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All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Fracture Network Quantification for Enhanced Reservoir Characterization in CO2 Storage Sites

Presentation slides on “Fracture Network Quantification for Enhanced Reservoir Characterization in CO2 Storage Sites” for the CCUS 2025 conference held in Houston, Texas March 3-5, 2025. Accurate reservoir characterization is fundamental for the safe and efficient operation of carbon capture, utilization, and storage (CCUS) projects. This process is not only critical during initial site selection but also plays a key role in continuously updating reservoir geomodels throughout injection operations to effectively manage subsurface storage sites. Our primary objective is to develop a comprehensive understanding of fracture networks within CO2 injection reservoirs, which are critical for predicting the behavior of injected fluids, ensuring storage integrity post-injection, and mitigating risks such as leakage or induced seismicity.

artifical intelligence / machine learning (AI/ML)↗
DOE OSTI2023

Mechanical Ventilation and Indoor Air Quality in Recently Constructed U.S. Homes in Marine and Cold-Dry Climates Data from Building America Project

Data were collected to characterize whole-house mechanical ventilation (WHMV) and indoor air quality (IAQ) in 55 homes in the Marine climate of Oregon and Cold-Dry climate of Colorado in the U.S. Sixteen homes were monitored for two weeks, with and without WHMV operating. Ventilation airflows; airtightness; time-resolved CO2, PM2.5 and radon; and time-integrated NO2, NOX and formaldehyde were measured. Participants provided information about IAQ-impacting activities, perceptions and ventilation use. All homes had operational cooktop ventilation and bathroom exhaust. Thirty homes had equipment that could meet the ASHRAE 62.2-2010 standard with continuous or controlled runtime and 34 had some WHMV operating as found. Thirty-five of 46 participants with WHMV reported they did not know how to operate it, and only half of the systems were properly labeled. Two-week homes had lower formaldehyde, radon, CO2, and NO (NOX-NO2) when operated with WHMV; and also had faster PM2.5 decays following indoor emission events. Overall IAQ satisfaction was similar in Oregon and Colorado, but more Colorado participants (19 vs. 3%) felt their IAQ could be improved and more reported dryness as a problem (58 vs. 14%). The collected data indicate that there are benefits of operating WHMV, even when continuous use may not be needed because outdoor pollutant concentrations are low and indoor sources do not present substantial challenges.

air quality↗
DOE OSTI2022

Optimal Power Dispatch of DGs in Radial and Mesh AC Grids: A Hybrid Solution Methodology between the Salps Swarm Algorithm and Successive Approximation Power Flow Method

In this paper, we address the problem of the optimal power dispatch of Distributed Generators (DGs) in Alternating Current (AC) networks, better known as the Optimal Power Flow (OPF) problem. We used, as the objective function, the minimization of power losses (P loss ) associated with energy transport, which are subject to the set of constraints that compose AC networks in an environment of distributed generation. To validate the effectiveness of the proposed methodology in solving the OPF problem in any network topology, we employed one 10-node mesh test system and three radial text systems: 10, 33, and 69 nodes. In each test system, DGs were allowed to inject 20%, 40%, and 60% of the power supplied by the slack generator in the base case. To solve the OPF problem, we used a master–slave methodology that integrates the optimization method Salps Swarm Algorithm (SSA) and the load flow technique based on the Successive Approximation (SA) method. Moreover, for comparison purposes, we employed some of the algorithms reported in the specialized literature to solve the OPF problem (the continuous genetic algorithm, the particle swarm optimization algorithm, the black hole algorithm, the antlion optimization algorithm, and the Multi-Verse Optimizer algorithm), which were selected because of their excellent results in solving such problems. The results obtained by the proposed solution methodology demonstrate its superiority and convergence capacity in terms of minimization of P loss in both radial and mesh systems. It provided the best reduction in minimum P loss in short processing times and showed excellent repeatability in each test system and scenario under analysis.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

