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DOE OSTI2023

Flexible Gasification of Coal and Biomass to Generate Carbon Free Electric Power and Hydrogen

This paper describes the development of a coal and biomass-fed plant concept to co-produce electric power and hydrogen with net-negative CO2 emissions under the aegis of the 21st Century Power Plant initiative of the U.S. Department of Energy (DOE), whose goal is to advance innovative power plant concepts that are capable of flexible, net-zero carbon emission operations while producing cost-effective “blue” hydrogen to support economy-wide decarbonization goals. The proposed standalone plant will be in Nebraska, USA. The specified design feedstock is a hybrid blend of Powder River Basin (PRB) subbituminous coal from Wyoming and local Nebraska biomass (corn stover), 50 wt.% each (dry basis). Other potential feedstocks, including woody biomass (eastern red cedar) and waste plastic (auto shredder residue) were evaluated or reviewed as alternates. The proposed process block comprises a high-pressure, oxygen-blown fluidized bed gasifier (GTI Energy U-GAS® process) coupled with water gas shift, the Selexol process for acid gas (H2S and CO2) removal, and pressure-swing adsorption (PSA) to yield 8,500 kg/h of high-purity hydrogen. The off gas from the PSA unit is used in the power block (gas turbine combined cycle) to generate electric power to support the gasification process, hydrogen production, and 50 MWe net electric power to the grid. All major plant equipment including the gasifier, gas cleanup system, and power generation are commercially available and proven in other applications and considered at TRL 8-9. However, gasification of corn stover biomass is considered at TRL 6. Overall thermal efficiency of the plant is 50% (net HHV) with net atmospheric CO2 removal at a rate of 250-300,000 tpa. Design activities necessary to provide input to a FEED study (Phase II of the project), including the development of the Environmental Information Volume (EIV) for the host site, and an investment case, based on a pro-forma pre-FEED level cost estimate, have been completed and are described in detail in this paper.

Gülen, S. Can↗

DOE OSTI2020

Harnessing the Hydroelectric Potential of Engineered Drops (Final Technical Report)

The potential for low-head hydropower in the engineered drops in both federal and private irrigation system is well known and significant. The environmental and socio/recreational impacts of harnessing this renewable energy resource in man-made conduits are much less, and often insignificant, compared with comparable hydro-electric potential in natural water features on rivers, lakes, and streams. Yet, few new plants have been commissioned in more than two decades. Over the same time period, low head hydro installations in Germany have more than doubled. The challenge is in finding economical ways to harness the hydro-electric potential in the engineered drops, and efficiently deliver the power to the grid. The objectives of Percheron Power, LLC's (Percheron Power) Project were to design, develop, permit, and operate an innovative low-head hydro-electric generation facility on an existing engineered drop of a large irrigation canal system. The hydro-electric generation facility was designed to employ a new type of turbine and technology, called an Archimedes Hydrodynamic Screw (AHS), to harness the existing potential of the engineered drop. The goal was to demonstrate the new lower cost AHS technology system to federal agencies, irrigation districts and other system owners and to support further development of new small hydropower projects at previously marginal low-head sites in the U.S. The objective of this funding opportunity of the Department of Energy Water Power Technologies Office was to reduce the Levelized Cost of Energy (LCOE) for small hydropower to less than ${$}$0.07/kWh (${$}$70/MWh) to be competitive with existing base-load power sources such as coal-powered power plants.

13 HYDRO ENERGY↗

DOE OSTI2025

Performance Comparisons for Artificially Propagated and Wild Pacific Lamprey Juveniles and Larvae

ABSTRACT Artificially propagated Pacific lamprey ( Entosphenus tridentatus ) are produced for restoration and for use in dam passage studies to reduce the demand for wild fish. Such uses require that animals are representative of their wild counterparts. Previous work indicated that this is true for Pacific lamprey larvae and juveniles reared in the hatchery with respect to the length of sustained swimming. However, more subtle differences in behaviour and performance that lamprey need to survive have not been assessed. In this study, artificially propagated and wild fish were compared in laboratory tests under no‐flow conditions to examine light avoidance, burrowing speed, burst swim speed, volitional routine swim speed and time to come to rest. Most larvae burrowed in less than a minute, and we found highly significant differences ( p < 0.001) between artificially propagated and wild larvae burrowing times, a critical escape behaviour. This could have implications for studies of larval entrainment at irrigation diversion canals or in turbine boils at dams. Interestingly, all of the wild juveniles tested came to rest quickly after introduction to the chamber (1.5 min), while artificially propagated lamprey swam robotically near the surface and 48% did not come to rest in the first 10 min (median time to rest = 9.5 min). In contrast, wild juveniles quickly (median = 1.47 min) sought areas near the tank bottom and attached strongly with their oral disc. Such behavioural differences could have important survival consequences for artificially propagated lamprey as they approach turbine intakes, bypass screens and irrigation diversion headgates. This study highlights the need to conduct behavioural assays that examine subtleties of fish behaviour that can be missed with traditional swim tunnel comparisons.

