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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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All sourcesNASA NTRSDOE OSTI
DOE OSTI2013

Marine Corps Base Camp Lejeune CLARIS-measured beach topography

Critical military training and testing on lands along the nation’s coastal and estuarine shorelines are increasingly placed at risk because of encroachment pressures in surrounding areas, impairments due to other anthropogenic disturbances, and changes in climate and sea level. The U.S. Department of Defense (DoD) intends to enhance and sustain its training and testing assets and also optimize its stewardship of natural resources through the development and application of an ecosystem-based management approach on DoD installations. To accomplish this goal, particularly for installations in estuarine/coastal environments, the Strategic Environmental Research and Development Program (SERDP) launched the Defense Coastal/Estuarine Research Program (DCERP) as a 10-year effort at Marine Corps Base Camp Lejeune (MCBCL) in North Carolina. The results of the second 5 years of the program (DCERP2) are presented in the DCERP2 Final Report.There were four overarching objectives of DCERP2. The first objective was to understand the effects of climate change impacts, including warming temperatures, variability in the hydrological cycle, storm events, and sea level rise on the coastal ecosystems at MCBCL from observations and measurements made over the 10-year program. The second objective was to understand the carbon cycle of the coastal and terrestrial ecosystems at MCBCL through a highly integrated sampling program. The third objective was to develop models, tools, and indicators to evaluate current and projected future ecosystem state changes and translate scientific findings into actionable information for installation managers. The last objective was to recommend adaptive management strategies to sustain ecosystem natural resources within the context of an active military installation.Coastal Lidar And Radar Imaging System collects X-band radar and terrestrial lidar from a mobile platform. Sensor position, orientation and elevation are corrected from simultaneous observations of platform motion and position via a POS LV (Applanix). Topography data are referenced to NAVD88 meters in the vertical and horizontal position, were originally collected in NAD83 North Carolina State plane meters, and have been transformed to geographic coordinates. Dense point cloud data from terrestrial lidar have been gridded to grid node spacing of 2m. Data span from the primary dune to the lower foreshore down the length of Onslow Beach (excluding northern ordinance exclusion zone).

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Time dependent supervisory control update with FARM using rolling window

This report describes improvements to the Feasible Actuator Range Modifier (FARM) component of the RAVEN-based HYBRID framework for analysis of Integrated Energy Systems (IES). FARM supports the HERON plug-in that solves the power dispatch problem. The solution to the dispatch problem involves economically optimal dispatches that satisfy limits on production variables and their rates of variation (explicit constraints) as well as process variables tied to the service life of equipment (implicit constraints). FARM serves to validate or confirm that a HERON solution for explicit constraints also satisfies the implicit constraints. FARM-alpha was released by Argonne National Laboratory in January 2021 followed by FARM-Beta in January 2022 with the latter providing increased flexibility for the user. In this report, FARM-Gamma, the latest version of the code, is described. The major improvement is the implementation of a system identification algorithm based on the Dynamic Mode Decomposition with Control (DMDc) coupled with a “Rolling Window” scheme that allows obtaining linear time-varying state-space models. This feature equips FARM with the most accurate approximation of system dynamics, and it relieves the user from the burden of performing an exhaustive off-line characterization of the dynamics. FARM-Gamma capabilities are assessed by solving the power dispatch problem for a representative IES unit. The simulation times corresponding to the different releases are estimated and compared. These values capture the increasing computational burden of the successively higher fidelity state-space models adopted by FARM-Alpha, FARM-Beta and FARM-Gamma. The code implementation provides significant flexibility, i.e., the user can always select the most suitable version of FARM according to the problem to be solved and the available computational resources. It is anticipated that FARM will play a role in addressing several future IES applications. We outline how it can support the coordinated management and safe operation of a nuclear plant coupled to industrial processes to produce hydrogen and synfuels.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2019

Roll-to-Roll Advanced Materials Manufacturing DOE Laboratory Collaboration - FY2018 Final Report

High-value R2R processing is used to support a wide range of products in applications which span many industrial business sectors. The overall R2R process technology can be considered as “mature” as the process methodology and has been in use for decades. This continuous processing technique traditionally involves deposition of material(s) onto moving webs or carriers or other continuous R2R, belt-fed, or conveyor-based processes that enable successive steps to build a final version which serves to support the deposited materials. Current process technologies, which typify “roll to roll”, include tape casting, silk-screen printing, reel-to-reel vacuum deposition/coating and R2R lithography. Products supported by R2R manufacturing include micro-electronics, electro-chromic window films, PVs, fuel cells for energy conversion, battery electrodes for energy storage, and barrier materials. Due to innovation in materials and process equipment, high-quality yet very low-cost multi-layer technologies can be manufactured on a very cost-competitive basis. To move energy-related products from high-cost niche applications to the commercial sector, a means must be available to enable manufacture of these products in a cost-competitive manner that is affordable by the general consumer. Fortunately, products such as fuel cells, thin- and mid-film PVs, batteries, electrochromic and piezoelectric films, water separation membranes, and other energy saving technologies readily lend themselves to manufacture using R2R approaches.Within the DOE EERE AMO, it was recognized that establishment of a program supported at the DOE National Laboratories, along with their immense design of materials and equipment modelling capabilities enabled with use of high-performance computing, could take advantage of available R2R infrastructure to manufacture new technologies. In FY 2016, a R2R Consortium was established and provided with initial “seed” funding to take an approach that was envisioned to be supportable by advanced manufacturing R2R processes. This collaborative approach was designed to foster identification and development of materials and processes related to R2R for clean-energy product development. Using computational and experimental capabilities by acknowledged subject matter experts within the supported National Laboratory system, this collaborative project would leverage the capabilities and expertise at each of four laboratories to further the development of an enabling high-volume cost-competitive platform technology. The collaboration team that is comprised of ORNL, ANL, NREL and LBNL, coordinating with EPB and other selected industry partners, was formed in April 2016 to initially address enhancing battery electrode performance and R2R manufacturing challenges. The research efforts were to predict and measure changes and results in electrode morphology and performance based on process condition changes; to evaluate mixed, active, particle size deposition and drying for novel electrode materials; to model various process condition changes and the resulting morphology and electrode performance; and to develop and validate NDE techniques for in-line measurement of battery electrode material properties. These efforts carried through FY 2017 and completed at the end of FY 2018.The approach was to look at compositions of materials with different particle sizes to make electrode samples using a R2R manufacturing process. The shape, size, and morphology of the materials, the chemistry of the formulation, the nature of slurries, their coating rate, the rate of drying all play a role in determining the final coating architecture, quality, and performance. A commercial cathode material was selected to make a series of cathodes and anodes by single pass, dual pass and slot die methods. Analysis of all the compiled results for this battery electrode development were that the best performing cathodes included: dual-pass electrode with large particles near the foil, mixed small and large particles, and small particles only. Whereas, the best performing anodes were with a mix of small and large graphite particles. An additional core project was added in FY 2017 to conduct studies of fuel cell materials that can be produced using R2R processes. The goal of this project is to explore, understand and optimize material and process parameters to support increased throughput, increased quality, and reduced cost for high volume production of gas-diffusion electrodes (GDEs) for PEMFCs. Project work in FY 2018 were to use a R2R process to fabricate electrodes without ionomer overlayer that can produce the equivalent mass activity as spray-coated electrodes with an ionomer overlayer. Oxygen-limiting current measurements were utilized to optimize oxygen mass transport. Alcohol-rich solvents were investigated, and results were that the alcohol and water ratio can be tuned to control ionomer distribution. Water-rich solvents produce a more dispersed ink which results in better high-current density performance.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Onslow Beach Washover Fan Morphology from 2012 to 2015