2023 Annual Report of Available Drawdowns for Each Oil Storage Cavern in the Strategic Petroleum Reserve

DOE maintains an up-to-date documentation of the number of available full drawdowns of each of the caverns at the U.S. Strategic Petroleum Reserve (SPR). This information is important for assessing the SPR’s ability to deliver oil to domestic oil companies expeditiously if national or world events dictate a rapid sale and deployment of the oil reserves. Sandia was directed to develop and implement a process to continuously assess and report the evolution of drawdown capacity, the subject of this report. This report covers impacts on drawdown availability due to SPR operations during Calendar Year 2022. A cavern has an available drawdown if, after that drawdown, the long-term stability of the cavern, the cavern field, or the oil quality are not compromised. Thus, determining the number of available drawdowns requires the consideration of several factors regarding cavern and wellbore integrity and stability, including stress states caused by cavern geometry and operations, salt damage caused by dilatant and tensile stresses, the effect of enhanced creep on wellbore integrity, and the sympathetic stress effect of operations on neighboring caverns. Finite-element geomechanical models have been used to determine the stress states in the pillars following successive drawdowns. By computing the tensile and dilatant stresses in the salt, areas of potential structural instability can be identified that may represent red flags for additional drawdowns. These analyses have found that many caverns will maintain structural integrity even when grown via drawdowns to dimensions resulting in a pillar-to-diameter ratio of less than 1.0. The analyses have also confirmed that certain caverns should only be completely drawn down one time. As the SPR caverns are utilized and partial drawdowns are performed to remove oil from the caverns (e.g., for oil sales, purchases, or exchanges authorized by the Congress or the President), the changes to the cavern caused by these procedures must be tracked and accounted for so that an ongoing assessment of the cavern’s drawdown capacity may be continued. A methodology for assessing and tracking the available drawdowns for each cavern is reiterated. This report is the latest in a series of annual reports, and it includes the baseline available drawdowns for each cavern, and the most recent assessment of the evolution of drawdown expenditures. A total of 222 million barrels of oil were released in calendar-year 2022. A nearly-equal amount of raw water was injected, resulting in an estimated 34 million barrels of cavern leaching. Twenty caverns have now expended a full drawdown. Cavern BC 18 has expended all its baseline available drawdowns, and has no drawdowns remaining. Cavern BM 103 has expended one of its two baseline drawdowns, and is now a single-drawdown cavern. All other caverns with an expenditure went from at-least-5 to at-least-4 remaining drawdowns.

02 PETROLEUM↗
DOE OSTI2026

Fluorescence Signatures of Rare Earth Metals during Precipitation in Various Conditions

Fluorescence spectroscopy is a widely used sensor methodology that analyzes light emitted from a compound or element as it decays from an excited state. This technique is very sensitive and selective, which is ideal to characterize analytes at lower limits of detection. Key example targets of significant industry and research interest include rare earth elements (REEs) such as dysprosium (Dy) and europium (Eu). These are widely used in advanced technologies including semiconductors, electric vehicle motors, lasers, and permanent magnets. Identifying new sources and responsible reutilization of REEs is essential, and new approaches to extract and recycle REEs could be notably enhanced through the integration of on-line sensors. The sensors can support faster process design, informed scale-up, and cost-effective deployment. This study covers the initial exploration of applying fluorescence-based on-line monitoring to REEs within a precipitation process. This study demonstrates the successful scale-up of a fluorescence -based sensing approach, from stationary cuvettes and small-volume microfluidic devices to continuous flow systems operating at the bench scale (10-25mL). This work also provides initial insight into the challenges of signal’s effects and utility within a turbid environment. Using a modular design for monitoring flowing solutions in a flow tube, fluorescence can be characterized for a variety of analytical targets. In this study, detection performance parameters between the cuvette and flow tube system were compared. Additionally, the response of Dy during precipitation by sodium bicarbonate in the two measurement designs was explored. This letter represents a starting point to bridge the gap between traditional fluorescence sensor measurements in a cuvette to future developments that explore the ability to integrate fluorescence sensors into extraction and separation processes at industrially relevant scales.

fluorescence↗
DOE OSTI2025

Accelerating Discovery of Solid‐State Thin‐Film Metal Dealloying for 3D Nanoarchitecture Materials Design through Laser Thermal Gradient Treatment

