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All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Design optimization of an ethanol heavy-duty engine using design of experiments and bayesian optimization

Diesel-fueled engines still hold a large market share in the medium and heavy-duty transportation sector. However, the increase in fossil fuel prices and the strict emission regulations are leading engine manufacturers to seek cleaner alternatives without a compromise in performance. Alcohol-based fuels, such as ethanol, offer a promising alternative to diesel fuel in meeting regulatory demands. Ethanol provides cleaner combustion and lower levels of soot due to its chemical properties, in particular its lower level of carbon content. In addition, the stoichiometric operating conditions of alcohol fueled engines enable the mitigation of NOx emissions in aftertreatment stage. With the promise of retrofitting diesel engines to run on ethanol to reduce emissions, the thermal efficiency of these engines remains the primary optimization target. In order to find the optimal ethanol-fueled engine design that maximizes the thermal efficiency, a large design space needs to be investigated using engineering tools. In this study, previous research by the authors on optimizing the design of a single-cylinder ethanol-fueled engine was extended to explore the design space for a heavy-duty multi-cylinder engine configuration. A heavy-duty engine setup with multiple operating conditions at different engine speeds and loads were considered. A design optimization analysis was performed to identify the potential designs that maximize the indicated thermal efficiency in an ethanol-fueled compression ignition engine. First, a computational fluid dynamics (CFD) model of the engine was validated using experimental data for four drive cycle points. Using a design of experiments (DoE) approach and a parameterized piston bowl geometry, the model was then exercised to explore the relationship among geometric features of the piston bowl and spray targeting angle and indicated thermal efficiency across all tested operating conditions. After evaluating 165~candidate designs, a piston bowl geometry was identified that yielded an increase between 1.3 to 2.2 percentage points in indicated thermal efficiency for all tested conditions, while satisfying the operational design constraints for peak pressure and maximum pressure rise rate. The increased performance was attributed to enhanced mixing that led to the formation of a more homogeneous distribution of in-cylinder temperature and equivalence ratio, higher combustion temperatures, and shorter combustion duration. Finally, a Bayesian optimization (BOpt) analysis was employed to find the optimal piston bowl geometry with a fixed spray injector angle for one of the operating conditions. Using BOpt, a piston candidate was identified that resulted in a 1.9~percentage point increase in thermal efficiency from the baseline design, yet only required 65\% of the design samples investigated using the DoE approach.

Tekgul, Bulut↗
DOE OSTI2021

Modular supply chain optimization considering demand uncertainty to manage risk

Supply chain under demand uncertainty has been a challenging problem due to increased competition and market volatility in modern markets. Flexibility in planning decisions makes modular manufacturing a promising way to address this problem. We report the problem of multiperiod process and supply chain network design is considered under demand uncertainty. A mixed integer two-stage stochastic programming problem is formulated with integer variables indicating the process design and continuous variables to represent the material flow in the supply chain. The problem is solved using a rolling horizon approach. Benders decomposition is used to reduce the computational complexity of the optimization problem. To promote risk-averse decisions, a downside risk measure is incorporated in the model. The results demonstrate the several advantages of modular designs in meeting product demands. A pareto-optimal curve for minimizing the objectives of expected cost and downside risk is obtained.

42 ENGINEERING↗
DOE OSTI2023

Hybrid Solar System (Final Scientific/Technical Report)

