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DOE OSTI2022

SAND Report Guide

This SAND Report Guide offers support to authors, technical writers, principal investigators, and others involved in the process of creating, formatting, or refining a SAND Report. It details what you need to know before you begin compiling a SAND Report, directs you to the SAND Report templates, outlines the order of elements in a SAND Report, and explains what to do when your report is completed and ready for Review and Approval and subsequent distribution. Supporting information is provided in the appendix, such as where to get technical assistance, trademarks, Microsoft Word, and equations.

96 KNOWLEDGE MANAGEMENT AND PRESERVATION↗
DOE OSTI2022

Land-Based Wind Market Report: 2022 Edition

The U.S. Department of Energy's 2022 edition of its Land-Based Wind Market Report provides an overview of key trends in the U.S. wind power market, with a focus on 2021. You can find a report, data file and presentation on the Files tab, below. Additionally, several data visualizations are available on the Visualizations tab. Despite ongoing supply chain challenges, wind energy in 2021 continued to see strong growth, technology improvements, and low prices in the U.S. Key highlights include: Wind comprises a growing share of electricity supply: U.S. wind power capacity grew at a strong pace in 2021, with the 13.4 GW of new additions representing a $\$20$ billion investment and 32% of all newly added U.S. generation capacity. Wind energy output rose to account for more than 9% of the entire nation’s electricity supply. At least 247 GW of wind are seeking transmission interconnection; 77 GW of this capacity are offshore wind and 19 GW are hybrid plants that pair wind with storage or solar PV. Wind project performance has increased over the decades: The average capacity factor among recently built projects was nearly 40%, considerably higher than projects built earlier. The highest capacity factors are seen in the interior ‘wind belt’ of the country. Turbines continue to get larger: Improved plant performance has been driven by larger turbines mounted on taller towers and featuring longer blades. In 2011, no turbines employed blades that were 115 meters in diameter or larger, but in 2021, 89% of newly installed turbines featured such rotors. Proposed projects indicate that total turbine height will continue to rise. Low wind turbine pricing has pushed down installed project costs over the last decade: Wind turbine prices averaged $\$800$–$\$950$/kW in 2021, a 5% to 10% increase from the year prior but substantially lower than in 2010. The average installed cost of wind projects in 2021 was $\$1,500$/kW, down more than 40% since the peak in 2010, though relatively stable in recent years. The lowest costs were found in Texas and the (non-ISO) West. Wind energy prices are on the rise, but generally remain low, around $\$20$/MWh in the interior of the country with higher prices in the West and East. After topping out above $\$75$/MWh for power purchase agreements (PPAs) executed in 2009, the national average price of wind PPAs has dropped—though supply-chain pressures have resulted in increased prices in recent years. In the interior ‘wind belt’ of the country, recent pricing is around $\$20$/MWh. In the West and East, prices tend to average above $\$30$/MWh. These prices, which are possible in part due to federal tax support, fall below the projected future fuel costs of gas-fired generation. Wind PPA prices are often attractive compared to wind’s grid-system market value: The value of wind in wholesale power markets is affected by the location of wind plants, their hourly output profiles, and how those characteristics correlate with real-time electricity prices and capacity markets. The market value of wind increased in 2021, averaging $\$16$/MWh in MISO, $\$19$/MWh in SPP, $\$23$/MWh in NYISO, $\$31$/MWh in ERCOT, $\$33$/MWh in PJM, $\$44$/MWh in ISO-NE, and $\$48$/MWh in CAISO. The average levelized cost of wind energy was $\$32$/MWh for plants built in 2021: Levelized costs, which exclude the impacts of federal tax incentives, vary across time and geography. The national average stood at $\$32$/MWh in 2021—down substantially historically, though relatively stable in recent years. Levelized costs were lowest in ERCOT, SPP, and the (non-ISO) West. The health and climate benefits of wind in 2021 were larger than its grid-system value, and the combination of all three far exceeds the current levelized cost of wind: Wind generation reduces power-sector emissions of carbon dioxide, nitrogen oxides, and sulfur dioxide. These reductions, in turn, provide public health and climate benefits that vary regionally, but together are economically valued at an average of over $\$90$/MWh-wind for plants built in 2021.

