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All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Informing and Engaging the Future Workforce on Generation IV International Forum Reactor Systems

Generation IV reactors are six nuclear reactor designs, Sodium Fast reactor (SFR), Very High Temperature Reactor (VHTR), Gas cooled Fast Reactor (GFR), Molten Salt Reactor (MSR), Lead Fast Reactor (LFR), and Supercritical Water Reactor (SCWR), that are considered to be the most promising in light of various criteria based on the following objectives: • continuation of the progress made by Generation III water reactors in terms of competitiveness and safety; • more effective use of uranium resources; • less radioactive waste, especially high-level, long-lived waste; • greater protection against malicious acts and the diversion or theft of nuclear materials. The GIF Education and Training Working Group (ETWG) launched two major initiatives in 2016 and in 2021 to not only inform and educate but also to engage the future workforce in support of these reactor systems. This paper will present an overview of the GIF EWTG webinar series as well as the 2021 Pitch your Gen IV Research Competition which is followed by the 2023 Pitch your Gen IV Research. Competition

Paviet, Patricia D.↗
DOE OSTI2021

An Indirect Search for Weakly Interacting Massive Particles in the Sun Using Upward-going Muons in NOvA

I present the first Dark Matter search results using the full data set collected with the upward-going muon trigger in NOvA. Weakly Interactive Massive Particles (WIMPs) are a theoretical non-baryonic form of Dark Matter. The nature of Dark Matter is one of the most exciting open questions in modern physics. Though its existence can be inferred by astrophysical evidence, its properties are not yet understood. If we assume that Dark Matter particles can produce Standard Model particles through their interactions, an indirect search can help shed light on this mystery.The NOvA collaboration has built a 14 kton, fine-grained, low-Z, total absorption tracking calorimeter at an off-axis angle to the NuMI neutrino beam. Even though the detector is optimized to observe electron neutrino appearance from a muon neutrino beam, it has a unique potential for more exotic searches given its excellent granularity and energy resolution and relatively low-energy neutrino thresholds. In fact, with an efficient upward-going muon trigger and sufficient background suppression offline, NOvA is capable of a competitive indirect Dark Matter search for low-mass WIMPs.The idea of the upward-going muon trigger is first to select high-quality muon tracks, then use the timing information of all of the hits of each track to estimate directionality. In this way, the background flux is suppressed by more than a factor of 10^5 at trigger level to a rate of approximately 1 Hz. To further optimize this search, we use only upward-going muons that point to the Sun, so our search occurs at night when the Sun is on the other side of the Earth. This strategy also allows us to use the time when the Sun is above the horizon as a control region to estimate the background. Ultimately, implementation of a cut based and maximum likelihood analysis provides a powerful tool for rejecting background and selecting a sample of neutrino-induced upward-going muons. The overall background rejection power achieved by the analysis is substantial and impressive. Starting with approximately 150,000 events per second, we reduced it to 40 events per year. Since no statistically significant excess was found, a 90\% C.L. upper limit on the expected muon flux of upward-going muons has been set using the upper limit on the number of events given the number of observed events in the signal region. Lastly, by assuming the theory behind the upward-going muon flux, a limit on the WIMP-nucleon spin-dependent cross-section in the Sun was estimated. Although the limits on the spin-dependent cross-section do not appear to be competitive with previous indirect Dark Matter searches, the upward-going muon flux limits are promising. The upward-going muon flux limits could extend these results to a broader class of models that are not specific to the dark matter theory but produce upward-going muons, leading to competitive results.

Principato, Cristiana↗
DOE OSTI2013

SBIR PHASE I FINAL REPORT: Adoption of High Performance Computational (HPC) Modeling Software for Widespread Use in the Manufacture of Welded Structures

