life cycle, and capital costs are observed across different storage technologies. Most O&M activities at UPVS related to correcting under-performance. Fires and venting issues are leading safety concerns, and owner operators have installed additional systems to mitigate these issues. There are ongoing O&M challenges due the lack of storage-specific performance metrics as well as poor vendor reliability and parts availability. Insights from this work will improve our understanding of O&M consideration at PV plus storage sites.

14 SOLAR ENERGY↗

Impact of Non-Steady State Operation on Cooling Water Consumption at Coal- and Natural Gas-Fired Power Plants

Increased renewable energy penetration in the electricity grid in coming decades will result in more frequent cycling at thermal power plants. Simultaneously, thermal power plants may face water scarcity with declining availability of cooling water. Therefore, to enhance thermal power plants’ resiliency to water shortages it is important to understand how non-steady conditions due to cycling will impact cooling water consumption and withdrawal intensity. Non-steady operation at power plants has been previously shown to decrease power plant thermal efficiency. Energy balance models have also demonstrated that a decrease in thermal efficiency is expected to increase cooling water consumption intensity. Furthermore, past work has used operating hours data to show idling and cycling gaps where cooling systems operate more than corresponding generators. As a result, an increase in cycling behavior may impact cooling water consumption and withdrawal intensity. This study uses data from the Energy Information Administration (EIA) and Environmental Protection Agency (EPA) to quantify the impact of cycling cooling water consumption intensity for recirculating cooling systems and withdrawal intensity for once-through cooling systems using energy balance and statistical approaches. In a novel application of a fixed effects model to study the effect of temperature on cooling water consumption and withdrawal intensity, this study finds temperature was consistently expected to increase consumption intensity and withdrawal intensity. Non-steady state conditions do not increase cooling water consumption intensity with statistical significance across unit types. However, additional validation of cooling water data is required to confirm these observed trends due to the sensitivity of these findings to model form and concerns with data quality of the dependent variables, cooling water consumption and withdrawal.

20 FOSSIL-FUELED POWER PLANTS↗

Generation Plant Cost of Operations and Cycling Optimization Model (Final Technical Report)

Modern coal plants are a masterpiece of engineering, having been refined and improved over more than a century. As they evolved, they have grown more efficient and cleaner. At the same time, they have grown much larger and increasingly designed to operate on very specific fuels at or near the maximum capacity, providing baseload power. In recent decades, however, they have been called on to operate at reduced capacity (cycled) at a loss of efficiency and possibly accelerated wear and tear. The purpose of this project was to develop a model to accurately estimate the cost of cycling large coal plants so that they can be operated efficiently as part of a comprehensive strategy for generation planning and dispatch. The final goal is a model which is commercial-ready that can be “tuned” to different plants for widespread use.

20 FOSSIL-FUELED POWER PLANTS↗

In-situ optical monitoring of gas turbine blade coatings under operational extreme environments

High temperature material systems consisting of thermal barrier coatings and the underlying superalloys are key to achieving higher gas temperatures which in turn control engine efficiencies and reduce emissions. With engine temperatures in excess of the limits that metallic blades and vanes can endure, advanced monitoring techniques that ensure the integrity and durability of these coatings are paramount to continuous and safe operation. Optical methods have the benefit of being non-invasive and are able to capture data under limited access available for monitoring the hot-section of turbines. Addressing Topic 5 on Advanced Instrumentation, the research and development effort for this project titled “In situ optical monitoring of gas turbine blade coatings under operational extreme environments” was completed by University of Central Florida researchers, including Raghavan (PI) and Ghosh (co-PI). In this project, the research team leveraged intrinsic properties of coatings and rare-earth dopants as active and intelligent “sensors” through their optical properties. The outcomes of this project pave the way for diagnostics of turbine blade coatings, under operating environments, through the development of the sensing thermal barrier coating configurations, calibration and associated instrumentation while ensuring coating integrity and durability goals are concurrently met.

42 ENGINEERING↗

HPC Analytics of Fused Thermal Plants Data to Optimize Operating Envelope

In this project, ORNL extensively reviewed the ORAP RAM data, and it guided us to develop machine learning models that can predict time to next failures and forecast failure trends, which will be useful for optimizing power plant operation strategies. More specifically, we trained multiple random forest models and evaluated the model accuracy to validate with 10+ years of historical data. In addition, we implemented a web-based graphical user interface system for the models to show how our models can be used in more intuitive ways. This proof of concept allowed exploration of model use with power plant operators in mind. Developed machine learning models will be helpful for managing risks, planning maintenance and operation, ultimately reducing the down time and increasing the service hours. For future work, there are several interesting research topics including but not limited to model enhancement, creating synergy with traditional failure modeling approaches, and data-driven actionable recommendation and suggestions.

