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DOE OSTI2025

A Hybrid Dynamic/Steady-State Tool With Protection Simulation for Cascading-Outage Analysis of Extreme Events in Power Systems

The bulk electric power grid is subject to vulnerabilities from component outages, which in certain combinations (extreme events) might lead to cascading outages. Some of these outages can be severe enough to trigger brownouts and blackouts. Much is known about mitigating the first few failures near the beginning of a cascade, but there are few established methods and tools for directly analyzing the risks of cascading component outages over a longer time scale. Current power system tools have limited ability to perform detailed and accurate cascading-outage analysis, which could be computationally intensive. The Dynamic Contingency Analysis Tool (DCAT) enables power system planning engineers to more realistically assess the consequences of extreme contingencies and potential cascading events across their systems and interconnections. DCAT has several unique features: (i) detailed hybrid dynamic and steady-state analysis of power systems to mimic real-world cascading outages, (ii) detailed modeling of protection systems embedded in the dynamic simulation, (iii) simulation of corrective action after transients, (iv) simulation of islanding , and (v) high-performance computing capability to simulate a large number of contingencies in a reasonable time. DCAT outputs will help find technically sound solutions to reduce the risk of cascading outages. This paper provides details of DCAT methodology and shows its capabilities with extreme events on real-world cases.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2022

The dynamic nature of risk in DOE facilities in the surveillance and maintenance program–with observations for risk communications

Here, we explore three case studies of facilities at two US Department of Energy (DOE) former nuclear weapons research and production sites—the Oak Ridge National Laboratory and the Hanford site—whose risk profiles have changed during their long-term management under the DOE's surveillance and maintenance (S&M) program. These case studies provide examples of the challenges faced in communicating to external stakeholders, such as federal and state regulators, local communities surrounding the site, as well as the general public, the circumstances surrounding unexpected events or the emergence/discovery of new risk-important information at historically high-risk sites. We identify common topics of importance from these case studies and suggest a taxonomy for risk communicators to use in informing the dialogues with individuals and organizations that may not be technically oriented or fully informed on the subject matter. The taxonomy is based on technical insights from the quintessential definition of risk known as the Kaplan–Garrick “risk triplet” as well as insights from regulatory guidance documents on risk communication with external stakeholders originally developed for the commercial nuclear power industry.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗

DOE OSTI2020

Fast Computational Algorithms for Partial Differential Equations and Uncertainty Quantifications

This project concerned the construction, testing and analysis of computational algorithms for solving parameterized and stochastic partial differential equations. The study and understanding of equations of this type is of fundamental importance in numerous engineering and scientific applications. Examples include simulation of plasma dynamics in models of electric propulsion and nuclear fusion, simulation of multiphase flows, such as the flow of water, gas and oil in reservoirs, and structural analysis of the dependence of structures on materials. Parametrization is used in such settings when properties of the models such as viscosity of fluids or electric resistivity of materials are not precisely understood and instead are treated as random variables. The resulting solutions are themselves random, and having such solutions will enable engineers to use probabilistic methods to assess the likelihood of events, for example, whether a pollutant in a liquid will exceed a limit, and to use such analyses to develop ways to ensure positive outcomes. Construction of accurate (high resolution) computational solutions is expensive, requiring significant computer time and computational resources, and there is need to reduce computational cost to make simulation useful and effective. The aim of the project was to construct algorithms to efficiently compute surrogate solutions to parameterized problems to allow for efficient and accurate simulation. The technical approach used focused on two related strategies, based on rank-reduction methods and reduced-order models. These methods construct surrogate solutions of parameter-dependent models by projection or interpolation into low-dimensional approximation spaces. Cost savings are achieved if the low-dimensional spaces can be identified and constructed efficiently and if the resulting low-dimensional algebraic systems can be solved cheaply. Accomplishments include: Theoretical and empirical demonstration of the effectiveness of fast multigrid solution strategies for computing low-rank representations of parameter-dependent solutions to discrete partial differential equations, including the first proof establishing so-called textbook convergence properties for low-rank methods. Development of efficient solution algorithms for solving nonlinear parameter-dependent partial differential equations used in models of fluid dynamics. Developent of efficient algorithms for low-rank representation of solutions of time-dependent simulations of fluid dynamics using multi-dimensional tensor representations of solutions.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2025