GTI Energy (GTI) teamed with the University of California at Merced (UCM) to scaleup the hybrid solar system (HSS) technology for demonstrating its performance at the US Gypsum (USG) plant in Plaster City, California. The technology integrates two-stage concentrating solar collector with matching particle thermal transport and storage (TSS) system to deliver cost-effective, and on-demand distributed high temperature industrial process heat up to 600°C with solar thermal, in this case to a gypsum kettle, to reduce its fuel use and carbon footprint. Current solar technologies, which reach these temperatures, are not distributable (towers) or cost-effective (dish). The research team developed a conceptual system design for host site retrofit, including preliminary heat balance, process flow diagram, particle to process heat exchanger and equipment placements at the site. Subsequently, parallel efforts were carried out at UCM to design, build and test a 12 m long commercial scale prototype concentrating thermal-only collector system and at GTI to design, build and test a matching 650°C capable particle TTS system. The nominal 50 kWth collector consists of a parabolic trough and three 4 m long two-stage receivers in series. Prior to on-sun testing, a 4 m long receiver was fabricated and successfully tested at 650 °C in a laboratory setting for 100 hrs of continuous operation showing less than 15% radiation loss. A 7 m wide x 17 m long parabolic trough was then installed at UCM for on-sun testing of the 12 m long receiver, and concurrently several 4 m long receivers were built. The optics of the parabolic trough were calibrated, and on-sun test were carried out on 12 m long receivers. During tests, the intense solar radiation (53x) caused the absorber tubes in the receivers to bend, reducing the overall optical efficiency. To address the bending issue, a self-consistent algorithm that includes ray tracing, thermal and deformation models was developed to perform thermal stress analysis on absorbers for parabolic solar collectors. Results obtained with this algorithm showed a dramatic rise in deformation as absorber tube length increases. A combined efficiency parameter that includes the occluded area for the mounts was developed to obtain an optimized tube length obtained. Based on the results, a length of 2.7 m for the absorber + 0.2 m for the coupler was chosen to minimize any bending and optimize optical efficiency while maintaining ease of mounting. The associated particle TTS system was designed, built and successfully tested at GTI. It includes storage, receiving and lock hoppers and piping that simulates the transfer of captured solar energy to an actual industrial furnace. Tests over 77 charge-discharge cycles demonstrated <2% particle degradation, with no problematic particle accumulations and no flow interruptions. The piping pressure drop was about 5 psi. The team also worked with Stanley Consultants (Stanley) to prepare conceptual and preliminary engineering packages to facilitate follow-on development and commercialization efforts. These include process and instrumentation diagram’s (P&ID’s), general arrangements, electrical one-line, project definitions document, equipment data sheets, schedule, and construction cost estimate for 2 MWth system. Updated HSS technology commercialization and customer engagement plans and detailed costs and evaluated market trade-offs and manufacturing.

03 NATURAL GAS↗
NASA NTRS2012

Safety and Long-Term Performance of Lithium-ion Pouch Cells

Lithium-ion batteries have the highest energy density of the batteries available in the commercial market today. Although most lithium-ion cell designs use a metal can design, this has changed significantly in recent years. Cell designs are offered in the pouch format as they offer better volumetric and gravimetric energy densities and in some cases, higher tolerance to abuse or off-nominal conditions. In the past decade, several state-of-the-art lithium-ion pouch cell designs have been tested. The pouch cell designs have become more robust in the past two years but there are still a few issues that need to be looked into for optimization. The pouch cells seem to have a tendency to swell when left in storage under ambient conditions. The cells also swell under overvoltage and undervoltage conditions. A significant issue that has been observed is the swelling of the cells under a vacuum condition which could lead to deformation of the cell pouch after this exposure. This last factor would be very critical in the use of these cell designs for space applications as vacuum exposure is used to check for cell and battery leaks before it is flown into space. In rare cases, corrosion of the aluminum layer of the pouches has been observed in stored cells. Pouch material analysis has been carried out in an effort to understand the strength of the pouches and determine if this is a factor in the corrosion as well as unsafe condition of the cells as deformation of the inner layers of the pouch could occur when the cells swell under the various conditions described above. Pouch materials are typically aluminized plastic, made up of a layer of Al sandwiched between one or more layers of polymeric material. Deformations or cell manufacturing processes could lead to a compromise of the inner polymeric layer/s of the pouch leading to the corrosion of the Al layer in the aluminized pouch material. The safety of the pouch cell designs has been determined for cells from various manufacturers. The results are varied and in some cases, unexpected. This paper presents a summary of the tests carried out on a few li-ion pouch cell designs from various cell manufacturers. The data will include performance under different conditions specifically cycling under vacuum conditions with and without restraints as well as safety test data. The presentation will also include detailed analysis of the pouch material for the cells studied.

