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DOE OSTI2022

Electrostatic powder spreading for metal powder bed fusion applications

Typical powder bed fusion processes spread each layer of powder by pushing it across the build area with a spreader bar or roller. While simple, these methods require good flowing powder and do not have the ability to place more than one powder type per layer. This naturally limits the ability to incorporate more than one material onto each powder layer in powder bed additive manufacturing processes. Here we demonstrate electrostatic powder spreading, a method to deposit a powder layer without mechanical contact with the previous layers. Electrostatic powder spreading (ESPS) uses an electric field formed between a powder container and a counter electrode to move powder particles from the container to the powder bed. We show that the rate at which powder is deposited can be controlled by adjusting the strength of the electric field. Correspondingly, the deposited layer thickness is controlled by the strength of the electric field and the recoating speed. To demonstrate the feasibility of ESPS for laser powder bed fusion powder spreading, nearly fully dense (> 99.8%) coupons were built in a commercial L-PBF machine using the ESPS setup. Finally, we achieve 2D patterning of a single layer by using an array of electrodes and switching the applied electric field on and off. ESPS represents a method to produce an arbitrary patterned multi-material powder bed without complicated powder removal steps and easy implementation into existing L-PBF machines. Furthermore, ESPS presents an opportunity to build parts with 3D gradients in material properties.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Computational models of direct and indirect X‐ray breast imaging detectors for in silico trials

Abstract Background To facilitate in silico studies that investigate digital mammography (DM) and breast tomosynthesis (DBT), models replicating the variety in imaging performance of the DM and DBT systems, observed across manufacturers are needed. Purpose The main purpose of this work is to develop generic physics models for direct and indirect detector technology used in commercially available systems, with the goal of making them available open source to manufacturers to further tweak and develop the exact in silico replicas of their systems. Methods We recently reported on an in silico version of the SIEMENS Mammomat Inspiration DM/DBT system using an open‐source GPU‐accelerated Monte Carlo x‐ray imaging simulation code (MC‐GPU). We build on the previous version of the MC‐GPU codes to mimic the imaging performances of two other Food and Drug Administration (FDA)‐approved DM/DBT systems, such as Hologic Selenia Dimensions (HSD) and the General Electric Senographe Pristina (GSP) systems. In this work, we developed a hybrid technique to model the optical spread and signal crosstalk observed in the GSP and HSD systems. MC simulations are used to track each x‐ray photon till its first interaction within the x‐ray detector. On the other hand, the signal spread in the x‐ray detectors is modeled using previously developed analytical equations. This approach allows us to preserve the modeling accuracy offered by MC methods in the patient body, while speeding up secondary carrier transport (either electron–hole pairs or optical photons) using analytical equations in the detector. The analytical optical spread model for the indirect detector includes the depth‐dependent spread and collection of optical photons and relies on a pre‐computed set of point response functions that describe the optical spread as a function of depth. To understand the capabilities of the computational x‐ray detector models, we compared image quality metrics like modulation transfer function (MTF), normalized noise power spectrum (NNPS), and detective quantum efficiency (DQE), simulated with our models against measured data. Please note that the purpose of these comparisons with measured data would be to gauge if the model developed as part of this work could replicate commercially used direct and indirect technology in general and not to achieve perfect fits with measured data. Results We found that the simulated image quality metrics such as MTF, NNPS, and DQE were in reasonable agreement with experimental data. To demonstrate the imaging performance of the three DM/DBT systems, we integrated the detector models with the VICTRE pipeline and simulated DM images of a fatty breast model containing a spiculated mass and a calcium oxalate cluster. In general, we found that the images generated using the indirect model appeared more blurred with a different noise texture and contrast as compared to the systems with direct detectors. Conclusions We have presented computational models of three commercially available FDA‐approved DM/DBT systems, which implement both direct and indirect detector technology. The updated versions of the MC‐GPU codes that can be used to replicate three systems are available in open source format through GitHub.

