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All sourcesNASA NTRSDOE OSTI
DOE OSTI2015

Pt-based Bi-metallic Monolith Catalysts for Partial Upgrading of Microalgae Oil

Valicor’s proprietary wet extraction process in conjunction with thermochemical pre-treatment was performed on algal biomass from two different algae strains, Nannochloropsis Salina (N.S.) and Chlorella to produce algae oils. Polar lipids such as phospholipids were hydrolyzed, and metals and metalloids, known catalyst poisons, were separated into the aqueous phase, creating an attractive “pre-refined” oil for hydrodeoxygenation (HDO) upgrading by Stevens. Oil content and oil extraction efficiency of approximately 30 and 90% respectively were achieved. At Stevens, we formulated a Pt-based bi-metallic catalyst which was demonstrated to be effective in the hydro-treating of the algae oils to produce ‘green’ diesel. The bi-metallic catalyst was wash-coated on a monolith, and in conjunction with a high throughput high pressure (pilot plant) reactor system, was used in hydrotreating algae oils from N.S. and Chlorella. Mixtures of these algae oils and refinery light atmospheric gas oil (LAGO) supplied by our petroleum refiner partner, Marathon Petroleum Corporation, were co-processed in the pilot plant reactor system using the Pt-based bi-metallic monolith catalyst. A 26 wt% N.S. algae oil/74 wt % LAGO mixture hydrotreated in the reactor system was subjected to the ASTM D975 Diesel Fuel Specification Test and it met all the important requirements, including a cetane index of 50.5. An elemental oxygen analysis performed by an independent and reputable lab reported an oxygen content of trace to none found. The successful co-processing of a mixture of algae oil and LAGO will enable integration of algae oil as a refinery feedstock which is one of the goals of DOE-BETO. We have presented experimental data that show that our precious metal-based catalysts consume less hydrogen than the conventional hydrotreating catalyst NiMo Precious metal catalysts favor the hydrodecarbonylation/hydrodecarboxylation route of HDO over the dehydration route preferred by base metal catalysts, and consumes less hydrogen, if methanation can be mitigated. Our methanation data on Pt and Rh indicate effective suppression of methanation. Our data also show that our catalysts are less susceptible to coking; and unlike NiMo and CoMo, precious metal catalysts are not deactivated by water, a by-product of HDO of algae oil. Finally, our catalysts do not need to be sulfided to be active. A rigorous techno-economic analysis of our process for commercial scale production of 10,000 barrels per day of hydrotreated algae oil, with nutraceuticals co-product claiming only 0.05% of the raw algae oil, indicates an estimated plant gate price of ~$10/gal. Sensitivity analysis shows that critical parameters affecting sale price include (1) algae doubling time (2) biomass oil content (3) CAPEX, and (4) moisture content of post extracted algae residue. Modest improvements in these areas will result in enhanced and competitive economics. Based on a life cycle assessment for greenhouse gas emission, we found that if algae oil replaced 10% of the US consumption, this would result in a CO2e reduction of 210,000 tons per day. Improving the drying process for animal feed by 50% would result in further significant reduction in CO2e.

09 BIOMASS FUELS↗
DOE OSTI2016

Adoption of High Performance Computational (HPC) Modeling Software for Widespread Use in the Manufacture of Welded Structures

