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

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All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Corrosion Protection and Dissimilar Material Joining for Next Generation Lightweight Vehicles

The Arconic Technology Center working with Honda R&D Americas, LLC and the Ohio State University evaluated the corrosion performance of several multi-material conditions and demonstrated the production worthiness of the Resistance Spot Riveting (RSR™) process. RSR is a new technology being developed by Howmet Fastening Systems (formerly Arconic, Inc.) that employs a fastener that is installed using conventional resistance spot welding equipment to produce multi-material joints. The goal of the 3-year project was to demonstrate the use of RSR to join aluminum to steel and aluminum to carbon fiber composites on a prototype scale. Deployment of this technology would help the automotive industry achieve an additional 10 to 20% weight reduction over high strength steels. These weight-savings to the body in white generally translates to 2.5-5.0% of overall vehicle curb weight. The resulting total weight-savings could provide a 1.5% to 3.0% total improvement in fuel efficiency for vehicles that incorporate RSR for multi-material joining. The RSR technology addresses several production barriers to achieving DOE’s fuel efficiency targets including eliminating the need of additional capital for new joining technologies and the flexibility to process conventional steel and multi-material structures with the same equipment. Additionally, the trend towards ultra-high strength steels limits the availability of conventional joining technologies that can effectively process these multi-material combinations. In order to accomplish these goals, the following program milestones were completed by the team: 1) Developed RSR process parameters, producing multi-material joints for mechanical testing and corrosion assessments. 2) Conducted corrosion evaluation of RSR and baseline joints assembled between automotive type aluminum alloys, steels, and carbon fiber using several corrosion mitigation strategies. 3) Developed a production ready feed system and integrate into a robotic resistance spot welding station to simulate automotive production conditions. 4) Produced demonstration assemblies for testing and evaluation.

36 MATERIALS SCIENCE↗
DOE OSTI2022

CRADA with FedIMPACT, LLC (Project 1): Cooperative Research and Development CRADA Number CRD-17-00713 (Final Report)

The funds-in under the CRADA will fund a team of National Renewable Energy Laboratory (NREL) researchers to participate in Energy I-Corps (formerly known as Lab-Corps). Energy I-Corps pairs teams of researchers with industry mentors for an intensive two-month training where the researchers define technology value propositions, conduct customer discovery interviews, and develop viable market pathways for their technologies. FedIMPACT, LLC and its affiliate IP Group, Inc. will evaluate the work completed at Energy I-Corps to determine whether it would like to pursue further commercialization and development of related technologies and background intellectual property.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2021

239 Pu(n,f) Neutron Multiplicity Evaluation with CGMF-Very First Release Candidate [Slides]

239 Pu(n,f) nu-bar evaluated with CGMF from E inc = 0.1-20 MeV. Changes compared to VIII.0: Prior: CGMF model included via Kalman and sensitivities of CGMF model parameters to nu-bar. Evaluation technique: Kalman including correction for PPP. Experimental data: Nearly all data that Phil took into account (I rejected: Huanqiao, Johnstone, Leroy, Nesterov, Smirenkin); New UQ for all experimental data; Marini; No correlations between unc. of different exp., except for Cf-252(sf) nu-bar uncertainty cross-correlating all uncertainties.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2021

Performance Evaluation of Comparative Vacuum Monitoring and Piezoelectric Sensors for Structural Health Monitoring of Rotorcraft Components

