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At least 955 records · Page 53

Unique Single-Axis Tracking Planar Waveguide Optical Collector for CSP Modules

During the project Agira was pursued: (a) R&D efforts leading to the development of an innovative and revolutionary future-generation waveguide concentrating solar collector that will have improved value or productivity when compared to best-in-class, near-commercial concentrating solar power (CSP) solar collector technologies; (b) demonstrate results supporting that the proposed innovation meets or goes beyond the 6 cents per kWh levelized cost of electricity (LCOE) goals set forth by the SunShot Initiative (c) pursue clear market- and application-driven objectives and partnerships as part of a credible pathway to commercial development and eventual deployment. The novel optical approach consisted of a primary light bending optics converting normal incidence light to shallow angles which is then input onto a shallow secondary reflector which redirects and concenrates the light onto the evacuated solar tube.

14 SOLAR ENERGY↗

Project Plan: Salt in Situ Heater Test

This project plan gives a high-level description of the US Department of Energy Office of Nuclear Energy (DOE-NE) Spent Fuel and Waste Disposition (SFWD) campaign in situ borehole heater test project planned for the Waste Isolation Pilot Plant (WIPP) site, titled the Brine Availability Test in Salt (BATS). BATS is the first stage in a planned sequence of tests to bolster the technical basis for disposal of heat generating waste in salt. This plan provides an overview of the schedule and responsibilities of the parties involved. This project is a collaborative effort by Sandia, Los Alamos, and Lawrence Berkeley National Laboratories to execute a series of small-diameter borehole heater tests in salt for the DOE-NE SFWD campaign. Design of a heater test in salt at WIPP has evolved over several years. The experiment has begun in January 2020 and the first phase will continue for several months with the possibility for follow on testing. BATS comprises a suite of modular tests, which consist of a group of adjacent horizontal boreholes in the wall of drifts at WIPP. Each test is centered around a packer-isolated heated borehole (12.2 cm [4.81 diameter) containing equipment for water-vapor collection and borehole closure monitoring, surrounded by smaller-diameter (up to 5.3 cm [2.11 diameter) satellite observation boreholes. Observation boreholes contain grouted-in temperature sensors, electrical resistivity tomography (ERT) sensors, and fiber optics; packer-isolated tracer release and sampling intervals; and acoustic emission (AE) piezoelectric sensors. A larger-diameter (12.2 cm [4.81) satellite borehole includes sorel and salt cement plugs, as part of an engineered barrier sealing test. The first two tests, to be implemented in parallel, are heated (target borehole wall temperature of 120 °C) and unheated, with similar arrays of observation borehole monitoring changes. Follow-on tests will be designed using information gathered from the first two tests, and may be conducted at other borehole wall temperatures, use multiple observation boreholes, and may include different measurement types and test designs. This 2020 update of the original 2018 project plan satisfies DOE-NE Spent Fuel and Waste Science and Technology (SFWST) milestone M3SF-205N010303034, as part of the SNL "Salt Disposal R&D" work package.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Co-Extrusion (CoEx) for Cost Reduction of Advanced High-Energy-and-Power Battery Electrode Manufacturing

Co-Extrusion (CoEx) is a deposition technology developed at PARC that uses engineered fluidic channels to cause multiple streams of dissimilar fluids to impart shape to one another. Here, we describe the use of CoEx to produce structured cathode electrode films to improve electrochemical performance of thick electrode films. CoEx enables us to create structured electrode films that have periodic regions of enhanced ionic conductivity, enabling higher utilization of thicker cathode films at high discharge rates. While increasing electrode thickness is a known method for increasing energy density of battery electrodes, this increase in energy density typically also results in reduced power density. This project, a collaboration between the Palo Alto Research Center, Oak Ridge National Laboratories, and Ford Motor Company, seeks to first validate the benefits of CoEx at the coin cell level, before performing the necessary R&D effort to scale production up to large (10+ Ah) pouch cells that will show increased energy density without a reduction in power density. We used conventional battery materials (commercially available NMC, PVDF, carbon black, and graphite) to produce structured electrodes via CoEx and compared them to thick and thin conventionally produced (unstructured) battery electrodes. CoEx electrodes show improved high rate performance compared to unstructured electrodes, resulting in higher energy density pouch cells compared to the baseline electrode of 7 and 11% in volumetric and gravimetric energy density, respectively. These electrodes also showed substantially improved electrochemical performance at high discharge rates compared to thick conventional electrodes.

