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DOE OSTI2020

Assessment of the 3420 Building Filtered Exhaust Stack Sampling Probe Location: Stack Verification Following Fan and Air Blender Additions

The Pacific Northwest National Laboratory (PNNL) 3420 Building, which is part of the Physical Sciences Facility (PSF), houses radiological capabilities that results in the requirement that emissions monitoring must be conducted for potential radionuclides in the exhaust air discharge of this building. The air monitoring system is required to conform to Title 40 of the Code of Federal Regulations part 61 (40 CFR 61) Subpart H, which in turns requires a sampling probe in the exhaust stream to conform to the criteria of American National Standards Institute / Health Physics Society (ANSI/HPS) N13.1-2011, Sampling and Monitoring Releases of Airborne Radioactive Substances from the Stack and Ducts of Nuclear Facilities. To support the air emissions permit for the 3420 Building on the PNNL campus, stack testing that used computational fluid dynamics (CFD) modeling as a surrogate stack and verification tests of velocity uniformity and flow angle on the retrofitted facility stack was performed. The ANSI/HPS N13.1-2011 criteria for the air monitoring probe location are that velocity uniformity, gaseous tracer uniformity, and particulate tracer uniformity must be less than or equal to 20%COV. Furthermore, no point in the sampling location may have a gaseous tracer concentration that varies from the mean concentration by more than 30%. Additionally, the flow angle at the sampling location must not be more than 20°. The CFD modeling of the stack, as reported by Recknagle et al. (2018) demonstrated that the stack meets the criteria at the probe location. The velocity uniformity and flow angle results from the 3420 stack verification tests, performed in October 2020, demonstrated that the CFD model results may be used to support the qualification of the stack sampling location. The measured velocity uniformity verification test result was 1.4%COV. This value is well within the uniformity criterion, which is that the velocity uniformity be =20%COV. Additionally, this value is well within the criterion that the actual stack measurement must be within 5% of the surrogate stack result of 2.1%COV when all four fans were operating. Additionally, the measured average flow angle at the 3420 stack monitor location was 15.5 degrees. Although this is higher than expected based on the CFD model, the result is =20 degrees, so the criterion is met. Based on these stack verification test results, the reconfigured 3420 Building filtered exhaust stack meets the qualification criteria given in the ANSI/HPS N13.1-2011 standard. Further changes to the system configuration or operating conditions that are outside the bounds described in this and the CFD report (Recknagle et al., 2018) may require additional tests and additional analysis to determine compliance with the standard.

3420 Building↗

NASA NTRS1991

High-power converters for space applications

Phase 1 was a concept definition effort to extend space-type dc/dc converter technology to the megawatt level with a weight of less than 0.1 kg/kW (220 lb./MW). Two system designs were evaluated in Phase 1. Each design operates from a 5 kV stacked fuel cell source and provides a voltage step-up to 100 kV at 10 A for charging capacitors (100 pps at a duty cycle of 17 min on, 17 min off). Both designs use an MCT-based, full-bridge inverter, gaseous hydrogen cooling, and crowbar fault protection. The GE-CRD system uses an advanced high-voltage transformer/rectifier filter is series with a resonant tank circuit, driven by an inverter operating at 20 to 50 kHz. Output voltage is controlled through frequency and phase shift control. Fast transient response and stability is ensured via optimal control. Super-resonant operation employing MCTs provides the advantages of lossless snubbing, no turn-on switching loss, use of medium-speed diodes, and intrinsic current limiting under load-fault conditions. Estimated weight of the GE-CRD system is 88 kg (1.5 cu ft.). Efficiency of 94.4 percent and total system loss is 55.711 kW operating at 1 MW load power. The Maxwell system is based on a resonance transformer approach using a cascade of five LC resonant sections at 100 kHz. The 5 kV bus is converted to a square wave, stepped-up to a 100 kV sine wave by the LC sections, rectified, and filtered. Output voltage is controlled with a special series regulator circuit. Estimated weight of the Maxwell system is 83.8 kg (4.0 cu ft.). Efficiency is 87.2 percent and total system loss is 146.411 kW operating at 1 MW load power.