This report summarizes the final product developed for the US DOE Small Business Innovation Research (SBIR) Phase II grant made to Engineering Mechanics Corporation of Columbus (Emc 2 ) between April 16, 2014 and August 31, 2016 titled ‘Adoption of High Performance Computational (HPC) Modeling Software for Widespread Use in the Manufacture of Welded Structures’. Many US 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 cost-efficient overall with higher quality. One significant advantage that has emerged in the US over the last two decades is the use of virtual design for fabrication of small and large structures in weld fabrication industries. Industries that use virtual design and analysis tools have reduced material part 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 Emc 2 ’s DOE SBIR Phase II final results to extend an existing, state-of-the-art software code, Virtual Fabrication Technology (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. Finally service performance (such as fatigue, corrosion, and fracture/damage) can be improved using this product. Emc 2 ’s DOE SBIR Phase II effort successfully adapted VFT® to perform efficiently in an HPC environment independent of commercial software on a platform to permit easy and cost effective access to the code. This provides the key for SMEs to access this sophisticated and proven methodology that is quick, accurate, cost effective and available “on-demand” to address weld-simulation and fabrication problems prior to manufacture. In addition, other organizations, such as Government agencies and large companies, may have a need for spot use of such a tool. The open source code, WARP3D, a high performance finite element code used in fracture and damage assessment of structures, was significantly modified so 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 extensively enhanced for solution on multiple processors greatly increasing overall speed. In addition, the graphical user interface (GUI) was re-written to permit SMEs access to an HPC environment at the Ohio Super Computer Center (OSC) to integrate these solutions with WARP3D. The GUI is used to define all weld pass descriptions, number of passes, material properties, consumable properties, weld speed, etc. for the structure to be modeled. The GUI was enhanced to make it more user-friendly so that non-experts can perform weld modeling. Finally, an extensive outreach program to market this capability to fabrication companies was performed. This access will permit SMEs to perform weld modeling to improve their competitiveness at a reasonable cost.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2015

Catalyst-Assisted Manufacture of Olefins from Natural Gas liquids: Prototype Development and Full-Scale Testing

The steam cracking of ethane to ethylene consumes the greatest amount energy of any process currently practiced by the US chemical industry. U.S. ethylene production consumed an estimated 450 trillion BTU of energy to produce nearly 53 billion pounds of ethylene in 2010. A significant portion of this energy consumption is to overcome the insulating effect of coke (carbonaceous deposits) on the internal surfaces of cracker furnace tubes. This buildup of coke is the result of both metal-catalyzed coke formation on the tube walls (“filamentous coke”), and deposition of gas-phase coke on the tube walls (“amorphous coke”). Coke buildup requires a continuous increase in energy input (firing of external coil tube wall) to achieve the same conversion of ethane feedstock to ethylene product, until the tubes must be taken out of service and the coke removed by steam treatment (“decoking”). This step interrupts production and increases the cost of ethylene. Coke buildup also shortens the coil life by increasing the rate of “creep” (sagging) that occurs due to higher temperature operation and migration of the deposited carbon into the coil metal.

03 NATURAL GAS↗
DOE OSTI2017

Impact of the EISA 2007 Energy Efficiency Standard on General Service Lamps

The Energy Policy and Conservation Act of 1975, as amended by the Energy Independence and Security Act of 2007 (EISA 2007), requires that, effective beginning January 1, 2020, the Secretary of Energy shall prohibit the sale of any general service lamp (GSL) that does not meet a minimum efficacy standard of 45 lumens per watt. This is referred to as the EISA 2007 backstop. The U.S. Department of Energy recently revised the definition of the term GSL to include certain lamps that were either previously excluded or not explicitly mentioned in the EISA 2007 definition. For this subset of GSLs, we assess the impacts of the EISA 2007 backstop on national energy consumption, carbon dioxide emissions, and consumer expenditures. To estimate these impacts, we projected the energy use, purchase price, and operating cost of representative lamps purchased during a 30-year analysis period, 2020-2049, for cases in which the EISA 2007 backstop does and does not take effect; the impacts of the backstop are then given by the difference between the two cases. In developing the projection model, we also performed the most comprehensive assessment to date of usage patterns and lifetime distributions for the analyzed lamp types in the United States. There is substantial uncertainty in the estimated impacts, which arises from uncertainty in the speed and extent of the market conversion to solid state lighting technology that would occur in the absence of the EISA 2007 backstop. In our central estimate we find that the EISA 2007 backstop results in significant energy savings of 27 quads and consumer net present value of $120 billion (at a seven percent discount rate) for lamps shipped between 2020 and 2049, and carbon dioxide emissions reduction of 540 million metric tons by 2030 for those GSLs not explicitly included in the EISA 2007 definition of a GSL.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2016