Critical military training and testing on lands along the nation’s coastal and estuarine shorelines are increasingly placed at risk because of encroachment pressures in surrounding areas, impairments due to other anthropogenic disturbances, and changes in climate and sea level. The U.S. Department of Defense (DoD) intends to enhance and sustain its training and testing assets and also optimize its stewardship of natural resources through the development and application of an ecosystem-based management approach on DoD installations. To accomplish this goal, particularly for installations in estuarine/coastal environments, the Strategic Environmental Research and Development Program (SERDP) launched the Defense Coastal/Estuarine Research Program (DCERP) as a 10-year effort at Marine Corps Base Camp Lejeune (MCBCL) in North Carolina. The results of the second 5 years of the program (DCERP2) are presented in the DCERP2 Final Report.There were four overarching objectives of DCERP2. The first objective was to understand the effects of climate change impacts, including warming temperatures, variability in the hydrological cycle, storm events, and sea level rise on the coastal ecosystems at MCBCL from observations and measurements made over the 10-year program. The second objective was to understand the carbon cycle of the coastal and terrestrial ecosystems at MCBCL through a highly integrated sampling program. The third objective was to develop models, tools, and indicators to evaluate current and projected future ecosystem state changes and translate scientific findings into actionable information for installation managers. The last objective was to recommend adaptive management strategies to sustain ecosystem natural resources within the context of an active military installation.These grid files were created from data collected using a Riegl 3-D laser scanner. Millions of x, y, and z points from the F2 Washover Fan on Onslow Beach were processed using the MARS software package to define a bare-earth model. Grid files were imported into Golden Software Surfer version 19 for editing and exported from that application as .grd files. Files can be opened in Surfer or ArcMap, but the coordinate system information will be lost if opened in ArcMap. These data were collected to quantify the morphological changes that occur on a washover fan through time.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

Impact of mechanical tolerances on partial turn skipping in helical flux compression generator

Maintaining tight mechanical tolerances of the components used in helical flux compression generators is crucial for optimizing device performance. Moving beyond current literature, which provides various approximations for acceptable tolerances, a 3D simulation of the armature stator interaction during generator operation was developed, revealing that existing equations frequently misestimate the tolerance limits. Without restricting the generality of the presented approach, the focus was primarily on the armature’s concentricity and roundness, comparing the acceptable tolerance limits between generators of different sizes. An analytical approach for select geometries was developed, confirming the 3D results. Quantitative results reveal that a steeper Gurney angle and increased winding pitch allow for less restrictive tolerances for eccentricity and ellipticity. Even small deviations from the ideal armature positioning and shape will result in fluctuations of the output current time-derivative, observed experimentally and in simulation. Larger deviations then cause partial turn skipping, associated with loss of magnetic flux. The simulation elucidates the impact of tolerance deviations on generator performance by offering precise tolerance ranges for various generator sizes, thereby facilitating informed design decisions.

42 ENGINEERING↗
DOE OSTI2015

Collision prediction software for radiotherapy treatments

Purpose: This work presents a method of collision predictions for external beam radiotherapy using surface imaging. The present methodology focuses on collision prediction during treatment simulation to evaluate the clearance of a patient’s treatment position and allow for its modification if necessary. Methods: A Kinect camera (Microsoft, Redmond, WA) is used to scan the patient and immobilization devices in the treatment position at the simulator. The surface is reconstructed using the SKANECT software (Occipital, Inc., San Francisco, CA). The treatment isocenter is marked using simulated orthogonal lasers projected on the surface scan. The point cloud of this surface is then shifted to isocenter and converted from Cartesian to cylindrical coordinates. A slab models the treatment couch. A cylinder with a radius equal to the normal distance from isocenter to the collimator plate, and a height defined by the collimator diameter is used to estimate collisions. Points within the cylinder clear through a full gantry rotation with the treatment couch at 0° , while points outside of it collide. The angles of collision are reported. This methodology was experimentally verified using a mannequin positioned in an alpha cradle with both arms up. A planning CT scan of the mannequin was performed, two isocenters were marked in PINNACLE, and this information was exported to AlignRT (VisionRT, London, UK)—a surface imaging system for patient positioning. This was used to ensure accurate positioning of the mannequin in the treatment room, when available. Collision calculations were performed for the two treatment isocenters and the results compared to the collisions detected the room. The accuracy of the Kinect-Skanect surface was evaluated by comparing it to the external surface of the planning CT scan. Results: Experimental verification results showed that the predicted angles of collision matched those recorded in the room within 0.5°, in most cases (largest deviation −1.2°). The accuracy study for the Kinect-Skanect surface showed an average discrepancy between the CT external contour and the surface scan of 2.2 mm. Conclusions: This methodology provides fast and reliable collision predictions using surface imaging. The use of the Kinect-Skanect system allows for a comprehensive modeling of the patient topography including all the relevant anatomy and immobilization devices that may lead to collisions. The use of this tool at the treatment simulation stage may allow therapists to evaluate the clearance of a patient’s treatment position and optimize it before the planning CT scan is performed. This can allow for safer treatments for the patients due to better collision predictions and improved clinical workflow by minimizing replanning and resimulations due to unforeseen clearance issues.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2013