Frick, Kinsey [Fish Ecology Division, Northwest Fi↗

DOE OSTI2021

Deep Learning for Automated Detection and Identification of Migrating American Eel Anguilla rostrata from Imaging Sonar Data

Adult American eels (Anguilla rostrata) are vulnerable to hydropower turbine mortality during outmigration from growth habitat in inland waters to the ocean where they spawn. Imaging sonar is a reliable and proven technology for monitoring of fish passage and migration; however, there is no efficient automated method for eel detection. We designed a deep learning model for automated detection of adult American eels from sonar data. The method employs convolution neural network (CNN) to distinguish between 14 images of eels and non-eel objects. Prior to image classification with CNN, background subtraction and wavelet denoising were applied to enhance sonar images. The CNN model was first trained and tested on data obtained from a laboratory experiment, which yielded overall accuracies of >98% for image-based classification. Then, the model was trained and tested on field data that were obtained near the Iroquois Dam located on the St. Lawrence River; the accuracy achieved was commensurate with that of human experts.

13 HYDRO ENERGY↗

DOE OSTI2026

SuperLab 2.0 Showcase: Connecting Five Labs to Tackle Grid Complexity and Unlock Unique Grid Asset Potential

SuperLab 2.0 (a five-lab demonstration) is a collaborative, national-scale experiment showcasing the coordination of geographically distributed energy assets in real time. The demonstration integrates 25 physical and digital assets, spanning wind, photovoltaics, batteries, electrolyzers, DC fast chargers, microgrid controllers, building automation systems, small modular reactors, control centers, and gas turbines, across five U.S. Department of Energy (DOE) national laboratories: National Laboratory of the Rockies (NLR), Idaho National Laboratory, National Energy Technology Laboratory, Lawrence Berkeley National Laboratory, and Sandia National Laboratories. These assets are unified using Energy Sciences Network (ESnet), a low-latency, high-performance DOE network, and are controlled via a centralized energy controller hosted at NLR's Advanced Research on Integrated Energy Systems facility. The demonstration validates the ability to stress-test hybrid energy systems under dynamic scenarios to de-risk advanced control strategies for greater resilience and flexibility.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2025

Hybridization Assessment of Trybrid Pumped Storage Hydropower System—Part 1: A Case Study of Corral Summit

This report is a part of the deliverables for technical assistance provided to Cat Creek Energy for the Coral Summit Trybrid (Triple Hybrid-Pumped Storage Hydropower, Battery Energy Storage System, and photovoltaic solar energy) energy project. This report explores the operational benefits and challenges of hybridizing an open loop PSH (200MW) located at Mackay, Custer County, Idaho with solar PV (Ground mount 300MW and floating 40MW) and battery (720MWhr). This document reports two activities performed as a part of the hybridization assessment task 1) optimal resource allocation and energy management strategy, and 2) power quality and reliability assessment. From optimal resource allocation and energy management strategy (activity 1), the following key findings can be observed: • Conventional PSH (CPSH) with two reversible pump turbines and separate penstocks can provide required flexibility equivalent to that from two ternary PSH with separate penstock. With single unit CPSH, upper reservoir head cannot be maintained accurately, the variation of water level is rapid and pump mode flexibility is not available. These disadvantages can be overcome by single unit TPSH. However, using two CPSH units with separate penstocks also overcome these disadvantages with the formation of the hydraulic short circuit between two conventional units. • Flooding of the lower reservoir is a severe concern when considering continuous operation for black start. This limits the duration of continuous operation from PSH alone to around 50 hours. Due to the complementary PV and battery action, the duration of continuous operation and smooth power output can be extended. • An optimization problem is framed that maximizes the power output on an hourly basis while minimizing constraint violations and respecting seasonal variations of solar PV and load profiles . Two value streams, arbitrage and baseload generation are served by this profile. It was uncovered that for smooth power output during regular operation, PV curtailment will be required, or the battery capacity needs to be increased above 90MW to accommodate additional PV. From power quality and reliability assessment (activity 2) the following takeaway points can be observed: • The Trybrid, when integrated at the Lost River bus, and limited to 250MW in generation mode and -150MW in the pump mode, causes no violation of voltage or flow.

