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DOE OSTI2024

Energy Requirements for Integration of Nuclear Reactors with Iron and Steel Plants

This report identifies energy needs of heavy energy users within the domestic iron and steel industry and suggests solutions for integrating nuclear energy. The iron and steel industry, composed of several types of plants which perform different processes with varied energy demands and vectors, is a heavy consumer of electric power and fossil fuels including coke and natural gas. Almost all major process temperatures exceed the temperatures of direct heat available from advanced reactors, and so electricity and hydrogen were considered instead. Reference units were adopted and estimated energy demands computed for the blast furnace (BF), direct reduced iron (DRI) unit, electric arc furnace (EAF), and reheat furnaces. By utilizing production capacity data from industry reports, the ranges of power demands were estimated, including for hydrogen production by high temperature steam electrolysis (HTSE). For the EAF and DRI unit, more detailed integration studies with thermodynamic modeling were also conducted and determined a possible solution with a specific reactor design and number of modules. Furthermore, because many unit processes are co-located, entire plants were considered by adding the energy demands of the unit processes to form four hypothetical reference plants. The range of power needs for the reference plants is compatible with multi-unit banks of microreactors at the low end, and would create a need for multiple larger-capacity SMRs at the high end (1 GWe plus 0.14 GWt). Although the overall power need at the high end is well-matched with one present-day large reactor offering (1.1 GWe), redundancy considerations may require a minimum of two reactors, potentially eliminating the single large reactor from consideration. Auxiliary or house loads would increase the reference plant estimates. Finally, the report provides total estimated energy needs under integration of all U.S. units of each process (BF, DRI, EAF, and reheat furnaces), representing a national potential for nuclear energy in the industry. U.S. iron and steel plants may be candidates for integration with nuclear reactors via electricity and hydrogen, and many sites have energy requirements that correspond well to the capacities of several advanced nuclear power designs.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2023

Achieving Economy-wide Net-Zero Solutions: The Essential Role of Nuclear Energy

The Biden administration has committed to full decarbonization of the U.S. electricity grid by 2035 and economy-wide net zero emissions by 2050. These aggressive goals demand immediate action if we are to be successful, and they require us to think more holistically about our clean energy options. Programs within the Department of Energy are addressing these holistic solutions. Traditionally, electricity generation and management and meeting energy demands for industry and transportation are considered independently. As we seek to achieve net zero, we need to reassess our energy demands. When we consider overall energy use, only one-third is in the form of electricity. Additional energy demands are in the form of heat or steam for industrial processes, as well as transportation. These sectors are much harder to abate, and electrification may not be the best option. Reducing environmental emissions at an affordable cost, while maintaining grid reliability and resilience, will require us to use all of the clean energy resources that we have available. That means coordinating the use of nuclear, renewables, and fossil fuels with carbon capture to meet growing demands for electricity, industrial applications, and mobility. Various energy applications and product streams beyond electricity are being evaluated, ranging from generation of potable water to production of hydrogen, fertilizers, synthetic fuels, and various chemicals. This presentation will highlight advanced nuclear technologies under development today and will provide a glimpse into the wide array of R&D being conducted across multiple DOE-funded programs.

08 HYDROGEN↗

DOE OSTI2024

Fabrication and Performance Evaluation of Double-Sided Copper Nanowire Arrays as Thermal and Electrical Interfacial Layers

Reducing contact interface thermal and electrical resistances is in great demand across various industries, particularly in the semiconductor industry. This study introduces an approach using double-sided copper nanowire (Cu NW) arrays on copper sheets as both thermal and electrical interfacial layers, designed to effectively accommodate the topographical inconsistencies between contact surfaces. Further, experimental outcomes reveal a significant reduction in thermal contact resistance (TCR), with a value of 2.5 mm 2 K W –1 , thereby exceeding the efficiency of reported nanostructural thermal interface materials (TIMs). Additionally, when utilized as an electrical interfacial layer, these double-sided Cu NWs arrays dramatically reduced electrical contact resistance (ECR), outperforming traditional conductive grease in applications necessitating separable bonding, though showing comparable performance to costly silver-based conductive epoxies required for permanent, inseparable bonds. The promising results of the double-sided Cu NWs arrays in reducing both TCR and ECR, confirmed by finite element simulation, highlight their substantial potential in advancing TIMs and electrical interconnection applications across various sectors.