Many US manufacturing companies have moved fabrication and production facilities off shore because of cheaper labor costs. A key aspect in bringing these jobs back to the US is the use of technology to render US-made fabrications more efficient overall with higher quality. A new initiative of the current administration has the goal of enhancing competitiveness to retain manufacturing jobs in the US. One significant competitive advantage that has emerged in the US over the last two decades is the use of virtual design for fabrication of large structures in the light and heavy materials industries. Industries that have used virtual design and analysis tools have reduced material parts size, developed environmentally-friendly fabrication processes, improved product quality and performance, and reduced manufacturing costs. Indeed, Caterpillar Inc. (CAT), one of the partners in this effort, continues to have a large fabrication presence in the US because of the use of weld fabrication modeling to optimize fabrications by controlling weld residual stresses and distortions and improving fatigue, corrosion, and fracture performance. This report describes Engineering Mechanics Corporation of Columbus (Emc2's) DOE SBIR Phase I results which extended an existing, state-of-the-art software code, VFT, currently used to design and model large welded structures prior to fabrication - to a broader range of products with widespread applications for small and medium-sized enterprises (SMEs). VFT helps control distortion, can minimize and/or control residual stresses, control welding microstructure, and pre-determine welding parameters such as weld-sequencing, pre-bending, thermal-tensioning, etc. VFT uses material properties, consumable properties, etc. as inputs. Through VFT, manufacturing companies can avoid costly design changes after fabrication. This leads to the concept of joint design/fabrication where these important disciplines are intimately linked to minimize fabrication costs. VFT currently is tied to a commercial solver which makes it prohibitively expensive for use by SMEs, as there is a significant licensing cost for the solver - over and above for the relatively minimal cost for VFT. Emc2 developed this software code over a number of years in close cooperation with CAT (Peoria, IL), who currently uses this code exclusively for worldwide fabrication, product design and development activities. The use of VFT has allowed CAT to move directly from design to product fabrication and helped eliminate (to a large extent) new product prototyping and subsequent testing. Additionally, CAT has been able to eliminate/reduce costly one-of-a-kind appliances used to reduce distortion effects due to fabrication. In this context, SMEs can realize the same kind of improved product quality and reduced cost through adoption of the adapted version of VFT for design and subsequent manufacture of new products. Emc2's DOE SBIR Phase I effort successfully adapted VFT so that SMEs have access to this sophisticated and proven methodology that is quick, accurate and cost effective and available on-demand to address weld-simulation and fabrication problems prior to manufacture. The open source code, WARP3D, a high performance finite element code mainly used in fracture and damage assessment of structures, was modified so that computational weld problems can be solved efficiently on multiple processors and threads with VFT. The thermal solver for VFT, based on a series of closed form solution approximations, was enhanced for solution on multiple processors greatly increasing overall speed. In addition, the graphical user interface (GUI) has been tailored to integrate these solutions with WARP3D. The GUI is used to define all the weld pass descriptions, number of passes, material properties, consumable properties, weld speed, etc. for the structure to be modeled. The GUI was improved to make it user-friendly for engineers that are not experts in finite element modeling. Finally, a plan for porting VFT onto the Ohio Supercomputer Center (OSC) through its hosted Manufacturing and Polymer Portal has been developed. This access route will permit SMEs to perform weld modeling to improve their competitiveness at a reasonable cost. All of these improvements are detailed in this repo

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2014

Jointly Sponsored Research Program on Energy Related Research

Cooperative Agreements, DE-FC26-08NT43293, DOE-WRI Cooperative Research and Development Program for Fossil Energy-Related Resources began in June 2009. The goal of the Program was to develop, commercialize, and deploy technologies of value to the nation’s fossil and renewable energy industries. To ensure relevancy and early commercialization, the involvement of an industrial partner was encouraged. In that regard, the Program stipulated that a minimum of 20% cost share be achieved in a fiscal year. This allowed WRI to carry a diverse portfolio of technologies and projects at various development technology readiness levels. Depending upon the maturity of the research concept and technology, cost share for a given task ranged from none to as high as 67% (two-thirds). Over the course of the Program, a total of twenty six tasks were proposed for DOE approval. Over the period of performance of the Cooperative agreement, WRI has put in place projects utilizing a total of $\$$7,089,581 in USDOE funds. Against this funding, cosponsors have committed $\$$7,398,476 in private funds to produce a program valued at $\$$14,488,057. Tables 1 and 2 presented at the end of this section is a compilation of the funding for all the tasks conducted under the program. The goal of the Cooperative Research and Development Program for Fossil Energy-Related Resources was to through collaborative research with the industry, develop or assist in the development of innovative technology solutions that will: • Increase the production of United States energy resources – coal, natural gas, oil, and renewable energy resources; • Enhance the competitiveness of United States energy technologies in international markets and assist in technology transfer; • Reduce the nation's dependence on foreign energy supplies and strengthen both the United States and regional economies; and • Minimize environmental impacts of energy production and utilization. Success of the Program can be measured by several criteria. Using the deployment of the federal funding with industrial participation as a performance criterion, over the course of the program, the cosponsors contributed more dollars than the federal funds. As stated earlier, a little more than half of the funding for the Program was derived from industrial partners. The industrial partners also enthusiastically supported the research and development activities with cash contribution of $\$$4,710,372.67, nearly 65% of the required cost share. Work on all of the tasks proposed under the Cooperative Agreement has been completed. This report summarizes and highlights the results from the Program. Under the Cooperative Agreement Program, energy-related tasks emphasized petroleum processing, upgrading and characterization, coal and biomass beneficiation and upgrading, coal combustion systems development including oxy-combustion, emissions monitoring and abatement, coal gasification technologies including gas clean-up and conditioning, hydrogen and liquid fuels production, and the development of technologies for the utilization of renewable energy resources. Environmental-related activities emphasized cleaning contaminated soils using microbial fuel cells, development of processes and sorbents for emissions reduction and recovery of water from power plant flue gas, and biological carbon capture and reuse. Technology enhancement activities included resource characterization studies, development of improved methods, monitors and sensors. In general the goals of the tasks proposed were to enhance competitiveness of U.S. technology, increase production of domestic resources, and reduce environmental impacts associated with energy production and utilization. Technologies being brought to commercialization as a result of the funds provided by the Cooperative Agreement contribute to the overall goals of the USDOE and the nation. Each has broad applicability both within the United States and abroad, thereby helping to enhance the competitiveness of U.S. energy technologies in international markets and assisting in technology transfer. Under the Cooperative Agreement Program, WRI has furthered the development of two different coal upgrading technologies. River Basin Energy technology was scaled-up and demonstrated at a nominal 40 tpd size. Similarly, WRI’s patented mercury removal technology further developed into WRITE Coal technology which was then integrated into oxy-combustion and gasification systems for IGCC and fuels production. Integrated systems with WRITE Coal technology applied at the front end represent substantial environmental and efficiency gains. A variation of the RBE coal upgrading technology is being commercialized as a torrefaction technology for woody biomass. WRI worked with EPRI and NIST to develop and improve mercury calibration standards for emissions monitoring. Working with Chart Energy and Chemicals, WRI scaled-up compact reactor technology for the synthesis of fuels and chemicals from syngas. Compact reactor technology represents a five-fold increase in productivity over conventional reactors making smaller-scale distributed synthesis plants an economical viability. Similarly, WRI's patented mixed alcohol synthesis catalyst production is being scaled-up in collaboration with a commercial catalyst manufacturer.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2015