Park, J. N.↗

DOE OSTI2022

Economic analysis of CCUS: Accelerated development for CO 2 EOR and storage in residual oil zones under the context of 45Q tax credit

Residual oil zones (ROZ) undergoing CO 2 Enhanced Oil Recovery (CO 2 -EOR) may benefit from specific strategies to maximize their value. We evaluated several strategies for producing from a Permian Basin, West Texas, USA field’s ROZ. This ROZ lies below the main pay zone (MPZ) of the field. Such brownfield ROZs occur in the Permian Basin and elsewhere. Since brownfield ROZs are hydraulically connected to the MPZs, development sequences and schemes influence oil production, CO 2 storage, and net present value (NPV). We conducted economic assessments of various CO 2 injection/production schemes in the stacked ROZ-MPZ reservoir based on flow simulations of a high-resolution geocellular model built from wireline logs and core data and calibrated through production history matching. Flow simulations of water alternating gas (WAG) injection, such as switching injection from the MPZ to the ROZ and commingled production, were studied. Simulation results showed that simultaneous CO 2 injection into the MPZ and ROZ lead to the largest oil production and, generally, the largest NPV. If instead, CO 2 was simultaneously injected into the MPZ and ROZ, then into the ROZ alone, this maximized CO 2 storage. CO 2 storage can be used as a tax credit under the Internal Revenue Code, Section 45Q. Storage performance depends on the development approach and WAG ratio. Developing the ROZ increased storage compared to only producing from the MPZ. The WAG ratio to maximize oil production did not always yield the largest NPV. These findings are potentially applied to other Brownfield ROZs, which are common below San Andres reservoirs in the Permian Basin and other basins. ROZ development can increase oilfields’ NPV and carbon storage potential. Our study can serve as an analog for similar reservoirs. Here this work provides valuable insights into the further optimization of brownfield ROZ development and information for operators to plan to develop stacked ROZ-MPZ reservoirs.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2020

A Direct Ammonia Fuel Cell with a KOH-Free Anode Feed Generating 180 mW cm −2 at 120 °C

The motivations to operate the direct ammonia fuel cell (DAFC) with no addition of aqueous base, include facilitated fuel management and prevention of corrosion and shunt currents in the DAFC stack. We describe here a polymer electrolyte DAFC, operating at a cell temperature (T cell ) of 120 °C on ammonia and water alone as anode feed, that demonstrated peak power of 180 mW cm −2 —a record for this type of fuel cell. We offer a detailed analysis of polarization curves recorded for PE-DAFCs in the T cell range of 60 °C–120 °C, allowing to estimate the effects of KOH-free operation on the ionic and faradaic resistances, R i and R F , that determine together the value of R app , CL – an , the apparent resistance of the anode catalyst layer. The latter resistance drops ten times between 60 °C and 120 °C as result mainly of the drop in R F . Consequently, DAFC performance at T cell > 100 °C improves substantially, including the cell performance on a KOH-free anode feed. The demsontrated performance levels reported here for KOH-free DAFCs support further development of this type of ammonia/air fuel cells.

Achrai, Ben↗

DOE OSTI2026

Williston basin associated co 2 storage field laboratory

The Williston Basin Associated CO 2 Storage Field Laboratory (WBCFL), led by the Energy & Environmental Research Center (EERC) in partnership with Denbury (now ExxonMobil), was established to advance understanding of CO 2 enhanced oil recovery (EOR) and associated geologic CO 2 storage in the Williston Basin. The specific objective of the WBCFL was to conduct field and laboratory activities to inform decisionmakers regarding the 1) efficacy of associated storage in stacked geologic reservoirs during EOR operations; 2) CO 2 injectivity, oil production, and storage in residual oil zones (ROZs); 3) use of a novel CO 2 storage monitoring, verification, and accounting (MVA) technology (active seismoelectric [ASE] monitoring), and 4) life cycle and techno-economic factors for EOR development scenarios targeting ROZs. The project location was the Pennel Field in southeast Montana, which is part of the Cedar Creek Anticline (CCA) geologic structure within the Williston Basin.