42 ENGINEERING↗

DOE OSTI2025

Biochemical Conversion of Herbaceous Biomass to Renewable Diesel: Net Greenhouse Gas and Air Pollutant Trade-offs

This study examines greenhouse gas (GHG) and criteria air pollutant (CAP) emissions trade-offs for renewable diesel across 12 scenarios, involving different biochemical conversion designs, biorefinery scales, and feedstocks. A conventional design uses lignin for on-site heat and power, which exports excess power to the grid. An alternative design exports lignin pellets, offsetting other pellet production methods but requiring grid electricity to meet biorefinery power demands. Net emissions were quantified in Iowa and Georgia, selected considering feedstock availability, coproduct displacement, and regional power grids, assuming grid-exported power avoids coal or low-carbon electricity. Results for the conventional design remained consistent across the electricity displacement scenarios. When comparing lignin utilization strategies, pelletizing lignin reduces sulfur dioxide, carbon monoxide, nitrogen oxides, and volatile organic compounds (net emissions –0.66 mg MJ –1 , 25 mg MJ –1 , 25 mg MJ –1 , 7.8 mg MJ –1 , respectively). However, lignin pelletization increases net particulate matter (fine and coarse) and ammonia (net emissions of 4.7 mg MJ –1 , 13 mg MJ –1 , and 0.26 mg MJ –1 , respectively), alongside indirect GHG emissions due to grid electricity dependence. Additionally, processing 2000 tonnes corn stover daily minimizes emissions for both designs. Only lignin pelletization with renewable electricity and additional particulate matter and ammonia controls reduces all CAP and GHG emissions simultaneously.

09 BIOMASS FUELS↗

DOE OSTI2023

Mechanical Analysis of Carbon Fiber Retaining Sleeve for A High-speed Outer Rotor SPM Electric Motor Design

Outer rotor motors can be designed with a larger airgap diameter than inner rotor motors for the same overall diameter and therefore provide higher torque which makes them ideal for high torque space constrained applications. This advantage fits well with the increasing demand of high-speed electric machines in many applications due to their inherent high-power density. However, increasing the motor speed results in significant centrifugal loads for the outer rotor motor design. Layers of carbon fiber sleeve winding on the rotor outer surface is necessary to guarantee its structural integrity without introducing too much weight on the motor itself. In this paper, we studied the mechanical stress of a carbon fiber retaining sleeve in a surface permanent magnet outer rotor motor that spins up to 20,000 RPM. Analytical results from finite element method (FEM) confirmed that the maximum stress experienced by the carbon fiber sleeve was under the material’s yield strength. The proposed sleeve will allow this outer rotor motor to operate at high speeds.

Lin, Lianshan↗

DOE OSTI2023

Development of multifunctional nylon 6,6-based nanocomposites with high electrical and thermal conductivities by scalable melt and dry blending methods for automotive applications

