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DOE OSTI2013

Experiences with new neutralization technologies for remediation after ISL mining of uranium in Straz Pod Ralskem

A big affection of the rock environment and groundwaters occurred during the chemical mining of uranium in the years 1966 to 1996 in the neighbourhood of the town Straz pod Ralskem in the Czech Republic. It is necessary to clean the residual technological solutions (RTS) from the underground. The pH of the solutions in some places is still less than 2 and the concentration of sulphates reaches up to 65 g/l. The remedial activities consist of pumping of the RTS from the ground and reprocessing of the RTS in the surface technologies. The implementation of the new neutralization technologies NDS ML and NDS 10 help us with increasing of the efficiency of the remedial process. The NDS ML technology ('Mother liquor reprocessing station') started its operation in 2009 and it processes the concentrated technological solution from the evaporation station after the alum crystallization (mother liquor) with the concentration of total dissolved solids up to 250 g/l. The principle is the neutralization of the acid solutions with the aid of the lime milk. The suspension is then filtrated in the filter press, the filter cake is deposited in the tailings pond and the filtrate is injected back into the underground rock environment. The NDS 10 technology ('Neutralization and Decontamination Station NDS 10') started its operation in 2012 and it works on the same technological principle as the NDS ML station. The difference is that the NDS 10 station can process higher volume (4.4 m{sup 3}/min) of the RTS with lower concentration of total dissolved solids 20 - 25 g/l. This poster describes the experiences of the state enterprise DIAMO with putting of these two neutralization technologies into operation and with using of the lime milk neutralization in such a large scale. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

Retrofitting Holcim Ste. Genevieve Cement Plant with CO2 Capture Plant Using Air Liquide Cryocap™ FG Technology

The global cement manufacturing industry is a major contributor to carbon dioxide emissions. The International Energy Agency's "Net Zero Emissions by 2050 Scenario" identifies CCS as a major strategy for meeting that goal. This project is among the first attempts to transfer capture technology developed at coal-fired power plants to the cement industry. The main objective of the project is to execute and complete a front-end engineering and design (FEED) studies for commercial-scale, carbon capture projects that separates 95% of the total CO2 emissions at the Holcim (US) Ste. Genevieve cement manufacturing facility using Air Liquide’s Pressure Swing Adsorption system (PSA) assisted Cryocap™ technology. The Holcim Ste. Genevieve cement plant in Missouri, US, boasts one of the largest single cement production lines in the world, with a capacity of approximately 12,000 t/day. The plant currently uses traditional fuels, namely coal and petcoke. The captured CO2 will be pipeline and geological storage grade. The industrial host site emits approximately 3.0 million tonne CO2/yr. Air Liquide’s Cryocap™ technology has been developed over the last 18+ years for CO2 capture applications. It has been shown to be applicable to a variety of industrial applications (e.g., steel, cement, SMR, Fluidized Catalytic Crackers (FCCs)). Cryocap™ FG consists of a Pressure Swing Adsorption (PSA) unit coupled with a Cryogenic System. The PSA pre-concentrates the CO2 from the flue gas, while the cryogenic unit enables the CO2 purity to be increased to the desired level. The project team is led by the Prairie Research Institute at the University of Illinois at Urbana-Champaign. The tasks include: complete FEED study for retrofitting the industrial facility with a carbon capture system to support developing a detailed cost estimate; business case analysis outlining the anticipated revenue and credits if projects was built and operated; technoeconomic analysis (TEA) outlining how capture system achieves DOE capture goals; and life cycle (LCA) analysis demonstrating zero net carbon emissions. The FEED study was successfully completed. This includes completing the process basis of design; preliminary engineering; outside battery limits (OSBL) detailed engineering including a Zero Liquid Discharge (ZLD) wastewater treatment system; inside battery limits (ISBL) detailed engineering [1]. An overall project capital cost estimate within a -20%/+30% accuracy was developed. The major contributors to the Total Plant Cost (TPC), by system, are the costs associated with the Outside Battery Limit (OSBL) section of the plant which includes a new river water intake structure and a Zero Liquid Discharge (ZLD) system. By cost category, the major contributors to the TPC are equipment and subcontractor costs, followed closely by engineering, construction management, home office and contractor fees. The TEA has been created to reflect the findings of the project. It analyzes the economic performance of the Cryocap™ technology by reviewing the estimated capital costs, operating cost, and revenue. The Cost of Capture (COC) associated with the Cryocap™ technology for 95% CO2 capture, when considering NETL 2018 economic assumptions (42/58 debt/equity ratio, 5.15% interest on debt and 1.42% return on equity in real dollars) and 2022 economic assumptions (42/58 debt/equity ratio, 8.82% interest on debt and 4.90% return on equity in real dollars) was found to be much lower than that for the DOE-NETL’s base-line cases. The highest contributors to the COC are annualized capital expenditures (CAPEX) and electricity consumption which can be offset by using lower cost renewable sources. The LCA was conducted using OpenLCA which is an open-source software that is recommended by NETL. The database utilized for this study was a modified version of TRACI 2.1 (developed by the US. Environmental Protection Agency’s National Risk Management Research Laboratory and modified by NETL). The Cryocap™ FG technology does not consume fuels in significant quantities and does not utilize specialized chemical solvents subject to decomposition, such as those utilized in amine-based carbon capture systems. The Cryocap™ FG technology mainly utilizes electricity as its energy input; hence, its calculated emissions are mainly associated with the generation of electricity offsite and are dependent on the energy matrix of the grid at the time of project implementation. The water consumption impact of the Cryocap™ FG is mostly for makeup of the water lost by evaporation in the cooling tower; however, the carbon capture plant will be equipped with a ZLD system to avoid effluent streams and minimize water consumption. The successful construction and operation of this plant based on this study results will provide a means to demonstrate an economically attractive and transformational capture technology that can be used to retrofit existing plants and be deployed at new plants.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2012