02 PETROLEUM↗

DOE OSTI2026

Hydrogen Production Cost from Proton-Conducting Solid Oxide Electrolysis

Rigorous stakeholder-vetted techno-economic analysis (TEA) was conducted to estimate the cost of hydrogen (H 2 ) production using Proton-Conducting Solid Oxide (PSO) electrolysis. The analysis evaluates Current (2025) and Future (2035) technology cases at centralized plant scales of 50 and 500 metric tonnes per day (MTD), assuming electricity, water, and air as the only system inputs. Untaxed, unsubsidized levelized cost of hydrogen (LCOH) is projected to range from 2020 $\$$1.81 to $\$$2.47/kg H 2 at an electricity price of $\$$0.03/kWh and 97% capacity factor under Nth-of-a-kind (NOAK) deployment assumptions. Total installed capital cost was developed using bottom-up Design for Manufacture and Assembly (DFMA) stack cost modeling and detailed balance-of-plant estimates, including mechanical and electrical subsystems, installation, site preparation, engineering, and contingency. Stack performance assumptions include thermoneutral operation, degradation over time, and periodic replacement. LCOH was calculated using the Hydrogen Analysis (H2A) discounted cash flow model in constant 2020 dollars. Results indicate PSO electrolysis has potential for competitive hydrogen production costs under low-cost electricity and mature manufacturing conditions.

08 HYDROGEN↗

DOE OSTI2022

Meta-Study of Particulate Detection Losses on Radioactive Air Sample Filters

Several mathematical relationships between air sample filter mass loading and the correlated analytical self-absorption factor were developed using data from other published research in this meta-study. Gross-alpha and -beta applications are addressed for this research. As filter media becomes loaded with particulate matter, there is potential for measurement losses due to self-absorption by mass loading. Components contributing to absorption include particulate dust, radioactive particulates, and filter material. Standards indicate a correction factor should be used when the penetration of radioactive material into the collection media or self-absorption of radiation by the material collected would reduce the detection rate by more than 5%. Previously, losses due to self-absorption have been reported up to 100% over a range up to ~10 mg∙cm -2 mass loading. These absorption losses then can be used to determine a correction factor for sample results. For low mass loadings (e.g., ≤0.1 mg∙cm -2 ) corrections factors in the 0.85 - 1 range have been recommended and used, while at higher mass loadings nearer to 10 mg∙cm -2 correction factors closer to 0 (representing near 100% losses) are used. Based on data from published studies, the different methods for relating percent loss due to self-absorption to mass loading include linear, exponential, quadratic, and trinomial derived functions. Where applicable, both forced zero and non-forced zero results were evaluated. From the derived functions evaluated, the trinomial function provided the best fit. Once the sample filter mass loading is known, the trinomial function can be applied to estimate losses and the corresponding self-absorption factor. When applied to routine operating conditions for radiological facility stacks monitored at the Pacific Northwest National Laboratory for an average sample filter mass loading of 0.09 ± 0.12 (2σ) mg∙cm -2 (excluding negative values and outliers) and a range from 0 - 0.24 mg∙cm -2 , the estimated trinomial function nominal self-absorption losses are less than 5% at 0.09 mg∙cm -2 and less than 10% at 0.24 mg∙cm -2 . The trinomial function is one method that may be used to adjust the activity results of an air sample when the sample-specific mass loading is determined. The application of no correction factor when the ANSI/HPS N13.1-2021 guidance of a 5% threshold for loss is not reached with typical stack sample mass loadings may be reasonable in high-efficiency particulate air filtered systems. For simplicity, it would be conservative in assigning the self-absorption correction factor at the 5% threshold (i.e., 0.95) for general uses but in cases of heavy mass loading to calculate the factor.

air sampling↗

NASA NTRS1971

Explosive bonded TZM-wire-reinforced C129Y columbium composites

Technique consists of positioning layers of TZM metal filaments between thin C129Y columbium sheets and joining multiple sheet stacks by single explosive joining operation. Metallurgical bonds are excellent, external heat is not required, process is relatively inexpensive, and resulting composites are considerably stronger than base alloy.

Reece, O. Y.↗

NASA NTRS1973

Atmosphere-entry behavior of a modular, disk-shaped, isotope heat source.

