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All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Optimization of WAAM Process to Produce AUSC Components with Increased Service Life

Additive manufacturing has the potential to revolutionize industrial hardware and unlock efficiency gains through the fabrication of geometries and architectures not possible by conventional processing. Wire Arc Additive manufacturing (WAAM) process is a class of directed energy deposition process enabling higher build rate and allowing custom wire feedstock allowing spatial variation of microstructure. The larger spot size and lower speed creates a larger melt pool, reducing residual stress and often time creating directional/columnar microstructure for Ni-superalloy. The use of flexible platform provides freedom in deposition strategy, which can accommodate complex substrates, including feature addition onto existing structures, non-flat layers, and repair methods. However, the certification of the final component needs to match the strength requirement. Hence, the quality of the component produced is stringently monitored to avoid buildup of residual stress, cracks, porosity and to reduce detrimental segregated phases commonly observed during alloy solidification. Simulation plays a huge role in predicting the melt pool dimension and can be used to optimize the process parameter. Similar development is also required to perform physics-based modeling of microstructural development in WAAM that can predict the microstructural features during solidification and can be used to optimize the process more effectively. To move toward this goal, Raytheon Technologies Research Center together with Siemens worked to create a set of computational tools to control the process parameters, enable on-line measurements and acquisition with feedback to the optimized process parameters, and eventually track material evolution through each step of the additive process. Computational fluid dynamics is used for accurate prediction and calibration of the thermal field during WAAM process. and phase field models for microstructure evolution as a function of processing parameters to establish a connection between additive parameters and the final microstructure. Here we report cellular automata (CA) model development to predict the dendritic microstructure evolution with surface and bulk nuclei for single track and multiple layers. The CA model was developed to account for secondary element addition and predict segregation, local melting, and latent heat release as well as prediction of Euler angles from orientation information and validated against experiments. This framework was utilized to tailor spatially-varying composition in a part by appropriately controlling the microstructure evolution during the additive process. Functionally graded Haynes 282 alloy with high Cr content at the surface was tested for oxidation and mechanical properties. An advanced physics-based reaction-diffusion model predicting the simultaneous creation of chromium oxide and alumina is developed and validated to extend life expectancy of the WAAM manufactured high temperature part. A machine-learning data-driven framework establishing the process-structure relationship from a dataset of real microstructure images and corresponding process history data has been developed and implemented in the NX Siemens design system. The digital twin configuration along with the tool path generation enabled prediction of WAAM component buildup time and the techno-economic analysis provided a favorable option for all 4 cases with 15-40% cost reduction.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2022

Characterization of Long-Term Service Coal Combustion Power Plant Extreme Environment Materials

The objective of this DOE-sponsored project was to develop a comprehensive database of mechanical properties, alloy microstructures, and to a lesser extent, the oxidation/corrosion behaviors of coal-fired power plant components, such as boiler tubing, steam headers, and steam piping, which had been in service for at least 100,000 operating hours (preferably more than 200,000 operating hours) under the operating conditions of high temperatures and high mechanical stresses where creep, fatigue, steam-side oxidation, and fireside corrosion were life-limiting factors. The components included in this database consisted of ferritic steels, creep strength enhanced ferritic (CSEF) steels, and 300-series H-grade stainless steels, as well as dissimilar metal welds (DMWs) among these types of materials. As a result of extensive metallurgical characterization and mechanical testing performed in this project, a comprehensive database on mechanical properties and detailed quantitative microstructural information was successfully developed for several long-term serviced EEM components. Such a database can be used by material research communities to develop, calibrate, refine, and validate mechanical behaviors, models, and other assessment tools for accurate prediction of remaining life of major components under similar EEM operating conditions.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2022