Clean Technology Evaluation & Workforce Development Program

The overall objective of the Clean Technology Evaluation portion of the award was to design a process to speed up the identification of new clean energy technologies and match organizations to testing and early adoption partners. The project was successful in identifying new technologies targeted to utilities and utility technology integrators, in developing a process to review and rank the new technologies, and in facilitating new partnerships for technology testing and adoption. The purpose of the Workforce Development portion of the award was to create an education outreach program for middle & high-school students focused on clean technology science and engineering. While originally targeting San Diego, California and Cambridge, Massachusetts, the scope of the program was expanded to include a major clean technology speaking series and expo as part of the USA Science & Engineering Festival on the National Mall in Washington, D.C.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2014

Technology Evaluation for Conditioning of Hanford Tank Waste Using Solids Segregation and Size Reduction

The Savannah River National Laboratory and the Pacific Northwest National Laboratory team performed a literature search on current and proposed technologies for solids segregation and size reduction of particles in the slurry feed from the Hanford Tank Farm. The team also investigated technology research performed on waste tank slurries, both real and simulated, and reviewed academic theory applicable to solids segregation and size reduction. This review included text book applications and theory, commercial applications suitable for a nuclear environment, research of commercial technologies suitable for a nuclear environment, and those technologies installed in a nuclear environment, including technologies implemented at Department of Energy facilities. Information on each technology is provided in this report along with the advantages and disadvantages of the technologies for this application. Any technology selected would require testing to verify the ability to meet the High-Level Waste Feed Waste Acceptance Criteria to the Hanford Tank Waste Treatment and Immobilization Plant Pretreatment Facility.

Hanford tank waste↗

DOE OSTI2016

Nuclear-Renewable Hybrid Energy Systems: 2016 Technology Development Program Plan

The United States is in the midst of an energy revolution, spurred by advancement of technology to produce unprecedented supplies of oil and natural gas. Simultaneously, there is an increasing concern for climate change attributed to greenhouse gas (GHG) emissions that, in large part, result from burning fossil fuels. An international consensus has concluded that the U.S. and other developed nations have an imperative to reduce GHG emissions to address these climate change concerns. The global desire to reduce GHG emissions has led to the development and deployment of clean energy resources and technologies, particularly renewable energy technologies, at a rapid rate. At the same time, each of the major energy sectors—the electric grid, industrial manufacturing, transportation, and the residential/commercial consumers— is increasingly becoming linked through information and communications technologies, advanced modeling and simulation, and controls. Coordination of clean energy generation technologies through integrated hybrid energy systems, as defined below, has the potential to further revolutionize energy services at the system level by coordinating the exchange of energy currency among the energy sectors in a manner that optimizes financial efficiency (including capital investments), maximizes thermodynamic efficiency (through best use of exergy, which is the potential to use the available energy in producing energy services), reduces environmental impacts when clean energy inputs are maximized, and provides resources for grid management. Rapid buildout of renewable technologies has been largely driven by local, state, and federal policies, such as renewable portfolio standards and production tax credits that incentivize investment in these generation sources. A foundational assumption within this program plan is that renewable technologies will continue to be major contributors to the future U.S. energy infrastructure. While increased use of clean renewable technologies will aid in achieving reduced GHG emissions, it also presents new challenges to grid management that must be addressed. These challenges primarily derive from the fundamental characteristics of variable renewable generators, such as wind and solar: non-dispatchability, variable production, and reduced electromechanical inertia. This document presents a preliminary research and development (R&D) plan for detailed dynamic simulation and analysis of nuclear-renewable hybrid energy systems (N-R HES), coupled with integrated energy system design, component development, and integrated systems testing. N-R HES are cooperatively-controlled systems that dynamically apportion thermal and/or electrical energy to provide responsive generation to the power grid.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2015