The authors have studied the entry and impact behavior of an isotope heat source for space nuclear power that disassembles into a number of modules which would enter the earth's atmosphere separately if a flight aborted. These modules are disk-shaped units, each with its own reentry heat shield and protective impact container. In normal operation, the disk modules are stacked inside the generator, but during a reentry abort they separate and fly as individual units of low ballistic coefficient. Flight tests at hypersonic speeds have confirmed that a stack of disks will separate and assume a flat-forward mode of flight. Free-fall tests of single disks have demonstrated a nominal impact velocity of 30 m/sec at sea level for a practical range of ballistic coefficients.

Vorreiter, J. W.↗

NASA NTRS1980

Engineering support for magnetohydrodynamic power plant analysis and design studies

The major factors which influence the economic engineering selection of stack inlet temperatures in combined cycle MHD powerplants are identified and the range of suitable stack inlet temperatures under typical operating conditions is indicated. Engineering data and cost estimates are provided for four separately fired high temperature air heater (HTAH) system designs for HTAH system thermal capacity levels of 100, 250, 500 and 1000 MWt. An engineering survey of coal drying and pulverizing equipment for MHD powerplant application is presented as well as capital and operating cost estimates for varying degrees of coal pulverization.

Carlson, A. W.↗

NASA NTRS1991

A synthetic environment for visualization and planning of orbital maneuvers

An interactive proximity operations planning system, which allows on-site planning of fuel-efficient, multi-burn maneuvers in a potential multi-space-craft environment has been developed and tested. This display system most directly assists planning by providing visual feedback in a synthetic virtual space that aids visualization of trajectories and their constraints. Its most significant features include (1) an 'inverse dynamics' algorithm that removes control nonlinearities facing the operator and (2) a stack-oriented action-editor that reduces the order of control and creates, through a 'geometric spreadsheet,' the illusion of an inertially stable environment. This synthetic environment provides the user with control of relevant static and dynamic properties of way-points during small orbital changes allowing independent solutions to otherwise coupled problems of orbital maneuvering.

Ellis, Stephen R.↗

NASA NTRS2011

Docking Offset Between the Space Shuttle and the International Space Station and Resulting Impacts to the Transfer of Attitude Reference and Control

The Space Shuttle does not dock at an exact 90 degrees to the International Space Station (ISS) x-body axis. This offset from 90 degrees, along with error sources within their respective attitude knowledge, causes the two vehicles to never completely agree on their attitude, even though they operate as a single, mated stack while docked. The docking offset can be measured in flight when both vehicles have good attitude reference and is a critical component in calculations to transfer attitude reference from one vehicle to another. This paper will describe how the docking offset and attitude reference errors between both vehicles are measured and how this information would be used to recover Shuttle attitude reference from ISS in the event of multiple failures. During STS-117, ISS on-board Guidance, Navigation and Control (GNC) computers began having problems and after several continuous restarts, the systems failed. The failure took the ability for ISS to maintain attitude knowledge. This paper will also demonstrate how with knowledge of the docking offset, the contingency procedure to recover Shuttle attitude reference from ISS was reversed in order to provide ISS an attitude reference from Shuttle. Finally, this paper will show how knowledge of the docking offset can be used to speed up attitude control handovers from Shuttle to ISS momentum management. By taking into account the docking offset, Shuttle can be commanded to hold a more precise attitude which better agrees with the ISS commanded attitude such that start up transients with the ISS momentum management controllers are reduced. By reducing start-up transients, attitude control can be transferred from Shuttle to ISS without the use of ISS thrusters saving precious on-board propellant, crew time and minimizing loads placed upon the mated stack.

Helms, W. Jason↗

NASA NTRS2015

Investigation of the Makeup, Source, and Removal Strategies for Total Organic Carbon in the Oxygen Generation System Recirculation Loop

Since 2007, the Oxygen Generation System (OGS) on board the International Space Station (ISS) has been producing oxygen for crew respiration via water electrolysis. As water is consumed in the OGS recirculating water loop, make-up water is furnished by the ISS potable water bus. A rise in Total Organic Carbon (TOC) was observed beginning in February, 2011, which continues through the present date. Increasing TOC is of concern because the organic constituents responsible for the TOC were unknown and had not been identified; hence their impacts on the operation of the electrolytic cell stack components and on microorganism growth rates and types are unknown. Identification of the compounds responsible for the TOC increase, their sources, and estimates of their loadings in the OGA as well as possible mitigation strategies are presented.

