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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 991 records · Page 55

Critical Minerals and Rare Earth Elements in Powder River Basin Coal and Associated Sediments, Wyoming, USA

The demand for Rare Earth Elements (REE) and other critical minerals (CM) required for consumer products, defense-related applications, and low-carbon energy technology is increasing rapidly. Unconventional sources of REE/CM, such as coal and associated sediments, could prove very important in building resilient and ethical energy supply chains. Utilization of existing infrastructure and the highly trained energy workforce in traditionally coal-producing regions in emerging REE/CM industries could provide an economic boost to coal communities. The Powder River Basin (PRB) of Wyoming and Montana, USA, is a prime candidate to investigate the feasibility of extracting REE/CM from coal and associated sediments. The PRB hosts thick (>50 ft) coal seams that are mined at the surface and more than 40% of the coal produced in the US comes from the PRB. Geochemical data from multiple locations in PRB coal systems show REE enrichments at the top and bottom margins and at internal partings in coal seams. This trend is exhibited in two cores drilled at Peabody’s North Antelope Rochelle mine in the east central PRB, the largest coal mine in the world. The two cores include the Wyodak Anderson coal zone as well as the over- and underlying shale units. The Wyodak Anderson coal zone is part of the Paleocene Tongue River Member of the Fort Union Formation in which most of the coal resources in the PRB reside. To understand REE/CM enrichment, a total of 188 samples were analyzed for their major and trace element chemistry from both cores, sampled at one foot or smaller intervals. The two cores show distinct REE enrichments in the uppermost and lowermost 3 to 12 feet of the Wyodak Anderson coal zone, as well as enrichments in bounding carbonaceous shale units. Total REE+Y (REY) concentrations as high as 2510 ppm (all concentrations reported on an ash basis), or 15 times average upper continental crust values (Taylor and McLennan, 1995), were identified in the coal. Partings within the coal zone also show relative REE enrichment, with concentrations up to 485 ppm REY. The remaining interior portions of the coal zone contain lower concentrations of REE, resulting in an average REY for all samples from both cores of 288 ppm. The proportion of high-value critical REE (Nd, Eu, Tb, Dy, Er, Y) compared to REY averages 36%, which is higher than the critical REE proportion in average upper continental crust of 33%. This finding highlights the relative enrichment of middle REE compared to light REE, in contrast to many conventional REE deposits. Other critical trace elements that show enrichments above average upper continental crust include Ga, Nb, and V. Within this sample suite, Ga concentrations range from 2.8 to 213 ppm, with an average of 29 ppm; Nb from 2.9 to 166 ppm with an average of 26 ppm; and V from 27 to 1695 ppm with an average of 188 ppm. None of these trace elements exhibit the same distinct pattern of enrichment as REE in the upper and lower bounding layers and internal partings of the coal zone. Major element chemistry indicates CaO concentrations averaging ~25% in the coal samples from both cores, which has important implications for the extractability of REE from coal. Calcium-rich PRB coal has been shown to be more amenable to REE extraction than lower calcium coals by some methods (Stuckman et al., 2019; Taggart et al., 2016), highlighting the importance of REE extractability in addition to REE concentration in assessing the value of potential feedstocks. The original coal resource in the PRB is estimated at 1.16 trillion short tons (Luppens et al., 2015). Thus, the PRB represents an important potential unconventional source for REE and other CM. Ongoing research to fully characterize the REE/CM resource, identify enrichment mechanisms, and further develop and scale extraction technologies is necessary to understand the full potential of this resource.