United States Data Center Energy Usage Report

This report estimates historical data center electricity consumption back to 2000, relying on previous studies and historical shipment data, and forecasts consumption out to 2020 based on new trends and the most recent data available. Figure ES-1 provides an estimate of total U.S. data center electricity use (servers, storage, network equipment, and infrastructure) from 2000-2020. In 2014, data centers in the U.S. consumed an estimated 70 billion kWh, representing about 1.8% of total U.S. electricity consumption. Current study results show data center electricity consumption increased by about 4% from 2010-2014, a large shift from the 24% percent increase estimated from 2005-2010 and the nearly 90% increase estimated from 2000-2005. Energy use is expected to continue slightly increasing in the near future, increasing 4% from 2014-2020, the same rate as the past five years. Based on current trend estimates, U.S. data centers are projected to consume approximately 73 billion kWh in 2020.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2015

The EV Project Price/Fee Models for Publicly Accessible Charging

As plug-in electric vehicles (PEVs) are introduced to the market place and gain more consumer acceptance, it is important for a robust and self-sustaining non-residential infrastructure of electric vehicle supply equipment (EVSE) to be established to meet the needs of PEV drivers. While federal and state financial incentives for electric vehicles were in place and remain so today, future incentives are uncertain. In order for PEVs to achieve mainstream adoption, an adequate and sustainable commercial or publicly available charging infrastructure was pursued by The EV Project to encourage increased PEV purchases by alleviating range anxiety, and by removing adoption barriers for consumers without a dedicated overnight parking location to provide a home-base charger. This included determining a business model for publicly accessible charge infrastructure. To establish this business model, The EV Project team created a fee for charge model along with various ancillary offerings related to charging that would generate revenue. And after placing chargers in the field the Project rolled out this fee structure.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2017

3D-FE Modeling of 316 SS under Strain-Controlled Fatigue Loading and CFD Simulation of PWR Surge Line

In financial year 2017, we are focusing on developing a mechanistic fatigue model of surge line pipes for pressurized water reactors (PWRs). To that end, we plan to perform the following tasks: (1) conduct stress- and strain-controlled fatigue testing of surge-line base metal such as 316 stainless steel (SS) under constant, variable, and random fatigue loading, (2) develop cyclic plasticity material models of 316 SS, (3) develop one-dimensional (1D) analytical or closed-form model to validate the material models and to understand the mechanics associated with 316 SS cyclic hardening and/or softening, (4) develop three-dimensional (3D) finite element (FE) models with implementation of evolutionary cyclic plasticity, and (5) develop computational fluid dynamics (CFD) model for thermal stratification, thermal-mechanical stress, and fatigue of example reactor components, such as a PWR surge line under plant heat-up, cool-down, and normal operation with/without grid-load-following. This semi-annual progress report presents the work completed on the above tasks for a 316 SS laboratory-scale specimen subjected to strain-controlled cyclic loading with constant, variable, and random amplitude. This is the first time that the accurate 3D-FE modeling of the specimen for its entire fatigue life, including the hardening and softening behavior, has been achieved. We anticipate that this work will pave the way for the development of a fully mechanistic-computer model that can be used for fatigue evaluation of safety-critical metallic components, which are traditionally evaluated by heavy reliance on time-consuming and costly test-based approaches. This basic research will not only help the nuclear reactor industry for fatigue evaluation of reactor components in a cost effective and less time-consuming way, but will also help other safety-related industries, such as aerospace, which is heavily dependent on test-based approaches, where a single full-scale fatigue test can cost millions of dollars and require years of effort to conduct. Toward our goal of demonstration of fully mechanistic fatigue evaluation of reactor components, we also started work on developing a component-level computer model of reactor components, such as 316 SS surge line pipe. This requires developing a thermal-mechanical stress analysis model of the reactor surge line, which, in turn, requires time-dependent temperature and stratification information along the boundary of the pipe. Toward that goal, CFD models of surge lines are being developed. In this report, we also present some preliminary results showing the temperature conditions along the surge line wall under reactor heat-up, cool-down, and steady-state power operation.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2017