The costs associated with the increasing maintenance and surveillance needs of aging structures are rising at an unexpected rate. Multi-site fatigue damage, hidden cracks in hard-to-reach locations, disbonded joints, erosion, impact, and corrosion are among the major flaws encountered in today’s extensive fleet of aging aircraft and space vehicles. Aircraft maintenance and repairs represent about a quarter of a commercial fleet’s operating costs. The application of Structural Health Monitoring (SHM) systems using distributed sensor networks can reduce these costs by facilitating rapid and global assessments of structural integrity. The use of in-situ sensors for real-time health monitoring can overcome inspection impediments stemming from accessibility limitations, complex geometries, and the location and depth of hidden damage. Reliable, structural health monitoring systems can automatically process data, assess structural condition, and signal the need for human intervention. The ease of monitoring an entire on-board network of distributed sensors means that structural health assessments can occur more often, allowing operators to be even more vigilant with respect to flaw onset. SHM systems also allow for condition-based maintenance practices to be substituted for the current time-based or cycle-based maintenance approach thus optimizing maintenance labor. The Federal Aviation Administration has conducted a series of SHM validation and certification programs intended to comprehensively support the evolution and adoption of SHM practices into routine aircraft maintenance practices. This report presents one of those programs involving a Sandia Labs-aviation industry effort to move SHM into routine use for aircraft maintenance. The Airworthiness Assurance NDI Validation Center (AANC) at Sandia Labs, in conjunction with Sikorsky, Structural Monitoring Systems Ltd., Anodyne Electronics Manufacturing Corp., Acellent Technologies Inc., and the Federal Aviation Administration (FAA) carried out a trial validation and certification program to evaluate Comparative Vacuum Monitoring (CVM) and Piezoelectric Transducers (PZT) as a structural health monitoring solution to specific rotorcraft applications. Validation tasks were designed to address the SHM equipment, the health monitoring task, the resolution required, the sensor interrogation procedures, the conditions under which the monitoring will occur, the potential inspector population, adoption of CVM and PZT systems into rotorcraft maintenance programs and the document revisions necessary to allow for their routine use as an alternate means of performing periodic structural inspections. This program addressed formal SHM technology validation and certification issues so that the full spectrum of concerns, including design, deployment, performance and certification were appropriately considered. Sandia Labs designed, implemented, and analyzed the results from a focused and statistically relevant experimental effort to quantify the reliability of a CVM system applied to Sikorsky S-92 fuselage frame application and a PZT system applied to an S-92 main gearbox mount beam application. The applications included both local and global damage detection assessments. All factors that affect SHM sensitivity were included in this program: flaw size, shape, orientation and location relative to the sensors, as well as operational and environmental variables. Statistical methods were applied to performance data to derive Probability of Detection (POD) values for SHM sensors in a manner that agrees with current nondestructive inspection (NDI) validation requirements and is acceptable to both the aviation industry and regulatory bodies. The validation work completed in this program demonstrated the ability of both CVM and PZT SHM systems to detect cracks in rotorcraft components. It proved the ability to use final system response parameters to provide a Green Light/Red Light (“GO” – “NO GO”) decision on the presence of damage. In additional to quantifying the performance of each SHM system for the trial applications on the S-92 platform, this study also identified specific methods that can be used to optimize damage detection, guidance on deployment scenarios that can affect performance and considerations that must be made to properly apply CVM and PZT sensors. These results support the main goal of safely integrating SHM sensors into rotorcraft maintenance programs. Additional benefits from deploying rotorcraft Health and Usage Monitoring Systems (HUMS) may be realized when structural assessment data, collected by an SHM system, is also used to detect structural damage to compliment the operational environment monitoring. The use of in-situ sensors for health monitoring of rotorcraft structures can be a viable option for both flaw detection and maintenance planning activities. This formal SHM validation will allow aircraft manufacturers and airlines to confidently make informed decisions about the proper utilization of CVM and PZT technology. It will also streamline future regulatory actions and formal certification measures needed to assure the safe application of SHM solutions.

42 ENGINEERING↗
DOE OSTI2022

Environmental Effects Assessment for Proposed Offshore Wind Farm off the Coast of Grays Harbor, Washington