High Temperature Syngas Cleanup Technology Scale-up and Demonstration Project

Gasification is a technology for clean energy conversion of diverse feedstocks into a wide variety of useful products such as chemicals, fertilizers, fuels, electric power, and hydrogen. Existing technologies can be employed to clean the syngas from gasification processes to meet the demands of such applications, but they are expensive to build and operate and consume a significant fraction of overall parasitic energy requirements, thus lowering overall process efficiency. RTI International has developed a warm syngas desulfurization process (WDP) utilizing a transport-bed reactor design and a proprietary attrition-resistant, high-capacity solid sorbent with excellent performance replicated at lab, bench, and pilot scales. Results indicated that WDP technology can improve both efficiency and cost of gasification plants. The WDP technology achieved ~99.9% removal of total sulfur (as either H 2 S or COS) from coal-derived syngas at temperatures as high as 600°C and over a wide range of pressures (20-80 bar, pressure independent performance) and sulfur concentrations. Based on the success of these tests, RTI negotiated a cooperative agreement with the U.S. Department of Energy for precommercial testing of this technology at Tampa Electric Company’s Polk Power Station IGCC facility in Tampa, Florida. The project scope also included a sweet water-gas-shift process for hydrogen enrichment and an activated amine process for 90+% total carbon capture. Because the activated amine process provides some additional non-selective sulfur removal, the integration of these processes was expected to reduce overall sulfur in the syngas to sub-ppmv concentrations, suitable for most syngas applications. The overall objective of this project was to mitigate the technical risks associated with the scale up and integration of the WDP and carbon dioxide capture technologies, enabling subsequent commercial-scale demonstration. The warm syngas cleanup pre-commercial test unit was designed and constructed on schedule and under budget and was operated for approximately 1,500 total hours utilizing ~20% of the IGCC’s total syngas as feed (~1.5 MM scfh of dry syngas). The WDP system reduced total sulfur levels to ~10 ppmv (~99.9% removal) from raw syngas that contained as high as 14,000 ppmv of total sulfur. The integration of WDP with the activated amine process enabled further reduction of total sulfur in the final treated syngas to the anticipated sub-ppmv concentrations (>99.99% removal), suitable for stringent syngas applications such as chemicals, fertilizers, and fuels. Techno-economic assessments by RTI and by third parties indicate potential for significant (up to 50%) capital and operating cost reductions for the entire syngas cleanup block when WDP technology is integrated with a broad spectrum of conventional and emerging carbon capture or acid gas removal technologies. This final scientific/technical report covers the pre-FEED, FEED, EPC, commissioning, and operation phases of this project, as well as system performance results. In addition, the report addresses other parallel-funded R&D efforts focused on development and testing of trace contaminant removal process (TCRP) sorbents, a direct sulfur recovery process (DSRP), and a novel sorbent for warm carbon dioxide capture, as well as pre-FEED, FEED, and techno-economic studies to consider the potential benefit for use of WDP for polygeneration of electric power and ammonia/urea fertilizers.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2016

Milestone Report:3.2.2.26 Appliances, HVAC & Water Heating R&D-Select Sorption Technology

The purpose of this report is to select a sorption technology based on recent work completed on characterizing working pairs for both absorption and adsorption technologies based on Global Warming Potential (GWP) of less than 100 (relative to carbon dioxide, 100-year atmospheric life span) and zero Ozone Depletion Potential (ODP). From a total of eighty-three potential working pairs (absorption technology), there were only two candidate working pairs for the absorption technology, and 8 potential working pairs for adsorption technology. After screening these ten potential candidates on the basis of sizes of the desorber, absorber/adsorber, evaporator, condenser, and rectifier (where applicable), the ORNL-Georgia Tech study concluded that best working pairs are NH3-H2O for the most compact system in terms of heat transfer equipment surface area, and NH3-LiNO3 and MeOH-[mmin][DMP] where efficiency is most important. Based on a single-stage absorption and adsorption modeling using the Engineering Equation Solver (EES), the performance of both sorption systems was evaluated from known heat transfer correlations, and thermos-physical properties. Based on these results, the technology chosen is absorption technology. The selected technology is absorption for the reasons cited in Section 4.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2017

Development of Manufacturing Technology to Accelerate Cost Reduction of Low Concentration and

