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All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

Conversion of landfill gas to liquid fuels through a TriFTS (tri-reforming and Fischer–Tropsch synthesis) process: a feasibility study

Biogas produced in landfills contains large amounts of methane (a potent greenhouse gas) and hence requires collection and treatment according to EPA regulations. Tri-reforming of such biogas (CH 4 + CO 2 ) is a combination of dry reforming, steam reforming, and partial oxidation to produce syngas (CO + H 2 ). This syngas can be converted to liquid hydrocarbons using Fischer–Tropsch Synthesis (FTS). A novel technology of combining tri-reforming and FTS (TriFTS) is proposed and utilized here to convert landfill gas (LFG) to high value added liquid hydrocarbon fuels such as gasoline, diesel, and jet fuel. This article explores the feasibility of TriFTS from an experimental and process economics point of view. Landfill gas collected from a local landfill was used in this study. After removing contaminant gases such as H 2 S and NH 3 via condensation and adsorption, NiMg/Ce 0.6 Zr 0.4 O 2 pellets were used in a tri-reforming reactor to produce H 2 and CO in a ratio suitable for FTS. The conversions of CH 4 and CO 2 were 99% and 60%, respectively. The H 2 /CO molar ratio was 1.7. In the FTS section, a Co/SiO 2 eggshell catalyst was used to synthesize liquid hydrocarbon with high selectivity for middle distillate cuts. The CO conversion in FTS was 71% and the liquid hydrocarbon product was similar to that of low sulfur diesel. The experimental results were used to conduct a preliminary economic analysis of a commercial scale TriFTS process. The results indicate that 45% of the energy contained in the LFG can be recovered in the liquid fuel generated, with the rest going to meet the energy demands of the conversion process including heat losses. The breakeven cost of diesel fuel produced was estimated as $3.24 per gal but reduces to 2.71 per gal if the LFG is assumed to be free of cost as would be the case for landfill operators. Additional renewable fuel credits will make the process even more economically attractive. This study suggests that conversion of LFG to liquid fuels is a promising new technology ripe for commercialization.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2018

Kinetics of D/H isotope fractionation between molecular hydrogen and water

At equilibrium, the D/H isotope fractionation factor between H 2 and H 2 O (α H 2 O-H 2 (eq) ) is a sensitive indicator of temperature, and has been used as a geothermometer for natural springs and gas discharges. However, δD H 2 measured in spring waters may underestimate subsurface temperatures of origin due to partial isotopic re-equilibration during ascent and cooling. In this work, we present new experimental data on the kinetics of D–H exchange for H 2 dissolved in liquid water at temperatures below 100 °C. Comparing these results with published exchange rates obtained from gas phase experiments (100–400 °C), we derive a consistent activation energy of 52 kJ/mol, and the following rate expressions; ln k =9.186 - 6298/ T and k 1 = 9764.61[H 2 O] e-6298/ T where T is absolute temperature (K), k is the universal rate constant ([L/mol]/hr), and k 1 is a pseudo-first-order constant (hr -1 ) applicable to water-dominated terrestrial systems by constraining [H 2 O] as the density of H 2 O (in mol/L) at the P-T of interest. The density-dependent rate constant accounts for the kinetic disparity of D–H exchange with H 2 when dissolved in liquid H 2 O relative to a gas/steam phase, exemplifed by 1/ k 1 at 100 °C of ~2 days in liquid, versus ~7 yrs in saturated steam. This difference may explain the high variability of δDH 2 observed in fumarolic gases. Fluids convecting in the crust frequently reach T > 225 °C, where isotopic equilibrium is rapidly attained (<1 hr). We compare fractionation factors measured in natural fluids (α OBS ) with values expected for equilibrium at the T of acquisition. Where these values differ, we use kinetic models to estimate cooling rates during upward advection that account for the observed disequilibrium. Models fit to fluids from Yellowstone Park and the Lost City (deep-sea) vent field, both recovered at ~90 °C, require respective transit times of ~7 hrs and ~11 days between higher temperature reaction zones and the surface. Using estimates of subsurface depths of origin, however, suggests similar mean fluid flow rates (10 s of meters/hr). Additional complications must be considered when interpreting the δDH 2 of lower-temperature effluent. When applied to data from deep-sea hydrothermal systems, our kinetic models indicate microbial catalysis accelerates D–H exchange once fluids cool below ~60 °C. The H 2 measured in both continental alkaline springs and fracture fluids from Precambrian shield rock is likely produced at T < 100 °C, through processes such as serpentinization. In these settings, δDH 2 values appear closer to equilibrium with H 2 O than those from geothermal systems. Considering kinetic isotope effects may yield H 2 that is out of equilibrium when generated at lower temperatures, we calculate maximum (isothermal) times to apparent isotopic equilibrium of 1.3 yrs at 50 °C, 9 yrs at 25 °C, and 35 yrs at 10 °C. A similar calculation applied to Antarctic brines (-13 °C), where measured δDH 2 is far from equilibrium, yields ~350 yrs. This time is shorter than the fluids have been isolated (2.8 ka), suggesting kinetic isotope effects associated with H 2 destruction or loss via diffusion may also be possible.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2013

Air-Cooled Condensers for Next Generation Geothermal Power Plants (Final Report)