25 ENERGY STORAGE↗

Atomic Armor for Optoelectronics and Accelerator Technologies

Researchers at Los Alamos National Lab have developed Atomic Armor that is the first and only “invisible” shielding for technological devices. This one-atom-thick coating allows transmission of electrons and photons while blocking undesired gas molecules, thus extending a device’s lifetime while maximizing its functionality. It is the thinnest, most durable, most flexible, and customizable shielding ever made. The technology has been recognized with a R&D 100 Award and a Gold Special Recognition Award for Market Disruptor - Products.

36 MATERIALS SCIENCE↗

Further Support of the Development of Advanced Multilayer Optics Coatings for X-Ray Imaging

SAO is working with LLNL to develop Wolter-I optics for x-ray imaging applications at energies of 15-50 keV and above at NNSA facilities. Our work includes R&D on advanced multilayer coatings as well as fabrication and testing of Wolter-I multilayer coated optics. It also includes delivery of custom 3.05-meter focal length Wolter optics with response at energies of interest to Sandia National Laboratories and LLNL. The mandrels for the custom optics are fabricated at MSFC. In previous contracts, SAO delivered several optics to LLNL with response at various energies. During this present contract period two tasks were carried out. Task1: the coating, replication and characterization of a custom optic with peak response at 22.8 keV, using the custom-designed SANZ mandrels. Task2: carrying out modifications to the coating chamber at SAO to accommodate new, longer, custom-designed mandrels (SANZlong) that will be fabricated at NASA MSFC in FY2020. The longer mandrels are necessary to mitigate end effects observed in the replication process for the small optics currently being fabricated.

36 MATERIALS SCIENCE↗

Further Support of the Development of Advanced Multilayer Optics Coatings for X-Ray Imaging

The Smithsonian Astrophysical Observatory (SAO) is working with Lawrence Livermore National Laboratory (LLNL) to develop Wolter-I optics for x-ray imaging applications at energies of 15-50 keV and above for National Nuclear Security Administration (NNSA) facilities. SAO work includes R&D on advanced multilayer coatings as well as fabrication and testing of Wolter multilayer coated optics. It also includes delivery of custom 3.05-meter focal length Wolter optics with response at energies of interest to Sandia National Laboratories and LLNL. The optics are fabricated using an electroform nickel replication technique which has been used to fabricate optics for X-ray astronomy satellites over the past two decades. This technique starts with a figured, polished mandrel from which the optics are replicated. To carry this technique over to fabricate optics for NNSA facilities, several additional barriers had to be overcome to deposit multilayer coatings on integral optics with radii as small as 25 mm. These breakthroughs allow fabrication of optics which meet the spatial and spectral specifications required by NNSA facilities. During this present contract period SAO delivered four custom optics to LLNL with spectral response at or near the Kα line of silver, 22.16 keV.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Initial Evaluation of Fuel-Reactor Concepts for Advanced LEU Fuel Development

The National Nuclear Security Administration (NNSA) Office of Defense Nuclear Nonproliferation R&D has commenced a project to evaluate and develop low-enriched uranium (LEU) fuel systems, materials, and fabrication technologies that could be used for compact, advanced LEU (aLEU) fuel, power-producing, high-burnup reactor applications. Potential applications are intended to be off-grid power sources for ship-borne systems and transportable systems to fixed locations, e.g., to a remote base or to a seawater desalination service location. Reactors with these qualities and fuel enrichments between 5 and 20% are atypical. The aLEU Fuel for Nonproliferation Applications Project addresses this technology gap.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Hydrogen Refueling Reference Station Lot Size Analysis for Urban Sites

