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DOE OSTI2016

Resilience Design Patterns - A Structured Approach to Resilience at Extreme Scale (version 1.1)

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2017

The SURE House (Solar Decathlon 2015)

Coastal towns and cities across the Northeastern US, with their high population density, aged utility infrastructure, and unique geography, are increasingly vulnerable to climate change related storm events. In October 2012 superstorm Sandy highlighted the fragility of our current coastal building types and made clear the need for a new model of design and construction which works to understand and mitigate these weaknesses. Dramatic changes in public policy, championed by both The Federal Emergency Management Agency (FEMA) and the National Flood Insurance Program (NFIP) are driving the rebuilding of these shore communities, often resulting in costly renovations, un-sustainable neighborhood configurations and in direct conflict with concurrent government policies such as The American with Disabilities Act (ADA). The SURE HOUSE demonstrates a series of new design solutions to these conflicting public policies and environmental imperatives. At Stevens Institute of Technology, the 2015 Solar Decathlon started with the challenge: Can we design a home for coastal New Jersey that dramatically reduces its energy use while protecting itself from the realities of a changing, more extreme climate? The SURE HOUSE merges the iconic 20th century shore home with 21st century building science. Utilizing innovative renewable energy technologies, a ‘Passive House’ level building envelope, and rugged glass-fiber-composite materials to flood-proof the home, the SURE HOUSE is a high-performance, net-zero-energy home, armored against extreme weather, designed for the contemporary lifestyle of the Jersey Shore and other vulnerable coastal communities. SUSTAINABLE At Stevens, we recognize that energy use in the home and workplace is directly connected to the growing problem of climate change. Reducing our energy consumption by designing higher performing, compact homes that are both functional, comfortable and desirable is the first critical step towards a modern, sustainable architecture for New Jersey and beyond. This is what informed the architectural design of the house. Configured about a compact form, thickly insulated and air-sealed walls eliminate thermal bridging and minimize energy losses while advanced glazing brings in free solar heat during the winter months. As a result of these passive design strategies, the SURE HOUSE has a greatly reduced carbon footprint requiring 91% less energy than a typical New Jersey home. Photovoltaic (PV) arrays on both the rooftop and operable shutters easily provide energy in excess of the home’s modest demands. The Stevens team considers a truly sustainable home in the era of climate change, one that prioritizes low energy use, and integrates right-sized renewable generation to supply the home’s needs. Low consumption, low production. RESILIENT In October of 2012, Hurricane Sandy wreaked havoc along the east coast of the US. In New Jersey alone there was an estimated 29.4 billion dollars in damages, 346,000 homes affected, and almost two and a half million people left without power, in some cases for over 10 days. Recovery from this storm and associated flooding is ongoing to this day, as many New Jersey homeowners grapple with the large costs of rebuilding and struggle to adapt to complicated new home building regulations. Damage from this storm to Hoboken, the home of the Stevens Institute of Technology’s campus, and to the New Jersey shore was extensive and many students on the SURE HOUSE team were directly affected by this historic event. The Stevens design team recognizes that in a world of more frequent and stronger storms, the ability to absorb and adapt to change is more important than ever. Successfully weathering the next storm and its aftermath is one of the primary goals in the design of the SURE HOUSE prototype. The SURE HOUSE introduces unique ‘dry flood-proofing’ methods to residential construction. Innovative wall and floor flood-proofing, utilizing durable composite sheathing materials adapted from the boating industry, were developed by the student team to render the SURE House’s building envelope flood proof up to the FEMA AE 6/7 Zone (+ 6/7 feet of water above sea-level). Designed and fabricated utilizing glass-fiber composite materials, the custom storm shutter system serves to protect the large glazed openings of the home from both air-borne debris impact and water infiltration during a storm event while also providing deterrence from the vandalism that often occurs in the aftermath of a calamitous event. During extended power outages, a ‘resilient’ solar array is capable of supplying critical amounts of energy and hot water to the home, without the use of battery storage or grid infrastructure. PV Description AC GRID-TIED PV SYSTEM The SURE HOUSE solar system consists of two distinct arrays, the grid-tied rooftop array which produces AC Powerand the shutter-mounted array which converts DC power generated by the modules directly into usable heat for the domestic hot water (DHW). The roof-mounted AC grid-tied array is comprised of three strings, two 11 module strings connected to an SMA SB 5000TL-US-223 inverter and a single 10 module string equipped and an SMA SB 3000TL-US-22 central inverter. All modules for the rooftop AC array are LG MonoX 2804 watt solar panels, chosen for their durability and efficiency. Inverter sizing and string size are optimized to the electrical characteristics of the chosen PV modules and the desired energy production, see Appendix 5B. The SURE HOUSE is projected to produce 12,353 kWh per year to meet 6,157 kWh per year of estimated consumption. Solar modules for the two AC grid-tied sub arrays are mounted on the main roof surface of the SURE HOUSE with a 10 degree tilt angle using a partially-ballasted polyethylene roof mounting system made by Renusol, which is particularly suited to the corrosive salt air of a coastal environment. This method was chosen for its installation simplicity and to limit detrimental roof penetrations. The 10 degree tilt optimizes the energy generated per roof area at a lower price, see Appendix 5A, and ensures that there is minimal wind uplift. DC SOLAR ELECTRIC DOMESTIC HOT WATER The SURE HOUSE’s approach to sustainable and resilient domestic hot water (DHW) consists of a unique, custom engineered DC solar electric hot water system. Employing the use of Advanced Energy’s DC electric PV heater (DCPVH)5 to heat domestic water well beyond the draw temperature, the SURE HOUSE is able to obtain a remarkably high solar fraction of 75% or more. The custom modified 80 gallon Vaughn DHW tank acts as a large solar ‘battery’ that stores heat energy in the form of hot water at almost 150 degrees, harvesting energy when the sun is out for use later in the day or overnight. The system, which uses electricity rather than heated fluid, is distinct from traditional ‘solar thermal’ systems by eliminating the dangers and associated maintenance issues of fluid based systems. By forgoing the use of external fluid loops, overheated solar collectors and pipes are not an issue for the SURE HOUSE system which never needs any yearly or seasonal flushing. In weather conditions where the integrated DCPVH unit cannot produce enough hot water via solar energy alone, the Vaughn hot water tank comes factory made with an AC powered 2.6 COP heat pump and a AC heating coil that serve as back-up heating elements. The DCPVH is powered by a DC array consisting of 10 custom-made Solbian by PVilion 180 watt, monocrystalline, flexible solar modules6. The Solbian modules are directly mounted to the top half of the operable storm shutters on the south façade of the SURE HOUSE. The SURE HOUSE team worked closely with PVillion, a PV system designer specializing in flexible architectural photovoltaics, to design an adhesive system that works with the glass-fiber storm shutter surface in a reliable manner over an extended period. Because this system operates in DC-only mode and never connects to the municipal power grid, the system can continue to create hot water safely and effectively even during grid disruption events. This hot water, and the energy stored within it, could be used for a range of activities including washing and cooking to more elaborate hydronic heating systems as desired. See Appendix 6 for system engineering, sizing and modeling.

