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DOE OSTI2024

Department of Energy/IDEA: More best-practices research

This article continues the overview of the U.S. Department of Energy and IDEA collaboration by highlighting additional case studies that demonstrate innovative engineering approaches in district energy systems. It focuses on how campuses are improving efficiency, integrating advanced technologies, and reducing energy use and emissions through data-driven strategies. The University of Cincinnati is featured for its highly efficient chilled water system, using advanced algorithms and upgraded “smart chillers” to optimize performance, reduce energy consumption, and lower costs. Wake Forest University emphasizes a data-informed modernization process, using system optimization and targeted building improvements to significantly boost efficiency and reduce overall energy use. Arizona Western College showcases creative solutions to extreme cooling demands, including system redesign, smart controls, and thermal storage to improve reliability and cut peak energy costs. Overall, the article demonstrates that combining innovative engineering, real-time data analysis, and system optimization can significantly enhance performance, reduce emissions, and deliver cost savings in district energy systems.

96 KNOWLEDGE MANAGEMENT AND PRESERVATION↗

DOE OSTI2021

Report on Field Test at INL Cask Farm of Single Detector Fast Neutron Spent Fuel Cask Verification System

Detecting diversion of spent fuel elements in dry storage casks is challenging due to the thick shielding used in cask construction. Measurements on top of the cask to map the underlying arrangement of the fuel elements and looking for anomalous changes over time has proven difficult to achieve using gamma rays due to the high scattering and attenuation from the thick steel structure, weakening information on the present or absence of fuel bundles. Simulations and laboratory experiments suggest that the high-energy neutron flux (>200 keV) measured directly above each fuel bundle is sufficient to produce a position map that enables detection of the present or absence of fuel bundles, and therefore diversion of a spent fuel bundle. A single-detector spent-fuel monitoring technique based on this principle was development at the Lawrence Livermore National Laboratory (LLNL). The INL Cask Farm in the INTEC technical area at Idaho National Laboratory (INL) offers the capability to test this technique on an MC-10 storage cask which has a distribution of full and empty fuel positions. An experimental test plan for the single-detector verification system was developed in consultation with INL personnel to be completed in FY2021. Due to travel advisories related to COVID-19, the experimental test plan was adapted to enable INL personnel to carry out the measurements in consultation with LLNL personnel following shipment of the LLNL system to INL. Field test measurements of the single detector verification system were successfully carried out at the INL cask farm on September 7-9, 2021. This document summarizes results of the field test.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS1995

Curation of Federally Owned Archeological Collections at NASA Langley Research Center

As a Federal agency, NASA has a moral and legal obligation to the public to manage the archeological heritage resources under its control. Archeological sites are unique, nonrenewable resources that must be preserved so that future generations may experience and interpret the material remains of the past. These sites are protected by a wide array of federal regulations. These regulations are intended to ensure that our nation's cultural heritage is preserved for the study and enjoyment of future generations. Once a site has been excavated, all that remains of it are the artifacts and associated records which, taken together, allow researchers to reconstruct the past. With the contextual information provided by associated records such as field notes, maps and photographs, archeological collections can provide important information about life in the past. An integral component of the federal archeology program is the curation of these databases so that qualified scholars will have access to them in years to come. Standards for the maintenance of archeological collections have been codified by various professional organizations and by the federal government. These guidelines focus on providing secure, climate-controlled archival storage conditions for the collections and an adequate study area in which researchers can examine the artifacts and documents. In the 1970's and early 1980's, a group of NASA employees formed the LRC Historical and Archeological Society (LRCHAS) in order to pursue studies of the colonial plantations that ha been displaced by Langley Research Center (LaRC). They collected data on family histories and land ownership as well as conducting archeological surveys and excavations at two important 17th-20th century plantation sites in LaRC, Cloverdale and Chesterville. The excavations produced a wealth of information in the form of artifacts, photographs, maps and other documents. Unfortunately, interest on the part of the LRCHAS membership waned before a report was written, and since 1982 the artifacts have moldered in a flimsy trailer with no climate controls, which had once served as a field laboratory but which threatened to become a tomb for the collection. A recent analysis of Langley's cultural resources by Gray & Pape, Inc. recommended that the collection be organized, cataloged, and placed in a proper curation facility in accordance with Federal regulations. The project for the LARSS program was to research curation standards, organize the collection, catalog it, and prepare it for transfer to a facility which could provide adequate long-term curation conditions for the artifacts and documents. The first phase was to organize the artifacts, which were lying about the lab in various stages of cleaning, analysis, and conservation. Once all of the artifacts from the various excavation units and levels had been regrouped, they were cleaned and/or repackaged in archivally-stable materials. A basic catalog was prepared which will provide interested parties with a rough idea of what we have and where it can be found. Another aspect of the project was to organize the records left by the LRCHAS. Bundles of papers, photographs, and field data found in every corner and drawer of the laboratory trailer were put into order and, where appropriate, copies were made on acid-free Permabond paper for long term storage. Finally, the entire collection and most of the lab equipment was transferred into a secure, climate controlled room which will serve as an archive and study space for qualified scholars interested in exploring LaRC's rich historical heritage.