Towards A Theory of Autonomous Reconstitution of Compromised Cyber-Systems

The ability to maintain mission-critical operations in cyber-systems in the face of disruptions is critical. Faults in cyber systems can come from accidental sources (e.g., natural failure of a component) or deliberate sources (e.g., an intelligent adversary). Natural and intentional manipulation of data, computing, or coordination are the most impactful ways that an attacker can prevent an infrastructure from realizing its mission goals. Under these conditions, the ability to reconstitute critical infrastructure becomes important. Specifically, the question is: Given an intelligent adversary, how can cyber systems respond to keep critical infrastructure operational? In cyber systems, the distributed nature of the system poses serious difficulties in maintaining operations, in part due to the fact that a centralized command and control apparatus is unlikely to provide a robust framework for resilience. Resilience in cyber-systems, in general, has several components, and requires the ability to anticipate and withstand attacks or faults, as well as recover from faults and evolve the system to improve future resilience. The recovery effort (and any subsequent evolution) may require significant reconfiguration of the system (at all levels – hardware, software, services, permissions, etc.) if the system is to be made resilient to further attack or faults. This is especially important in the case of ongoing attacks, where reconfiguration decisions must be taken with care to avoid further compromising the system while maintaining continuity of operations. Collectively, we will label this recovery and evolution process as “reconstitution”. Currently, reconstitution is performed manually, generally after-the-fact, and usually consists of either standing up redundant systems, check-points (rolling back the configuration to a “clean” state), or re-creating the system using “gold-standard” copies. For enterprise systems, such reconstitution may be performed either directly on hardware, or using virtual machines. A significant challenge within this context is the ability to verify that the reconstitution is performed in a manner that renders the cyber-system resilient to ongoing and future attacks or faults. Fundamentally, the need is to determine optimal configuration of the cyber system when a fault is determined to be present. While existing theories for fault tolerance (for example, Byzantine fault tolerance) can guarantee resilience under certain conditions, in practice, these theories can break down in the face of an intelligent adversary. Further, it is difficult, in a dynamically evolving environment, to determine whether the necessary conditions for resilience have been met, resulting in difficulties in achieving resilient operation. In addition, existing theories do not sufficiently take into account the cost for attack and defense (the adversary is generally assumed to have infinite resources and time), hierarchy of importance (all network resources are assumed to be equally important), and the dynamic nature of some attacks (i.e., as the attack evolves, can resilience be maintained?). Alternative approaches to resilience based on a centralized command and control structure suffer from a single-point-failure. This paper presents preliminary research towards concepts for effective autonomous reconstitution of compromised cyber systems. We describe a mathematical framework as a first step towards a theoretical basis for autonomous reconstitution in dynamic cyber-system environments. We then propose formulating autonomous reconstitution as an optimization problem and describe some of the challenges associated with this formulation. This is followed by a brief discussion on potential solutions to these challenges.

asymmetric resilience↗
DOE OSTI2013

Building a Community Infrastructure for Scalable On-Line Performance Analysis Tools around Open|SpeedShop

In this project we created a community tool infrastructure for program development tools targeting Petascale class machines and beyond. This includes tools for performance analysis, debugging, and correctness tools, as well as tuning and optimization frameworks. The developed infrastructure provides a comprehensive and extensible set of individual tool building components. We started with the basic elements necessary across all tools in such an infrastructure followed by a set of generic core modules that allow a comprehensive performance analysis at scale. Further, we developed a methodology and workflow that allows others to add or replace modules, to integrate parts into their own tools, or to customize existing solutions. In order to form the core modules, we built on the existing Open|SpeedShop infrastructure and decomposed it into individual modules that match the necessary tool components. At the same time, we addressed the challenges found in performance tools for petascale systems in each module. When assembled, this instantiation of community tool infrastructure provides an enhanced version of Open|SpeedShop, which, while completely different in its architecture, provides scalable performance analysis for petascale applications through a familiar interface. This project also built upon and enhances capabilities and reusability of project partner components as specified in the original project proposal. The overall project team’s work over the project funding cycle was focused on several areas of research, which are described in the following sections. The reminder of this report also highlights related work as well as preliminary work that supported the project. In addition to the project partners funded by the Office of Science under this grant, the project team included several collaborators who contribute to the overall design of the envisioned tool infrastructure. In particular, the project team worked closely with the other two DOE NNSA laboratories Los Alamos and Sandia leveraging co-funding for Krell by ASC’s Common Computing Environment (CCE) program as laid out in the original proposal. The ASC CCE co-funding, coordinated through LLNL, was for 50% of the total project funding, with the ASC CCE portion of the funding going entirely to Krell, while the ASCR funding itself was split between Krell and the funded partners. This report covers the entire project from both funding sources. Additionally, the team leveraged the expertise of software engineering researchers from Carnegie Mellon University, who specialize in software framework design, in order to achieve a broadly acceptable component framework. The Component Based Tool Framework (CBTF) software has been released to the community. Information related to the project and the released software can be found on the CBTF wiki page at: http://sourceforge.net/p/cbtf/wiki/Home.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2023

Dispatch analysis of flexible power operation with multi-unit small modular reactors