Sengupta, Aunnasha↗

DOE OSTI2024

Extending Rucio with modern cloud storage support

Rucio is a software framework designed to facilitate scientific collaborations in efficiently organising, managing, and accessing extensive volumes of data through customizable policies. The framework enables data distribution across globally distributed locations and heterogeneous data centres, integrating various storage and network technologies into a unified federated entity. Rucio offers advanced features like distributed data recovery and adaptive replication, and it exhibits high scalability, modularity, and extensibility. Originally developed to meet the requirements of the high-energy physics experiment ATLAS, Rucio has been continuously expanded to support LHC experiments and diverse scientific communities. Recent R&D projects within these communities have evaluated the integration of both private and commercially-provided cloud storage systems, leading to the development of additional functionalities for seamless integration within Rucio. Furthermore, the underlying systems, FTS and GFAL/Davix, have been extended to cater to specific use cases. This contribution focuses on the technical aspects of this work, particularly the challenges encountered in building a generic interface for self-hosted cloud storage, such as MinIO or CEPH S3 Gateway, and established providers like Google Cloud Storage and Amazon Simple Storage Service. Additionally, the integration of decentralised clouds like SEAL is explored. Key aspects, including authentication and authorisation, direct and remote access, throughput and cost estimation, are highlighted, along with shared experiences in daily operations.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2023

Identification and Evaluation of Thermal Transport Components for Integrated Energy Systems

A proper evaluation and selection of component technologies is a critical aspect in the development of Integrated Energy System (IES). This study aims to investigate the key components and associated technologies required to build high-temperature heat transport systems for IES. Of particular interest is the component technologies needed to design and construct IES that combines advanced nuclear reactors with high-temperature industrial processes. This study particularly delved into knowledge base, evaluation metrics, and state-of-the-art commercial technologies, aiming to facilitate the evaluation and selection process of various thermal transport components. In addition, an evaluation process was proposed in order to assist in the optimal selection of the thermal transport components based on the knowledge base and evaluation metrics investigated through this study.

42 ENGINEERING↗

DOE OSTI2025

Cost Effective Electrochromic Glazing Repositioning For Insulating Glass & Secondary Windows

This project addressed both technical and economic objectives toward significantly increasing the availability of ElectroChromic (EC) dynamic architectural glass at reduced cost. In contrast to the prevailing industry location of the EC device layer on the exterior light of an Insulating Glass (IG) unit, Project Objectives assessed the feasibility of a) repositioning the device layer midway between two IG panes to configure triple glazing, and b) independently framed to enable positioning to the building interior independent of the original glass configured as a dynamic secondary window. Parallel research complementing both EC-IG and EC-WinSert configurations addressed integral Photo Voltaic, and ceiling mounted “broadcast” power to circumvent the significant onsite electrical con tracting normally associated with the installation of commercial EC glazing.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2019

Large Area Airborne Contamination Monitoring

Current D&D operations at Hanford have demonstrated a flaw in the current state of the art capability of defining airborne contamination boundaries. Airborne particulate emissions of Pu-239 from CM2H operations on the Hanford Pu Finishing Plant were detected well beyond areas controlled for airborne plutonium, putting numerous workers at risk for radiological assimilations. Forty-two Hanford workers had positive bioassay results for plutonium uptake. Work areas determined to be free of airborne contamination as measured by state-of-the-art continuous alpha monitoring (CAM) systems were later discovered not to be. Airborne contamination was scattered to a such degree that CAM systems were surveying insufficient volumes of air to accurately predict where respiratory protection was required. A $\$ 19,000$ state of the art portable CAM system used at both Hanford and at SRS screens air for alpha activity at the rate of 1 CFM. This research project will explore the feasibility of using commercially available air purifying systems to screen significantly larger volumes of air for airborne actinide contamination. Commercial household HEPA based air purifying units screen large volumes of air, a simple $\$ 300$ unit being looked at for this study could screen a volume of air that would require over 300 of the $\$ 19,000$ CAMs. The goal of the project was to determine the feasibility of building a detection system capable of screening the air purifiers pre-filters and HEPA filters for any actinide bearing hot particles that have been captured. The simplest technologies available to Field-Radiological-Protection personnel are hand-held alpha field survey meters. With the size and the corrugated structure of these HEPA filters, hand screening is not practical. This project researched alternatives capable of automating this function. Two potential technologies were examined. One technology evaluated was the measurement of xray emissions from the actinides, taking advantage of the higher emission rates of the L x-rays compared to the gamma emissions of isotopes such as Pu-238 or Pu-239. High resolution to low resolution systems were evaluated. Branching ratio data on the actinides in the literature is incomplete, and a study was initiated to measure branching ratios of the various L emissions of a number of the plutonium isotopes. A Monte Carlo simulation was also run to calculate the effect the attenuating HEPA media would have on x-ray measurements on spectrometers centered in each quadrant above the surface of the HEPA. The second technology evaluated was measuring the light from a scintillating media applied to the surface of the HEPA filter using a ThorLabs Scientific-Grade Digital Camera Model 8051M. A light tight enclosure capable of holding the 2’x2’x1” HEPA filter was fabricated. Numerous scintillation media were evaluated for both the sensitivity and for resolution of measuring alpha activity. Figure 1 shows images of a 4”x4” section of HEPA filter with a 3 x 3 grid of Pu-238 contamination loaded inside the crevices of the HEPA.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2020