Low Global Warming Potential Refrigerants for Commercial Refrigeration Systems

Supermarket refrigeration systems account for approximately 50% of supermarket energy use, placing this class of equipment among the highest energy consumers in the commercial building domain. In addition, the commonly used refrigeration system in supermarket applications is the multiplex direct expansion (DX) system, which is prone to refrigerant leaks due to its long lengths of refrigerant piping. This leakage reduces the efficiency of the system and increases the impact of the system on the environment. The high Global Warming Potential (GWP) of the hydrofluorocarbon (HFC) refrigerants commonly used in these systems, coupled with the large refrigerant charge and the high refrigerant leakage rates leads to significant direct emissions of greenhouse gases into the atmosphere. Environmental concerns are driving regulations for the heating, ventilating, air-conditioning and refrigeration (HVAC&R) industry towards lower GWP alternatives to HFC refrigerants. Existing lower GWP refrigerant alternatives include hydrocarbons, such as propane (R-290) and isobutane (R-600a), as well as carbon dioxide (R-744), ammonia (R-717), and R-32. In addition, new lower GWP refrigerant alternatives are currently being developed by refrigerant manufacturers, including hydrofluoro-olefin (HFO) and unsaturated hydrochlorofluorocarbon (HCFO) refrigerants. The selection of an appropriate refrigerant for a given refrigeration application should be based on several factors, including the GWP of the refrigerant, the energy consumption of the refrigeration system over its operating lifetime, and leakage of refrigerant over the system lifetime. For example, focusing on energy efficiency alone may overlook the significant environmental impact of refrigerant leakage; while focusing on GWP alone might result in lower efficiency systems that result in higher indirect impact over the equipment lifetime. Thus, the objective of this Collaborative Research and Development Agreement (CRADA) between Honeywell and the Oak Ridge National Laboratory (ORNL) is to develop a Life Cycle Climate Performance (LCCP) modeling tool for optimally designing HVAC&R equipment with lower life cycle greenhouse gas emissions, and the selection of alternative working fluids that reduce the greenhouse gas emissions of HVAC&R equipment. In addition, an experimental evaluation program is used to measure the coefficient of performance (COP) and refrigerating capacity of various refrigerant candidates, which have differing GWP values, in commercial refrigeration equipment. Through a cooperative effort between industry and government, alternative working fluids will be chosen based on maximum reduction in greenhouse gases at minimal cost impact to the consumer. This project will ultimately result in advancing the goals of reducing greenhouse gas emissions through the use of low GWP working fluids and technologies for HVAC&R and appliance equipment, resulting in cost-competitive products and systems.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2017

Regulatory Incentives and Disincentives for Utility Investments in Grid Modernization

Electric power is America's most capital-intensive industry, with more than $100 billion invested each year in energy infrastructure. Investment needs are likely to grow as electric utilities make power systems more reliable and resilient, deploy advanced digital technologies, and facilitate new services to meet some consumers' expectations for greater choice and control. But do current regulatory approaches provide the appropriate incentives for grid modernization investments? This report presents three perspectives: -Financial analyst Steve Kihm begins by explaining that any major investor-owned electric utility that wants to raise capital today can do so at a reasonable cost. The question is whether utility managers want to raise capital for grid modernization. Specifically, they look for investments that create the most value for their existing shareholders. In cases where grid modernization investments are not the best choice in terms of shareholder value, Kihm describes shareholder incentive mechanisms that regulators could consider to encourage such investments when they are in the public interest. -From an institutional perspective, Dr. Janice Beecher finds that the traditional rate-base/rate of return regulatory model provides powerful incentives for utilities to pursue investments, cost control, efficiency and even innovation, and it is well suited to the policy objectives of grid modernization. Prudence of grid modernization investments (fair returns) depends on careful evaluation of the specific asset, and any special incentives (bonus returns) should be used only if they promote economic efficiency consistent with the core goals of economic regulation. According to Beecher, realizing the promises of grid modernization depends on effective implementation of the traditional regulatory model and ratemaking tools to serve the public interest. -Conversely, former commissioner and clean energy consultant Ron Lehr says that rapid electric industry changes require a better alignment of utility investment incentives with changes challenging the electricity sector, emerging grid modernization options and benefits, and public policies. For example, investor-owned utilities typically have an incentive to make capital investments, but rarely to employ expense-based solutions, since utilities do not earn profits on expenses. Further, Lehr cites a variety of factors that stand in the way of creating well targeted and well aligned utility incentives, including litigated regulatory processes. These may be a poor choice for finding the right balance among competing interests, establishing rules of prospective application, justifying demonstrations of new technologies and approaches to meeting emerging consumer demands, and keeping pace with rapid change.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2017