The purpose of this project was to accelerate deployment of cost-effective US-based manufacturing of Solaria’s unique c-Si module technology. This effort successfully resulted in the development of US-based manufacturing technology to support two highly-differentiated, market leading product platforms. The project was initially predicated on developing Solaria’s low-concentration PV (LCPV) module technology which at the time of the award was uniquely positioned to exceed the SunShot price goal of $0.50/Wp for standard c-Si modules. The Solaria LCPV module is a 2.5x concentrator that leverages proven, high-reliability PV module materials and low silicon cell usage into a technology package that already had the lowest direct material cost and leading Levelized Cost of Electricity (LCOE). With over 25 MW commercially deployed globally, the Solaria module was well positioned to continue to lead in PV module cost reduction. Throughout the term of the contract, market conditions changed dramatically and so to did Solaria’s product offerings to support this. However, the manufacturing technology developed for the LCPV module was successfully leveraged and optimized to support two new and different product platforms. BIPV “PowerVision” and High-efficiency “PowerXT” modules. The primary barrier to enabling high-volume PV module manufacturing in the US is the high manual labor component in certain unique aspects of our manufacturing process. The funding was used to develop unique manufacturing automation which makes the manual labor components of these key processes more efficient and increase throughput. At the core of Solaria’s product offerings are its unique and proprietary techniques for dicing and re-arranging solar cells into modules with highly-differentiated characteristics that address key gaps in the c-Si market. It is these techniques that were successfully evolved and deployed into US-based manufacturing site with SunShot funding. Today, Solaria is currently positioned to become the market leader with these two technologies over the coming 24 months largely due to the successful innovations of the underlying manufacturing technology. This success will leverage US-based manufacturing technology and the associated US-jobs to support. Solaria views the project as highly successful and a great example of SunShot funding enabling the creating of US jobs and the deployment of ubiquitous solar energy products.

14 SOLAR ENERGY↗

DOE OSTI2017

Material Protection, Accounting and Control Technologies (MPACT) Implementation Plan: Lab-Scale Demonstration of Advanced Safeguard and Security Systems

The Materials Protection, Accounting, and Control Technologies (MPACT) campaign is working towards the goal of developing and demonstrating the next generation of nuclear materials management for the peaceful use of civilian nuclear energy. A major milestone of the campaign is the “Lab-scale demonstration of an advanced safeguards and security system,” due in 2020. This implementation plan describes how tools developed in the MPACT campaign will be used to meet this milestone. These tools consist of instrumentation and devices as well as computer software for modelling, simulation and integration of data and information for safeguard and security analysis. The plan is focused on demonstrating an advanced safeguard and security systems for electrochemical processing plants, but also identifies activities needed to address advanced reactor, aqueous processing and other advanced fuel cycle facilities. A key component to achieving the 2020 milestone is the development of a virtual distributed test bed that incorporates the instruments, data, analysis tools, and models currently under development and provides a framework to link and normalize the data in a way that simulates a facility, including uncertainty quantification. This virtual distributed test bed will integrate computer simulated facilities that make up a fuel cycle of interest, with distributed test beds located in actual operating facilities and laboratories. The MPACT campaign recently issued roadmaps for both Modelling & Simulation and Advanced Integration which address this component, and activities necessary to achieve the 2020 milestone. Research, development and testing of specific technologies have been supported by the MPACT campaign in coordination with other DOE-NE and DOE-NNSA programs. These technologies provide the essential data needed by the safeguard and security systems, and feed into the data analysis and facility models. This plan will identify these technologies, their current status and activities needed to demonstrate the technologies at the laboratory scale. Wherever possible, test of technologies in field conditions using suitable nuclear materials will be used to define performance. Where necessary, surrogate materials and/or simulation will be used to provide useful information for the demonstration. When completed, the 2020 milestone will provide a demonstration of advanced safeguard and security technologies, including advanced modelling, simulation and analysis approaches, applied to electrochemical processing. It will also identify applications of the technology and approaches in other advanced fuel cycle and reactor concepts.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗

DOE OSTI2018

Advancing the science and impact of blockchain technology at Oak Ridge National Laboratory

Over the last decade, blockchain technology has experienced unprecedented growth from its humble beginnings as the decentralized currency Bitcoin in 2009 to a $500 billion industry today with applications including decentralized cloud computing, peer-to-peer lending, governance, social media, cybersecurity and the development of decentralized, trustless smart contracts and applications. Although it has not yet reached maturity, the blockchain technology industry (sometimes hailed as the “Web 3.0”) is experiencing exponential growth and adoption: new projects and partnerships are announced almost daily, and top research institutions are beginning to develop novel initiatives in this space. In this white paper, I will outline a vision for the future of blockchain technology at Oak Ridge National Laboratory (ORNL). Specifically, I will (1) introduce the fundamental concepts of blockchain technology and provide a survey of the current state-of-the-art, (2) identify the wide-ranging applications that blockchain technology can have across groups, divisions, and directorates at ORNL, (3) summarize the newly initiated programs in blockchain technology at ORNL’s core partnership universities that may lead to future collaboration opportunities, (4) suggest critical ways that blockchain technology can advance ORNL’s strategic objectives for excellence in science and technology, laboratory operations, and community engagement, and (5) outline the most likely funding strategies to support new blockchain initiatives and partnerships at the Lab. Finally, I will propose a vision for the future of a Blockchain Institute at ORNL.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2019