In situ Detection of Plasma Induced Surface Interaction based on Deep Learning based Visual Diagnostics (Technical Report)

It is characteristic for many plasma devices to undergo plasma-material interaction leading to surface erosion. These processes, often not easily detectable, lead to changes in device performance and lifespan. State-of-the-art lifetime tests and wear experiments require over 1000s hours. A self-consistent model for accurately predicting the erosion's effects is not available. In situ detection of these processes is not a trivial task since the surface variations at the early stages have a micron scale. Such limitations not only restrict testing and prediction capabilities but also slow the development of new thrusters and limit mission duration. To address these challenges, an in-situ diagnostic for real-time erosion assessment has been developed, aiming to expedite lifetime testing and broaden experimental campaigns. Several works were dedicated to real-time and in situ monitoring of material erosion during plasma exposure using laser holography, microscopy, and with telemicroscopes. However, the applicability of these approaches is limited due to complexity, cost and less flexibility as they often require placing diagnostic equipment inside the vacuum chamber. In collaboration with Princeton Collaborative Research Facility (PCRF), Princeton Plasma Physics Laboratory (PPPL), a new diagnostic approach is developed, where geometry modifications to the ceramic channel walls were introduced that would result in accelerated channel erosion. We employed Long-distance microscope (LDM) imagery, combined with Deep-Learning based Shape from focus or depth from focus (DFF or SFF) approach, that provides an accessible and cost-effective solution. LDM employs focus variation techniques to continuously capture multiple images of the target object at distinct focal planes. DFF, an optical focus variation method, generates a 3D topographical surface depth map from a sequence of variably focused images. Combined with the developed diagnostic, this approach offers a controllable means to study erosion under accelerated conditions. In this work, we develop Neural Network-based DFF algorithm applicable for LDM data to quantitatively evaluate plasma induced surface modification from LDM data. Next, we develop Deep Learning-based super-resolution depth map image reconstruction technique to increase the resolution of depth maps obtained from DFF algorithm to improve the accuracy of erosion measurements. Thirdly, we develop several image processing techniques to remove noise and improve the quality of depth map image. Here we report the results of initial tests for this approach. An experimental setup designed and built in PPPL was employed that consists of a 3-cm gridded ion source that produces a neutralized argon beam with energies up to 600 eV. A hexagonal boron nitride (h-BN) ceramic target, designed based on computational predictions, was used. Tests were conducted to reconstruct the complex geometry of the target under the lighting conditions of the operated ion source.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2023

The role of international collaboration in the United States geologic disposal research program

Abstract. More than a decade ago, the United States disposal program discontinued all research activities focused on the unsaturated fractured tuff formation at Yucca Mountain as the geologic disposal site for spent fuel and high-level radioactive waste. A new research and development (R&D) program was initiated to provide a sound technical basis for alternative disposal options across clay, crystalline, and salt rocks. The goals of this broad program were (and still are) to (1) increase confidence in the robustness of generic disposal concepts, (2) develop the science and engineering tools needed to support disposal concept implementation, and (3) conduct R&D on the direct disposal of existing dual-purpose (storage and transportation) canisters. Recognizing the benefits of international collaboration toward the common goal of safely and efficiently managing the back end of the nuclear fuel cycle, the program emphasized international cooperation as an effective strategy for sharing information and knowledge. In a multi-laboratory effort coordinated by Lawrence Berkeley National Laboratory, the United States Department of Energy (DOE) program established formal and informal cooperation partnerships with several international initiatives and institutions and developed a number of collaborative R&D activities in important research areas, such as engineered barrier integrity, near-field perturbations, radionuclide transport, performance assessment, and methods for characterization and monitoring of engineered and natural barriers. This presentation gives an overview of these R&D activities, with a specific focus on activities that improve our current understanding of the coupled thermal–hydrological–mechanical–chemical (THMC) processes occurring in engineered and natural barriers. We start with a brief review of selected international collaboration initiatives and then describe a few specific collaboration projects. We focus specifically on such studies that use experimental data sets provided by international research cooperation for joint modeling work to increase confidence in performance-relevant predictions of coupled processes. Overall, the focus on international collaboration has allowed deep engagement of US researchers with the international waste management R&D community in terms of best practices, new scientific advances, state-of-the-art simulation tools, new monitoring and performance confirmation approaches, and lessons learned. The joint R&D with international researchers, worldwide sharing of knowledge and experience, and access to relevant data and experiments from a variety of host rocks have helped our researchers to significantly improve their understanding of the current technical basis for disposal in a range of potential host rock environments. International collaboration also provides ample opportunity for training and educating junior staff that are well suited to move the United States disposal research program forward into the next decades, a promising avenue for developing a next-generation workforce of disposal scientists.