Energy Efficiency Financing for Low- and Moderate-Income Households: Current State of the Market, Issues, and Opportunities

Ensuring that low- and moderate-income (LMI) households have access to energy efficiency is equitable, provides energy savings as a resource to meet energy needs, and can support multiple policy goals, such as affordable energy, job creation, and improved public health. Although the need is great, many LMI households may not be able to afford efficiency improvements or may be inhibited from adopting efficiency for other reasons. Decision-makers across the country are currently exploring the challenges and potential solutions to ramping up adoption of efficiency in LMI households, including the use of financing. The report’s objective is to offer state and local policymakers, state utility regulators, program administrators, financial institutions, consumer advocates and other LMI stakeholders with an understanding of: -The relationship between LMI communities and financing for energy efficiency, including important considerations for its use such as consumer protections -The larger programmatic context of grant-based assistance and other related resources supporting LMI household energy efficiency -Lessons learned from existing energy efficiency financing programs serving LMI households -Financing products used by these programs and their relative advantages and disadvantages in addressing barriers to financing or to energy efficiency uptake for LMI households

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2017

National Plug-In Electric Vehicle Infrastructure Analysis

This document describes a study conducted by the National Renewable Energy Laboratory quantifying the charging station infrastructure required to serve the growing U.S. fleet of plug-in electric vehicles (PEVs). PEV sales, which include plug-in hybrid electric vehicles (PHEVs) and battery electric vehicles (BEVs), have surged recently. Most PEV charging occurs at home, but widespread PEV adoption will require the development of a national network of non-residential charging stations. Installation of these stations strategically would maximize the economic viability of early stations while enabling efficient network growth as the PEV market matures. This document describes what effective co-evolution of the PEV fleet and charging infrastructure might look like under a range of scenarios. To develop the roadmap, NREL analyzed PEV charging requirements along interstate corridors and within urban and rural communities. The results suggest that a few hundred corridor fast-charging stations could enable long-distance BEV travel between U.S. cities. Compared to interstate corridors, urban and rural communities are expected to have significantly larger charging infrastructure requirements. About 8,000 fast-charging stations would be required to provide a minimum level of coverage nationwide. In an expanding PEV market, the total number of non-residential charging outlets or 'plugs' required to meet demand ranges from around 100,000 to more than 1.2 million. Understanding what drives this large range in capacity requirements is critical. For example, whether consumers prefer long-range or short-range PEVs has a larger effect on plug requirements than does the total number of PEVs on the road. The relative success of PHEVs versus BEVs also has a major impact, as does the number of PHEVs that charge away from home. This study shows how important it is to understand consumer preferences and driving behaviors when planning charging networks.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2017

Summary of FY17 ParaChoice Accomplishments

As part of analysis support for FCTO, Sandia assesses the factors that influence the future of FCEVs and Hydrogen in the US vehicle fleet. Using ParaChoice, we model competition between FCEVs, conventional vehicles, and other alternative vehicle technologies in order to understand the drivers and sensitivities of adoption of FCEVs. ParaChoice leverages existing tools such as Autonomie (Moawad et al., 2016), AEO (U.S. Energy Information Administration, 2016), and the Macro System Model (Ruth et al., 2009) in order to synthesize a complete picture of the co-evolution of vehicle technology development, energy price evolution, and hydrogen production and pricing, with consumer demand for vehicles and fuel. We then assess impacts of FCEV market penetration and hydrogen use on green- house gas (GHG) emissions and petroleum consumption, providing context for the role of policy, technology development, infrastructure, and consumer behavior on the vehicle and fuel mix through parametric and sensitivity analyses.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2017