17 WIND ENERGY↗
DOE OSTI2022

Solving Coupled Surface and Subsurface Flow with Multirate Time Integration [Slides]

This report details an end of summer internship. The report lists the objective, "Add more multirate time integration methods to Amanzi" and concludes that, "Multirate methods can be used to speed up simulations and to get higher orders of accuracy", and "Coupled surface and subsurface simulations could benefit from using multirate schemes".

47 OTHER INSTRUMENTATION↗
DOE OSTI2022

Modeling and evaluating 239 Pu and 235 U PFNS and average prompt-neutron multiplicity [Slides]

The following are currently in VIII.1 LANL and IAEA test files: 239 Pu nu-bar including CGMF modeling and CEA data, 239 Pu PFNS including Chi-Nu & CEA data, 239 Pu(n,f) cross section including fission TPC data. The following are currently being tested: 235 U nu-bar including CGMF modeling and 235 U PFNS including Chi-Nu data. Upcoming tasks include the correction of 235 U Chi-Nu PFNS at higher E inc , benchmarking 235 U PFNS and nu-bar evaluations, and getting 238 U nu-bar.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2022

Fabrication of Advanced Nanocarbon-Metal Composites for Improved Energy Efficiency

We fabricated nanocarbon metal composites (NCMC) of Al alloys with a process called “electrocharging assisted process” (EAP). This method consists of the application of a high current to a mixture of liquid metal and carbon particles. We investigated aluminum alloys (6061 and 1350) and used activated carbon and graphite powder as the source of carbon. The high current induces the formation of carbon chains and ribbons in the liquid metal. Upon solidification of the metal an epitaxial relation between the carbon nanostructures and the metal lattice is produced. The purpose of the project was to find the parameters during the reaction that would give rise to a high density of nanoribbons extending throughout the metal such that the electrical conductivity and the mechanical strength of the composite increased and that the method could be extended to large scale manufacturing. For this purpose, we designed two reactors for the incorporation of nanocarbon ribbons in aluminum metal. The first reactor was designed to have more control of the region with the high current density. However, there were problems with getting good mixing of the carbon in small volumes. A second reactor was designed with a stirrer that allowed for better mixing of the carbon by the introduction of argon gas through the shaft of the stirrer. NCMC were fabricated with a series of parameters to understand the role of current, time of applied current, type and shape of the cathode electrode and stirring speed of the mixture. We analyzed the composites by Raman scattering to gain information on the crystallite size of the nanocarbon, XRD to obtain the crystal structure of the composite, SEM and TEM to characterize the grain size of the aluminum grains and the quality of the crystal structure. We also measured the electrical conductivity and mechanical properties of selected samples. The nanocomposites showed increase in crystallite size of the nanocarbon with a linear dependence of the crystallite size on the duration of the applied current. There is a minimum current density necessary for the crystallite size to increase compared to the ~ 10 nm size of the activated carbon source used in the fabrication. The electrical conductivity of the nanocomposites increased with crystallite size of the nanocarbon and with the concentration of converted carbon. The maximum increase in electrical conductivity was 5.7% above the baseline for samples with ~ 4 wt % nanocarbon with crystallite size larger than 30 nm. These samples presented a hardness ~ 8% higher than the baseline samples with no carbon.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2022

Discontinuous Aligned Carbon Fiber Intermediates for Automotive and Related Applications

This work focused on preferentially aligning discontinuous carbon fibers in wet-laid or air-laid processes. It is well known that aligned fibers provides higher directional strength and stiffness. Discontinuous fibers further allow higher degree of draw and formability as the gaps in the fibers allow for higher material movement. The current processes are limited in their ability to align carbon fibers during processing. The aligned fibers have several benefits - (a) in applications where chopped fibers can replace continuous fibers for targeted strength and stiffness metrics, but at a substantially reduced cost; (b) they can tolerate deeper draws than continuous fiber composites in thermo-stamping and compression molding processes; (c) they can be tailored for pultrusion and unidirectional applications. Although pultrusion is primarily a process that adopts continuous fibers, stitch bonded entangled discontinuous fibers can provide unique intermediates. This is analogous to natural coir fibers which get aligned and entangled to produce ropes/rods for example, (d) they can be processed in cross-ply and multi-directional formats, like composite laminates. In this work Neenah Paper partnered with IACMI, UT and ORNL to evaluate structure-process-property relationships with Zoltek carbon fiber. A few process parameters such as machine speed, weight basis, fiber length, effect of fiber sizing, direction of mat lay-up etc. were investigated. The produced mats were converted to thermoplastic composite laminates using polyamide 6 (PA6, nylon) resin. The specific objective of this project is to produce a wet-laid nonwoven carbon fiber mat with a high degree of unidirectional fiber alignment, using discontinuous carbon fibers. The report provides details about the processing, characterization, and lower-upper bound properties.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Sensitivity Analyses for Monte Carlo Sampling-Based Particle Simulations

