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DOE OSTI2015

Using learning curves on energy-efficient technologies to estimate future energy savings and emission reduction potentials in the U.S. iron and steel industry

Increasing concerns on non-sustainable energy use and climate change spur a growing research interest in energy efficiency potentials in various critical areas such as industrial production. This paper focuses on learning curve aspects of energy efficiency measures in the U.S iron and steel sector. A number of early-stage efficient technologies (i.e., emerging or demonstration technologies) are technically feasible and have the potential to make a significant contribution to energy saving and CO 2 emissions reduction, but fall short economically to be included. However, they may also have the cost effective potential for significant cost reduction and/or performance improvement in the future under learning effects such as ‘learning-by-doing’. The investigation is carried out using ISEEM, a technology oriented, linear optimization model. We investigated how steel demand is balanced with/without the availability learning curve, compared to a Reference scenario. The retrofit (or investment in some cases) costs of energy efficient technologies decline in the scenario where learning curve is applied. The analysis also addresses market penetration of energy efficient technologies, energy saving, and CO 2 emissions in the U.S. iron and steel sector with/without learning impact. Accordingly, the study helps those who use energy models better manage the price barriers preventing unrealistic diffusion of energy-efficiency technologies, better understand the market and learning system involved, predict future achievable learning rates more accurately, and project future savings via energy-efficiency technologies with presence of learning. We conclude from our analysis that, most of the existing energy efficiency technologies that are currently used in the U.S. iron and steel sector are cost effective. Penetration levels increases through the years, even though there is no price reduction. However, demonstration technologies are not economically feasible in the U.S. iron and steel sector with the current cost structure. In contrast, some of the demonstration technologies are adapted in the mid-term and their penetration levels increase as the prices go down with learning curve. We also observe large penetration of 225kg pulverized coal injection with the presence of learning.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2016

Characteristics of Low-Priced Solar Photovoltaic Systems in the United States

Despite impressive recent cost reductions, there is wide dispersion in the prices of installed solar photovoltaic (PV) systems. We identify the most important factors that make a system likely to be low priced (LP). Our sample consists of detailed characteristics for 42,611 small-scale (< 15 kW) PV systems installed in 15 U.S. states during 2013. Using four definitions of LP systems, we compare LP and non-LP systems and find statistically significant differences in nearly all factors explored, including competition, installer scale, markets, demographics, ownership, policy, and system components. Logit and probit model results robustly indicate that LP systems are associated with markets with few active installers; experienced installers; customer ownership; large systems; retrofits; and thin-film, low-efficiency, and Chinese modules. We also find significant differences across states, with LP systems much more likely to occur in some than in others. Our focus on the left tail of the price distribution provides implications for policy that are distinct from recent studies of mean prices. While those studies find that PV subsidies increase mean prices, we find that subsidies also generate LP systems. PV subsidies appear to simultaneously shift and broaden the price distribution. Much of this broadening occurs in a particular location, northern California, which is worthy of further investigation with new data.

14 SOLAR ENERGY↗
DOE OSTI2017

Large Pilot Scale Testing of Linde/BASF Post-Combustion CO 2 Capture Technology at the Abbott Coal-Fired Power Plant

The work summarized in this report is the first step towards a project that will re-train and create jobs for personnel in the coal industry and continue regional economic development to benefit regions impacted by previous downturns. The larger project is aimed at capturing ~300 tons/day (272 metric tonnes/day) CO 2 at a 90% capture rate from existing coal- fired boilers at the Abbott Power Plant on the campus of University of Illinois (UI). It will employ the Linde-BASF novel amine-based advanced CO 2 capture technology, which has already shown the potential to be cost-effective, energy efficient and compact at the 0.5-1.5 MWe pilot scales. The overall objective of the project is to design and install a scaled-up system of nominal 15 MWe size, integrate it with the Abbott Power Plant flue gas, steam and other utility systems, and demonstrate the viability of continuous operation under realistic conditions with high efficiency and capacity. The project will also begin to build a workforce that understands how to operate and maintain the capture plants by including students from regional community colleges and universities in the operation and evaluation of the capture system. This project will also lay the groundwork for follow-on projects that pilot utilization of the captured CO 2 from coal-fired power plants. The net impact will be to demonstrate a replicable means to (1) use a standardized procedure to evaluate power plants for their ability to be retrofitted with a pilot capture unit; (2) design and construct reliable capture systems based on the Linde-BASF technology; (3) operate and maintain these systems; (4) implement training programs with local community colleges and universities to establish a workforce to operate and maintain the systems; and (5) prepare to evaluate at the large pilot scale level various methods to utilize the resulting captured CO 2 . Towards the larger project goal, the UI-led team, together with Linde, has completed a preliminary design for the carbon capture pilot plant with basic engineering and cost estimates, established permitting needs, identified approaches to address Environmental, Health, and Safety concerns related to pilot plant installation and operation, developed approaches for long-term use of the captured carbon, and established strategies for workforce development and job creation that will re-train coal operators to operate carbon capture plants. This report describes Phase I accomplishments and demonstrates that the project team is well-prepared for full implementation of Phase 2, to design, build, and operate the carbon capture pilot plant.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2016