14 SOLAR ENERGY↗

DOE OSTI2018

Residential Electricity Prices: A Review of Data Sources and Estimation Methods

This paper presents an empirical study of residential electricity prices based on a compilation of tariff data collected for Lawrence Berkeley Lab's Tariff Analysis Project (TAP). We also review other data sources commonly used to estimate residential sector electricity prices, including utility data published by the Energy Information Administration (EIA), the Typical Bills reports published by the Edison Electric Institute, and household-level electricity consumption and expenditure data included with the EIA's Residential Energy Consumption Surveys. We define three different types of price that can be estimated from the data, construct estimation methods, compare the results and evaluate the relative strengths and weaknesses of each approach. We examine several sources of variation including seasonal, regional, industry structure, and the magnitude of baseline household consumption. The tariff data are also used to explore the impact of moving households from standard tariffs to time-of-use pricing, and to summarize how this affects predictions of electricity bill savings for both demand reduction and demand shifting. (auth)

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2019

Enabling Staged Pressurized Oxy-Combustion: Improving Flexibility and Performance at Reduced Cost

Introduction: The staged pressurized oxy-combustion (SPOC) process, developed by Washington University in St. Louis (WUSTL), is an oxy-combustion carbon capture technology that employs a steam power cycle to generate electricity. As with atmospheric-pressure oxy-combustion processes, carbon dioxide (CO 2 ) capture rates of 90% or higher can be achieved. The staged-combustion approach of the SPOC process, when operated at elevated gas pressure, allows for near elimination of flue gas recycle (FGR) and leads to significant improvements in efficiency and reduced costs. The primary goal of this project was to investigate the potential for SPOC for flexible operation beyond the capabilities of conventional coal-fired power plants, particularly those employing carbon capture and storage (CCS). Oxy-combustion differs from conventional coal combustion in that the combustion of coal is carried out using oxygen as opposed to air. The resultant flue gas is a mixture of primarily CO 2 and water, greatly simplifying CO 2 capture. As SPOC does the oxy-combustion process under pressure, it is higher efficiency and lower cost than atmospheric oxy-combustion. The project was led by the Electric Power Research Institute, Inc., with the assistance of WUSTL, Doosan Babcock (DBL – boiler plant original equipment manufacturer), and Air Liquide (AL – air separation experts). The specific objectives of the project were to: (1) Evaluate the SPOC concept and develop a risk-based approach to the heating surface layout ensuring that performance (gas and steam side), manufacturing, transportation, and plant erection considerations were fully accounted for in the system design. (2) Improve the technology to ensure its performance and cost potential are substantially better than today’s baseline pulverized coal power plant with post-combustion capture (PCC) or atmospheric oxy-combustion, and show progress toward performance commensurate with projected commercial operation, including 90% or more CO 2 capture. (3) Address critical technology gaps and improving overall system performance for the technology. (4) Perform combustion tests at scale under commensurate pressure to the commercial operating system validate combustor and advance the SPOC combustion modeling tools that will facilitate full-scale design. Combustion Testing: Testing was initially carried out at atmospheric pressure with methane to ensure that all systems were correctly operating. Following this, the testing then proceeded to moderate pressure operation at 4 bara, where different stoichiometric conditions were used across an extended heat input range, showing that a stable flame could be maintained. Testing then proceeded at 10 and 15 bara where it was shown that the ignition system needed to be replaced at these operating conditions. When testing recommenced, a similar stable flame shape was achieved, without any methane support, and the full 100 kWth coal oxy-combustion was demonstrated. Heat flux measurements showed 400 kW/m 2 (0.126 MMBtu/hr-ft 2 ) from the flame, within the 450 kW/m 2 (0.142 MMBtu/hr-ft 2 ) preferred limit defined by DBL for the full-scale design case. Carbon monoxide and carbon-in-ash measurements showed that complete combustion was possible with ultra-low excess oxygen at 1 vol % in the product flue gas. This allowed the full-scale models to be calculated based on this level of excess oxygen, improving the performance of the system as lower feed oxygen is produced in the air separation unit (ASU), saving auxiliary power. Full-Scale Design: The full-scale design is sized to deliver 550 MWe net electrical power output to allow direct comparison with the National Energy Technology Laboratory (NETL) baseline cases using the same Montana Powder River Basin (PRB) fuel. The cases used for direct comparison are: Case S12A (supercritical [SC] coal without CO 2 capture), Case S12B (SC coal with PCC at 90% CO 2 capture, and Case S12F (atmospheric oxy-combustion SC coal with 90% CO 2 capture). The SPOC stages were configured to be identical arrangements, allowing for a more straightforward design, construction, and control strategy. Each stage consists of two PVs, the first being the combustor PV module and the second being the convective PV module. The combustor module is the tallest vessel, with local coal feeding equipment and the burner FGR and oxygen plenums at the top and ash management at the bottom. The combustor module is effectively an open cross section with membrane tubes around the circumference – this unobstructed slender profile ensures that the relatively slower burnout mechanism needed for the low-speed turbulent mixing burner can proceed unimpeded and that molten ash will not attach to any surfaces at an angle to the predominant flue gas flow. The steam turbine used in the SPOC design is essentially the same unit utilized in the atmospheric oxy-combustion case except the degree of heat recovery possible allows the low-pressure (LP) feedwater heater train to be eliminated. This is a result of being able to capture the latent heat of evaporation of the moisture produced in the combustion (normally lost to the stack). The SPOC system outperforms the NETL