Computational design-based optimization is a well-used tool in science and engineering. Our report documents the successful use of a particle sensitivity analysis for design-based optimization within Monte Carlo sampling-based particle simulation—a currently unavailable capability. Such a capability enables the particle simulation communities to go beyond forward simulation and promises to reduce the burden on overworked analysts by getting more done with less computation.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2022

High-Energy X-ray Diffraction Microscopy for Nuclear Forensics FY2022 Project Report

Morphological information on nuclear material has been identified using visible light and scanning electron microscopy. These identify qualitative differences in particle morphology. Three-dimensional imaging of materials through alternating scanning electron microscopy imaging and focused ion beam milling has also been used. Unfortunately, these techniques are time- and labor-intensive, with significant sample preparation required and lengthy analysis times. Further, the resulting 3D images are qualitative, require manual identification, and do not capture statistically-representative populations. High energy X-ray 3D imaging using a direct-beam or diffracted-beam (High-Energy Diffraction Microscopy) have been developed at the Advanced Photon Source and can produce quantitative information on grains (phase, location, etc.) and pores (size distribution, sphericity) in a material. These techniques require only minutes to characterize a sample volume and are non-destructive, thus suitable for a wide range of existing samples and for confirmatory analyses to be carried out using conventional microscopy techniques. In this first year of the project, all uranium oxide samples were synthesized and characterized using conventional analyses by the analytical chemistry laboratory. Conventional analysis methods included powder x-ray diffraction, scanning electron microscopy, impurity analysis via inductively coupled plasma mass spectrometry, and infrared spectroscopy. Impurity analysis shows a drop in boron content from UO 3 to the lowest U 3 O 8 calcination temperature, but otherwise no appreciable difference in any sample. Analysis of diffraction data shows a flip of peaks from UO 3 dominated for the 600 °C calcined sample to U 3 O 8 dominated at 700 °C and 800 °C. Analysis of scanning electron microscopy images shows that with increased calcination temperature the size distribution of particles seems to increase and broaden. Both of these last findings are in line with previously published data, though this work used significantly fewer particles to simply show similar trends instead of getting truly quantitative particle analysis. Infrared analysis similarly shows ingrowth of U 3 O 8 as calcination temperature is increased, along with depression of peaks associated with UO 3 and water. Samples were prepared for analysis at the Advanced Photon Source at beamline 1-ID. It is anticipated that analysis will occur in November of 2022. AI/ML techniques to de-noise data coming out of 1-ID during the analyses was also developed during this time using previously gathered data. Preliminary results using a self-supervision technique called Noise2Selfshow good de-noising of data. Once the uranium oxide samples are analyzed, real data will be used to test the de-noising and other AI/ML techniques that may be developed in the second year of the project.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Producing ENDF/B-quality Evaluations of 239 Pu(n,f) and 235 U(n,f) Average Prompt Neutron Multiplicities using the CGMF Model