Birkholzer, Jens T.↗

DOE OSTI2021

Progress and prospects of thermo-mechanical energy storage – A critical review

The share of electricity generated by intermittent renewable energy sources is increasing (now at 26% of global electricity generation) and the requirements of affordable, reliable and secure energy supply designate grid-scale storage as an imperative component of most energy transition pathways. The most widely deployed bulk energy storage solution is pumped-hydro energy storage (PHES), however, this technology is geographically constrained. Alternatively, flow batteries are location independent and have higher energy densities than PHES, but remain associated with high costs and low lifetimes, which highlights the importance of developing and utilizing additional larger-scale, longer-duration and long-lifetime energy storage alternatives. Here, we review a class of promising bulk energy storage technologies based on thermo-mechanical principles, which includes: compressed-air energy storage (CAES), liquid-air energy storage (LAES) and pumped-thermal electricity storage (PTES). The thermodynamic principles upon which these thermo-mechanical energy storage (TMES) technologies are based are discussed and a synopsis of recent progress in their development is presented, assessing their ability to provide reliable and cost-effective solutions. The current performance and future prospects of TMES systems are examined within a unified framework and a thermoeconomic analysis is conducted to explore their competitiveness relative to each other as well as when compared to PHES and flow battery systems. This includes carefully selected thermodynamic and economic methodologies for estimating the component costs of each configuration in order to provide a detailed and fair comparison at various system sizes. The analysis reveals that the technical and economic characteristics of TMES systems are such that, especially at higher discharge power ratings and longer discharge durations, they can offer promising performance (round-trip efficiencies higher than 60%) along with high lifetimes (> 30 years), low specific costs (often below 100 $/kWh), low ecological footprints and unique sector-coupling features compared to other storage options. TMES systems have significant potential for further progress and the thermoeconomic comparisons in this paper can be used as a benchmark for their future evolution.

25 ENERGY STORAGE↗

DOE OSTI2024

TEAMER: Results of Investigating Structural Design Concepts and Alternative Materials for a Wave Power System

Included here are materials from a study on the design of a three-body Wave Energy Converter (WEC) utilizing a heave plate, dual Power Take Offs (PTOs), and single point mooring. A material trade study has been conducted to evaluate the effects of introducing various metallic and fiber-reinforced polymer (FRP) elements to the design. The baseline design is C-Power's patented k2 Wave Power System (WPS). This Testing Expertise and Access for Marine Energy Research (TEAMER) Request for Technical Support (RFTS) 9 effort resulted in alternative designs of the WPS center member, the nacelle. The analysis resulting from this study will inform the design of a lightweight structure with lower manufacturing and operating costs that increases energy conversion and power-to-weight ratio of the device. The dataset contains several components: finite element analysis (FEA) data, hand calculations, and CAD models. FEA files includes those used for and generated by finite element simulations. Calculations include hand calculations performed using Microsoft Excel, which assess core laminate properties, buckling, and other structural aspects in accordance with risk management DNV-RP-C201 standards. CAD materials include Solidworks files for parts, assemblies, and drawings of the evaluated models.