Fiscal Year 2022. Filtration of Hanford Tank 241-AP-101 Supernatant at 16 °C

Bench-scale filtration testing of ~9 liters of supernatant from Hanford waste tank 241-AP-101, chilled to 16 °C, was conducted using a backpulse dead-end filter (BDEF) filtration system equipped with a feed vessel and a Mott inline filter Model 6610 (Media Grade 5) in the hot cells of the Radiochemical Processing Laboratory at Pacific Northwest National Laboratory. This was done to assess the performance of the anticipated third feed to the Tank Side Cesium Removal (TSCR) system. The as-received samples were diluted to the target sodium concentration and transferred to 1.5-liter polyethylene bottles and held at 16 °C for approximately 1 week prior to filtration. The feed was filtered through the BDEF system at a targeted flux of 0.065 gpm/ft 2 to match the prototypic operation of the TSCR system. During filtration, the differential pressure required to effect filtration at 0.065 gpm/ft 2 increased little over the filtration campaign and never reached 2 psid (the TSCR action limit). This indicates that the TSCR filter should perform well when processing AP-101 supernatant. After completing filtration of the AP-101 feed, the filter was cleaned. Solids concentrated from the backpulse solutions displayed sodium nitrate-type phases, aluminum and silicon phases reported as cancrinite or nitrate-cancrinite, a mixed chromium-aluminum oxide, iron oxides, and Ca-bearing phases (calcite). Scanning electron microscopy analyses showed that the average particle size was 0.5 micron.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2022

Industrial Assessment Center for Energy Efficiency, Smart Manufacturing and Cyber Security of Illinois and Northwestern Indiana Small and Medium Sized Manufacturing Companies and Water Facilities (Final Technical Report)

The University of Illinois Chicago (UIC) established and implemented a U.S. Department of Energy (DOE) sponsored Industrial Assessment Center (IAC) from September 1, 2016 through December 31, 2021. The established UIC IAC focused on providing 1) technical assistance to small and medium-sized enterprises (SMEs) and water and wastewater facilities in Illinois and northwestern Indiana and 2) education and training university students developing the future energy workforce. The technical assessments incorporated energy efficiency, increasing productivity via smart manufacturing, energy management systems, enhancing on-site cyber security practices, and the promotion of DOE best practices and tools. The educational training enabled UIC faculty and staff to provide classroom education, exposure to industry research, multiple targeted training sessions, real world experience with industry professionals, and live training to implement professional grade audits and recommendations.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2022

Produced Water and Waste Heat-aided Blowdown Water Treatment: Using Chemical and Energy Synergisms for Value Creation