Jeevarajan, Judith↗
NASA NTRS1992

EOS workstation

This final report summarizes the work done from mid-1989 until January 1992 to develop a prototype set of tools for the analysis of EOS-type images. Such images are characterized by great multiplicity and quantity. A single 'snapshot' of EOS-type imagery may contain several hundred component images so that on a particular pixel, one finds multiple gray values. A prototype EOS-sensor, AVIRIS, has 224 gray values at each pixel. The work focused on the ability to utilize very large images and continuously roam through those images, zoom and be able to hold more than one black and white or color image, for example for stereo viewing or for image comparisons. A second focus was the utilization of so-called 'image cubes', where multiple images need to be co-registered and then jointly analyzed, viewed, and manipulated. The target computer platform that was selected was a high-performance graphics superworkstation, Stardent 3000. This particular platform offered many particular graphics tools such as the Application Visualization System (AVS) or Dore, but it missed availability of commercial third-party software for relational data bases, image processing, etc. The project was able to cope with these limitations and a phase-3 activity is currently being negotiated to port the software and enhance it for use with a novel graphics superworkstation to be introduced into the market in the Spring of 1993.

Leberl, Franz↗
DOE OSTI2020

Pumped Storage Hydropower (PSH) FAST Commissioning Prize Technical Analysis

The US energy landscape has undergone major changes over the past 10 years and will continue to see significant changes in future decades as the power grid increases its reliance on variable renewable energy resources. Because of the inherent variability of these resources, renewable energy growth may require additional energy storage capacity to provide flexible load-following capabilities and other grid services that can quickly adjust to changes in energy demand and generation. Pumped storage hydropower (PSH)—one such energy storage technology—uses pumps to convey water from a lower reservoir to an upper reservoir for energy storage and releases water back to the lower reservoir via a powerhouse for hydropower generation. PSH facility pump and generation cycling often follows economic and energy demand conditions. Across the United States, 43 PSH facilities are in operation and 55 projects are in various permitting or licensing stages. Altogether, the 43 operational projects provide the wide majority (95%) of utility-scale electricity storage in the United States. These facilities also provide significant power and nonpower grid benefits, including large-scale electrical system reserve capacity, grid reliability support, and electricity supply-demand balancing through quick-response capabilities and operational flexibility. PSH systems can accomplish these at a scale (e.g., size) and cost that makes these systems highly attractive from a technical standpoint. Although these research concepts are still in their infancy, they demonstrate promising potential as future PSH energy storage technologies. Although PSH has many advantages, development in the United States has effectively stalled since the 1990s, partially because of the magnitude of project costs and financing interest during development and construction, the length of time from project investment until project revenue begins, permitting challenges, construction risks, competition from other storage technologies (e.g., batteries, hydrogen storage), and electricity market evolution and uncertainty. In short, the time, cost, and risk associated with modern PSH development have resulted in limited growth in the United States recently, despite the growing energy storage demand stemming from increased wind and solar power deployment. Technology innovation is needed to help reduce PSH commissioning time, cost, and risk, particularly during the post-licensing phase of project development. To address challenges facing the PSH industry and to improve PSH commissioning timelines, the US Department of Energy (DOE) Water Power Technologies Office (WPTO) initiated the PSH Furthering Advancements to Shorten Time to (FAST) Commissioning Prize project.

13 HYDRO ENERGY↗
DOE OSTI2023

Using National-Scale Data to Inform Coal Power Plant Redevelopment and Coal Community Revitalization Planning