Phillips, Erin↗

Zero Energy Ready Out of the Box

In this conference paper for the ASHRAE Buildings XV conference, December 2022, PNNL staff share key metrics for companies who are combining off site construction with certification to the U.S. Department of Energy’s Zero Energy Ready Home program to create homes that are both cost effective to construct and high performance to live in. Key performance metrics and measures for modular, panelized, and SIP homes are compared against all homes in the DOE Zero Energy Ready Home program and against new homes built to code. These metrics show that off-site construction homes got similar or better energy performance to site-built homes, and in the case of modular and panelized, at considerably lower average cost than site-built homes. The paper also highlights the experiences of two DOE Zero Energy Ready Home builders who employ offsite construction methods. One builder constructs production homes using pre-assembled panels. The other builder designs and ships kit homes all over the United States. The paper will focus on the optimum value engineering aspects of the panelized construction processes used by each builder to identify management and production practices employed by the builders to operate profitably while meeting high energy performance goals, despite a year marked by skyrocketing materials costs and supply chain and labor shortages. Cost and labor savings methods will be discussed in the context of these two unique business models.

U.S. Department of Energy Building Technologies Pr↗

Thin Triples Expand the Affordable High-Performance Window Options For Retrofit

Sales of high-performance triple-pane windows make up only a small fraction (~3%) of total window sales in the United States with relatively stagnant market growth over the past 20 years. High costs have been the most commonly cited barrier to adoption. The emergence of thin triples that can fit into the glazing pocket of existing double pane windows has the potential to revolutionize the high-performance window market in particular the retrofit market by enabling glass only upgrades for situations where the frames are still in good condition. The retrofit market has other unique challenges not found in new construction that can be solved or reduced by thin triple pane windows. Insert replacements are often pursued instead of full frame replacement, in retrofits, this method reduces the net free area of a window and can turn an egress window into one that no longer meets the net free area requirements for egress. Thin frames minimize such occurrences. However, these thin frames can often not accommodate the weight of a traditional triple pane, thin triples can bring high performance to this situation. Thicker frames can also increase retrofit labor costs because the interior drywall and/or trim molding needs to be cut back to accommodate a thicker frame while thin triples can fit into frames that match the thickness of the existing window. This paper presents information about field test experiences the highlight these retrofit advantages from experiencing the challenges associated with retrofitting a thick frame as well as the supply chain, purchasability, material and labor costs, and real-world energy and non-energy performance associated with the IGU only replacement method.

window retrofits, thin triple-pane windows, high p↗

Summary Analysis of Different Offshore Wind Capacity Density Drivers in Proposed U.S. Projects and Impacts on Progress Towards State and Federal Deployment Targets

Understanding the density of offshore wind development - or the "capacity density" - is important for state and federal offshore wind planning efforts and to track progress towards policy goals. NREL has traditionally assumed a capacity density of 3 megawatts per square kilometer (MW/km2) when estimating the U.S. project pipeline (Musial et al. 2022), but capacity densities for existing European offshore wind farms ranged from 2-19 MW/km2 (Borrmann et al. 2018). We track the expected capacity densities of the proposed U.S. projects in the East Coast and make an analysis by state and by developer to identify what are the capacity density norms in the industry and whether the state in which the development efforts are taking place has some impact on capacity density. We also analyze the effects of the area occupied by station keeping systems on capacity density for lease areas dedicated to floating projects and provide a list of main capacity density drivers. This summary analysis sets a baseline to study how different capacity density drivers could impact the progress towards state and federal deployment targets. Given the currently delineated Renewable Energy Areas in the Outer Continental Shelf (OCS) and the basis from the summary analysis, we estimate the expected offshore wind deployment over time federally and by state and compare it to the state and federal deployment targets. The proposed analysis helps identify gaps and needs to meet state and federal targets, which provides sufficient information to propose strategic supply chain and policy planning with the objective of meeting deployment goals.