The project objective was to develop a cooling blowdown water (BDW) treatment process utilizing produced water (PW) and low-grade heat to maximize water reuse and saleable by-product generation while reducing chemical and energy footprints of the treatment. The proposed treatment process consists of mixing, softening, organics and suspended solids removal, reverse osmosis (RO), thermal desalination, and brine electrolysis. BDW samples collected from a local coal-fired power plant and PW samples from two shale gas production wells were used in this study. Each treatment unit was first designed and tested to quantify its treatment efficiency, and its chemical and energy requirements. In addition, a process model was developed and model simulations were conducted based on the experimental results and literature data to optimize the treatment process. A techno-economic analysis was conducted to quantify chemical and energy savings as well as production of 10-lb brine as a saleable product. With the field-collected BDW and PW samples, mixing experiments determined a volumetric mixing ratio 10:1 (BDW:PW) resulted in the best performance of multivalent ions removal and largest chemical savings for softening. Softening of the BDW/PW mixtures using alkaline chemicals (Na 2 CO 3 and NaOH) achieved 95%-100% removal of scaling-forming cations (Ca, Mg, Fe, Ba, Sr) and 60% of silicon, and 10% of total organic carbon (TOC). The mixing and softening treatments yielded an effluent with total dissolved solids (TDS) concentration of 23 g/L. Activated carbon (AC) filtration removed TOC to a low level (< 3 mg/L) and further removed remaining scale-forming divalent metals and silica from the softened water. The AC filtration resulted in a slight reduction of TDS from 23 g/L to 20 g/L, leaving behind only mostly monovalent ions (i.e., sodium and chloride) in the filtered water. These pretreatments yielded a feed water that met the criteria of the downstream reverse osmosis (RO) to prevent membrane fouling. A cross-flow RO system was used to further concentrate the TDS of the AC effluent. Various factors including TDS, pH, and applied pressure were examined and optimal conditions were determined for the co-treatment process. An integrated process consisting of mixing, softening, AC filtration and RO was used to treat a continuous flow (0.25 – 1.2 L/min, or 0.07 – 0.32 gpm) and successfully generated RO permeate as product water (TDS < 0.5 g/L) for reuse in cooling operation, and a concentrate (TDS ~ 45 g/L) to be further treated in a thermal desalination unit. These flow rates meet the FOA’s criterion of 0.01 – 1 gpm. Overall, the co-treatment of BDW/PW allowed shorter ramp-up time compared to treatment of BDW alone. It resulted in 40% and 55% savings of Na 2 CO 3(s) and NaOH, respectively, compared to treating the BDW and PW individually for the same level of softening. The co-treatment also resulted in a 29% energy saving compared to treatment of BDW only for the level of TDS concentration. A thermal desalination system was designed using CFD simulations and manufactured in the WVU Innovation Hub for further treatment of the RO concentrate to generate 10-lb brine. The system has a design flow rate of 2 gpm and has been successfully tested. A bench-scale brine electrolysis system was developed for on-site generation of chlorine/hypochlorite (Cl 2 /OCl - ) and caustic soda (NaOH) as useful chemicals for the co-treatment process. Using salt solutions (0.5 M and 1 M), the system achieved faradaic efficiencies of 93%-97% and 70%-77% for caustic soda and chlorine/hypochlorite generation, respectively. An economic analysis showed that the electricity costs for on-site generation of these chemicals were significantly lower than the chemical prices offered by suppliers. An industrial-scale process model consisting of mixing, softening, AC filtration, RO, thermal desalination, and brine electrolysis was developed using the Aspen Plus V9 in conjunction with Aspen Custom Modeler V9. The model serves as a solvable Aspen Plus model and as basis to form the costing infrastructure. In addition, techno-economic analysis considering capital, operating, and transportation costs was conducted. An optimization solution showed that produced water for mixing is still advantageous in low quantities. The optimum solution approaches a leveled cost of water (LCW) of 2 $/m 3 which becomes cost competitive with nominal water treatment prices.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2020

Data from Rossi-α and Pulsed Neutron Prompt Neutron Time Decay Measurements at the Oak Ridge Critical Experiments Facility

This report briefly describes the prompt neutron decay measurements by the Rossi-α and pulsed neutron methods performed at the Oak Ridge Critical Experiments Facility. It briefly describes the measurement equipment, the type of data, and how to access the actual data from the Laboratory Records Department at Oak Ridge National Laboratory and the International Nuclear Criticality Safety Benchmark Evaluation Program at Idaho National Laboratory. Most of the data was acquired between 1960 and 1975 with weapons-grade enriched uranium metal assemblies. It also includes measurement of these types performed at Los Alamos National Laboratory by Oak Ridge National Laboratory with the JEZEBEL and FLATTOP criticality assemblies and other plutonium metal parts. The purpose of this report is to support future mining of the data for publication of additional information that can be used to verify calculational methods and nuclear cross sections. Present calculational methods can be used to directly calculate the measured data.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2022

National Bureau of Standards Reactor LEU Fuel Element Flow Test Conceptual Design

As part of the U.S. National Nuclear Security Administration’s (NNSA’s) mission to eliminate or minimize the civilian use of weapon-grade highly enriched uranium (HEU) fuels, the NNSA Office of Material Management and Minimization (M 3 ) Reactor Conversion Program is collaborating with six U.S. High Performance Research Reactors (USHPRR), including one critical facility, to convert from the use of HEU to low-enriched uranium (LEU) fuel. The M3 conversion objectives for the USHPRR are to develop LEU fuel element designs that will ensure safe reactor operations and maintain the existing experimental performance of each facility. The work is being conducted through many interrelated activities that are being completed by stakeholders across organizations.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Carrier Dynamics of Polar, Semipolar, and Nonpolar InGaN/GaN LEDs Measured by Small-Signal Electroluminescence

