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DOE OSTI2022

Distributed Transient Safety Verification via Robust Control Invariant Sets: A Microgrid Application

Modern safety-critical energy infrastructures are increasingly operated in a hierarchical and modular control framework which allows for limited data exchange between the modules. In this context, it is important for each module to synthesize and communicate constraints on the values of exchanged information in order to assure system-wide safety. To ensure transient safety in inverter-based microgrids, we develop a set invariance-based distributed safety verification algorithm for each inverter module. Applying Nagumo's invariance condition, we construct a robust polynomial optimization problem to jointly search for safety-admissible set of control set-points and design parameters, under allowable disturbances from neighbors. We use sum-of-squares (SOS) programming to solve the verification problem and we perform numerical simulations using grid-forming inverters to illustrate the algorithm.

Bouvier, Jean-Baptiste H.↗

DOE OSTI2020

A Closed-Loop Distribution System Restoration Tool for Natural Disaster Recovery. Final CRADA report

We propose to continue the development of the restoration algorithms and the tool’s user interface, both of which have been developed under the GMLC-0131 project. This project aims to develop a distribution restoration decision support tool that will assist utilities in performing distribution restoration after extreme weather events in an optimal and efficient manner. The tool will integrate the weather information/forecasts and system fragility assessment together with the field measurement data to improve the situational awareness and estimate the system damage status. Advanced optimization models will be leveraged to dispatch repair crews and associated resources. New resources (e.g., automatic switches and distributed generators (DGs)) enabled by distribution automation and smart grid development will be utilized to reconfigure distribution grids and pick up loads promptly to reduce the outage sizes and durations. The closed-loop feature of the tool will make the tool adaptive to the evolving weather events and varying restoration capabilities. In this CRADA, we will collaborate with S&C Electric Company (S&C) to refine ANL-1060 (07/17/2019) the restoration algorithms that can be potentially applicable for any utility systems and vendor products, including: 1) Customizable information from both utility users and vendor users; 2) User interface design.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2023

Preliminary HEA Solid Phase Processing Development Report

The development of high temperature fuel cladding materials to withstand a variety of extreme environments have received much attention. Several potential materials systems that have been identified for the fuel systems and core structural materials application in advanced reactor systems are ferritic/martensitic steel (e.g., HT9), austenitic stainless steels (e.g., 316 LN), oxide-dispersion strengthened steels (e.g., 12 YWT), Ni-based alloys and ceramic-based composites depending on the type of the reactors. Though these material systems have promising properties conducive for radiation-resistant performance, they suffer beyond the design-limit from one or more damage processes such as void swelling, radiation embrittlement, phase instability, corrosion, and limited creep life.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

Advances in Modeling Capabilities for Critical Mineral Separation Technologies: A PrOMMiS Overview

This is an oral presentation at the TechConnect conference on the work developed by PrOMMiS. PrOMMiS builds on and extends capabilities developed within the Department of Energy’s (DOE) Institute for the Design of Advanced Energy Systems (IDAES), Integrated Platform, and Water Treatment Technoeconomic Assessment Platform (WaterTAP), which have been successfully leveraged by other Department of Energy research areas. The open-source toolkit facilitates validation, reproducibility, and accountability, allowing for easy extension of the framework to other systems. This talk presents an overview of the PrOMMiS capabilities, including unit model library, advances in thermophysical properties models, and capital cost libraries for simulation and optimization of mineral processing technologies. The PrOMMiS applications include (1) conceptual design and superstructure optimization for screening different process configurations and identifying promising technologies; (2) dynamic modeling and optimization to enable the creation of digital twins; (3) surrogate modeling tools to leverage data when predictive thermodynamic models are not currently available; (4) technical risk reduction via uncertainty quantification and robust optimization to identify process designs that are robust to process variability and uncertainties; and (5) deployment of uncertainty quantification tools to maximize knowledge gained from experimental campaigns, while reducing the number of experiments required

critical minerals and materials↗

DOE OSTI2021

Insights from PPL's DERMS Implementation

PPL Electric Utilities’ Keystone Solar Future Project (KSFP) is part of the U.S. Department of Energy’s Office of Energy Efficiency and Renewables, Energy Enabling Extreme Real-time Grid Integration of Solar Energy (ENERGISE) grant. The three-year project, beginning in October, 2017, funded an innovative pilot program to develop and evaluate a technology platform and framework for managing high levels of distributed energy resources (DER), and improving future DER interconnection. The KSFP aimed to bridge gaps between existing and future technology, including Distributed Energy Resource Management Systems (DERMS), by monitoring, managing, and optimizing a system with high penetration of solar and other DER. Specifically, the project worked to make Demand Management Systems (DMS) applications, devices, and real-time communications technology DER-aware to allow for advanced applications for utility operations. Here, by installing and implementing a DERMS, project designers transformed how DERs interact with PPL’s distribution system, offering learnings and results worth sharing industry-wide.