Eastman, John Arnold↗

DOE OSTI2023

Experimental Aging and Lifetime Prediction in Grid Applications for Large-Format Commercial Li-Ion Batteries

Due to the growth of electric vehicle and stationary energy storage markets, the production and use of lithium-ion batteries has grown exponentially in recent years. For many of these applications, large-format lithium-ion batteries are being utilized, as large cells have less inactive material relative to their energy capacity and require fewer electrical connections to assemble into packs. And especially for stationary energy storage systems, where energy delivered is the only revenue source, the economics of these battery systems is highly dependent on cell lifetime. However, testing of large-format lithium-ion batteries is time consuming and requires high current channels and large testing chambers, making information on the performance of commercial, large-format lithium-ion batteries hard to come by. Here, accelerated aging test data from four commercial large-format lithium-ion batteries is reported. These batteries span both NMC-Gr and LFP-Gr cell chemistries, pouch and prismatic formats, and a range of cell designs with varying power capabilities. Accelerated aging test results are analyzed to examine both cell performance, in terms of efficiency and thermal response under load, as well as cell lifetime. Cell thermal response is characterized by measuring temperature during cycle aging, which is used to calculated a normalized thermal resistance value that may help estimate both cell cooling needs or to help extrapolate aging test results to different thermal environments. Cell lifetime is evaluated qualitatively, considering simply the average calendar and cycle life across a range of conditions, as well as quantitatively, using statistical modeling and machine-learning methods to identify predictive aging models from the accelerated aging data. These predictive aging models are then used to investigate cell sensitivities to stressors, such as cycling temperature, voltage window, and C-rate, as well as to predict cell lifetime in various stationary storage applications. Results from this work show that cell lifetime and sensitivity to aging conditions varies substantially across commercial cells, necessitating testing for specific cell formats to make quantitative lifetime predictions. That being said, all commercial cells tested here are predicted to reach at least 10-year lifetimes for stationary storage applications. Based on the aging test results and modeling, some cells are expected to be relatively insensitive to temperature and use-case, making them suited for simple use cases with little or no thermal management and simple controls, while the lifetime of other cells could be extended to 20+ years if operated with thermal management and degradation-aware controls.

battery↗

DOE OSTI2026

Seismic Elastic Double-Beam Characterization of Faults and Fractures for CO₂ Storage Site Selection

Site characterization for underground injection and storage of gigatonne-scale CO₂ requires reliable and cost-effective methods to detect and characterize faults and fractures and to assess their stress state and fault activation potential. This is critical, as wastewater injection and disposal have been shown to activate faults and induce earthquakes, and CO₂ leakage remains a key concern for long-term storage. In this project, we developed seismic methods to detect and characterize large-scale sedimentary and crystalline basement faults and associated small-scale fractures below conventional seismic imaging resolution using multicomponent (9C) surface seismic data. Machine learning was used to automatically interpret large-scale faults, providing key information for estimating the maximum magnitude of potential induced earthquakes. High-fidelity imaging was achieved by exploiting redundancy across multiple elastic wave modes, where independent images from different modes and frequencies cross-validate each other. We also used our nonlinear signal comparison (NLSC) method for ground roll removal, improving data quality in complex near-surface conditions. The methods were validated using field data acquired in central Montana. Results show that basement faults extend into the sedimentary section and that small-scale fractures are widespread above the basement. The inferred stress orientation is consistent with regional stress data, and the estimated maximum induced earthquake magnitude is small (Mw ~2.3). The developed workflow provides a practical approach for fault and fracture characterization and for assessing induced seismicity and leakage risk. It is directly applicable to CO₂ storage site selection and to other subsurface systems.