The carrier dynamics in InGaN/GaN light-emitting diodes (LEDs) are directly tied to their efficiency and maximum modulation speed, which are important metrics for solid-state lighting, displays, and optical communication. In this work, we measure the carrier dynamics of a variety of InGaN/GaN LEDs using small-signal electroluminescence methods [1]. A rate equation approach and associated small-signal circuit are used to model carrier injection, recombination in the active region, recombination in the cladding regions, and carrier escape. The model is fit to the measured optical frequency response (S21) and input impedance (S11) of the LEDs to extract the various carrier lifetimes, the carrier density, and the radiative and non-radiative recombination rates. We specifically study planar nonpolar and semipolar LEDs, which show record-high modulation speeds for III-nitride LEDs and present the modulation characteristics of core-shell nanowire-based LEDs. The planar nonpolar m-plane ($101\bar{0}$) micro-LEDs achieve a record-high -3dB modulation bandwidth for a III-nitride LED of 1.5 GHz [2]. The -3dB response of an electrically injected nanowire-based micro-LED with nonpolar facets is also reported, showing a -3dB bandwidth of 1.2 GHz [3]. The high speed is attributed to the shorter carrier lifetime associated with the nonpolar orientation. We also study the carrier dynamics in semipolar ($20\bar{2}\bar{1}$) LEDs for various temperatures [4]. Finally, we present carrier dynamics measurements on commercial-grade c-plane epitaxy for various active region designs, including a wavelength series and a growth quality series. The wavelength series offers insight into the contributions of the quantum confined Stark effect (QCSE) and InGaN material quality on the green gap [5]. The growth quality series investigates the role of non-radiative centers on the LED performance. Extraction of the carrier dynamics using small-signal electroluminescence offers insight into the factors limiting the efficiency and high-speed performance of III-nitride emitters and can be leveraged to ultimately improve the devices.

LEDs, InGaN, electroluminescence, bandwidth, modul↗
DOE OSTI2022

Radiolysis of Organic Solvents in the Presence of Plutonium

In this report, we describe a set of organic solvent radiolysis experiments performed at Lawrence Livermore National Laboratory. The goal of these experiments was to test for radiolytic solvent damage due to the presence of plutonium (Pu) particulates in solvent baths that are part of a materials production and cleaning workflow. The solvents (NOVEC 72DE and NOVEC 7500) were tested at a Pu activity level of ~1 microCi/mL using weapons grade Pu -- equivalent to 0.35 g Pu dispersed in a 5 gallon fluid bath filled to 4.5 gallons. Experiments were performed using fresh solvent and solvent that was 95% evaporated; the evaporated solvent was meant to represent fluids that may be in the solvent bath and subjected to evaporation and refilling without a full solvent replacement.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
DOE OSTI2022

Reducing the Overnight Capital Cost of Advanced Reactors Using Equipment-Level Seismic Protective Systems

Consideration of the effects of earthquake shaking on the design and construction of nuclear power plants adds substantially to the overnight capital cost, with anecdotal estimates as high as 35+%, attributed to additional construction materials, need for one-off and sub-optimal designs of equipment due to conflicting design choices, the high cost of seismic qualification of equipment, and regulatory review. Safety-critical equipment in large light water reactors is designed and qualified for seismic demands imposed by the supporting reactor building, optimal mechanical designs are not possible, and designs of a given piece of equipment may vary with height above grade. Similar negative impacts are expected for advanced reactors unless the seismic design paradigm is changed. The overarching goal of this transformational MEITNER project, which involved a multidisciplinary engineering team and designers of three fundamentally different advanced reactors, was to adapt proven seismic isolation and damping technologies to operationalize modular protective systems for safety-class equipment inside advanced reactor buildings. Such seismic protective systems would be tightly integrated into design development for reactor support systems and balance-of-plant construction. The adoption of the technology, which is widely used in non-nuclear sectors, would simplify plant design, enable the use of standardized equipment and buildings, optimized for operational performance, and reduce plant size and weight. The need for site-specific equipment would be eliminated, enabling identical equipment to be used across multiple plants sited across the US and economies of scale, and catalyzing new interest and investment. The equipment-based protective systems would allow siting of advanced reactors in regions of high seismic hazard.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Microstructural Characterization of the Second High Fluence Baffle-Former Bolt Retrieved from a Westinghouse Two-loop Downflow Type PWR