This report documents evaluations of the neutron-induced 239 Pu and 235 U average prompt neutron multiplicities, $\overline{v}_p$, using the CGMF model developed at LANL. These evaluations are not updates of existing ENDF/B-VIII.0 nuclear data, but were both re-done from "scratch". That is, all experimental data were extracted from EXFOR, re-normalized to the newest nuclear data representing monitor observables, and detailed uncertainties were estimated from information in EXFOR as well as from templates of expected measurement uncertainties. We also included experimental data that were not yet available for ENDF/B-VIII.0, for instance, the data of Marini et al. for 239 Pu(n,f) $\overline{v}_p$ or the data of Khoklov et al. for 235 U(n,f) $\overline{v}_p$. Finally, we include the CGMF model; it computes $\overline{v}_p$ based on model parameters that at the same time calculate fission fragments as a function of mass, Y (A), the average total kinetic energy as a function of incident-neutron energy, $\langle TKE \rangle$(E inc ), etc. Such a detailed fission model that ties together many fission quantities has not been used to date for any $\overline{v}_p$ evaluation in ENDF/B. Here, we show that we can get evaluated 235 U(n,f) and 239 Pu $\overline{v}_p$ that not only correspond well to experimental $\overline{v}_p$, but that the associated evaluated model parameters also yield parameterizations of Y (A), $\langle TKE \rangle$(E inc ), etc., that correspond well to their respective experimental data. The new evaluated 239 Pu(n,f) $\overline{v}_p$ was also combined into a 239 Pu test file with the newest nuclear data for the 239 Pu prompt-fission neutron spectrum and fission cross sections. This new 239 Pu file performed reasonably well in predicting PU-MET-FAST assemblies, reaction rates in Jezebel and Flattop and three LLNL pulsed spheres. Due to that, the new 239 Pu(n,f) $\overline{v}_p$ evaluation presented here is being considered for ENDF/B-VIII.1. Hence, we can show here that CGMF is able to produce ENDF/B quality $\overline{v}_p$ nuclear data.

239Pu, 235U, Average Prompt-fission Neutron Multip↗
DOE OSTI2022

High Throughput Coefficient Thermal Expansion Testing Utilizing Digital Image Correlation

Dr. Fitzgerald, a postdoc at Sandia National Laboratories, works in a materials of mechanics group characterizing material properties of ductile materials. Her presentation focuses specifically on increasing throughput of coefficient of thermal expansion (CTE) measurements with the use of optical strain measurements, called digital image correlation (DIC). Currently, the coefficient of thermal expansion is found through a time intensive process called dilatometry. There are multiple types of dilatometers. One type, a double push rod mechanical dilatometer, uses and LVDT to measure the expansion of a specimen in one direction. It uses a reference material with known properties to determine the CTE of the specimen in question. Testing about 500 samples using the double push rod mechanical dilatometer would take about 2 years if testing Monday through Friday, because the reference material needs to be at a constant temperature and heating must done slowly to ensure no thermal gradients across the rod. A second type, scissors type dilatometer, pinches a sample using a “scissor-like” appendage that also uses a LVDT to measure thermal expansion as the sample is heated. Finally, laser dilatometry, was created to provide a non-contact means to measure thermal expansion. This process greatly reduces the time required to setup a measurement but is still only able to measure one sample at a time. The time required to test 500 samples gets reduced to 3.5 weeks. Additionally, to measure expansion in different directions, multiple lasers must be used. Dr. Fitzgerald solved this conundrum by using an optical measurement technique called digital image correlation to create strain maps in multiple orientations as well as measuring multiple samples at once. Using this technique, Dr. Fitzgerald can test 500 samples, conservatively, in 2 days.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Towards Software Bill of Materials in the Nuclear Industry

Large, modern industrial facilities often incorporate thousands of digital assets in their operational technology. Regulated facilities, such as nuclear power plants (NPPs), maintain robust cybersecurity and configuration management programs that often use bills of materials (BOMs) for these assets, including make, model, and version of hardware, firmware, and software. However, these BOMs typically capture only first- or second-tier information provided by the original equipment manufacturer (OEM). Unfortunately, as indicated by the increasing number and sophistication of software supply chain attacks, this level of detail is insufficient for identifying all the potential vulnerabilities and risks in software applications. Software BOMs (SBOMs) provide detailed enumeration of components and dependencies within the product or devices, including firmware. SBOMs can be combined with vulnerability data sources and vendor vulnerability attestations to improve vulnerability management and enable rapid identification of affected components when new software vulnerabilities are discovered. Ideally, SBOMs are created by the OEM prior to installation. However, since this practice is not yet commonplace and since NPPs are typically slow to adopt new technology, most NPPs do not incorporate SBOMs into their asset or configuration management programs. Fortunately, SBOMs can be generated by NPPs on existing digital assets to provide further insight into risk management decisions. This report provides an overview of the current SBOM ecosystem and recommends guidance on how to get started in a “crawl, walk, run” manner to develop and implement a sustainable SBOM program for digital assets in an NPP.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