Hydrogen Fueling Infrastructure Research and Station Technology (H2FIRST) is a project initiated by the DOE in 2015 and executed by Sandia National Laboratories and the National Renewable Energy Laboratory to address R&D barriers to the deployment of hydrogen fueling infrastructure. One key barrier to the deployment of fueling stations is the land area they require (i.e. "footprint"). Space is particularly a constraint in dense urban areas where hydrogen demand is high but space for fueling stations is limited. This work presents current fire code requirements that inform station footprint, then identifies and quantifies opportunities to reduce footprint without altering the safety profile of fueling stations. Opportunities analyzed include potential new methods of hydrogen delivery, as well as alternative placements of station technologies (i.e. rooftop/underground fuel storage). As interest in heavy-duty fueling stations and other markets for hydrogen grows, this study can inform techniques to reduce the footprint of heavy-duty stations as well. This work characterizes generic designs for stations with a capacity of 600 kg/day hydrogen dispensed and 4 dispenser hoses. Three base case designs (delivered gas, delivered liquid, and on-site electrolysis production) have been modified in 5 different ways to study the impacts of recently released fire code changes, colocation with gasoline refueling, alternate delivery assumptions, underground storage of hydrogen, and rooftop storage of hydrogen, resulting in a total of 32 different station designs. The footprints of the base case stations range from 13,000 to 21,000 ft 2 . A significant focus of this study is the NFPA 2 requirements, especially the prescribed setback distances for bulk gaseous or liquid hydrogen storage. While the prescribed distances are large in some cases, these setback distances are found to have a nuanced impact on station lot size; considerations of the delivery truck path, traffic flow, parking, and convenience store location are also important. Station designs that utilize underground and rooftop storage can reduce footprint but may not be practical or economical. For example, burying hydrogen storage tanks underground can reduce footprint, but the cost savings they enable depend on the cost of burial and the cost land. Siting and economic analysis of station lot sizes illustrate the benefit of smaller station footprints in the flexibility and cost savings they can provide. This study can be used as a reference that provides examples of the key design differences that fueling stations can incorporate, the approximate sizes of generic station lots, and considerations that might be unique to particular designs.

08 HYDROGEN↗

Study of the Mu2e sensitivity to the $\mu^-\rightarrow e^+$ conversion process

The Mu2e experiment at Fermilab (Batavia, IL) will search for the coherent neutrinoless conversion of a muon into an electron in the electric field of an aluminum atom. The conversion process results in a monochromatic electron with energy slightly below the muon rest mass ($E_e= 104.97$ MeV). The experiment goal is to improve the previous measurement by four orders of magnitude and reach a single event sensitivity of $3 \times 10^{-17} $ on the conversion rate with respect to the muon capture rate. \\ The experiment will deliver a very intense pulsed negative muon beam to an aluminum target to achieve a total number of $10^{18}$ stopped muons in three years of running. Production and transport of the muons are accomplished with a sophisticated magnetic system comprised of a Production, a Transport and a Detector solenoid, with the last one hosting a Straw-tube Tracker and a Crystal Calorimeter. The entire detector region is surrounded by a Cosmic Ray Veto system. Mu2e is und er construction at the Muon Campus of Fermilab. \\ The INFN italian group is responsible for the design and construction of the crystal calorimeter, which plays a crucial role in the Mu2e measurement, providing particle identification capabilities fundamental for the rejection of the different background sources that can mimic a conversion electron. The calorimeter information allows also to improve the tracking performances it provides a fast standalone trigger for the experiment.\\ After a long R\&D phase, the final drawings see a calorimeter comprised of 1348 pure CsI crystals arranged in two annular disks. Each crystal is readout by two custom UV-extended Silicon Photomultipliers (SiPMs). Performances of the selected components were verified with an electron beam test, carried out in 2017 at the Beam Test Facility (BTF) at the National Laboratories of Frascati, on a large size prototype of 51 crystals and 102 SiPMs, confirming excellent energy ($\sigma_{E}/E = \mathcal{O }(10\%)$) and timing ($\sigma_{T} <500$ ps) resolutions in a! greement with the Mu2e specifications.\\ In the first chapters of this thesis, I describe my involvement in the calorimeter activities, with particular emphasis on the data analysis of the prototype energy response and resolution, that I was personally leading. Moreover, a description of the tuning of the simulation and the careful data-MC comparison is also reported.\\ An auxiliary measurement that can be performed with Mu2e is the search for a Lepton Number Violation (LNV) process where the negatively charged muon converts, without neutrinos, into a positron, $\mu ^{-} +N(A,Z) \rightarrow $ e$^+ +N(A,Z-2)$. At the moment of writing, Neutrinoless Double Beta Decay (0$\nu \beta \beta$) has set the most stringent limit on the LNV processes (T$^{0\nu \beta \beta}_{1/2} > 1.1 \times 10^{26} $ yr at 90$\%$ CL) with the GERDA experiment. In 0$\nu \beta \beta$ a pair of free electrons is created in the transformation from a nucleus $(A, Z)$ into its daughter $(A, Z + 2)$, namely: $(A,Z)\rightarrow (A, Z+2) =2 e^-$. Similar transitions could proceed through the emission of a pair of positrons, double electron capture (EC), or EC and single emission of a positron, with the nucleus changing from $(A, Z)$ to $(A, Z - 2)$. All these variations are equally interesting when discussing of new Physics, since they all manifest a non-conservation of the number of leptons.\\ Moreover, recent studies show that, because of flavor effect, off-diagonal processes, such as the $\mu^- -e^+$ conversion, can have their rate enhanced with respect to processes occurring in the $e-e$ sector.\\ Mu2e will search for $\mu^- + Al(27,13) \rightarrow e^+ +Na(27,11)$, only considering ground state transition, producing a conversion positron with energy $E_{e^+}= 92.32 $ MeV.\\ This thesis is focused on this search. In particular, I developed an algorithm to account for the radiative corrections to be applied to the conversion positrons that resulted in a few percent reduction in s ignal acceptance.\\ One of the most prominent background to ! this sear! ch is the Radiative Muon Capture (RMC) $ \mu+ N(Z,A)\rightarrow \gamma + \nu_{\mu} + N(Z-1,A)$. The produced photon can convert, virtually or in the detector materials (in the following referred as internal or external conversion respectively) in an electron-positron pair, producing positrons with energies approaching the expected conversion energy. Experimental results from previous experiments indicate the RMC endpoint ($\kmax$) to be of $\sim$ 90 MeV. A precise modeling of this background is relevant due to the proximity of the photon spectrum endpoint to the positron conversion energy. The calorimeter group is obviously interested to reconstruct the RMC distribution having also the opportunity to improve the current knowledge of the process. \\ A toy MC has been developed to evaluate the number of $e^+$ from external RMC background in the signal window. Knowing this value and ev...