atmospheric oxy-combustion baseline case by 3.3% points and the PCC case by 7.5% points. This performance increase is mainly a result of the improved heat recovery possible from the product flue gas and from the reduced auxiliary power consumption from the ASU and the CO 2 compression and purification unit over the atmospheric equivalent. The combined improvement in boiler efficiency and reduction in the steam turbine heat rate resulted in a net improvement in the overall plant efficiency by 0.61%, to 35.6% on a HHV basis. This relatively small improvement in plant efficiency between sub-bituminous and bituminous coals shows the value of useful moisture latent heat recovery offered by the SPOC system when using low rank fuels. Flexibility and Turndown: The SPOC system has inherent high turndown capabilities because of a demonstrated high range of combustion stability and the ability to bypass stages, thereby reducing steam generation rates proportionally without altering firing rates in operating stages. ASU units do not generally offer significant turndown opportunities as they are limited by the performance of the compression plant. The baseline SPOC design has a 2-train ASU configuration, needed to be able to meet the 10,500 tonnes per day duty, that can deliver efficient turndown points between 85–100% load with both trains operating, and at 45–50% load with a single train operating. Outside these operating points, the flexibility and efficiency are limited and may be uncompetitive at loads below 45% as the ASU systems are unable to turndown beyond 85% for the base case and 70% for the flexible case. The ASU cold box for the flexible case was designed to operate at loads between 40-100%, below this operating range the purity of the produced oxygen cannot be guaranteed, resulting in additional load for the CPU equipment. The additional power consumption of these cases yields an uneconomic operating condition with poor efficiency when operating at low loads such as 25% and 12%. To address this flexibility constraint, AL evaluated how the ASU configuration could be altered to deliver efficient oxygen supply over the load range. This involved integrating the compressor duties across both ASU trains into a shared duty arrangement with multiple compressors, strategically sized to deliver the duty required across all load ranges between 40–100% by enabling different combinations of the main air compressors and the booster air compressors. The oxygen purity cannot be guaranteed below 40% load for each train – the power consumption at 25% and 12% loads were estimated based on the multi-compressor configuration at maximum turndown as these load cases were not considered in the flexible ASU design. With a different cold box configuration, i.e. number of trains, the entire load range could be delivered within oxygen purity specifications. Although there is a small efficiency reduction at full load, there are significant improvements in overall plant performance during low-load operation. The exact ASU configuration needed will therefore be dependent on the expected operating profile of the unit. Economic Analysis: Cost estimates for the baseline and the flexible cases were developed using NETL baseline case data for common BOP items and an Association for the Advancement of Cost Engineering International Class 5 (conceptual/screening study) assessment of key components unique to the SPOC system. The capital, operating, and maintenance costs were assessed along with the first-year power cost, levelized cost of electricity, and CO 2 captured and avoided cost for the SPOC cases were compared against the relevant NETL baseline cases in January 2019 dollars. Both SPOC cases achieve a lower cost that the alternative NETL baseline cases (with the flexible SPOC case being slightly higher than the baseline SPOC case due to the compounded impact of higher capital costs and lower efficiency at full load). The SPOC cases deliver a lower cost of CO 2 avoided than the NETL baseline cases due to greater efficiency in generating low-carbon power. However, the cost of CO 2 captured is higher because the higher efficiency of the SPOC process generates less CO 2 , hence less needs to be captured, resulting in a high capital cost being shared over a reduced CO 2 quantity. The flexible ASU adds 1.6% overall to the plant cost in comparison to the baseline case, but the efficiency improvements at loads below 50% are significant. Subsequently, depending on the plant load-profile expectation, the flexible ASU would be beneficial if the plant spends a significant portion of its operating life below 50% load. This kind of operating profile is likely to be required for all fossil plants when more renewable electricity generators are installed on the local grid, particularly solar power that can be predicted ahead of time, allowing for appropriate pricing signals to be incorporated into the diurnal cycle. R&D Recommendations: SPOC, while a promising technology, is a relatively recent concept and, as such, operability issues of combustor design and steam-side integration for such systems at a scale relevant to commercial deployment have not been evaluated. WUSTL has conducted extensive small pilot-scale (100 kWth) research to understand and advance pressurized oxy-combustion processes, including investigation of combustion and flame characteristics, radiative heat flux, burner operability, turn down, char burnout, ash characteristics, water-wash column operation, etc. for pressurized oxy-combustion systems. Nonetheless, at this stage in the development of the SPOC process, what is needed is a large-scale pilot plant that can serve to study pressurized oxy-combustion systems and components at a scale commensurate with the maturity of the technology. A scale of 10 MWth, which includes steam-side integration and two stages would yield essential information with respect to heat transfer characteristics both in the radiative and convective sections of the pressure vessels, and the ability to operate the fuel staging process. In addition, while modeling results indicate that combustion and flame characteristics improve with scale, direct studies of the combustor at this scale will ensure that the models can be relied upon for scale up to commercial scale. Furthermore, a detailed analysis must be performed to understand the scaling aspects of key components and systems.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2019

Dose Calculation Methodology and Data for Solid Waste Performance Assessment and Composite Analysis at the Savannah River Site