In the United States, individual coal plants have high variation in their construction and operation. Coal plants commonly have multiple units, with different commissioning ages, operational position, and maintenance conditions – even multiple fuels. These units may be in changing states of utilization, with variation in productivity depending on economic contexts. Coal plants themselves may be temporarily offline, mothballed, retired, or decommissioned due to owner/operator portfolios or market conditions, and the current posture of the plant may be difficult to ascertain without local news sources (Tarekegne et al. 2021). Anticipated dates of plant closures are prospectively represented to regulators and to the Energy Information Administration (EIA), but may also experience uncertainty due to the engineering, environmental, economic and social complexity of closing a very large power plant. As noted in this report, closure of the first unit to the last within a single plant may span more than 20 years. Yet tracking and predicting the position of our nation’s coal fleets on a national scale is deeply important. In developing a case for federal datasets and an approach to building and curating these data, this report identified that data must have high fidelity at the plant-level to be meaningful in aggregate. Plant-scale detail is also a match for its application: national priorities in federal investment range from economic revitalization for coal plant communities to maintaining reliable electric grid operations. This document is organized into a statistical review of coal plant retirements, past and prospective, in the United States; trends in the relationship between closures and existing federal investment programs for community revitalization; and potential methods for accelerating site redevelopment through advanced geospatial analysis based on federal data.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2025

R&D Effort of Geologic Hydrogen Production at the National Renewable Energy Lab (NREL)

Geologic hydrogen (geoH2) is an emerging technology with massive current market interest and distinct potential to change the paradigm of hydrogen production. Two major subsurface processes influence the amount of geoH2 that are available for energy extraction: 1) geochemical reactions of H2O and Fe2+-bearing rocks which can produce hydrogen in the subsurface environment, where 2) various active microbial communities consume hydrogen as an energy source before the hydrogen reaches the surface. The net gain of hydrogen from these two competing processes dictates the production rate of geoH2. A recent study (Templeton et al., 2024) suggested that for most natural geoH2 systems, five orders of magnitude of production rate enhancement are needed to make geoH2 production economical in the near term. Effective enhancement of the production rate requires an in-depth understanding of the two geoH2 processes, in order to promote the H2-generating geochemical processes and suppress the H2-consuming microbial processes. However, current significant knowledge gaps in these two processes hinders the efforts to formulate strategies to enhance geoH2 production. The National Renewable Energy Laboratory (NREL) is a U.S. Department of Energy National Laboratory with the core mission of leading research, innovation, and strategic partnership to deliver solutions for a clean energy based economy. NREL's extensive research portfolio in hydrogen, bioenergy, geothermal, industrial decarbonization, and energy analysis makes us well positioned to conduct interdisciplinary research and facilitate technology deployment in the geoH2 space. In this presentation, we will discuss ongoing geoH2 research and engagement efforts at NREL, including: 1) geochemical investigation to understand the reaction mechanisms and production rate and potential of different source minerals and rocks, 2) microbiological investigation to understand methanogenesis and acetogenesis in the subsurface geoH2 environment, and identify effective inhibitors for these microbial processes, and 3) preliminary analysis for geoH2 production in the State of Minnesota, where abundant Fe-rich rocks for stimulated geoH2 production and ample opportunity to utilize geoH2 in transforming iron and steel industries are currently available.

08 HYDROGEN↗
NASA NTRS2003

The Cam Shell: An Innovative Design With Materials and Manufacturing

Most of the personal audio and video recording devices currently sold on the open market all require hands to operate. Little consideration was given to designing a hands-free unit. Such a system once designed and made available to the public could greatly benefit mobile police officers, bicyclists, adventurers, street and dirt motorcyclists, horseback riders and many others. With a few design changes water sports and skiing activities could be another large area of application. The cam shell is an innovative design in which an audio and video recording device (such as palm camcorder) is housed in a body-mounted protection system. This system is based on the concept of viewing and recording at the same time. A view cam is attached to a helmet wired to a recording unit encased in a transparent body-mounted protection system. The helmet can also be controlled by remote. The operator will have full control in recording everything. However, the recording unit will be operated completely hands-free. This project will address the design considerations and their effects on material selection and manufacturing. It will enhance the understanding of the structure of materials, and how the structure affects the behavior of the material, and the role that processing play in linking the relationship between structure and properties. A systematic approach to design feasibility study, cost analysis and problem solving will also be discussed.