16 TIDAL AND WAVE POWER↗

DOE OSTI2020

Underground Test Area (UGTA) Sampling Plan for Corrective Action Units 101 and 102: Central and Western Pahute Mesa, Nevada National Security Site, Nevada

The purpose of this groundwater sampling plan (referred to herein as “the Plan”) is to describe the approach for collecting and analyzing groundwater samples to meet the objectives of the U.S. Department of Energy (DOE), Environmental Management (EM) Nevada Program’s Underground Test Area (UGTA) Activity. The Plan is focused on the Central and Western Pahute Mesa corrective action units (CAUs 101 and 102). The remaining UGTA CAUs are in the final stage of the UGTA strategy (Closure Report [CR] stage), and monitoring requirements for these CAUs are described in their respective CRs. The Plan supersedes the Nevada National Security Site Integrated Groundwater Sampling Plan and its ensuing Record of Technical Change (ROTC) (DOE/EMNV, 2019b). The Plan is designed to ensure compliance with the UGTA Quality Assurance Plan (QAP) and its ensuing ROTC (DOE/EMNV, 2018), and the Federal Facility Agreement and Consent Order (FFACO) (1996, as amended). The Plan is implemented by the Environmental Program Services (EPS) contractor. Implementation of the Plan provides data to complete corrective actions prescribed by the FFACO to protect the public from groundwater contaminated by historical underground nuclear testing. The Plan’s scope comprises sample collection and analysis requirements for assessing the extent of groundwater contamination from underground nuclear testing. Sampling wells located in the communities surrounding the Nevada National Security Site (NNSS) is performed by other organizations (e.g., management and operating [M&O] contractor) and is therefore not included within the Plan. The results of the community sampling are presented in the annual NNSS environmental reports.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2022

Bottom-up assessment of industrial heat pump applications in U.S. Food manufacturing

Decarbonization of the industrial process heat supply through electrification could contribute significantly to climate change mitigation efforts. In the U.S. industry, thermal processes accounted for more than two-thirds of the total final energy demand in 2021. Cross-cutting electrification technologies like industrial heat pumps are suitable for the process heat supply to several industrial unit operations in a sustainable way while also improving overall energy efficiency. This study employs a bottom-up approach to investigate the techno-enviro-economic potentials of deploying high-temperature and steam-generating heat pumps in the major U.S. food manufacturing sectors in different timeframes. The results show that the annual technical potential energy and CO 2 savings by electrifying process heat supply are 325 PJ (or approximately 20% of the total final energy demand in U.S. food manufacturing) and 31 MtCO 2 (equivalent to the annual CO 2 emissions from over 6 million cars in the U.S.) in 2050, respectively; however, these incur additional costs in each sector. Although there may be individual cost-effective opportunities for electrifying heat supply in specific industrial sites, the overall costs are estimated to be high in the food sectors due to the large disparity between electricity and natural gas prices and low heat source temperatures. To overcome the identified techno-economic barriers, comprehensive action plans for different stakeholders are needed. In conclusion, this study provides novel insights that should inform policymakers’ and executives’ decisions about the electrification of the current and future U.S. industrial heat supply in relevant industrial sectors.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2021

Vehicle Technologies and Hydrogen and Fuel Cell Technologies Research and Development Programs Benefits Assessment Report for 2020

The U.S. Department of Energy’s Vehicle Technologies and Hydrogen and Fuel Cell Technologies Offices (VTO and HFTO) support research and development of efficient and sustainable transportation technologies that will improve energy efficiency, minimize emissions, and enable America to use less petroleum. VTO and HFTO regularly revisit and update relevant research and development goals and areas of emphasis in response to the latest technological advancements and in alignment with current national priorities. As such, analyses of expected benefits resulting from VTO and HFTO investments and anticipated goal achievements are updated periodically and will be again for 2021 in the context of the latest national-level transportation decarbonization goals. The analysis in the present report is based on technical progress goals established in VTO and HFTO in the years immediately prior to and including 2020, and it summarizes the estimated energy and emissions benefits corresponding to achievement of those goals. The goals span research activities on batteries, electric drive technologies (EDT), combustion, lightweight materials, fuel cells, and hydrogen storage. The evaluation includes detailed analyses into the benefits of technology improvements on the U.S. light-duty (LD) vehicle fleet and separately on the U.S. medium- and heavy-duty (MDHD) vehicle fleet. This report summarizes the outcomes from each of these analyses both independently and in combination.