Systematic Technology Evaluation Program for SiC-based BWR Channel Box

Silicon carbide (SiC) –based accident-tolerant fuel (ATF) cladding of light water reactors (LWRs) has become a topic of great interest in nuclear material development since the Fukushima Dai-ichi Nuclear Power Plant accident. Extensive development of SiC cladding has identified benefits of the concept, including its inherent accident resistance and neutronic performance. Advancements achieved during the development of SiC-based ATF cladding have made it attractive for use in accident-tolerant cores of LWRs. In this document, we consider the use of SiC-based materials to replace the zirconium alloy used for the channel boxes of boiling water reactors. Both accident resistance and prevention of the bowing observed in current grades of channel boxes are needs driving the exploration of a new channel box system. To provide a pathway for channel box development, this document lays out (1) a current technology overview, (2) the technology gap, and (3) a systematic technology evaluation plan. The objectives of the technology evaluation plan are to address key feasibility issues revealed by the knowledge gap analysis and to contribute to advancing the technology readiness level. Further development will be required in the technology implementation phase. The technology evaluations include understanding the behavior of channel boxes under both normal and off-normal conditions, identifying potential mitigation strategies for the issues if necessary, and improving channel box performance based on the knowledge obtained. The structure of the technology evaluation plan and each task are shown in Figure S.1. The knowledge gap analysis identified key research areas, including irradiation effects, hydrothermal corrosion, accident behavior, and design and manufacture. These are common issues between SiC-based channel boxes and SiC-based fuel cladding, although technical evaluations specific for the channel box components are required. This document also describes details of the technical feasibility evaluation methods and plans.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2019

Assessment of Technologies for I-129 Remediation in the 200-UP-1 Operable Unit

Iodine-129 (I-129) generated at the U.S. Department of Energy Hanford Site during plutonium production was released to the subsurface, resulting in several large, dilute plumes in the groundwater, including the plume in the 200-UP-1 operable unit (OU). A requirement in the Record of Decision (ROD) for interim remedial action at the 200-UP-1 OU is to “evaluate potential treatment options for I-129 as part of the selected remedy through further technology evaluation. If one or more viable technologies are identified, treatability tests will be conducted for those technologies.” The requirements also state: “In the event a viable treatment technology is not available, the use of a technical impracticable waiver under 40 CFR 300.430(f)(l)(ii)(c) may need to be considered as part of the final remedy.” Recent work has increased the understanding of iodine behavior in the Hanford subsurface. A thorough review of potential remediation technologies has also been completed, including laboratory testing of promising technologies to evaluate their effectiveness for the iodine conditions at the 200-UP-1 OU. Using the combined information from these efforts, this report evaluates potential remediation technology options for the 200-UP-1 OU with respect to the need for conducting treatability tests and to document the technology status in support of future OU decisions for addressing the I-129 plume.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2019

Final Report – Cooperative Research and Development Agreement between National Energy Technology Laboratory and Oxergy, Inc.

