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All sources NASA NTRS DOE OSTI

DOE OSTI2023

Durable Low-Cost Pressure Vessels for Bulk Hydrogen Storage

Long-duration energy storage (LDES) in the form of gaseous hydrogen is vital for fossil fuel power plants to reduce frequent shutdowns and rapid start-ups. It's also crucial in renewable energy power plants for grid stabilization. WireTough Cylinders (WTC) has developed a Type II-S pressure vessel that uses steel liners that are hoop-wrapped with multiple layers of high-strength, cost-effective, and readily available steel wires. This design enables the vessel to withstand significantly higher pressures. It addresses hydrogen embrittlement issues and cyclic loading from repeated pressurization and depressurization during service. The WireTough design is cost-efficient, robust, and fatigue-resistant (with a 30-year design life) and is ASME certified for ground storage of hydrogen at a maximum operating pressure (MOP) of 350 bar and a design pressure of 500 bar. The cylinder has a 645 mm outside diameter and a water capacity of 1,715 liters, capable of storing 40.7 KG of hydrogen at MOP. Two prototypes were successfully produced to showcase the manufacturing technologies, with one being certified under ASME Section VIII Division 3 rules. Preliminary design work for a similar Type II-S vessel with a 500 bar MOP was also completed. The 350 bar and 500 bar Type II-S vessels were shown respectively to be 47.5% to 60% more cost-effective and 55% and 62.5% lighter based on per KG of hydrogen stored, when compared with their Type 1 counterparts.

08 HYDROGEN↗

DOE OSTI2024

LLNL FESP Theory Highlights: October 2024

I. Novikau, I. Y. Dodin, E. A. Startsev, I. Joseph, Quantum algorithms for simulating dissipative linear and nonlinear dynamics of plasmas. Invited talk at the 66th Annual Meeting of the APS Division of Plasma Physics, Atlanta, Georgia. Novikau I., Dodin I.Y., Startsev E.A., Encoding of linear kinetic plasma problems in quantum circuits via data compression, Journal of Plasma Physics. 2024;90(4):805900401, doi:10.1017/S0022377824000795. We propose an algorithm for encoding linear kinetic plasma problems in quantum circuits. The focus is on modelling electrostatic linear waves in a one-dimensional Maxwellian electron plasma. The waves are described by the linearized Vlasov–Ampère system with a spatially localized external current that drives plasma oscillations. This system is formulated as a boundary-value problem and cast in the form of a linear vector equation to be solved by using the quantum signal processing algorithm. The latter requires encoding of a matrix in a quantum circuit as a sub-block of a unitary matrix. We propose how to encode in a circuit in a compressed form and discuss how the resulting circuit scales with the problem size and the desired precision.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2025

Pacific Northwest National Laboratory Facility Radionuclide Emission Points and Sampling Systems

Battelle–Pacific Northwest Division operates numerous research and development laboratories in Washington State. The U.S. Department of Energy (DOE) contracts to Battelle at Richland facilities on both the DOE Hanford Site and the Pacific Northwest National Laboratory (PNNL) Richland campus. These facilities have the potential for radionuclide air emissions. The PNNL contract with DOE also includes operations at the PNNL-Sequim campus in Sequim, where there is also the potential for radionuclide air emissions. This document is a periodic update that describes current PNNL facility emission units and sampling systems. The National Emission Standard for Hazardous Air Pollutants (NESHAP [40 Code of Federal Regulations 61, Subpart H]) requires an assessment of all emission units that have the potential for radionuclide air emissions. Emission units are registered with the State of Washington. Potential emissions from emission units are assessed annually by PNNL staff. Sampling, monitoring, and other regulatory compliance requirements are designated based on the potential to-emit dose criteria, a graded approach to facility-identified potential impact categories, and regulatory requirements. The purpose of this document is to describe the facility radionuclide air emission sampling program and provide current and historical facility emission unit system performance, operation, and design information. For sampled emission units, the building, exhaust unit, control technologies, and sample extraction details are provided. Additionally, applicable configuration drawings, figures, and photographs are included. For non-sampled emission units, emission estimation and radionuclide source details are provided. Site-wide permits for the lowest potential impact category are described. Deregistered/transitioned emission unit details are also provided as necessary for at least 5 years post-closure/transition. Currently, five emission units are sampled continuously for particulate radionuclides at PNNL managed facilities on the PNNL-Richland campus (3 of the 5) and on the Hanford Site (2 of the 5). Four of these units have sampling systems that comply with the American National Standards Institute/Health Physics Society (ANSI/HPS) N13.1–2011 standard for sampling from stacks and ducts of nuclear facilities, and the fifth is grandfathered and compliant with the older ANSI N13.1–1969 standard. In addition, the PNNL-managed Hanford Site 325 Building EP 325-01-S stack is sampled continuously for emissions of tritium. No emissions sampling is required for the single licensed emission unit on the PNNL-Sequim campus.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2025