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

Herbaceous Feedstock 2019 State of Technology Report

The U.S. Department of Energy (DOE) promotes the production of advanced liquid transportation fuels from lignocellulosic biomass by funding fundamental and applied research that advances the State of Technology (SOT). As part of its involvement with this mission, Idaho National Laboratory (INL) completes an annual SOT report for biomass feedstock logistics. This report summarizes supply system impacts of Bioenergy Technologies Office (BETO)-funded research and development efforts at INL and elsewhere (such as the High-Tonnage Feedstock Logistics projects (Webb et al. 2013a, Webb et al. 2013b, Webb et al. 2013c, Webb and Sokhansanj 2014, Sokhansanj et al. 2014)) that lead to improvements in feedstock supply systems. These include improvements to and observed performance of innovative harvest and collection methods, storage technologies, transportation and handling approaches, and advanced preprocessing technologies. Biomass quality and variability, and the interface between feedstock quality and conversion performance are key drivers in addition to delivered feedstock cost. In this report, we estimate the benefits of R&D improvements to individual supply system unit operations and present the status of feedstock logistics technology development for converting biomass into biofuels. These analyses are supported by experimental data where possible and help to align the SOT relative to the cost goals defined in the Multi-Year Program Plan. The 2019 Herbaceous SOT incorporates several technology changes in feedstock preprocessing and introduces opportunities from the integrated landscape management (ILM) strategy and increased grower participation to reduce biomass access costs, while maintaining or improving grower profitability. During FY18 uneven flow from the horizontal bale grinder was identified as a significant issue limiting preprocessing system throughput. Based on FSL-funded research at INL, the 2019 Herbaceous SOT replaces the horizontal bale grinder used in the first stage size reduction with a bale processor. The improved uniformity of biomass flow entering the PDU eliminated slugging flow from the first stage size reduction and improved the throughput of downstream operations. In order to achieve moisture reduction through frictional heating during grinding (which allowed elimination of the costly rotary drum dryer in previous SOTs), the second stage grinder was changed from a rotary shear, which does not remove moisture, back to a hammer mill. Finally, the 2019 Herbaceous SOT introduces modified three-pass and two-pass corn stover supply curves derived from the BT16 resource assessment, based on FY19 modeling results (WBS 4.2.1.20) quantifying economic benefits of ILM in the supply area, together with modeling results (WBS 1.2.1.5) identifying ILM strategies to increase grower participation. The 2019 Herbaceous SOT report documents the current modeled cost of an herbaceous feedstock supply system from harvest to the pretreatment reactor throat for hydrocarbon fuel production via biochemical conversion, based on equipment and processes now available or potentially available in the near term. The modeled cost also considers both the required quality and the availability of the biomass resources. The 2019 Herbaceous SOT predicts a modeled delivered feedstock cost of $81.37 /dry ton (2016$); this is a $2.30/dry ton (2016$) decrease from the 2018 Herbaceous SOT. Technology improvements that contributed to this modeled cost reduction include reduced cost for the new preprocessing design and quantification of the opportunities of the integrated landscape management (ILM) strategy and an increased grower participation rate to reduce the grower payment portion of biomass access costs, while maintaining or improving grower profitability. A greenhouse gas emissions (GHG) assessment was completed by Argonne National Laboratory using the 2019 Greenhouse Gases, Regulated Emissions, and Energy use in Transportation model, estimating an increase of 14.89 kg CO2e/ton from the 2018 SOT (69.27 kg CO2e/ton in 2018 to 84.16 kg CO2e/ton in 2019). The increase of energy consumption during preprocessing along with higher transportation distance to access low cost biomass from further distance contributed to the increase of GHG emissions in the 2019 Herbaceous SOT. The reason for the increased transportation distances was the cost tradeoff of going farther from the biorefinery to access the cheaper ILM-derived counties (the cheaper price outweighed the cost of increased supply radius).