This report summarizes the efforts performed under the ARRA project “Air-Cooled Condensers in Next Generation Conversion Systems”. This project examined technologies that provide near-term improvements to the performance of binary power plants utilizing air-cooled condensers. The motivation for pursuing these improvements is to reduce the power generation costs for enhanced geothermal system (EGS) resources. The study is based on two premises. • Water will not be readily available, and there will be no consumptive use of it in the surface energy conversion system. • The EGS resources utilized for power production will be at greater depths, requiring expensive wells to access the heat. In addition, these resources will have costs associated with the creation of the subsurface reservoir where heat that powers the energy conversion system is extracted. The costs associated with the well field development and EGS reservoir creation provide the impetus for using more efficient energy conversion systems, as well as conversion systems that have higher efficiencies at ‘off-design’ conditions. In identifying the more efficient conversion systems, this work focused on: • Existing technologies with the potential to increase conversion efficiency. These are commercially available technologies that are not typically used in plants operating on hydrothermal resources, • Design strategies to increase plant output during operation at higher ambient temperatures, as well as at ‘off-design’ conditions (operation at resource and ambient temperatures other than those for which the plant was designed), • The feasibility of using mixed working fluids in binary plants using air-cooled condensers. Mixtures have been shown to have the potential to increase binary plant performance by 10% to 20%. This project was originally proposed to also evaluate the use of air-cooled condensers in flash-steam geothermal plants. However, reduced funding subsequent to starting work resulted in elimination of that task.

15 GEOTHERMAL ENERGY↗
DOE OSTI2017

Design and Testing for a New Thermosyphon Irradiation Vehicle

The High Flux Isotope Reactor (HFIR) at the Oak Ridge National Laboratory (ORNL) requires most materials and all fuel experiments to be placed in a pressure containment vessel to ensure that internal contaminants such as fission products cannot be released into the primary coolant. It also requires that all experiments be capable of withstanding various accident conditions (e.g., loss of coolant) without generating vapor bubbles on the surface of the experiment in the primary coolant. These requirements are intended to artificially increase experiment temperatures by introducing a barrier between the experimental materials and the HFIR coolant, and by reducing heat loads to the HFIR primary coolant, thus ensuring that no boiling can occur. A proposed design for materials irradiation would remove these limitations by providing the required primary containment with an internal cooling flow. This would allow for experiments to be irradiated without concern for coolant contamination (e.g., from cladding failure of advanced fuel pins) or for specimen heat load. This report describes a new materials irradiation experiment design that uses a thermosyphon cooling system to allow experimental materials direct access to a liquid coolant. The new design also increases the range of conditions that can be tested in HFIR. This design will provide a unique capability to validate the performance of current and advanced fuels and materials. Because of limited supporting data for this kind of irradiation vehicle, a test program was initiated to obtain operating data that can be used to (1) qualify the vehicle for operation in HFIR and (2) validate computer models used to perform design- and safety-basis calculations. This report also describes the test facility and experimental data, and it provides a comparison of the experimental data to computer simulations. A total of 51 tests have been completed: four tests with pure steam, 12 tests with argon, and 35 tests with helium. A total of 10 tests were performed at subatmospheric pressure, and four of these were performed with pure steam. One test was conducted at a high power of 92.7 kW, six tests were HFIR startups, and two tests were HFIR loss of offsite power (LOOP). Pressures up to 10 MPa, vapor temperatures up to 583 K (310°C), and heater temperatures above 600 K (327°C) have been reached in these tests. Two computer programs, RELAP5-3D and TRACE, have been used to simulate the tests. The TRACE code has shown good agreement with the test data and has been used to model a variety of tests. This experimental facility has been very useful in demonstrating the viability of this new type of irradiation facility.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

Annular Flow Simulation Supported by Iterative In-Memory Mesh Adaptation

Various flow regimes exist in a boiling water reactor (BWR) as the steam quality increases in the uprising coolant flow, from bubbly flow, slug/churn flow, to annular flow. The annular flow is characterized by the presence of a fast-moving gas core and the surrounding liquid film flowing on the conduit wall. Additionally, entrained droplets can be observed in the gas core with ingested bubbles in the liquid film. The dynamics occurring on the wavy interface between the liquid film and gas core plays a crucial role in affecting the heat transfer rate and pressure drop within the BWR core. However, a fundamental understanding of annular flow is still lacking, partly due to the difficulty in obtaining detailed local data in annular flow experiments. In the current study, a novel simulation framework is developed for the annular flow by coupling a computational fluid dynamics flow solver with state-of-the-art meshing software. The gas-liquid interface is tracked with the level set method. Based on the computed flow solutions, the computational mesh is dynamically adapted in memory to meet the local mesh resolution requirement. This iterative simulation-adaptation framework can ensure the fine mesh resolution across the interface, which not only helps mitigate the mass conservation degradation known to level set methods but also improves the representation of dramatic interface topological changes such as wave breaking and droplet entrainment. The present investigation will shed light onto the complex interfacial processes involved in annular flow and generate much needed simulation data for annular flow modeling.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2021