20 FOSSIL-FUELED POWER PLANTS↗

In-Situ Applied Coatings for Mitigating Gas Hydrate Deposition in Deepwater Operations (Final Scientific/Technical Report)

The Project objectives of this work were focused on the need to develop, investigate, and validate for field and commercial deployment robust pipeline surface treatments to prevent / minimize hydrate and other flow assurance solids deposition in subsea oil flowlines. A robust pipeline treatment that can prevent hydrate and wax/asphaltene adhesion/deposition will be a major fundamental breakthrough in hydrate and flow assurance science and engineering, and to critical Deepwater field operations. The project addressed the current major outstanding issue of mitigating gas hydrate and other solids deposition in different pipeline conditions, a major outstanding issue that has not been solved to-date, despite previous attempts/studies. The major goal of this project was to develop and investigate for deployment robust pipeline coatings to mitigate gas hydrate deposition in Deepwater oil flowlines, which will be critical in offshore leak and spill prevention. As oil and gas production wells mature, the water content and oil composition can change and increase the risk of gas hydrate, wax, and asphaltene deposition and blockages in flowlines, with the cost of complete inhibition becoming prohibitive. The ability to mitigate flow assurance risks in maturing flowlines can extend the life of the field, significantly reduce operational costs from inhibitor injection and prevent potential safety hazards to personnel and equipment and can prevent potential environmental hazards leading to catastrophic hydrocarbon emissions. This research allows for a novel, cost-effective method of mitigating gas hydrate and other pipeline solids deposition/blockages in flowlines, extending the life of the field while being minimally disruptive to normal flowline operation. The omniphobic surface treatment developed in this work can significantly improve the economics of energy transport by providing flow assurance and limiting catastrophic blowouts.

02 PETROLEUM↗

Glass Property-Composition Models for Support of Hanford WTP LAW Facility Operation

Current plans for the River Protection Project envision starting to vitrifying low-activity waste (LAW) by 2023 using a Direct Feed Low-Activity Waste (DFLAW) approach and subsequently using a full-pretreatment approach. The Hanford Tank Waste Treatment and Immobilization Plant (WTP) LAW Facility will be operated and controlled using a LAW glass formulation algorithm (GFA), which requires several inputs based on research and development results. LAW glass property-composition models for several product quality and processing properties are key inputs for the LAW GFA. It is envisioned that the preliminary LAW GFA discussed by Kim and Vienna (2012) will be used for commissioning and initial radioactive operations of the WTP LAW Facility under Bechtel National, Inc. using the DFLAW approach. Then, an updated LAW GFA will be developed for implementation by the WTP operating contractor that takes over after WTP LAW Facility commissioning. This report documents the enhanced LAW glass property-composition models developed for use in the updated LAW GFA. The properties for which models were developed include Product Consistency Test (PCT) response, Vapor Hydration Test (VHT) response, viscosity at 1150 °C, electrical conductivity at 1150 °C, melter SO3 tolerance at 1150 °C, and K-3 refractory corrosion at 1208 °C. Table S.1 lists the tables in this report that contain the recommended models for each of these properties. The model types recommended include partial quadratic mixture (PQM) models for viscosity, electrical conductivity, melter SO 3 tolerance and K-3 corrosion, bias corrected PQM model (bcPQM) for PCT, and logistic PQM model for VHT. The fits of model and validation subsets were found to be well predicted by the recommended models.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Robotics Plan in Support of DOME Testbed Operations