GATEWAY Demonstrations: LED System Performance in a Trial Installation--Two Years Later, Yuma Border Patrol, Yuma, Arizona

Along the Yuma Sector Border Patrol Area in Yuma, Arizona, the GATEWAY program conducted a trial demonstration in which the incumbent quartz metal halide area lighting was replaced with LED at three pole locations at the Yuma Sector Border Patrol Area in Yuma, Arizona. The retrofit was documented to better understand LED technology performance in high-temperature environments. This report follows the GATEWAY Yuma Phase 1.1 Report and reflects LED system results documented two years after the demonstration began.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2017

Energy Efficiency Upgrades for the Clinic and the Tannery and Wind Energy for Power to the Tannery

Under this grant agreement, the Native Village of Shishmaref (Shishmaref) will complete weatherization retrofits to two community buildings, the Clinic and the Tannery, based on recent energy audits. Located 5 miles from the mainland, 126 miles north of Nome and 100 miles south of Kotzebue, Shishmaref sits on Sarichef Island in the Chukchi Sea. As such, Shishmaref experiences a transitional climate between the frozen Arctic and the continental Interior. Summers can be foggy, with average temperatures ranging from 47 to 54 °F (Fahrenheit); winter temperatures average -12 to 2 °F. With heating fuel costs of almost $7/gallon, the goal of this project is to reduce energy costs at the Clinic and the Tannery by at least 30 to 50% through energy efficiency and weatherization measures and through the installation of a residential-size wind turbine to supplement power for the Tannery building.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2016

Materials and Methods for Streamlined Laboratory Analysis of Environmental Samples, FY 2016 Report

The International Atomic Energy Agency (IAEA) relies upon laboratory analysis of environmental samples (typically referred to as “swipes”) collected during on-site inspections of safeguarded facilities to support the detection and deterrence of undeclared activities. Unfortunately, chemical processing and assay of the samples is slow and expensive. A rapid, effective, and simple extraction process and analysis method is needed to provide certified results with improved timeliness at reduced costs (principally in the form of reduced labor), while maintaining or improving sensitivity and efficacy. To address these safeguard needs the Pacific Northwest National Laboratory (PNNL) explored and demonstrated improved methods for environmental sample (ES) analysis. Improvements for both bulk and particle analysis were explored. To facilitate continuity and adoption, the new sampling materials and processing methods will be compatible with existing IAEA protocols for ES analysis. PNNL collaborated with Oak Ridge National Laboratory (ORNL), which performed independent validation of the new bulk analysis methods and compared performance to traditional IAEA’s Network of Analytical Laboratories (NWAL) protocol. ORNL efforts are reported separately. This report describes PNNL’s FY 2016 progress, which was focused on analytical application supporting environmental monitoring of uranium enrichment plants and nuclear fuel processing. In the future the technology could be applied to other safeguard applications and analytes related to fuel manufacturing, reprocessing, etc. PNNL’s FY 2016 efforts were broken into two tasks and a summary of progress, accomplishments and highlights are provided below. Principal progress and accomplishments on Task 1, Optimize Materials and Methods for ICP-MS Environmental Sample Analysis, are listed below. • Completed initial procedure for rapid uranium extraction from ES swipes based upon carbonate-peroxide chemistry (delivered to ORNL for evaluation). • Explored improvements to carbonate-peroxide rapid uranium extraction chemistry. • Evaluated new sampling materials and methods (in collaboration with ORNL). • Demonstrated successful ES extractions from standard and novel swipes for a wide range uranium compounds of interest including UO 2 F 2 and UO 2 (NO 3 ) 2 , U 3 O 8 and uranium ore concentrate. • Completed initial discussions with commercial suppliers of PTFE swipe materials. • Submitted one manuscript for publication. Two additional drafts are being prepared. Principal progress and accomplishments on Task 2, Optimize Materials and Methods for Direct SIMS Environmental Sample Analysis, are listed below. • Designed a SIMS swipe sample holder that retrofits into existing equipment and provides simple, effective, and rapid mounting of ES samples for direct assay while enabling automation and laboratory integration. • Identified preferred conductive sampling materials with better performance characteristics. • Ran samples on the new PNNL NWAL equivalent Cameca 1280 SIMS system. • Obtained excellent agreement between isotopic ratios for certified materials and direct SIMS assay of very low levels of LEU and HEU UO 2 F 2 particles on carbon fiber sampling material. Sample activities range from 1 to 500 CPM (uranium mass on sample is dependent upon specific isotope ratio but is frequently in the subnanogram range). • Found that the presence of the UF molecular ions, as measured by SIMS, provides chemical information about the particle that is separate from the uranium isotopics and strongly suggests that those particles originated from an UF6 enrichment activity. • Submitted one manuscript for publication. Another manuscript is in preparation.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗
DOE OSTI2017