CSP Gen3: Liquid-Phase Pathway to SunShot

The United States Department of Energy (DOE) established the Concentrating Solar Power Generation 3 (CSP Gen3) program to promote the development of advanced CSP systems capable of producing electricity at a levelized cost of energy (LCOE) less than $60/MWh, based on criteria published in the CSP Gen3 Roadmap and a subsequent funding opportunity announcement (Gen3 FOA). This report documents the progress and potential of the “Liquid Pathway” to meet these objectives. The Liquid Pathway proposes the use of low-cost molten chloride salts for energy storage, mated with an operationally flexible solar receiver that employs liquid-metal sodium for heat capture and transfer to the storage salt. This approach leverages molten-salt technology from the current state-of-the-art CSP power towers embodied by plants such as Gemasolar, Crescent Dunes, Noor III, and the DEWA 700 CSP project. Furthermore, the design builds on the knowledge gained over decades of use of liquid-metal sodium as a high-temperature heat transfer fluid (HTF) in solar tests and nuclear-power applications. The commercial representation of the proposed Gen3 design incorporates a high-efficiency sodium receiver operating at ~740°C, with a liquid-liquid heat exchanger feeding a two-tank, molten-chloride salt storage system. Chloride salt is dispatched to a supercritical CO 2 (sCO 2 ) power cycle to provide electric power to the grid. The design integration is a conceptual match for the current sodium receiver → solar salt storage → steam-Rankine power cycle promoted by developer Vast Solar, which may facilitate commercial acceptance and development.

14 SOLAR ENERGY↗
DOE OSTI2016

Packed Bed thermal storage for compact Light water-cooled Small Modular Reactors

Nuclear power plants (NPPs) have less flexibility to follow grid load demand than their natural-gas fueled counterparts. Most of the natural-gas power plants can supply peak-loads by adding more fuel, and thus, can generate far more revenue during those peak hours. On the other hand, use of NPPs for peak load following is quite complex due to technical constraints associated with reactor behavior. These technical challenges include the adequate handling of reactivity swings caused by time-varying fuel and moderator temperatures, a higher fuel-failure probability due to thermal-structural cycling, and spatial variations in xenon concentration. Although there are presently some reactors around the world that are operating with flexible load-following capabilities, such operation is restricted to slowly-varying powers, 2-3 times a day, and only up to 80% of the fuel cycle. Thus, a more convenient and effective method to facilitate load following by NPPs would be to integrate energy storage Authors have previously developed models and performed exergy analysis for integrating liquid type TES with LWRs and SMRs. These exergy based models show that technical feasibility index of integrating thermal energy storage is very high. But most of these previous studies include integration based on existing layout of NPPs with heat exchange between storage Heat Transfer Fluid (HTF) and Reactor Coolant (RC). However, most of the Light Water-cooled Small modular reactor (LW-SMR) based NPP designs can not accommodate additional heat exchange equipment. Although power production is only reduced to 1/20 scale, the containment volume in thus NuScale LW-SMR is reduced to {approx} 1/170 scale. As steam is the secondary or working fluid which exits out of the reactor containment in LW-SMRs, the simplest and most practical way to integrate thermal storage with LW-SMRs is to directly store the energy from steam. Indirect heat exchange between steam and another heat transfer fluid during the storage process, and then heat recovery again via indirect heat exchange is inefficient process due to heat transfer resistance. This inefficiency is due to what is called as 'Pinch point' which occurs whenever there is indirect heat transfer between two media where one undergoes phase change and other undergoes change in sensible heat. Another existing popular option is to use a steam accumulator which stores dry or wet steam directly inside the pressure vessels, however, due to large volumetric requirements it is not a viable option. This work proposes a new method of integrating packed bed TES systems with LW-SMRs, where steam produced in the secondary side of LW-SMRs can be injected into the packed bed of inert particles with sufficient thermal conductivity and capacity to efficiently store energy with high energy density. The changes in the load demand will not effect the LWSMR operation and the excess steam will be diverted to TES. When the demand increases this stored energy in hot packed beds can be recovered by injecting cold pressurized water. Although there are some existing packed bed TES designs and models which consider steam as HTFs, these models have not been extended for wide range of process parameters important for this integration. Authors have previously developed a packed bed thermal model for steam injection and validated it using experimental data. This thermal model is extended to assess behavior of packed bed thermal energy storage (TES) system under storage and recovery cycles. Steam is the only heat transfer fluid (HTF) which exits the reactor vessel, so any application such as process heat or TES integration should be evaluated with steam as process fluid. This project will develop a process system integration model of LW-SMR with packed bed type TES using steam as HTF. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2020

Quarterly Technical Progress Report Piperazine Advanced Stripper (PZAS™) Front End Engineering Design

EXECUTIVE SUMMARY This document summarizes the status of Cooperative Agreement DE-FE0031844, “Piperazine Advanced Stripper (PZAS™) Front-End Engineering Design,” during the reporting period of January 1 through March 31, 2020. The objective of this project is to develop accurate installed costs by conducting a Front-End Engineering Design (FEED) of PZAS™ at Golden Spread Electric Cooperative’s (GSEC) Mustang Station located in Denver City, TX. Complementary benefits include positioning the technology for a commercial project with the 45Q tax credits, qualifying PZAS™ for use on a Natural Gas Combined Cycle (NGCC) Cogen facility, and to provide cost detail to optimize PZAS™ and help guide R&D of second-generation solvent CO2 capture technologies. Results from the FEED will be used to evaluate the economic feasibility of the process at Mustang Station. This project is funded by the U.S. DOE National Energy Technology Laboratory under the aforementioned Cooperative Agreement. Exxon, Total, Chevron, UOP-Honeywell, and the University of Texas (UT) are project co-funders. AECOM and Trimeric are project team members; UT is the prime contractor. Summary of Progress Cooperative Agreement DE-FE0031844 was established in October 2019. The current reporting period, January 1 through March 31, 2020, is the second technical progress reporting period for the project. Several milestones were accomplished during this reporting period, including: • Kickoff Meeting with DOE on February 3, 2020. • Kickoff Meeting with GSEC on March 30, 2020. (Note: Due to Covid-19 travel restrictions and shelter-in-place guidelines, the kickoff meeting was conducted remotely via videoconferencing. See attached notes from that telecon.) • Updated Project Management Plan March 2020, submitted with this quarterly report Other activities during the quarter included progress on contracting and other legal agreements (e.g., non-disclosure agreements), internal kickoff meetings at both AECOM and Trimeric, and development of a Technical Implementation Plan (TIP). The TIP will help the team to make critical, early process decisions and, ultimately, to develop a project and process design basis. Note that all agreements between project team participants are complete as of this submittal, except the vendor agreement with Kiewit (steam cycle modeling). Plans for Next Reporting Period Activities during the next reporting period (April 1, 2020 through June 30, 2020) include: the completion of the Project Design Basis and progress towards the Process Design Basis/Process Design Package (PDP). The Project Design Basis is due as a deliverable and milestone during the next reporting period.