Leader, Jared↗

DOE OSTI2020

Top Loading Helium Cryostat Integrated with High-Pressure Cell with Fast Remote Pressure Control (Final Report for SBIR Phase 1)

A large number of physical phenomena, such as superconductivity and quantum critical phenomena, often appear only at very low temperatures below 5 K. There is an immense interest to investigate these phenomena at high pressure as a means of tuning interatomic distances, and thus the interaction parameters controlling these phenomena, in a continuous and controlled fashion. The current P-T condition for neutron scattering experiments are limited to either relatively low pressures of about 2 GPa at temperatures below 5 K, or to relatively high temperatures at pressures or tens of GPa. The purpose of this research is to develop neutron sample environment instrumentation for reaching 10-20 GPa at 1-2K with rapid and reliable online pressure and temperature control (i.e. without having to interrupt the experiment). The ultimate goal of the project is to design an integrated fast-cooling low-temperature sample environment cryogenic system compatible with state of the art neutron diamond anvil cells suitable for single-crystal neutron scattering experiments for temperatures down to 2K and pressures of several tens of GPa. The integrated system will consist of top-loading Helium flow cryostat with in-situ sample alignment mechanisms, large-volume diamond anvil cells (DAC) made from novel superalloy Pascalloy and optimized for fast cooling and heating, and a compact remote pressure control mechanism for the DAC based on a novel concept of inflatable bellows integrated with a lever-arm based force amplifier. In Phase I, we have designed, manufactured, and tested prototypes of the novel compact force-amplified pneumatic pressure control mechanism for Neutron Diamond Anvil Cell (nDAC), which allows to use pneumatic bellows system for smooth remote pressure control in the nDAC inside a top-loading cryostat with bore size of 70 mm or larger. This allows significant minimum temperature decrease in remotely controlled nDAC from 5-10 K down to 2 K. We also studied mechanical properties of a novel non-magnetic superalloy Pascalloy with different heat-treatment conditions and preliminary results indicate that up to date this is probably the strongest and most suitable material for making more compact and lightweight cryogenic nDACs for neuron scattering experiments at extreme conditions, allowing much faster cooling and heating. Potential applications: The new developments will allow to create a wide range of compact Diamond Anvil Cells for neutron diffraction which can reach several tens of GPA pressure at 2-4 K while preserving accurate remote pressure control capabilities. The new concepts can be used for developing sample environment instrumentation outside the neutron scattering field. The new development have very strong potential for expanding experimental capabilities in materials sciences and have high commercialization potential. The proposed new cryogenic high-pressure system or any of its individual components will be in high demand not only in neutron scattering facilities, but also at synchrotron beamlines and other high-pressure research facilities around the world.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Optimized Highly Efficient SSCB Using Organic Substrate Packaging for Electric Vehicle Applications

Solid State Circuit Breakers (SSCBs) are an attractive protection solution for their arcless current interruption and fast actuation speeds over mechanical breakers. This paper proposes a Bidirectional SSCB (BSSCB) with a thermally defined and digitally controlled current time profile for fault protection in EV and other low-voltage DC systems. The paper proposes an organic packaging approach utilizing flex circuitry to develop a reliable, cost-effective power module for BSSCBs. The paper studies transient heat transfer in the power modules using finite element analysis (FEA). An RC themal ladder network is extracted to define a fusing curve. To demonstrate and verify the design, a 1kV/50 A SiC MOSFET BSSCB prototype is fabricated and tested, having a power density of 60 W/cm3 and 4x reduction in form factor over presently researched breakers. Also, given are results for 750 V/150 A operation showing interruption in 2.4 μs.

organic power packaging↗

DOE OSTI2023

Multiscale Electrothermal Design of a Modular Multilevel Converter for Medium-Voltage Grid-Tied Applications