Grays Harbor Wind LLC (GHW) is proposing to develop a floating offshore wind farm offshore of west Grays Harbor County, Washington (Grays Harbor). The proposed GHW Offshore Wind Project (Project) would entail construction, installation and operation of a 1,000-megawatt (MW) offshore wind farm consisting of approximately 75 floating units, each containing a floating foundation and wind turbine generator (WTG). The Project location is approximately 25 miles (21.7 nautical miles [nmi]) offshore west of Grays Harbor, at waters depths of 360 to 700 feet. The Pacific Northwest National Laboratory (PNNL) was contracted by Herrera Environmental Consultants, Inc. on behalf of GHW to carry out this preliminary scoping study to evaluate baseline conditions and potential effects on fish and marine mammals from development and operation of a floating offshore wind farm installed within a designated area off the coast of Washington1. Floating offshore wind units installed in an ocean environment as part of the Project would interact with marine wildlife. This Study report provides an initial data aggregation and analysis, using publicly available data, of the Project effects, both negative and positive, on the marine environment. The scope of this assessment is limited by the fact that the Project development is presently at the conceptual level. Data on marine organisms were aggregated and evaluated; however seabirds were evaluated by Herrera Environmental Consulting and, along with bats, were not included in the scope of this study. Significant additional work is necessary to characterize ocean, seafloor, and environmental conditions; select appropriate floating offshore wind technologies; identify construction methods and locations; and assess facility locations, including electrical interconnection. Data aggregation and analysis of seabirds and bats is also needed. Evaluation of the full range of potential environmental effects would be conducted following an award of a lease from the Bureau of Ocean Energy Management (BOEM) as part of the leasing, National Environmental Policy Act (NEPA)/State Environmental Policy Act (SEPA) environmental review and permitting processes. While this initial data aggregation and analysis uses best available public scientific information and current assumptions about the Project configuration, the effects discussed herein are based on the status of review to-date and may change as Project-specific details are developed.

17 WIND ENERGY↗
DOE OSTI2021

Final Report on Aerosol Pretreatment Technology Performance and Benchmarking

Solvent-based post-combustion CO 2 capture (PCC) technology remains one of the leading methods to combat global CO 2 emissions produced from large-scale coal-fired power production. Advanced solventbased PCC technology has made significant improvements in design and performance that reduce capital and operating costs to enable its commercial use. Key to low cost, manageable logistics, and environmentally safe operation of solvent-based PCC technology are minimal solvent losses from the process through the treated gas stream exiting PCC plant absorbers. High flue gas aerosol particle concentrations (>10 5 particles/cm 3 ) for particles in the range of 70-200 nm have been shown to cause significant amine solvent losses for solvent-based PCC processes through several mechanisms including absorption of solvent and water into growing aerosol particles. Flue gas aerosol pretreatment technology is the only realistic and economically attractive method to reduce very high aerosol particle concentrations (>10 7 particles/cm 3 ) to enable solvent-based PCC for existing power plants lacking sufficient particle removal systems, such as baghouses. The overall goal of this project was to design, construct, independently test, and evaluate three flue gas aerosol pretreatment technologies identified to significantly reduce high aerosol particle concentrations (>10 7 particles/cm 3 ) in the 70-200 nm particle size range: (1) a novel, high-velocity water injection spray concept developed by RWE and tested by Linde, (2) an innovative electrostatic precipitator (ESP) device with optimized operating conditions developed by Washington University in St. Louis (WUSTL), and (3) a non-regenerative sorbent-based filter technology developed by InnoSepra for SO x and NO x removal from coal-fired power plant flue gas. Each technology has been validated with tests on 500-1000 scfm of actual coal-fired flue gas and evaluated in terms of particle removal efficiency (%), cost competitiveness, and environmental impact. Aerosol measurements were performed upstream and downstream of each aerosol reduction unit during independent testing of each technology using advanced instrumentation and analytical methods provided by WUSTL. To perform aerosol measurements, isokinetic probes were inserted into flanged pipes attached to the flue gas piping, and a small suction pump was used to sample gas containing aerosol particles. Aerosol particle number concentrations (# particles/cm 3 ) and size distributions were then measured using a scanning mobility particle sizer (SMPS, TSI Inc.) for very fine particles (<1,000 nm) and a particle counter manufactured by GRIMM for particles larger than 1,000 nm. This report summarizes the aerosol removal performance results from pilot scale testing of each technology. Performance results have been benchmarked against pre-defined targets and other flue gas aerosol pretreatment technologies with documented performance. Linde Gas North America LLC has been the prime contractor to DOE responsible for overall project management and provided the design for the high-velocity water spray-based aerosol removal technology based on a design concept developed by the German utility company RWE.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2020