capacity density↗

Biofuel Air Emissions Analysis

U.S. has goals to produce 3 billion gallons of sustainable aviation fuel (SAF) annually by 2030, increasing to 35 billion gallons by 2050 to decarbonize the aviation sector. Meeting these production targets will require large number of biorefineries to be set up. However, ability to comply with federal air quality standards is prerequisite to being issued a construction permit. Negotiating the permitting process for a new biorefinery can be quite onerous and cost the investors significant time and money. Although there can be numerous reasons for delayed biorefinery construction, air permitting is fraught with pitfalls because the permitting process relies on precedence, which the future SAF biorefineries lack. NREL's Biofuel Air Emissions Analysis project is unique and innovative in terms of the tools, approaches, and analyses provided. NREL is the only national laboratory that is actively working at the intersection of Federal air quality regulations, emissions and air quality analysis across the supply chain, and process design. This project is focused on providing much needed data and analyses that address biorefinery air permitting. This project develops models and quantitative analyses and measures progress towards meeting air quality regulatory requirements. These models and methods are applied to analyze air permitting related to wastewater sludge to biofuel conversion pathways using hydrothermal liquefaction (HTL), impacts of HTL pathway on local and regional air quality including an assessment of health and equity impacts. In addition to filling research gaps, this project also disseminates the findings to the relevant stakeholders at BETO, other national labs, and regulatory agencies.

air quality↗

LWRS 2019 Accomplishments Report

Nuclear energy is an important part of supplying our nation’s energy—safely, dependably, and economically—with reduced carbon dioxide emissions. The United States (U.S.) Department of Energy-Office of Nuclear Energy (DOE-NE) supports a strong and viable domestic nuclear industry. In collaboration with industry programs, the Light Water Reactor Sustainability (LWRS) Program supports the continued operation of the commercial fleet of nuclear power plants. DOE’s role in this program focuses on enhancing the safe, efficient, and economical performance of the nation’s nuclear fleet. This report describes the accomplishments of the LWRS Program during Fiscal Year 2019. DOE-NE’s0F primary mission is to advance nuclear power as a resource capable of making major contributions in meeting the nation’s energy supply, environmental, and energy security needs. Under the guidance of three research objectives, NE resolves barriers to technical, cost, safety, security, and proliferation resistance through early stage research, development, and demonstration (RD&D) to: • Enhance the long-term viability and competitiveness of the existing U.S. reactor fleet • Develop an advanced reactor pipeline • Implement and maintain national strategic fuel-cycle and supply-chain infrastructures.

42 ENGINEERING↗

Fast Reactor Materials R&D Update

Presentation detailing Major focus: Deployment of A709 for fast reactor structural applications in the area of Design, Fabrication, Supply Chain, and Adx Rx Operation. Also discuss additional work to support A709 development, High level timeline for Irradiation design data, and processing parameters.

36 MATERIALS SCIENCE↗

Securing Solar for the Grid: Spring 2024 IAB Meeting

The Spring 2024 IAB meeting will focus on updates from the research team and collective feedback and inputs for an updated Roadmap for Solar Cybersecurity. Researchers from the four DOE National Laboratories will present with industry counterparts for the major research tasks within the S2G program, including: Solar Cybersecurity Standards and Certifications, Solar Risk Assessments & Mitigation, Solar Supply Chain Assessment, Network Monitoring Tools and Analysis, and Training and Workforce Development. Sandia National Laboratories developed an original Roadmap for PV Cybersecurity in 2017. This year, we are updating that roadmap to reflect the current state of research and industry and identify gaps and priorities still to be addressed. We look forward to the IAB’s input on key topics for the roadmap.

14 SOLAR ENERGY↗

Power Electronics for Electrolyzer Applications to Enable Grid Services

The Power Electronics for Electrolyzer Applications to Enable Grid Services project aims to develop smart converter for dedicated electrolyzer applications to enable grid services via standardization of control interfaces between hydrogen electrolyzer system low-level controls and power converter controls. The project provides additional revenue source for electrolyzer through participation in grid services and reduces the cost of deployment and controls integration through standardization and risk due to supply-chain issues. It also enables the adoption of green hydrogen via standardizing the integration of energy storage, renewables, and distributed energy resources. Furthermore, the work provides a controlled validation environment to evaluate scalable integration solution for hydrogen production technologies, improves overall reliability and maintainability of the electrolyzer system for grid applications, and directly contributes to DOE HFTO's "Hydrogen Shot" goal.

energy transitions↗

Securing Solar for the Grid (S2G): SETO Peer Review

In this session at the SETO Peer Review, several solar cybersecurity projects will be discussed. INL will provide an overview of the multi-lab Securing Solar for the Grid (S2G) project. We will highlight the focus areas of standards development and best practices, cybersecurity tool kits and supply chain analysis, and education and workforce development.