02 PETROLEUM↗

DOE OSTI2020

Powering the Blue Economy: Progress Exploring Marine Renewable Energy Integration With Ocean Observations

The blue economy is a dynamic and rapidly growing movement that captures the interplay between economic, social, and ecological sustainability of the ocean and encompasses numerous maritime sectors and activities (e.g., commerce and trade; living resources; renewable energy; minerals, materials, and freshwater; and ocean health and data). The demand for ocean data to inform scientific, risk reduction, and national security needs is leading to a large increase in the number of deployed ocean observation and monitoring systems, most of which require increased power. Because ocean observation systems are often placed in remote locations, they primarily rely on energy storage (or in some cases in situ energy generation) to power instruments and equipment, which imposes limits on sampling rates, deployment times, and spatiotemporal resolution of data. The U.S. Department of Energy Water Power Technologies Office is exploring the potential for marine renewable energy (MRE) devices (largely wave and tidal energy converters) to provide power to support multiple blue economy opportunities. A portion of these opportunities focus on power at sea markets for providing power in off-grid and offshore locations to support a variety of ocean-based activities, including ocean observation and navigation, underwater vehicle charging, marine aquaculture, marine algae farming, and seawater mining. Initially, research has focused on better understanding how and where MRE can provide a consistent source of reliable power to extend ocean observing missions, including operation of autonomous underwater vehicles. Online surveys as well as phone and inperson interviews were conducted with experts in the field of ocean observing systems and observatories to gather end-user requirements, determine energy needs, identify opportunities for codevelopment, and pinpoint constraints for MRE to meet those needs. The surveys and interviews provided feedback on the potential for powering devices and vehicles using MRE, including identifying common themes and challenges that will inform foundational research and development steps needed to advance the integration of MRE with ocean observing systems. In most cases, additional power generation on the order of watts was identified as significantly beneficial to enhancing ocean observations capabilities.

marine renewable energy, powering the blue economy↗

DOE OSTI2020

Enabling Power at Sea: Opportunities for Expanded Ocean Observations through Marine Renewable Energy Integration

The blue economy is a dynamic and rapidly growing movement that captures the interplay between economic, social, and ecological sustainability of the ocean and encompasses numerous maritime sectors and activities (e.g., commerce and trade; living resources; renewable energy; minerals, materials, and freshwater; and ocean health and data). The demand for ocean data to inform scientific, risk reduction, and national security needs is leading to a large increase in the number of deployed ocean observation and monitoring systems, most of which require increased power. Because ocean observation systems are often placed in remote locations, they primarily rely on energy storage (or in some cases in situ energy generation) to power instruments and equipment, which imposes limits on sampling rates, deployment times, and spatiotemporal resolution of data. The U.S. Department of Energy Water Power Technologies Office is exploring the potential for marine renewable energy (MRE) devices (largely wave and tidal energy converters) to provide power to support multiple blue economy opportunities. A portion of these opportunities focus on power at sea markets for providing power in off-grid and offshore locations to support a variety of ocean-based activities, including ocean observation and navigation, underwater vehicle charging, marine aquaculture, marine algae farming, and seawater mining. Initially, research has focused on better understanding how and where MRE can provide a consistent source of reliable power to extend ocean observing missions, including operation of autonomous underwater vehicles. Online surveys as well as phone and in-person interviews were conducted with experts in the field of ocean observing systems and observatories to gather end-user requirements, determine energy needs, identify opportunities for codevelopment, and pinpoint constraints for MRE to meet those needs. The surveys and interviews provided feedback on the potential for powering devices and vehicles using MRE, including identifying common themes and challenges that will inform foundational research and development steps needed to advance the integration of MRE with ocean observing systems. In most cases, additional power generation on the order of watts was identified as significantly beneficial to enhancing ocean observations capabilities.