This report provides a detailed description of the methodology developed to perform dose calculations for E-Area Low Level Waste Facility Performance Assessments and Savannah River Site Composite Analyses. Chapters 2 – 8 give a complete set of equations to be used to calculate dose for individual exposure pathways. The first set of dose scenarios assume that a member of the public establishes residence near the waste site and uses contaminated groundwater or contaminated surface water for personal consumption and to irrigate a garden and pasture where produce and farm animals are raised. Products from the garden and farm animals are used for personal consumption. This scenario applies to both E-Area Performance Assessments and Savannah River Site Composite Analyses. General dose exposure pathways for the resident farmer scenario are: 1. Ingestion pathways described in Chapter 2, 2. Inhalation pathways described in Chapter 3, 3. External exposure pathways described in Chapter 4, and 4. Recreational pathways described in Chapter 5 (Composite Analysis only). Doses from all of the above pathways are directly related to the contaminant concentration in the water. Additional dose scenarios considered for E-Area Performance Assessment assume that an inadvertent intruder encroaches on the waste disposal site after loss of institutional control. General dose exposure pathways considered for the inadvertent intruder are: 1. Ingestion pathways described in Chapter 6, 2. Inhalation pathways described in Chapter 7, and 3. External exposure pathways described in Chapter 8. Doses from all of the intruder pathways are directly related to the contaminant concentration in the buried waste. Special dose considerations related to human consumption of meat and dairy, and treatment of tritium in dose calculations are discussed in Chapter 9. Chapter 10 describes an Excel database named “Radionuclide, Element and Dose Parameter Data Package” that has been created to provide a system for maintaining the data required to perform radionuclide transport and dose calculations. This data includes: Isotope physical parameters and radioactive decay data needed for both transport and dose calculations, Isotope-specific dose coefficients and soil shielding factors associated with exposure pathways, Radionuclide drinking water concentration limits either published by the Environmental Protection Agency or derived from internal dose coefficients to meet the groundwater protection requirements in Department of Energy Order 435.1, Element-specific bio-transfer factors used in dose calculations, Dose equations and values of physical parameters and human factors used in dose calculations, and Key physical constants used in dose calculations. Revision 1 incorporates updated information developed since this report was issued for use in the next revision of the E-Area Low-Level Waste Facility Performance Assessment.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2013

Ford Thermoelectric HVAC Project (Final Report)

Current light-duty vehicles provide passenger thermal comfort primarily through the use of a centralized HVAC (Heating, Ventilation, and Air Conditioning) unit that distributes conditioned air to vent locations throughout the vehicle. A substantial portion of the air energy content is spent conditioning various elements of the vehicle's interior structures. This is not an overwhelming issue in today’s vehicles, but as pressure builds to improve powertrain efficiency, the energy available to provide occupant comfort will decrease. Thermoelectric devices were identified by the US Department of Energy as one method to potentially reduce HVAC-related energy consumption in vehicles. The objective of the Ford Thermoelectric HVAC Project was to identify a technical and business approach to accelerate research and development of light-duty automotive thermoelectric HVAC technology. A zonal HVAC system was developed to provide thermal comfort to each occupant, with the objective of reducing the overall power consumed by the HVAC system compared with a baseline system. The system was designed to provide a basis for a down-sized central HVAC unit, while providing equivalent comfort and equivalent heating/cooling time-to-comfort at startup, and reduce the energy consumed to provide these functions. Project success was evaluated using occupant comfort and energy consumption metrics, based on a novel thermal comfort-modeling approach, and empirical testing. The ability to produce and market the thermoelectric devices developed in this program was assessed by a business analysis that outlined key steps required for thermoelectric HVAC devices to come to market. Key hardware and controls attribute requirements were identified to determine how they contribute to the commercialization potential of the technology. Final testing and analysis showed that use of thermal comfort and zonal design criteria reduced the energy consumption of the climate control system in both heating and cooling tests, and were significantly better in low vehicle occupancy cases where zonal strategies could be employed. Thermoelectric devices were utilized in the vehicle design to support achieving the technical performance goals of the project. It was found that these devices need additional development in order to address commercial issues, due to their cost and performance limitations.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2020

Zeolite Membrane Reactor for Pre-Combustion Carbon Dioxide Capture (Final Scientific/Technical Report)

Water-gas shift (WGS) reaction followed by carbon dioxide (CO 2 ) separation is a critical step in the integrated gasification combined cycle (IGCC) process for fossil-fuel-fired electrical power generation with CO 2 capture. To intensify the IGCC process hydrogen-permselective zeolite membrane reactor offers promise to replace the conventional energy-intensive fixed-bed reactors and solvent-based CO 2 capture units. The objectives of this project were to develop a bench-scale zeolite membrane reactor (total membrane area: 932 cm 2 for a 21-tube membrane bundle) for the water-gas-shift reaction of raw syngas from an oxygen-blown coal-gasifier for H 2 production with simultaneous CO 2 separation at the capability of about 2 kilograms H 2 per day (equivalent to 2 kW IGCC power plant) and to demonstrate significant progress toward achieving overall performance goal of 90% CO 2 capture rate with 95% CO 2 purity at the cost of electricity 30% less than the baseline carbon capture approaches. This report summarizes results obtained in this project on scaling up the zeolite membrane reactor by a factor of 200 in membrane area, tests of the bench-scale zeolite membrane reactor for the water-gas-shift reaction at high temperature and high-pressure, and techno-economic analysis of the integration of the zeolite membrane reactor in IGCC power plant for the electrical generation with CO 2 capture. With effective pore modification by catalytic cracking deposition of MDES (methyldiethoxysilane), fabrication of MFI-type zeolite membranes was successfully scaled-up from a lab-scale disk type to bench-scale multiple-tube bundles on low-cost alumina supports. A Co-Mo based sour shift catalyst was evaluated and used in the zeolite membrane reactors for water-gas-shift reaction. The reaction kinetic and gas-permeation equations were developed and employed in mathematic models to guide/predict experiments/performance of zeolite membrane reactors for water-gas shift reaction. Multiple-tube zeolite membrane bundles and reactors were designed, fabricated and tested for gas separation and water-gas-shift reactions with real raw syngas from a coal-fired gasifier operated at high temperature and pressure. The zeolite membrane reactors demonstrated good long-term thermal and chemical stability and constant H 2 permeance (>300 GPU) together with a Knudsen selectivity (~4.7) for H 2 over CO 2 in the field test (cumulative time >28 hours) with high-sulfur coal-derived syngas. The zeolite-membrane-reactor integrated IGCC process was designed using the performance experimentally measured by the University of Cincinnati team with a single-tube zeolite membrane reactor that offers a CO conversion >98% with more than 90% of CO 2 and H 2 captured. With the above integrative approaches, a techno-economic analysis for a cost-benefit comparison was performed to uncover features that determine the power output, capital expenditure, operating expenditure, cost of electricity and cost of CO 2 capture in a 550-MW zeolite-membrane-reactor integrated IGCC process. The integration of the zeolite membrane reactor in IGCC could provide a significant reduction of 80% and 27% in the power consumption for Selexol™ Acid Gas Removal and CO 2 compression, respectively, which lowers the total auxiliary power consumption by 12.5%. However, the low pressure required at permeate stream for maintaining the driving force of hydrogen permeation through the zeolite membrane costs a huge power in permeate compressor, compensating the power consumption reduction achieved with the membrane reactor. Thus, for coal-fired IGCC for electricity generation with 90% CO 2 captured, the integration of the membrane reactor could provide a CO conversion ~99% and a significant drop in cost-of-electricity using zeolite membrane with H 2 permeance >600 GPU and the H 2 /CO 2 selectivity over 70.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2020