Rochelle, Gary T.↗
DOE OSTI2021

Development of a Modular, Crushed-Rock Thermal Energy Storage Pilot Design

The goal of this project, primarily funded by the U.S. Department of Energy, is to design a next-step pilot to advance near-term energy storage integrated with a fossil plant to provide a facility capable of being viable and effective in a market with growing penetration of variable renewable energy (VRE). Thermal energy storage (TES) represents an ideal technology for this purpose. The current effort will complete a feasibility study to prepare for the Phase II pre-front end engineering design (pre-FEED) for implementing a crushed-rock TES system integrated with a natural gas combined cycle (NGCC) plant. The crushed rock storage technology, which is being developed by Brenmiller Energy, is a modular TES system termed bGen™, which can accommodate both thermal and electrical inputs and output steam, hot water, or hot air. For this application, the estimated efficiency is 80% thermal to thermal. The TES technology is being designed to operate on a slipstream from NYPA’s Eugene W. Zeltmann Power Project (Zeltmann) natural gas combined cycle (NGCC) plant. The projected size of the system will be up to 4 MWe with at least 4 hours of storage duration, or 16 MWh-e total. Final sizing is being determined during the ongoing feasibility study. The next-step pilot being designed as part of the current project will represent a 5-fold increase in scale for this TES technology, and will be used to validate the technology’s ability to provide effective and economical energy storage. This pilot would represent the next-to-last demonstration scale before the technology could be commercial ready at GWh-e scales in the 2030 timeframe. This project is expected to design the critical next-step pilot, which will be undertaken in real-world operating conditions to better determine the crushed rock TES technology’s ability to be integrated with an NGCC plant and assess degradation over transient cycling at rates befitting various marketplaces. The crushed-rock TES pilot design is a technically feasible next step in the development of the technology and is built upon years of prior testing and demonstration. The proposed TES technology was developed by Brenmiller over the last 8 years and has been tested in 3 generations of demonstration units at various sites, globally. During this field testing, different characteristics and performance of the technology were validated, including the following key features: energy storage capacity, energy storage charge/discharge rate, energy storage loses, energy storage mechanical testing. This presentation will provide an update on the results of the conceptual design study for the modular crushed-rock TES system, integrated with a NGCC power plant.

03 NATURAL GAS↗
DOE OSTI2024

Co-synthesis of Hydrogen and High-Value Carbon Products from Methane Pyrolysis

The ARPA-E Methane Pyrolysis Project successfully developed a scalable technology for hydrogen production with low-CO x emission through methane pyrolysis, co-producing high-value carbon nanotubes (CNTs). The project focused on optimizing reactor design, enhancing catalyst performance, and assessing techno-economic feasibility to create a commercially viable and environmentally sustainable process. The fluidized bed reactor achieved over 90% methane (CH 4 ) conversion by using a 5% CO 2 co-feed, which stabilizes carbon yields and minimizes catalyst deactivation. This setup allowed for continuous operation across ten cycles, each consisting of a 14-minute pyrolysis phase followed by a 10-minute dislodging phase to remove a fraction of the accumulated carbon, resulting in stable performance and high-quality CNT production. In parallel, monolith reactors coated with Fe demonstrated a sustained methane conversion of 73% while producing CNTs with high crystallinity. Although promising for continuous operation, monolith reactors face challenges in coating durability and scalability, highlighting areas for further optimization in commercial applications. Catalyst formulation played a key role in enhancing process efficiency. The core catalyst used was 5%Fe/Al 2 O 3 (wt%), optimized through wet impregnation, which improved CNT morphology, yielding longer and more uniform CNTs. The catalyst's performance was further enhanced by adding promoters: 2.5 wt% Ni increased methane conversion close to the thermodynamic limit, while 2.5 wt% Mn improved CNT alignment and crystallinity, and 1.5 wt% NaCl boosted CNT morphology but slightly lowered methane conversion. These adjustments allowed the reactor to maintain high methane conversion while producing high-quality CNTs, enabling stable performance over multiple cycles. To address carbon buildup and ensure uninterrupted operation, a pneumatic conveying tube was implemented for effective carbon dislodging in the fluidized bed configuration. CO 2 and H 2 O co-feeds were also introduced to enhance carbon removal, with CO 2 boosting CNT yield by approximately 15%. This setup enabled stable reactor operation across multiple cycles, preventing clogging and minimizing catalyst wear, making the process suitable for industrial scaling. Techno-economic analysis (TEA) projected hydrogen production costs between $\$$1.00 and $\$$1.64 per kilogram, with CNT values assumed at $\$$375/ton and $\$$100/ton. The life cycle assessment showed that CO 2 emissions could be as low as 0.64 kg CO 2 e/kg H 2 at 95% methane conversion assuming an electricity input of 50 kg CO 2 e/MWh. Even at 50% methane conversion, emissions remained below 1 kg CO 2 e/kg H 2 , demonstrating the process's low-emission potential and making it a viable alternative to traditional steam methane reforming. Overall, the results from this project demonstrate the feasibility of a pyrolysis process where carbon is continuously removed from the catalyst surface and hydrogen is continuously produced until a catalyst regeneration step is required to fully clean the catalyst surface and renew catalyst performance. Major open challenges are related to avoiding the loss of catalyst material in the dislodged carbon during fluidized bed conditions, since our best result demonstrated a carbon purity of ~70 wt. % (rest being iron and alumina). A monolith reactor was used to favor dislodgement of carbon compared to fluidized bed conditions but our results do not demonstrate an advantage of the monolith configuration. Catalyst performance was similar to fluidized bed conditions with slower deactivation rates overall, but we could not observe carbon dislodging in any of the tens of experiments that were run at Stanford. Our results show that the most relevant areas of improvement are related to the fundamental understanding of the iron-carbon interface for dislodging, and the development of catalyst that can produce CNTs via a base-growth mechanism such that catalyst is not lost in the dislodgement steps. The final report documents all findings and methodologies in detail, providing a valuable resource for the scientific community. By building on these results, researchers can further advance methane pyrolysis technology, moving toward a more sustainable, scalable pathway for hydrogen production. This work lays the foundation for future research and commercial efforts to reduce emissions in hydrogen production while generating valuable carbon products.