16 TIDAL AND WAVE POWER↗

DOE OSTI2021

Blockchain-Based Smart Contracts Use for Photovoltaic Energy Trade Transactions

In recent decades, interest in renewable energy via solar energy has increased, especially in California and Nevada. In a region that can produce enough solar power for self-use, prosumers must use or sell surplus energy. Solar energy self-consumption is essential in modern energy transactions in the grid. This paper proposes an approach towards grid services that includes photovoltaic hardware to store the excess energy in battery storage. Such energy can then be sold to power companies while the transaction is handled using blockchain. Software, security architecture and data flow requirements based on the Ethereum Blockchain are included. Furthermore, this solution protects the private information of seller and buyer and secures transactions.

14 SOLAR ENERGY↗

DOE OSTI2020

Policy Considerations When Federating Facilities for Experimental and Observational Data Analysis

Today’s computational, experimental, and observational facilities afford us tremendous opportunities to couple theory and experiment at increasingly large scales. Empirical sensing capabilities are growing dramatically with beam line and detector improvements, and with advances in our ability to deploy large-scale data gathering observations of the natural world. The coupling of computational simulations and analysis to process the data from experimental and observational facilities is giving rise to cross-facility workflows. Such federations of facilities are in fact becoming an explicit requirement for large-scale scientific discovery. As we scale up these pipelines of scientific discovery, each participating facility needs to establish and align policies so that the federation can work seamlessly in an end-to-end manner. This chapter outlines specific policy considerations in enabling the federation of facilities for data analysis. Design choices and vital policy decisions cover the areas of data acquisition and storage, data transfer, computational resource allocation and co-scheduling, seamless federated user access, and cross-cutting governance. By highlighting the explicit and implicit interdependencies between facilities, we aim to provide facility designers and policymakers the information on policy issues to address early in a facility’s operations, thus enabling successful cross-facility federation and improved experimental and observational data analysis outcomes.

Shankar, Mallikarjun (Arjun)↗

DOE OSTI2025

Packages of Distributed Energy Technologies Demonstrating Demand Flexibility at Community Scale