Evaluating Energy Efficiency Opportunities from Connected and Automated Vehicle Deployments Coupled with Shared Mobility in California

Connected and Automated Vehicles (CAVs) can be considered to be a disruptive transportation technology, with the potential to significantly improve overall transportation system efficiency; however, CAVs may increase induce vehicle miles traveled (VMT) and bring on greater energy consumption. Further, shared mobility is another disruptive transportation event that is reshaping our travel patterns. The primary goal of this project was to extensively collect data from vehicles and associated infrastructure equipped with CAV technologies from both real-world experiments and simulation studies mainly deployed in California, and develop a comprehensive framework for evaluating energy efficiency opportunities from large-scale (e.g., statewide) introduction of CAVs and a wide deployment of shared mobility systems in a variety of scenarios. To quantify the combined impact of CAV and shared mobility on travel behavior, traffic performance, and energy efficiency, a unique mesoscopic simulation-based model was developed for mobility and energy efficiency evaluation considering these disruptive transportation technologies. As a complement to existing studies on nationwide evaluation of CAVs’ energy impacts, this project was focused on data collection efforts and CAV applications under congested traffic environments that are frequently experienced on a massive scale across the major metropolitan areas in California. Extensive real-world data collection supplemented with simulation studies were conducted to cover a variety of CAV and shared mobility scenarios, particularly on scenarios less-explored in the existing research. Another key component of this project was to consider the interaction between different CAV technologies and shared mobility models, and the compound effect on energy efficiency. A comprehensive modeling suite was developed to quantify the impact of new mobility technologies on travel behavior and traffic performance. The developed modeling framework includes an energy intensity module, mode choice module and activity generation module that are integrated into an agent-based BEAM simulation platform to perform impact analysis based on a variety of scenarios. In addition, the RouteE model has been upgraded to incorporate the impact of CAVs on traffic flow, VMT and energy intensity, using micro-simulation data collected from both freeways and urban arterials. A novel fundamental influencing factor (FIF) mode choice model was developed to link CAV and shared mobility components with travel behaviors, and adapted into the BEAM-centered model framework. A statewide energy inventory was constructed under various CAV technology deployment scenarios by incorporating datasets and models for predicting vehicle market share and vehicle usage, which are tightly associated with the penetration of shared mobility systems. Based applying this modeling suite to a calibrated network in Riverside California, it was found that cooperative automated driving in general will improve mobility, but automated vehicles, even when deployed in a shared autonomous fleet, will likely bring an increase of VMT (up to 36%) due to mode shifts and deadheading. Ride-hailing vehicles typically have better energy efficiency and a higher share of electric vehicles, which helps offset the negative impact from VMT increases when estimating the system-level energy consumption. In general, simulation results show a 6% increase in energy consumption for the scenarios with an increasing shift to ride-hailing modes. The statewide analysis based on the National Household Travel Survey (NHTS) sample data is consistent with the findings from the Riverside network and validate the developed clustering-prediction modeling methodology. The outcomes from this project will help close the knowledge gap on recognizing the potential performance and energy impacts of a broad deployment of CAV and shared mobility technologies across a wide range of roadway infrastructure with varying levels of congestion. Results from this project: 1) will support policymakers in steering CAV development and deployment towards an energy favorable direction; 2) reduce uncertainties in estimating energy saving opportunities from new mobility technologies and services; 3) increase the confidence of CAV technology investors both on the infrastructure side (i.e., transportation agencies) and on the vehicle side (i.e., OEMs); and 4) expedite the deployment of energy-efficient CAV and shared mobility applications.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2022

Cooling Egypt: Cost and benefits of room air conditioner efficiency improvement in Egypt

Egypt is one of the largest countries in the Middle East and North Africa region with a population of a total of 106 million (as of July 2022). Increasing urbanization, population growth, and increasing temperatures will likely continue to drive demand for electricity from air conditioning, with corresponding negative impacts on the peak load, air quality, and greenhouse gas emissions from refrigerant use and energy consumption. Since 2003, Egypt has adopted a standards and labeling program for various appliances, and has improved its room air conditioner (RAC) energy efficiency requirements in 2016 and 2017. However, its market is still dominated by inefficient fixed-speed drive (FSD) RACs due to a price-sensitive market. Seasonal metrics such as Cooling Season Performance Factor (CSPF) measure the energy efficiency of FSD and variable-speed drive (VSD) RACs on the same scale. Leading markets, most notably China, have already adopted a new MEPS in 2020 and 2022, which align largely with the United for Efficiency (U4E) Model Regulations Guidelines. India has also adopted a CSPF metric. Both India and China are now experiencing (1) increased demand and consumption of higher efficiency VSD RACs, as well as (2) a corresponding drop in prices from the economies of scale of production of these higher efficiency RACs. Because China is a leading manufacturer in the global air conditioner (AC) market, its adoption of the model U4E regulations have effectively raised the energy efficiency of the ACs in the global market. To achieve the benefits of taking a similar approach to Egypt’s market, we offer the following recommendations: 1. Adopt a common metric to measure the efficiency of both FSD and VSD RACs 2. Raise the stringency of MEPS to the level of the U4E Model Regulation Guidelines 3. Restructure the labeling program from the “A++” labeling scheme to a simpler A through E or a star-rating program 4. Strengthen the compliance regime governing the Egyptian AC MEPS 5. Assist small and medium AC manufacturers in Egypt to transition manufacturing lines to produce low-cost, high-efficiency VSD RACs. Adopting these recommendations would reduce Egypt’s electricity consumption to 11 TWh in 2030 and 89 TWh in 2050—with corresponding carbon dioxide (CO2) emissions reductions and avoided generation capacity requirements compared to the baseline.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2022