Health and Safety Audit Design Manual

The Health and Safety Audit is an electronic audit tool developed by the Oak Ridge National Laboratory to assist in the identification and selection of health and safety measures when a home is being weatherized (i.e., receiving home energy upgrades), especially as part of the US Department of Energy (DOE) Weatherization Assistance Program, or during home energy-efficiency retrofit or remodeling jobs. The audit is specifically applicable to existing single-family homes (including mobile homes), and is generally applicable to individual dwelling units in low-rise multifamily buildings. The health and safety issues covered in the audit are grouped in nine categories: mold and moisture, lead, radon, asbestos, formaldehyde and volatile organic compounds (VOCs), combustion, pest infestation, safety, and ventilation. Development of the audit was supported by the US Department of Housing and Urban Development Office of Healthy Homes and Lead Hazard Control and the DOE Weatherization Assistance Program.

47 OTHER INSTRUMENTATION↗
DOE OSTI2017

Analysis of hydrogen as a Transportation Fuel FY17 Report

This report summarizes the results of literature reviews, surveys and analyses performed to evaluate the potential of hydrogen-fueled vehicles to be an economically viable transportation alternative. Five existing and important drivers of expanding hydrogen-fueled transportation adoption are multi-billion dollar sales reservations of Nikola Class 8 trucks, CALSTART viability analysis of hybrid-hydrogen drayage trucks in the shipyard cargo application, analysis showing economic advantages of Fuel Cell Electric Vehicles (FCEV)s over Battery Electric Vehicles (BEV)s beginning at 150-mile ranges, the announcement of a commercial 5kg electrolyzer, and commercial plans or vehicle availability by nine vehicle manufacturers of FCEV passenger vehicles. But hydrogen infrastructure availability needed to support broad adoption of hydrogen-fueled vehicles is limited to less than 50 publicly-available refueling stations, primarily in California. The demand side (consumer) economics associated with FCEV adoption showed strong economic sensitivity to the original vehicle’s fuel economy (mpg), distance traveled, and hydrogen (H2) generation costs. Seven use cases were used to evaluate the broad range of potential FCEV purchasers, including autonomous vehicle applications. Each consumer use case analysis resulted in a different hydrogen fuel cost that would be equivalent to the current fuel cost being paid by the consumer. The H2 generation costs (supply side) were sensitive to the volume of H2 supplied and H2 production costs needed to repay H2 supply facility capital costs and produce competitively-priced energy. H2FAST was used to more accurately incorporate capital, maintenance and production costs into a viable H2 supply cost to the consumer. When the H2 generation and consumer economics were combined, several applications with positive economics became clear. The availability of low-cost hydrogen pipeline connections, and therefore low-cost hydrogen, greatly benefits the California drayage truck application with hybrid-hydrogen retrofits being repaid within seven years. Class 8 trucks could also take advantage of these low-cost, but regional hydrogen supplies. In addition, the IVYS electrolyzer-based hydrogen generation product showed the potential to deliver hydrogen economically in an urban or freeway off-ramp setting to a limited number of passenger vehicles in areas with low-cost electricity. These positive, manually developed results show the need to develop more advanced tools to provide an expanded evaluation of the economics of hydrogen-based fuel applications. The use cases evaluated showed significant potential for hydrogen-fueled vehicles to have a sustainable impact as a transportation fuel. The positive impact is not limited to transportation fuels, but also grid resilience and flexibility through the use of controllable and variable electrolyzer output to rapidly adjust to changing grid conditions and enable greater integration of solar and wind generated power. This capability would directly enable alternative fuel vehicles to impact energy consumption, GHG emissions, and the economy at the regional and national levels.