Thin‐film solid‐state metal dealloying (thin‐film SSMD) is a promising method for fabricating nanostructures with controlled morphology and efficiency, offering advantages over conventional bulk materials processing methods for integration into practical applications. Although machine learning (ML) has facilitated the design of dealloying systems, the selection of key thermal treatment parameters for nanostructure formation remains largely unknown and dependent on experimental trial and error. To overcome this challenge, a workflow enabling high‐throughput characterization of thermal treatment parameters is demonstrated using a laser‐based thermal treatment to create temperature gradients on single thin‐film samples of Nb‐Al/Sc and Nb‐Al/Cu. This continuous thermal space enables observation of dealloying transitions and the resulting nanostructures of interest. Through synchrotron X‐ray multimodal and high‐throughput characterization, critical transitions and nanostructures can be rapidly captured and subsequently verified using electron microscopy. The key temperatures driving chemical reactions and morphological evolutions are clearly identified. While the oxidation may influence nanostructure formation during thin‐film treatment, the dealloying process at the dealloying front involves interactions solely between the dealloying elements, highlighting the availability and viability of the selected systems. Further, this approach enables efficient exploration of the dealloying process and validation of ML predictions, thereby accelerating the discovery of thin‐film SSMD systems with targeted nanostructures.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Coal direct chemical looping process: 250 kW pilot-scale testing for power generation and carbon capture

Chemical looping combustion (CLC) is an energy conversion technology that can produce concentrated CO 2 stream without the need for a gas separation step, and thus, has the potential to drastically reduce the energy consumption and cost associated with CO 2 capture in power generation. The coal-direct chemical looping (CDCL) process is a CLC technology that uses a moving bed reducer configuration that can directly consume coal as a feedstock without requiring an upstream gasification step. An integrated 250 kW th CDCL pilot unit using iron-based oxygen carriers was constructed and demonstrated for over 1000 h of testing. The principles for the CDCL pilot unit design and operation are summarized in this article. During the 288-hour continuous operation testing, the CDCL pilot unit achieved >96% coal conversion with a CO 2 purity of >97%. Low carbon carryover into the combustor, i.e. <2%, was also confirmed during the test, which shows the capability of the moving bed reactor to retain and convert coal using the oxygen available on the iron-based oxygen carrier. The results from the pilot unit testing confirms the CDCL concept as a promising coal combustion technology for heat and power generation with CO 2 capture.

10 SYNTHETIC FUELS↗
DOE OSTI2020

CO 2 Capture Using Electrochemically Mediated Amine Regeneration

We describe the current status of our research on, and the development of, the Electrochemically Mediated Amine Regeneration (EMAR) process for the capture of CO2 from flue gases. The absorption step in the EMAR process is the same as in the widely used amine process, but the desorption step is accomplished electrochemically as opposed to by a thermal swing used in the amine process. Our laboratory unit has operated continuously for over 200 h, spanning 130 absorption/desorption cycles. We have established an understanding of the thermodynamics of the EMAR process and provided engineering estimates of key features (energetics and sizing) of this technology. The EMAR system does not rely on steam integration, making it a truly plug-and-play unit that can be easily deployed for a range of applications. The EMAR system can also be scaled-down for distributed, modular, and small-scale operations (e.g., stainless steel mini-mills, etc.). Here, results to date indicate that the EMAR process has the potential to be a viable option for post-combustion CO2 capture.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Energy Storage for Manufacturing and Industrial Decarbonization (Energy StorM)

This report summarizes the needs, challenges, and opportunities associated with carbon-free energy and energy storage for manufacturing and industrial decarbonization. Energy needs and challenges for different manufacturing and industrial sectors (e.g., cement/steel production, chemicals, materials synthesis) are identified. Key issues for industry include the need for large, continuous on-site capacity (tens to hundreds of megawatts), compatibility with existing infrastructure, cost, and safety. Energy storage technologies that can potentially address these needs, which include electrochemical, thermal, and chemical energy storage, are presented along with key challenges, gaps, and integration issues. Analysis tools to value energy storage technologies in the context of manufacturing and industrial decarbonizations are also presented. Material is drawn from the Energy Storage for Manufacturing and Industrial Decarbonization (Energy StorM) Workshop, held February 8 - 9, 2022. The objective was to identify research opportunities and needs for the U.S. Department of Energy as part of its Energy Storage Grand Challenge program.