Replacement of Clerestory Windows at TA-03-0039 Technical Shops Building

The U.S. Department of Energy, National Nuclear Security Administration, Los Alamos Field Office (Field Office) proposes an undertaking to replace 86 clerestory windows in Building 39 in Technical Area 3 (Technical Shops Building; TA-03-0039) at Los Alamos National Laboratory. TA-03-0039 was evaluated and determined eligible for listing in the National Register of Historic Places in a report titled ESA Division’s Five-Year Plan: Consolidation and Revitalization at Technical Areas 3, 8, 11, and 16. This determination was concurred on by the State Historic Preservation Office on June 22, 2003 (McGehee et al. 2003).

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2025

2024 Results for Avian Monitoring at the Technical Area 36 Minie Site, Technical Area 39 Point 6, Technical Area 16 Burn Ground, and DARHT at Los Alamos National Laboratory

Los Alamos National Laboratory (LANL) biological subject matter experts in the Environmental Protection and Compliance Division initiated a multi-year program in 2013 to monitor avifauna (birds) at two open detonation sites and one open burn site on LANL property. Additional monitoring began in 2017 at a third firing site, the Dual-Axis Radiographic Hydrodynamic Test (DARHT) Facility. In this annual report, we compare monitoring results from these efforts among years to identify and evaluate firing and open burn site impacts on the local bird community. The objectives of this study are • to determine whether LANL operations impact bird abundance, species richness, or diversity; • to examine occupancy and nest success of secondary-cavity nesting birds that use nest boxes; and • to examine chemical concentrations (such as radionuclides, inorganic elements, and/or organic compounds) in nonviable eggs and deceased nestlings that are collected opportunistically with the upper-level bounds of background concentrations, when available. During May through July 2024, LANL biologists completed multiple avian point count surveys at each of the following treatment sites: • Technical Area (TA) 36 Minie Site, • TA-39 Point 6, • TA-16 Burn Ground, and • DARHT. We recorded a total of 1,088 birds that represented 65 species at the four treatment sites and compared these results with data from their associated control sites. In 2024, abundance and species richness at treatment and control sites continued to trend similarly from year to year, with minor random deviations expected from bird communities. Species richness at firing sites differed little from the previous year’s values. Two new bird species were observed at the firing sites—cedar waxwing (Bombycilla cedrorum) and pinyon jay (Gymnorhinus cyanocephalus). Shannon diversity values at TA-36 Minie Site, TA-39, and DARHT were statistically higher than one or more of their associated controls. Annual species diversity at treatment sites was high in 2024 across all firing sites relative to similar habitat control sites. We also monitored avian nest boxes to compare occupancy and nest success data from nest boxes at treatment sites with the overall avian nest box monitoring network and against a subset of relevant control sites. Nest box success has decreased at both treatment and control sites since monitoring began, suggesting that overlapping climatic factors are responsible for patterns of declining nest success. In 2024, nonviable avian eggs and one nestling were opportunistically collected at Bandelier National Monument, TA-16 Burn Ground, TA-36 Minie, TA-39 Point 6, and DARHT. All egg samples and the one nestling sample were evaluated for per- and polyfluoroalkyl substances, which were detected from all locations, including the control site at Bandelier National Monument. Overall results from 2024 continue to suggest that operations at the four treatment sites are not negatively impacting bird populations. This long-term project will continue to monitor for any changes over time.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2024