With the advent of intelligent automobile technology, the demand for multifunctional composites with higher electrical and thermal conductivities is increasing. We have herein reported for the first time the effect of polyolester on the dispersion of carbon nanotube (CNT) in the short-carbon fiber (CF)/nylon 6,6 (PA66) composite using a scalable melt-mixing and dry-blending method and its subsequent improvement in electrical and thermal conductivities. Masterbatches were prepared with a higher concentration of CNT (both untreated and polyolester-treated) followed by dry blended with reference composite (30 wt% CF and 10 wt% mineral fiber filled PA66) before making coupons via injection molding. A 500% and 63% improvements in electrical (3.14 S cm -1 ) and thermal conductivities (in-plane) (1.99 W m -1 K -1 ) conductivities were observed by adding 1.5 wt% treated CNT compared to the reference composite. The improvements were even higher than that of untreated CNT due to better dispersion. Furthermore, the electromagnetic shielding effectiveness reached 61 dB for 1.5 wt% treated CNT-filled composite (39% enhancement). In conclusion, these results are significant in imparting multiple functionalities to the automotive composite parts.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Achieving a Net-Zero Future: The Role of Nuclear Energy

Governments and private industry around the world have established aggressive goals to achieve net-zero emissions for the power, industrial, and transportation sectors by 2050. These aggressive goals demand immediate action if we are to be successful, and they require us to think more holistically about our clean energy options. Programs within the U.S. Department of Energy (DOE) are addressing these holistic solutions. Traditionally, electricity generation and management are considered independently from meeting energy demands for industry and transportation. As we seek to eliminate emissions across all energy use sectors we need to reassess how energy demands are met. When we consider overall energy use, only one-third is in the form of electricity. Additional energy demands are in the form of heat or steam for industrial processes, in addition to direct fuel use for transportation. These sectors are much harder to abate, and electrification may not be the best option. Reducing environmental emissions at an affordable cost, while maintaining grid reliability and resilience, will require us to leverage all of the clean energy resources available. The DOE Office of Nuclear Energy (DOE-NE) program on Integrated Energy Systems (IES) is led by researchers at Idaho National Laboratory (INL), and work is conducted in partnership with an array of other DOE laboratories, industry, and academia. The primary focus of IES research is to assess the technical and economic potential of nuclear-driven IES to enhance the flexibility and utilization of nuclear reactors working alongside renewable generators to meet an array of energy demands—thereby maximizing the utilization of clean energy resources across all energy sectors. Various energy applications and product streams beyond electricity are being evaluated, ranging from generation of potable water to production of hydrogen, fertilizers, synthetic fuels, and various chemicals. The DOE-NE program additionally partners with the Hydrogen and Fuel Cell Technologies Office under the DOE Office of Energy Efficiency and Renewable Energy to jointly fund the development of analysis tools, technologies, and nuclear-integrated hydrogen demonstration projects. This presentation will highlight the wide array of R&D being conducted across multiple DOE-funded programs to develop and deploy nuclear-based IES that will be key to achieving our net-zero goals. By working with key collaborators in the nuclear industry, analytical studies are now becoming a reality in demonstration projects.

08 HYDROGEN↗

DOE OSTI2022

The Essential Role of Integrated Nuclear-Renewable Energy Systems in Achieving Economy-wide Net Zero Solutions

Background/Objectives. The Biden administration has committed to full decarbonization of the U.S. electricity grid by 2035 and economy-wide net zero emissions by 2050. These aggressive goals demand immediate action if we are to be successful, and they require us to think more holistically about our clean energy options. Focused laboratory initiatives, such as the INL Integrated Energy Systems (IES) Initiative, and multiple programs within the Department of Energy are working together to address these holistic solutions. Approach/Activities. Traditionally, electricity generation and management and meeting energy demands for industry and transportation are considered independently. As we seek to achieve net zero, we need to reassess our energy demands. When we consider overall energy use, only one-third is in the form of electricity. Additional energy demands are in the form of heat or steam for industrial processes, as well as transportation. Emissions across these sectors are much harder to abate, and electrification may not be the best option. Reducing environmental emissions at an affordable cost, while maintaining grid reliability and resilience, will require us to use all of the clean energy resources that we have available. That means coordinating the use of nuclear, renewables, and fossil fuels with carbon capture to meet growing demands for electricity, industrial applications, and mobility. The primary focus of IES research is to assess the technical and economic potential of various IES solutions to enhance the flexibility and utilization of nuclear energy generators working alongside renewable generators to meet an array of energy demands—thereby maximizing the utilization of clean energy resources across all energy sectors. Various energy applications and product streams beyond electricity are being evaluated, ranging from generation of potable water to production of hydrogen, fertilizers, synthetic fuels, and various chemicals. Results/Lessons Learned. This presentation will highlight the wide array of RD&D being conducted to develop and deploy nuclear-based IES that will be key to achieving our net zero goals. By working with key collaborators in the nuclear industry, analytical studies are now becoming a reality in multiple demonstration projects.