08 HYDROGEN↗
DOE OSTI2016

Pollutant Concentrations and Emission Rates from Scripted Natural Gas Cooking Burner Use in Nine Northern California Homes

METHODS: Combustion pollutant concentrations were measured during the scripted operation of natural gas cooking burners in nine homes. In addition to a base condition of closed windows, no forced air unit (FAU) use, and no mechanical exhaust, additional experiments were conducted while operating an FAU and/or vented range hood. Test homes included a 26m2 two-room apartment, a 134m2 first floor flat, and seven detached homes of 117–226m2. There were four single-story, four two-story and one 1.5 story homes. Cooktop use entailed boiling and simmering activities, using water as a heat sink. Oven and broiler use also were simulated. Time-resolved concentrations of carbon dioxide (CO2), nitric oxide (NO), nitrogen oxides (NOX), nitrogen dioxide (NO2), particles with diameters of 6 nm or larger (PN), carbon monoxide (CO), and fine particulate matter (PM2.5) were measured in the kitchen (K) and bedroom area (BR) of each home. CO2, NO, NO2, and PN data from sequential experiments were analyzed to quantify the contribution of burner use to the highest 1h and 4h time-integrated concentrations in each room. RESULTS: Four of the nine homes had kitchen 1h NO2 exceed the national ambient air quality standard (100 ppb). Two other homes had 1h NO2 exceed 50 ppb in the kitchen, and three had 1h NO2 above 50 ppb in the bedroom, suggesting substantial exposures to anyone at home when burners are used for a single substantial event. In all homes, the highest 1h kitchen PN exceeded 2 x105 cm-3-h, and the highest 4h PN exceeded 3 x105 cm-3-hr in all homes. The lowest 1h kitchen/bedroom ratios were 1.3–2.1 for NO in the apartment and two open floor plan homes. The largest K/BR ratios of 1h NO2 were in a two-story 1990s home retrofitted for deep energy savings: ratios in this home were 3.3 to 6.6. Kitchen 1h ratios of NO, NO2 and PN to CO2 were used to calculate fuel normalized emission factors (ng J-1). Range hood use substantially reduced cooking burner pollutant concentrations both in the kitchen and bedroom of several homes. A hood with large capture volume and a measured flow of 108 L/s reduced concentrations 80-95%. IMPLICATIONS: These measurements demonstrate that operation of natural gas cooking burners without venting can cause short-term kitchen concentrations of NO2 to exceed the US outdoor health standard, and can elevate concentrations of NO, NO2, and ultrafine particles throughout the home. Results are generally consistent with a recent simulation study that estimated widespread 1h NO2 exposures exceeding 100 ppb in homes that use gas burners without venting. While operating a venting range hood can greatly reduce pollutant levels from burner use (and presumably from cooking as well), performance varies widely across hoods. Increased awareness of the need to ventilate when cooking would substantially reduce in-home exposure to NO2 and ultrafine particles in California homes. Helping consumers select effective hoods, for example by publishing capture efficiency performance ratings, also would help reduce exposure.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2018

Coal-Powered Electric Generating Unit Efficiency and Reliability Dialogue: Summary Report