Various robotic tooling options have been evaluated for the NRIC DOME concept of operations (ConOps). Framatome was contracted to develop a wide-ranging list of commercial off the shelf (COTS) and custom robotic systems to be considered for performing the DOME ConOps functions. Subsequent project tasks from Framatome narrowed down the list and scored the most viable options. The abbreviated list, and associated scoring, has been reviewed and assessed to provide formal recommendations for the robotic ConOps functions of DOME. The overhead telescoping mast & Kraft arm assembly is recommended as the primary system for reactor demobilization and removal. The estimated cost is $\$700$K with a timeline to develop and deliver of about 2.5 years. The mast & Kraft arm would still require an overhead lift system for mobilization and installation. Either the refurbished polar crane or a new gantry crane delivery platform could both serve as the overhead lift and delivery system. The estimated costs for the refurbishment polar crane and new gantry crane systems are, respectively, $\$4.4$M and $\$3$M with about 2.5 years to develop and deliver. A Brokk + Kraft crawler & arm is recommended as a secondary robotic system to support the overhead mast & Kraft arm system. The Brokk + Kraft crawler & arm would cost an estimated $\$726$k and would take about 1.5 years to develop and deliver. The Boston Dynamics SPOT robot is also recommended for the in-service monitoring during experimentation operations. The estimated cost is $\$220$K with a timeline to deliver of 8-14 months. The Elios 3 aerial drone is recommended to perform large area radiation dose rate mapping and visual inspections. The estimated cost is a $\$100$K and will also need about 8-14 months to develop and deliver. A mockup rig is also recommended to be procured an employed to test & verify the robotic capabilities as well as provide needed training for operations personnel. It is estimated that a mockup rig would cost about $\$500$k and would take up to a year to develop and build.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Bat Smart Curtailment: Efficacy and Operational Testing

Curtailment, or blanket curtailment, is a leading method to mitigate the impacts to bats from operating wind turbines. Although this strategy results in considerable decreases in bat fatalities, it also results in decreased energy production. In 2019, Natural Power was awarded funding by the Department of Energy to assess the readiness of the informed smart curtailment technology, EchoSense (formerly referred to as Detection and Active Response Curtailment, [DARC]). The research undertaken by this project expands the understanding of alternative methods, known as smart curtailment, to maintain a reduction in bat fatalities while simultaneously recovering lost energy associated with blanket curtailment. The overall project was composed of three major tasks; Task 1 was focused on cybersecurity compliance of the EchoSense system in accordance with the North American Electric Reliability Corporation Critical Infrastructure Protection (“NERC CIP”) standards, Task 2 assessed the mechanical loads exerted on turbines when operating under a smart curtailment regime, and Task 3 assessed the efficacy of the EchoSense system at an operational wind farm. Regarding Task 1, an external review by the National Renewable Energy Laboratory determined that the EchoSense system did not create any new cybersecurity weaknesses and was compliant with the NERC CIP standards. As a result of this process, Natural Power developed some best practices (10.1) for wind- wildlife technology developers. In conjunction with the National Renewable Energy Laboratory, the results (10.2) of the loads testing demonstrated that the periodic curtailment and release of turbines by the EchoSense system did not have any detrimental impact on the mechanical components of a wind turbine (Task 2). During the late summer to fall of 2020 and 2021, Natural Power demonstrated that the use of the EchoSense smart curtailment system resulted in no significant difference in bat fatalities compared to blanket curtailment with cut-in speeds at 6.9 m/s (2020) and 5.0 m/s (2021) while resulting in a significant difference in decreased lost energy (Task 3). This translates to an average of 41% (2020) and 56% (2021) reduction in per turbine energy loss compared to blanket curtailment. The reduction in energy loss that would have been achieved by EchoSense curtailment compared to blanket curtailment, if applied across all 69 turbines, is roughly equivalent to having an additional turbine on site. These results are notable for finding a balance between the environmental impact of wind energy and the economic feasibility in energy production associated with mitigating that impact. https://www.naturalpower.com/us/expertise/service/engineering-operations/echosense

17 WIND ENERGY↗

Improving Efficiency of DWPF Operations via Automating Process Calculations and Vitrifying High-Curie Feed- 24529

The Liquid Waste Organization (LWO) at the Savannah River Site (SRS) uses a “Power As One®” motto to process and dispose of radioactive waste. The Defense Waste and Processing Facility (DWPF) treats the high-level waste through a process of vitrification. The DWPF receives three incoming waste streams that are added to the Sludge Receipt and Adjustment Tank (SRAT): sludge, Monosodium Titanate/Sludge Solids (MST/SS), and Strip Effluent (SE). The liquid waste is mixed with pre-fabricated frit and treated with high temperatures in the melter prior to being poured into stainless steel canisters. The liquid cools to form solid glass within these canisters that are suitable for long-term storage and disposal. Savannah River Mission Completion (SRMC), the SRS liquid waste contractor for the U.S. Department of Energy, has implemented several facility improvements to further enhance the operations to support the Liquid Waste Operation (LWO) mission. Two of these operational enhancements include implementing the electronic Material Tracking Program Calculator (eMTPC)software and increasing the DWPF canister heat rate limit.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Understanding the Capabilities and Limitations of the Controls and Operations of High Voltage Direct Current (HVdc) Converters in Interconnected Electric Power Systems