Hawai‘i National Marine Renewable Energy Center (HINMREC)

The Hawaii National Marine Renewable Energy Center (HINMREC) was established to facilitate the commercialization of wave energy converter (WEC) devices, and to accelerate development and testing of Ocean Thermal Energy Conversion (OTEC) technologies. Housed at the Hawaii Natural Energy Institute (HNEI) of the University of Hawaii (UH), this program started with execution of the contract between the US Department of Energy (DOE) and UH in March 2009, and activities ran through the end of the project in September 2019. The DOE tasked HINMREC with facilitating and accelerating the build-out of the Navy’s Wave Energy Test Site (WETS), the nation’s first grid-connected open water wave energy conversion test facility, located off Marine Corps Base Hawaii (MCBH) in Kaneohe, on the island of Oahu. WETS was expanded from an existing test berth at 30m water depth to include test berths at 60m and 80m water depths. In recognition of the high costs associated with at-sea testing and evaluation of WEC devices, it was deemed imperative that HINMREC seek ways to reduce costs to developers by providing key research support to these early-stage technologies. WETS and HINMREC’s support allowed development of wave energy technology by providing a testing infrastructure that allows technology developers to test, demonstrate and evaluate their WEC devices, and generate data in order to advance WEC designs toward commercial readiness. HINMREC’s roles have included support in the establishment of the full site, including of wave resource characterization and site survey, followed by the essential roles of independent WEC device power performance assessment and environmental monitoring in support of deployed pre-commercial WECs. This DOE-funded work transitioned effectively to continue Navy-funded tasks for OTEC development, and activities at WETS, now under Naval Facilities Engineering Command (NAVFAC) funding. A secondary objective in the establishment of HINMREC was to assist the private sector in moving OTEC systems beyond proof-of-concept to pre-commercialization, primarily focused on system and component engineering, and local and global investigations into the potential environmental impacts of OTEC systems. HINMREC was tasked with maintaining high-resolution models of ocean thermal resources and the potential sustainable power output of OTEC systems. Ongoing tests begun previously under Navy funding at the OTEC Heat Exchangers (HXs) Test Facility at the Natural Energy Laboratory of Hawaii Authority (NELHA), in Kona on Hawaii Island, have been continued to identify cost-effective aluminum alloys for use in OTEC systems operating in the corrosive marine environment.