The NETL Raman Gas Analyzer (RGA) has been demonstrated to have an extremely fast response (<1 second) multi-gas analysis capability. All but the noble gases are Raman active, although the Raman interaction is weak. The RGA uses a reflectively lined capillary as the optical cell, providing both a small sample volume for fast gas exchange, and a much greater Raman signal collection than traditional instrument configurations. This allows very fast measurement of fuel gases (hydrogen, methane, ethane, propane) as well as other common industrial gases (carbon monoxide, carbon dioxide, nitrogen, oxygen, and water). This provides a new enabling technology for faster, smarter process control based on the chemical composition of the gases in the process – including improved fuel flexibility and efficiency for power generation systems. Research and development up to 2016 resulted in the construction of two field prototypes of the NETL RGA, which has been in applied to various laboratory applications for testing. The results of the testing have been used to improve the RGA design, with the intent to support technology transfer. The quality of the optical capillary used in the RGA is critical to its performance, and prior work at NETL produced a few optical capillaries superior to those commercially available. The production of high optical quality capillaries, however, was inconsistent in its results. With the support of the DOE Office of Technology Transitions, through the Technology Commercialization Fund program, this project was undertaken to address this commercialization barrier and to also evaluate the possible application of Raman gas analysis to a supercritical water gasification process being developed by Oxergy Inc. Oxergy, a small business located in Fairbanks, Alaska, is developing ultra-compact thermochemical reaction devices built with advanced manufacturing processes. Chief Technology Officer Jonathan Kamler holds the (pending) patent to Oxergy’s core reactor technology. Oxergy maintains wet-lab and combustion-lab space at the University of Alaska Fairbanks Center for Sustainable Living in Palmer, Alaska, where Mr. Kamler operates a pilot-scale, supercritical water gasification system designed and built by Oxergy. Mr. Kamler also operates an All Powers Labs Power Pallet gasifier coupled to a 10KW electrical generator as a dry biomass test platform at the Palmer facility. Both systems are suitable for real-world, collaborative testing of Raman gas analysis applications. The objectives of the CRADA include making the production of high-quality optical capillaries consistent and high yield, investigating other options for optical waveguides, and testing the capillaries for measurements in supercritical water gasification. Success on these objectives will support commercialization of both the RGA and supercritical water gasification technologies. Through the work performed on this project, a new apparatus was constructed and optimized to provide consistent production of high-quality optical capillaries. Several thick-walled capillaries were coated using this apparatus and shipped to Oxergy in September 2018 for testing in both dry gasification and supercritical water gasification process monitoring applications at University of Alaska Fairbanks facilities in Palmer. The strong earthquake near Anchorage and Palmer in November 2018 caused extensive damage and closure of the facilities used by Oxergy, preventing Oxergy from proceeding with experimental testing before the end of the project; the facility has been closed indefinitely. Earthquake damage prohibited the completion of all the project objectives prior to the end of the project. However, significant progress was made toward addressing a core technology commercialization barrier. The largest and most mature potential market for Raman gas analysis is its use in analytical instruments, which require sensitivity and low detection limits, and Oxergy’s market research found that market inertia is a barrier to commercial success in this market. Although NETL’s innovations in capillary coating have substantially improved Raman gas analysis capability, the likely market is expected to be niche applications that value the fast detection of real-time changes in gas composition.

Chorpening, Benjamin↗

DOE OSTI2020

Boride-Carbon Hybrid Technology to Produce Ultra-Wear and Corrosion Resistant Surfaces for Applications in Harsh Conditions (Final Technical Report)

Engineered functional surfaces play an important role to enable new products and manufacturing processes that can endure harsh service conditions such as high impact and contact loads, highly abrasive wear, extreme temperatures, and corrosive environments. Engineered surfaces can also be instrumental to improving the efficient use of energy by reducing frictional losses and extending service life. The main objective of this project was to develop a hybrid surface engineering technology that combines the advantages of a novel ultrafast boriding process with the next generation of superhard carbon coatings. The hypothesis was that this hybrid process will offer an unprecedented combination of wear and corrosion resistance, low frictional losses and affordability for treated parts so that it can be utilized in many applications. During this project, a duplex process was developed that combines the advantages of ultra-fast electrochemical boriding with those of hard tetrahedral amorphous carbon coatings. Both technologies can be combined to form a hybrid technology that is characterized by low friction and wear properties combined with corrosion and fatigue resistance. Good adhesion of both layers to each other was one main goal of this project, that has been achieved with HF1 adhesion through the Rockwell-C adhesion test. In this project, the mechanical properties of the hybrid coating were modeled through a finite-element analysis approach. We can conclude that the FEA model resembles the actual samples and be utilized to predict mechanical behavior under impacts. Based on this model, application-oriented load conditions can be simulated for optimal layer design regarding thickness and mechanical properties. To exemplify, one conclusion that can be drawn from the nanoindentation model is a boride layer thickness of 50 µm is sufficient to effectively support the carbon coating on the identified AISI 1045 low carbon steel substrate material. The duplex treatment yields wear rates as low as 6 x 10 -8 mm 3 N -1 m -1 and a coefficient of friction of 0.14 when tested against a steel counter face in a ball-on-disk test setup. On the other hand, the wear rate of the only-borided AISI 1045 steel was 5 x 10 -5 mm 3 N -1 m -1 , about three orders of magnitude higher than the duplex coating. At the same time, duplex treated samples experience corrosion resistance, which could not be achieved with single-layer carbon coatings. The developed surface treatment withstands a 3-hour exposure to 15% HCl, while the only carbon coated counter sample shows severe delamination of the coating due to pin hole corrosion. The boride layer is chemically stable and pin hole free because it is formed through an electrochemical process under high current densities (700 mA/cm 2 ) and high temperature. Additionally, the hybrid coating led to at least 3x increase in fatigue strength of the steel substrate, which exceeds the target performance of 30% improvement. There are numerous potential applications for the duplex coatings. A representative application is bearing ball coatings for off-shore windmills. Compared to currently employed surface technologies in this field, the initial costs of applying our technology might be higher due to more process steps but the performance benefits lead to an increased life time of treated parts, which will lower the maintenance and replacement costs in the long-term. To validate the technology for this specific application, the team is currently investigating the process of white etching crack initiation of the duplex coating in collaboration with ANL. Overall, this project successfully validated that the boride-carbon hybrid technology can withstand harsh conditions. One possible approach to commercialization under consideration is to transfer the technology to a startup or an existing coatings company.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Proceedings from the State of the Science and Technology for Minimizing Impacts to Bats from Wind Energy