A Lizard-inspired Tube Inspector (LTI) Robot

This final report summarizes the research findings of the current project. This project is a collaboration between New Mexico State University (NMSU) as a lead (Recipient) and Arizona State University (ASU) as a Co-Recipient. Tubular structures are common components of boilers and heat exchangers in power plants. Over time, these components may suffer corrosion, cracks, and stress-corrosion cracks in either the body or the welded connections. A single tube leakage can cause an outage of several weeks. Regular inspection is a key safety factor when ensuring that power plants are maintained in reliable, operational condition. This inspection, however, is challenging, time-consuming, and in many cases impossible due to accessibility issues and safety concerns. Recent developments in robotic-based inspection can offer a great solution. Hard-to-reach places can be inspected without overhauling the unit, saving time and cost. Although several robots have been designed and implemented successfully for inspecting power plant components, in particular tubular structures, their mobility and flexibility are limited. Most of these robots use wheels for mobility which reduces their maneuverability of these robots. Moreover, they usually use magnets to attach to tubes which will not work on tubes with non-ferromagnetic materials. These robots usually carry measurement tools for a particular non-destructive testing (NDT) method such as ultrasound testing (UT) that requires a couplant to perform a point-by-point (scanning) inspection of the tubular structure. In this project, we developed a versatile lizard-inspired tube inspector (LTI) robot with embedded inspection sensing components for tube inspection which removes the need for point-by-point scanning of tube surface for crack and corrosion detection. Inspired by a “lizard”, the novelty of the current project is the integration of couplant-free ultrasound sensing and transmission, advanced data-driven defect detection and imaging, and friction-based mechanical mobility components in a single robot to eliminate a need for smooth surfaces and simple geometry for mobility and scanning. The LTI robot could replace the wheel-based approach with friction-based mobility to significantly increase the flexibility and maneuverability of the robot. The LTI robot can get into a power plant unit, such as a boiler, from a small area allowing it to access a component of interest for inspection (e.g., move on OD, curved and flat surfaces, non-ferromagnetic or ferromagnetic materials, and tubes with rough surfaces and complex geometries). Additionally, an advanced data-driven method using ultrasound data was pioneered to allow the robot to detect defects in the entire area between the robot’s multi-functional mobility system (grippers). Integrating a couplant-free ultrasound sensing in the robot’s grippers as well as using advanced data-driven methods allowed the LTI to detect defects in the entire cross-section of a tube using its grippers when stationary and when mobile.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2022

Final Report: Next Generation Diamond Drumhead X-Ray Optics

Problem / Opportunity Statement: Future high-impact scientific applications at synchrotron and Free-Electron Laser (FEL) X-ray sources require the development of processing and mounting methods for ultra-thin diamond crystals to meet the most challenging needs of pioneering research at next generation light source facilities. These methods should be capable of manufacturing crystal plates as thin as 10 micrometers over an area of a few mm2, and with a surface cut in different crystal orientations, such as the diamond {100}, {111}, {110} and {113} planes. Project Purpose and Approach: In Phase I, Great Lakes Crystal Technologies (GLCT) partnered with Stonybrook University (SUNY) to created thin diamond drumhead crystals. The purpose of the Phase I project is to transfer the drumhead membrane window etching technology from SUNY to GLCT. Testing of a device using the beamline at Stanford Linear Accelerator Laboratory was initially planned, however, a delay on the part of a third party service provided required us to get beamline testing done at Argonne National Laboratory. Phase I Taskwork: Testing of a high purity diamond plate thinning and etching process was performed. By SUNY and GLCT. Plates were sent to a third party service provider for thinning to ~100 microns, however, delays required that GLCT develop an in-house thinning process to complete the taskwork. GLCT successfully developed this in-house capability even though it was initially planned to be part of the Phase II Taskwork. Multiple practice and deliverable plates were provided to SUNY to be etched into the target drumhead devices. GLCT practiced and refined an in-house plate thinning process and produced five plates with thicknesses in the 60 – 150 micron range. Processing of the plates has begun and will continue in a no-cost extension period necessitated by the third party service provider delay. GLCT also procured and installed a reactive ion etching/inductively coupled plasma system. In addition, one of the thinned plates was measured at the Applied Photon Source at APL for a pre-processing assessment of the crystalline strain. After processing the plate into a drumhead and annealing, a post-processing assessment of the strain will be performed. Phase I Results: The initial data from GLCT’s plate thinning process development, SUNY’s drumhead etching processing, and characterization at APS/ANL demonstrate our teams capabilities to achieve the project goals. Commercial Applications & Benefits: The proposed technology will benefit advanced x-ray science performed at BNL and the 70+ additional advanced beamlines around the world. There are also a number of medical and homeland security applications which could benefit from the technology.