Analysis of Supply Chain Challenges in the U.S. Solar Industry: Focus on Build America, Buy America Act and Inverter Supply Issues

The United States (U.S.) solar industry has been undergoing significant transformation, driven largely by meeting U.S. climate goals while simultaneously maintaining national security. At the forefront of this movement is the Inflation Reduction Act (IRA) and the Build America, Buy America (BABA) Act. The IRA has driven investment in clean energy generation deployments while the BABA Act, enacted under Division G, Title IX of the Infrastructure Investment and Jobs Act (IIJA) establishes domestic content procurement preference for all federal financial assistance obligated for infrastructure projects. While these pieces of legislation aim to reduce reliance on foreign-made solar components and increase domestic production, the sector continues to face notable supply chain challenges. These are particularly pronounced with inverters, a critical component in solar photovoltaic (PV) systems. This report explores the current state of these supply chain challenges, with a specific focus on the impact of the BABA requirements and the associated complexities in inverter manufacturing and supply.

14 SOLAR ENERGY↗

DOE OSTI2025

Electrocatalyst Engineering and Device Benchmarking for Low Temperature CO2 Electrolysis

This oral presentation is for an invited talk in Division of Energy and Fuels, Symposium: "CO2 Conversion and Utilization-II: Electrochemical CO2 Conversion to Fuels and Valuable Chemicals" at ACS Spring 2025 (March 23-27, 2025) in San Diego, CA. The presentation will primarily discuss the crucial role of electrocatalyst design in the CO2 conversion to sustainable, carbon-neutral gas and liquid products. Some preliminary benchmarking studies of off-the-shelf electrocatalysts will be also shown in different device configurations to achieve good selectivity at industrially relevant current densities.

CO2 electrochemical reduction↗

DOE OSTI2025

A Quantum Approach for Implementing Fixed-Point Arithmetic in Solving Ordinary Differential Equations

Differential equations (DEs) serve as fundamental tools in mathematical modeling across scientific disciplines, yet classical numerical solvers face limitations with large-scale or computationally intensive problems. This study explores a quantum-inspired approach to solving DEs, combining quantum- inspired techniques with classical methods. It focuses on fixed- point arithmetic on quantum circuits, utilizing basic quantum gates to manipulate DE solutions. We expand upon the techniques introduced by Zanger et al. [Quantum, 5, 502 (2021)] by offering a precise computation for a fixed-point signed multiplication scheme, while also presenting a quantum circuit capable of executing the fixed-point division algorithm. We demonstrate the feasibility of our approach through the simulation of a linear Ordinary Differential Equation (ODE), where initial conditions and parameters are encoded into quantum circuits using fixed- point representation. By executing sequences of quantum gates mimicking numerical integration steps, we obtain approximate solutions to the ODE with specified fixed-point precision.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2025

Modified 316H constitutive model updated with high temperature stress relaxation test data

This report describes the calibration of a new high temperature constitutive model for 316H stainless steel, suitable for use with the ASME Boiler & Pressure Vessel Section III, Division 5, Class A rules for design by inelastic analysis. The model retains the same mathematical form used by the reference model included in Nonmandatory Appendix Z of the Code, but refits the model to an expanded dataset including all the data used to fit the original model plus seven new stress relaxation tests. The addition of these high temperature stress relaxation tests improves the model's accuracy in predicting relaxation at temperatures greater than 700 ⁰C, without compromising the accuracy of the model versus the original calibration data.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Findings on subtask 3.3 – applicability of automated brine chemistry determinations for treatment and recovery processes through facility automation/modularization: engineering design study