Chung, W. Richard↗
DOE OSTI2023

Economic and environmental feasibility of recycling flexible plastic packaging from single stream collection

As demand for plastic increases, there is an urgent need to ramp up its collection and recycling rate. This study reports results of a pilot study in the United States to recycle flexible plastic packaging (FPP) from single stream curbside collection focusing on both the economic feasibility and carbon footprint. To explore the marketability of recycled FPP, four down-stream market pathways were studied, including roof coverboard, plastic pellets, pallets, and film. In this work, results indicated that (1) the cleaning and pelletizing process at reclaimers contributed the most to the total greenhouse gas (GHG) emissions of recycled FPP products, and (2) the GHG emissions of recycled FPP products in all four pathways are lower than the comparator products. Therefore, using a higher percentage of recycled FPP substituted in a product can result in greater GHG emission reductions. All the recycled FPP products also showed favorable economics compared to their direct competitors.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

Development of a Portable In Situ Phosphorous Sensor

While phosphorus is a critical nutrient for all forms of life, runoff leads to phosphorus accumulation in surface water where it can cause a variety of health, environmental, and economic problems. The Department of Energy is interested in conducting long-term field experiments to monitor the impact of phosphorus in terrestrial and aquatic environments, and to better understand a cost vs. benefit analysis of reducing phosphorus pollution. Performing such long-term experiments requires affordable sensors capable of monitoring low-level phosphorus concentrations under challenging environmental conditions. However, such sensors are currently not available. The goal of this proposed project is to develop and demonstrate a low-cost portable phosphorus sensor suitable for in situ measurements. We will determine the technical requirements for a Raman-based sensor system, design and build a signal amplifier, integrate it with a Raman-based sensor, and demonstrate a proof-of-concept level sensor system. The expected accomplishments for Phase I include the identification of the technical requirements of a combined Raman laser/spectrometer and cavity enhancement system, building a proof-of-concept level sensor system capable of detecting orthophosphate compounds at the desired level of 0.25 mg P/L and organic P compounds, and verification of the sensor performance under laboratory and field conditions. In addition, we will identify initial hardening requirements that will need to be implemented during Phase II. While we plan to develop an integrated sensor system for monitoring phosphorus, the cavity-based enhancement system can also be used in combination with other (non-phosphorus) Raman sensors that we plan to develop or that are already commercially available. A recent market report highlights the increasing demand for such environmental monitoring applications, with the market for chemical detection anticipated to grow at a compound annual growth rate of 6.5% (2020-2025). Wide-spread monitoring of phosphorus could reduce the damage from eutrophication in freshwater, which is estimated to be $2.2 billion annually, thereby increasing biodiversity, reducing costs required for drinking water treatment, and decreasing economic losses related to recreation and angling and lake property values.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Comprehensive Study of the Potential of Extracting and Processing Critical Minerals from Coal-Based Resources - Phase I

The Phase I report prepared for the Department of Energy addresses U.S. Executive Order 13817 titled A Federal Strategy to Ensure Secure and Reliable Supplies of Critical Minerals, issued on December 20, 2017, that lists 35 critical minerals that are vulnerable to supply disruption. A comprehensive review of each of the minerals was conducted to determine the criticality based primarily on extractability from coal-based resources. Several other factors were also considered such as gaps in supply and demand, use in current technology, and the existence of viable substitutes. It was determined that the critical minerals that show highest potential for extraction from coal-based resources are lithium, rare earth elements (REEs), cobalt, and manganese. All four of the critical minerals listed serve an important role in the technology industry, have few substitutes, and have a heavy import reliance. Most notably are lithium, which is widely used in the electric vehicle industry, and the REEs which can be found in virtually all electronic devices. The research of critical mineral extraction from coal-based resources was completed using a combination of literature review from public sources as well as cooperation from coal mines and power plants across the United States. Samples collected from six different geographical locations across the U.S. were subjected to sample preparation (i.e., pH measurement, moisture content, particle size analysis) and characterization studies using Inductively Coupled Plasma-Mass Spectroscopy (ICP-MS) and Scanning Electron Microscopy, Energy Dispersive X-Ray Spectroscopy (SEM-EDX) instruments. 27 samples of coal waste materials such as refuse, sludge, and fly ash were tested to characterize the rare earth element concentration by total rare earth elements (TREEs), heavy rare earth elements (HREEs), and light rare earth elements (LREEs). Of the 27 samples tested, 22 contained a TREE concentration higher than the threshold of 300 ppm, which is considered a viable feedstock material. 3 samples contained less than 300 ppm of TREEs; however, they were within 20 ppm of the threshold, and could potentially be considered viable sources in the future pending the advancement of more efficient extraction technologies. 2 of the 27 samples had significantly low TREE concentrations, which does not imply any potential for being a source for REEs. For the minerals identified as most critical in the literature review, a conceptual process flow diagram (PFD) was developed for their extraction from different coal-based feedstocks. The process targets selective recovery of one commodity (i.e., rare earths, lithium, cobalt, and manganese) via several hydrometallurgical separation methods. By identifying potentially extractable coal-based critical mineral resources, a study of the current and future market environments for each critical mineral, and a review of current processing methodologies for critical mineral extraction from coal-based resources, the foundation has been laid to further characterize and explore new resources and extraction techniques. As reliance on technologies in industries such as the production of electronic devices, batteries, and alloys containing critical minerals utilizing critical minerals continues to increase, a sound understanding of our nation’s dependence on and even the global criticality of certain critical minerals, will serve as a catalyst for innovation in virtually all fields of science.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2024