As one of the pressurized water reactor (PWR) internal components, baffle-former bolts (BFBs) are subjected to significant mechanical stress and neutron irradiation from the reactor core during the plant operation. Over the long operation period, these conditions lead to potential degradation and reduced load-carrying capacity of the bolts. In support of evaluating long-term operational performance of materials used in core internal components, the Oak Ridge National Laboratory (ORNL), through the Department of Energy (DOE), Light Water Reactor Sustainability (LWRS) Program, Materials Research Pathway (MRP) has harvested two high fluence BFBs from a commercial Westinghouse two-loop downflow type PWR. The two bolts of interest, i.e. bolts # 4412 and 4416, were withdrawn from service in 2011 as part of a preventative replacement plan. No identification of cracking or potential damage was found for these bolts during their removal in 2011. However, the bolts required a lower torque for removal from the baffle structure than the original torque specified during installation. Irradiation displacement damage levels in the bolts range from 15 to 41 displacements per atom. The goal of this project is to perform detailed microstructural and mechanical property characterization of BFBs following in-service exposures. The information from these bolts will be integral to the LWRS program initiatives in evaluating end of life microstructure and properties. Furthermore, valuable data will be obtained that can be incorporated into model predictions of long-term irradiation behavior and compared to results obtained in high flux experimental reactor conditions. In this report, we present our latest study in FY22 on microstructural characterizations of the second high fluence baffle-former bolt, i.e., bolt # 4412. Analytical electron microscopy and atom probe tomography characterization were performed. The radiation-induced defects in the material add to the large wealth of knowledge for neutron-induced defects in 304/316 grades of stainless steels, specifically for radiation-induced precipitation after high fluence commercial PWR irradiation. The main findings are summarized as follows: 1) The cavity size was considerably larger in the bolt thread section than in the bolt head, with the bolt thread section having a bimodal distribution of cavities greater than ~6 nm in diameter and less than ~3 nm in diameter. The bolt head only had the small-sized cavities. In addition, there was a denuded zone of large cavities near grain boundaries in the thread section of the bolt. 2) Radiation-induced precipitation in the BFB #4412 was highly complex, with the volume fraction, size, and number density of Ni/Si and Cu-rich precipitates depending strongly on the radiation temperature/dose. In many cases, co-precipitates of adjoined clusters were found with Ni/Si-rich precipitates sandwiched between Cu-rich clusters and Mo/Cr/P-rich clusters. 3) Solute segregation out of solution was highest for most solutes in the thread section of the bolt #4412 with the exception of Cu, which experienced more separation out of solution into Curich clusters in the bolt head section. This highlights the difference in the mechanisms for precipitation of Ni/Si clusters, which have the Ni 3 Si phase composition, and precipitation of Cu-rich clusters. 4) There appear to be multiple simultaneous influences that affect the microstructural variation along the length of the bolt that overcomes the ~2X difference in irradiation dose between the bolt head and the bolt thread. The irradiation temperature, thermal/fast neutron ratio variation, potential strain gradient, and exposure to PWR coolant water that each section of the bolt sees may have more influence on the microstructural evolution than the total irradiation dose. The bolt thread and shank, with higher temperature, higher relative fast neutron flux, higher strain, and exposure to coolant but lower dose, underwent more enhanced cavity formation, precipitation, and solute segregation than the bolt head section.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2022