25 ENERGY STORAGE↗
DOE OSTI2023

Pros and Cons Analysis of HALEU Utilization in Example Fuel Cycles

The Systems Analysis and Integration campaign assessed the pros and cons of high-assay low-enriched uranium (HALEU) utilization in advanced reactors and associated fuel cycles. The assessment was done for three example fuel cycles at equilibrium states: once-through, limited recycle, and continuous recycle (CR) starting with HALEU. Front- and back-end fuel cycle parameters and the Levelized Cost of Fuel (LCF), which is the Levelized Cost of Electricity excluding reactor cost, of the three example fuel cycles were calculated using a single Analysis Example Reactor. The pros and cons of HALEU utilization were assessed by normalizing the fuel cycle parameters and LCF to a unit of electricity generation (GWe-year) and comparing them with a Basis of Comparison. In this study, a sodium-cooled reactor with sodium-bonded metallic fuel having a burnup of ~100 GWd/t was used as the Analysis Example Reactor because its technology readiness level is high, and the burnup and fuel enrichment are in the middle of those ranges of advanced reactor concepts that are under development. The current once-through Light Water Reactors (OT-LWRs) with <5% low-enriched uranium and 50 GWd/t burnup were used as the Basis of Comparison. In addition, a series of sensitivity analyses was conducted by varying burnup, enrichment, fuel forms, and reactor types to capture the design variations in two once-through Advanced Reactor Demonstration Program (ARDP) reactors, Natrium with sodium-free metallic fuel having a burnup of ~150 GW/t and Xe-100 with Tristructural-Isotropic (TRISO) pebble fuel having a burnup of ~168 GWd/t.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Energy Improvements of Fire Station 71

Since 2018, the City of Shawnee, Kansas has completed two phases of the State of Kansas Facility Conservation Improvement Program (FCIP), an initiative that guarantees operational cost and energy savings through targeted construction improvements on City facilities and infrastructure. The City is currently in the third phase of this FCIP, where one of the projects included an investment in energy improvements for Fire Station 71 (FS 71). The City partnered with Navitas, an Energy Service Company (ESCO), to implement a Photovoltaic Solar Array on FS71. The purpose of this project was to invest in sustainable building improvements with Energy Conservation Measures (ECM) to bring cost savings to the City and to provide sustainable benefits to the residents of Shawnee. In the first task of the project, Navitas collaborated with the City of Shawnee and the Community Development Department to determine the optimal layout and schedule for the installation of the solar array on FS 71. In the second task of the project, Navitas installed the 99.8 kW DC Photovoltaic solar array system. This system installation comprised of racking, inverters, optimizers, load center, and disconnect, which were all installed at a total ECM price of $\$$247,948. The third task focused on start-up and commissioning of the array. Navitas installed a real-time data analytics information management system integrated with utility meters, which evaluates the operations of the utility system and verifies operation of equipment and ensures optimum operation for energy efficiency. In the final task of this project, this analytics system was used for monitoring and verification, which will continue to be used to evaluate the success of the project for the coming years. The primary goal of the project was to install the 99.8 kW DC PV solar array at FS 71 to demonstrate the viability of solar energy systems in essential municipal facilities. Fire stations are energy demanding structures, as they require a constant intake of power and have a high baseline energy usage. The success of solar arrays on a fire station exemplifies their energy efficiency and effectiveness and displays their potential for application on other city facilities. By installing a solar array at such a facility, the City sought not only to offset electricity usage but also to serve as a model for ECMs in other municipal facilities and infrastructure projects. From an economic standpoint, this project demonstrates the feasibility of renewable energy at the municipal level. The total project cost of $\$$247,948 was split evenly between city funds and award funding, minimizing financial risk while ensuring guaranteed long-term savings. Any excess savings that are beyond the guaranteed minimums remain with the city, which enables future investment in sustainable energy initiatives. This project provides many benefits to the public. In addition to reducing the environmental footprint of city operations, it lowers taxpayer-funded utility spending and improves the energy security of a critical facility. The knowledge gained from this implementation motivates the City to focus on similar efforts across other public facilities in future FCIP phases and other City projects.

