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DOE OSTI2024

Autonomous thermal tracking reveals spatiotemporal patterns of seabird activity relevant to interactions with floating offshore wind facilities

Planning is underway for placement of infrastructure needed to begin offshore wind (OSW) energy generation along the West Coast of the United States and elsewhere in the Pacific Ocean. In contrast to the primarily nearshore windfarms currently in the North Atlantic, the seabird communities inhabiting Pacific Wind Energy Areas (WEAs) include significant populations of species that fly by dynamic soaring, a behavior dependent on wind and in which flight height increases steeply with wind speed. Therefore, a more precise and detailed assessment of their 3D airspace use is needed to better understand the potential collision risks that OSW turbines may present to these seabirds. Toward this end, a novel technology called the ThermalTracker-3D (TT3D), which uses thermal imaging and stereo vision, was developed to render high-resolution (on average within ±5 m) flight tracks and related behavior of seabirds. The technology was developed and deployed on a wind-profiling LiDAR buoy in the Humboldt WEA, located 34 to 57 km off California’s coast. During the at-sea deployment between 24 May and 13 August 2021, the TT3D successfully tracked birds moving between 10 and 500 m from the device, around the clock, and in all weather conditions; a total of 1407 detections and their corresponding 3D flight trajectories were recorded. Mean altitudes of detections ranged 6-295 m above sea level (asl). Considering the degree of overlap with anticipated rotor swept zones (RSZ), which extend 25-260 m asl, 79% of detected birds (per m 3 of airspace) moved below the RSZ, 21% moved at heights overlapping the RSZ, and another 0.04% occurred at heights exceeding the RSZ. The high-resolution tracks provided valuable insight into seabird space use, especially at heights that make them vulnerable to collision during various environmental conditions (e.g., darkness, strong winds). Observations made by the TT3D will be useful in filling critical knowledge gaps related to estimating collision and avoidance between seabirds and OSW facilities in the Pacific and elsewhere. Future research will focus on enhancing the TT3D’s identification capabilities to the lowest taxon through validation studies and artificial intelligence, further contributing to seabird conservation efforts associated with OSW.

17 WIND ENERGY↗

DOE OSTI2024

Baseload Hydrogen Production Using Nuclear and Renewable Energy: A Comparative Analysis

As the global push towards net zero carbon gains momentum, the demand for clean hydrogen is expected to grow rapidly across various sectors, including transportation, industries and electrical grids. To meet this growing hydrogen demand, baseload hydrogen production facilities capable of providing a continuous and reliable supply of hydrogen will be necessary throughout the world. This paper explores the technoeconomic feasibility of establishing baseload electrolytic hydrogen production facilities in the United States, utilizing different clean generation resources. The key criteria include maintaining a consistent supply of clean hydrogen without putting baseload demand stress to already vulnerable power grid. In order to do that, the proposed facilities will host onsite clean power generation and energy storage technologies. The proposed facilities can capitalize on available investment and production incentives and have ability to export excess electricity to the utility at a bulk price. Several scenarios are considered based on the clean energy resources to support the electrolysis process including light water reactors (LWRs) currently evaluating retirement options, wind, solar PVs, and advanced small modular reactors (SMRs). For each scenario, a hypothetical hydrogen production facility is considered in a location in the US where the primary generation resource is at its peak strength. Comparative analysis in this paper reveal that the nuclear power plants are most economically viable for baseload hydrogen production facilities, outperforming renewable-based facilities with significantly lower levelized cost of hydrogen (LCOH). Even under best-case scenarios for resource availability, incentives and export prices, renewable-based facilities face challenges due to daily and seasonal generation variability, resulting in large installation sizes and lower capacity factors. Among renewable-based facilities, complementarity hybrids, providing more stable power supply, demonstrate superior economics compared to facilities based on a single renewable technology. While LWR-powered facility can achieve a negative LCOH with incentives, SMR-powered facilities can provide economic hydrogen supply with LCOH below $1/kg with high temperature electrolysis option. The analysis in this paper underscores the pivotal role of nuclear energy in the future hydrogen economy.