Renewable Electricity: Insights for the Coming Decade

A sophisticated set of renewable electricity (RE) generation technologies is now commercially available. Globally, RE captured approximately half of all capacity additions since 2011. The cost of RE is already competitive with fossil fuels in some areas around the world, and prices are anticipated to continue to decline over the next decade. RE options, led by wind and solar, are part of a suite of technologies and business solutions that are transforming electricity sectors around the world. Renewable deployment is expected to continue due to: increasingly competitive economics; favorable environmental characteristics such as low water use, and minimal local air pollution and greenhouse gas (GHG) emissions; complementary risk profiles when paired with natural gas generators; strong support from stakeholders. Despite this positive outlook for renewables, the collapse in global oil prices since mid-2014 and continued growth in natural gas supply in the United States--due to the development of low-cost shale gas--raise questions about the potential impacts of fossil fuel prices on RE. Today, oil plays a very minor role in the electricity sectors of most countries, so direct impacts on RE are likely to be minimal (except where natural gas prices are indexed on oil). Natural gas and RE generating options appear to be more serious competitors than oil and renewables. Low gas prices raise the hurdle for RE to be cost competitive. Additionally, although RE emits far less GHG than natural gas, both natural gas and RE offer the benefits of reducing carbon relative to coal and oil (see Section 4.1 for more detail on the GHG intensity of electricity technologies). However, many investors and decision makers are becoming aware of the complementary benefits of pairing natural gas and renewables to minimize risk of unstable fuel prices and maintain the reliability of electricity to the grid.

14 SOLAR ENERGY↗
DOE OSTI2014

Development of the Mathematics of Learning Curve Models for Evaluating Small Modular Reactor Economics

The cost of nuclear power is a straightforward yet complicated topic. It is straightforward in that the cost of nuclear power is a function of the cost to build the nuclear power plant, the cost to operate and maintain it, and the cost to provide fuel for it. It is complicated in that some of those costs are not necessarily known, introducing uncertainty into the analysis. For large light water reactor (LWR)-based nuclear power plants, the uncertainty is mainly contained within the cost of construction. The typical costs of operations and maintenance (O&M), as well as fuel, are well known based on the current fleet of LWRs. However, the last currently operating reactor to come online was Watts Bar 1 in May 1996; thus, the expected construction costs for gigawatt (GW)-class reactors in the United States are based on information nearly two decades old. Extrapolating construction, O&M, and fuel costs from GW-class LWRs to LWR-based small modular reactors (SMRs) introduces even more complication. The per-installed-kilowatt construction costs for SMRs are likely to be higher than those for the GW-class reactors based on the property of the economy of scale. Generally speaking, the economy of scale is the tendency for overall costs to increase slower than the overall production capacity. For power plants, this means that doubling the power production capacity would be expected to cost less than twice as much. Applying this property in the opposite direction, halving the power production capacity would be expected to cost more than half as much. This can potentially make the SMRs less competitive in the electricity market against the GW-class reactors, as well as against other power sources such as natural gas and subsidized renewables. One factor that can potentially aid the SMRs in achieving economic competitiveness is an economy of numbers, as opposed to the economy of scale, associated with learning curves. The basic concept of the learning curve is that the more a new process is repeated, the more efficient the process can be made. Assuming that efficiency directly relates to cost means that the more a new process is repeated successfully and efficiently, the less costly the process can be made. This factor ties directly into the factory fabrication and modularization aspect of the SMR paradigm—manufacturing serial, standardized, identical components for use in nuclear power plants can allow the SMR industry to use the learning curves to predict and optimize deployment costs. Thus, SMR deployment cost estimates can be modeled using learning curve theory to provide some insight into how and when SMRs would be competitive with both the GW-class reactors and other mutual competitors. However, assuming static learning curve behavior for all aspects of SMR construction is likely an invalid approach—not all components and systems in SMRs will be subject to learning, and those that are subject to learning may not learn at the same rate. A learning curvebased model must be capable of tracking these unique behaviors. At the same time, the behavior of the aggregated and integrated SMR deployment is a more useful metric for discussion and comparison—ultimately, the most useful learning curve information is that which describes power plant deployment as a whole. Therefore, the goal of SMR component and systems learning modeling includes a method to produce an overall power plant learning model. This report describes the mathematics of learning curves that can be used for estimating unit cost in future production for individual components and aggregated systems. All necessary assumptions are provided to support the derivations presented. Future work will demonstrate the implementation of this methodology and provide example calculations of SMR cost