The U.S. Department of Energy Wind Energy Technologies Office (DOE WETO), and the National Renewable Energy Laboratory convened a workshop entitled the State of the Science and Technology for Minimizing Impacts to Bats from Wind Energy on 13–14 November 2019. The objectives of the workshop were to (1) Identify the current impact minimization measures that are, or can be, used to reduce bat fatalities at wind energy facilities, (2) Assess the current effectiveness of those minimization measures, (3) Identify and assess the research and development (R&D) opportunities needed to optimize and improve the effectiveness of current minimization and deterrent technologies and inform the development of future solutions; and (4) Identify potential emerging or novel methods for informing impact minimization measures at or around wind energy facilities. Specifically, the workshop focused on deterrent and curtailment strategies. For deterrents, the discussion centered on the existing technology (i.e., ultrasonic deterrents, dim-UV light, and texture coating), integration with wind turbines (either retrofitting or out of the box installation), effectiveness, validation studies, and cost (e.g., technology, installation, validation, and maintenance). For curtailment, the conversation was divided into blanket curtailment (i.e., based on time and wind speed) and smart curtailment (i.e., blanket curtailment plus additional variables such as temperature or bat activity). The workshop included plenary presentations, panels, and breakout sessions to share data and stakeholder perspectives, and engage participants. Although there are several priority topics related to bat and wind energy, this workshop focused the discussion on the current technologies and strategies that are, or can be, used to reduce bat fatalities at wind energy facilities, status of research and development (R&D) of minimization measures, opportunities to optimize costs and improve effectiveness, and potential emerging or novel approaches to explore. This workshop took a holistic approach and discussed all aspects associated with advancing deterrent technologies and curtailment strategies, including the technological, biological, economic, and regulatory barriers faced by the wind energy and wildlife community.

13 HYDRO ENERGY↗

DOE OSTI2021

Novel Algae Technology for CO2 Utilization

The United States, the world’s largest energy user and second largest CO2 emitter, is heavily dependent on fossil energy. In 2014, U.S. coal burning utilities emitted ~1562 million (MM) tons/year (TPY) of CO2 into the atmosphere, accounting for 76% of the total US power sector emissions1. Hence, reducing the CO2 emission footprint from coal plants is widely viewed as a key element in mitigating global warming. Despite significant interest, implementation of CO2 capture technologies has been constrained by the high capture cost which significantly increases the total cost of electricity. Not only is capturing CO2 with traditional technologies expensive, but generally the CO2 has little value and additional expense must be incurred for sequestration. This project funded by a SBIR grant from the U.S. D.O.E. to Helios-NRG in collaboration with the State University of New York at Buffalo (UB) and Membrane Technology and Research Inc. (MTR) aimed to develop a novel, algae based technology to capture CO2 from the effluent of coal-based power plants and convert it to renewable bio-fuels and higher value co-products such as animal feed and nutraceuticals with the potential to enable a substantial reduction in the net cost of carbon capture. The Phase 2 project was aimed at further demonstrating the technical feasibility of the proposed multi-stage continuous (MSC) flow CO2 capture system and the generation of high-value co-products to offset the CO2 capture cost. The project was completed and the project objectives were met and exceeded. A first-of-a-kind integrated, laboratory scale MSC process unit was fabricated and tested in a greenhouse. The tests were conducted with the preferred algae species identified in Phase I and simulated flue gas containing contaminants at levels typically present in the post flue gas desulfurization (FGD) stream, including ~12% CO2, acid gas (SOX, NOX), and a large number of heavy metals. The tests were successful and demonstrated a 25g/m2/day seasonal average algae productivity and an 80% CO2 capture efficiency. Two new algae species were identified for high-value nutraceutical production. Studies to improve growth rate and nutraceutical content of these algae species were performed and a pathway for further improvements was identified. A new dewatering technology called DeAqua was further advanced. Significant improvement in the performance index was achieved. The anti-fouling membrane was developed and fabricated into a module. The fabricated membrane module was tested with algae slurry and demonstrated improved fouling resistant properties, that can potentially reduce the cost and energy of the critical dewatering step. Test data were used to simulate operation of the overall process. The preliminary economic analysis was updated and modelled based on a 5000-acre algae farm. To the extent possible, the financial and operating assumptions used were the same as those used in the DOE’s 2022 projections for algae technology for CO2 capture and utilization. The results showed the proposed technology’s potential to significantly reduce the cost of CO2 capture compared to current options and that the high value products generated from the CO2 captured can make a step change in the cost of carbon capture. Plans to advance the technology to Phase 2B were developed and potential end-user partners were identified.