Estimating Energy Consumption of Mobile Fluid Power in the United States

This report estimates the market size and energy consumption of mobile off-road applications utilizing hydraulic fluid power, and summarizes technology gaps and implementation barriers. Mobile fluid power is the use of hydraulic fluids under pressure to transmit power in mobile equipment applications. The mobile off-road fluid power sector includes various uses of hydraulic fluid power equipment with fundamentally diverse end-use application and operational requirements, such as a skid steer loader, a wheel loader or an agriculture tractor. The agriculture and construction segments dominate the mobile off-road fluid power market in component unit sales volume. An estimated range of energy consumed by the mobile off-road fluid power sector is 0.36 - 1.8 quads per year, which was 1.3 percent - 6.5 percent of the total energy consumed in 2016 by the transportation sector. Opportunities for efficiency improvements within the fluid power system result from needs to level and reduce the peak system load requirements and develop new technologies to reduce fluid power system level losses, both of which may be facilitated by characterizing duty cycles to define standardized performance test methods. There are currently no commonly accepted standardized test methods for evaluating equipment level efficiency over a duty cycle. The off-road transportation sector currently meets criteria emissions requirements, and there are no efficiency regulations requiring original equipment manufacturers (OEM) to invest in new architecture development to improve the fuel economy of mobile off-road fluid power systems. In addition, the end-user efficiency interests are outweighed by low equipment purchase or lease price concerns, required payback periods, and reliability and durability requirements of new architecture. Current economics, low market volumes with high product diversity, and regulation compliance challenge OEM investment in commercialization of new architecture development.

13 HYDRO ENERGY↗
DOE OSTI2017

Fluid-Structure Interaction of Deforming Porous Media

Sandia National Laboratories (SNL) and the Procter and Gamble Company (P&G) collaborated to develop a computational tool that predicts the in-use performance of consumer good products based on specific loading, geometries, materials, and boundary conditions. This computational tool is particularly useful in exploring the consumer-product interface and product performance. The benefit to P&G was many-fold, as the numerous project-tasks that were funded under this agreement led to advanced analysis software that allowed P&G to improve the performance and manufacturing of many of their products across several business units. The benefit to SNL was many-fold as well, including improved reduced-order models for thin-region dynamics (used for customers through DSA, NW, and EC PMUs), improved computational mechanics capability for capillary hydrodynamics, porous flow, structural mechanics, and more. Example applications of these improved capabilities at SNL include, but are not limited to, encapsulation, welding, soldering, and brazing models for NW, interface sliding models for DoD SPP programs, and porous-elastic subsidence modeling for energy and climate applications. Moreover, many current code developers on the ASC program’s SIERRA applications gained valuable skills working on this CRADA.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2017

ParaChoice Model.

Analysis with the ParaChoice model addresses three barriers from the VTO Multi-Year Program Plan: availability of alternative fuels and electric charging station infrastructure, availability of AFVs and electric drive vehicles, and consumer reluctance to purchase new technologies. In this fiscal year, we first examined the relationship between the availability of alternative fuels and station infrastructure. Specifically, we studied how electric vehicle charging infrastructure affects the ability of EVs to compete with vehicles that rely on mature, conventional petroleum-based fuels. Second, we studied how the availability of less costly AFVs promotes their representation in the LDV fleet. Third, we used ParaChoice trade space analyses to help inform which consumers are reluctant to purchase new technologies. Last, we began analysis of impacts of alternative energy technologies on Class 8 trucks to isolate those that may most efficaciously advance HDV efficiency and petroleum use reduction goals.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2017

Coeur d’Alene Tribe Benewah Market Energy Efficiency Project Final Technical Report