The relevance of nuclear power plant flexible power operation (FPO) is rising due to increased penetration of variable renewables. Small Modular Reactors (SMRs) such as NuScale are envisaged to have multiple units on one site. This provides opportunities for coordinating FPO between units, but also introduces challenges as common services (e.g., refueling equipment) must be shared between units and fuel loadings may be standardized. It is therefore important to quantify whether FPO with SMRs is economically beneficial. Here, this paper quantifies the economics of FPO on different timescales to analyze refueling outages of such multi-unit SMRs. A 24-h price-taker profit maximization of SMR operation is first solved considering revenues from wholesale power and ancillary service (AS) markets. The results are then used to find the most profitable operation strategy over several years for multiple units at the site accounting for the physics and materials limits on NPP operation, including refueling outages. Results show a small but appreciable participation of nuclear into AS, contributing 4% of revenues. Due to the longer fuel cycle, over a decade of operation the units’ refueling outages drifted by 3 months, ultimately leading to refueling during summer.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2021

Heat Based Power Augmentation for Modular Pumped Hydro Storage in Smart Buildings Operation

In the U.S., building sector is responsible for around 40% of total energy consumption and contributes about 40% of carbon emissions since 2012. Within the past several years, various optimization models and control strategies have been studied to improve buildings energy efficiency and reduce operational expenses under the constraints of satisfying occupants’ comfort requirements. However, the majority of these studies consider building electricity demand and thermal load being satisfied by unidirectional electricity flow from the power grid or on-site renewable energy generation to electrical and thermal home appliances. Opportunities for leveraging low grade heat for electricity have largely been overlooked due to impracticality at small scale. In 2016, a modular pumped hydro storage technology was invented in Oak Ridge National Laboratory, named Ground Level Integrated Diverse Energy Storage (GLIDES). In GLIDES, employing high efficiency hydraulic machinery instead of gas compressor/turbine, liquid is pumped to compress gas inside high-pressure vessel creating head on ground-level. This unique design eliminates the geographical limitation associated with existing state of the art energy storage technologies. It is easy to be scaled for building level, community level and grid level applications. Using this novel hydro-pneumatic storage technology, opportunities for leveraging low-grade heat in building can be economical. In this research, the potential of utilizing low-grade thermal energy to augment electricity generation of GLIDES is investigated. Since GLIDES relies on gas expansion in the discharge process and the gas temperature drops during this non-isothermal process, available thermal energy, e.g. from thermal storage, Combined Cooling, Heat and Power system (CCHP), can be utilized by GLIDES to counter the cooling effect of the expansion process and elevate the gas temperature and pressure and boost the roundtrip efficiency. Several groups of comparison experiments have been conducted and the experimental results show that a maximum 12.9% cost saving could be achieved with unlimited heat source for GLIDES, and a moderate 3.8% cost improvement can be expected when operated coordinately with CCHP and thermal energy storage in a smart building.

Chen, Yang↗
DOE OSTI2013

Recovery Act: Strategies for Voltage Control and Transient Stability Assessment

As wind generation grows, its influence on power system performance will becoming increasingly noticeable. Wind generation differs from traditional forms of generation in numerous ways though, motivating the need to reconsider the usual approaches to power system assessment and performance enhancement. The project has investigated the impact of wind generation on transient stability and voltage control, identifying and addressing issues at three distinct levels of the power system: 1) at the device level, the physical characteristics of wind turbine generators (WTGs) are quite unlike those of synchronous machines, 2) at the wind-farm level, the provision of reactive support is achieved through coordination of numerous dissimilar devices, rather than straightforward generator control, and 3) from a systems perspective, the location of wind-farms on the sub-transmission network, coupled with the variability inherent in their power output, can cause complex voltage control issues. The project has sought to develop a thorough understanding of the dynamic behaviour of type-3 WTGs, and in particular the WECC generic model. The behaviour of such models is governed by interactions between the continuous dynamics of state variables and discrete events associated with limits. It was shown that these interactions can be quite complex, and may lead to switching deadlock that prevents continuation of the trajectory. Switching hysteresis was proposed for eliminating deadlock situations. Various type-3 WTG models include control blocks that duplicate integrators. It was shown that this leads to non-uniqueness in the conditions governing steady-state, and may result in pre- and post-disturbance equilibria not coinciding. It also gives rise to a zero eigenvalue in the linearized WTG model. In order to eliminate the anomalous behaviour revealed through this investigation, WECC has now released a new generic model for type-3 WTGs.

17 WIND ENERGY↗
DOE OSTI2023

Adaptive primal–dual control for distributed energy resource management

With the increased adoption of distributed energy resources (DERs) in distribution networks, their coordinated control with a DER management system (DERMS) that provides grid services (e.g., voltage regulation, virtual power plant) is becoming more necessary. One particular type of DERMS using primal–dual control has recently been found to be very effective at providing multiple grid services among an aggregation of DERs; however, the main parameter, the primal–dual step size, must be manually tuned for the DERMS to be effective, which can take a considerable amount of engineering time and labor. To this end, we design a simple method that self-tunes the step size(s) and adapts it to changing system conditions. Additionally, it gives the DER management operator the ability to prioritize among possibly competing grid services. Here we evaluate the automatic tuning method on a simulation model of a real-world feeder in Colorado with data obtained from an electric utility. Through a variety of scenarios, we demonstrate that the DERMS with automatically and adaptively tuned step sizes provides higher-quality grid services than a DERMS with a manually tuned step size.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2022

Coupled Heat Power Operation of Smart Buildings via Modular Pumped Hydro Storage

In the United States, building sector is responsible for around 40% of total energy consumption and contributes about 40% of carbon emissions since 2012. Within the past several years, various optimization models and control strategies have been studied to improve buildings’ energy efficiency and reduce operational expenses under the constraints of satisfying occupants’ comfort requirements. However, the majority of these studies consider building electricity demand and thermal load being satisfied by unidirectional electricity flow from the power grid or on-site renewable energy generation to electrical and thermal home appliances. Opportunities for leveraging low-grade heat for electricity have largely been overlooked due to impracticality at small scale. In 2016, a modular pumped hydro storage technology was invented in Oak Ridge National Laboratory, named Ground Level Integrated Diverse Energy Storage (GLIDES). In GLIDES, employing high-efficiency hydraulic machinery instead of gas compressor/turbine, liquid is pumped to compress gas inside high-pressure vessel creating head on ground level. This unique design eliminates the geographical limitation associated with the existing state-of-the-art energy storage technologies. It is easy to be scaled for building level, community level, and grid level applications. By using this novel hydro-pneumatic storage technology, opportunities for leveraging low-grade heat in building can be economical. In this research, the potential of utilizing low-grade thermal energy to augment electricity generation of GLIDES is investigated. Since GLIDES relies on gas expansion in the discharge process and the gas temperature drops during this non-isothermal process, available thermal energy, e.g., from thermal storage, combined cooling, heat and power system (CCHP), can be utilized by GLIDES to counter the cooling effect of the expansion process and elevate the gas temperature and pressure and boost the roundtrip efficiency. Here, several groups of comparison experiments have been conducted, and the experimental results show that a maximum 12.9% cost saving could be achieved with unlimited heat source for GLIDES, and a moderate 3.8% cost improvement can be expected when operated coordinately with CCHP and thermal energy storage in a smart building.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2016