Quayle, Paul↗
DOE OSTI2022

Final Scientific/Technical Report-FREE-piston Zero Emissions Refrigerator (FREEZER)

The FREE-piston Zero Emissions Refrigerator (FREEZER™) is a natural refrigerant Stirling-cycle cooler developed by AMSC in partnership with Heatcraft, targeted as a replacement refrigeration system for walk-in coolers or freezers found commonly in restaurants, convenience stores, supermarkets, etc. The FREEZER™, combined with a closed-loop CO2 heat-transfer system, had the goal to provides an efficient (Target COP = 1.4), zero ODP (Ozone Depletion Potential) and near zero GWP (Global Warming Potential) refrigeration solution with no synthetic, flammable, or toxic refrigerants. Other near zero GWP refrigeration systems do not exist at the scale and performance level of FREEZER. ARPA-E Continuation Funding enabled the design and fabrication of one Advanced Development Unit (ADU) cooler and two Field Test Unit (FTU) coolers, and a new revised Field Test Unit (new FTU). Heatcraft was to extensively test the various coolers at their facilities, which closely simulate real-world conditions. The original plan was to install and operate FREEZER FTUs alongside a traditional cooling solution at one or more customer locations to obtain data on direct performance comparisons with existing commercial refrigeration systems. Success in this FREEZER refinement and field-test project will establish the basis for a new class of environmentally friendly refrigeration systems that will revolutionize the industry. The hardware developed under the program is shown below in Figure 1. Five Stirling-cycle machines were built within the program, with a sixth cooler still under construction. The original DU and the ADU coolers met the performance target with a coefficient of performance (COP) of 1.2. The FTU was underperforming during the initial tuning of the free-piston Stirling cycle dynamics when there was a catastrophic failure of the fasteners on pressure boundary. This caused a pause to the program while the failure mechanism was investigated. The root cause was an inadequate flange design that allowed an excessive cyclic loading on the fasteners, leading to a fatigue failure. It was determined that existing FTU design could not be reasonably salvaged in a safe manner, and that fact, combined with the lower-than-expected performance of the new experimental heat exchanger modules lead to the design of the “new FTU” with a more conventional shell-and-tube heat exchanger design which should get close to the design target COP of 1.4, but have a higher overall machine cost. The program ran out of time before the fabrication of the new FTU was completed, but AMSC is still working on the cooler, with the majority of the parts fabricated, and hopes to have the unit under test sometime in early 2022, after which it will be shipped to Heatcraft for additional testing.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

Sensing Electrical Networks Securely & Economically (SENSE)

The growing adoption of distributed energy resources (DERs) like battery energy storage systems and roof top solar/PV and the rapid penetration of electric vehicles (EVs), the electric grid is undergoing a major transformation with elevated stress on legacy grid assets. Despite a lot of expenditure to address these challenges, both in dollars and manpower, utilities have not been able to receive the value that was promised. The gains have been most visible at the transmission and substation level, especially where the main objective was improving operational and economic efficiency for the utility. Improving visibility and control at a few select points enhances the existing and established paradigm of centralized command and control. With changing load patterns, load types and the overall transition to an “active grid”, the centralized control and coordination paradigm gets challenged. To address the challenges, a new architecture and mechanism is needed, one that supports decentralized control and decision making, extracting value streams at the grid edge, particularly as the changes are fueled by transitions occurring in the distribution system. To address this, a communications and data processing platform, “GAMMA” was developed and demonstrated through the project. At the heart of the platform, are distributed, intelligent edge nodes with sensing and compute capabilities, that can record and analyze information locally. They are embedded in sensors and actuators specific to different distribution system applications. Phase 1 of the project focused on developing novel sensor technology that can be used for monitoring utility pole top distribution transformers. The sensors were designed with the objective of being low-cost, communicating with the GAMMA cloud using novel “delay-tolerant” networking using Bluetooth and a secure mobile application. They were non-intrusive in nature so that they can be installed quickly in the field, resulting in overall low cost of deployment and operations. Following the successful completion of Phase 1, the team manufactured 100 units for a field demonstration in Phase 2. The field demonstration was carried out on two real feeder systems with the local utility partner. In total, 100 sensors were installed and operated over a period of 6 months in the state of Georgia. The platform is operational end to end, with the cloud infrastructure deployed on a distributed, serverless environment that can serve multiple data streams, an analytics engine and a portal to securely view the data from multiple assets. The data collected through the GAMMA Mobile Phone app showcased the viability of the novel delay tolerant networking architecture, and the data processing algorithms developed through the course of the project, were successful in extracting important information about the overall network, improving the utility’s visibility and situational awareness in the distribution feeder.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2021