Coal continues to play a critical role in powering the Nation’s electricity generation, especially for baseload power plants. With aging coal generation assets facing decreased performance due to the state of the equipment, and with challenges exacerbated by the current market pressures on the coal sector, there are opportunities to advance early-stage technologies that can retrofit or replace equipment components. These changes will eventually result in significant improvements in plant performance once further developed and deployed by industry. Research and development in areas such as materials, fluid dynamics, fuel properties and preparation characteristics, and a new generation of plant controls can lead to new components and systems that can help improve the efficiency and reliability of coal-fired power plants significantly, allowing these assets to continue to provide baseload power. Coal stockpiles at electricity generation plants are typically large enough to provide 30 to 60 days of power prior to resupply—significantly enhancing the stability and reliability of the U.S. electricity sector. Falling prices for non-dispatchable renewable energy and mounting environmental regulations, among other factors, have stimulated efforts to improve the efficiency of these coal-fired electric generating units (EGUs). In addition, increased reliance on natural gas and non-dispatchable energy sources has spurred efforts to further increase the reliability of coal EGUs. The Coal Powered EGU Efficiency and Reliability Dialogue brought together stakeholders from across the coal EGU industry to discuss methods for improvement. Participants at the event reviewed performance-enhancing innovations in coal EGUs, discussed the potential for data-driven management practices to increase efficiency and reliability, investigated the impacts of regulatory compliance on coal EGU performance, and discussed upcoming challenges for the coal industry. This report documents the key findings and research suggestions discussed at the event. Discussions at the workshop will aid DOE in developing a set of distinct initiatives that can be pursued by government and industry to realize promising technological pursuits. DOE plans to use the results of the Dialogue coupled with ongoing technical analysis of efficiency opportunities within the coal-fired fleet, and additional studies to develop a comprehensive strategy for capitalizing on thermal efficiency improvements. Expected Power Plant Efficiency Improvements include developing cost-effective, efficient, and reliable technologies for boilers, turbines, and sensors and controls to improve the reliability and efficiency of existing coal-based power plants. The Office of Fossil Energy at DOE plans to work with industry to develop knowledge pertaining to advanced technologies and systems that industry can subsequently develop. These technologies and systems will increase reliability, add operational flexibility and improve efficiency, thereby providing more robust power generation infrastructure. The following table lists the research suggestions and questions for further investigation that were identified by participants in each session of the dialogue.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2018

STTR Phase I: Low-Cost, High-Accuracy, Whole-Building Carbon Dioxide Monitoring for Demand Control Ventilation

This STTR Phase I project assessed the feasibility of a new CO 2 sensing system optimized for low-cost, high-accuracy, whole-building monitoring for use in demand control ventilation. The focus was on the development of a wireless networking platform and associated firmware to provide signal conditioning and conversion, fault- and disruptiontolerant networking, and multi-hop routing at building scales to avoid wiring costs. Early exploration of a bridge (or “gateway”) to direct digital control services was also explored. Results of the project contributed to an improved understanding of a new electrochemical sensor for monitoring indoor CO 2 concentrations, as well as the electronics and networking infrastructure required to deploy those sensors at building scales. New knowledge was acquired concerning the sensor’s accuracy, environmental response, and failure modes, and the acquisition electronics required to achieve accuracy over a wide range of CO 2 concentrations. The project demonstrated that the new sensor offers repeatable correspondence with commercial optical sensors, with supporting electronics that offer gain accuracy within 0.5%, and acquisition accuracy within 1.5% across three orders of magnitude variation in generated current. Considering production, installation, and maintenance costs, the technology presents a foundation for achieving whole-building CO 2 sensing at a price point below $0.066 / sq-ft – meeting economic feasibility criteria established by the Department of Energy. The technology developed under this award addresses obstacles on the critical path to enabling whole-building CO 2 sensing and demand control ventilation in commercial retrofits, small commercial buildings, residential complexes, and other highpotential structures that have been slow to adopt these technologies. It presents an opportunity to significantly reduce energy use throughout the United States.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2018

Development and Implementation of Air Barrier Systems for New and Existing Buildings