08 - HYDROGEN↗

DOE OSTI2021

Long-term carbon emission reduction potential of building retrofits with dynamically changing electricity emission factors

Buildings account for approximately 36% of the United States' total carbon emissions and building retrofits have great potential to reduce carbon emissions. Current research adopts a constant electricity emission factor although it changes over time due to the increase of renewable energy generation. Here, to accurately predict emission reduction potential of building retrofits, this study develops a novel method by using dynamically changing electricity emission factors. Using medium office buildings as an example, we predicted emission reduction of eight building retrofit measures from 2020 to 2050 in five locations in the U.S. with distinct climates and renewable adoption rates. To evaluate emission reduction potential sensitivity to the compositions of electricity generation, five scenarios for renewable energy adoptions are investigated. The results reveal several new phenomena on emission reduction potential of building retrofits for medium offices in the U.S.: (1) it decreases from 2026 to 2050; (2) it has the same trend with coal usage; and (3) it reaches the maximum under the high renewable cost scenario. Based on the results, it is recommended that building retrofits should focus on 1) improving lighting and equipment efficiency; 2) locations with higher coal usage rate, and 3) buildings under the high renewable cost scenario. The new method can also be used for predicting emission reduction potential of the building sector in the U.S. by applying to other building types and regions.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2022

COVID-19 impacts on residential occupancy schedules and activities in U.S. Homes in 2020 using ATUS

Many aspects of the daily lives of those living in the United States were substantially impacted by the COVID-19 pandemic in the year 2020. A broad diversity of measures was implemented to curb the spread of the virus, many of which included adjustments to where and how people worked, went to school, and otherwise conducted their daily lives compared to pre-pandemic times. This has impacted how residential buildings are used, how much time people spend in their homes, and as a result, how much energy these buildings consume. The main objective of this study is to analyze, at a national scale, the differences in the occupancy schedules and activities conducted in homes in the U.S., as compared to pre-pandemic. 15 years of American Time Use Survey and Current Population Survey data, from 2006 to 2020, was used in this study to analyze the occupancy schedules for both pandemic (2020) and pre-pandemic (2006–2019) times. These impacts were also analyzed with respect to variables including, weekday/weekend, month of the year, age of the occupants, household income, and household size. The impact of the pandemic on occupant schedules were most substantial in the initial months, whereas as the months progressed, these occupancy profiles slowly changed. Across 2020, people spent, on average, 8 % more time (1.9 h) in their home on weekdays, and 3–6 % (1.2 h) on weekend days. The percentage of time spent for different activities and locations within homes were also studied. For 1-member households, their time spent at home decreased whereas for 2-, 3-, and 4- member households, they spent more time at home. Overall, people spent around 45% more time doing office- and work-related activities at home compared to pre-pandemic, which is likely due to increased remote working and schooling. This research helps to improve the understanding of the occupancy presence and absence profiles in U.S. residential buildings due to the pandemic and provides new insights as to modified profiles for researchers, building designers, and policy makers.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

Integrating a Microgrid Controller with a Local OpenADR Server

When military microgrids isolate themselves from the main electrical grid, they must locally balance electricity supply and demand. Since local generation may be limited, the current strategy is to shed all but the most critical loads by tripping smart circuit breakers, which must then be reset manually (e.g., ESTCP project EW-201350). This strategy is typically applied at the building level, meaning that entire buildings housing mission critical activities must be excluded from any load management, while those considered non-critical may lose service entirely. The remotely controlled switchgear needed to manage load in this way is very expensive ($\$30,000$-$\$50,000$ per building). While effective at shedding load, this strategy disrupts installation operation and risks damaging equipment during both disconnection and re-energization. With the goals of lowering costs, protecting equipment, and enhancing the agility of DoD microgrids, this report demonstrates the use of cybersecure automated demand response (ADR) technology to manage microgrid loads during grid-independent (a.k.a. "islanded") operation. This automated approach achieves load shedding and shifting through communication signals sent to equipment controllers rather than by cutting off the flow of electricity within the microgrid itself. Because it operates only on the base network, with no connection to external entities, this strategy avoids the main cybersecurity concern raised by past applications of ADR on military bases.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2023