A Full Multigrid Method for the Self-Adjoint Angular Flux Equation Based on Cellwise Block Jacobi Iteration

Previous work by Densmore et al. has demonstrated that multigrid methods for the self-adjoint angular flux (SAAF) equation with cellwise block Jacobi smoothing can be extremely effective at solving for the angular flux in one dimension. The extension of that work to two dimensions demonstrated that while the smoother works well, the use of a direct coarse-grid approximation can severely limit the rate of convergence for optically thin cells. In that paper, this convergence limit was evaded through the use of a partially Galerkin coarse-grid approximation. However, relying on a Galerkin coarse-grid approximation is not ideal as constructing the coarse-grid discretization in this approach is complicated. The motivation for this summary is to find a method that can work without the need for a Galerkin coarse-grid approximation. The Full Multigrid (FMG) method is well known as a method that can theoretically solve a problem to its discretization accuracy with optimal linear computational complexity, that is in just O(N) operations for N unknowns. Indeed, we develop an FMG method for the 2-D SAAF equation that yields discretization accuracy and does not require the use of a Galerkin coarse-grid approximation. Until recently, aside from proofs about the order of the error for FMG, little work had been done in quantifying when and how FMG can obtain discretization accuracy. However, recent work by Rodrigo et al. has introduced a Fourier analysis technique called worst-case right-hand side analysis used to calculate the FMG accuracy measure. The FMG accuracy measure is the upper bound on the constant of proportionality between the error of the FMG solution and the discretization error. In this summary, we develop and implement an FMG method for the 2-D Cartesian SAAF equations. We then perform worst-case right-hand side analysis and give numerical examples that demonstrate under what circumstances the method can solve the 2-D SAAF equations to discretization accuracy, for optically thin cells, without the need for a Galerkin coarse-grid approximation. (authors)

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2025

Field Validation of Thermoelectric Generation System at Holcim Cement Plant in Alpena, Michigan