A Cooperative Research and Development Agreement (CRADA) was established between Oak Ridge National Laboratory (ORNL) and the Air Barrier Association of America (ABAA) to assess key aspects that influence the performance of air barrier systems commonly use d in residential and commercial buildings. This collaboration was intended to include laboratory experiments and evaluations in a natural exposure test facility, as well as building envelope retrofits that improved the airtightness of existing buildings. Even though the Department of Energy discontinued funding this work after two years, the gathered results provided insight on the effect of air leakage on energy use and material durability, as well as the contribution of common air leaks to energy consumption. Furthermore, ORNL and ABAA have continued collaborating in other projects such as the development of a free online calculator that estimates energy and cost savings due to improvements in airtightness.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2018

RFA for Solar/Geothermal Hybrid Thermal Energy Storage Modeling: Cooperative Research and Development Final Report, CRADA Number CRD-16-646

Hyperlight Energy is an innovative concentrated solar power (CSP) company whose business charter is to commercialize a disruptively low-cost, CSP collector system that is ultimately for providing heat for solar thermal/geothermal hybrid power plants, process heat applications (e.g., enhanced oil recovery), and solar thermal power generation. Hyperlight's CSP collector system utilizes a linear Fresnel reflector (LFR) configuration. This LFR configuration consists of mirrors mounted in low-cost, precision plastic extrusions, which are integrated into raft assemblies and floated on low-cost, sealed waterbeds. Hyperlight's CSP collector technology has been developed under private equity investment, government grant and commercial funding. Hyperlight has been awarded a 1.5-million DOE COLLECTS contract with an additional 1.6 million in matched funds from private investment and the California Energy Commission. This DOE project will support the final steps of product development for bulk commercialization and deployment of the Hyperlight CSP collector system. The work will culminate in a final operational deployment at a commercially relevant site. Several such site options are currently under evaluation, including two geothermal sites. Hyperlight identified a very low-cost way to put renewable energy electrons on the grid at peak times, upgrading underutilized geothermal plants with Hyperlight's low cost CSP and thermal energy storage (TES). While Hyperlight's CSP collector work is maturing quickly for commercial pilot launch, an optimal TES system for solar thermal/geothermal hybridization needs to be evaluated and ultimately developed so Hyperlight can develop commercial retrofit projects at a scale of hundreds of megawatts of renewable energy power output at sites across the United States, followed by greenfield projects in a multi-GW sized market.

15 GEOTHERMAL ENERGY↗
DOE OSTI2018

Final CRADA Report for Enhanced and Miniaturized Wireless Valve Position Indicator Prototype

Most operating nuclear power plants (NPPs) in the United States have received approval to extend their operating licenses to 60 years. Now the nuclear industry is preparing to extend operating licenses to 80 years. While NPPs are preparing for extensions (60 years and beyond), the nuclear industry is facing a unique economic sustainability challenge in the current energy market. According to the Nuclear Energy Institute (NEI), generating costs of U.S. reactors have risen by 28% over the last 12 years, which is impacting the competitiveness of nuclear power in a market being increasingly penetrated by natural gas and renewable energy. This is partly because of the fact that the present nuclear work practice is dependent on a large technical staff which results in high operation and maintenance (O&M) costs, accounting for approximately 66% of the total operating cost. To address these concerns and abide by the NEI’s “Delivering the Nuclear Promise Initiative,” the U.S. utilities are embracing digitalization of their work practice to lower the O&M costs and increase productivity and efficiency while maintaining a safe and reliable operation. To address these above-mentioned concerns, Idaho National Laboratory (INL) researchers (proposal team) have developed a wireless valve position indication (VPI) sensor system that can be retrofitted on three main manual valve types (extendible to other manual valve types) to replace manual valve position verification with digital verification and enable online monitoring of manual valves. The developed technology 1) is evaluated for electromagnetic interference, 2) has a low power consuming and miniaturized electronic board, 3) is mounted on adjustable and reconfigurable sensor mounting unit that can fit on an actual flow-loop (at Idaho State University-ISU) to enable online monitoring of manual valve types without any valve body modification, and 4) ensures robust, secure, and reliable real-time communication of manual valve position.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2018

An Integrated Supercritical System for Efficient Produced Water Treatment and Power Generation