16 TIDAL AND WAVE POWER↗

DOE OSTI2020

Demonstration of μCHP in Light Commercial Hot Water Applications

Internal combustion engine driven combined heat and power (CHP) systems produce power while the waste heat is recovered and used for another purpose. For µCHP systems (less than 50kWe output) overall efficiencies can reach over 90% for products currently on the market throughout the world. On a fuel basis this offers an advantage over using grid-based power and another fuel for heat. Additionally, the cost of natural gas on an energy unit basis is significantly less expensive than electric power. This difference can lead to substantial savings for the end user of a CHP system. In some parts of the world, particularly Germany and Japan, µCHP has become a common part of the heat and distributed generation equipment mix. Market analysis conducted in 2012 showed that in North America there is potential of a 5,300 units per year market for µCHP, resulting in an annual energy savings of approximately 13.5 TBtu and more than $84 million in annual customer savings. However, µCHP still has not seen much market penetration in North America. This study helps to identify some of the reasons why, address roadblocks that still need to be overcome and provide experience to established best practices. Nine commercial sites were initially identified (fitness club, surgical center, senior community, resort and spa, commercial laundry, two multi-family housing, restaurant and manufacturing facility). Systems from two different manufacturers were installed at five sites total, but due to unforeseen circumstances, only three of those sites were finally commissioned: test data were collected by Oak Ridge National Laboratory. While not all systems were installed as intended, the project resulted in the following key findings: Micro combined heat and power is an unfamiliar technology for building owners and plumbing and electrical contractors that serve the buildings most suited for µCHP. Manufacturers will need to be aggressive in providing training and providing broad support to successfully bring the technology to market.; The proper integration of µCHP into other building systems is the most critical part of a successful installation. Manufacturers will need to be able to provide the expertise to train, advise and support the mechanical contractors during the design and installation of the heat integration system.; Regulations governing µCHP varies across the country. There are a few UL standards (UL 2200 and UL 1741) that apply nationally. Emissions are governed by EPA except in California where the California Air Resources Board (CARB) has established their own standard. Requirements that dictate installation and interconnection are dependent on local building codes and local utility processes and requirements. Some out of date building codes do not offer clear guidance for these requirements, leading to confusion. This makes developing training and determining broadly applicable best practices difficult.; Installation costs of µCHP are a key factor in making an installation successful. It is critical that these costs and all national, state and local regulations be understood and accounted for by all parties involved in the installation before a project is undertaken.; A robust customer service organization is important to meet the needs of the customers. These systems require annual maintenance and service and local capability is needed to keep costs inline.

03 NATURAL GAS↗

DOE OSTI2024

Development of Low-Cost, High-Performance, Easy-To-Apply, Non-Flammable, Inorganic Phase Change Material (PCM) Technology (Project Final Report)

This report describes a 45-months long research program focused on the development of novel, easy-to-apply, non-flammable, and high-performance inorganic phase change materials (PCMs) for building and industrial applications. The University of Massachusetts Lowell (UML) formed a world-class team consisting of researchers form InsolCorp (only N. American manufacturer of inorganic PCM systems for building applications), and a group of industrial advisors, to develop a universal/multipurpose, simple-to-manufacture and cost-effective PCM technology. The project team expects that the results of this work will spur in the future the adoption of thermal storage materials – a key building energy saving technology as identified by DOE BTO – for a variety of building envelope applications. The main goal of this project was to demonstrate a suite of low-cost, multipurpose, and durable inorganic PCM formulations with phase transition temperatures encompassing typical building applications (between +5 o C and +55 o C). The first objective was to design, fabricate, and experimentally validate a performance of inexpensive, durable, highly efficient, non-flammable, and easy to manufacture PCMs. To allow a variety of building applications, the project team focused on formulations that exhibit repeatable phase transitions between +5 o C and +55 o C. To follow the DOE BTO cost efficiency target without compromising thermal performance, our work was based on inorganic compounds (mostly salt hydrates) and their blends, which represent a fraction of the cost of most of organic PCMs with about twice as high density as well as significantly higher thermal conductivity and phase change enthalpy. The second objective was to develop easy-to-manufacture and -install packaging/encapsulation designs that are 1) a superior barrier to current state-of-the-art macro-packaging, which significantly reduces the risk of loss of hydration water and PCM leak, and 2) optimal in enhancing the heat exchange rates with the surroundings and within the PCM core to ensure complete charging/discharging of the entire PCM within the product. Finally, the project’s intend was to scale-up the fabrication process to demonstrate installation on system-scale applications, and to validate the performance under field conditions. This work aimed at developing low-cost, high-energy storage, and reliable latent heat storage technology for building applications. This development was realized by formulating and integrating the following two technology components: 1) inorganic salt hydrate based PCMs that have high latent enthalpies and are low-cost and durable, and 2) PCM encapsulation (packaging) technology that maximizes PCM concentration and enhances heat transport characteristics in the product and with the external environment/materials. High thermal storage capacity, low cost and fire resistance are key to the building market entry for PCM technology. Therefore, the project’s focus was on salt-hydrate-based formulations which satisfy all these criteria. Packaging and/or encapsulation of PCM is a key processing step. The project team recognized that a low-cost and simple-to-manufacture salt hydrate-based PCM technology holds the best chance to be successful in the building construction market, a market which is traditionally extremely sensitive to cost and where commodity thermal insulations are the benchmark for envelope-related energy saving measures. That is why, in this project, the main intention was to minimize the production cost and maximize the product energy storage density without sacrificing the PCM performance. It was achieved through: 1. Minimizing the non-PCM components (plastics, additives, packaging/encapsulation materials, etc.) because they are significantly more expensive than salt hydrates, 2. Using highly thermally conductive and lightweight PCM carrier (packaging material) to facilitate more complete phase cycling, and 3. Optimizing the thickness and minimizing air spaces in product design (such as in pouched PCM). For this purpose, our approach was to enable an easy system design, including selection of the PCM operating temperatures, optimizing the necessary heat storage capacity (by stacking together several layers of PCM products), and if needed, a synchronized usage of PCM products of different temperatures. A specially designed, robust, highly thermally conducting and highly impermeable packaging (to retain salt hydrate water during phase transition cycles) was designed and tested to increase the overall system thermal performance and durability. All PCM products developed during this project were tested in both lab scale and in full scale field conditions. It is expected that, after further developments and commercialization, the developed PCM technologies may be also applied in space conditioning, energy storage technologies, and heat transfer applications.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2022