08 HYDROGEN↗

DOE OSTI2020

A Comprehensive Scheduling Framework using SP-ADMM for Residential Demand Response with Weather and Consumer Uncertainties

This paper presents a comprehensive scheduling framework for residential demand response (DR) programs considering both the day-ahead and real-time electricity markets. In the first stage, residential customers determine the operating status of their responsive devices such as heating, ventilation, and air conditioning (HVAC) systems and electric water heaters (EWHs), while the distribution system operator (DSO) computes the amount of electricity to be purchased in the day-ahead electricity market. In the second stage, the DSO purchases insufficient (or sells surplus) electricity in the real-time electricity market to maintain the supply-demand balance. Due to its computational complexity and data privacy issues, the proposed model cannot be directly solved in a centralized manner, especially with a large number of uncertain scenarios. Therefore, this paper proposes a combination of stochastic programming (SP) and the alternating direction method of multipliers (ADMM) algorithm, called SP-ADMM, to decompose the original model and then solve each sub-problem in a distributed manner while considering multiple uncertain scenarios. The simulation study is performed on the IEEE 33-bus system including 121 residential houses. Here, the results demonstrate the effectiveness of the proposed approach for large-scale residential DR applications under weather and consumer uncertainties.

24 POWER TRANSMISSION AND DISTRIBUTION↗

NASA NTRSDate not supplied

Qualification of a Pulsed, Millinewton Class Metal Plasma Thruster for Broad Mission Applications

In the field of low power (<100W) electric propulsion, all thruster options demand significant trade-offs between operating parameters, reliability and scalable cost. With many systems on the market there are concerns with reliability, the need for extra considerations such as electron neutralizers for pure ion plumes, and the cost or craft compatibility of propellants. The Metal Plasma Thruster (MPT) is a new type of electric propulsion technology intended for low power applications. The system imparts momentum using inert, solid metal pucks as a propellant by using pulsed power to convert the metal into high velocity (~17km/s for Mo) jets of quasi-neutral plasma. The MPT technology does not require gas or liquid propellants, neutralizers, standby heaters, high voltage electronics, high electric or magnetic fields to operate. This comparatively simple pulsed operation is amenable to closed loop control, which provides for fine thrust control and S/C directed impulse on demand. Furthermore, the technology can use any metal as propellant, opening up unique opportunities for In-Situ Resource Utilization (ISRU) as well as customizability of performance for meeting specific mission needs. This paper describes implementation and direct measurement of this closed loop control mode as well as impulse measurement of multiple metals consistent with the aim of ISRU at NASA Glenn Research Center (GRC).

Electric Propulsion↗

NASA NTRSDate not supplied

Qualification of a Pulsed, Millinewton Class Metal Plasma Thruster for Broad Mission Applications