13 - HYDRO ENERGY↗

DOE OSTI2020

Evaluating the WFIP2 updates to the HRRR model using scanning Doppler lidar measurements in the complex terrain of the Columbia River Basin

The wind-energy (WE) industry relies on numerical weather prediction (NWP) forecast models as foundational or base models for many purposes, including wind-resource assessment and wind-power forecasting. During the Second Wind Forecast Improvement Project (WFIP2) in the Columbia River Basin of Oregon and Washington, a significant effort was made to improve NWP forecasts through focused model development, to include experimental refinements to the High Resolution Rapid Refresh (HRRR) model physics and horizontal grid spacing. In this study, the performance of an experimental version of HRRR that includes these refinements is tested against a control version, which corresponds to that of the operational HRRR run by National Oceanic and Atmospheric Administration/National Centers for Environmental Protection at the outset of WFIP2. Furthermore, the effects of horizontal grid resolution were also tested by comparing wind forecasts from the HRRR (with 3-km grid spacing) with those from a finer-resolution HRRR nest with 750-m grid spacing. Model forecasts are validated against accurate wind-profile measurements by three scanning, pulsed Doppler lidars at sites separated by a total distance of 71 km. Model skill and improvements in model skill, attributable to physics refinements and improved horizontal grid resolution, varied by season, by site, and during periods of atmospheric phenomena relevant to WE. In general, model errors were the largest below 150 m above ground level (AGL). Experimental HRRR refinements tended to reduce the mean absolute error (MAE) and other error metrics for many conditions, but degradation in skill (increased MAE) was noted below 150 m AGL at the two lowest-elevation sites at night. Finer resolution was found to produce the most significant reductions in the error metrics.

17 WIND ENERGY↗

NASA NTRS2010

History of Space Shuttle Main Engine Turbopump Bearing Testing at the Marshall Space Flight Center

The Space Shuttle is propelled into orbit by two solid rocket motors and three liquid fed main engines. After the solid motors fall away, the shuttle engines continue to run for a total time of 8 minutes. These engines are fed propellants by low and high pressure turbopumps. A critical part of the turbopump is the main shaft that supports the drive turbine and the pump inducer and impeller. Rolling element bearings hold the shaft in place during rotation. If the bearings were to fail, the shaft would move, allowing components to rub in a liquid oxygen or hydrogen environment, which could have catastrophic results. These bearings are required to spin at very high speeds, support radial and axial loads, and have high wear resistance without the benefit of a conventional means of lubrication. The Rocketdyne built Shuttle turbopumps demonstrated their capability to perform during launches; however, the seven hour life requirement was not being met. One of the limiting factors was the bearings. In the late 1970's, an engineering team was formed at the Marshall Space Flight Center (MSFC), to develop a test rig and plan for testing the Shuttle s main engine high pressure oxygen turbopump (HPOTP) bearings. The goals of the program were to better understand the operation of bearings in a cryogenic environment and to further develop and refine existing computer models used to predict the operational limits of these bearings. In 1982, testing began in a rig named the Bearing and Seal Material Tester or BSMT as it was commonly called. The first testing investigated the thermal margin and thermal runaway limits of the HPOTP bearings. The test rig was later used to explore potential bearing improvements in the area of increased race curvatures, new cage materials for better lubrication, new wear resistant rolling element materials, and other ideas to improve wear life. The most notable improvements during this tester s time was the incorporation of silicon nitride balls and bronze filled polytetrafluoroethylene (PTFE) cage inserts into the bearings and the anchoring of the SHABERTH bearing model and SINDA thermal computer model for cryogenic bearing analysis. In the mid 1990's, Pratt and Whitney (P&W) won the contract to deliver new high pressure turbopumps for the Shuttle s engines. P&W used two new bearing materials for the rings, Cronidur 30 and AISI 9310 steel and testing was needed on these new materials. A test rig had been designed and delivered to MSFC for testing hydrostatic bearings but with the need by Pratt to validate their bearings, the rig was reconfigured for testing of two ball bearings or a ball bearing and a roller bearing. The P&W bearings are larger than the Rocketdyne bearings and could not be installed in the BSMT. This new test rig was called the LH2 test rig and began operation in 1995. The LH2 test rig accumulated 75,000 seconds of run time in hydrogen. This test rig was valuable in two areas: validating the use of silicon nitride balls and rollers in Alternate Turbopump Development (ATD) bearings, which Pratt eventually used, and in proving the robustness of the balls and rollers after river marks appeared on the surface of the rolling elements. Individual test reports have been presented at conferences and symposiums throughout the years. This paper is a comprehensive report of all the bearing testing done at Marshall. It represents thousands of hours of dedication and labor in all engineering and technical fields that made this program a success.