The main goal of this project was to evaluate the feasibility of an integrated supercritical (SC) water desalination and power generation system for treatment of produced waters from CO 2 sequestration, oil production, and coal-bed methane recovery. This system may offer a transformative approach to generating power from coal or natural gas (NG) and purifying saline water or produced water with high total dissolved solids (TDS) in a zero-liquid discharge plant. The closed-loop steam cycle of conventional power plants was replaced with an open-loop steam cycle that heated the pretreated produced water above the SC point of water (374 °C and 221 bar) to precipitate and separate the salts dissolved in the water. After separation of the precipitated salt, the SC steam required further treatment to reduce the salt content from ~100 mg/L (ppm) to <1 ppm to make it suitable for use in turbines for power generation. A SC membrane distillation unit was used to polish the SC steam, which could be sent through a series of turbines for power generation, and the steam exiting the low-pressure turbine could be condensed by cooling water to produce pure water. Project tasks included a process simulation and a techno-economic evaluation of the integrated system; design and assembly of SC salt precipitation and membrane distillation systems; development and characterization of advanced carbon membranes for SC membrane distillation; and pretreatment, desalination, and purification of different produced water samples with salt concentrations of 30,000–200,000 ppm to a high-purity (<1 ppm) level. Process simulations were performed for 550 MW SC coal-fired or NG baseline cases and various scenarios for the proposed integrated SC system using produced water as the water source and coal or NG as the fuel source. Simulation results indicated that the net plant efficiency loss of the proposed SC cogeneration process would be in the range of <1% to ~4%, in which NG and lower TDS produced water cases would have higher efficiencies. The proposed process for coal-fired cases could provide all water needs for the power generation process and generate additional pure water for beneficial use. A techno-economic analysis was performed to estimate the cost of produced water treatment (dollars /kgal of treated water) by conventional treatment processes compared with the proposed cogeneration process. The cost estimation for the proposed cogeneration system included the cost of pretreatment, the cost of power loss to integrate the water desalination process into the power generation system, and the cost of plant modification or retrofitting. The cost of produced water treatment was calculated by assuming three different scenarios in which converting a baseline power plant to the proposed cogeneration plant would increase the cost of the boiler and feed water system by 10%, 50%, and 100%. Results indicated that the cost of produced water treatment, even with a 100% cost increase, was in the range of $8.6–11.6 dollars per kgal, which is about half of the treatment cost by conventional methods. The cost of produced water treatment by the proposed cogeneration system could be further reduced or a considerable income could be generated if the values of saltwater and freshwater products are considered. Overall, the techno-economic analysis results indicated that the proposed integrated SC system could potentially treat produced water at a cost significantly lower than the cost of produced water treatment by conventional technologies. To evaluate the feasibility of the proposed treatment system at a laboratory scale, a SC salt precipitation and membrane distillation system was designed and fabricated to treat a simulated brine or pretreated produced water by precipitating salts and further polishing the SC steam containing ~100 ppm salts to a high-purity steam. Through baseline tests with NaCl solutions, with concentrations ranging from 30,000 to 200,000 ppm, it was demonstrated that concentrated feed solutions could be treated by precipitating salt at SC conditions to a TDS level of 130 ppm. Produced water samples were collected from a potential CO 2 sequestration site, a coal-bed methane site, and an oilfield in Illinois. Representative samples were characterized for various water quality parameters, including pH; turbidity; conductivity; and concentrations of selected anions, cations, alkalinity, dissolved organic carbon, total suspended solids, TDS, and total petroleum hydrocarbons. The produced water samples were first treated by conventional pretreatment methods to remove residual oil, dissolved organic matter, and scale-forming species. Pretreatment methods included coagulation, sedimentation, filtration, activated carbon adsorption, and ion-exchange adsorption. Pretreated produced waters were treated at SC conditions in which salts were precipitated. Analysis of treated samples revealed that the concentration of Na (the main cation) in produced waters was reduced dramatically from 14,000–47,400 ppm in the feed to 21–80 ppm in treated waters. Concentrations of other main cations (Ca, Mg, Sr, K) also decreased significantly from initial values of ~1,000–22,000 ppm to ~1 ppm or less. However, a significant increase in the concentrations of Fe, Ni, Cu, and Co was observed, mainly caused by leaching of these elements from the system (vessels, filters, tubing), which is manufactured from alloys containing Fe, Ni, Cu, and Co. To polish the SC steam containing a salt content of ~100 ppm to a high-purity level of <1 ppm, a SC membrane distillation treatment using carbon membranes was employed. Different types of self-standing or supported carbon membranes were developed from graphite, graphene, carbon nanotubes, carbon nanofibers, and pyrolytic carbon. Screening tests revealed that only a limited number of developed carbon membranes were suitable for the purification of steam at SC conditions. Membranes that were either fragile and lacked mechanical strength or had large pores and showed limited salt rejection (<20%) were found to be unsuitable for the purification of SC steam. Promising carbon membranes that were successfully tested for purifying SC steam included two graphite membranes (i.e., AF-5, a porous graphite material, and FGS, a flexible graphite sheet) and a carbon nanotube membrane grown on a Hastelloy substrate and then further modified using a proprietary method (i.e., membrane C). The AF-5 membrane exhibited a stable water flux of ~50 kg/m 2 ∙h and ~40% salt rejection. The FGS membrane had a high salt rejection of 95%–98% but a lower water flux of ~15 kg/m 2 ∙h. Membrane C showed an extremely high flux of 200-800 kg/m 2 ∙h, which is one order of magnitude higher than the water flux of conventional membranes. Membrane C also exhibited 87%–93% salt rejection. Overall, a two-stage or multistage polishing treatment by these membranes could lower the salt content of the SC steam from initial values of ~100–200 ppm to the steam quality of <1 ppm or to parts per billion levels required for the power cycle.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2018