08 HYDROGEN↗
DOE OSTI2019

Dynamic Earth Energy Storage: Terawatt-Year, Grid-Scale Energy Storage using Planet Earth as a Thermal Battery (GeoTES): Seedling Project Final Report

Grid-scale energy storage has been identified as a needed technology to support the continued build-out of intermittent renewable energy resources. As of April 2017, the U.S. had approximately 24.2 GW of energy storage on line, compared to 1,081 GW of installed generation capacity (Litynski et al. 2006, Hellstrom 2003). This represents a large shortfall of the storage needed to stabilize the U.S. grids with the rising penetration of renewable energy. Our team proposed to address this shortfall through the storage of excess energy as geothermal brine in deep geologic formations. This concept, known as geologic thermal energy storage (GeoTES), relies on the storage of thermal energy in geologic formations for recovery and use in large-scale direct use geothermal applications. As such, GeoTES has the potential to play a significant role in meeting the energy storage shortfall in the coming decades by assisting with peak demand ramping, easing stress on transmission, providing regional storage to support sustainable direct use geothermal applications, and providing a variety of grid stabilization benefits due to renewable outages or inaccurate forecasting and rotor stability.

15 GEOTHERMAL ENERGY↗
DOE OSTI2016

Subtask 2.18 - Advancing CO 2 Capture Technology: Partnership for CO 2 Capture (PCO 2 C) Phase III

Industries and utilities continue to investigate ways to decrease their carbon footprint. Carbon capture and storage (CCS) can enable existing power generation facilities to meet the current national CO 2 reduction goals. The Partnership for CO2 Capture Phase III focused on several important research areas in an effort to find ways to decrease the cost of capture across both precombustion and postcombustion platforms. Two flue gas pretreatment technologies for postcombustion capture, an SO 2 reduction scrubbing technology from Cansolv Technologies Inc. and the Tri-Mer filtration technology that combines particulate, NOx, and SO 2 control, were evaluated on the Energy & Environmental Research Center’s (EERC’s) pilot-scale test system. Pretreating the flue gas should enable more efficient, and therefore less expensive, CO 2 capture. Both technologies were found to be effective in pretreating flue gas prior to CO 2 capture. Two new postcombustion capture solvents were tested, one from the Korea Carbon Capture and Sequestration R&D Center (KCRC) and one from CO 2 Solutions Incorporated. Both of these solvents showed the ability to capture CO 2 while requiring less regeneration energy, which would reduce the cost of capture. Hydrogen separation membranes from Commonwealth Scientific and Industrial Research Organisation were evaluated through precombustion testing. They are composed of vanadium alloy, which is less expensive than the palladium alloys that are typically used. Their performance was comparable to that of other membranes that have been tested at the EERC. Aspen Plus® software was used to model the KCRC and CO 2 Solutions solvents and found that they would result in significantly improved overall plant performance. The modeling effort also showed that the parasitic steam load at partial capture of 45% is less than half that of 90% overall capture, indicating savings that could be accrued if 90% capture is not required. Modeling of three regional power plants using the Carnegie Mellon Integrated Environmental Control Model showed that, among other things, the use of a bypass during partial capture may minimize the size of the capture tower(s) and result in a slight reduction in the revenue required to operate the capture facility. The results reinforced that a one-size-fits-all approach cannot be taken to adding capture to a power plant. Laboratory testing indicated that Fourier transform infrared spectroscopy could be used to continuously sample stack emissions at CO 2 capture facilities to detect and quantify any residual amine or its degradation products, particularly nitrosamines. The information gathered during Phase III is important for utility stakeholders as they determine how to reduce their CO 2 emissions in a carbon-constrained world. This subtask was funded through the EERC–U.S. Department of Energy (DOE) Joint Program on Research and Development for Fossil Energy-Related Resources Cooperative Agreement No. DE-FC26-08NT43291. Nonfederal funding was provided by the North Dakota Industrial Commission, PPL Montana, Nebraska Public Power District, Tri-Mer Corporation, Montana–Dakota Utilities Co., Basin Electric Power Cooperative, KCRC/Korean Institute of Energy Research, Cansolv Technologies, and CO 2 Solutions, Inc.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2016