The combination of increased electric load growth across all sectors, deferred electrical infrastructure investment, and other factors resulting in variable electric power supply, has created technical challenges to maintaining a resilient and reliable grid. Many federal, regional, and local efforts are in play to modernize the electric grid, including advancing building technologies and distributed energy resources (DERs) that are utilizing smarter controls to become responsive to both occupant and grid needs. This report reviews ten pilot projects demonstrating how groups of buildings combined with behind-the-meter (BTM) DERs such as electric vehicle (EV) charging, battery storage, flexible HVAC and domestic hot water systems, and photovoltaic systems can reliably and cost effectively provide grid services. Each of the ten pilot projects aim to deliver both energy efficiency and demand flexibility (DF) while supporting load growth. The ten demonstration teams are piloting flexible DER packages across diverse communities of residential and commercial buildings to address a variety of regional grid needs. The outcomes of these pilot projects will be used to inform future scaling through utility program development. This paper characterizes the ten teams, showcasing the decision-making process used by each group to develop their packages (Section 2), the grid services they plan to deliver (Section 3), the types of DER packages selected for deployment within building sectors (Section 4) and trends between building sector, DER types, and grid services In order to achieve community scale benefits, the pilot projects must utilize aggregated control mechanisms for coordinating buildings and DERs together. Several types of coordinated control architectures have evolved amongst the teams, influenced by use type, existing market conditions, and integration type. Three coordinated controls architectures have been characterized, highlighting their use cases, benefits, challenges, and tradeoffs in their design. These insights can aid utilities, control vendors, and developers in scaling community-level energy systems (Paul, 2024). Ultimately, the technology packages selected by the ten teams will be coordinated to provide power system services, also known as grid services. Insights from these demonstrations will be useful for grid operators, regulators, aggregators and other stakeholders as they look to deploy demand flexible resources as grid services in the future. The grid services that each team is targeting for demonstration are described in Section 3 and Section 4. Methods for evaluating the grid services have been described in the paper Metrics for Evaluating Grid Service Provision from Communities of Grid-interactive and Efficient Buildings and other DER (MacDonald, 2023). To identify technology packages for demonstration, Section 2 shows that project teams used a range of analysis approaches, including building energy modeling, AMI data analysis, cost-benefit frameworks, and utility pilot data. Some teams emphasized technical modeling to quantify grid impacts and demand reduction potential, while others prioritized economic evaluations, stakeholder input, or exploratory pilots to inform deployment decisions. This diversity reflects the need to tailor selection methods to project goals, available data, and organizational context. Section 5 discusses trends between the DER technologies deployed and the grid service provisions from each team. Residential buildings (multifamily and single family) lean towards technologies that enhance energy efficiency (e.g. weatherization upgrades, smart thermostats) and onsite power generation integration (e.g. solar PV). Commercial building demonstrations prioritize technologies that ensure operational reliability (e.g. battery storage) and centralized energy management systems and optimization solutions. Teams that are deploying controllable storage-based technologies are more likely to provide grid services that require a near real-time response. Teams incorporating load shifting technologies like smart thermostats with HEMs are likely to include energy markets participation and customer bill management offerings. Campus demonstrations are adopting diverse sets of DERs to emphasize renewable generation, paired with centralized control. This section also describes technologies that were considered during project planning but ultimately excluded from final deployment. These demonstrations reveal that effective DER package design should be tailored to building type, customer segment, and construction vintage. Multifamily buildings benefit from centralized HVAC upgrades and supervisory controls, while single-family homes are well-suited for individualized technologies like solar, storage, and smart home energy monitors. Commercial and campus settings prioritize EMIS integration and load optimization. New construction enables cost-effective integration of DER-ready infrastructure, whereas retrofits require deployments aligned with owner and tenant value streams. For utility program planners, early coordination with developers and building owners, paired with segmented and modular program offerings, can improve adoption, scalability, and grid impact.

24 POWER TRANSMISSION AND DISTRIBUTION↗

NASA NTRS1980

Telemetry Computer System at Wallops Flight Center

This paper describes the Telemetry Computer System in operation at NASA's Wallops Flight Center for real-time or off-line processing, storage, and display of telemetry data from rockets and aircraft. The system accepts one or two PCM data streams and one FM multiplex, converting each type of data into computer format and merging time-of-day information. A data compressor merges the active streams, and removes redundant data if desired. Dual minicomputers process data for display, while storing information on computer tape for further processing. Real-time displays are located at the station, at the rocket launch control center, and in the aircraft control tower. The system is set up and run by standard telemetry software under control of engineers and technicians. Expansion capability is built into the system to take care of possible future requirements.

Bell, H.↗

NASA NTRS1987

Expert systems applied to fault isolation and energy storage management, phase 2

A user's guide for the Fault Isolation and Energy Storage (FIES) II system is provided. Included are a brief discussion of the background and scope of this project, a discussion of basic and advanced operating installation and problem determination procedures for the FIES II system and information on hardware and software design and implementation. A number of appendices are provided including a detailed specification for the microprocessor software, a detailed description of the expert system rule base and a description and listings of the LISP interface software.

Source record↗

NASA NTRS1989

Determinations of molecular weight and molecular weight distribution of high polymers by the rheological properties

Several methods are reviewed by which the molecular weight (MW) and the molecular weight distribution (MWD) of polymeric material were determined from the rheological properties. A poly(arylene ether) polymer with six different molecular weights was used in this investigation. Experimentally measured MW and MWD were conducted by GPC/LALLS (gel permeation chromatography/low angle laser light scattering), and the rheological properties of the melts were measured by a Rheometric System Four rheometer. It was found that qualitative information of the MW and MWD of these polymers could be derived from the viscoelastic properties, with the methods proposed by Zeichner and Patel, and by Dormier et al., by shifting the master curves of the dynamic storage modulus, G', and the loss modulus, G'', along the frequency axis. Efforts were also made to calculate quantitative profiles of MW and MWD for these polymers from their rheological properties. The technique recently proposed by Wu was evaluated. It was found that satisfactory results could only be obtained for polymers with single modal distribution in the molecular weight.