Executive Summary Project Background The Industrial Technology Validation (ITV) program aims to identify and demonstrate the performance of new, emerging, and underutilized energy-saving technologies in the industrial sector to help inform decisions to help accelerate their commercialization and deployment, as well as to help make industries more competitive. This ITV demonstration evaluated a thermoelectric generation (TEG) technology at a cement plant, aiming to reduce energy demand in the cement industry. A median cement plant consumes 5.73 million British thermal units per ton of clinker production (resulting in 0.838 metric tons of carbon dioxide [CO₂] emissions per ton of clinker) (Boyd and Zhang 2011, EPA 2021), equivalent to approximately 6.9 trillion British thermal units (TBtu) per year in energy consumption at a cement plant producing 3,300 tons of clinker per day.¹ Collaborating with Holcim, Advanced Thermovoltaic Systems (ATS) developed and deployed a pilot-scale thermoelectric power system to efficiently capture and convert waste heat to electricity. The system leverages the Seebeck effect to convert temperature differences on two sides of semiconductor cartridges into electrical power (ScienceDirect, n.d.). This generation is realized with minimal moving parts compared to existing waste-heat-to-generation solutions and allows capture from heat sources with temperatures as low as 150°C. This project aimed to validate a scalable solution applicable for capturing medium-temperature waste heat, including ambient losses from other high-temperature processes, and high-temperature sources less suitable for other waste-heat-to-power solutions. By recovering this otherwise wasted heat, this project intends to validate improvements to overall process efficiency through reduction in purchased electricity, thereby reducing operational costs while enhancing resiliency and competitiveness. Description and Scope This study evaluated the performance of a TEG system from ATS as a solution to convert waste heat into useful power at a Holcim cement plant in Alpena, Michigan. This plant is a fully integrated cement plant that has been operating since 1907. The facility operates continuously (24/7/365) with approximately 250 employees and five long dry kilns, yielding a total production capacity of 7,852 tons of cement per day (EPA 2023). Currently, the Alpena plant uses waste heat boilers to convert waste heat from the exhaust of each kiln into steam, which drives steam turbine generators. The ATS TEG is being evaluated for its potential to supplement the steam turbines by capturing the remaining lower grade heat. This technology is also being considered for other Holcim plants where steam turbines are not a viable option. ATS installed a pilot-scale TEG unit with an array of 582 individual thermoelectric semiconductor cartridges, of which 573 were operational. The cartridges are sandwiched between 48 hot plates and 49 cold plates. Each cartridge is designed to generate 20 watts (W) of gross power at a hot-side temperature of 240°C and cold-side temperature of 20°C. As such, the total gross generation capacity of the installed system is 11.5 kilowatts (kW) at design conditions. The system configuration for the evaluation was designed to prioritize convenience of installation and minimize disruption to production at the site, while ensuring that the heat required can be obtained for evaluating the TEG system at various operational conditions. To accomplish this, a portion of the steam supplied to Alpena’s steam turbine generation system was diverted to be used as the heat source for the TEG system, while water was supplied to the cold side of the system from nearby Lake Huron. This configuration was designed for the evaluation of the pilot-scale system to assess the performance at different conditions. A commercial-scale system will likely vary from the pilot system depending on typical configurations, including both scale and application. Future commercial applications of the ATS system would involve integrating the system into the exhaust from kiln preheaters, clinker coolers, or radiant heat capture from kiln shells for the heat source. For the cold source, a range of cooling solutions can be considered, including a mechanical cooling system, depending on the location and the application. To increase the generation capacity for commercial applications, the technology provider is working toward developing a commercial-scale TEG system, which would combine multiple TEG units (each similar in design to the pilot system) together. The scope of this evaluation includes the pilot-scale TEG system and all impacted equipment including pumps, controllers, and power handling equipment. Study Objectives The evaluation's goal was to assess the potential of the ATS TEG system to generate useful electrical power by capturing waste heat from cement production kilns. The objectives of this study are to evaluate and verify the following claims made by ATS regarding the pilot-scale system installed at the Holcim Alpena plant. The following design parameters and claims are also outlined in Table ES- 1 and Table ES- 2: • Gross Power: The thermoelectric system converts heat into power to create gross power, the total measured power generated by the system. The 573 active cartridge pilot-scale system is expected to generate 11.5 kW of gross power at the designed hot-side temperature of 240°C and cold-side temperature of 20°C. Power production is dependent on the temperature difference between the heat source (ultimately from the waste heat) and cold temperature supply source. • Net Power: The net power is the total usable power provided to the site by the TEG system after deducting parasitic power loads from the gross generated power. Supplementary equipment is required to operate the TEG system including pumps, controllers, and, in certain anticipated applications, mechanical cooling, which introduce parasitic loads to system operation. After deducting the parasitic loads from the gross power generation, ATS anticipates achieving a net power generation of 7.5 kW from the pilot-scale system. • Thermal Efficiency: The thermal efficiency is the percent of the total heat transferred to the TEG system that is converted to gross power. Historically, TEGs have a thermal efficiency of 2%–5% (DOE 2008). Prior industrial-scale TEG systems, such as the E1 TEG offered by Alphabet Energy, operated at an efficiency of 2.5% (Lamonica, 2014). ATS anticipates achieving an average efficiency of 4.8% or higher in converting heat energy to usable electricity. • Cartridge Performance: The TEG system comprises 573 active individual semiconductor cartridges, each of which generates a portion of the total power. Cartridge optimization and selection is an important design consideration for potential future TEG system design performance. Therefore, understanding the distribution of gross power and efficiency within the pilot system is vital to understanding what is achievable. At a design hot-side temperature of 240°C and cold-side temperature of 20°C, ATS anticipates a cartridge performance of 20 W of gross power per cartridge at an efficiency of 4.8% per cartridge. In addition to evaluating the claimed performance of the TEG pilot-scale unit, the study estimated the potential annual impacts of a scaled-up commercial system used to capture kiln waste heat over annual operations. The evaluation estimated the gross and net annual electric generation achievable by capturing heat from the two proposed tap-in points: the kiln exhaust and the clinker cooler exhaust; see Section 2.1 for details. Two use cases were examined: • Holcim Alpena: The Holcim Alpena site consists of long dry kilns with superheater boilers, which differs from the rest of Holcim’s cement plant portfolio and results in lower waste heat temperatures. The study estimates gross and net annual generation using the superheater boiler exhaust and clinker cooler exhaust, based on 2023 operational data. • Typical Installation: Common cement plants have preheater kilns with higher exhaust temperatures than Holcim Alpena across a range of production rates. The study estimates gross and net annual generation using the preheater exhaust and clinker cooler exhaust, with a sensitivity analysis to account for the typical range of preheater exhaust temperatures, clinker cooler exhaust temperatures, and clinker production rates. Methodology The evaluation methodology followed a measurement and verification (M&V) strategy based on the International Performance Measurement and Verification Protocol Option B through comprehensive measurements and analyses of the affected systems. Evaluation data was collected from March 9 to March 11, 2024, the test period of the pilot TEG system. During the test period, in coordination with the ITV team, the ATS team adjusted system operations to capture the range of variability expected for each of the variables pertinent to performance of the system. The methodology consisted of two parts: evaluating the performance of the pilot unit's TEG system and estimating the annual TEG impact in terms of gross and net power based on a given waste heat profile. First, the evaluation of the thermoelectric generation performance of the pilot unit relative to the claims was performed by analyzing the collected test data. Gross power of the pilot TEG system was directly measured. Net power was determined by deducting the measured parasitic power from the gross power. The gross power generation was compared to heat transferred to the system by the working fluid (which was heated by steam generated from the kiln waste heat) to calculate the thermal efficiency achieved by the system. Performance of individual semiconductor cartridges within the pilot array was also assessed in terms of measured gross cartridge power and calculated cartridge thermal efficiency. The second part of the evaluation estimated the annual TEG impacts in terms of gross power and net power (calculated from the difference between gross power and parasitic power). This analysis comprised development of mathematical regression models for gross power and parasitic power, with assessment of each model’s goodness-of-fit characteristics to ensure satisfaction of statistical requirements. The models predicted the gross power generation, the parasitic load based on the temperature difference between the hot working fluid and the cold-side fluid (cold water from Lake Huron) entering the system, the volumetric flow rate of the cold-side fluid at the inlet, and the volumetric flow rate of the hot working fluid at the inlet. The annual impact analysis considered a theoretical commercial-scale system sized to capture the available waste heat at a cement plant, consisting of linked pilot-scale units that receive heat from a theoretical gas-to-working-fluid heat exchanger. To estimate annual impacts at the Alpena plant, the gross power and parasitic power regression models were applied to the arrays in the theoretical commercial-scale system. The heat supplied to the unit was calculated based on the kiln run time, annual production, kiln exhaust waste heat, and clinker cooler waste heat derived from 2023 Holcim Alpena kiln operational data. Net power impacts were calculated by deducting the resulting parasitic power from the estimated gross power. Inputs for the model were generated from a combination of hourly data, assumed design considerations for TEG system scale-up from the pilot-scale unit, and assumptions regarding TEG system operations. This analysis was then used as the basis for estimating annual impacts of typical TEG installation at cement plants, by applying sensitivity analyses to key kiln operational characteristics including kiln preheater exhaust temperatures, cooler clinker exhaust temperatures, and plant daily production rates across a range of expected values. Project Results/Findings Table ES- 2 and Table ES- 2 provide a summary of the operating conditions and evaluation results compared to the stated claims from the technology provider. Key takeaways include: • Gross Power: The peak gross power achieved during the testing period was 10.0 kW, compared to the 11.5 kW expected for 573 active cartridges. The claimed gross power was associated with a target hot side of 240°C; however, the system only received a maximum hot-side mean plate temperature of 212°C during the testing period. • Net Power: The pilot-scale unit exceeded the claims for net power, achieving a peak of 7.7 kW net compared to a claim of 7.5 kW. One factor contributing to the higher achieved net power is the relatively high water pressure available through Lake Huron. The pilot TEG system did not require cold-side pumps during the test, whereas most installations would. This reduced the parasitic loads on the system, ultimately contributing to higher net power relative to the gross power. • Thermal Efficiency: The pilot-scale unit outperformed the claimed efficiency, achieving a peak system efficiency of 5.0% thermal efficiency compared to the stated 4.8%. • Cartridge Performance: To compare cartridge performance against claims, the study focused on the third day of testing, which aimed for conditions closest to the design specifications, with a hot side of 240°C and cold-side exit temperature of 6.4°–30°C. On this day, the mean gross power observed in the cartridges within the TEG array was 18.1 W/cartridge, and the peak performance was 34.7 W/cartridge. The estimated mean cartridge efficiency was 5.2%, and the estimated efficiency at peak gross cartridge power was 10%. The regression models developed for gross power generation and parasitic loads were used to estimate the generation impact for given heat input to the TEG from the working fluid (captured from the waste heat) and from the cold loop (Lake Huron) on an hourly basis for a year of operation. Based on this analysis, installation of a commercial-scale TEG system at the Holcim cement plant in Alpena, Michigan, with a waste heat exchanger of 0.85 effectiveness, would generate up to 391 kW of net power, translating to between 920,000 and 1,800,000 kilowatt-hours (kWh) in net electricity per year. Based on typical grid emissions for Alpena, this would avoid estimated net emissions by 752 metric tons of CO₂ annually.² The sensitivity analysis estimated that typical TEG system installations at cement plants could generate an average of 56–1,040 kW of net power, or between 488,000 and 9,110,000 kWh of net energy. This generation potential is most significantly affected by plant production rates and also influenced by preheater and clinker cooler exhaust temperatures. Applying the national average emission rate, typical commercial-scale installations at Holcim plants are projected to avoid between 182 and 3,401 metric tons of CO₂ annually per site. Table ES- 3 shows a summary of the estimated annual impacts.³ While parasitic loads are significant and vary by application, this analysis assumed the use of heating loop pumps and access to Lake Huron as a cold sink. This setup assumed no need for cooling loop pumps due to the available water pressure at the test site. Applications that require cooling towers or additional equipment are likely to experience higher parasitic loads. Therefore, the study’s estimates are most applicable to scenarios with similar parasitic load configurations—namely, access to a high-pressure cold sink. Applicability to other locations may be limited, as differing conditions could necessitate additional pumps and cooling systems, potentially impacting performance significantly.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2016