08 HYDROGEN↗

DOE OSTI2023

WellSTIC: A Cost-Effective Sensor for Performing Point Dilution Tests to Measure Groundwater Velocity in Shallow Aquifers

Many individual measurement points are required to characterize groundwater velocity within an aquifer. Groundwater velocity is most commonly measured using a network of >5 cm diameter monitoring wells, which, if not already present at a site, are expensive and labor-intensive to install. Drive-point piezometers—simple, cost-effective wells that can be installed by hand—are a common tool for sampling groundwater in shallow, alluvial aquifers, but most groundwater velocity measurement techniques require equipment that is too large for these narrow (usually <2 cm inside diameter) piezometers. In this technical note, we introduce a low-cost sensor and well packer system (<$90 USD) for performing point dilution tests in narrow piezometers. Field data show that the magnitude of groundwater velocity measured with this technique agrees with velocities computed from natural gradient tracer tests. Additionally, with proper calibration, these sensors can be used to continuously monitor in-well specific conductance, either during inter-well tracer tests with saline tracers or for water quality monitoring. Finally, this system is a viable tool for rapid assessment of the magnitude of groundwater velocity in shallow aquifers.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2026

Integrating Marine Hydrokinetic and Offshore Wind Energy: A Review of Technologies, Deployment, and Challenges

Together, offshore wind (OSW) and marine hydrokinetic (MHK) technologies have vast potential to expand the world’s access to abundant energy resource. With more than 60 GW of offshore wind energy capacity and 527 MW of ocean energy deployed globally by 2023, there is a significant amount of available resources; however, technical and non-technical challenges prevent the combined large-scale deployment of these technologies. There is still a lack of research that provides a parallel review of both MHK and OSW technologies in order to better understand their synergistic working principles. This paper aimed to address that research gap by presenting a comprehensive side-by-side review of the worldwide technological landscape, global deployment trends, integration strategies, and modeling approaches for MHK and OSW. A particular focus has been given on analyzing existing modeling and simulation techniques, assessing integration and control strategies, and comparing technologies based on water depth. Furthermore, this study provides important insights into the readiness levels of both technologies by highlighting ongoing international projects. By addressing these issues, this review will give researchers and industry stakeholders an outline for assessing the maturity of OSW and MHK systems and facilitating their transition to large-scale, sustainable deployment.

16 - TIDAL AND WAVE POWER↗

DOE OSTI2023

Robust Real-Time Modeling of Distribution Systems with Data-Driven Grid-Wise Observability (Final Technical Report)

The overall objective of this project is to leverage existing and emerging sensor measurements to develop data-driven observability enhancement algorithms as well as robust state estimation and parameter identification techniques to enable real-time grid-wise monitoring and modeling of loads and distributed energy resources (DERs). The project resulted in a holistic framework with the following key components: 1) data-driven and machine learning-based grid-edge visibility enhancement, 2) robust branch-current-based state estimation (BCSE), and 3) robust real-time steady-state and dynamic-state modeling of loads and DERs. The research outcomes have provided utility companies better network visibility, higher-fidelity load/DER models, and more accurate assessment of DERs’ impacts, thus, facilitating the integration of renewable energy sources. The synergistic collaborative project among Iowa State University (ISU), Argonne National Laboratory (ANL), Electric Power Research Center (EPRC), SIEMENS Industry, Alliant Energy, Cedar Falls Utilities (CFU), and Maquoketa Valley Electric Cooperative (MVEC) to leverage the team’s extensive expertise and experience in power distribution systems, state estimation, online modeling and identification, and DER integrations. The proposed frameworks have been verified with industry adopted software and attempted integrated with existing tool wherever possible