Huang, J. Y.↗

NASA NTRS1996

Computer Program for Calculation of Complex Chemical Equilibrium Compositions and Applications II. Users Manual and Program Description: Users Manual and Program Description - 2

This users manual is the second part of a two-part report describing the NASA Lewis CEA (Chemical Equilibrium with Applications) program. The program obtains chemical equilibrium compositions of complex mixtures with applications to several types of problems. The topics presented in this manual are: (1) details for preparing input data sets; (2) a description of output tables for various types of problems; (3) the overall modular organization of the program with information on how to make modifications; (4) a description of the function of each subroutine; (5) error messages and their significance; and (6) a number of examples that illustrate various types of problems handled by CEA and that cover many of the options available in both input and output. Seven appendixes give information on the thermodynamic and thermal transport data used in CEA; some information on common variables used in or generated by the equilibrium module; and output tables for 14 example problems. The CEA program was written in ANSI standard FORTRAN 77. CEA should work on any system with sufficient storage. There are about 6300 lines in the source code, which uses about 225 kilobytes of memory. The compiled program takes about 975 kilobytes.

McBride, Bonnie J.↗

NASA NTRS2004

Lunar and Planetary Science XXXV: Image Processing and Earth Observations

The titles in this section include: 1) Expansion in Geographic Information Services for PIGWAD; 2) Modernization of the Integrated Software for Imagers and Spectrometers; 3) Science-based Region-of-Interest Image Compression; 4) Topographic Analysis with a Stereo Matching Tool Kit; 5) Central Avra Valley Storage and Recovery Project (CAVSARP) Site, Tucson, Arizona: Floodwater and Soil Moisture Investigations with Extraterrestrial Applications; 6) ASE Floodwater Classifier Development for EO-1 HYPERION Imagery; 7) Autonomous Sciencecraft Experiment (ASE) Operations on EO-1 in 2004; 8) Autonomous Vegetation Cover Scene Classification of EO-1 Hyperion Hyperspectral Data; 9) Long-Term Continental Areal Reduction Produced by Tectonic Processes.

Source record↗

DOE OSTI2021

Side-channel Leakage Assessment Metrics: A Case Study of GIFT Block Ciphers

Determination of an adequate level of security and providing subsequent mechanisms to achieve it, is one of the most pressing problems regarding embedded computing devices. While there are some solutions available for resource-rich computer systems, direct application of these solutions to resource-constrained environments are often unfeasible. The fundamental problem for such resource-constrained systems is the fact that current cryptographic algorithms utilize significant energy consumption and storage overhead. Both the cryptographic algorithm and its physical implementation affect the resilience of a cryptosystem against side-channel attacks. A side-channel attack represents a process that exploits leakages in order to extract sensitive information such as the key. This paper focuses on Correlation Power Analysis (CPA) which is side-channel attack based on the power consumption leakage. In 2016 the U.S. Commerce Department’s National Institute of Standards and Technology (NIST) initiated the call for proposals of new cryptographic algorithms to strengthen the cryptographic defense of networked devices against cyberattacks and to protect the data created by those innumerable device. This work evaluates S-boxes used by NIST candidates PICCOLO, GIFT, and PRESENT, as well as several S-box variants that demonstrated sufficient weaknesses against classical cryptanalysis, for a quantitative comparison in terms of resiliency to CPA attack. Three well-known theoretical metrics are evaluated: transparency order (TO and RTO), nonlinearity, and signal-to-noise (SNR) ratio, aiming to characterize the resistance of these S-boxes against adversaries exploiting physical leakages. Experimental results from attacks on an 8- bit XMEGA were obtained via the ChipWhisperer platform and of all the S-boxes evaluated, GIFT64 with a PICCOLO S-box was found to be the most susceptible to CPA. Results showed that variations in TO and RTO were not sufficient to ensure practical CPA resistance and that among S-boxes with equal non-linearity there were no significant differences in the TO and SNR variants.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2021