Scale-dependent enhancement of productivity and stability in xenic Nannochloropsis cultures

Although bacterial amendments can enhance algal productivity and stability, the development of algal-bacteria consortia for commercial-scale utilization is limited. Here, for this work, we used an established high-throughput approach to generate algal-bacteria consortia, and tested consortia performance at spatial scales from microplates to 320 L raceway ponds. We used both lab and field-reared strains of Nannochloropsis oceanica to build consortia. In some experiments, we imposed environmental perturbations to test the ability of bacteria to enhance algal culture stability. In repeated assays at the scale of well plates, flasks, and bioreactors, strong effects of bacterial amendments on N. oceanica were observed. These effects were most dramatic when cultures experienced stressors such as temperature perturbations or removal of CO 2 augmentation. Isolates that were advanced for field testing included species in the genera Algoriphagus, Oceanicaulis, and Marinobacter. When consortia were generated in the field, positive effects of bacterial amendments were not observed. The amended bacteria were outcompeted, and bacterial community composition across treatments converged after the first grow out. These results highlight the complexity of using consortia in open systems, where interactions between the existing bacterial community, inoculated bacteria, and changing environmental conditions are layered upon other differences in scale and cultivation regimes. Moreover, functionally redundant bacteria are likely present in the field. Following this work, we hypothesize that tight interactions (e.g., obligate relationships between partners) will scale more predictably to outdoor systems. We suggest relying on true synthetic ecological approaches in which the relationships between bacteria and algae partners are well understood, or synthetic ecological approaches coupled with high throughput approaches to design and test consortia. We also recommend future work to examine the effect of algae-bacteria inoculation ratios on productivity and stability, track dynamics of partners through time, and manage ponds to retain beneficial symbioses.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2022

Evaluation of the Reliability of Passive Infrared (PIR) Occupancy Sensors for Residential Indoor Lighting