As a key feature of modular multilevel converters (MMCs), a large number of semiconductor devices are employed in the converter and distributed over a stack of submodules. Each submodule has a strict temperature limit that imposes constraints on the operating range of the converter. Different loading conditions/losses in the submodules lead to unavoidable temperature variations inside the MMC, which consequently affect the system-level performance and reliability. This paper is focused on the electrothermal analysis and design of a medium-voltage silicon carbide (SiC)-based MMC system, from submodule power semiconductors to the overall MMC system integration of multiple submodules, for grid-connected applications. Loss calculations are performed to estimate the cooling requirements and aid thermal design at different levels. The performance of a forced-air cooling approach is analyzed within a numerical modeling framework. Maximum temperature of the SiC power modules is predicted using numerical tools. Thermal design of the MMC cabinet with various arrangements of air inlet(s) and outlet(s) is investigated and compared from a cooling performance perspective. A fully resolved model of the arrangement that yields optimal results is developed to accurately predict the temperature profile of the essential components in the submodules.

computational fluid dynamics↗

DOE OSTI2020

Design and Development of a High-Efficiency Single Cylinder Natural Gas-Fueled Jet Ignition Engine

The current energy climate has created a push toward reducing consumption of fossil fuels and lowering emissions output in power generation applications. Combined with the desire for a more distributed energy grid, there is currently a need for small displacement, high efficiency engines for use in stationary power generation. An enabling technology for achieving high efficiencies with spark ignited engines for such applications is the use of jet ignition which enables ultra-lean (λ > ~1.6) combustion via air dilution.This paper provides a comprehensive review of the development of a 390cc, high efficiency single cylinder natural gas-fueled jet ignition engine operating ultra-lean. The engine was developed as part of the Department of Energy’s Advanced Research Projects Agency–Energy (DOE ARPA-E) GENSETS program. Design choices for minimizing friction are highlighted as well as test results showing further friction reduction through downspeeding. Extensive hardware optimization of the combustion system has been performed and results are presented for air-flow path optimization and the jet igniter. The efficiency benefits related to enleanment and downspeeding are analyzed using an efficiency loss breakdown based on the First Law of Thermodynamics. Through optimization efforts a peak brake thermal efficiency in excess of 34% was achieved, representing an increase of greater than 20% over the current state-of-the-industry for comparably sized CNG engines.

Peters, Nathan↗

DOE OSTI2021

A Hybrid Heavy-Duty Diesel Power System for Off-Road Applications - Concept Definition

A multi-year Power System R&D project was initiated with the objective of developing an off-road hybrid heavy-duty concept diesel engine with front end accessory drive-integrated energy storage. This off-road hybrid engine system is expected to deliver 15-20% reduction in fuel consumption over current Tier 4 Final-based diesel engines and consists of a downsized heavy-duty diesel engine containing advanced combustion technologies, capable of elevated peak cylinder pressures and thermal efficiencies, exhaust waste heat recovery via SuperTurbo™ turbocompounding, and hybrid energy recovery through both mechanical (high speed flywheel) and electrical systems. The first year of this project focused on the definition of the hybrid elements using extensive dynamic system simulation over transient work cycles, with hybrid supervisory controls development focusing on energy recovery and transient load assist, in Caterpillar’s DYNASTY™ software environment. Three key off-road applications were the focus of the hybrid concept definition with an aim of understanding the system’s modular capability for the diverse off-road heavy-duty market. Core engine performance 1D and 3D simulations isolated the efficiency contributions from the downsized engine, turbocompounding, and in-cylinder thermal barrier coatings. A fuel consumption improvement range of 14 to 24% was predicted, resulting in successful project progression to the design and experimental validation phase. Furthermore, an overview of the experimental engine and hybrid system status concludes the discussion along with the multi-year project’s next steps.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2022

Electric Vehicles at Scale (EVs@Scale) Laboratory Consortium Deep-Dive Technical Meetings: High Power Charging (HPC) Summary Report

Electric vehicle (EV) adoption will change the composition of EV charging load to higher-power charging as more medium- (MD) and heavy-duty (HD) applications are electrified, and as all vocations, including light-duty (LD) vehicles, are capable of faster charging. These shifts provide the opportunity for high-power charging (HPC) and facility equipment to evolve and improve efficiency, cost, and space. High-Power Electric Vehicle Charging Hub Integration Platform (eCHIP) project designs and develops a high-power, interoperable charging experimental platform to research, develop, and demonstrate the integration approaches and technology solutions. The project addresses (1) interconnection and management of a grid-tied inverter; (2) development of a DC distribution system that is responsible for system energy management, interoperability, and DC protection; (3) modular DC/DC conversion for vehicle charging; (4) EV charging interface and DC/DC integration; and (5) smart charge control and vehicle-to-edge (vehicle-to-building [V2B], vehicle-to-everything [V2X]) capability. This summary presentation is the first technical progress output of the project. It provides insight for the first deep-dive technical meeting outputs in terms of research presentations and also includes summary of the discussions occurred in the follow-up breakout sessions. The summary presentation covers three technical areas: (1) HPC: State of the art power architectures and the design of the power electronics, (2) Modeling, energy management, and power control in the HPC station, and (3) Codes and standards work that are in line with the previous two topic areas.