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2016

Economic Assessment of Hydrogen Technologies Participating in California Electricity Markets

As the electric sector evolves and increasing amounts of variable renewable generation are installed on the system, there are greater needs for system flexibility and sufficient capacity, and greater concern for overgeneration from renewable sources not well matched in time with electric loads. Hydrogen systems have the potential to support the grid in each of these areas. However, limited information is available about the economic competitiveness of hydrogen system configurations. This paper quantifies the value for hydrogen energy storage and demand response systems to participate in select California wholesale electricity markets using 2012 data. For hydrogen systems and conventional storage systems (e.g., pumped hydro, batteries), the yearly revenues from energy, ancillary service, and capacity markets are compared to the yearly cost to establish economic competitiveness. Hydrogen systems can present a positive value proposition for current markets. Three main findings include: (1) For hydrogen systems participating in California electricity markets, producing and selling hydrogen was found to be much more valuable than producing and storing hydrogen to later produce electricity; therefore systems should focus on producing and selling hydrogen and opportunistically providing ancillary services and arbitrage. (2) Tighter integration with electricity markets generates greater revenues (i.e., systems that participate in multiple markets receive the highest revenue). (3) More storage capacity, in excess of what is required to provide diurnal shifting, does not increase competitiveness in current California wholesale energy markets. As more variable renewable generation is installed, the importance of long duration storage may become apparent in the energy price or through additional markets, but currently, there is not a sufficiently large price differential between days to generate enough revenue to offset the cost of additional storage. Future work will involve expanding to consider later year data and multiple regions to establish more generalized results.

25 ENERGY STORAGE↗
DOE OSTI2014

University of Utah, Energy Commercialization Center

During the Energy Commercialization Center’s (ECC) three years in operation, the only thing constant was change. The world of commercialization and cleantech evolved significantly during the time the ECC was formed and operating, including: the availability of cleantech funding lessoned, the growth of incubators and accelerators skyrocketed, the State of Utah created an office dedicated to energy development, the University of Utah was both praised and criticized for its success in commercialization, and the Federal government temporarily shut down. During the three-year grant there were three principle investigators on the grant, as well as three directors for the University’s Commercialization Office. Change can be hard for an organization,but as we instruct the companies we support, “Fail fast and fail often, because it is the fastest path to success.” Although there were some unanticipated challenges along the way, the local ecosystem is stronger because of the ECC’s efforts. Perhaps the greatest lesson learned was the importance of aligned incentives between key stakeholders in the commercialization process and the need for resources at the company and individual entrepreneur levels. The universities have systems and incentives to commercialize technologies, but creating value and companies generally rest with the individuals and entrepreneurs. Unfortunately the ECC was unable to create a viable mechanism to transfer the commercialization process that successfully aligned incentives and achieve a more effective ecosystem within the Rocky Mountain West. However, the ECC was successful in adding value to the individual ecosystems, and connecting national resources to regional and local needs. Regarding the ECC’s effectiveness in developing a cleantech commercialization ecosystem, initial inroads and relationships were established with key stakeholders. However, incentives, perceived or real competition, differences in commercialization processes, and culture all played a role in inhibiting the development and distribution of a regional ecosystem and commercialization process. Had the University and the ECC been able to develop a software platform, some of these challenges may have been overcome, but without the final development and release of the Western Innovation Network, the ECC realistically could not scale and distribute a commercialization platform. Further, cleantech startups need to engage in a more intensive customer validation process, and establish strong community connections if they are to succeed in commercializing their products. The university system incentivizes research and access to research funding and risk capital is competitive, so by nature collaboration on commercialization was difficult. Each of the local ecosystems within the Rocky Mountain West was unique. Utah did not, and does not, have a system outside of the universities to support entrepreneurs and cleantech commercialization. Through the ECC’s efforts developing a regional ecosystem, it became clear that successful ecosystems had a community and associated mechanisms that supported local entrepreneurs and startups. Most importantly the ECC aided in the creation of Utah’s cleantech ecosystem, one that supports entrepreneurs and startup companies that need help and support in their efforts to commercialize clean technologies. The absence of support for clean tech from state government and local organizations was a significant impediment to cleantech commercialization. To overcome this challenge, the ECC has formed Sustainable Startups. Sustainable Startups is a new non-profit organization designed to build a culture and community in Utah that supports and understands the importance of cleantech and sustainable development. While the ECC generated mixed success in building a regional commercialization ecosystem for cleantech, the organization did provide tremendous benefit to startups and the broader public. Over 60 companies were given direct business development support by the ECC, many of whom then generated direct economic development impacts. In addition, the ECC served an important role as community convener, educator and relationship builder through hosting numerous public and private events including: Energize 2013; Millennial Train whistle stop; business plan competition supporter; Clean Tech Open Accelerator organizer; Sustainable Startups Series developer, and much more. While the ECC did not fully apply, develop, and transmit the University of Utah’s TCO commercialization model to cleantech, it nevertheless assisted numerous inventors, entrepreneurs and institutions in furthering the growth of clean energy and energy efficiency technologies. The TCO’s commercialization model was not applied to regional clean tech initiatives for several main reasons. First, flaws with the commercialization model were realized after the ECC’s formation. Second, leadership changes within the TCO and ECC hampered early organizational development and implementation initiatives. Third, misaligned incentives between the ECC, regional universities, institutions, and the State of Utah resulted in a lack of collaboration and knowledge transfer regarding commercialization. In principle, everyone was aligned and willing to collaborate, but reality was much different and challenging.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2016