Spectroscopic Investigations of Molecular Symmetry Breakdown

This project addressed precise measurements of the spectra of molecules to address fundamental questions in chemical physics in the realm of nuclear spin symmetries and their breakdown in molecules, and parity non-conservation caused by the weak nuclear force. Nuclear spin symmetry is intimately connected to parity in symmetrical molecules and plays a central role in the physical and chemical properties of symmetric molecules, their collisional relaxation, and the establishment of thermodynamic equilibrium in an ensemble. Such effects are present in every molecular system or process, but their small size means they are often only directly observable under special conditions. However, their measurement is of fundamental, and often practical importance, and strongly relates to the themes of coherence in light and matter in the recent Basic Energy Sciences Advisory Committee (BESAC) report “Challenges at the Frontiers of Matter and Energy: Transformative Opportunities for Discovery Science”. We begin by addressing lifetime broadening of spectroscopic lines caused by self-collisions in acetylene, where efficient resonant rotational energy transfer between a pair of molecules separated in energy by rotational quantum number ΔJ = ± 2, can result in a different pressure broadening for ortho- and para- nuclear spin state molecules. This work was prompted by a controversial report [Iwakuni et al. Phys. Rev Letts. 117 (2016) 143902] of the observation of such an effect in the v 1 +v 3 combination band transition of acetylene discussed in the original proposal. After delays caused by the COVID-19 pandemic, we have completed these measurements and a paper was published in the Journal of Chemical Physics describing the work. The measurements pointed out that the use of an approximate model in the analysis of the original work was the cause of the erroneous conclusion that ortho and para acetylene molecules had substantially different collisional lifetime broadening. In the process, much improved broadening measurements have been made that will permit more reliable modeling of the effects in the future. Subsequently, we have completed a new set of measurements of self- and nitrogen-collisional broadening at a series of low and intermediate temperatures to characterize the temperature dependence of the effects in the molecule. This work is currently being analyzed and will be the subject of a paper to be published in the relatively near future. In addition, some very preliminary measurements of CH 4 as described in the proposal, have been completed. If facilities and time permit, these will continue as an undergraduate research project.

74 ATOMIC AND MOLECULAR PHYSICS↗

DOE OSTI2026

Theory Guided Fine‐Tune of Strain Effects in Pt Ternary Alloy via Rare Earth Templating: Achieving High Performance PEMFCs Catalysts

The sluggish kinetics and insufficient durability of platinum-based catalysts remain crucial barriers limiting proton-exchange-membrane fuel cells (PEMFCs) deployment. Here, we report a theory-guided synthesis combined with rare-earth templating to realize a previously inaccessible Pt 5 Co-like phase with tailored atomic-scale strain. Guided by density functional theory (DFT) calculations, we identified that a Pt 5 Co-like sublayer can induce a unique mild compressive strain (−1.24%) to the Pt(111) shell and an optimal *OH binding energy shift (ΔE ≈ 0.11 eV). This shift positions the alloy catalyst near the apex of the oxygen reduction reaction activity volcano. This prediction guided the synthesis of ternary alloy Pt 5 (Ce)Co@Pt multilayer nanoparticles, featuring a Ce-stabilized core, a Pt 5 Co-like sublayer, and a Pt-rich shell. This catalyst demonstrates both exceptionally high activity and durability, achieving a mass activity of 2.6 A∙mg Pt −1 in rotating disk electrode testing. In fuel cell membrane electrode assembly tests, Pt 5 (Ce)Co@Pt achieves a current density of 1.9 A∙cm −2 at 0.7 V under heavy-duty vehicle conditions. Remarkably, it maintains 1.2 A∙cm −2 after 1 80 000 AST cycles, doubling the U.S. DOE 2025 target. This work demonstrates a rational design strategy that DFT-guided strain engineering integrates with rare-earth templating to advance Pt-based catalysts for fuel cell applications.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2023

Multifamily Building Stock Modeling: Cooperative Research and Development Final Report, CRADA Number CRD-17-00701