Catalysis Science Initiative: Catalyst Design by Discovery Informatics

Catalysts selectively enhance the rates of chemical reactions toward desired products. Such reactions provide great benefit to society in major commercial sectors such as energy production, protecting the environment, and polymer products and thereby contribute heavily to the country’s gross national product. Our premise is that the level of fundamental understanding of catalytic events at the atomic and molecular scale has reached the point that more predictive methods can be developed to shorten the cycle time to new processes. The field of catalysis can be divided into two regimes: heterogeneous and homogeneous. For the heterogeneous catalysis regime, we have used the water-gas shift (WGS) reaction (CO + H2O + CO2 + H2O) over supported metals as a test bed. Detailed analysis and strong coupling of theory with experiment have led to the following conclusions: • The sequence of elementary steps goes through a COOH intermediate • The CO binding energy is a strong function of coverage of CO adsorbed on the surface in many systems • In the case of Au catalysts, the CO adsorption is generally too weak on surface with close atomic packing, but the enhanced binding at corner atoms (which are missing bonding partners) of cubo-octahedral nanoparticles increases the energy to a near optimal value and produces very active catalysts. • Reaction on the metal alone cannot account for the experimental results. The reaction is dual functional with water activation occurring at the metal-support interface. It is clear from our work that the theory component is essential, not only for prediction of new systems, but also for reconciling data and testing hypotheses regarding potential descriptors. Particularly important is the finding that the interface between nano-sized metal particles and the oxides that are used to support them represent a new state of matter in the sense that the interfacial bonding perturbs the chemical state of both metals atoms and the support atoms in the interfacial region. Some of the first theoretical descriptions of this important chemistry and potential new source of control of catalyst properties are be in preparation for submission. On the homogeneous catalysis side, we have used single site olefin polymerization as the testbed. This system is important because changes in a single ligand bonded to the catalytically active metal site can alter the rates of individual steps in the polymerization sequence and thereby change the properties of the resulting polymer, potentially improving its value in a hundred million pound per year industry. We have made a major advance in understanding such systems by developing a population balance kinetic model that allows us to predict the molecular weight distribution (MWD) of the product. That, in turn, allows use of MWD data to fit kinetic parameters. By combining monomer loss data, MWD, measurement of the number of working active sites, and polymer end group analysis, we have a rich data set that is highly discriminating of kinetic mechanism. Thus, we have a robust tool for producing high quality, detailed kinetic parameters, which we have used to refine mechanisms presented in the literature and discover relationships between steric and electronic properties of group IV catalysts and individual rate constants in a number of systems. Our recent work on six-coordinate Zr, Ti, and Hf amine bis(phenolate) systems, we have shown that: • The sterics (bulkiness) of the ligands specifically affect the chain termination reaction • The electron density on the metal controls misinsertion (flipped orientation) of the olefin into the growing polymer • Steric effects related to the size of the ortho ligand on the catalyst have been shown to strongly affect its the degree of dormancy, i.e. tendency to stop reacting • Changes in the size of the amine pendent group on the catalyst can have such a strong effect on chain termination as to change the catalyst from one that produces only oligomers to one that incorporates oligomers in polymer chains to introduce chain branching. These effects control the length of molecular chains, the number of errors in the regularity of the chains, and the variation of chain lengths in the final product distribution. These characteristics, in turn, determine the properties of the resulting polymer material. Predictive modeling of polymerization process cannot be done without the quantitative rate constant determination that our unique and comprehensive approach has produced. This tool, combined with insights on how catalyst chemistry affects the rate constants, is an important step toward establishing the quantitative relationships between catalyst chemistry and polymer properties that will allow more efficient searches for new catalysts and speed the discovery process. Thus, in both the heterogeneous and homogeneous catalysis areas, this work has brought important new understanding to the field. The technical effectiveness of our approach is demonstrated by its success. For heterogeneous catalysis, experimental work alone showed the important of the metal-support interface, but the integration with theory has allowed deeper understanding of the fundamental source of the effects and shown the path for how to use this understanding for discovery. In the case of homogeneous catalysis, methodology for determination of which reactions are needed to account for the data and the extraction of quantitative values for rate constants for those reactions allows accurate modeling of reaction behavior. This allowed correlation of trends in catalyst properties with alterations of specific rates, thus contributing to a data base that will guide catalyst discovery. While not yet realized, the economic benefits of this approach will come in significantly shortened cycle times for discovery and ability to fill product demand at lower price.