Updated Reference VTR Core for CD-1

A preliminary reference core design was previously developed for the Versatile Test Reactor. The main features are that it is a 300 MW th sodium-cooled fast reactor using ternary metallic fuel U-20Pu-10Zr and able to achieve peak fast fluxes (E n > 0.1 MeV) in excess of 4.0x10 15 n/cm 2 -s. The plutonium in the fuel was assumed to be “reactor grade”, with a fissile quality of about 72% (i.e., 239 Pu and 241 Pu comprise 72% of the plutonium isotopes), and the uranium was assumed to be low-enriched uranium with 5% 235 U. This preliminary core design has been used through the CD-0 phase of the VTR project. Progression of the work after CD-0 led to revising, updating and refining the reference VTR core design, based on considerations from the various VTR teams: fuel, experiment, safety, and plant design teams. The objective of this report is to summarize the various changes made and details added to the model, to provide a description of the updated reference VTR core design and of its performance characteristics. This includes the traditional reactor physics characteristics, fuel cycle details, reactivity coefficients, temperature distributions, control rod worths and shutdown requirements. All of these define the updated “reference VTR core” intended to be used through CD-1.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2022

Life-Cycle Inventory of Critical Materials: Nickel, Copper, Titanium, and Rare-Earth Elements

The United States has developed a list of critical minerals/materials whose sustained and reliable supply is pivotal to the robust functioning of critical industrial sectors. A key concern with these minerals is their environmental effects as a function of their production location. This requires material and energy flow details for their processing steps. This report provides a life-cycle inventory (LCI) for producing four critical minerals and/or material systems (nickel, copper, titanium, and rare-earth elements) incorporated in the updated GREET® (Greenhouse gases, Regulated Emissions, and Energy use in Technologies) model. For these systems, we provide an LCI as a function of production location – domestic (within the United States) and international (geographies from where the US imports these minerals). Our LCI also considers variations in ore grades for nickel and copper. This report also provides an LCI for all intermediate materials used to produce these critical materials.

58 GEOSCIENCES↗
DOE OSTI2023

Benchmarking Microscale Ductility Measurements (Final Report of the Project DE-NE0008799)

Conventional macroscale experimentation is generally considered to be straightforward with few limitations. Conversely, micro/nanoscale experimentation presents numerous challenges in loading device design, sample preparation and handling, as well as accurate understanding of grain size and local texture effects on recorded measurements. Despite these challenges, nanopillar compression, MEMs based micro-tension, and nanoindentation approaches have been able to provide fundamental contributions to the understanding of material behavior at small lengthscales. However, the overarching shortcoming of these micro/nanoscale experimentation approaches, is the inability to directly translate measurements evaluated at the nm and µm length scales (e.g., hardness) to macroscale tensile material behavior (i.e., elastic modulus, yield strength, and ductility). The objectives of the proposed study are, 1) to establish best practices for obtaining tensile microscale ductility measurements, and 2) to validate methodologies to for comparing microscale ductility measurements to macroscale ductility measurements. In order to achieve these objectives, a multi-lengthscale, multi-temperature testing protocol and simulation framework are executed first on copper as a model material to validate the following approach, and second on reactor grade Zircaloy-2. Experiments are conducted on specimens extracted from the same test piece to ensure nominally identical grain size and texture from specimens to specimen. Motivated by the need to isolate the contribution of size-effects on obtained mechanical property measurements, specimens are manufactured with thicknesses at the micro- (1-10 µm), meso- (10-100's µm), and macroscales (sub-sized ASTM E8). In-situ full-field deformation techniques (scanning electron microscopy (SEM) grid methods and optical DIC) are incorporated into testing at each specimen length-scale to capture plasticity localization and evolution. Experimental testing for all specimens is conducted at both room temperature and elevated temperatures to probe the role of thermal activation on plastic deformation accommodation processes. Simulation efforts focus on examining the mechanical behavior of microscale specimens using a finite element approach with explicitly resolved grain morphologies, and an embedded crystal plasticity model. The cost-efficient implementation method allows for the modeling of a statistically significant number of both real (i.e., digital twin) and generated microstructures to obtain an understanding of the interrelationships between specimen microstructure and geometric variables (grain size, texture, specimen geometry, etc.) on microscale mechanical behavior.