Herbaceous Feedstock 2022 State of Technology Report

The U.S. Department of Energy promotes production of advanced liquid transportation fuels from lignocellulosic biomass by funding fundamental and applied research that advances the state of technology (SOT). As part of its involvement in this mission, Idaho National Laboratory completes an annual SOT report for nth-plant and 1st-plant herbaceous biomass feedstock logistics. The purpose of the SOT is to provide the status of feedstock supply system technology development for herbaceous biomass to biofuels relative to technical targets and cost goals from specific design cases, based on data and experimental results. Although conventional feedstock supply systems form the backbone of the emerging biofuels industry, they have limitations that restrict widespread implementation on a national scale. To meet the demands of the future industry, the feedstock supply system must shift from the conventional system to what has been termed “advanced” supply systems. In advanced designs, a distributed network of aggregation and processing centers, termed “depots,” are employed near the points of biomass production (i.e., the field or forest) to reduce feedstock variability and produce feedstocks of a uniform format, moving toward biomass commoditization. The 2022 Herbaceous SOT is part of a vision of achieving an implemented advanced feedstock supply system, which produces a stable, tradable commodity at the decentralized distributed depot. It utilizes feedstock fractionation by incorporating technologies that can separate the biomass into its anatomical fractions (leaves, husks, stems and cobs) to reduce impurities and produce fractions that satisfy downstream quality considerations. By using a series of air classification steps, this strategy can reduce the extrinsic ash in corn stover and produce enriched tissue fractions that can be blended to a conversion specification or converted individually in optimized biochemical conversion campaigns. Additionally, a majority of the leaves (which do not meet the quality specification) are separated out early and can be supplied to alternate markets. The 2022 Herbaceous SOT incorporates an advanced biomass fractionation and processing system to produce pellets enriched tissues from three-pass corn stover. The resulting enriched pellets are delivered to the biorefinery individually where they can be blended to a specification or converted in campaigns where the conditions are optimized for each tissue. Unused fractions can be sent to a a midstream market or to a different conversion process that is better suited to their properties to offset the cost of the delivered feedstock. The main benefits from the proposed system can be summarized as: (1) $6.86/dry ton (2016$) lower cost for the air classification due to elimination of the requirement to discard the high ash lights fraction; (2) $1.56/dry ton lower delivered cost by selling the unsuitable leaf fraction into the feed market as a midstream co-product (assuming a selling price that is 11% higher than their cost of production); (3) 0.98% increase in carbohydrate content (from 60.16% to 61.14%); and (4) 0.97% decrease in ash content (from 6.00% to 5.03%) compared to the 2021 Herbaceous SOT. Overall, the 2022 nth-plant Herbaceous SOT predicts a modeled delivered feedstock cost of $78.64/dry ton (2016$) if it is assumed that the enriched leaf fraction is sold at its production cost; this is a slight increase of $0.43/dry ton increase from the 2021 Herbaceous SOT nth-Supply case cost. The increased cost derived from a $0.38/dry ton increase in transportation and handling cost to procure more biomass (to replace the enriched leaf fraction that was not delivered to the biorefinery. The total preprocessing cost was $0.27/dry ton higher than the 2021 result because of updates to energy consumption, purchasing price and dry matter loss data for the rotary shear ($3.00/dry ton increase) and the pelleting mill ($4.52/dry ton increase). The data utilized were generated in pilot-scale tests in the Biomass Feedstock National User Facility (BFNUF) at INL and at Forest Concepts, including tests for rotary shear and pelleting of the air classified fractions. A greenhouse gas emissions analysis was performed by Argonne National Laboratory using the most up to date version of the Greenhouse Gases, Regulated Emissions, and Energy use in Transportation model (GREET®). The analysis showed an increase of 17.34 kg CO2e/dry ton from the 2021 SOT (67.71 kg CO2e/ton in the 2021 Herbaceous SOT to 85.05 kg CO2e/ton in the 2022 Herbaceous SOT). The net increase is primarily attributed to increased energy consumption in pelleting mill.