This project will seek to build a fundamental understanding, and capability, to model and simulate the controls and operations of high voltage direct current (HVdc) converter stations in an electromagnetic simulation environment. While HVdc stations have been operated in the United States for over 50 years, these are typically simple two terminal point-to-point systems. Recently multi-terminal systems have begun to be deployed. The challenge with these new multi-terminal systems is that they often use different control schemes on the different terminals. The interactions of existing and new controls, and the fact that HVdc systems are rates in the 1,000’s of MWs means that small control instabilities can have dramatic impacts to bulk power systems. Despite these challenges, the operational capabilities of HVdc make them an attractive option for the transfer of the large amounts of renewable electricity that will be necessary for decarbonization of the nation’s electrical infrastructure and other sectors.

42 ENGINEERING↗

The Digital Engineering Vision for DOME: Facilitating Design, Deployment, and Operations [Poster]

DOME is a planned microreactor test facility at INL’s Materials and Fuels Complex. It is a complex system with several interdependent sub-systems such as the reactor (up to 20 MWth), radioactive confinement, temperature and pressure regulation system, ventilation system, etc. The engineering design process for such a system traditionally involves several documents from various sources and the system information is scattered across these documents. Digital engineering represents a paradigm shift through which systems are designed using digital models and integrated data. The digital engineering vision for DOME utilizes a model-based systems engineering (MBSE) approach. The system architecture, physical components, control logic, and verification experiments are all designed using MathWorks MATLAB and Simulink. This hierarchical model can combine data from multiple sources at various levels of abstraction. It can be used to simulate the facility’s operations and to test the system using different sets of parameters. Its capabilities can be expanded by interfacing it with high-fidelity multi-physics models, risk analysis tools, etc. The same model can evolve into a digital twin that can monitor operations and conduct predictive analysis using real-time sensor data from the facility. The eventual goal of this effort is to transform the end-to-end engineering of nuclear facilities in every phase of their lifecycle, including design, deployment, and operations.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Environmental Validation of Materials and Design Concepts to Enable Operational Flexibility of Existing Coal Power Plants

Increasingly, coal-fired power plants are required to balance power grids by compensating for the variable electricity supply from renewable energy sources. Fossil-fueled power plants, originally designed to be base loaded, will increasingly need to operate on a load following or cyclic basis. This demanding requirement for operational flexibility will need to be evaluated for resilience to frequent start-ups, meeting major and rapid load changes, and providing frequency control duties. Our research objective was to evaluate and improve flexibility of existing power plants by improving and redesigning components and defining new operational strategies, with acceptable impacts on component life, efficiency and emissions.

20 FOSSIL-FUELED POWER PLANTS↗

Ash Fouling Free Regenerative Air Preheater for Deep Cyclic Operation

The University of Kentucky (UKy) project titled “Ash Fouling Free Regenerative Air Preheater for Deep Cyclic Operation”, DE-FE0031757, was conducted from 8/15/2019 to 8/14/2024 in two Budget Periods. Other participants included PPL Corporation and Black Dragon Double Boiler. The overall goal was to investigate the proposed self-cleaning technology to achieve ash fouling free air preheater operation in a coal-fired power plant, especially during deep cycling. All project deliverables, milestones, and success criteria were met. UKy obtained the following scientific findings. • Temporary and periodic high temperature of heating elements (450 ~ 500 °F) can prevent ash accumulation and maintain air preheater free of clogging. • The ash samples analysis and unit operation provide solid evidence of ABS formed during low load with SCR ammonia slip being the major cause of ash accumulation, and air preheater clogging can be prevented by raising the heating element temperature up to 450 °F~ 500 °F at which ABS is decomposed. • In-situ self-cleaning can be controlled by monitoring temperature and/or presetting fixed number of cleanings per day. Both approaches in pilot testing show positive results for maintaining an ash free state for the air preheater. • Temperature criteria (cold end or gas outlet temperature) for entering self-cleaning service is critical to balance the number of cleaning cycles with maintaining the ash level. • Temperature criteria (cold end or gas outlet temperature) for exiting self-cleaning service is critical to balance the duration of the cleaning cycles with maintaining the ash level.