Assisting the Tooling and Machining Industry to Become Energy Efficient

The Arizona Commerce Authority (ACA) conducted an Innovation in Advanced Manufacturing Grant Competition to support and grow southern and central Arizona’s Aerospace and Defense (A&D) industry and its supply chain. The problem statement for this grant challenge was that many A&D machining processes utilize older generation CNC machine tool technologies that can result an inefficient use of resources – energy, time and materials – compared to the latest state-of-the-art CNC machines. Competitive awards funded projects to develop innovative new tools and technologies that reduce energy consumption for older generation machine tools and foster working relationships between industry small to medium-sized manufacturing enterprises and third-party solution providers. During the 42-month term of this grant, 12 competitive awards were made. Final reports have been included with this submission.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2018

New Photolithography Stepping Machine Close Out Report CRADA No. TSB-842-94

The semiconductor industry, due to performance driven competition, continues to achieve unprecedented technological advancements. For example, the memory density of DRAM chips increases four fold every three years or so. Advances in integrated circuit technology drive the producers of processing equipment to achieve commensurate advances, or conversely, advances in manufacturing technology allow advances in integrated circuits. A vital U.S. technology addressed by this project is step-and-repeat photolithography. It demands motion control to tens of nanometers, nearly perfect optical systems and competitive throughput of product. The failure to keep this domestic technology competitive and profitable places the whole U.S. semiconductor industry at risk to foreign interests.

47 OTHER INSTRUMENTATION↗
DOE OSTI2018

Final Scientific Findings Report- Hydro Research Foundation- Research Awards Program

The Research Awards Program was established in 2014 by the Hydro Research Foundation (Foundation) to support research efforts for the hydropower industry. Using the previously funded Fellowship Program that ran from 2010-2015, the Research Awards Program (RAP or program) captured the lessons learned from the Fellowship program and fine-tuned a nation-wide graduate level research program to support innovation, research and workforce development. The RAP was funded through a $2 million-dollar grant through the Department of Energy’s Water Power Program within the Energy Efficiency and Renewable Energy office (DOE). This award made possible, 33 research projects by 32 students from 21 universities in 11 states. The grant widely engaged the industry by providing the opportunity to work with 25 organizations as well as 63 students and advisors. The funded research focused on a topic list selected by industry and worked to cover a breadth of research needs across many disciplines, basins and types of hydropower issues. The funded work, answered pressing research needs in the fields of the following disciplines; civil engineering, mechanical engineering, environmental engineering, electrical engineering, geography, fisheries, wildlife, water resources, geology, energy science and materials innovation. The Foundation estimates that 116 individuals benefited from this research through either direct mentorship (42), research (32), overseeing the research (31), partnerships (7) and the day-to-day management of the program (4). This investment by DOE showcases how private-public partnerships can leverage limited funds to create a wide range of research products. The project objective was to build on the successful Fellowship Program to develop and execute the RAP on a national level. The program sought to provide competitively awarded hydropower-related graduate-level research awards. The intent of the RAP was to support beneficial, innovative research related to conventional or pumped-storage hydropower. It also sought to stimulate interest among students and universities in this research arena and provide students with a foundation for productive careers within the hydropower industry. The outcome was 33 research findings with 100% of proposed research completed. In addition, 87% of students chose to either join the hydropower industry or continue their hydropower related research at their universities. These research findings advanced the understanding of pressing research topics within the hydropower industry and met the objective of the funding. An ancillary benefit the program identified through this funding was, not only did 63 students and advisors work on hydropower within the academia space, but now there are more professors and students teaching hydropower at the university level. The program saw an addition of 12 new professors, teaching assistants, and graduate researchers continuing to simulate interest in hydropower. Another interesting outcome is that during this grant funding, the program saw alumni of the predecessor program, who are now professors, applying for the RAP with their students. A unique element of this funding is there was significant cost-share provided by host universities, who did not charge facilities and administration overhead to the student’s research awards. In addition, each university provided laboratories, computing capacity and research facilities to support the research which is extraordinarily unique to grant funding at the university level. The total cost share exceeded 30% of the total grant cost. The funding clearly reached many sectors of the industry to provide helpful work and continue building hydropower’s next generation of innovation and workforce. The Foundation has established a broad network of universities interested and engaged in hydropower. The work was supported by the hydropower industry through donations of meeting space, conference registrations, in-kind contributions, mentorship and support of students. The Foundation would recommend finding a vehicle to further advance programs like the graduate level research through competitions, competitively funded awards and student research. It will take many universities to advance hydropower’s most pressing challenges. To let a program like the RAP dwindle away would incapacitate research at universities.