09 BIOMASS FUELS↗
DOE OSTI2020

Integrated Risk-Informed Condition Based Maintenance Capability and Automated Platform: Technical Report 1

Due to continuing global energy market trends, driven heavily by the abundant preserves of natural gas, there is an immediate need to reduce costs associated with operation and maintenance (O&M) for the current domestic nuclear power industry and for future reactor developments. This is to ensure that nuclear power generation remains an economically competitive and viable option in the energy market. O&M costs include labor-intensive preventive maintenance (PM) programs, which involve manually-performed inspection, calibration, testing, and maintenance of plant assets at periodic frequency and time-based replacement of assets, irrespective of their condition. This has resulted in an expensive, labor-centric business model to achieve high capacity factors. Fortunately, there are technologies (advanced sensors, data analytics, and risk assessment methodologies) that can enable the transition from a labor-centric business model to a technology-centric business model. The technology-centric business model will result in a significant reduction of PM activities, laying the foundation for real-time condition assessment of plant assets, reducing overall labor and part costs. To enable this transition, PKMJ Technical Services LLC is partnering with the U.S. Department of Energy’s Idaho National Laboratory (operated by the Battelle Energy Alliance, LLC) and the Public Services Enterprise Group (PSEG) Nuclear, LLC in the Integrated Risk-Informed Condition-Based Maintenance Capability and Automated Platform Project. In this report, the configuration of a digital cloud platform using Microsoft Azure is discussed, data from the PSEG Salem Nuclear Generating Station Units 1 & 2 are imported into a digital cloud platform, and the data is used for an evaluation of several key areas: cost impact analysis, risk-informed model development, and preventive maintenance strategy optimization. First, the cost impact analysis reviews which plant assets are potential good candidates for condition-based monitoring. Next, INL utilized the data in their local environment to develop the risk-informed model; which provides estimates of failure rates and probability of failures of assets based upon their past performance. The developed model is performed on assets selected from the cost impact analysis. Lastly, engineers assess the preventive maintenance strategy for the selected assets at PSEG against maintenance strategies in the nuclear industry for similar assets to potentially identify acceptable justification for the extension of current maintenance frequencies.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2023

Report on the Creation and Progress of the Hydrogen Regulatory Research Review Group