01 COAL, LIGNITE, AND PEAT↗

Workflow for Developing and Operating Subsurface Hydrogen Storage Facilities in Porous Reservoirs

Long-duration (seasonal) storage of natural gas (NG), which primarily consists of methane (CH 4 ), has been practiced for more than a hundred years at underground gas storage (UGS) facilities that use depleted hydrocarbon reservoirs, saline aquifers, and salt caverns. To enable hydrogen (H 2 ) to be used as a long-duration, energy-storage medium, similar facilities are envisioned for underground H 2 storage (UHS) of either H 2 or H 2 /NG mixtures. Experience with UGS can be used to guide recommended practices for developing and operating UHS facilities in porous reservoirs. The most important factors (formation/fluid properties and engineering choices) that influence the performance of UHS reservoirs have been identified and quantified in previous studies. These factors and choices influence phenomena that determine the sweep efficiency of the stored working gas. These phenomena include viscous fingering, hysteretic capillary trapping, and gravity override of the working gas, as well as the upconing of nonproductive fluid that determine the sweep efficiency of the stored working gas. This report describes initial recommended-practices and a project-development workflow for UHS facilities that utilize porous reservoirs, based on the current state-of-knowledge about H 2 behavior in the subsurface. The workflow sequentially addresses all aspects of UHS project development, including the identification of H 2 sources and users, site ranking and down-selection, geologic and reservoir-engineering characterization, reservoir design, testing, risk management, commissioning, operations, and monitoring for a UHS facility. The goal is to enable UHS facilities to be developed in an efficient and timely manner, while carefully managing project risks. This workflow is similar to that which has been developed for UGS facilities (see Figure 1 of API, 2022), with the addition of tasks and subtasks specific to H 2 and UHS. The project-development workflow is broken down into three major stages: (1) define the H 2 use case; (2) rank, down-select, and characterize potential, candidate UHS sites; and (3) reservoir design, integrity testing, risk assessment, commissioning, operations, and monitoring for selected UHS sites. Each major stage is further broken down into tasks and subtasks, which are described at a high level. This report also provides more detailed descriptions of all tasks and subtasks that involve reservoir analysis and testing.

08 HYDROGEN↗

A Framework for the Optimization of Water Treatment Processes Under Uncertainty Assessed through Process Operability

Conference presentation conveying work conducted on developing a framework for the optimization of water treatment processes after applying robust optimization and process operability tools. The objective of this framework is to optimize treatment processes under the uncertainty of source water conditions. This work contributes to robust optimization and process operability methodologies, allowing for the extension of probability from statistical models to operability calculations.

Barber, Hunter↗

A Multidisciplinary Approach to Integrated Energy Systems: Advanced Nuclear Plants with Thermal Storage for Dynamic and Flexible Operation in Diverse Markets

Energy supply, distribution, and demand are continuously evolving in accordance with the integration of new power generation sources. In the United States, there is a progressive shift toward incorporating fluctuating energy sources such as wind and solar into the energy mix, alongside the distributed generation. Simultaneously, we are seeing a revolution in consumer technologies such as electric vehicles, energy devices for both residential and commercial use, and industrial processes—all contributing to a fundamental change in energy consumption dynamics. These scenarios have led to huge demand for enhanced flexibility from nuclear power plants (NPPs), requiring them to operate with unprecedented adaptability. Furthermore, advanced NPPs (A-NPPs) could potentially apply to scenarios in which power generation flexibility is prioritized over its current and conventional baseload generation capacity for traditional demand patterns. The present work covers several configurations for coupling nuclear energy production with thermal energy storage (TES). Previous work evaluated systems entailing a simple nuclear-TES configuration that used steam as a heat source for the TES of three different advanced reactors (ARs), but its heat diversion ratio (HDR) for charging was limited. The present work proposes a new configuration that features full decoupling of the nuclear reactor and the power cycle, using reactor coolant (i.e., gas) as a heat source for the TES and offering a theoretically unlimited HDR. This configuration is, however, more complex, as both high- and low-temperature TES (HT-TES and LT-TES) systems are required in order to cover the extended temperature range. Although this configuration imposes certain limitations on the discharge system configuration, it also presents the opportunity to design a more efficient system. For this case in particular, a steam reheat cycle is advantageous. Conventional TES systems take advantage of nominal efficiency when discharging, whereas the reheat cycle in the fully decoupled TES system affords a significant efficiency increase over conventional cases. Material selection, component/equipment sizing, and costing analyses were performed, followed by economic dispatch and size optimization. Dynamic models were developed for the decoupled system in order to generate insights into aspects of off design operation (e.g., drops in cycle efficiency), and these models enable exploration of potential mitigation strategies for addressing such drops. The models also highlight the need to design fail-safes that ensure continuous operational stability and minimize the impact of power ramping on the reactor parameters.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