96 KNOWLEDGE MANAGEMENT AND PRESERVATION↗
DOE OSTI2018

Envision Charlotte Project Final Report

The Envision Charlotte Project (EC Project), supported by partners at the Center for Climate and Energy Solutions, the University of North Carolina at Charlotte’s Center for Sustainably Integrated Buildings and Sites and the City of Charlotte, has successfully demonstrated that existing buildings can benefit from operations improvements and low-cost efficiency upgrades, and that behavioral change campaigns can be effectively designed for measurability, longevity and impact. Support from this grant gave Envision Charlotte and its partners the resources and flexibility to demonstrate a variety of approaches to improve coordination with stakeholders in the implementation of programs to reduce the consumption of energy, water and waste. The project team also gained insights into the motivations and abilities that influence stakeholder engagement in sustainability initiatives at multiple levels. Importantly, as this report describes, strong partnerships between nonprofits, industry partners and research institutions can produce tangible impacts and replicable results in building efficiency. Further, building operators working alongside student researchers can form productive relationships that can advance building energy management goals. Key Findings of the EC Project This project focused on advancing solutions to energy efficiency in U.S. commercial buildings. The Building Re-Tuning™ Training (BRT) developed by the U.S. DOE’s Pacific Northwest National Lab (PNNL), designed to detect energy savings opportunities and implement improvements with resources and online tools, provided the starting point for the curriculum developed by stakeholders in the EC Project. Although the project partners encountered some issues with data consistency, the overall project outcomes fell short of the energy savings stated in the original proposal, and the total participating building targets were lower than anticipated, important findings, outcomes and lessons learned were achieved. EC Project grantees observed that the PNNL BRT, as currently written, was not compatible with the skills of average frontline mechanical personnel in the Charlotte region where the grant program was performed. Frontline staff are not, typically, energy managers, engineers or building commissioning agents, but they can play a key role in building performance. As detailed in this report, the grantees therefore focused on changes to the BRT that improved the level of training and competency of the frontline workers in this region. Among the technical observations related to improving the BRT that were observed in the EC Project: centralized facilities management often has an impact on building performance; operators can be overly reliant on service contracts; individual behaviors matter, and technology cannot be viewed as a crutch; current Building Automation Systems (BAS) are often too complex to support building efficiency optimization, but BAS coupled with appropriate training can support better outcomes; the “perfectly optimized” building is not a near-term possibility, but better education, especially of executives and managers, on the role of behavioral intervention is a promising direction the building science community can and should pursue; a lack of standards and protocols, and competition between proprietary software from service contracts, remain challenges for this industry. These technical observations, in turn, informed the EC Project’s overall findings, which were: Accomplishing building efficiency is a process of education for all involved in the building design, construction and operation supply chain. Building operators, as a professional class, have an opportunity for further training and education that will lead to better on-the-job performance. An updated Building Re-Tuning™ Training curriculum, based on the findings of this report, could be an avenue for these operators’ professional development.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Hybrid Power Plants for Energy Resilience: A Case Study

As renewable energy technologies are increasingly adopted, they pose an opportunity to improve the sustainability and resilience of distributed grids, especially when their design and operation is coordinated as a hybrid power plant. When included in hybrid power plants, distributed wind turbines in particular have the potential to enhance the resilience of distributed grids in areas with good wind resource, due to their ability to provide more consistent generation and ancillary services as compared to photo-voltaic (PV) solar panels. Despite this benefit, U.S. distributed wind adoption is lower than other comparable renewable energy technologies. In this study, we seek to demonstrate how hybrid power plants that include distributed wind turbines can contribute to distribution grid resilience by meeting loads (especially critical loads) more consistently, increasing reserve capacity, and providing value to customers during outages. To demonstrate these contributions, we integrate three separate frameworks and apply them to a case study in a rural electric cooperative in Iowa. Through this case study, we simulate and compare hybrid power plant design and operation during two hazard events: a tornado that causes a 48-hour distribution outage and a winter weather event that causes a 6-hour generation outage. The inclusion of a hybrid power plant that leverages 1) increased battery duration and 2) advanced forecasting and dispatch strategies that reserve capacity leading up to a hazard event best reduce lost loads as well as diesel consumption that would otherwise be used to meet those loads during short- and long-duration hazard events. Depending on the hybrid power plant capacity and operation, we find that the outage mitigation value of a hybrid power plant (measured in value to customers to avoid an outage and avoided lost revenues for the utility) is significant in both hazard events; adding wind, solar, and battery assets to the existing system adds about $50-$100M in avoided lost load and at least $4-$8k in utility value in the tornado hazard event, and $570k-$2.2M in avoided lost load and at least $220-$650 in utility value in the winter hazard scenario. In both the tornado and winter hazard scenarios, optimizing the operation of the hybrid system for resilience can lend similar value as increasing battery duration by 5 MWh for the lower capacity systems considered.

17 WIND ENERGY↗