The current U.S. nuclear generation fleet is increasingly recognized by governmental, scientific, public policy, and industrial communities as having a strategic role in support of the ongoing national transition to a clean energy future. Federal incentives and actions are aligning to expand the role of nuclear power as a viable and more flexible contributor to the evolving national clean energy mix through programs and initiatives such as nuclear power loan guarantees; the Inflation Reduction Act’s (IRA) clean nuclear electrical, steam, and hydrogen incentives; the Infrastructure Investment and Jobs Act (IIJA, also referred to as the Bipartisan Infrastructure Act or BIL); and near term Department of Energy (DOE) funding opportunities related to nuclear based hydrogen hubs and nuclear integrated hydrogen demonstration projects. . Additionally, leveraging clean nuclear electricity and steam is being explored by industries desiring to transition away from carbon-intensive energy sources. Even with all these emerging enablers, notable barriers remain for the widespread adoption of these opportunities within the U.S. nuclear fleet, including the following: • Assurance of the markets for alternate products needed to support decision-making for large capital modification investments • Electric utility mindset and business history centered solely on producing electricity • Design change complexity and regulatory uncertainty associated with plant modifications needed to support alternate product streams The DOE Light Water Reactor Sustainability (LWRS) Flexible Plant Operations and Generation (FPOG) Pathway is developing options to help U.S. nuclear power plants (NPP) in all these areas to enable NPPs designed for steady baseload operation to integrate with intermittent wind and solar capacity to assure reliable clean energy for the nation. Current and near-term laboratory research is focusing on the technical, regulatory, safety, demonstration, and economic elements in support of improving nuclear plant flexibility through hybrid production of electricity and other non-electric products such as hydrogen and energy arbitrage.

42 ENGINEERING↗
DOE OSTI2024

Insights from FEED studies for retrofitting existing fossil power plants with carbon capture technology

Recent United States Department of Energy (DOE) sponsored front-end engineering design (FEED) studies for retrofitting existing fossil-fueled power plants with state-of-the-art carbon capture technology contain previously overlooked real-world design considerations for near-term deployment of carbon capture. Insights from examining seven recently published FEED study reports are summarized in this paper. This includes a discussion of the design, performance, and cost implications associated with (1) location-specific considerations such as water availability, land availability, and accessibility; (2) host-plant-specific factors such as flue gas specifications, allowable degree of integration between the capture system and host plant, and operational mode; and (3) miscellaneous factors such as market conditions, permitting requirements, and business case incentives. In conclusion, this manuscript highlights (1) water availability as a key design and cost driver, with host plant steam extraction increasing capture system cooling water availability, (2) modularization and constructability impacts on the number of capture trains, (3) the impacts of host plant operational mode and capacity factor on the business case for installing capture, and (4) the merit of continued research, development, and demonstration efforts addressing steam extraction, host plant tie-in at the stack, solvent reclamation and air emissions control.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

Demonstration of acoustic monitoring for structural health of microreactors: Through use of neural networks and resonant ultrasound spectroscopy

Nuclear microreactors prioritize modularity and portability and are intended to be a cost-effective technology for non-conventional nuclear markets. As such, the development of microreactors into a safe and feasible solution for energy security applications will necessitate the development of non-destructive technologies to monitor the integrity of inaccessible reactors components during operation. This demonstration applies linear and nonlinear acoustic techniques, in combination with machine learning, to detect and classify mechanical changes (stress and damage) in a test article which are broadly representative of potential operating challenges within a functioning microreactor. All necessary data has been collected for this demonstration, with minor experimental issues identified that can be addressed in follow-on work. Motivated by the expected conditions within a functioning microreactor, we have demonstrated our monitoring techniques on a core-block-like test article using an unstructured excitation source that approximates the noisy acoustic environment expected during reactor operation. At all stress states mechanically applied to the test article, a machine learning model using an artificial neural network was able to classify with 100% accuracy whether a 3D laser vibrometry point measurement was made on an intact or artificially defective test article. Further, model predictions about whether the defect interface was rough or smooth were 95% accurate, indicating the ability of acoustic techniques to recover defect characteristics. Resonant ultrasound spectroscopy (RUS) was also applied to the dataset to provide further quantitative insights about material properties. RUS analysis was ultimately hampered by several minor experimental and data issues, limiting results to certain cases for this demonstration. Last, analysis using nonlinear RUS exhibited sensitivity to changing levels of applied stresses for each intact and defective state. As presented in this demonstration, acoustic monitoring exhibits sensitivity to stress changes, which are of concern due to high thermal gradients expected during startup and operation. Further, our techniques distinguish between measurements made on intact and damaged test articles.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