13 HYDRO ENERGY↗
DOE OSTI2019

Roll-to-Roll Advanced Materials Manufacturing DOE Laboratory Collaboration - FY2018 Final Report

High-value R2R processing is used to support a wide range of products in applications which span many industrial business sectors. The overall R2R process technology can be considered as “mature” as the process methodology and has been in use for decades. This continuous processing technique traditionally involves deposition of material(s) onto moving webs or carriers or other continuous R2R, belt-fed, or conveyor-based processes that enable successive steps to build a final version which serves to support the deposited materials. Current process technologies, which typify “roll to roll”, include tape casting, silk-screen printing, reel-to-reel vacuum deposition/coating and R2R lithography. Products supported by R2R manufacturing include micro-electronics, electro-chromic window films, PVs, fuel cells for energy conversion, battery electrodes for energy storage, and barrier materials. Due to innovation in materials and process equipment, high-quality yet very low-cost multi-layer technologies can be manufactured on a very cost-competitive basis. To move energy-related products from high-cost niche applications to the commercial sector, a means must be available to enable manufacture of these products in a cost-competitive manner that is affordable by the general consumer. Fortunately, products such as fuel cells, thin- and mid-film PVs, batteries, electrochromic and piezoelectric films, water separation membranes, and other energy saving technologies readily lend themselves to manufacture using R2R approaches.Within the DOE EERE AMO, it was recognized that establishment of a program supported at the DOE National Laboratories, along with their immense design of materials and equipment modelling capabilities enabled with use of high-performance computing, could take advantage of available R2R infrastructure to manufacture new technologies. In FY 2016, a R2R Consortium was established and provided with initial “seed” funding to take an approach that was envisioned to be supportable by advanced manufacturing R2R processes. This collaborative approach was designed to foster identification and development of materials and processes related to R2R for clean-energy product development. Using computational and experimental capabilities by acknowledged subject matter experts within the supported National Laboratory system, this collaborative project would leverage the capabilities and expertise at each of four laboratories to further the development of an enabling high-volume cost-competitive platform technology. The collaboration team that is comprised of ORNL, ANL, NREL and LBNL, coordinating with EPB and other selected industry partners, was formed in April 2016 to initially address enhancing battery electrode performance and R2R manufacturing challenges. The research efforts were to predict and measure changes and results in electrode morphology and performance based on process condition changes; to evaluate mixed, active, particle size deposition and drying for novel electrode materials; to model various process condition changes and the resulting morphology and electrode performance; and to develop and validate NDE techniques for in-line measurement of battery electrode material properties. These efforts carried through FY 2017 and completed at the end of FY 2018.The approach was to look at compositions of materials with different particle sizes to make electrode samples using a R2R manufacturing process. The shape, size, and morphology of the materials, the chemistry of the formulation, the nature of slurries, their coating rate, the rate of drying all play a role in determining the final coating architecture, quality, and performance. A commercial cathode material was selected to make a series of cathodes and anodes by single pass, dual pass and slot die methods. Analysis of all the compiled results for this battery electrode development were that the best performing cathodes included: dual-pass electrode with large particles near the foil, mixed small and large particles, and small particles only. Whereas, the best performing anodes were with a mix of small and large graphite particles. An additional core project was added in FY 2017 to conduct studies of fuel cell materials that can be produced using R2R processes. The goal of this project is to explore, understand and optimize material and process parameters to support increased throughput, increased quality, and reduced cost for high volume production of gas-diffusion electrodes (GDEs) for PEMFCs. Project work in FY 2018 were to use a R2R process to fabricate electrodes without ionomer overlayer that can produce the equivalent mass activity as spray-coated electrodes with an ionomer overlayer. Oxygen-limiting current measurements were utilized to optimize oxygen mass transport. Alcohol-rich solvents were investigated, and results were that the alcohol and water ratio can be tuned to control ionomer distribution. Water-rich solvents produce a more dispersed ink which results in better high-current density performance.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Combined Heat and Power in Mexico: Market Opportunity Analysis

Energy reforms in Mexico have emphasized the need for a more diversified energy portfolio to enhance energy security, decrease environmental degradation, and increase Mexico’s economic competitiveness. Starting in 2013, these reforms provide new opportunities for the cogeneration of heat and power (also called combined heat and power, or CHP) in the following ways: (1) they include efficient CHP under clean electricity generation provisions, allowing them to generate Clean Energy Certificates (CEL); and (2) they facilitate investment and competition in natural gas, the primary fuel source of CHP, expanding access to and reducing the price of gas, and increasing the competitive advantage of CHP. Considering the changing regulatory environment in Mexico, and the potential opportunities offered to suppliers of CHP technologies, the U.S. Department of Energy commissioned a report to identify opportunities and challenges facing U.S. suppliers of CHP technology and services within the context of the current regulatory environment in Mexico. This report, prepared by the U.S. Department of Energy Oak Ridge National Laboratory, also provides an overview of the current energy policy environment and the electricity market dynamics related to the CHP sector in Mexico.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2013