Solid-state lighting (SSL) technologies have penetrated the general illumination market in recent years, largely replacing conventional technologies such as incandescent and fluorescent lighting. Most of the initial excitement about light-emitting diode (LED) sources for SSL devices focused on their energy savings potential resulting from vast improvements in source efficiency and luminous efficacy compared with conventional illumination products. More recently, the focus has shifted toward other aspects of lighting application efficiency, namely intensity effectiveness and spectral efficiency, because of the ease of controlling both the light intensity of LEDs with drive voltage and the color properties of the LED-based illuminators. To capitalize on the energy savings of increased intensity effectiveness and spectral efficiency, a lighting control system (LCS) is often used. While the current penetration of LCSs is relatively modest, it is anticipated that lighting controls (i.e., connected lighting, controls and LED and conventional lighting) could have an installed penetration as higher as 46% by the year 2035, saving an additional 1.3 quads of energy. Despite the large energy savings that can be gained from using LCSs, standard test methods for evaluating sensors employed in LCSs and reliability data of the LCSs and their components are generally lacking. The National Electrical Manufacturers Association (NEMA) developed the only standard, NEMA WD 7-2011 (R2016), to test occupancy and motion sensor performance (herein referred to as “the NEMA protocol”). In a previous U.S. Department of Energy (DOE) effort, some concerns of the NEMA protocol were identified (e.g., strict height and weight limits on test subjects, large amounts of manual effort, sometimes inconsistent repeatability). During the current work, a consistent detection length test (DLT) and a Robotic Sensor Evaluation System (RoboSES) were developed to alleviate some of these concerns. RoboSES acts as a human surrogate by using thermal pads on a mannequin and a remote-controlled mobile base to test a sensor’s field of view (FOV). This report builds on the earlier DOE efforts to understand sensor technologies used in LCSs for general illumination. Specifically, this report describes the optimization of RoboSES, characterizes and establishes test methods to assess the reliability of multiple passive infrared (PIR) sensors, and reports the findings of robustness and reliability testing on two commercial PIR sensors intended for residential applications. The information presented in this report is gained from up to 4,000 hours (hrs) of accelerated stress tests (ASTs).

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2021

Challenges and future perspectives on sodium and potassium ion batteries for grid-scale energy storage

The energy crisis and environmental pollution require the advancement of large-scale energy storage techniques. Among the various commercialized technologies, batteries have attracted enormous attention due to their relatively high energy density and long cycle life. Nevertheless, the limited supply and uneven distribution of lithium minerals, as well as their high cost, has greatly hindered the application of lithium-ion batteries in large-scale energy storage. Therefore, building next-generation alternative rechargeable batteries that feature low cost, long service life, and high safety is of the utmost importance. Over the past several years, we have witnessed many successful research outcomes for sodium and potassium ion batteries (SIBs and PIBs) in regard to electrode and electrolyte materials. In this Perspective, we summarize the current developments on SIBs/PIBs and their challenges when facing practical applications, including their cost, energy density, ion diffusivity in solids/electrolytes/interphases, cycle life, and safety concerns. Furthermore, we provide an overview of strategies to overcome the remaining challenges for achieving better electrochemical performance. Finally, we outline several possible directions for the future development of these two battery chemistries, with the hope of aiding the transition from the laboratory to next-generation practical applications for SIBs/PIBs batteries in grid-scale energy storage.

Energy Storage↗

DOE OSTI2020

dGen™ (Distributed Generation Market Demand Model) [SWR-17-09]

The Distributed Generation Market Demand (dGen™) model is a geospatially rich, bottom-up, market-penetration model that simulates the potential adoption of distributed energy resources (DERs) for residential, commercial, and industrial entities in the continental United States through 2050. The National Renewable Energy Laboratory (NREL) developed dGen to analyze the key factors that will affect future market demand for distributed solar, wind, storage, and other DER technologies in the United States within a single modeling platform. The dGen model builds on, extends, and provides significant advances over NREL’s SolarDS model (Denholm et al. 2009), which is now deprecated. All Authors and Contributors are alphabetized in the Developers section with Authors of Code listed first, followed by Contributors and do not reflect equal contributions.