14 SOLAR ENERGY↗
DOE OSTI2026

Dual-loop Solvent-based CCS for Net Negative CO 2 Emissions with Lower Cost

This final technical report details the successful design, construction, and operational validation of an innovative dual-loop CO 2 capture technology designed to achieve deep decarbonization (>99%) from Natural Gas Combined Cycle (NGCC) power plants that results in the electricity with carbon intensity of approximate 42 kg CO 2 -eq/MWh, less than the electricity produced by solar PV. The integrated process couples a primary aqueous solvent (in this project, a water lean solvent – WLS) absorption loop for bulk CO 2 removal with a secondary potassium hydroxide (KOH) polishing loop featuring electrochemical regeneration. This architecture leverages the higher exergy efficiency of the primary loop while utilizing the fastest kinetic of the secondary loop to capture dilute residual CO 2 , achieving an overall capture rate of 99.9% and co-producing pure hydrogen after moisture being condensed and dehydrated. Technical feasibility was established through a comprehensive 2,000-hour experimental campaign on a bench-scale fully-integrated unit (using 4” absorber and 4” stripper) with the feeding flue gas flowrate in the range of 8-20 cfm, confirming the attainment of Technology Readiness Level (TRL) 4. The project executed extensive parametric testing followed by 1,000 hours of continuous steady-state testing, demonstrating exceptional process stability with the electrochemical regenerator exhibiting less than a 10% reduction in electrical conductivity over the duration of the campaign. Operational characterization gathering on the bench unit revealed distinct energy profiles for the hybrid system: the primary loop required approximately 280 kJ mol -1 for bulk removal, while the polishing loop required approximately 1,600 kJ mol -1 specifically when reducing dilute CO 2 concentrations from ~740 ppm down to <50 ppm. (Please note those energy values/numbers can only be viewed as relative relationship and should not be extrapolated as absolute values required for CO 2 capture). Furthermore, dynamic testing validated the system’s flexibility for utility applications, demonstrating a rapid process response time of <30 minutes to changes in flue gas flowrate. Emission monitoring confirmed that the dual-loop architecture effectively mitigates solvent losses, utilizing a water wash to remove entrained aerosols to <1 ppm. The Techno-Economic Analysis (TEA) indicates a cost of capture of $\$$59.3/tonne and a Levelized Cost of Electricity (LCOE) of 71.7 $\$$/MWh at the overall capture efficiency of 99.8% of total carbon in the flue gas stream, with sensitivity analysis identifying an economic optimum when the primary loop captures 97% of the total CO 2 . A Life Cycle Assessment (LCA) confirms the technology’s potential for net-negative emissions, determining a Global Warming Potential (GWP) of 52 kg CO 2 -eq/MWh—significantly lower than the baseline—which further decreases to 42 kg CO 2 -eq/MWh when crediting the displacement of conventional hydrogen production.

03 NATURAL GAS↗
DOE OSTI2025

A derecho climatology (2004–2021) in the United States based on machine learning identification of bow echoes