BWR Spent Nuclear Fuel Acquisition and Testing to Support DOE-NE High Burnup Spent Fuel Data Project

The Office of Spent Fuel and Waste Disposition (SFWD) within the US Department of Energy (DOE) Office of Nuclear Energy (NE) established the Spent Fuel and Waste Science and Technology (SFWST) campaign to conduct research and development (R&D) activities related to the storage, transportation, and disposal of spent nuclear fuel (SNF) and high-level radioactive waste. The SFWST program was created within SFWD to address issues of extended or long-term SNF storage and transportation. Some near-term objectives of SFWST are to use a science-based, engineering-driven approach to: Support the enhancement of the technical bases to support the continued safe and secure dry storage of SNF for extended periods; Support the enhancement of the technical bases for retrieving SNF after extended dry storage; Support the enhancement of the technical bases for transporting high burnup (HBU) fuel and transporting low burnup fuel and HBU fuel after dry storage DOE-NE, in partnership with the Electric Power Research Institute, developed the High Burnup Spent Fuel Data Project to perform a large-scale demonstration and laboratory-scale testing of HBU pressurized water reactor (PWR) fuels (exceeding 45 gigawatt-days per metric ton of uranium [GWd/MTU]). Under this project, 25 sister rods—which are rods that have the same design, power histories, and other characteristics—were removed from assemblies at the North Anna Nuclear Power Station and sent to Oak Ridge National Laboratory (ORNL) in January 2016. ORNL performed detailed nondestructive examination (NDE) on all 25 rods. The NDE consisted of visual examinations, gamma and neutron scanning, profilometry and rod length measurements, and eddy current examinations. After completing the NDE, 10 of the sister rods were delivered to Pacific Northwest National Laboratory (PNNL) in a NAC International, Inc. legal-weight truck cask in September 2018 for destructive examination (DE). To date, SFWD work has focused on the PWR fuel that is part of the Sister Rod Test program. No boiling water reactor (BWR) fuel has been tested in the program, and the data needs that were identified for the PWR fuel have not been collected for BWR fuel. The goal to obtain six to nine BWR rods and test them at ORNL will support closing this important data gap. BWR fuel comprises approximately 56% of the total fuel assemblies currently in storage at nuclear power plants in the United States. BWR nuclear fuel and cladding designs and manufacturing are significantly different from PWRs. Differences include the following: BWR fuel pellets are larger than PWR pellets; Variations of Zircaloy-2 (including liners) are used instead of the Zircaloy-4 cladding materials used in PWRs; Clad manufacturing and stress-relief processes are different between PWRs and BWRs; The fuel rod dimensions are different because larger rod diameters and thicker cladding are used in BWRs; BWR fuel typically has lower internal rod pressures and sees vastly different operating conditions than PWR fuel (i.e., two-phase flow); BWR assemblies are “canned,” meaning each assembly is surrounded by a metal fuel channel; BWR cladding is often composed of an inner pure Zr liner that has widely different mechanical properties than the Zircaloy-2 alloy and exhibits a stronger affinity for hydrogen; The BWR SNF generally has more total hydrogen in the cladding/liner than typical PWR fuel; The construction of the PWR and BWR assemblies is vastly different; BWR rods are solidly attached to the assembly nozzles and experience a much different vibration and shock load than PWR rods, which are “floating” within a grid system attached to guide tubes, and the rods sit loosely on the bottom end plates. These numerous differences will affect the way the BWR SNF responds under dry storage preparation processes (e.g., vacuum drying) and during transportation. The results collected in the PWR experimental program must be compared with a subset of similar data collected on BWR SNF to establish a technical basis for whether the larger PWR database is sufficient to bound the BWR SNF end-of-life conditions as is currently assumed for several fuel/clad properties. Changes that occur in both fuel types at HBU could exacerbate any mechanical property differences. As the fuel burnup increases, several changes occur that might affect the performance of the fuel, cladding, and assembly hardware in storage and transportation. These changes include increased cladding corrosion layer thickness, increased cladding hydrogen content, increased cladding creep strains, increased fission gas release, and the formation of the HBU structure at the surface of the fuel pellets. The Nuclear Regulatory Commission (NRC) limits the current maximum rod-averaged burnup to 62 GWd/MTU due to these changes and the lack of data at higher burnups.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