Design Optimization of Liquid Fueled High Velocity Oxy- Fuel Thermal Spraying Technique for Durable Coating for Fossil Power Systems

High-velocity oxy–fuel (HVOF) thermal spraying was developed in 1930 and has been commercially available for twenty-five years. HVOF thermal spraying has several benefits over the more conventional plasma spray technique including a faster deposition rate which leads to quicker turn-around, with more durable coatings and higher bond strength, hardness and wear resistance due to a homogeneous distribution of the sprayed particles. HVOF thermal spraying is frequently used in engineering to deposit cermets, metallic alloys, composites and polymers, to enhance product life and performance. HVOF thermal spraying system is a highly promising technique for applying durable coatings on structural materials for corrosive and high temperature environments in advanced ultra-supercritical coal- fired (AUSC) boilers, steam turbines and gas turbines. HVOF thermal spraying is the preferred method for producing coatings with low porosity and high adhesion. HVOF thermal spray process has been shown to be one of the most efficient techniques to deposit high performance coatings at moderate cost. Variables affecting the deposit formation and coating properties include hardware characteristics such as nozzle geometry and spraying distance and process parameters such as equivalence ratio, gas flow density, and powder feedstock. In the spray process, the powder particles experience very high speeds combined with fast heating to the powder material melting point or above. This high temperature causes evaporation of the powder, dissolution, and phase transformations. Due to the complex nature of the HVOF technique, the control and optimization of the process is difficult. In general, good coating quality with suitable properties and required performance for specific applications is the goal in producing thermal spray coatings. In order to reach this goal, a deeper understanding of the spray process as a whole is needed. Although many researchers studied commercial HVOF thermal spray systems, there exists a lack of fundamental understanding of the effect of hardware characteristics and operating parameters on HVOF thermally sprayed coatings. Motivated by these issues, this study is devoted to investigate the effect of hardware characteristics (e.g. spraying distance) and operating parameters (e.g. combustion chamber pressure, equivalence ratio, and total gas flow rate) on HVOF sprayed coatings using Inconel 718 alloy. The current study provides extensive understanding of several key operating and process parameters to optimize the next generation of HVOF thermally sprayed coatings for high temperature and harsh environment applications. A facility was developed to support this endeavor in a safe and efficient way, including a HVOF thermal spray system with a Data Acquisition and Remote Controls system (DARCS). The coatings microstructure and morphology were examined using X-Ray Diffraction (XRD), Scanning Electron Microscope (SEM) and Nanoindentation.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2020

Multi-Gas Sensors for Enhanced Reliability of SOFC Operation

GE Research, in partnership with SUNY Polytechnic Institute (SUNY Poly), designed, built, and tested gas sensors for in situ monitoring of H 2 and CO anode tail gases produced with on-site steam reforming in solid oxide fuel cell (SOFC) systems. The knowledge of the H 2 /CO ratio of these anode tail gases should allow accurate determination and control of the efficiency of the reforming process in the SOFC system and should deliver a lower operating cost for SOFC customers. The project objectives were to achieve multi-gas monitoring capability with a single multivariable sensor, and to sustain this performance in the presence of gaseous interferences and a potential poison for the sensor. The duration of the project was 24 months with the project structure that included three technical tasks such as (1) development of design rules of photonic nanostructures for H 2 and CO gas detection, (2) laboratory validation of photonic nanostructures for selective H 2 and CO gas detection, and (3) validation of photonic nanostructures for initial stability and poison-resistance against H 2 S. To build multivariable sensors for selective H 2 and CO gas detection in the presence of interferences, we expanded our earlier knowledge of multi-gas sensors into new fabrication and functionalization methodologies as well as into new methodologies for the spectral data analysis of multi-gas responses. We have advanced our design rules of the three-dimensional (3D) photonic nanostructures that allowed detection of H 2 and CO at high temperatures as individual gases and as their mixtures and rejection of interferences such as CO 2 , H 2 O, CH 4 , and other hydrocarbons for SOFC applications. Our advanced design rules should be attractive for building the new generation of cost-effective industrial sensors. Stability and poison resistance of our 3D photonic nanostructures was tested in the laboratory conditions. While initially we utilized conventional machine learning data analysis tools, we have found that they were unable to correct for the sensor drift. Thus, we have implemented new methods of machine learning for the analysis of our spectral data. These learnings pave the way to move the future studies into advanced testing of effects of interferences, aging and field tests. In future, our work will continue to advance our sensing designs to operate in conditions with known and unknown interferences by implementing nanostructures with enhanced spectral diversity of responses to gaseous species of interest and interferences. Our systematic reduction of technical risks in this completed project and in future studies will ensure transition of this sensing technology to commercialization.