Due to their persistent widespread severe winds, derechos pose significant threats to human safety and property, with impacts comparable to many tornadoes and hurricanes. Yet, automated detection of derechos remains challenging due to the absence of spatiotemporally continuous observations and the complex criteria employed to define the phenomenon. This study presents an objective derecho detection approach capable of automatically identifying derechos through both observations and model results. The approach is grounded in a physically based definition of derechos and integrates three algorithms: (1) the Python Flexible Object Tracker (PyFLEXTRKR) algorithm to track mesoscale convective systems (MCSs), (2) a semantic segmentation convolutional neural network to identify bow echoes, and (3) a comprehensive classification algorithm to detect derechos within MCS life cycles and distinguish derecho-producing from non-derecho-producing MCSs. Using this approach, we developed a novel high-resolution (4 km and hourly) observational dataset of derechos and accompanying derecho-producing MCSs over the United States east of the Rocky Mountains from 2004 to 2021. The dataset consists of two subsets based on different gust speed data sources and is analyzed to document the climatology of derechos in the United States. On average, 12–15 derechos are identified per year, aligning with previous estimations (∼6–21 events annually). The spatial distribution and seasonal variation patterns are consistent with prior studies, showing peak occurrences in the Great Plains and the Midwest during the warm season. Additionally, during the study period, derechos account for approximately 3.1 % of measured damaging gusts (≥25.93 m s−1) over the eastern United States. The dataset is publicly available at https://doi.org/10.5281/zenodo.14835362 (Li et al., 2025).

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

Electrical Fault and Power Quality Detection Algorithms and Customer-Owned DERs Monitoring with a Cyber Grid Guard System and DLT

In this study, the electrical fault and power quality detection algorithms and customer-owned DERs monitoring use cases were implemented, with a Cyber Grid Guard system and DLT. Electrical utilities continue to deploy more intelligent electronic devices (IEDs) inside and outside electrical substations, and are associated with customer-owned distributed energy resources (DERs). Data from these IEDs, such as power meters and protection relays, must be kept confidential and of high integrity. Blockchain technology has the potential to increase microgrid resilience by enhancing data sharing security. The growing use of IEDs and customer-owned renewable energy sources (DERs) may make it necessary to connect Distributed Ledger Technology (DLT) with power system applications. We implemented the electrical faulted phase detection and power quality monitoring algorithms with a Cyber Grid Guard (CGG) system using DLT. In addition, the DERs (wind turbine farms) use case and protective relay cyber-event tests were assessed, by using the CGG system with DLT. In the experimental model, the testbed was created by using a real-time simulator and CGG system with power meters/ protective relays in the loop. The data collected from the CGG system and IEDs were compared with the same time stamp source. These results showed the successful assessment of protection, control and monitoring applications using a CGG system with DLT. In the future, power system applications for the ESGT with DERs and the CGG system will be based on executing smart contracts between electrical utilities and customer-owned DERs.

Piesciorovsky, Emilio↗
DOE OSTI2020

Availability of Shielding Benchmark Experiment Data in the ICSBEP Handbook

The International Criticality Safety Benchmark Evaluation Projects (ICSBEP) has over two decades of experience under the auspices of the Organisation for Economic Co-operation and Development (OECD) Nuclear Energy Agency (NEA) to identify, evaluate, and compile a comprehensive data set of criticality safety benchmark data [1]. The activities of the ICSBEP have led to the continued success of the International Handbook of Evaluated Criticality Safety Benchmark Experiments (ICSBEP Handbook) [2]. The contents of the ICSBEP Handbook include benchmark specifications derived from nuclear facilities around the world, which have been utilized to support criticality safety efforts and also integral testing of nuclear data [3]. The 2020 edition of the ICSBEP Handbook will include data from 582 evaluations containing benchmark specifications for 5,053 critical, subcritical, or near-critical configurations. There are seven criticality-alarm-placement/shielding evaluations containing a total of 45 benchmark configurations, and ten fundamental physics evaluations containing a total of 237 measurements relevant to criticality safety applications. The purpose of this paper is to summarize those benchmarks relative to validation needs in shielding applications currently found within the ICSBEP Handbook. The current and future plans of shielding benchmarks with regards to the ICSBEP will also be discussed.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Lifecycle Management of Nuclear Security Radiation Detection Systems: Testing and Evaluation

The lifecycle of radiation detection systems functioning within a State’s Nuclear Security Detection Architecture encompasses all activities associated with acquisition, deployment, and eventual disposal. Throughout a system’s lifecycle, testing and evaluation activities are needed to ensure requirements are continually met, as underscored by recent experiences.This paper provides:1.A discussion of reasons why testing should be part of the radiation detection equipment lifecycle before, during, and after acquisition.2.A general process for determining applicable evaluation methods.3.A discussion of issues related to integrating testing and evaluation into procurement and operational processes and mitigation strategies.