14 SOLAR ENERGY↗

Ad-Mat: Adaptations of Mature Manufacturing Strategies for Accelerated Redox Flow Battery Deployment

The concept of the Ad-Mat approach is to leverage existing adjacent markets across a broad scope of technologies in order to reduce the manufacturing learning curve and ultimately accelerate redox flow battery (RFB) deployment at scale. Lithium-ion batteries (LIBs) are currently the dominant energy storage technology, and they came to technological maturity under unique market conditions when there was no meaningful competition in the consumer electronic and electric vehicle (EV) space. Today, alternative chemistries that may be technologically better-suited for long-duration storage applications are experiencing a high barrier to entry. This is in large part due to the substantial bias towards the scaled-up production and supply chain that now exists for LIBs. In the case of RFBs in particular, numerous analyses have suggested that RFBs should theoretically have a much lower system cost than LIBs - however, this relies on a mature and competitive manufacturing landscape, which has been extremely challenging to achieve for both flow batteries and other LIB competitors. At the moment, LIB alternatives tend to have isolated small-scale manufacturing pathways, which preclude the economies of scale that would be required to compete with the mature LIB industry. In the present state of the industry, niche manufacturing tools and approaches have evolved to support each alternative technology, such that there is substantial replication and duplication in effort. Continuing to pursue a strategy of isolated manufacturing processes/approaches for each LIB-alternative may never allow for at-scale deployment. In order for RFBs to meaningfully compete with LIBs in the realm of LDES, a new disruptive approach based on cross-industry learning and coordination is needed - and this is exactly what our Ad-Mat concept aims to tackle. In this re-envisioned manufacturing landscape, tools and processes from mature industries can be adapted and deployed across the range of alternative energy storage technologies. Adapting tools, equipment, processes, and industrial learning from mature industries to meet the technological requirements of RFBs would open new markets for existing OEMs in adjacent industries, would prevent unnecessary duplication and re-development, would improve efficiency across the manufacturing chain, and would ultimately support reduced costs and accelerated deployment of RFBs at scale.

adaptive manufacturing↗

Miscanthus: An Environmental Choice for Marginal Lands

Miscanthus x giganteus, or Giant Miscanthus, is a tall, perennial grass originally from Asia. It is considered a sterile hybrid that has been bred to not produce viable seeds. Instead, rhizomes are planted to establish the crop. Here, the rhizome is an underground modified stem mass that puts out shoots and roots supporting new growth each year. This perennial crop takes two to three years to reach maturity, but established stands can reach upwards of 12 ft. tall with a very thick canopy (Pyter, 2007). Miscanthus has shown potential for high dry matter yields compared to other biomass crops, which could in turn lead to more efficient land use especially when applied to a bioenergy and bioproduct supply chain. In one study, switchgrass (Panicum virgatum) yielded 10.3 Mg/ha of biomass on average, while miscanthus yielded 22.4 Mg/ha (Heaton et al., 2004). Additionally, miscanthus production has been associated with many environmental benefits, including benefits to water quality, nutrient load removal, soil stabilization, and soil health (Bhardwaj et al., 2011; Hussain et al., 2019). Many of the possible practical and environmental benefits that are associated with miscanthus production may be attractive to stakeholders who are interested in alternative land use options, particularly in areas considered to be marginal in productivity.