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2020

Solar Energy Research Institute for India and the United States (SERIIUS): Lessons and Results from a Binational Consortium

This book describes the development, functioning, and results of a successful binational program to promote significant scientific advances in Earth-abundant photovoltaics (PV) and concentrated solar power (CSP), advanced process/manufacturing technologies, multiscale modeling and reliability testing, and analysis of integrated solar energy systems. SERIIUS is a consortium between India and the United States dedicated to developing new solar technologies and assessing their potential impact in the two countries. The consortium consists of nearly 50 institutions including academia, national laboratories, and industry, with the goal of developing significant new technologies in all areas of solar deployment. In addition, the program focused on workforce development through graduate students, post-doctoral students, and an international exchange program. Particular emphasis was placed on the following efforts: creating disruptive technologies in PV and CSP through high-impact fundamental and applied research and development (R&D); identifying and quantifying the critical technical, economic, and policy issues for solar energy development and deployment in India; overcoming barriers to technology transfer by teaming research institutions and industry in an effective project structure; building a new platform for binational collaboration using a formalized R&D project structure, along with effective management, coordination, and decision processes; creating a sustainable network and workforce development program from which to build large collaborations and fostering a collaborative culture and outreach programs. This includes using existing and new methodologies for collaboration based on advanced electronic and web-based communication to facilitate functional international teams. The book summarizes the general lessons learned from these experiences.

14 SOLAR ENERGY↗

DOE OSTI2020

FY2019 Performance Assessment Annual Review for the E-Area Low-Level Waste Facility

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2020

FY2019 Performance Assessment Annual Review for the E-Area Low-Level Waste Facility

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2021

FY2020 performance assessment annual review for the E-area low-level waste facility

The Savannah River Site (SRS) E-Area Low-Level Waste Facility (ELLWF) consists of six types of disposal units described in the Performance Assessment (PA) (WSRC, 2008): Low Activity Waste Vault (LAWV), Intermediate Level Vault (ILV), Trenches [Slit Trenches (STs), Engineered Trenches (ETs), and Component-in-Grout (CIG) Trenches], and Naval Reactor Component Disposal Areas (NRCDAs). The ELLWF is a part of the Solid Waste Management Facility (SWMF). SWMF is managed and operated by the SRS Management and Operations prime contractor, Savannah River Nuclear Solutions (SRNS). Within SRNS, the Solid Waste Management (SWM) organization is responsible for operating the SWMF, and the Savannah River National Laboratory (SRNL) is the technical agency responsible for preparing and maintaining the PA. SWMF operations have been performed at SRS since 1952. The mission of the SWMF is to provide storage, processing, disposal, and shipment of radioactive, hazardous, and mixed waste. The SWMF is committed to treat, store, and dispose of these waste products in a manner that protects the environment and the health and safety of the facility worker, the co-located worker, and the offsite general public. Wastes handled in the SWMF include low level waste, transuranic waste, hazardous waste, Toxic Substances Control Act waste, and mixed waste (containing both hazardous and radioactive constituents). The FY2020 PA Annual Review for the ELLWF affirms that the disposal facility continued to operate within the bounds of the current PA and Composite Analysis (CA) baseline and the subsequent SA’s and satisfied all the requirements, conditions, and limitations identified in the 2008 DAS (DOE 2008a), RWMB SRNL_STI-2020-00588 Revision 0 vi (McGill, 2020), and ELLWF Low-Level Waste Acceptance Criteria (SRS-1S, 2014). This annual review affirms that the supporting studies performed in FY2020 do not alter the conclusions of the ELLWF PA (WSRC, 2008) and that there is a reasonable expectation that the ELLWF will meet the performance objectives delineated in DOE Manual 435.1-1 (DOE 2011)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2022

Development and Demonstration of a Fuel-Efficient, Class 8 Tractor & Trailer Engine System (SuperTruck II)