Bowman, Elizabeth M.↗

NASA NTRSDate not supplied

Gateway Command and Data Handling Network Implementation and Validation

As initial Lunar Gateway modules approach design maturity, the Artemis Network Validation and Integration Lab (ANVIL) has begun demonstrations to validate avionics network dataflows. The flight architecture design includes utilizing Time-Triggered Ethernet (TTE) and layer-3 switching capabilities to enable greater automation and flexibility of critical and best effort traffic. Critical traffic is considered as Time-Triggered (TT), Rate Constrained (RC) and prioritized Best Effort (BE) traffic classes. End systems, such as mission computers, power control, and robotics, use three planes and all traffic classes while other devices interface via Best Effort. Typical best effort devices include video, laptops, wireless access points, and payloads. Other devices have a various hybrid approach of interfaces including alarms, telemetry/logging, and communication units. In the paper, we will present an update of the Gateway network architecture and how the system will operate nominally and during a stack topology reconfiguration. We will also discuss the network risks, and trade-offs of performance, flexibility, and redundancy. Finally, we will show the process for validation, demonstration, and verification approaches to the vehicle network.

Gateway↗

DOE OSTI2026

Public Reference Data for Megawatt-Scale Hydrogen Electrolysis - NLR Historical Wind

The U.S. Department of Energy and the National Laboratory of the Rockies (NLR) demonstrate hydrogen electrolysis from variable sources, hydrogen compression and storage, and hydrogen fuel cell power production using megawatt-scale equipment at NLR’s Flatirons Campus as part of the Advanced Research on Integrated Energy Systems (ARIES) initiative. This dataset represents part of that effort and is intended for academic, national laboratory, industrial, and other stakeholders to plan, design, and validate models of megawatt-scale hydrogen technologies and diverse energy infrastructure nationwide. These data provide a baseline for how existing hydrogen electrolysis technologies perform when coupled with various energy technologies. Future datasets will demonstrate how existing hydrogen fuel cell technologies can provide controllable, dispatchable, and variable power output for artificial intelligence (AI) data centers and other variable loads. This dataset entry describes hydrogen production by conducting a statistical analysis of historical wind data over a five-year period (2020-2025) from a single 1.5MW turbine manufactured by General Electric (GE) located at NLR’s Flatirons Campus, to generate an experimental test profile that was deployed on a 1.25-MW proton exchange membrane type MC250 electrolyzer system manufactured by Nel Hydrogen . [1] While the electrolyzer balance-of-plant supports up to 2.5 MW of electrolysis, NLR only has a single 1.25-MW electrolysis stack. The historical wind data provided several metrics, however, the analysis particularly focused on the measured power output by the wind turbine. The power output time series of data for each day was categorized by total energy generation and standard deviation, and the day that represented the highest combination of these two metrics was chosen – December 25th, 2022. This process was then repeated for a moving four-hour window within this day to identify the most statistically variable period. Finally, this four-hour period was scaled by 65% to match the 1.25 MW electrolyzer. The electrolysis system controls hydrogen production by varying DC current applied to the stack, from a maximum of 3000 A to a minimum safe operation of 300 A, or 10%. Because the current – voltage characteristic changes as the stack ages and efficiency degrades, the actual minimum safe operating power changes over time. The historical wind profiles were translated from power (kilowatts) to current (amperes) using a curve fit with calibration data and sent to the electrolyzer power supply at 1 Hz frequency. For more details on the statistical analysis process, see the presentation labeled “ Public Reference Data for Megawatt-Scale Hydrogen Electrolysis” provided with each data entry. These datasets report relevant hydrogen balance-of-plant and system data, all captured at 1 Hz, including hydrogen mass production measured with an Emerson Coriolis flow meter. Each .zip file represents a single wind turbine electrolysis experiment and is formatted as follows: {technology}_{scaling factor}-{electrolyzer ramp rate in amperes/second} For instance, “wind-GE1.5MW_0.65-400.zip” represents the hour-long experiment using historical data from the wind-GE1.5MW turbine, scaled to 65%, with the electrolyzer power supply set to a maximum ramp rate (gain and slew) of 400 A/s. Each .zip folder contains the following files: A .csv file containing raw data An .xlsx file explaining all the fields in the raw data. A .png plot showing the time series of hydrogen production, electrolysis power consumption, and wind power input. A PDF file detailing the historical wind data statistical analysis used to generate the wind profile. An experiment labeled “characterization_200.zip” demonstrates the MC250 electrolyzer steady-state response with 30-minute load steps for a total duration of 5 hours. Finally, a .csv file is provided with all simulated wind experiments combined into one dataset labeled "combined_historical_wind_experiments.csv". NLR also built an AI/machine-learning predictive model based on these datasets. The model ingests the electrolyzer current command in amperes, as well as various pressures and temperatures across the system, and predicts hydrogen output in kilograms per hour. The complete model can be found at https://huggingface.co/NatLabRockies/ptmelt-hydrogen-electrolysis [1] nelhydrogen.com/product/mc-series-electrolyser .