Gibson, Howard↗

DOE OSTI2026

SuperLab 2.0 Showcase: Connecting Five Labs to Tackle Grid Complexity and Unlock Unique Grid Asset Potential

SuperLab 2.0 (5-Lab Demo) is a collaborative, national-scale experiment showcasing the coordination of geographically distributed energy assets in real time. The demonstration integrates 25 physical and digital assets, spanning wind, PV, batteries, electrolyzers, DC fast chargers, microgrid controllers, building automation systems, small modular reactor (SMR), control centers, and gas turbines, across five DOE national laboratories-NLR, INL, NETL, LBNL, and SNL. These assets are unified using Energy Sciences Network (ESnet), a low-latency, high-performance U.S. Department of Energy's (DOE) network, and controlled via a centralized energy controller hosted at NLR's ARIES facility. The demonstration validates the ability to stress-test hybrid energy systems under dynamic scenarios to de-risk advanced control strategies for greater resilience and flexibility. SuperLab 2.0 (5-Lab Demo) showcased a major advancement in federated national laboratory collaboration, enabling real-time, cross-laboratory experimentation to coordinate geographically dispersed distributed energy resources (DERs) using various communication protocols and networks. SuperLab 2.0 (5-Lab Demo) built on previous demonstrations conducted between NLR-PNNL and NLR-INL connecting diverse assets including distant protection devices, a SMR simulator, and a high temperature electrolyzer (HTE). Previous demos were based on a single connection between two labs with minimal coordination challenges. The 5-Lab demo with a centralized controller, distributed testbeds across different geographical locations, and use of protocols-based communication represents a scenario closer to real-world grid operations that coordinate resources across a region to meet system needs. This experiment studied how local DER controllers interact with a centralized energy controller during normal and abnormal events to maintain reliability. The SuperLab team across the five labs implemented a notional power system model equivalent of transmission and distribution lines, represented by the data networks interconnecting the labs. Each lab continuously exchanged local parameters (such as P and Q) from its Hardware-In-Loop (CHIL) and Power Hardware-In-Loop (PHIL) assets through centralized energy controller at NLR, enabling real-time interaction and coordination across sites. By leveraging ESnet as the communication backbone, the team successfully operated the distributed assets as a unified power system, with each bus represented by a different laboratory. This setup mirrors how assets interact in real-world power systems across dispersed locations with various protocols and latencies. At each lab site, assets were operated using their own local controllers which were coordinated through an overarching operation and control layer of centralized energy controller, equivalent to how an energy management system (EMS) orchestrates assets across a regional or national grid. SuperLab's federated connectivity utilized a Digital Real-Time Simulators (DRTS)-type gateway to connect Controller Hardware-In-Loop (CHIL) and PHIL assets between labs. To enable this federated connection through ESnet, a deterministic network was established where latency variations were consistent. This consistency allowed the development of digital filters for the power system assets across CHIL and PHIL interfaces to avoid unstable and unreliable grid conditions. This report provides an overview of the cross-laboratory configuration and offers insights into interconnecting geographically distributed research assets to test them as if they were co-located. This experiment represents a step toward linking nine DOE national laboratories, enabling nation-wide simulations that can address utility-driven challenges with grid resilience, flexibility, and modernization.

24 POWER TRANSMISSION AND DISTRIBUTION↗