54 ENVIRONMENTAL SCIENCES↗

Conceptualizing Energy Security and Resilience

Climate resilience and energy resilience are inextricably linked, since the transition to a safe and secure grid powered by renewables is central to both adaptation and mitigation efforts. As geopolitical tensions intensify and it becomes clear how integral supply chains are to our clean energy future, the term "energy security" has become a central concept, similar to resilience in the climate and energy lexicon. This project seeks to understand the role of energy system resilience within energy security. The key research questions are: "How are energy system resilience and energy security related?" and "What is the role of renewables within both security and resilience?" A strong conceptual understanding of these terms will set the stage for truly accelerating secure and resilient innovations at scale.

climate resilience↗

Heavy-Duty Hydrogen Fueling Station Corridors

In this short technical report, we explore the range of levelized costs of dispensed hydrogen (H2) from hydrogen refueling (or fueling) stations (HRS) for H2 heavy-duty fuel cell electric vehicles (FCEVs) that are feasible in the 2030 timeframe. We explore different scenarios by varying hydrogen delivery distances, HRS sizes, HRS utilization rates, and economies of scale in the Hydrogen Delivery Scenario Analysis Model (HDSAM). Thus, we observe how the contribution to the levelized cost of each supply chain component changes.

DIRECT ENERGY CONVERSION,HYDROGEN↗

Options for Achieving Cost Reduction in Advanced Reactors through Open Architecture

A key contributor to high capital costs and schedule overruns for new nuclear power plants is lack of standardization, driven by site-specific customization and construction of multiple designs by competing vendors rather than commitment to a single standardized program. While advanced reactor vendors typically individually target repeat construction of standardized units, the many competing designs could exacerbate the problem. “Open Architecture”, the open specification of requirements and interfaces for structures, systems and components (SSCs), has been proposed as a means of promoting standardization, by facilitating existing non-nuclear suppliers to enter the industry and/or allowing SSCs to be configured for more than one reactor within the same technology type. Contracting mechanisms that facilitate information sharing and alignment of incentives between stakeholders may complement such an approach. A preliminary scheme is presented for selection of SSCs for which such strategies could be adopted, based on a vendor make/buy decision model and stakeholder interviews. SSCs are categorized according to number of suppliers and their contribution to the reactor’s competitive edge. SSCs with many potential suppliers and a high contribution to competitive edge may be attractive for widening the supply chain via open specification of system requirements and interfaces, e.g., SSCs in the power island. SSCs with few suppliers and low contribution to competitive edge may be potential avenues for common system specification between vendors, e.g., some of the auxiliary SSCs. Potential cost reductions from such strategies will depend upon the size of the build program and the reactor type.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

SMR Current Status: Development Needs and Global Perspectives

Defined as nuclear reactors with a power output up to 300 megawatts electrical (MWe) by the International Atomic Energy Agency (IAEA) and targeted for multipurpose applications, small modular reactors (SMRs) have been recognized as a very promising, clean, affordable, and sustainable energy source by many countries. At present, more than 80 SMRs are under design, development, demonstration, deployment, and beyond (4D+) phases worldwide. This study focuses on the current world status of SMRs and focuses on the necessary developments to accelerate the process of adopting SMRs as a major energy source globally. SMRs are not a new concept, but they do represent a new vision for older concepts if the challenges inherent within them are mitigated with strategic and realistic solution approaches. The major challenges for SMRs 4D+ like any new reactors are: (a) qualifying the advanced fuel-to-reactor design; (b) supporting rapid scaled/prototypic experimentations; (c) maintaining local and global codes, standards, and licensing; (d) supply chain issues;(e) effective cradle-to-grave nuclear fuel cycle and fuel material transportation, and (f) mitigating financial and environmental risks. These upfront challenges can be mitigated with a synergistic solution approach among the various stakeholders: industry, academia, research, government, and international entities.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Advanced Fuels Campaign Execution Plan