Port of New York and New Jersey Drayage Electrification Analysis

The National Renewable Energy Laboratory (NREL) evaluated the potential for drayage electrification in the Port of New York and New Jersey (PoNYNJ), with a focus on operators: Harbor Freight Transport (HF), Safeway Trucking (SWT), and International Motor Freight Inc (IMF). This report summarizes the data collection and electrification evaluation of all three drayage operators, includes detailed operational data, and identifies the performance requirements for battery electric tractors (BETs) and corresponding infrastructure operated within the context of PoNYNJ drayage operation. This report also details a methodology to evaluate opportunities, strategies, and challenges associated with future expansions of BETs in meeting PANYNJ emissions goals. The Port Authority has established a goal of achieving Net Zero carbon emissions by 2050 across all facilities, including from tenant and stakeholder sources such as drayage trucks. NREL used real-world performance data collected on the three PoNYNJ drayage operations, along with modeling and analysis tools to compare BET to diesel trucks. From March to July 2021, NREL collected 1Hz vehicle and engine data from 46 drayage trucks at the three operators totaling nearly 121,000 miles of operation, providing enough information to assess vehicle operations for electrification potential. A Future Automotive Systems Technology Simulator (FASTSim) electric truck powertrain model was validated using PoNYNJ data and scenarios were run to evaluate drayage truck electrification requirements over the real-world cycles. The first scenario examined BET viability with minimal changes to existing operations. This assumes the trucks charge when stopped for two hours or longer, have a functional battery size of 375 kWh, and can charge at 270 kilowatts (kW) average which are the specification of the commercially available Freightliner eCascadia. The second scenario looked at what operational, charging infrastructure, and BET technology changes would be needed to fully electrify. Finally, detailed analysis was run on charging rate structure to understand operational costs to the fleets. The studied drayage trucks averaged 5.1 MPG, spent roughly 9% of their energy at idle, and drove an average of 140 miles per day with a maximum daily distance of 573 miles. The FASTSim model results indicate a comparable BET would use 417 kWh of energy per day on average accounting for cargo weight, which is close to the full usable capacity of the eCascadia currently available on the market. Based on the daily average operating data, partial fleet electrification is possible with current technology. However, some specific days of operation would require over 1,600 kWh of energy due to longer distances traveled by the trucks and more intense operation. Trucks used for long distance and intense operation cannot be readily electrified with current technology without operational changes. Full adoption of BETs could reduce CO 2 emissions from these fleets by roughly 75% today, eliminating 76 metric tons of CO 2 (MTCO 2 ) per vehicle each year, which equates to 24,100 MTCO 2 per year for all three operators. Commercially available direct current fast chargers (DCFC) have charge rates up to 350 kW. Based on the average daily modeled energy use for each operator, current industrial rate structures, and the assumption of 350 kW peak charging, full drayage electrification would increase electricity consumption. In addition, peak demand usage would increase with unmanaged charging along with cost of electricity having a direct impact on cost per mile for electric vehicles. The resulting cost per mile for BETs along with comparable cost per mile for conventional diesel trucks are also examined at $\$$4.00 per gallon of diesel. It will be important for PANYNJ and the drayage operators within the PoNYNJ to consider these load impacts to their existing electrical infrastructure and devise operational strategies that avoid coincident charging of vehicles to mitigate demand charges. Despite these electricity cost increases, savings from reductions in diesel consumption will help offset the costs of this increased electricity consumption. However, prices of both electricity and diesel are subject to change based on various factors meaning the realized savings will vary over time. This shows BETs could be cost-competitive on an energy cost per mile basis for all scenarios while diesel is above $\$$3.00/gal. Further, if diesel prices dropped to the 15-year low of $2.33/gal, it would still be cost competitive to operate the EVs with electricity costs of 16.3 ¢/kWh or less.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2022

Resilience Design Patterns: A Structured Approach to Resilience at Extreme Scale (V.2.0)