U.S. multifamily buildings house 35 million households, consuming 4 quads of source energy and spending $48 billion on utility bills every year. Almost all of these households live in urban areas, where cities are taking the lead on setting aggressive energy goals. Cities currently do not have the data and tools necessary to identify and target opportunities to save energy in their building stock. Building on the open-source, OpenStudio-based ResStock platform, this project will extend the publicly-available ResStock modeling capabilities to the multifamily sector, enabling Radiant Labs, and others, to partner with cities to market and strategically deploy cost-effective, energy efficiency (EE) upgrades directly to high-priority households. Radiant Labs has been successful in using ResStock's single-family capabilities to provide value to the City of Boulder, Colorado. However, lack of multifamily capabilities in ResStock is a roadblock for Radiant Labs working with New York City, San Francisco, Washington, D.C., and other cities that have expressed significant interest in working with them. In addition, other cities, companies, and utilities can use these open-source capabilities to grow their EE portfolios, thereby multiplying the impact of this project. This work also enables national-scale analysis of EE potential in multifamily buildings, which is of strong interest to a variety of stakeholders, including the U.S. Department of Energy (DOE) Office of Energy Policy and Systems Analysis (EPSA), DOE Weatherization Assistance Program (WAP), U.S. Department of Housing and Urban Development (HUD), and the Bonneville Power Administration (BPA).

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2022

Achieving 50% Energy Savings in Chicago Homes: A Case Study for Advancing Equity and Climate Goals

Since 2019, the National Renewable Energy Laboratory (NREL) and Elevate have collaborated to identify pathways to deep energy retrofits in Chicago's housing stock, document equity implications and co-benefits of this transition, and validate the findings by implementing retrofits in real Chicago homes. This document summarizes our analysis process to model advanced retrofit packages that lead to greater than 50% energy savings in Chicago homes. Based on these findings, we have also developed a roadmap with the City to guide implementation, and are deploying the recommended retrofit packages in real Chicago homes to realize these energy savings. This work was developed in collaboration with two key stakeholders - the City of Chicago and Commonwealth Edison (ComEd) - and funded by the U.S. Department of Energy (DOE). NREL's Residential Buildings team maintains the best-in-class ResStock™ energy model of the U.S. residential building stock. For this work, we calibrated ResStock to Chicago's unique local housing stock to accurately simulate energy use in Chicago homes both for current conditions and with various retrofit scenarios. We simulated a wide range of potential building retrofits covering all aspects of residential energy use and then grouped these into packages based on energy and utility bill savings. ResStock can model diverse building types and housing characteristics, so we're able to observe the range of outcomes that might occur when these upgrades are deployed across the entire housing stock. We can then estimate potential energy savings from an advanced retrofit program on Chicago's housing stock by comparing the modeled energy use before versus after a retrofit. This novel version of ResStock, calibrated to Chicago with data from Elevate, can help City officials, ComEd, and other partners plan for community-scale decarbonization via residential retrofits. Specifically, this work contributes the following project goals: Develop a building retrofit prioritization strategy for Chicago single-family and 2- to 4-unit buildings; Identify neighborhoods and home types that have the highest potential for savings from electrification; and Assess the impact of advanced building retrofits on energy use, utility bills, and CO2 emissions at the city and building level. Although this study is specific to Chicago, its methods and learnings are applicable across the United States. These findings are especially notable for heat pumps and electrification retrofits in cold climates.

building energy modeling↗

DOE OSTI2023

Effects of additively manufactured surface roughness on small diameter plenums with multiple side discharges for high temperature gas turbine blade cooling applications

Combined heat and power (CHP) applications have significant environmental and economic benefits that are consistent with the goals of the U.S. Department of Energy (DOE). One area that is currently being studied includes the potential benefits of CHP turbine operation at higher turbine inlet temperatures. Internal cooling concepts enabled by additive manufacturing (AM) are of primary interest. Here, the effectiveness of internal cooling is hindered by many factors such as velocity distribution of the cooling air to the hot surface considering impingement cooling. To simulate cooling air exiting from a series of orifices for internal cooling in an airfoil, a straight smooth wall tubing with multiple side discharging orifices is used and compared to additively manufactured tubing (Ti6Al4V Grade 23) with orifice size and spacing as well as inner and outer diameters identical to the smooth wall tubing. Similar to flow discharging form perforated pipes, the flow discharged from individual orifices along the tubes in this study is found to be nonuniformly distributed, and the horizontal (axial direction) momentum can be observed from the experimental data. Discharge velocities have been measured with two-dimensional (2D) particle imaging velocimetry (PIV) and single element hot wire anemometry. Numerical analysis has also been conducted to predict the velocity distributions along the orifices in the smooth wall and additive manufacturing (AM) tubing, which are inherited with surface roughness. Numerical and measured results in this study are compared, presented, and discussed.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2020