Electric Propulsion↗

DOE OSTI2020

An Optimization-Based Planning Tool for On-Demand Mobility Service Operations

Regions worldwide are adopting and exploring low-speed automated electric shuttle (AES) service as an on-demand shared mobility service in dense geofenced urban areas. Building on this concept, the National Renewable Energy Laboratory (NREL) recently developed the Automated Mobility District (AMD) toolkit. The AMD toolkit—comprising of a travel micro-simulation model and an energy estimation model—estimates the mobility and energy impacts of a given shuttle configuration within an AMD. Early-stage AMD deployments need to find optimal operational configurations that include: (a) passenger capacity of an AES, (b) time-dependent routes, and (c) fleet size (AES units) to satisfy the demand for the region. This research extends the AMD toolkit functionality by developing an optimization-based planning module that will assist in the operations of AES units. We developed a constrained mixed-integer program accounting for passenger waiting time, battery range, and passenger capacity of AES units. For scalability, we demonstrated the Tabu search-based solution technique for a real-world network—a proposed AMD deployment in Greenville, South Carolina, USA. Compared to rule-based operations, our developed solution yields higher travel time and energy savings for the network at different demand levels. The sensitivity analyses for waiting time thresholds indicate nonlinearity in the system performance, underscoring the need to meet shared-use mobility user-level expectations. The developed optimization framework can be adapted and extended to accommodate different categories of shared-use on-demand mobility services.

ADVANCED PROPULSION SYSTEMS,ENERGY PLANNING, POLIC↗

DOE OSTI2021

ENERGY STAR Residential Water Heater Specification and Test Method for Connected Residential Water Heaters

Electric water heaters have long been used as a tool for demand response due to their inherent thermal storage and large electric load. Traditionally, electric water heaters have been controlled by external load control switches, but that type of control does not work well with more efficient heat pump water heaters and cannot ensure that consumers have adequate hot water. Water heater manufacturers are adding more sophisticated controls that allow utilities or consumers to control their water heaters in new ways that can provide demand response without impacting consumer comfort. Further, the electric utility grid has seen a rapid increase the availability of renewable energy, which, depending on the type of renewable energy, can provide large amounts of energy for a portion of the day, but reduced or no energy at other times. In response to these advances in controls, availability of periodic renewable energy, and in an effort to have a standard which can be applied at a national level, ENERGY STAR and the Department of Energy have developed a Product Specification and Test Method for Connected Residential Water Heaters. In this session, we will discuss the new specification and test method, as well as show some initial results from running the new test method with two different HPWHs at NREL.

connected water heater↗

DOE OSTI2025

Commercial building HVAC demand flexibility with model predictive control: Field demonstration and literature insights

Model Predictive Control (MPC) for building Heating Ventilation and Air Conditioning (HVAC) systems is beginning to gain traction in the market, with a few controls companies incorporating it into their product offerings. However, it remains difficult to assess whether the energy cost savings are enough to justify the cost of MPC implementation for a particular building, given the limited number of reported demonstrations. For small commercial and residential buildings with relatively uniform systems, standardized approaches can help lower implementation costs. In contrast, for large buildings or district systems, the potential magnitude of cost savings could justify more customized solutions. Estimating the cost-effectiveness of MPC becomes more challenging for medium and large commercial buildings, where a one-size-fits-all solution may not be suitable, and the potential energy cost savings may be insufficient to justify a customized solution. To make MPC technology more appealing, incorporating additional value streams beyond energy efficiency alone can significantly increase its attractiveness. One such revenue stream is demand flexibility, in response to dynamic electricity prices, where MPC can leverage the thermal mass of the building to shift the load and support the grid. Building on an extensive literature review of MPC field studies focused on cost savings and demand flexibility, this paper presents the results of implementing MPC control in a large office building HVAC system in Berkeley, CA. Four different dynamic electricity price profiles were integrated into the MPC objective function to shift building demand while maintaining comfort, and field testing was performed with each price profile across four seasons. The results show potential for 40–65 % demand decrease percentage and up to 61 % annual cost savings compared to the existing rule-based control strategy, under the tested dynamic price scenarios. This paper also presents a sensitivity analysis on the cost savings with respect to the price profile variability, discusses the implementation effort for the price-responsive MPC, and compares the cost savings found in this study to those found in literature on the basis of dynamic price variability, or so-called Electricity Price Relative Standard Deviation.