09 BIOMASS FUELS↗

Analysis of Solutions for the Geologic Disposal of Dual-Purpose Canisters

Commercial spent nuclear fuel (SNF) is accumulating at 72 sites across the U.S., at the rate of about 2,000 metric tons of uranium (MTU) per year. There are currently more than 2,700 dualpurpose canisters (DPCs) loaded with SNF, which are designed for storage and transportation but not disposal. If current storage practices continue, about half the eventual total U.S. SNF inventory will be in about 5,500 dry storage systems by 2035, with the entire inventory stored in 10,000 or more by 2060. The quantity of SNF in DPCs is now much greater than that anticipated in the past, leading the DOE to investigate the technical feasibility of direct disposal of SNF in DPCs. Studies in 2013-2015 concluded that the main technical challenges for disposal of SNF in DPCs are thermal management, handling and emplacement of large, heavy waste packages, and postclosure criticality control (Hardin et al. 2015). Of these, postclosure criticality control is the most challenging, and the R&D needed for this aspect of DPC direct disposal is the primary focus of this report.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Science-informed Machine Learning to Increase Recovery Efficiency in Unconventional Reservoirs

Production of hydrocarbons from fractured, unconventional reservoirs is inherently inefficient. But machine learning offers a pathway both to increasing recovery efficiency at a site and to improving forecasts of production, thereby improving the economics of operations in unconventional reservoirs. Los Alamos—in partnership with DOE, NETL, and WVU—has been developing a science-informed workflow and platform for optimizing pressure-drawdown at a site, which will allow an operator to make reservoir-management decisions that optimize recovery in consideration of future production. This work relies on a hybridization of physics-based prediction and machine learning, whereby accurate synthetic data (in combination with available site data) can enable the application of machine learning methods for rapid forecasting and optimization. The physics-based prediction is built upon experimental and theoretical work to determine transport characteristics in shale at various scales, with an emphasis on materials from MSEEL-I; this fundamental shale R&D was conducted in partnership with DOE, NETL, and several other national labs. This work has resulted from a coordinated leveraging of developments across several projects within DOE FE30, along with internal investments from Los Alamos via LDRD. The development has utilized data from the MSEEL–I site for calibration and demonstration; however, the workflow and platform are readily extendable to operations at other sites, plays, and basins. This machine-learning method can aid operators to improve both recovery efficiency and competitiveness; to this end, future work would quantify processes for other plays/basins and integrate production details with economics.