ADVANCED PROPULSION SYSTEMS,POWER TRANSMISSION AND↗

DOE OSTI2023

Electric Vehicles at Scale (EVs@Scale) Laboratory Consortium Deep-Dive Technical Meetings: High Power Charging (HPC) Summary Report

Electric vehicle (EV) adoption will change the composition of EV charging load to higher-power charging as more medium- (MD) and heavy-duty (HD) applications are electrified, and as all vocations, including light-duty (LD) vehicles, are capable of faster charging. These shifts provide the opportunity for high-power charging (HPC) and facility equipment to evolve and improve efficiency, cost, and space. High-Power Electric Vehicle Charging Hub Integration Platform (eCHIP) project designs and develops a high-power, interoperable charging experimental platform to research, develop, and demonstrate the integration approaches and technology solutions. The project addresses (1) interconnection and management of a grid-tied inverter; (2) development of a DC distribution system that is responsible for system energy management, interoperability, and DC protection; (3) modular DC/DC conversion for vehicle charging; (4) EV charging interface and DC/DC integration; and (5) smart charge control and vehicle-to-edge (vehicle-to-building [V2B], vehicle-to-everything [V2X]) capability. This summary presentation is the first technical progress output of the project. It provides insight for the first deep-dive technical meeting outputs in terms of research presentations and also includes summary of the discussions occurred in the follow-up breakout sessions. The summary presentation covers three technical areas: (1) HPC: State of the art power architectures and the design of the power electronics, (2) Modeling, energy management, and power control in the HPC station, and (3) Next Generation Profiles for high power charging characterization.

ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2023

Twenty Years and Counting—Where are they? Practical Recommendations for Commercializing AI/ML for Intrusion Detection in the Nuclear Industry

Research and development into applications for improving equipment condition monitoring programs at nuclear facilities has been around since the 1990s. However, while the field has moved from using data-driven machine learning (ML) algorithms for detection and prediction of equipment degradation and failure to prognostic capabilities, these applications are still not widely used in the U.S. nuclear industry. Additionally, there has been significant effort in designing both data-driven and physics-based artificial intelligence (AI) and ML models for many other potential applications in the nuclear industry, including cyber intrusion detection systems (IDS). However, as the last twenty years in condition-based maintenance research has shown us, there are significant hurdles that must be overcome for deployment of IDS on plant systems. This paper provides a discussion on the practical recommendations that researchers should consider for successful adoption of AI/ML IDS in the nuclear industry.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗

DOE OSTI2025

NOVEL METHODS FOR IN SITU HIGH DENSITY SURFACE CLEANING SCRUBBING OF ULTRAHIGH VAC LONG NARROW TUBES TO REDUCE SECONDARY ELECTRON YIELD AND OUT GASSING

This project developed new methods for cleaning the inside surfaces of very long, narrow vacuum tubes used in particle accelerators. Traditional cleaning approaches are expensive, slow, or difficult to implement in accelerator tunnels. We designed and tested a portable plasma discharge cleaning system that uses lower-cost microwave and magnetron technologies to reduce outgassing and secondary electron emission from stainless steel and copper surfaces. The system, called the Plasma Discharge Test System (PDTS), allows accelerator components to be scrubbed more efficiently, which can improve performance and reduce maintenance costs for research and industrial applications.