Under the Energy & Environmental Research Center’s (EERC’s) ~$\$$22 million Phase II Brine Extraction and Storage Test (BEST) Program, a multimillion-dollar brine treatment technology test bed facility was established in western North Dakota to provide a platform for evaluating developing technologies and approaches for brine treatment and volume reduction. The initial facility, and associated research effort, was funded by the U.S. Department of Energy (DOE), with in-kind contributions provided by several industry participants and the state of North Dakota. Since its opening, the Brine Technology Test Facility (BTTF) has supported performance evaluations of desalination technologies capable of treating high-salinity produced water (PW) and enabled data collection for multiple approaches of PW management and critical material recovery. As part of the decommissioning process for the original project, facility ownership and liability were transferred to Select Water, which is providing the EERC with a continuing site access option for state or federal research and/or commercial technology development. This report documents the findings from a design study conducted by the EERC and the engineering firm that was originally contracted to design and construct the facility (Advanced Engineering and Environmental Services, LLC [AE2S]) that evaluated the current status of BTTF and its systems and developed a retrofit design to increase the facility’s capabilities through automation and modularization of its PW treatment infrastructure. The proposed retrofit will provide DOE and industry with an expanded range of conditioned PW that can be produced at the facility for evaluating fit-for-purpose water treatment technologies, online instrumentation for brine chemistry determination, and systems that recover critical materials like lithium and magnesium. The current facility consists of an 9600-square-foot facility that includes a 40-foot by 65-foot Class 1, Division 2-rated demonstration area and associated control rooms and lab-ready space capable of sourcing oil and gas PW and wastewater from industrial sources or tailoring brine compositions up to 300,000 mg/L total dissolved solids (TDS) and supplying them at rates up to 25 gpm for extended-duration technology demonstrations. The colocation of the facility with Select Water’s water management facilities allows for access and unloading of more than 10,000 bbl/day of trucked water delivered to site and associated access to on-site Class I and Class II brine disposal wells and nearby hazardous waste landfills operated and/or contracted by Select Water to dispose of concentrate and/or effluents associated with the testing.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Advancing 1D thermo-hydraulic tools for large cryogenic facilities

The Cryogenic Division at Fermilab develops large-scale cryogenic systems for particle accelerators and superconducting test facilities. To support design and diagnostics, a Python-based code was created to calculate pressure drops in components such as valves and pipes. This paper presents recent enhancements to the code, including new heat transfer functions that improve the accuracy of thermal and hydraulic predictions. The first application models pressure and temperature changes in PIP-II relief pipes, aiding pipe sizing and protecting relief valves. The second example analyzes heat load evolution in a pipe carrying sub-atmospheric helium, helping interpret temperature sensor data and understand gas return behavior to cold compressors. These improvements significantly expand the tool’s capabilities, offering a practical resource for designing and troubleshooting cryogenic systems under dynamic thermal and flow conditions.

Beckwith, Rosalyn [Fermilab]↗

DOE OSTI2025

Helium recovery system at IB3a

The increasing need for optimal and sustainable use of cryogenic resources to support Fermilab’s scientific mission has highlighted the necessity of improving the Laboratory’s helium management practices. An assessment of cryogenic test facilities identified the Technical Division’s Industrial Building 3a (IB3A) as a key site requiring upgrades to integrate a helium recovery system. The IB3A facility is essential for characterizing and testing superconductors, cables, and coils for various R&D projects, including the US High-Luminosity LHC Accelerator Upgrade Project (AUP), Mu2e, and other external collaborations. Currently, the facility relies on 500 L helium Dewars and vents the vaporized helium directly into the atmosphere, leading to significant helium loss. Given the non-renewable nature of helium, recovering and reusing this resource is critical for the sustainability of Fermilab’s operations. To address this challenge, a project has been initiated to connect IB3A to an existing helium purification station and refrigeration system located in another building via a dedicated pipeline pass over the roof of several buildings. This solution will enable the efficient capture of vented helium, its transfer to the purification station, and subsequent liquefaction for reuse in future operations. The project includes a detailed design phase, specifying the pipeline route, flow control mechanisms, and integration with the existing cryogenic infrastructure, followed by phased implementation and commissioning. By implementing this pipeline connection and upgrading IB3A, Fermilab aims to significantly reduce helium waste, lower operational costs, and align with its commitment to sustainability. This initiative provides a model for resource-efficient cryogenic operations and reinforces the Laboratory’s capacity to support its science mission for the long term.