Navistar presents the SuperTruck II (ST II) Final Report to the Unites States Department of Energy (US DOE), which covers the five Budget Periods (BPs) from 10-1-2016 through 6-30-2022. For ST II, Navistar built on the achievements of the SuperTruck I (ST I) Program as a catalyst to continue critical research, design and development, testing, and operations to reach the ambitious goals of the ST II project. This approach allowed Navistar to continue contributing to the essential needs of our nation for safe, efficient, and cost-effective delivery of goods and services, as we reduced negative environmental effects and improved operational productivity. This document contains information specified in DOE F 4600.2, Final Scientific/Technical Report DOE F 241.3, B. SCIENTIFIC/TECHNICAL REPORTS, explaining how we met and exceeded program requirements. Throughout this Final Report, Navistar extracted information from documents prepared during the project that represent our management, design and development, building, and testing efforts to meet and exceed SuperTruck II project goals. Navistar followed Plan requirements to achieve / exceed Project Objectives: a) >100% improvement in vehicle freight efficiency (FE) (on ton-MPG basis) relative to 2009 baseline with stretch goal of 140% improvement [actual: 170%); b) >55% engine brake thermal efficiency (BTE) demonstrated in operational engine at a 65-mph cruise point on a dynamometer – ≥31% increase from 2009 baseline [actual: 55.20% of combined BTE) ; and c) development and implementation of commercially cost effective technologies (in terms of a simple payback). Technology selection / development path focused on developing technologies applicable for production within 3-year approach, while ensuring technology readiness and cost of ownership for end users. The Program was organized into five budget periods: Requirements / Technology Assessment and Initial Hardware Testing; Technology Development and Concept Readiness Demonstration; Technology Finalization and Validation Tractor / Trailer Fabrication, Integration and Commissioning Demonstration; and Fuel Economy (FE) and Brake Thermal Efficiency (BTE) and Program Completion. Leadership was provided by DOE, with tasks performed by laboratories (Argonne National Laboratory, Lawrence Livermore National Laboratory); partners at Bosch, TPI, Dana, and J.B. Hunt; , and support from University of Michigan and Clemson University. Navistar lead this team with Principal Investigator / Contracting Officer; Project Manager (PM); Vehicle, Engine, and Aftertreatment Engineers; Finance Manager, Technical Program Leads, and Legal/IP; and other key personnel. Work also included personnel in risk management; funding / budget / finance. Work involved analysis, development, testing, and down selection of individual/system engine, aftertreatment, and vehicle technologies, with integration of selected technologies into a prototype vehicle for demonstration of fuel-efficiency gain. Work also included component/integrated system level development of truck and trailer aerodynamics, base engine efficiency, advanced aftertreatment, combustion efficiency, waste heat recovery, hybrid powertrain, reduced rolling resistance, weight reduction, idle reduction, and driver feedback. As ST II progressed, Navistar performed computer-based modeling / simulations of technologies focused on the primary operational areas: Engine, Aftertreatment, and Vehicle. During the ST II Program, the COVID Virus outbreak unexpectedly challenged by the effects of, which affected staffing, scheduling, design, supplies, availability of materials, production procedures, and testing. The DOE responded by extending the program by three quarters to ensure that project tasks were completed for this vital project. Focus continued on analyzing, developing, testing, and down selecting individual-/system-level engine and vehicle technologies for integration of the final selected technologies into a prototype vehicle that would demonstrate fuel-efficiency gains made possible through these technologies. This included component/integrated system-level development of truck and trailer aerodynamics, base engine efficiency, advanced aftertreatment, combustion efficiency, waste heat recovery, solar power, distributed and intelligent vehicle power, hybrid powertrain, reduced rolling resistance, weight reduction, idle reduction, and driver feedback. Throughout the program, function, reliability, and performance at all levels were ensured through testing. Proof of this approach was demonstrated in multiple, on-road demonstrations: Scenario A (Flatland) Fuel Economy, Scenario B (Hilly) Fuel Economy, and City Cycle Tests. Other benefits derived from ST II included new/improved products, publications, patents, and next-step capabilities related to electric/hydrogen vehicles and autonomous driving.

Zukouski, Russ↗