Side-channel Leakage Assessment Metrics: A Case Study of GIFT Block Ciphers

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2020

Technical Performance of Refractory Liners for Molten Chloride Salt Thermal Energy Storage Systems

A chloride-based molten-salt system that uses a ternary blend of MgCl2/KCl/NaCl is investigated to provide higher temperature thermal energy storage capability. Despite higher thermal stability, molten chlorides present several unique challenges, including the design of internal refractory-ceramic liners to prevent the corrosion and thermal stress of alloy tank shells. This work discusses issues and potential solutions related to containment of molten chloride salt, specifically the optimization of the refractory material at the molten salt interface (hot face). The down-selected hot face candidate limits permeation of salt through the material and forms a highly stable secondary surface phase in equilibrium with the molten salt. A mortar is created using the corrosion resistant hot face brick. Brick and mortar composite are subjected to mechanical stress/strain analysis, in order to calculate composite material properties and better inform thermomechanical models. The U.S. Department of Energy Generation 3 (DOE Gen3) program seeks to develop higher efficiency CSP plants that can provide cost-competitive, flexible power in the U.S. electric grid. The proposed Gen3 Liquid Pathway CSP plant closely resembles the configuration of current nitrate salt power towers with two-tank storage (Gen2). The differences between Gen2 and Gen3 include the types of compatible materials used in salt storage tank construction. Stainless steel loses strength at Gen3 temperatures, and although nickel superalloys would be capable of withstanding sustained high temperatures, these materials are prohibitively expensive at scale. Uninsulated tank shells also pose a significant risk as common steels are highly susceptible to chemical attack from molten chloride salt. To address these concerns, refractory-ceramic based containment materials are proposed to line the inside of the hot and cold storage tanks. In doing so, stainless or carbon steel shells may be used in construction depending on the level of insulation provided. The composition of the internal liner requires careful consideration to maximize the efficacy of multiple parameters including corrosion resistance, strength at operating temperature, durability, and cost. This is particularly true for the material at the interface with the salt, known as the "hot face", which is responsible for protecting the insulating layers between the tank shell and the hot face brick layer. The molten salt in this system is superheated over 300 °C above its freeze temperature. Therefore, unlike other industrial processes which use refractory-lined vessels, it is not expected that a freeze plane will develop in the hot face. Therefore, the hot face must be designed to withstand chemical corrosion and inhibit permeation of molten salt into the insulating layers. A down selection was performed to identify a hot face candidate best equipped to maintain thermal, mechanical, and chemical integrity when exposed to molten salt over extended periods of time. Long-duration chemical capability experiments were conducted with the down selected hot face refractory fully immersed in molten chloride salt for up to 3000 hours. The average salt penetration does not exceed 100 microns. When extrapolated to 20 and 30 years of continuous exposure, the expected salt penetration depth is approximately 2.0 mm and 2.9 mm, respectively. A magnesium-rich secondary phases develops at the salt/refractory interface. X-ray diffraction identifies the material as forsterite (Mg2SiO4), which is reported to form synthetically in molten chloride salt solutions. These results suggest the selected hot face will adequately inhibit salt permeation. While there is optimism that the hot face brick will inhibit salt permeation, mortar joints are typically the weakest point of a refractory brick liner. From a thermochemical perspective, differing thermal expansion coefficients may result in the mortar and brick to grow independent of each other, creating gaps through which molten salt can penetrate. To address this issue, NREL has developed an in-house mortar composed of the down selected hot face brick that has been shown to be compatible with the salt. Compressive stress/strain analyses have been performed on the brick/ mortar composites to generate stress/strain curves. Modulus of elasticity and Poisson's ratio of the composite may be calculated from the stress/strain curves, in order to provide more representative data to finite element mechanical models for accurate approximation of stress on the tank shell and the amount of thermal expansion expected within the tank liner.

41 EE - Solar Energy Technologies Office (EE-4S)↗