Mercury Remediation Technology Development for Lower East Fork Poplar Creek (FY2020 Update)

Mercury (Hg) remediation is a high priority for the US Department of Energy (DOE) Oak Ridge Office of Environmental Management. Mercury contamination in the environment can be found at all three DOE facilities in Oak Ridge, but probably the greatest environmental risk concern relative to Hg on the Oak Ridge Reservation is associated with historical Hg losses at and near the Y-12 National Security Complex (Y-12). Water and fish from East Fork Poplar Creek (EFPC) downstream of Y-12 exceed regulatory thresholds. Because of the complexities of Hg transport and fate in the aquatic environment, conventional remedial options for EFPC are highly uncertain. DOE is using a phased adaptive management approach to Hg remediation at Y-12 with a focus in the next few years on construction of the Mercury Treatment Facility (MTF) to treat the most contaminated Y-12 outfall entering EFPC (DOE 2017a; DOE 2017b). Once operational, the MTF will provide additional protection against inadvertent releases of Hg into the stream from decontamination and decommissioning of Y-12 Hg-use buildings. Although the MTF is anticipated to substantially decrease Hg water concentrations and flux in the upper part of EFPC, research and technology development are needed to develop appropriate and long-term remedial solutions for the downstream environment. Since late 2014, the Oak Ridge Office of Environmental Management and URS | CH2M Oak Ridge LLC/Restoration Services, Inc. have supported DOE’s Oak Ridge National Laboratory (ORNL) Environmental Sciences Division staff in conducting field and laboratory studies to develop Hg remedial technology solutions for lower EFPC (LEFPC). A technology development strategy for LEFPC was developed in 2014 that was consistent with the adaptive management paradigm and DOE’s technology readiness level (TRL) guidelines (Peterson et al. 2015). Initially, a thorough review of the literature was conducted and site-specific information was collected to develop a broad number of potential technologies that might be applied in LEFPC. An adaptive management approach was then used to focus on technologies that might have the most promise and potential remediation benefit. Field and laboratory studies conducted from 2014 to 2020 have identified the major drivers of Hg flux and bioaccumulation in EFPC and narrowed the list of high-merit technologies that might be of use in remediating the downstream environment.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

Bat Survey for the Lawrence Livermore National Laboratory Experimental Test Site 300

Pursuant to Subcontract Number B644180 between ECORP Consulting, Inc. (ECORP) and Lawrence Livermore National Security, LLC. at Lawrence Livermore National Laboratory (LLNL), ECORP conducted focused bat surveys at LLNL’s Experimental Test Site (Site 300) during the spring of 2021. The surveys targeted two focal species including the Western red bat (Lasiurus blossevillii) and pallid bat (Antrozous pallidus) on the approximately 6,800-acre Site 300 in Alameda and San Joaquin Counties. The results of these surveys will provide supporting information for a Site-Wide Environmental Impact Statement.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