Harris, Tyrone↗
DOE OSTI2021

Inline Rolling Shear Alignment: Deposition and Long-Range Order of Block Polymer Templates in a Fast, Single-Step Process

We report the first demonstration of a rapid, single-step technique to align block polymer, thin-film nanostructures that is amenable to continuous speeds ≥10 mm/s. This method, termed Inline Rolling Shear Alignment (IRSA), uses an elastomeric roller coupled with an electric hysteresis brake to shear films before the casting solvent fully evaporates, and it can enable high throughput, large-area manufacturing of patterns such as nanowire templates. IRSA is adaptable to various polymer systems including diblock and triblock polymers, and a post-shear annealing step can yield high-quality nanostructures with orientation parameters >0.99 and defect densities as low as 5 defect-pairs/μm 2 . To demonstrate the effectiveness of IRSA, platinum nanowires were produced from this rapid deposition and alignment approach using poly(styrene-b-2-vinylpyridine), followed by open-air, atmospheric-pressure plasma etching. Furthermore, this integrated concept, with 50x faster operation than existing processes, could be leveraged for cost-effective manufacturing of macroscopically aligned nanostructures in roll-to-roll systems.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Smart Composite Pressure Vessels (SCPV) with Integrated Health Monitoring

The U.S. Department of Energy (DOE) is promoting and developing more energy efficient and environmentally friendly technologies that will enable America to use less petroleum. Hydrogen fuel cells – which directly convert the chemical energy in hydrogen to electricity with only water and heat as byproducts – are a very attractive solution that can enable this to happen. To date, DOE's efforts have culminated in commercial demonstration of on-board vehicular hydrogen storage systems that can allow for a driving range of greater than 300 miles. This requires storing 5 Kgs of hydrogen onboard a light vehicle. In order to store this quantity of hydrogen, the hydrogen gas needs to be stored in a composite overwrapped pressure vessel (COPV) at a very high internal pressure. The objective of the program was to demonstrate continuous and predictable health-monitoring of composite pressure vessels. A higher confidence in the operational safety of the vessels will lead to reduced burst factor of safety imposed by regulatory standards and hence will help reduce the structural wall thickness that drives the cost of the vessel. Highly optimized Type III (metal lined) and Type IV (polymer lined) COPVs that are manufactured using filament winding process have been designed and qualified for the above mentioned application. However, the main structural component of the COPVs is carbon fiber and the high cost of carbon fiber composite in a pressure vessel is a primary challenge in reducing the cost of gaseous hydrogen storage. Continuous and remote monitoring of structural health of the COPVs as well as optimization of the strength translation of carbon fibers have the potential to allow for reduced factor of safety, thereby reduced amount of carbon and associated cost of the vessel. In the current program, the project team including Steelhead Composites (SHC), University of Tennessee, Knoxville (UTK), Teijin Carbon America, Oak Ridge National Laboratory (ORNL) and LUNA designed, fabricated, and tested smart composite pressure vessels with integrated sensors. Iterative loops of design and testing using coupons, subscale STEB vessels and full size vessels proved that a new generation of high performance carbon fiber can be used for efficient design of Type 3 vessels for H2 storage. Novel analysis techniques were developed to predict the initiation and propagation of interlaminar damage inside the composite shell due to impact damage, a real threat in practical operation. Such an analysis scheme is typically not used in tank design but is an essential tool for health monitoring of composite vessels. Remote sensing of the key signatures of the tank’s operating parameters such as pressure, acceleration and humidity was demonstrated using a unique device that can wirelessly transmit and stream the data to a remote server. Fiber optic sensors were successfully integrated during fabrication of the tanks. These sensors provide a wealth of information regarding the structural health of the vessel when it is subsequently pressurized or subjected to impact damage. Excellent correlation was demonstrated between the fiber optic sensor and mechanical strain gage data, and between the measurements and analytical predictions.

08 HYDROGEN↗