Maloney, James↗

DOE OSTI2022

The False Dilemma: Rethinking AF Science and Technology Officer Talent Management

In 2019, Secretary of the Air Force (SECAF) Heather Wilson launched the 2030 Science and Technology (S&T) Strategy by stating, “The advantage will go to those who create the best technologies and who integrate and field them in creative operational ways that provide military advantages.” In 2021, 15% of Air Force general officers responsible for creating and integrating this technological edge had a science, technology, engineering, and math (STEM) graduate degree, and less than 1% of generals had a STEM doctorate. As one point of comparison, at least 32% and 13% of founding CEOs of Fortune 500 technology companies had a master’s and doctoral STEM degree, respectively. The gulf is larger when you consider that these CEOs used their technical degrees throughout their careers whereas most general officers do not. In large organizations, if the leader does not possess technical knowledge, it is difficult to drive innovation systems and connect ideas to reality. The evidence for this disconnect is abundant in acquisition challenges for high-tech systems, significant pushback to the “revolution in military affairs”, and failure of the “Third Offset” to take hold and deliver capabilities to offset Chinese and Russian capabilities. Indeed, when the former Air Force and Space Force Chief Software Officer, Nicolas M. Chaillan, offered his resignation, one of the main reasons for leaving was “the failure of OSD and the Joint Staff to deliver on their own alleged top ‘priority’, JADC2 – they couldn’t ‘walk the walk.’” Senior leaders have recognized this disconnect, and several inquiries and studies regarding STEM competency have been conducted. Many have posed a false dilemma: a large, STEM-cognizant or small, STEM-expert force. However, current and future STEM human capital needs are managed at the unit and functional area level. This leads to “silos” and the tactical “needs of the present” dominating the strategic “needs of the future”, highlighted by only two functional areas systematically tracking future STEM needs. Therefore, the decision on force structure appears to have been historically made by default through these and other perceived structural realities, and a vast majority of recommendations have focused on the small STEM community – an exercise in diminishing returns. In essence, the solution often boils down to finding unicorns – officers that have chartered the unforgiving pathway through the traditional “gates” to general officer while obtaining sufficient STEM proficiency along the way. Fortunately for the Air Force, these officers exist, albeit at a rate below what the evidence would suggest is necessary. However, this approach fundamentally limits the ability to develop a deep pool of officers with the ability to create and integrate technologies and ensures the Dunning-Kruger effect is prevalent. The Dunning-Kruger effect is a cognitive bias where those with limited knowledge in an area lack the expertise necessary to recognize their lack of expertise and consequently are prone to overestimate their knowledge and performance. In short, we need less leaders overestimating their STEM knowledge and more with hard-earned STEM competency required to “walk the walk” to create and integrate technologies for military advantage. This will not be accomplished by restricting the emphasis to the traditional scientists and engineering (S&E) career fields – the pool, only 10% of line officers, and general officer progression is just too small. Fortunately, the recent SECAF’s Management Initiatives and Chief of Staff’s (CSAF) Action Orders, both containing emphasis on organic expertise to “accrue advantage in military-technological competition,” present an opportunity to truly develop a framework for the force of the future.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2022

Barriers to Broader Utilization of Fault Detection Technologies for Improving Residential HVAC Equipment Efficiency

Faults in residential heating, ventilating, and air conditioning (HVAC) equipment may occur due to poor installation practices or develop over time, and these faults can negatively impact system efficiency, thermal comfort, and equipment lifespan. Automated fault detection and diagnostic (AFDD) technologies identify energy wasting HVAC faults, such as low indoor airflow and improper refrigerant charge, and guide technicians in improving system efficiency. For residential HVAC, AFDD consists of a range of fault detecting and diagnostic capabilities, sensor configurations, and target applications. AFDD technology can either be permanently installed by the original equipment manufacturer (OEM) using embedded sensors or as an add-on product either during or after installation. Additionally, several advanced installation tools and refrigerant gauge sets include AFDD features for temporary use during equipment installation and tune-ups. Some technologies can detect a fault but have limited diagnostic capabilities. For example, a single-point measurement from the home's thermostat or energy monitor can provide certain fault detection capability by analyzing the equipment runtime or energy consumption. These technologies, though limited at determining the cause of a given fault, may have significant energy savings potential due to their low cost and prevalence in the residential HVAC market. Despite the potential benefits, fault detection technologies face many technical and market barriers preventing broad adoption. Beyond the cost barriers due to the added sensor requirements and technology development, fault detection technologies face many implementation and adoption barriers such as installer training, customer awareness, standardized communication protocols, and methods of test for evaluating accuracy. The purpose of this whitepaper is to characterize market and technical barriers impeding broader utilization of fault detection technology for residential HVAC energy efficiency applications.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