Carnivore Survey Results for the Lawrence Livermore National Laboratory Site 300

ECORP Consulting, Inc. conducted a suite of carnivore surveys at the Lawrence Livermore National Laboratory’s (LLNL) Experimental Test Site (Site 300; project site). The project site is located east of the City of Livermore and southwest of the City of Tracy, Alameda and San Joaquin Counties, California. Mesocarnivore surveys were conducted on the project site in 2002 in preparation for the 2005 LLNL Site-Wide Environmental Impact Statement (SWEIS; Clark et al. 2003). The 2002 surveys included a combination of spotlighting, camera stations, and scat detection dog surveys. Additional scat detection dog surveys for San Joaquin kit fox (Vulpes macrotis mutica) were performed on Site 300 and the adjacent California Department of Fish and Wildlife’s (CDFW) Corral Hollow Ecological Reserve in 2018 and 2020 (Woollett 2019, 2021). A variety of species, including American badger (Taxidea taxus), coyote (Canis latrans), and bobcat (Lynx rufus), were detected during the previous surveys; however, no San Joaquin kit fox or mountain lion (Puma concolor) were detected. In support of the preparation of the new SWEIS, ECORP performed carnivore surveys to document the carnivores and other animals present on Site 300, with a focus on determining if the federally listed (endangered) and state listed (threatened) San Joaquin kit fox, CDFW Species of Special Concern (SSC) American badger, and/or mountain lion are present on Site 300. American badgers are known to occur on the property and there have been a few sporadic sightings of mountain lions, but San Joaquin kit fox have not been documented on Site 300. Although mountain lion were not detected during the 2002 survey, it has been added as a focal species for this survey because the southern and central coast evolutionary significant units of mountain lions were recently advanced by CDFW as a Candidate species for listing as “threatened” under the California Endangered Species Act.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

Passerine Bird Surveys for the Lawrence Livermore National Laboratory Site 200

Pursuant to Subcontract Number B644180 between ECORP Consulting, Inc. (ECORP) and Lawrence Livermore National Security, LLC. (LLNS) at Lawrence Livermore National Laboratory (LLNL), ECORP conducted passerine bird and waterfowl surveys at LLNL Livermore Site 200 (Site 200) during the spring and summer of 2021. While the point-count surveys were considered passerine and waterfowl surveys, other non-passerine species (e.g. raptors, doves, woodpeckers, hummingbirds) were surveyed for as well. LLNL conducts annual monitoring for nesting raptors at the Livermore Site 200. Because of this, raptors were not included as target species in this scope of work. The purpose of the surveys was to document the presence and abundance of all avian species in support of a Site-wide Environmental Impact Statement. Particular focus of the survey was on special status bird species.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

Arroyo Mocho Habitat Suitability Assessment for Sensitive Reptiles, Amphibians, and Fish

Sequoia Ecological Consulting, Inc. (Sequoia) has prepared this habitat suitability assessment for the purpose of assessing current habitat suitability and evaluating the potential presence of special-status species at and near the Arroyo Mocho Pumping Station (Arroyo Mocho). The Study Area is located 7.5 miles southeast of the City of Livermore in Alameda County, California. Our analysis provides a description of presence and habitat suitability for special-status reptiles, amphibians, and fish within the Study Area and identifies potential conservation measures. Special-status animals are designated by the US Fish and Wildlife Service (USFWS) and the California Department of Fish and Wildlife (CDFW). This analysis focuses on California tiger salamander (Ambystoma californiense), California red-legged frog (Rana draytonii), foothill yellow-legged frog (Rana boylii), western pond turtle (Emys marmorata), Alameda whipsnake (Masticophis lateralis euryxanthus), Coast horned lizard (Phrynosoma blainvilli), and central California coast distinct population segment (DPS) steelhead (Oncorhynchus mykiss), per the request of Lawrence Livermore National Laboratory.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

Avian Surveys Report for the Lawrence Livermore National Laboratory Arroyo Mocho Pumping Station

Pursuant to Subcontract Number B644180 between ECORP Consulting, Inc. and Lawrence Livermore National Security, LLC. at Lawrence Livermore National Laboratory (LLNL), ECORP conducted passerine bird and raptor surveys at the Arroyo Mocho pumping station site during the spring and summer of 2021. While the point-count survey was considered a passerine survey, other non-passerine species (e.g. doves, woodpeckers, hummingbirds) were surveyed for as well. The purpose of the surveys was to document the presence and abundance of all avian species within the survey area in support of a Site-wide Environmental Impact Statement. Particular focus of the survey was on special status bird species.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