The Coeur d’Alene Reservation has been the home of the Coeur d’Alene Tribe since time immemorial and it is fitting that the Tribe’s name in the Coeur d’Alene language is schitsu’umsh, “the ones who were found here.” The Reservation is located in northern Idaho, is approximately 345,000 acres and is comprised of forest land, agricultural land, several streams, Coeur d’Alene Lake and the St. Joe River and a small amount of developed land. The project area was conducted within the boundaries of the Coeur d’Alene Reservation. The population of the Reservation is 6,760 (2010 Census). Currently, there are approximately 2,463 enrolled Coeur d’Alene Tribal members (Coeur d’Alene Tribe Enrollment 2016). The Benewah Market is a Tribally-owned and operated facility located at 1111 B St. Plummer, ID 83851. The Benewah Market is an approximately 23,500 square foot single-story structure. The majority of the building is occupied by a grocery store with a full meat department, deli, and bakery. Approximately 20% of the floor area at the northeast corner is occupied by an Ace Hardware retailer. The largest part of the building is approximately 17,000 square feet, is separately metered and houses the grocery store which was constructed in 1984. The market is the largest full service market serving the Coeur d’Alene Reservation and is the only full service market in a 35-mile radius. The Tribe has benefited greatly from the Benewah Market Energy Efficiency Project and will continue to do so for many years: The health and safety of the food has been improved greatly now that the refrigeration and freezer cases are at a constant and safe temperature on a monitoring and alarm system. There is no longer a thaw and freeze cycle that allows fluctuations in temperature. If the power goes out, there is an immediate alarm and contact so that time may be tracked and food kept safe during an outage. The overall annual energy use in the Benewah Market has dropped by 22.9% -Energy costs for the Market decreased by an estimated 11,620 dollars in one year due to this project. The Tribe has seen an increase in the cost of energy from Plummer Power and this was offset by the reduction in energy consumed. This estimate assumes that the Tribe would have consumed the same amount of energy as the prior year. -Maintenance costs are estimated to have decreased by $10,000 in just the one year since installation in contract repair and maintenance. The Tribe estimates that it has saved 24,000 dollars over a one-year time period in labor costs to maintain the older system. Due to having a more efficient store, with safer, more attractive display of food and lower energy and maintenance costs, the store is able to be more viable economically. The store has increased its sales and has been able to pass along operations and maintenance savings to its customers and employees. The Tribe hosted a ribbon-cutting ceremony on February 28, 2017 at the Benewah Market with Chris Deschene, then Office of Indian Energy Director, as well as representatives from the Coeur d’Alene Tribe and Bonneville Power Administration. While the ribbon-cutting ceremony was going on, the Tribe’s media outlets covered the ceremony and placed information about the project on the Tribe’s Facebook page on two separate occasions. The Coeur d’Alene Tribe’s Natural Resources Department and the Tribe’s Development Corporation are thankful for the opportunity that the Benewah Market Energy Efficiency Project has afforded the Coeur d’Alene Tribal community. Without the U.S. Department of Energy’s Indian Energy Program funding and its dedicated staff, this project would not have been completed. This has been a lot of work for all parties involved but has provided benefits to thousands of people for many years to come.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2017