Porwisiak, D. [Fermilab]↗

DOE OSTI2024

Improved digital construction binder solution utilizing calcium aluminate additive for Infrastructure Scale Additive Manufacturing

Oak Ridge National Laboratory (ORNL) worked with Kerneos Inc., a Division of Imerys USA, Inc. to develop an improved digital construction binder using calcium aluminate additives produced by Kerneos along with locally available concrete materials. When the two-stage (2K) binder formulation was added to commercially available Portland Limestone Cement and sand to form a digital construction mortar, its strength exceeded a number of commercially available digital construction binders both at early and later ages. At the same time, the developed formulation showed precise control of setting time after addition and showed very low shrinkage making it a strong, reliable, and easily customizable alternative to fixed proprietary digital construction binders.

36 MATERIALS SCIENCE↗

DOE OSTI2025

FY25 Status Update on A709 Code Case Testing at ANL

This report provides an update on the status of the creep rupture testing on the precipitation-treated (PT) Alloy 709 samples fabricated from the first, the second and the third commercial heats, in support of the first, 100,000-hour Alloy 709 Code Case development under the American Society of Mechanical Engineers (ASME) Section III, Division 5 for high-temperature reactor construction. In Fiscal Year (FY) 25, no new tests were initiated, while 5 previously loaded tests were completed. This report presents an overview of the creep-rupture data gathered at Argonne National Laboratory (ANL) since FY21 that totaled 52 completed tests. Metallographic images showing crack morphologies in some representative samples ruptured in FY25 are also included. Key conclusions include: 1) the creep behavior of the three heats of Alloy 709 can be well described by the Larson-Miller relationship; 2) higher temperatures and larger stresses lead to shorter creep life and higher minimum creep rate; 3) Alloy 709 is overall very ductile under creep; 4) the crack morphologies near fracture surfaces are dependent on material’s grain size and test conditions.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2025

Improved digital construction binder solution utilizing calcium aluminate additive for Infrastructure Scale Additive Manufacturing

36 MATERIALS SCIENCE↗

DOE OSTI2024

Classification Using Support Vector Machines with Uncertainty Quantification

Binary classification using machine learning is needed to address engineering problems such as identifying passing/failing parts based on measured features from aging hardware. In these classifications, providing the uncertainty of each prediction is essential to support engineering decision making. One popular classifier is the support vector machine (SVM). There are many variations, with the simplest being a linear division between two classes with a hyperplane. Kernel methods can be implement

Taylor, Sofia Nitsche↗

DOE OSTI2021

Annual Site Environmental Report: 2020 (ASER) for the SLAC National Accelerator Laboratory

To satisfy the requirements of the United States Department of Energy (DOE) SLAC Site Office approved Site Compliance Plan for DOE Order 231.1B (Change 1, 2012, “Environment, Safety and Health Reporting,” the Environment, Safety and Health Division (ES&H) of the SLAC National Accelerator Laboratory prepares an annual report describing its environmental programs and activities. This Annual Site Environmental Report: 2020 summarizes the SLAC National Accelerator Laboratory compliance with standards and requirements, describes the management and monitoring systems in place, and highlights significant accomplishments for the year.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2020

Annual Site Environmental Report: 2019 (ASER) for the SLAC National Accelerator Laboratory

To satisfy the requirements of the United States Department of Energy (DOE) SLAC Site Office approved Site Compliance Plan for DOE Order 231.1B, “Environment, Safety and Health Reporting,” the Environment, Safety and Health Division (ES&H) of the SLAC National Accelerator Laboratory prepares an annual report describing its environmental programs and activities. This Annual Site Environmental Report: 2019 summarizes the SLAC National Accelerator Laboratory compliance with standards and requirements, describes the management and monitoring systems in place, and highlights significant accomplishments for the year.

54 ENVIRONMENTAL SCIENCES↗