08 HYDROGEN↗

DOE OSTI2022

Proton-Conducting Ceramic Electrolyzers for High-Temperature Water Splitting

This project is centered on an exciting new class of proton-conducting ceramic materials that are emerging from the laboratory to play important roles in the commercial sector. While proton-conducting ceramics have been studied since the early 1980s, the unique properties of these materials are only now being harnessed to address societal challenges. The objective of this project is to develop advanced high-temperature water splitting (HTWS) systems for production of hydrogen at a cost less than $2 / kg H2. The specific objectives include development of efficient and durable electrolytic cells and stacks using innovative proton-conducting ceramic materials and operating at a temperature ≥ 500°C. The technical performance targets for the electrolysis stack include: specific resistance of ≤ 0.30 Ω cm 2 , stack electrical efficiency > 95% LHV H2 with current density > 1 A / cm 2 , and a projected stack lifetime of ≥ 7 years. In this program, FuelCell Energy (FCE) teamed with Colorado School of Mines (CSM) to deliver a novel protonic-ceramic electrolysis cell (PCEC) stack capable of producing over 1 kg H2 / day. These targets were demonstrated in an HTWS stack with a capacity for producing ≥1 kg H2 / day.

08 HYDROGEN↗

DOE OSTI2023

Environmental Air Monitoring at LANL: 2023 External Program Assessment [Slides]

Radioactive Air Emissions Management evaluates radiological impacts of LANL operations on members of the public, identifies and quantifies releases, and assesses impacts. It is not directly affiliated with cleanup operations or programmatic work and has independent oversight. The focus areas in Environmental Compliance Programs are stack emissions measurements, ambient air measurements, minor source operations evaluations, data management and quality assurance, collaboration with Meteorology program, and collaboration with Dose Assessment program (EPC-ES).

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2022

Red-Ox Robust SOFC Stacks for Affordable, Reliable Distributed Generation Power Systems

While SOFC systems are expected to operate reliably and with limited degradation in steady state or transient performance, SOFC stacks may ultimately fail due to the loss of structural integrity of one or several of the cells as a result of the weakening of the materials and interfaces due to physico-chemical changes that occur during continuous operation as a result of plastic and creep deformations, modification of the temperature profile, and/or degradation of the electrochemical performance of the cells. Degradation mechanisms originating from the cell components include coarsening of the microstructure over time; decomposition of materials; chemical reaction of electrode materials with electrolyte at the interface; delamination from each other; and for the anode, coking and sulfur poisoning. Of all the reliability issues that may occur for SOFCs, the main limitation for Ni-based cermet anodes (e.g., NiO-YSZ) is the poor stability during reduction-oxidation (red-ox) cycling. This project was aimed at the development of ceramic anode SOFCs based on SFCM (SrFe0.2Co0.4Mo0.4O3), which is a conductive perovskite that is red-ox stable. Additionally, the project involved the development of a red-ox robust stack. Scale up of SFCM-based cells to a large format (10 cm by 10 cm) cell size was achieved as well as a maximum power density of 0.9 W/cm 2 at 600 °C (>0.6 W/cm 2 at 0.6 V). Up to a 10-cell stack was successfully assembled and demonstrated, and cells showed similar performance in reformed, pipeline natural gas as in hydrogen. Finally, a 3-cell stack was red-ox cycled without degradation for 40 cycles at ~600 °C.

03 NATURAL GAS↗