Tailoring Cementitious Materials Towards Value-Added Use of Large CO 2 Volumes

Hydraulic cements with alternative chemistries were developed for large-volume and value-added use of carbon dioxide. The hydraulic cements were processed using the energy-efficient mechanochemical technique at room temperature and atmospheric pressure. Carbon dioxide was captured directly from combustion emissions during processing. For this purpose, mechanochemical processing of hydraulic cements was accomplished under a flow of combustion emissions prior to the release of emissions to the atmosphere. The process removed a significant fraction of carbon dioxide from combustion emissions. The hydraulic cements captured carbon dioxide at about 10% of their weight. Two hydraulic cement chemistries were developed, and their mechanochemical processing was successfully scaled-up. The characteristic feature of one chemistry was its relatively low (near-neutral) pH where the integration of carbon dioxide yielded clear value. The second cement chemistry was based on alkali activation of industrial wastes. This chemistry could make value-added use of carbon dioxide, but it had to be refined to control the pH drop caused by CO 2 integration. These two cements render binding effects upon hydration by forming a combination of stable carbonates and aluminosilicates or phosphates. Efforts to develop cement chemistries based solely on carbonates were not successful. The mechanochemical process was found to integrate carbon dioxide into the alternative cement chemistries in the form of disordered and metastable carbonates. During hydration reactions, the disordered/metastable carbonates are either transformed into stable carbonate phases with desired binding efforts, or carbonates get integrated into the primary inorganic binders (hydrates). When compared with mechanochemical processing in pure carbon dioxide, mechanochemical processing in combustion emissions produced hydraulic cements with improved engineering properties. The mechanochemical process was scaled-up, and its variables as well as the raw materials formulations were optimized for implementation at pilot scale. Scale-up was found to enhance the carbon capture potential and the engineering qualities of the resulting hydraulic cements. This was because scale-up raises the intensity of mechanical energy input to raw materials. Certain mechanochemical phenomena cannot be induced, irrespective of the cumulative mechanical energy input, unless the intensity of impact is raised above a minimum level that cannot be achieved in laboratory-scale implementation of the process. Due to this effect, the duration of the mechanochemical process as well as its energy demand could be reduced significantly (by an order of magnitude) upon transition from laboratory to pilot scale, with the hydraulic cements produced at pilot scale offering engineering properties that were superior to those realized in laboratory-scale mechanochemical processing. The hydraulic cements produced at pilot scale via mechanochemical processing under a flow of combustion emissions were thoroughly characterized. They were found to meet standard requirements for ‘General Use’ hydraulic cements. They were compatible with the industrial-scale concrete production and construction practices that are used with the currently prevalent hydraulic cements. The new hydraulic cements with integrated carbon dioxide were found to offer distinct advantages over the currently prevalent Portland cement in terms of net carbon footprint and energy content. The combined raw materials and energy costs of the new hydraulic cements are competitive, and major cost savings can be realized because of the simplified production process that significantly lowers the capital investment in cement production plants. Mechanochemical processing of the new hydraulic cements under a flow of combustion emissions can be implemented using some existing components of cement manufacturing plants; this facilitates adoption of the technology by the cement industry.

36 MATERIALS SCIENCE↗