Reliability is a serious concern for future extreme-scale high-performance computing (HPC) systems. Projections based on the current generation of HPC systems and technology roadmaps suggest the prevalence of very high fault rates in future systems. The errors resulting from these faults will propagate and generate various kinds of failures, which may result in outcomes ranging from result corruptions to catastrophic application crashes. Therefore, the resilience challenge for extreme-scale HPC systems requires coordination between various hardware and software technologies that are capable of handling a broad set of fault models at accelerated fault rates. Also, due to practical limits on power consumption in future HPC systems, they are likely to embrace innovative architectures, increasing the levels of hardware and software complexities. Therefore, the techniques that seek to improve resilience must navigate the complex trade-off space between resilience and the overheads to power consumption and performance. While the HPC community has developed various resilience solutions, application-level techniques as well as system-based solutions, the solution space of HPC resilience techniques remains fragmented. There are no formal methods to integrate the various HPC resilience techniques into composite solutions, nor are there methods to holistically evaluate the adequacy and efficacy of such solutions in terms of their protection coverage, and their performance & power efficiency characteristics. Additionally, few implementations of current resilience solutions are portable to newer architectures and software environments that will be deployed on future systems. We developed a new structured approach to the management of HPC resilience using the concept of resilience-based design patterns. In general, a design pattern is a repeatable solution to a commonly occurring problem. We identified the well-known solutions that are commonly used to deal with faults, errors and failures in HPC systems. In the initial design patterns specification (version 1.0), we described the various solutions, which address specific problems in the design of resilient HPC environments, in the form of patterns. Each pattern describes a problem caused by a fault, error or failure event in an HPC environment, and then describes the core of the solution of the problem in such a way that this solution may be adapted to different systems and implemented at different layers of the system stack. The catalog of these resilience design patterns provides designers with a collection of design elements. To construct complete resilience solutions using combinations of various patterns, we defined a framework that enhances HPC designers' understanding of the important constraints and the opportunities for the design patterns to be implemented and deployed at various layers of the system stack. The design framework is also useful for establishing interfaces and mechanisms to coordinate flexible fault management across hardware and software components, as well as to consider the trade-off between performance, resilience, and power consumption when constructing a solution. The resilience design patterns specification version 1.1 included more detailed explanations of the pattern solutions, the context in which the patterns are applicable, and the implications for hardware or software design. It also provided several additional examples and detailed case studies to demonstrate the use of patterns to build realistic solutions. In version 1.2 of the specification document, we have improved the pattern descriptions, including graphical representations of the pattern components. These improvements are largely based on critical comments, feedback and suggestions received from pattern experts and readers of the previous versions of the specification. The pattern classification has been modified to further clarify the relationships between pattern categories. This version of the specification also introduces a pattern language for resilience design patterns. The pattern language presents the patterns in the catalog as a network, revealing the relations among the resilience patterns. The language provides designers with the means to explore alternative techniques for handling a specific fault model that may have different efficiency and complexity characteristics. Using the pattern language also enables the design and implementation of comprehensive resilience solutions as a set of interconnected resilience patterns that can be instantiated across layers of the system stack. The overall goal of this work is to provide hardware and software designers, as well as the users and operators of HPC systems, a systematic methodology for the design and evaluation of resilience technologies in HPC systems that keep scientific applications running to a correct solution in a timely and cost-efficient manner despite frequent faults, errors, and failures of various types. Version 2.0 expands the resilience design pattern classification and catalog to include self-stabilization patterns and reliability, availability and performance models for each structural pattern.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2023

Preheating of Cold, High Moisture Particulate Biomaterials to Reduce Drying Time

Forest Concepts led a two-year project to reduce fossil fuel consumption and improve the energy efficiency of dryers through the application of radio frequency (RF) energy impartation to preheat cold-wet bulk particulate biomass materials. A comprehensive biomass heating and drying mathematical model was developed that enables simulation of drying systems for biomass as well as most other bulk porous particulate materials. Experimental and modeling results conclude that energy consumption for both RF preheating and hot-air preheating are essentially equal for cold, high-moisture feedstocks that are above fiber saturation and therefore not economically beneficial for those conditions. Further results suggest that RF heating may have a direct energy consumption benefit in the late stages of drying and in case of preheating biomass that has a moisture content below fiber saturation. This work was funded in part by the US Department of Energy under contact DE-EE0009130.

09 BIOMASS FUELS↗

DOE OSTI2023

Photon-to-Digital Converters for Neutron Imaging Instruments (Final Report)

Oak Ridge National Laboratory (ORNL) collaborated with the Université de Sherbrooke (UdeS) to design a modular and scalable tile of innovative digital photodetectors called Photon-to-Digital Converters (PDC) and the required subsystems to demonstrate the feasibility of large area single-photon detectors to support high-resolution, depth-of-interaction, fast neutron radiography based on scintillation detectors. The goal is to demonstrate the advantages of using PDC over conventional Silicon Photomultiplier (SiPM) for neutron imaging systems. The basic building blocks of analog SiPM and PDC are Single-Photon Avalanche Photodiodes (SPAD). The main difference between conventional SiPMs and PDCs, is in the fact that analog SiPMs sum the charge produced by individual SPAD passively, while in PDCs each SPAD is read out individually by an active electronic circuit. Hence, PDCs provide a direct photon-to-bit conversion where a logic “1” means that there was a detection in a given SPAD. Conversely, an analog SiPM requires a sophisticated preamplifier (current amplifiers or transimpedance amplifier) followed by a shaping amplifier and an analog-to-digital converter. Moreover, since the charge from each SPAD varies slightly, the passive sum of the analog SiPM will have signal fluctuations for the same amount of photon detected. This is one of many issues that is completely eliminated by individual one-to-one SPAD read out in PDCs. The large area required for scintillator readouts for neutron imaging is such that the output capacitance of a large area of SiPM arrays is very high. This creates a burden on the signal-to-noise optimization with respect to the power budget. For PDC, the power consumption is dictated by rate of the incident photon flux, or in photon-starved environments, the dark noise rate of the SPAD array. In other words, the power consumption in the absence of events is extremely low. Hence, the power consumption of a PDC read out system is much lower than its analog counterpart. Further, the large SiPM capacitance may introduce signal distortions on the scintillator fast rise or decay time with undesired effects on timing and pulse shape discrimination. The problem is absent in PDCs, as their readout is independent on device capacitance. UdeS is the world leader in 3D vertical integration of frontside illuminated SPAD arrays over CMOS readouts. These capabilities allow future production of “3D PDC” with maximum photosensitive fill factor and electronic functionalities tailored to the application. UdeS' vast knowledge of SPADs and CMOS design made the team an ideal collaborator in the development of large area high-resolution fast neutron radiography.