Assessment of the Distributed Generation Market Potential for Solid Oxide Fuel Cells

The focus of the solid oxide fuel cell (SOFC) program at the National Energy Technology Laboratory (NETL) is to develop low-cost, highly efficient solid oxide fuel cell power systems that are capable of simultaneously producing electric power with carbon capture when integrated with gasification. To accomplish this goal, research and demonstration projects are being undertaken to enhance the reliability and the robustness of the SOFC system. NETL’s SOFC technology roadmap is focused on developing and demonstrating progressively larger megawatt electric (MWe) class natural-gas-based systems to validate and advance SOFC technology for natural gas and gasified coal-based utility scale power generation. As the SOFC technology advances from its current state to utility scale, it is possible that MWe class systems could penetrate the distributed generation (DG) market segment. If the SOFC technology were to penetrate the DG market, this would have the added benefit of lowering system costs by establishing operational experience and a manufacturing base. This report analyzed the strengths of the SOFC system in conjunction with relevant DG market segments in the United States (U.S.) and determined that natural gas compressor stations, grid strengthening, and data centers were potential early market-entry opportunities. These three DG market segments are projected to demand two gigawatts (GWs) of additional power between now and 2018 and 25 GWs between now and 2040. Historical experiences with related technology, including effects of increased production capacity on capital costs, were used to evaluate the market penetration necessary for a cost competitive DG SOFC system. This analysis showed that the DG SOFC system becomes cost competitive with other fossil-fuel based DG technologies after 25 MWe of installed capacity, around 2025, based on the demonstration of the first SOFC DG unit in the year 2020. The SOFC DG application validates and enables the technology for utility scale systems with carbon capture and forms an essential first phase of the NETL technology development roadmap, which is based on the vision to develop a commercially competitive utility-scale system with carbon capture.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2019

A Model for Lean Corporate/ Startup Interfaces: Unlocking Resources of Midcap Corporations Providing a Pathway to Advanced Energy Technologies

Commercializing energy technologies through traditional market pathways is challenging for early-stage energy innovators. Development cycles in energy are long and expensive, and adoption is difficult, making energy technologies of limited interest to venture capital relative to industries with faster growth and shorter product life cycles such as life sciences and software. As such, partnerships with established corporations are one of the most promising, and in some cases only, go-to-market pathways for energy technologies. Startups often seek to work with, large well-known Fortune 500 (and similar) companies. However, the size and risk aversion of those firms often makes partnering challenging. It can take well over 12 months for a large corporation to agree to commercial terms and get internal board / management approval to move forward with a binding agreement with a startup for even a simple starting partnership. This timeline is prohibitive for most early-stage companies who are both time and money constrained, and often working in highly competitive commodity sectors. Mid-cap corporations ($\$ $100M to $\$ $10B) are a promising but untapped resource for partnering with technology developers because they are often nimbler, tend to be fiercely competitive, and are looking for new revenue or cost-saving opportunities. These factors make them both more receptive to disruptive technologies, and more capable of integrating them. However, while Fortune 500 companies often have venturing groups that facilitate the initial connection process, most midcap incumbents do not have the resources to create standalone corporate venture groups. As a result, although they could help each other significantly (startup technologies make midcaps more competitive; midcaps offer a faster commercialization pathway to startups), midcap companies and startups rarely work together. In 2017, ADL Ventures (ADL) received Award #DE-EE0008111 from DOE EERE’s Innovative Pathways program to unlock the domain expertise and material resources of midcap companies. The goal of the award was to support energy technology commercialization via an innovation platform for startups to interface with midcap corporations. During the grant period, we have developed a novel open innovation platform that allows financially conservative incumbents to efficiently engage with energy innovators and startups, thereby unlocking the incumbents’ domain expertise, strategic capital, R&D facilities, supply chain, and pathways to market. We have executed full-scale open innovation challenges for three clients, exceeding the initial proposed goal of two. We also built a diversified opportunity pipeline which resulted in four projects contracted for 2020, meeting the goals of the proposal, with others pending.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2018

Clean Energy Trust Challenge

Over the past three years, Clean Energy Trust (CET) supported student education and early-stage entrepreneurship in the clean energy sector by managing and effectively executing the Cleantech University Prize (Cleantech UP) initiative. CET has a long track record running these competition-style events; CET built on its past successes with the National Clean Energy Business Plan Competition (NCEBPC) and the Clean Energy Trust Challenge (the Challenge) - CET's annual business plan competition and summit event - to excel during this initiative. CET's goals with this Cleantech UP program were to enhance student engagement and participation across colleges and universities in the Midwest region. This broad objective was outlined by increasing the number of applicants, the number and geographic footprint of universities and colleges actively engaged and, most importantly, the trajectory for the student businesses that participate in our programs.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2020

First Look West (FLoW 2.0) (Final Technical Report for Closeout)