The Uniform Methods Project: Methods for Determining Energy Efficiency Savings for Specific Measures: January 2012 - September 2016

This is the complete set of Uniform Methods Project protocols for determining energy efficiency savings for specific measures, all within one report. The report includes the following chapters: Chapter 1: Introduction. Chapter 2: Commercial and Industrial Lighting Evaluation Protocol. Chapter 3: Commercial and Industrial Lighting Controls Evaluation Protocol. Chapter 4: Small Commercial and Residential Unitary and Split System HVAC Cooling Equipment-Efficiency Upgrade Evaluation Protocol. Chapter 5: Residential Furnaces and Boilers Evaluation Protocol. Chapter 6: Residential Lighting Evaluation Protocol. Chapter 7: Refrigerator Recycling Evaluation Protocol. Chapter 8: Whole-Building Retrofit with Consumption Data Analysis Evaluation Protocol. Chapter 9: Metering Cross-Cutting Protocol. Chapter 10: Peak Demand and Time-Differentiated Energy Savings Cross-Cutting Protocol. Chapter 11: Sample Design Cross-Cutting Protocol. Chapter 12: Survey Design and Implementation for Estimating Gross Savings Cross-Cutting Protocol. Chapter 13: Assessing Persistence and Other Evaluation Issues Cross-Cutting Protocol. Chapter 14: Chiller Evaluation Protocol. Chapter 15: Commercial New Construction Evaluation Protocol. Chapter 16: Retrocommissioning Evaluation Protocol. Chapter 17: Residential Behavior Evaluation Protocol. Chapter 18: Variable Frequency Drive Evaluation Protocol. Chapter 19: HVAC Controls (DDC/EMS/BAS) Evaluation Protocol. Chapter 20: Data. Center IT Efficiency Measures Evaluation Protocol. Chapter 21: Estimating Net Savings - Common Practices. Chapter 22: Compressed Air Evaluation Protocol. Chapter 23: Combined Heat and Power Evaluation Protocol. Chapter 24: Strategic Energy Management (SEM) Evaluation Protocol

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2018

NREL Energy Performance Testing of Asetek's RackCDU System on a Single Rack of Twin Blade Servers: Cooperative Research and Development Final Report, CRADA Number CRD-13-518

The project will entail Asetek retrofitting 1 - 2 compute racks of servers at the National Renewable Energy Laboratory (NREL) to test and validate RackCDU's cooling performance and long-term reliability. The project will also entail measuring and reporting energy savings under a real workload by comparing total power input to the system vs. total heat removed by liquid and air. Direct measurements will be made to compare and contrast energy consumption and performance both before and after RackCDU installation. The scope of this project is strictly demonstration and feedback on the system. No development work will be performed under this CRADA.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