04 OIL SHALES AND TAR SANDS↗

Production of Biocrude in an Advanced Photobioreactor-Based Biorefinery

Algenol Biotech, the National Renewable Energy Laboratory (NREL), Georgia Institute of Technology, Arizona State University, and Reliance Industries formed a team to advance the state of the art in algal biomass production and downstream processing technologies, with the end goal of a sustainable, economically viable biofuel intermediate (BFI, biocrude) product. The project included examination of high value co-product production as a market entry strategy and for enhancing the economics of a biorefinery for BFI production. The project targeted innovations in biology, operations, and engineering. The goals of the project were: BFI productivity greater than 4,000 gal-BFI/acre-yr on an annualized basis; energy efficient innovations in downstream operations resulting in an energy expenditure less than 10% of the BFI energy content and a carbon footprint reduction of more than 60% compared to fossil alternatives; and a comprehensive Techno-Economic Analysis (TEA) that identifies limiting factors for commercial viability of a photobioreactor (PBR)-based biofuel product. The project achieved the overall objectives. Strain development efforts led to the identification of a strain (Cyanobacterium sp. AB1166) that, relative to the previous best strain (Cyanobacterium sp. AB1), exhibited a ~10% increase in productivity under commercially-relevant cultivation conditions and also resulted in cultures with a >50% reduction in viscosity such that harvesting efficiency was improved; these results represent achievement of key project milestones. Progress was also made at NREL in altering the biochemical composition of algal biomass to improve the yield of BFI produced via HTL. These strain enhancements coupled with improved outdoor cultivation practices, including semi-continuous operation, increased areal biomass productivity by nearly 80% over the established baseline productivity. The annualized productivity achieved (26.8 g/m2-d), paired with HTL conversion yields realized at NREL and RIL (38% ± 2% BFI), translates to 4,100 gal-BFI/acre-yr, exceeding the FY20 BETO goal of 3,700 gal-BFI/acre-yr. Significant progress was also demonstrated in large scale PBR-based production system design, operability, and cost reduction. A 24,000-L production module comprised of 240 interlinked PBRs was constructed and successfully operated outdoors for over one year in Fort Myers, Florida. Aided by a state-of-the-art productivity model, the productivities achieved convincingly demonstrated scalability of laboratory results determined at the mL to L scale to large-scale outdoor operations exceeding 20,000 L. The system was used to cultivate Arthrospira platensis (Spirulina), an industrially-relevant cyanobacterium and source for phycocyanin, an approved blue food colorant that Algenol is developing as a risk reduction strategy for future biofuel projects and as a potential business opportunity. A key project milestone to develop phycocyanin extraction and purification technologies was achieved ahead of schedule, and product samples received positive feedback from potential customers. The production and downstream operations data generated in this project were used to conduct and refine Techno-Economic and Life Cycle Assessments to provide research guidance for reducing the costs and environmental footprint of algal biofuel and co-product manufacturing plants. Several CO 2 supply scenarios for an algal biorefinery were identified as being capable of providing a large (>60%) reduction in carbon footprint in comparison to gasoline. The TEA assessments incorporated detailed comparisons of PBR versus open pond production systems, yielding a 3-fold higher areal productivity for PBRs and suggesting overall production cost parity for the two systems. The progress in this ABY2 project addressed many of the the barriers identified for the Advanced Algal Systems R&D Program and are directly relevant to achieving the established BETO goals associated with large scale biofuel production and cost reduction.

09 BIOMASS FUELS↗

Cost Efficient and Highly Weather-Resistant Solar Panel Backsheet Produced through Continuous Co-Extrusion Processing

The efficient generation and delivery of ‘clean energy” through photovoltaic (PV) technology relies heavily on the cost, performance and reliability of solar panels, along with the individual components used in assembly of those panels. In order to continue towards the Department of Energy’s (DOE) goals of driving costs down, the lifetime of high-output power generation equipment (i.e. solar modules) must be extended to reduce costs associated with power output degradation and replacement of failed or degraded panels. One of the major sources of module failures in the past 30 years has been the failure of the solar panel backsheet. Failure of this component causes severe output losses due to oxidation and yellowing of the module while creating safety concerns as the major electrical insulation of the module is compromised. Tomark-Worthen LLC was formed in 2012 with the goal of designing and manufacturing novel PV backsheets and encapsulants that would be produced in the United States of America and exceed expectations of domestic and international module producers. These backsheets would improve upon known backsheet design failures (i.e. Isovoltaic’s AAA backsheet) and create domestic manufacturing jobs in the PV sector. This goal became a reality with a first-generation product in 2018 and now, with the support of the DOE, Tomark-Worthen has launched a second-generation product known as PhotoMark® Reflections™ 205-3 and 360-3. This 2+ year effort began in late 2017 with a screening of potential polymeric materials and backsheet structural designs. Performance evaluations of each material provided the necessary data needed to select the proper material combinations and move forward into the design of the manufacturing process. These decisions were made by teaming with a local university, well-respected government laboratories, and private research organizations who provided the tools necessary to predict long-term performance of these materials in much shorter periods of time. Once the go/no-go criteria were met at the mid-point of the project, the effort transitioned to predicting 30+ year performance, achieving certifications, and improving manufacturing efficiencies designed to lower costs in order to be competitive in a cost-driven market. Major project accomplishments include recognition of the new backsheet by Underwriters Laboratories (UL) and international certification for 1000V and 1500V modules by TUV Sud. Both 1000V and 1500V products have been proven on several module manufacturing lines and initial customer orders have been received by both domestic and international module producers. Accelerated exposure testing has shown that the performance of this backsheet exceeds the prior polyamide-based backsheet known to fail in the field. Cost-models and initial customer orders have shown the ability to produce this backsheet at a cost acceptable to many domestic manufacturers, while International costs for standard backsheet remains extremely low. Tomark-Worthen remains one of the only U.S. companies manufacturing backsheet domestically and this has drawn interest from many domestic module manufacturers looking to improve their material supply logistics by avoiding long lead times and custom’s headaches while avoiding current tariffs on Chinese-made components. Along with the launch of a new PV backsheet, this project has provided a critical deliverable to the PV R&D community. This deliverable is the knowledge that not all polyamide-containing backsheets are doomed to failure as the earlier versions did. There has been a fear amongst the PV community to consider these materials due to the failure of one design. This effort has brought a new level of interest to the scientific community as it has been shown that polyamides can be used successfully in a well-designed backsheet. As we move forward from this project, we are excited to see how backsheet technology and manufacturing in the U.S. will continue to progress and grow.