03 NATURAL GAS↗
DOE OSTI2021

Wyandotte Integrated Renewable Energy Strategy (WIRES 2) (Final Technical Report)

Wyandotte Municipal Services (WMS), a Michigan Municipal Utility offering electric generation, transmission & distribution, water filtration & distribution and Broadband/Video sought to deploy a set of renewable energy projects for their Electric Utility that contributed to reducing the City’s environmental and energy impact, provided examples that would encourage businesses and citizens to adopt cleaner energy practices and help WMS meet the required renewable energy standards of the State of Michigan (10% in 2015, 15% in 2021). WMS generates and delivers roughly 280,000 megawatt hours (MWh) of electricity annually to more than 10,000 homes and 1,000 businesses within the City of Wyandotte. The Wyandotte Integrated Renewable Energy Strategy – WIRES 2 resulted in deployment of a set of community-scale micro-wind turbines, evaluation and installation of energy-efficient and low-maintenance light-emitting diode (LED) street lights and park lights in highly visible locations in the City and expansion of the geothermal heating and cooling district that already included residential geothermal systems, to include larger scale business/institutional systems at the Utility’s largest electric customer and at the City Library. Finally, WMS identified the need for job training in energy efficiency and renewable energy technologies to further develop a local skilled workforce in these areas. Partially funded by the grant, the wind turbine project provides a benchmark for WMS, local businesses and residents in the evaluation of utility-scale wind v. micro-wind in an urban environment as a renewable energy strategy. Also partially funded by the grant, the LED project benefited the City of Wyandotte by reducing load on the electric system for the public utility but also reduced City costs for streetlighting, parking lot lighting and park lighting without a compromise in security. The project also resulted in a visual success that has led to additional approvals for non-Grant related LED lighting installations resulting in further reduction in the electric load in the City. Commercial Geothermal installations resulted in the Utility being able to eliminate steam customers who formerly utilized the byproduct of steam from WMS electric production. Due to the reduction in natural gas prices and the overall reduction in market purchased power, it was no longer feasible for WMS to operate its Power Plant as a base load plant and to only operate on a market dispatch philosophy when market prices dictated that WMS could produce electricity cheaper than the market purchase price. This has resulted in fewer operating days for the WMS Power Plant, resulting in less environmental impact. WMS has now completely exited the steam business and the ability to offer a geothermal option to two (2) former steam customers (BASF-Wyandotte and the Bacon Memorial Library) allowed for that. In addition, peak loads have been shaved for these two (2) large customers due to the consistent temperature offered by geothermal heating and cooling, reducing the swings associated with thermostat changes caused by outside temperature changes during extreme high and low temperatures. Finally, energy efficiency and renewable energy college-level classes at Wayne County Community College allowed a group of interested students to pursue studies in those technologies through grant provided tuition, books and course materials. This effort provided a foundation of potential future employees not only for WMS but other energy efficiency/renewable energy employers such as Franklin Energy, a partner with WMS in energy optimization efforts with Wyandotte businesses.

17 WIND ENERGY↗
DOE OSTI2017

Performance of a Steel/Oxide Composite Waste Form for Combined Waste Steams from Advanced Electrochemical Processes

The results of electrochemical corrosion tests and modeling activities performed collaboratively by researchers at the University of Illinois at Chicago and Argonne National Laboratory as part of workpackage NU-13-IL-UIC-0203-02 are summarized herein. The overall objective of the project was to develop and demonstrate testing and modeling approaches that could be used to evaluate the use of composite alloy/ceramic materials as high-level durable waste forms. Several prototypical composite waste form materials were made from stainless steels representing fuel cladding, reagent metals representing metallic fuel waste streams, and reagent oxides representing oxide fuel waste streams to study the microstructures and corrosion behaviors of the oxide and alloy phases. Microelectrodes fabricated from small specimens of the composite materials were used in a series of electrochemical tests to assess the corrosion behaviors of the constituent phases and phase boundaries in an aggressive acid brine solution at various imposed surface potentials. The microstructures were characterized in detail before and after the electrochemical tests to relate the electrochemical responses to changes in both the electrode surface and the solution composition. The results of microscopic, electrochemical, and solution analyses were used to develop equivalent circuit and physical models representing the measured corrosion behaviors of the different materials pertinent to long-term corrosion behavior. This report provides details regarding (1) the production of the composite materials, (2) the protocol for the electrochemical measurements and interpretations of the responses of multi-phase alloy and oxide composites, (3) relating corrosion behaviors to microstructures of multi-phase alloys based on 316L stainless steel and HT9 (410 stainless steel was used as a substitute) with added Mo, Ni, and/or Mn, and (4) modeling the corrosion behaviors and rates of several alloy/oxide composite materials made with added lanthanide and uranium oxides. These analyses show the corrosion behaviors of the alloy/ceramic composite materials are very similar to the corrosion behaviors of multi-phase alloy waste forms, and that the presence of oxide inclusions does not impact the corrosion behaviors of the alloy phases. Mixing with metallic waste streams is beneficial to lanthanide and uranium oxides in that they react with Zr in the fuel waste to form highly durable zirconates. The measured corrosion behaviors suggest properly formulated composite materials would be suitable waste forms for combined metallic and oxide waste streams generated during electrometallurgical reprocessing of spent nuclear fuel. Electrochemical methods are suitable for evaluating the durability and modeling long-term behavior of composite waste forms: the degradation model developed for metallic waste forms can be applied to the alloy phases formed in the composite and an affinity-based mineral dissolution model can be applied to the ceramic phases.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2018