Zanetti, Ettore↗

DOE OSTI2022

Low-Cost Sulfur Thermal Storage for Increased Flexibility and Improved Economics of Fossil-Fueled Electricity Generating Units (Final Report)

The US electric grid relies on conventional fossil fuel power plants for reliable and secure power, but these plants suffer from physical and financial strain due to the influx of inexpensive and variable solar and wind electricity. Conventional power plants need to generate electricity flexibly and on-demand to accommodate these renewable resources on the grid. Integrating a low-cost thermal energy storage (TES) gives fossil assets the ability to regulate their output efficiently and optimize the plant operation to maximize revenue in the wholesale electricity market. Element 16’s TES concept uses sulfur, a byproduct of the oil & gas industry, as the storage media that is 10 times cheaper than molten salt used in commercial two-tank TES technology. In this project, the team completed a detailed feasibility and technoeconomic study establishing the impact, cost and performance of molten sulfur TES system integrated with fossil assets.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2023

Tunisia Air Conditioner Market Assessment

Air conditioners contribute significantly to peak power demand during Tunisia's hot summers. In 2021, the Tunisian Electricity and Gas Company (STEG) recorded a peak demand of 4,472 megawatts in August, estimating that 44% of that demand was due to the operation of air conditioners. The Tunisian government, through its Agence Nationale pour la Maitrise de L'Energie (ANME) and all of its partners, is called on to take advantage of the significant potential for energy efficiency and to achieve the objectives it has set for itself by accelerating the implementation of programs that expand the adoption of efficient appliances, including air conditioners. This report aims to assess the Tunisian market for air conditioners, particularly in terms of energy performance. The report provides an overview of the size and characteristics of the AC market in Tunisia, including product types, origins, and proportion of imports to locally manufactured units; an estimation of the informal market; energy performance; and price.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2022

Estimating Fast Charging Infrastructure Requirements to Fully Electrify Ride-Hailing Fleets Across the United States

Ride-hailing electrification is made challenging by a variety of factors, including limited driver access to overnight charging and a nascent network of public direct-current fast charging (DCFC). This article projects the DCFC infrastructure needed to electrify ride-hailing across 384 cities in the United States. Research leveraging a novel infrastructure projection tool, Electric Vehicle Infrastructure Tool for On-Demand Mobility Services model (EVI-OnDemand), estimates that 25,400 DCFC ports capable of charging vehicles at a mean power of 150 kW are required to electrify 1.45 million ride-hailing vehicles in the baseline scenario. Results show that ride-hailing vehicles require 17.5 DCFC ports per 1000 vehicles, three times that of personal electric vehicles (EVs). Infrastructure demand is also shown to vary across cities; 63% more DCFC ports are needed to support 1000 battery EVs in Chicago versus Miami. The analysis also includes sensitivity studies that explore variation in charging demand across input assumptions, finding that charging power, vehicle class, overnight charging access rates, and port utilization influence the network size needed. Projections vary from 18,600 to 41,300 DCFC ports across sensitivity scenarios, indicating that ride-hailing electrification will require significant expansion of access to fast charging even in the most optimistic scenarios, and investments into supporting assets can reduce the scale of the public charging expansion needed.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2023

Energy Arbitrage with Hydrogen: HTSE + Combustion Turbine

The Light Water Reactor Sustainability (LWRS) program seeks to keep Nuclear Power Plants (NPPs) competitive in the changing energy market. The Flexible Plant Operation and Generation (FPOG) pathway investigates Energy Storage Systems (ESS) to give operators an alternative to curtailment or paying to put power on the grid. This work investigates the concept of diverting heat and electricity to High Temperature Steam Electrolysis (HTSE) to produce hydrogen when grid demand is low, storing that hydrogen, then burning it in a combustion turbine to produce zero-emission electricity when grid demand is high. A process model of the combustion turbine was developed in Aspen HYSYS, which was used to complete a parametric analysis and techno-economic analysis.

08 HYDROGEN↗