36 MATERIALS SCIENCE↗
DOE OSTI2023

LH CO 2 MENT Colorado Project (Final Report)

The objective of Electricore’s pre-FEED project “LH CO 2 MENT COLORADO PROJECT” is to accelerate the implementation of a 1.5 million tonnes per year (TPY), and first-of-a-kind (FOAK) at world scale, Svante VeloxoTherm™ carbon capture plant. This project represents a quantum leap to a large-scale facility that will launch Svante’s carbon capture technology into the next era of accomplishments and market acceptance. By completing the Front-End Loading (FEL) Feasibility Study Report (FEL-2) for a fit-for-purpose design at the HOLCIM cement plant, located near Florence Colorado, USA, this technology can be proven as the future of large-scale deployment for carbon capture and storage. This carbon capture plant was designed with the goal of reaching a target of near Net Zero Emissions by capturing 90% of the carbon dioxide (CO 2 ) emissions from the HOLCIM cement plant and from the boiler which produces steam required to regenerate the adsorbent. Additionally, this project will be leveraging a renewable Power Purchase Agreement (PPA) using solar energy to acquire power at the target price of 0.04 $/kWh or less. In its current configuration CO 2 emissions from the HOLCIM cement plant is around 700 – 800 kg/ton of clinker produced. The proposed new carbon capture plant will allow a reduction of CO 2 emissions to about 100 kg/ton of clinker produced. The scope of work consists of the process design and capital & operating cost estimation (Class IV) for a total plant capacity of 4,750 TPD of pipeline grade CO 2 . The Svante VeloxoTherm™ technology is comprised of a Rotary Adsorption Machine (RAM) for intensified Thermal Swing Adsorption (TSA) using Structured Adsorbent Beds (SABs) and related Balance of Plant (BOP), including CO 2 compression. A business case (financial analysis) evaluation has been undertaken for the Owner’s management review. Recommendations on how best to proceed to the next stage of the project have been conveyed and are documented within this report. This analysis has relied on a detailed and comprehensive Project Financial Model, evaluating the Total Project IRR (after tax, unlevered, and including all forecast 45Q PTCs and 100% tax efficiency) – the project financial analysis (as opposed to standard TEA analysis) only considered a 12 year plant economic lifetime as a result of 45Q being the sole driver considered at this stage. The Total Project IRR was evaluated across a large number of potential scenarios. The evaluation demonstrated that if the 45Q PTD is increased to $85/MT for sequestration, there are a large number of feasible scenarios which demonstrate economic returns.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2022

Damage Accumulations Predictions for Boiler Components Via Microstructurally Informed Material Models

The goal of the project was to model material behavior and degradation during cyclic plasticity— with and without hold time—for nickel-based superalloys used in USC (ultra-super-critical) and A-USC (advanced-ultra-super-critical) boiler components. The study provided physically informed models, capturing the microstructural changes taking place in the industrial components under cyclic loading and long duration stress (up to 300,000 hours) and high temperature exposure (1100°F/593°C to 1400°F/760°C). The major developments were: 1) Qualitative and quantitative understanding of microstructure evolution (gamma prime precipitates), deformation (dislocation density), and damage mechanisms of Haynes ® 282 alloy. 2) Qualitative understanding of microstructural features generating local strain variations. 3) A continuum damage mechanics model (CDM) for Haynes ® 282 alloy at 1100°F to 1400°F capturing cyclic behavior with and without hold time. 4) Structural analysis for creep and LCF life predictions of an USC thick-wall Grade 91 superheater steel header and understanding life sensitivity to wall thickness of an AUSC Haynes ® 282 header.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2022