14 SOLAR ENERGY↗

Filtration Performance Results: Sierra Peaks Material No. 4

Sandia National Laboratories (SNL) assessed the filtration performance of materials from Sierra Peaks to identify alternatives which may perform similarly to materials used in FDA-approved N95 respirators. This work is meant to characterize the aerosol performance of materials to give Sierra Peaks information for them to determine if they elect to submit masks made using these materials for follow-on N95 certification testing at an accredited facility. The R&D testbed used is a large-scale filtration system designed to test commercial filter boxes. System modifications were performed to simulate, where possible, parameters defined by the National Institute for Occupational Safety and Health (NIOSH) for certification of filter materials for N95 respirators (NIOSH 2019). The system is a pull-through design. Air enters through a Laminar Flow Element (LFE) and the volumetric flow is measured based on the pressure drop across the LFE. Pressure is measured via a Pressure Transducer (PT). The air then passes through a High Efficiency Particulate Air (HEPA) filter to purge the air of ambient airborne particulates. Test aerosol is injected into the flow shortly after and mixing is induced via a coarse mesh. The airflow is allowed to fully develop prior to arriving at the test section. The aerosol then passes through the test material mounted in a box in the test section. Pressure drop across the test article is measured and aerosol sampling probes measure the aerosol concentrations upstream and downstream of the sample. The air passes through a second HEPA filter prior to being exhausted to ambient by a blower. A Topas aerosol generator is used to produce the test aerosol from Sodium Chloride (NaC1) dissolved in deionized (DI) water. Generated aerosol passes through a heated mixing chamber and a desiccant dryer to produce nanosized solid-state particulates. A dilution loop allows for the aerosol concentration to be regulated. The aerosol sampling probes upstream and downstream of the test section are aligned with the flow path. These are ducted directly to the aerosol sizing and counting instruments. A Laser Aerosol Spectrometer (LAS) was used for data collection in the original configuration of the system and was also used for initial testing in this project. Because the lower measurement range for the LAS is 90 nanometers (nm), the LAS was switched out for a more complicated Scanning Mobility Particle Sizer (SMPS) spectrometer system. The SMPS is comprised of an Electrostatic Classifier (EC), Differential Mobility Analyzer (DMA), and a Condensation Particle Counter (CPC). This enabled data collection at 75 nm, the particle size called out in the NIOSH guidelines.

36 MATERIALS SCIENCE↗

Evaluation of Steam Cycle Upgrades to Improve the Competitiveness of U.S. Coal Power Plants (Final Scientific / Technical Report)