Ceramic Proppant Design for In-situ Microbially Enhanced Methane Recovery

This project designed a new type of multi-functional lightweight proppant. The proppant is utilized as the conventional lightweight proppant but also transports microorganisms to coalbed reservoirs. The proppant is coated with a polymer which protects the methanogenic microorganisms and serves as a time-release delivery for methane generation. To produce the multifunctional proppant, we assigned five tasks: 1) culturing methanogenic microbes from natural carbon sources; 2) identifying optimized growth and methanogenesis conditions for the microbial consortia; 3) synthesizing the lightweight ceramic proppant; 4) encapsulating the consortia and proppant; and 5) demonstrating lab scale simulated performance by monitoring in-situ methane generation and hydraulic conductivity. Task 1) To evaluate the feasibility of ex-situ cultivation, natural microbial populations were collected from various hydrocarbon-rich environments and locations characterized by natural methanogenesis. Different rank coals, complex hydrocarbon sources, hydrocarbon seeps, and natural biogenic environments were incorporated in the sampling. Three levels of screening allowed selection of microbial populations, favorable nutrient amendments, sources of the microbial community, and quantification of methane produced from various coal types. Incubation periods of up to 24 weeks were evaluated at 23°C. Headspace concentrations of CH 4 and CO 2 were analyzed by gas chromatography. After a two-week incubation period of the most promising microbes, generated headspace gas concentrations reached 873,400 ppm for methane and 176,370 ppm for carbon dioxide. Task 2) A central composite design (CCD) was used to explore a broad range of operational conditions, examine the effects of the important environmental factors, such as temperature, pH and salt concentration, and query a feasible region of operation to maximize methane production from coal. Coal biogasification was optimal for this consortium at an initial pH value of 5.5, at 30 °C, and at a NaCl concentration 3.7 mg/cm 3 (i.e., 145,165 ppm). Task 3) To create the lightweight ceramic proppant, the kaolinite and iron oxide (Fe 2 O 3 ) mixture were sintered under reducing atmosphere varying partial pressures of oxygen from 1.7×10 -13 atm to 1.8×10-11 atm. The Fe 2 O 3 reduces to FeO and reacts with kaolinite decomposed to mullite to form Fe 2 SiO 4 , FeSiO 3 , and FeAl 2 O 4 . As a result the proppant develops large pores (~100 µm), giving it a low bulk density (1.43 g/cm 3 ), and high porosity (45.2 vol%) at P_(O_2 )of 1.8×10 -11 atm. The proppant sintered at P_(O_2 )of 1.7×10 -13 atm is characterized by smaller pores (26 µm), higher density (1.72 g/cm3) and lower porosity (37.5 vol%). Crush resistance testing at 9,000 psi yields 6.8 wt% fine particles increasing to 17.7 wt% in porous samples. Acid solubility varies from 5.5 wt% loss increasing to 12.9 wt% in porous samples. Task 4 and 5) The microbial consortia obtained from the optimized condition and lightweight proppant were encapsulated by calcium-alginate polymer. The encapsulation system, including microbes and a proppant, was stored at 20°C and 36°C. The sample stored at 36°C generated 7.1×[10] 3 ppm of methane at 670 h, whereas the sample incubated at 20°C generated 1.1×[10] 3 ppm of methane. Benchtop lab-scale bioreactors were constructed and showed with real-time measurements that, as the microbes produced methane, the pH decreased, and hydrogen and carbon dioxide gases were consumed. A calcium ion-selective sensor revealed the release mechanism of the microbes from encapsulation. The calcium ions interconnecting the alginate monomers were disassociated by counter cations such as protons and potassium ions. The counter cations bound to the carboxyl group on the alginate monomer, which thus lost its ionic interactions with the calcium ions, resulting in decomposition of the hydrogel structure. Furthermore, the conductivity was increased to ~700 mD-ft from ~530 mD-ft once the encapsulated sample was applied to the coal pack. The particle size of coal was reduced when the encapsulated sample was added to the coal. The reduced coal size implied that the microbes would consume the hydrocarbon in coal.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2016

Collision Welding of Dissimilar Materials by Vaporizing Foil Actuator: A Breakthrough Technology for Dissimilar Metal Joining

This work demonstrated and further developed Vaporizing Foil Actuator Welding (VFAW) as a viable technique for dissimilar-metal joining for automotive lightweighting applications. VFAW is a novel impact welding technology, which uses the pressure developed from electrically-assisted rapid vaporization of a thin aluminum foil (the consumable) to launch and ultimately collide two of more pieces of metal to create a solid-state bond between them. 18 dissimilar combinations of automotive alloys from the steel, aluminum and magnesium alloy classes were screened for weldability and characterized by metallography of weld cross sections, corrosion testing, and mechanical testing. Most combinations, especially a good number of Al/Fe pairs, were welded successfully. VFAW was even able to weld combinations of very high strength materials such as 5000 and 6000 series aluminum alloys to boron and dual phase steels, which is difficult to impossible by other joining techniques such as resistance spot welding, friction stir welding, or riveting. When mechanically tested, the samples routinely failed in a base metal rather than along the weld interface, showing that the weld was stronger than either of the base metals. As for corrosion performance, a polymer-based protective coating was used to successfully combat galvanic corrosion of 5 Al/Fe pairs through a month-long exposure to warm salt fog. In addition to the technical capabilities, VFAW also consumes little energy compared to conventional welding techniques and requires relatively light, flexible tooling. Given the technical and economic advantages, VFAW can be a very competitive joining technology for automotive lightweighting. The success of this project and related activities has resulted in substantial interest not only within the research community but also various levels of automotive supply chain, which are collaborating to bring this technology to commercial use.

36 MATERIALS SCIENCE↗