The Advanced Fuels Campaign (AFC) Execution Plan outlines the strategy, mission, scope, near-term and long-term goals, structure, and organization associated with nuclear fuels and materials research, development, and demonstration activities within the Department of Energy’s (DOE) Nuclear Fuel Cycle and Supply Chain (NFCSC) program. NFCSC has been given responsibility to identify and mature advanced fuel technologies for the DOE using a science-based approach, focused on developing a fundamental understanding of nuclear fuels and materials to drive development of integrated nuclear fuel and materials technology. This science-based approach combines theory, experiments, and multiscale modeling and simulation to achieve a predictive understanding of relevant behaviors ranging from fuel fabrication processes (and their resulting fuel microstructures) through fuel/cladding performance under irradiation (in contrast to more empirical, observation-based approaches frequently used in fuel performance modeling and fuel qualification). The traditional scope of AFC includes the evaluation and development of multiple fuel forms to support two fuel cycle options: once-through and full recycle. The word “fuel” is used generically to include conventional fuels, transmutation targets, and any associated cladding or duct materials. The once-through fuel cycle addresses advanced light water reactor fuels with enhanced performance, extended burnup, and reduced waste generation. In fiscal year (FY) 2012, AFC’s scope expanded to include research, development, and demonstration (RD&D) for light water reactor (LWR) fuels with enhanced accident tolerance. Fuel fabrication activities include the development of innovative methods to enhance process efficiencies, reduce waste, and improve control over as-fabricated fuel microstructural properties to achieve desired in-reactor performance. Using modern modeling and simulation approaches, the objective is to predict fresh fuel properties given the feedstock characteristics and fabrication process parameters. The performance-related activities include small-scale, in-reactor, and out-of-reactor phenomenological testing (distinct from, but synergistic with, integral prototypic testing) and extensive, quantitative characterization (focusing on characterization of fuel and cladding materials at the scale of microstructure) both before and after testing. Larger-scale, prototypic experiments are conducted in concert with phenomenological testing to drive a Fuel Development and Qualification program, incorporating a fundamental understanding of fuel behavior performance characteristics. Then, using the tools developed under the productive science-based approach, fuels will be optimized to meet specific performance requirements, thereby minimizing the need to repeatedly perform large-scale, integral experiments over a wide parametric range as a means of experimental exploration. Two significant initiatives are underway within AFC. First, a gap analysis completed in early FY 2019 identified critical irradiation testing needs that are lacking within the national light water reactor (LWR) fuels testbed since the shutdown of the Halden Reactor in 2018. The identified gaps are for instrumented, prototypic testing of LWR fuels, especially under boiling water reactor conditions, ramp conditions, and conditions leading to fuel failure; these needs exist for supporting current LWR fuels and their possible extension to higher burnups, but are especially urgent relative to near-term development and qualification of accident-tolerant fuels. Recommendations that resulted from the Halden Gap Analysis focused on enhancements at Advanced Test Reactor (ATR) and Transient Reactor Test Facility (TREAT) to fill gaps in testing capabilities relative to these needs. Second, a concerted effort to develop and demonstrate a systematic approach to accelerating the development, testing, and qualification of new fuel systems has been initiated. This is highlighted by a test strategy that combines the considerable advances in multiscale, mechanistic fuel modeling of recent years with a MiniFuel separate effects test program in the High Flux Isotope Reactor (HFIR) and a Fission Accelerated Steady-state Testing (FAST) semi-integral accelerated test program in ATR. This approach is being tested/demonstrated using the metallic fuel system, but if successful it is expected to be extensible to multiple fuel types and diverse applications. This document includes an overview of the NFCSC program, a definition of science-based development of nuclear fuels, near-term goals for Advanced LWR fuels (ALFs), and longer-term goals for Advanced Reactor Fuels (ARFs) RD&D. This includes the activities that will be conducted to achieve success toward the grand challenge, as well as the goals and milestones to be achieved over the next few decades of research and development. Long-term goals are based on the DOE Office of Nuclear Energ

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

The potential of wire arc directed energy deposition

A diverse team of materials scientists, systems engineers and computational scientists at the Manufacturing Demonstration Facility at Oak Ridge National Laboratory (ORNL) is working closely with industry to employ WA-DED to transform the current manufacturing supply chains and change industry perception of metal-AM-fabricated components.

36 MATERIALS SCIENCE↗