2020 Annual Site Environmental Report for Sandia National Laboratories, New Mexico

Sandia National Laboratories, hereinafter referred to as Sandia, is a multimission laboratory managed and operated by National Technology & Engineering Solutions of Sandia, LLC, a wholly owned subsidiary of Honeywell International Inc., for the U.S. Department of Energy’s National Nuclear Security Administration. This Annual Site Environmental Report was prepared in accordance with and as required by DOE O 231.1B, Admin Change 1, Environment, Safety and Health Reporting , and is approved for public release. The U.S. Department of Energy (DOE) and its management and operating contractor for Sandia are committed to safeguarding the environment, continually assessing sustainability practices, and ensuring the validity and accuracy of the monitoring data presented here. This report summarizes the environmental protection, restoration, and monitoring programs in place for Sandia National Laboratories, New Mexico (SNL/NM), during calendar year 2020.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

Evaluation of Niowave's Proposed Solvent Washing Approach

Niowave, Inc., is a domestic supplier of medical and industrial isotopes from uranium (U) and radium (Ra). The company has recently entered into a cooperative agreement with the U.S. Department of Energy’s National Nuclear Security Administration (NNSA) and plans to deploy a superconducting electron accelerator (LINAC) to fission U for molybdenum-99 ( 99 Mo) production without the need for a nuclear reactor or highly enriched uranium (HEU). NNSA provided funding to the Savannah River National Laboratory (SRNL) to support Niowave in this effort. SRNL evaluated the application of the solvent washing process for Niowave.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

2020 Annual Site Environmental Report for Sandia National Laboratories, Tonopah Test Range, Nevada, and Kaua'i Test Facility, Hawai'i

Sandia National Laboratories is a multimission laboratory managed and operated by National Technology & Engineering Solutions of Sandia, LLC, a wholly owned subsidiary of Honeywell International Inc., for the U.S. Department of Energy’s National Nuclear Security Administration. The National Nuclear Security Administration’s Sandia Field Office administers the contract and oversees contractor operations at Sandia National Laboratories, Tonopah Test Range (SNL/TTR) in Nevada and Sandia National Laboratories, Kaua‘i Test Facility (SNL/KTF) in Hawai‘i. Activities at SNL/TTR are conducted in support of U.S. Department of Energy weapons programs and have operated at the site since 1957. SNL/KTF has operated as a rocket preparation launching and tracking facility since 1962. The U.S. Department of Energy and its management and operating contractor are committed to safeguarding the environment, assessing sustainability practices, and ensuring the validity and accuracy of the monitoring data presented in this Annual Site Environmental Report. This report summarizes the environmental protection, restoration, and monitoring programs in place at SNL/TTR and SNL/KTF during calendar year 2020. Environmental topics include air quality, ecology, environmental restoration, oil storage, site sustainability, terrestrial surveillance, waste management, water quality, and implementation of the National Environmental Policy Act. This report is prepared in accordance with and as required by DOE O 231.1B, Admin Change 1, Environment, Safety and Health Reporting , and has been approved for public distribution.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2020

SECARB 2020 Semi-Annual Field Review Reports - Anthropogenic Test

The Southern States Energy Board (SSEB) managed the overall Southeast Regional Carbon Sequestration Partnership (SECARB) Phase III project and the Electric Power Research Institute (EPRI) managed all activities associated with the Anthropogenic Test site. Advanced Resources International, Inc. (ARI) assisted EPRI with the management of site activities. EPRI and ARI followed reporting procedures that included monthly and quarterly technical progress reports, as well as periodic reporting on key field activities. Subsequent sections of this report catalog the field activities and are organized in a semi-annual chronology. The SECARB Anthropogenic Test was the largest demonstration of a fully integrated, pulverized coal-fueled carbon capture and storage (CCS) project in the United States as of 2012 and supports a commercial prototype of CO 2 capture; transportation; subsurface storage; and monitoring, verification, and accounting (MVA); and assessment. The demonstration-scale, post-combustion CO 2 capture facility at Alabama Power Company’s Plant Barry diverted flue gas (25MW equivalent) from its Unit #5 coal burning facility and captured the CO 2 using Mitsubishi Heavy Industries (MHI) KM-CDRTM advanced amine technology. The captured CO2 was compressed at Plant Barry and transported by pipeline to the injection location southeast of Citronelle, Alabama. The Citronelle Project’s geologic storage and MVA sites were located on the flanks of the Citronelle Dome, approximately three miles southeast of the city of Citronelle. The injection zone, the Paluxy Formation, a saline formation that occurs at approximately 9,400 feet and overlies the oil production horizon of the Citronelle oilfield, presents a favorable injection reservoir in terms of areal extent and petrophysical characteristics. The confining zone, the basal shale of the overlying Washita-Fredericksburg Formation, is persistent throughout the Citronelle area and possesses the appropriate criteria to act as an effective CO 2 seal.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2021