Global Value Chain and Manufacturing Analysis on Geothermal Power Plant Turbines

Currently, geothermal project developers customize the size of the power plant to fit the resource being developed. The turbine is designed and sized to optimize efficiency and resource utilization for electricity production; most often, other power plant components are then chosen to complement the turbine design. These custom turbine designs demand one-off manufacturing processes, which result in higher manufacturing setup costs, longer lead-times, and higher capital costs overall in comparison to larger-volume line manufacturing processes. In contrast, turbines produced in standard increments, manufactured in larger volumes, could result in lower costs per turbine. In this study, we developed a manufacturing cost model to identify requirements for equipment, facilities, raw materials, and labor. Then we used discounted cash flow (DCF) analysis to calculate the minimum sustainable price (MSP). We analyzed three different cases 1) 1 MWe geothermal ORC turboexpander 2) 5 MWe ORC turboexpander and 3) 20 MWe geothermal steam turbine, and calculated the cost of manufacturing the major components, such as the impellers/blades, shaft/rotor, nozzles, inlet guide lanes, disks, and casings. The results showed that MSP could highly vary between 893 /kW and 30 /kW based on turbine size, standardization and volume of manufacturing. The analysis also showed that the economy of scale applies both to the size of the turbine and the number manufactured in a single run. As an example, the unit price of a 5 MW standard design turbine could be 150 /W cheaper than the custom design. Sensitivity analysis indicated that these savings come largely from reduced labor costs for design and engineering and manufacturing setup. In addition to manufacturing cost savings, there is a delivery time saving up to 10 months, which could have a positive effect to construction financing operation time. Another advantage of these standard turbines is their adaptability to different geothermal systems by operating at off-design conditions. We also modeled off-design turbine efficiencies within the commercially-favorable operating range of a standard ORC compared to custom-designed ORC equipment. Than we used these performance calculations and power output capacities in a discounted cash flow (DCF) analysis of plant operations and financing, thereby creating representative techno economic models of a total geothermal power plant. I this scope we used NREL's System Advisor model (SAM) and performed DCF analysis of standard and custom design turbines using results from IPSEpro over range of temperatures of interest. In this scope 63 different off-design cases were analyzed. This helped us to answer the question; 'Can today's capital cost savings compensate the future revenue losses due to lower electricity generation?' The results showed that, the net capital cost savings for the modeled 5 MW case study may reach up to plus 1,298,672. Also, the difference between NPV of standard design and custom design turbine could reach up to 733,940. To sum up, when all the things mentioned above are taken into consideration, it can be said that, the standard turbines are competitive over a wide range of temperatures and flow rates and the give positive NPV differences for certain cases near their design point.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2018

2018 Research Highlight in Manufacturing: Global Value Chain and Manufacturing Analysis on Geothermal Power Plant Turbines

Currently, geothermal project developers customize the size of the power plant to fit the resource being developed. The turbine is designed and sized to optimize efficiency and resource utilization for electricity production; most often, other power plant components are then chosen to complement the turbine design. These custom turbine designs demand one-off manufacturing processes, which result in higher manufacturing setup costs, longer lead-times, and higher capital costs overall in comparison to larger-volume line manufacturing processes. In contrast, turbines produced in standard increments, manufactured in larger volumes, could result in lower costs per turbine. In this study, we developed a manufacturing cost model to identify requirements for equipment, facilities, raw materials, and labor. Then we used discounted cash flow (DCF) analysis to calculate the minimum sustainable price (MSP). We analyzed three different cases 1) 1 MWe geothermal ORC turboexpander 2) 5 MWe ORC turboexpander and 3) 20 MWe geothermal steam turbine, and calculated the cost of manufacturing the major components, such as the impellers/blades, shaft/rotor, nozzles, inlet guide lanes, disks, and casings. The results showed that MSP could highly vary between 893 $/kW and 30 $/kW based on turbine size, standardization and volume of manufacturing. The analysis also showed that the economy of scale applies both to the size of the turbine and the number manufactured in a single run. As an example, the unit price of a 5 MW standard design turbine could be 150 $/W cheaper than the custom design. Sensitivity analysis indicated that these savings come largely from reduced labor costs for design and engineering and manufacturing setup. In addition to manufacturing cost savings, there is a delivery time saving up to 10 months, which could have a positive effect to construction financing operation time. Another advantage of these standard turbines is their adaptability to different geothermal systems by operating at off-design conditions. We also modeled off-design turbine efficiencies within the commercially-favorable operating range of a standard ORC compared to custom-designed ORC equipment. Than we used these performance calculations and power output capacities in a discounted cash flow (DCF) analysis of plant operations and financing, thereby creating representative techno economic models of a total geothermal power plant. I this scope we used NREL's System Advisor model (SAM) and performed DCF analysis of standard and custom design turbines using results from IPSEpro over range of temperatures of interest. In this scope 63 different off-design cases were analyzed. This helped us to answer the question; 'Can today`s capital cost savings compensate the future revenue losses due to lower electricity generation?' The results showed that, the net capital cost savings for the modeled 5 MW case study may reach up to +$1,298,672. Also, the difference between NPV of standard design and custom design turbine could reach up to +$733,940. To sum up, when all the things mentioned above are taken into consideration, it can be said that, the standard turbines are competitive over a wide range of temperatures and flow rates and the give positive NPV differences for certain cases near their design point.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