Defining the Prototype Convenience Store Building Characteristics

The US Department of Energy supports the development of commercial building energy codes and standards. To support commercial building energy research activities and the development of commercial building energy codes and standards, continuous efforts have been made to convert 30 prototype building models (20 different building types), which cover 80% of US commercial building floor space, to OpenStudio prototype buildings. Additionally, the suite of prototype building models was expanded to include the addition of new building prototype models (e.g., courthouse, college building). This report documents the building and system characteristics of the prototype convenience store building model. Multiple sources, including databases, documented projects, and personal communications, were used to define the prototype convenience store building characteristics, and a one-story, 3,000 ft 2 building was considered as the prototype convenience store to represent an average-sized convenience store in the United States. The Oak Ridge National Laboratory team defined the operational hours of the convenience store as 17 hours per day. The types of exterior walls, roof, and floor were defined as brick wall, metal surfacing roof, and slab-on-grade floor, respectively. Double glazing was selected, and the window-towall ratio was set as 15% on the front side. For the system part, packaged system and centralized water heater were selected for the space heating and cooling system and water heater system, respectively. In terms of the refrigerator system, the number of refrigerators and freezers were determined as eight closed cases and two walk-in units.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

A Novel Process for Carbon Dioxide Conversion to Fuel

In this project, TDA developed a new mixed metal oxide-based sorbent that converts CO2 (captured from coal fired power plants) to CO, which can then be combined with renewable H2 generated by water electrolysis or H2 from steam methane reforming to produce different liquid fuels. TDA’s absorbent-based CO2 conversion process uses a redox process, which splits the catalytic reforming of methane with CO2 reaction into two stages: CO2 reduction to CO and CH4 reforming into H2 and CO which eliminates the equilibrium limitations. The CO produced in the two-stage reactor system can then be further reacted with renewable H2 to produce methanol, naphtha, diesel, or gasoline. We worked with the Advanced Power & Energy Program (APEP) of University of California, Irvine (UCI) to design and develop the liquid fuel synthesis process that is built around this new material. We demonstrated the techno-economic viability of the new sorbent based redox process to convert CO2 into synthesis gas by demonstrating continuous carbon dioxide reduction in a prototype test system for over 585 hours while converting up to 10 kg CO2/day. With the successful completion of the R&D effort, the technology is now ready for a larger pilot-scale demonstration and the technology readiness has been raised from TRL 3 to TRL 5. In collaboration with UCI, we completed a high-fidelity process design and economic analysis. The required sale price (RSP) for gasoline (Case 1 NG-MTG) is $4.91/gal and naphtha and diesel (Case 2 NG-FT) are $4.23/gal and $6.07/gal, respectively, on a 2011 dollar basis. To put these costs in perspective, the California prices in current dollars (with its strict specifications) for regular grade gasoline from last year to current year have varied from a low of $3.10/gal in January 2021 to a high of $5.76/gal in March 2022, while prices for diesel from last year to current year have varied from a low of $3.40/gal in January 2021 to a high of $6.41/gal in May 2022 according to the U.S. Energy Information Agency data. It should be noted that the gasoline and diesel produced by these designs of Case 1 and Case 2 would be of very high quality and both nitrogen and sulfur free. These RSPs are based on a cost of imported electricity of $64/MWh based on the low-end current wind generated electricity cost (Genevieve 2011). This cost is by far the largest component of the variable costs used in computing the RSPs. A sensitivity analysis of these RSPs to the cost of imported electricity shows that the cost of the imported electricity has a significant effect on the RSPs. The life cycle analysis (LCA) shows that the total cradle-to-gate CO2 emissions for both liquid fuels (diesel and gasoline) were negative, indicating that overall more CO2 is consumed than released during production of the fuel from CO2 feed stack for both cases (-296 kgCO2 per MT gasoline for Case 1 and -705 kgCO2 per MT diesel for Case 2). On a cradle-to-grave comparison, the use of diesel produced using TDA’s process (2,457 kgCO2 per MT diesel) would release 37.6% less CO2 compared to petroleum based diesel (3,937 kgCO2 per MT diesel) while the use of gasoline produced using TDA’s process (2,792 kgCO2 per MT gasoline) would release 29.3% less CO2 compared to petroleum based gasoline (3,946 kgCO2 per MT gasoline). With the successful completion of the R&D effort, the technology is now ready for a bench-scale demonstration and the technology readiness has been raised from TRL 3 (Analytical and experimental critical function and/or characteristic proof of concept) to TRL 5 (Laboratory scale similar system validation in relevant environment).

20 FOSSIL-FUELED POWER PLANTS↗