DOE’s Cleantech UP was an annual business plan competition, operating nationally between 2015 and 2018 through eight regional nodes that included Caltech’s FLOW. Cleantech UP focused on supporting university students at all levels creating cleantech startups. FLOW operated nationally with a focus on California. In support of the DOE’s objectives FLOW developed an immersive five point program that targeted major gaps in the educational support and practical resources available to scientists and engineers starting their first cleantech companies that prevented such young innovators from becoming entrepreneurs. Specifically, the FLOW program augmented the number of participants entering the energy entrepreneurship pipeline via the Cleantech UP competition; helped the US remain competitive by increasing the viability and financing potential of these cleantech companies started by young academics; and helped build the regional, state and national infrastructure that spurs and supports entrepreneurship. Each year the FLOW featured two major judging rounds for candidates drawn from as many as 80 applicants annually, providing essential experience and feedback that helped define the direction of these young entrepreneurs. The FLOW winners competed at the DOE’s national event, and FLOW companies took the top prize twice in the total history of the DOE program which was started in 2011.

96 KNOWLEDGE MANAGEMENT AND PRESERVATION↗
DOE OSTI2021

Roll-to-Roll Advanced Materials Manufacturing DOE Laboratory Collaboration (FY2020 Final Report)

R2R processing is used to manufacture a wide range of products for various applications which span many industrial business sectors. The overall R2R methodology has been in use for decades and this continuous technique traditionally involves deposition of material(s) onto moving webs, carriers or other continuous belt-fed or conveyor-based processes that enable successive steps to build a final version which serves to support the deposited materials. Established methods that typify R2R processing include tape casting, silk-screen printing, reel-to-reel vacuum deposition/coating, and R2R lithography. Products supported by R2R manufacturing include micro-electronics, electro-chromic window films, PVs, fuel cells for energy conversion, battery electrodes for energy storage, and barrier and membrane materials. Due to innovation in materials and process equipment, high-quality yet very low-cost multilayer technologies have the potential to be manufactured on a very cost-competitive basis. To move energy-related products from high-cost niche applications to the commercial sector, the means must be available to enable manufacture of these products in a cost-competitive manner that is affordable. Fortunately, products such as fuel cells, thin- and mid-film PVs, batteries, electrochromic and piezoelectric films, water separation membranes, and other energy saving technologies readily lend themselves to manufacture using R2R approaches. However, more early-stage research is needed to solve the challenge of linking the materials (particles, polymers, solvents, additives) used in ink and slurry formulations and the coating and drying processes to the ultimate performance of the final R2R product, especially for a process that uses multiple layers of deposition to achieve the end product. To solve the problems associated with these challenges, the R2R Collaboration is executing a research program with outcomes that will ultimately link modeling, processing, metrology and defect detection tools, thereby directly relating the properties of constituent particles and processing conditions to the performance of final devices. This collaborative approach was designed to foster identification and development of materials and processes related to R2R for clean-energy materials development. Using computational and experimental capabilities by acknowledged subject matter experts within the supported National Laboratory system, this project leverages the capabilities and expertise at each of five National Laboratories to further the development of multilayer technologies that will enable high-volume, cost-competitive platforms. A typical R2R process has three steps: (1) mixing of particles and various constituents in a slurry, (2) coating of the ink/slurry mixture on a substrate, and (3) drying/curing and processing of the coating. Final performance of devices made via R2R processes is dependent on the active materials (e.g., electrochemical particles in battery or fuel cell electrodes) and the device structure that stems from the governing component interactions within the various steps. However, a fundamental understanding of the underlying mechanisms and phenomena is still lacking, which is why industrial-scale R2R process development and manufacturing is still largely empirical in nature. The FY 2019 through FY 2021 program addresses aspects of the following two targets from the AMO Multi-Year Program Plan: (1) Target 8.1 Develop technologies to reduce the cost per manufactured throughput of continuous R2R manufacturing processes. (A) Increasing throughput of R2R processes by 5 times for batteries (to 50 square feet per minute (50 ft 2 /min)) and capacitors and 10 times for printed electronics and the manufacture of other substrates and MEs used in support of these products. (B) Developing resolution capabilities to enable registration and alignment that will detect, align, and co-deposit multiple layers of coatings and print < 1-micron (1 µm) features using continuous process scalable for commercial production. (C) Developing scalable and reliable R2R processes for solution deposition of ultra-thin (<10 nm) films for active and passive materials. (D) Develop in-line multilayer coating technology on thin films with yields greater than 95%. (2) Target 8.2 Develop in-line instrumentation tools that will evaluate the quality of single and multilayer materials in-process. (A) Developing in-line QC technologies and methodologies for real-time identification of defects and expected product properties “in-use/application” during continuous processing at all size-scales with a focus on the “micro” and “nano” scale traces, lines, and devices, i.e., <1 μm at 300 ft./min for R2R processing in air and <10 nm at 20 ft./min for vacuum (B) Developing technologies to increase the measurement frequency of surface rheology without significant cost increases with a goal of a 10-nanometer in-line profilometry at a production rate of 100,000 square millimeters per minute (100,000 mm 2 /min).

42 ENGINEERING↗