Increasing the competitiveness of the existing pulverized-coal utility fleet in the United States may be achieved by decreasing heat rate, via increases in steam cycle efficiency through upgraded steam temperatures and use of latest technology available in steam turbine and blading design. The average net plant efficiency of the US coal-fired fleet is approximately 33% (HHV). Plant efficiency increases to approximately 41.4% (HHV) at 1,350°F (732°C) steam temperature. However, achieving these Advanced Ultra-Super Critical (AUSC) steam conditions requires the use of advanced high-temperature materials. While there has been a significant amount of DOE-funded materials R&D, most of the related design work has focused on new (greenfield) units, rather than on opportunities to retrofit this advanced technology to the existing utility fleet. If technology, based upon the advanced materials required for AUSC steam conditions, may be applied to the existing fleet, using an economically viable retrofit, a higher capacity factor can be expected as a result of the increased plant competitiveness. The Electric Power Research Institute (EPRI) was awarded a project by the US Department of Energy to examine the technical and economic feasibility of a series of steam cycle upgrades to the two most prevalent types of U.S. coal power plants: 2,400 psig (16.6 MPa) subcritical and 3,500 psig (24.1 MPa) supercritical pulverized coal units. The nine upgrade options that were originally being considered included increasing the main and reheat steam temperatures from 1,000°F (538°C) to 1,100°, 1,200°, and 1,350°F (593°C, 649°C, and 732°C) while holding the steam pressures constant at their original design values, and cases where just the main steam or reheat steam temperatures were increased. The objective was to minimize the modifications required to the existing power plant while still providing a significant improvement in heat rate. The upgrade options assumed that the boiler enclosure envelope remained unchanged from each base case, and that all applicable OEM design guidelines for normal commercial units were imposed. For the highest temperature supercritical case, an option of using a low-pressure molten salt loop to transfer heat from the furnace to the steam was examined. The first major task of the work scope was designed to examine the technical feasibility of various upgrade options, while the subsequent work determined economic viability of the technically feasible upgrade options. Prior to evaluating the effect of these increased temperatures, a “base case” model of a subcritical and supercritical PC boiler was created, which was used for comparative purposes. Upgrade options were evaluated at full-load, part-load and dynamic transient conditions. Once the technical feasibility of each upgrade option was evaluated, the economic value of the heat rate improvement of each feasible option was determined by detailed modeling of unit dispatch in several regional power markets. The dispatch model was used to estimate the amount of revenue from power sales the upgraded unit would receive in comparison to a non-upgraded version of the same power plant. As a parallel task to the dispatch analysis, the capital cost of implementing the upgrades was estimated. The capital cost estimates were then compared to the increased revenue estimated by the dispatch modeling to determine the economic attractiveness of each upgrade option. Several upgrade options were determined to be technically feasible. The net present value (NPV) of the costs for steam cycle upgrades considered in this study ranged from approximately $\$$111 to $\$$130 million. The economic modeling results show that the unit dispatch changes resulting from steam cycle upgrades are relatively small, due largely to heat rate (and operating cost) changes being relatively small. Additionally, the cost of each upgrade exceeds the net revenue increases associated with the upgrade case. Note that the breakeven values are higher for subcritical retrofits, but the capital costs for the subcritical upgrades are also slightly higher. In typical new pulverized coal plants, fuel accounts for approximately 25% of the cost of electricity (COE), while capital costs represent around 50% of the COE. Therefore, in order to improve the heat rate by 4% one can only afford to increase the capital cost by 2%, at the same cost of electricity. The conclusion of this study is that without a cost for emitting CO 2 , it will be difficult to pay for significant efficiency improvements on plants firing low cost coals.

01 COAL, LIGNITE, AND PEAT↗

VersaBuild: A Novel, Multi-scale, Versatile 3d Printer Concept

Our team has identified and attempted to solve a major challenge limiting the increased deployment of additive manufacturing in full-scale production environments. As engineers desire for greater flexibility of design grows, and as the diversity of properties achievable and materials usable in additive manufacturing increases, additive manufacturing becomes increasingly valuable and useful. However, the machines used to produce AM parts have largely stagnated in terms of configurability, technology, and design. We have conceptualized a system which enables a single machine to provide the functionality of multiple machines, with minimal operator changes. The gap that was identified by the team was the lack of a system that could accept user-configurable changes to the print resolution and printbed size. This would enable manufacturers flexibility in the size, quality, and quantity of parts produced in a facility of a given size. Significant floorspace savings could be achieved in a facility deploying our proposed solution due to the flexibility of the machine, lowering operational cost. Our envisioned design is similar in concept to a standard Delta robot, which is a three-armed robot that is used in many industrial applications. However, we intend for our design to have extensible delta arms that include position sensing, allowing for a greater range of motion and thus print volume while maintaining precise control over the printhead position. Some of the key risks associated with are system are caused by the novelty of the concept. Our system must undergo significant R&D and requires a fully integrated software, electrical, and mechanical system to be developed.

42 ENGINEERING↗

HOSS: Hybrid Optimization Software Suite

HOSS software, developed at LANL, is a powerful, flexible, and parallelized package that enables the user to predict deformation and failure of materials in a variety of situations. LANL’s HOSS software is an R&D 100 finalist that integrates solid mechanics and computational fluid dynamics into a multi-physics platform able to handle millions of interacting and fracturing solids and/or particle systems. This nextgeneration simulation software integrates solid mechanics and computational fluid dynamics into a multi-physics platform able to provide state-of-the-art simulation solutions for a wide field of applications including oil and gas, construction, mining, defense, material sciences, and biomechanics.

36 MATERIALS SCIENCE↗