Regal Beloit Final Technical Report

The original project proposal submitted from NovaTorque Inc (NovaTorque) in 2016 was to improve the existing motor with 95% efficiency by reducing the losses by 21% to achieve 96%. A few months after the proposal was submitted, NovaTorque lost funding and went out of business. The assets of NovaTorque were then acquired by Regal Beloit Corporation (“Regal Beloit” or “Regal”). When the NovaTorque proposal was selected, the project was transferred to Regal Beloit. Once we had production samples from the new Regal production line, they were tested at the Regal Beloit test lab in Wausau, WI. The original NovaTorque motor had an efficiency of 95%, but when the technology was transferred to Regal Beloit, there were multiple manufacturing improvements made, even though the basic electromagnetic design did not change. The test results in Wausau showed that the motors made at the Regal Beloit plant had an efficiency of 96%. Since the goal of the project was to reduce the losses by 21%, a new efficiency target of 96.8% became the project objective. In the first budget period, motors were tested to get the baseline performance. We then used FEA modeling with ANSYS Maxwell to model the existing motor to get correlation between the FEA simulations and the actual test results. Once the model was validated, we evaluated some changes that could be made to the stator to reduce the losses and improve efficiency without changing the rotor or stator housing, keeping the modifications easy to implement. The changes were primarily in the area of making the stator axially shorter and adding Soft Magnetic Composite (SMC) tooth tips. In the second budget period, we proceeded to design and build the new stator that was identified above and identified additional improvements in the process that included a stator machining modification and the use of rectangular wire. When we actually built the motor, the choice of rectangular wire turned out to be a problem. The wire was made by squishing round wire to get the rectangular shape, which caused work hardening, making the wire too stiff to make the desired coils. We shifted to annealed square wire which was better, but we still could not maintain the proper coil envelope. The result was that we had reduced cross section area for stator laminations. We also had to have a radial offset resulting in a radial misalignment between the stator and rotor because of the oversized coils. After the motor was completed, it was shipped to Texas A&M University for testing. With the loss of flux from these issues, the measured motor efficiency was only 96.3%. The primary focus of this motor was to make sure our FEA simulation model predicted the measured losses and overall efficiency, this we moved on to the FEA simulation. The FEA simulations of the motor “as built” with misalignments had good correlation with the test results, so the next step was to use that model to optimize the design of the motor for a final build. This time we considered changes to the stator and rotor and also minor changes to the housing diameter. In the third budget period, we did the detailed design and construction of the final prototypes. The final prototypes had a slight increase in the stator diameter to fit in a standard Regal Beloit housing. We shortened the stator and use more layers of wire in the coils. We also increased the cone angle of the rotor and stator from the original 110 degrees to 130 degrees to get some additional efficiency and optimized the stator cross section. The predicted efficiency from the FEA simulations was 96.9%. When completed, the motors were tested. We were a little short of reaching our target efficiency goal of 96.8%. We were only able to get to 96.7% efficiency. While it may be possible with additional iterations in designs and future builds to gain that additional 0.1%, we believe that we are close to the best we can achieve from a practical viewpoint, and additional iterations would be more work than the potential gains would be worth. No other motor in this class can even reach the 96% that we started with.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