POOLE, JOE HENRY [PRESIDENT]↗

DOE OSTI2022

Considerations for Developing a Regulatory Roadmap for Distributed Energy Resource (DER) Integration in Colombia

The USAID-NREL Partnership in Colombia, in conjunction with SURE and USEA, selected four action plan teams from the Young Professionals Leadership Program to receive tailored NREL technical assistance to support action plan implementation. The four plans selected represent various aspects associated with planning for the efficient integration of DERs, including electric mobility, residential and commercial energy applications, distributed generation modeling, and regulatory considerations. In response to national grid modernization, decentralization, digitalization, and electrification trends, CREG is looking to update Colombia's electric distribution code, with an emphasis on the integration of electric vehicles and charging stations, but also energy storage systems, non-conventional sources of renewable energy, and other distributed energy resources (DERs). CREG aims to establish the general steps that must be carried out to update the distribution code for the integration of DERs, with a view to the design and development of new markets. The objective of the TA provided to CREG was to support them in identifying and outlining the general processes and approaches to consider when updating Colombia's distribution code for the integration of electric vehicles, distributed renewable energy systems, and energy storage systems, with a view to the design and development of new markets.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2020

Integrated Energy System Investigation for the Eastman Chemical Company, Kingsport, TN Facility

The industrial manufacturing industry is looking to implement new methods of energy production to ensure a consistent energy supply while reducing economic costs and environmental impacts. Much of the manufacturing industry relies on fossil fuels—primarily coal and natural gas—of which there are finite resources subject to price volatility due to an inelastic demand. These resources also come with significant negative environmental impacts related to emissions. While complete independence from fossil fuels is not immediately realistic, options are available to significantly reduce dependency on fossil fuel supplies, including integrated energy systems (IESs) which tightly couple nuclear energy source generators with energy consumers (i.e., industrial factories) to fulfill power and energy requirements. Once realized, optimized IESs may yield significant economic and environmental benefits over traditionally isolated generator and consumer facilities. This report presents a feasibility study for siting an IES to meet the steam and electricity needs of Eastman Chemical Company’s facility in Kingsport, Tennessee. This study explored reactor technology options, evaluation,and optimization,with a focus on meeting the facility’s operational and reliability requirements. This work is part of an ongoing effort by Eastman to be good environmental stewards and meet the demands of their customers by shifting to more environmentally sustainable solutions for their energy needs. Outcomes of this report are also of general interest and value to any design or development team seeking to deploy an IES,as many topics described herein are generally applicable to any nuclear power facility.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2024

Connected Thermostat Alternatives for Room Air Conditioners and Minisplit Heat Pumps

The availability of smart, connected thermostats has improved climate control, energy efficiency, and grid demand-response programs for central HVAC systems. However, a significant gap exists in addressing integrated control systems for point-source heating and cooling systems such as window air-conditioners (window ACs) and mini-split heat pumps (MSHPs). This report examines the emerging market of third-party connected thermostats tailored for these systems, focusing on their effectiveness, reliability, and potential barriers to adoption.This study evaluates several commercially available products designed for room ACs and MSHPs through a series of laboratory tests. While these infrared-based (IR-based) thermostats offer remote temperature control and scheduling via mobile apps, our findings reveal that none are seamless, with reliability of basic functions being a critical factor. Promising features include integration of indoor air quality metrics and time-of-use pricing, but the latter are not yet available in the U.S. Barriers to broad user acceptance include non-seamless setup processes, challenges in thermostat placement, and unclear product differentiation. There is a pressing need for research and development in enabling MSHPs and central thermostats to coordinate, enhancing energy savings and comfort in retrofit applications. This study underscores the importance of further innovation in connected thermostat technology to address the diverse needs of single-zone HVAC systems and promote efficient energy management in households.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2020

Global kinetic modeling of NH 3 -SCR with two sites of NH 3 storage on Cu-SSZ-13

A comprehensive selective catalytic reduction (SCR) model is developed to detail the global kinetic reactions in the catalyst which is involved in two type of sites for high- and low-temperature NH 3 adsorption/desorption, as well as a low temperature H 2 O storage. The model accounts for the formation of ammonium nitrate in fast SCR and the decomposition formation of ammonium nitrate in the absence of NO, and addresses N 2 O relative to NO and NO 2 reactions with NH 3 . The model has been validated against commercial Cu-SSZ-13 measurements of NH 3 inventory, NH 3 oxidation, NO oxidation, standard SCR, fast SCR and NO 2 SCR at both comprehensive steady-state and transient conditions. In addition, the application of the SCR model for emissions control over a transient drive cycle at cold start was demonstrated based on diesel oxidation catalyst (DOC) and SCR aftertreatment system for a passenger car. In conclusion, the results show that the SCR model can provide the detailed emissions estimations for steady-state and transient conditions, can assist with understanding the impact of the SCR reaction mechanism, and can assist with the design and optimization of SCR catalysts to develop innovative technologies for co-optimization of engine fuel economy and emissions control technologies.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