42 ENGINEERING↗

DOE OSTI2023

The Regenerative Current Mirror: A Very Low Power Front-End Amplifier for Silicon Pixel Detectors

In pixelized detectors, reducing power consumption in the front- end ASIC chips becomes a crucial demand. Optimization based on mature pre-amplifier schemes today is unlikely to bring sufficient improvements. A new CMOS front-end gain stage topology with very low power consumption called regenerative current mirror is developed to fulfill the demand. The circuit takes advantage of high-speed performance of current amplification while operating with relatively low bias current. The regenerative current mirror uses a NMOS current mirror and a PMOS current mirror, both with nominal gain of 1, to form a loop-back topology that provides a positive feedback. An NMOS FET with an external adjustable voltage applied to it gate terminal is used to limit open loop gain of the current mirrors to be slightly lower than 1. This yields a net gain of the positive feedback loop to be much larger than 1 while operating the current mirrors under relatively low bias currents. Simulation shows that in 65 nm fabrication process, the power consumption of the gain stages suitable for silicon pixel detectors can be controlled < 10 micro-Watts per channel. Another novel low-power circuit called Pseudo-Thyristor presented in another document will replace traditional discriminator and the Regenerative Current Mirror plus Pseudo- Thyristor will provide a full solution for the silicon pixel low-power frontend ASIC.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2024

Retrofitting Buildings with Solar-Reflective Roofs and Walls and its Impact on Peak Power Demand

Buildings are a major consumer of electricity in the United States and a significant portion of the consumption comes from heating, ventilation, and air-conditioning (HVAC) applications. Passive cooling strategies in the building envelope help to reduce the energy consumption for HVAC as well as peak electricity demand. Although being one of the most cost-effective passive cooling strategies, modern reflective roofing and reflective exterior wall technology is not well documented for its impact on peak demand. This study utilized whole building energy simulations on residential and commercial building prototype models to quantify the impact of cool roofs and cool exterior walls. The analysis was performed in three climate zones with varying insulation levels and solar reflectances for roofs and exterior walls. For both the residential and commercial buildings, the baseline building had a roof solar reflectance value of 0.10 and an exterior wall solar reflectance value of 0.25. The results from the simulations show that roofs and exterior walls with higher reflectance values increase cooling energy savings but can also increase heating energy consumption. The impact of changes in solar reflectances was greater in buildings with low roof/wall insulation levels compared to roofs/walls with higher insulation levels. A baseline for the simulations was set with the roof and exterior wall solar reflectances set at 0.1 and 0.25, respectively and simulations having varying roof and exterior wall thermal resistances were compared to the baselines.

14 SOLAR ENERGY↗

DOE OSTI2024

Methane Conversion and Byproduct Determination in a Hollow Scaffold Solid State Bioreactor

The concern over greenhouse gases, methane (CH 4 ) and carbon dioxide (CO 2 ), is increasing rapidly. There have been strides to find solutions to this global issue but there is not a clear path to a successful end goal. The concentration of CH 4 and CO 2 in the atmosphere has increased significantly over the last 60 years, methane is a great source of concern due to its ability to trap a high amount of heat in the atmosphere. These greenhouse gases contribute to global warming which has caused changes in the environment, including the melting of ice caps, and altered weather patterns. Solutions for these pressing challenges have led to different avenues of methane mitigation one of which is the development of solid-state bioreactors. These reactors harness the power of biological species that have evolved to use methane as an energy source. These methanotrophs, Methylomicrobium buryatense (5GB1), have been known to produce acetate and formate as a byproduct of the methane consumption cycle. The development of Hollow Scaffold Solid State Bioreactors (HS-SSBR) utilizes these microorganisms by way of hydrogel immobilization and infiltration of 3D printed scaffolds. The scaffolds act as a substrate for methanotroph growth and methane interaction. Methane consumption was monitored by way of gas sensors which indicated a reduction in methane concentration during the first 4 hours of closed loop methane recirculation. The byproducts of formate and acetate were confirmed by way of 1 H-NMR which indicated the 5GB1 methanotrophs were producing these molecules as a result of methane consumption.

36 MATERIALS SCIENCE↗

DOE OSTI2024

wa-hls4ml: A GNN Surrogate Model for hls4ml

Recent advancements in use of machine learning techniques on field-programmable gate arrays (FPGAs) have allowed for implementation of embedded neural networks with extremely low latency. This is invaluable for particle detectors at the Large Hadron Collider, where latency and used area must be strictly bounded. The hls4ml framework is a procedure for converting from trained machine learning model software, to a synthesis result that can be used on an FPGA. However, running the pipeline is a time-consuming procedure, and there is a strong risk of failure. In particular, it is possible that the model is unable to be converted into a synthesis result, or that the resource consumption of the model will exceed the resources of the target FPGA. To aid with this development, we introduce wa-hls4ml, a surrogate model which uses a graph neural network to emulate the structure of the source models. The goal is to estimate the chance of success and resource consumption of an arbitrary model when passed through the hls4ml procedure, without the time consumption of actually running the pipeline.

43 PARTICLE ACCELERATORS↗

DOE OSTI2024

Smart Pixels: In-pixel AI for on-sensor data filtering

We present a smart pixel prototype readout integrated circuit (ROIC) designed in CMOS 28 nm bulk process, with in-pixel implementation of an artificial intelligence (AI) / machine learning (ML) based data filtering algorithm designed as proof-of-principle for a Phase III upgrade at the Large Hadron Collider (LHC) pixel detector. The first version of the ROIC consists of two matrices of 256 smart pixels, each 25$\times$25 µm\textsuperscript{2} in size. Each pixel consists of a charge-sensitive preamplifier with leakage current compensation and three auto-zero comparators for a 2-bit flash-type ADC. The frontend is capable of synchronously digitizing the sensor charge within 25 ns. Measurement results show an equivalent noise charge (ENC) of $\sim$30e\textsuperscript{-} and a total dispersion of $\sim$100e\textsuperscript{-} The second version of the ROIC uses a fully connected two-layer neural network (NN) to process information from a cluster of 256 pixels to determine if the pattern corresponds to highly desirable high-momentum particle tracks for selection and readout. The digital NN is embedded in-between analog signal processing regions of the 256 pixels without increasing the pixel size and is implemented as fully combinatorial digital logic to minimize power consumption and eliminate clock distribution, and is active only in the presence of an input signal. The total power consumption of the neural network is $\sim$ 300 $\mu$W. The NN performs momentum classification based on the generated cluster patterns and even with a modest momentum threshold, it is capable of 54.4\% – 75.4\% total data rejection, opening the possibility of using the pixel information at 40MHz for the trigger. The total power consumption of analog and digital functions per pixel is $\sim$ 6 $\mu$W per pixel, which corresponds to $\sim$ 1 W/cm\textsuperscript{2} staying within the experimental constraints.

Parpillon, Benjamin↗