Sigrin, Benjamin↗

DOE OSTI2020

dGen™ (Distributed Generation Market Demand Model) [SWR-17-09]

Preus, Robert↗

DOE OSTI2020

Sandia Labs Academic Alliance 2019 Collaboration Report

Sandia's Academic Alliance (SAA) program takes a deliberate approach to building partnerships with universities that combine strengths in key academic disciplines, contain sizable portfolios of relevant research capabilities, and demonstrate a strong institutional commitment to national security. The SAA Program aims to solve significant problems that Sandia could not address alone, sustain and enrich Sandia's talent pipeline, and accelerate the commercialization and adoption of new technologies.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2022

Residential Energy Efficiency Design Guide for Tribal Lands

Homeowners and renters on tribal lands have historically faced a disproportionate energy burden compared to the United States as a whole. The Indian Health Service (IHS), which serves these communities, strives to meet aggressive energy performance goals when constructing their residential housing. Challenges common in rural locations can hinder progress toward those goals, such as availability of materials, access to specialized labor, and budget constraints. This guide is for architects and builders who aim to incorporate energy efficiency (EE) into their residential designs. This report presents commercially viable energy efficiency packages for a variety of locations and home inputs to help guide home builders in choosing improvements for energy performance. The intention is to provide a diverse set of packages that can be used during the design phase to achieve energy savings compared to a code minimum building design. By presenting a set of diverse options with similar expected energy savings and life-cycle costs, final decisions can be left up to the building designers who can better determine the appropriate package given local costs, materials, and labor availability. Although this guide was developed for IHS projects, it can be used to help designers and construction professionals better make cost-effective choices when a detailed, project-specific building energy analysis is not possible.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2025

Decay heat analysis for advanced reactor spent fuel transportation and storage applications

Accurate characterization of nuclide inventories and decay heat in spent nuclear fuel is critical for ensuring its safe handling, storage, transportation, and disposal. Although extensive research has been conducted on light-water reactor fuel, advanced reactors present unique challenges due to their diverse core configurations, fuel characteristics, neutron energy spectra, and burnup levels. Building upon previous efforts that developed representative reactor core models for various advanced reactor types and fuels, this study evaluates reactor-specific decay heat characteristics. The results highlight significant variations across advanced reactor types as well as across reactor designs within the same reactor type, and they provide comparison to typical commercial light-water reactor fuel. For example, thermal-spectrum reactor fuels were observed to have an approximately 100-fold decrease in decay heat over the first decade of cooling, whereas the reduction was 10-fold for fast-spectrum reactor fuels. Mass-specific decay heat at discharge can differ by three orders of magnitude among the fast and thermal reactor systems considered. Overall, for the analyzed advanced reactor fuel, fewer than 17 nuclides account for over 99% of total decay heat at 0.5 years, and that number drops to fewer than 7 nuclides at 100 years of cooling. By quantifying reactor-specific decay heat trends and nuclide contributions, this work provides a technical basis to support the development of spent fuel management strategies for advanced reactor fuels as well as safety evaluations for storage, transportation, and long-term waste disposal.

Advanced reactors↗

DOE OSTI2026

Advanced Micro Combined Heat and Power Device

U.S. buildings account for approximately 40% of total U.S. energy consumption and 75% of electricity use, emphasizing the need for efficient, resilient, and secure energy solutions. Micro-combined heat and power (micro-CHP) systems provide an effective approach by simultaneously generating electricity and recovering waste heat for thermal use. However, current commercial micro-CHPs face challenges in achieving higher efficiency, lower emissions, and reduced cost. To address these limitations, a novel micro-CHP prototype powered by a unique opposed-piston four-stroke (OP4S) engine was developed. The OP4S features a simplified, low-cost design with reduced heat losses and dual-piston operation that enables higher thermal efficiency. Experimental results demonstrated up to 35.2% AC electrical efficiency under lean combustion, surpassing the best-performing ICE-based micro-CHPs reported publicly. In addition, the micro-CHP enables a total CHP efficiency exceeding 93%. The prototype operates reliably for over 600 hours, providing flexible and efficient thermal and electrical outputs. This novel OP4S-based micro-CHP offers a resilient, low-cost, and energy-efficient solution suitable for residential, light commercial, and remote community applications across diverse climate zones.

Gao, Zhiming [ORNL] (ORCID:0000000271397995)↗