Mobility, Energy, and Electric Vehicle Typology for New York State

Mobility patterns, technology adoption and associated energy outcomes vary tremendously across settlement types. This paper explores how a highly geographically resolved exploration of the social, economic, techno-infrastructural and environmental domains of New York State is key to understanding observed variations in transportation technology adoption and associated mobility and energy outcomes. Current socioeconomic and mobility data sets at the census block group level are integrated in a hierarchical clustering approach to show how variations in mobility and energy outcomes are shaped by these domains - which may enhance progress on investments, or effectively inform planning and other decisions for state-wide goals. The clustering produces four settlement types to predict dependent variables of electric vehicle (EV) adoption rates, commute mode, vehicle fuel economy, and vehicles per household. This typology shows EV adoption rates among the core urban population, which is wealthy and highly-educated, are high - 3 EVs/1000 vehicles versus 1 EV/1000 vehicles among the urban working class. Commuting mode is closely linked with population and employment density - more than 90% of core urbanites use transit or active modes, compared with only 22% of suburbanites and 17% of rural residents. Household vehicle ownership also varies, with 2 vehicles per household in rural areas and only 0.5 in core urban settings. Important findings on differences among the rural, suburban, urban, and urban core settlement types suggest a need to explore how best to manage and anticipate very different types of services that may be supportive in achieving energy-efficient and affordable mobility systems state-wide.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

Salt Hydrate Eutectic Thermal Energy Storage for Building Thermal Regulation (Final Technical Report)

Thermal energy storage is anticipated to play an important role in developing the power grid of the future - a power grid that meets increasing demands of users, is resistant to disruptions, but also allows for greater penetration of renewable resources. Specifically, thermal energy storage materials can be integrated into HVAC systems and building envelopes, where they can be used to shift power demands for building climate control from periods of peak demand to periods of low demand. Phase change materials (PCMs) are compelling as low-cost, high energy density thermal energy storage materials for building thermal management. However, there is a lack of high performance low-cost PCMs within the specific temperature ranges which would most effectively allow for power load shifting. Inorganic salt hydrates represent a promising class of PCMs, but their inherent limitations cause them to be currently unavailable for reliable building applications. The overarching goals of this research effort are to: 1) Discover low-cost, high volumetric density salt hydrate eutectic PCMs to store low-quality heat (10 to 40 °C); 2) Introduce a high thermal conductivity matrix to reduce the time constant for energy storage to ~0.1 to 1 hr, incorporate nucleation catalysts to decrease undercooling, and utilize microencapsulation and shape stabilization approaches, minimizing moisture loss/gain, mitigating phase separation, and maintaining stable melting behavior over the lifetime of the compounds; 3) Evaluate the impact these systems have on peak load shifting, and the potential for overall energy savings under different climatic scenarios and building configurations. These goals will be achieved by an integrated research program consisting of six cohesive research subtasks: 1) Materials discovery of eutectic salt hydrate PCMs by using computationally predicted thermodynamic equilibria, coupled with high-throughput experimental validation, 2) Rapid experimental screening of nucleation catalysts identified through robust computational databases, 3) Embedding salt hydrate PCM into a low cost and scalable high conductivity matrix, 4) Microencapsulation of salt hydrate microspheres using hybrid inorganic-polymer microencapsulation approach, 5) Shape stabilization by thermoreversible salt hydrate salogels, and 6) Analysis of end-use using thermal simulations, and characterization of mock-up energy storage finished components.

25 ENERGY STORAGE↗

DOE OSTI2025

DER Inverter Control Fault Ride Through Model in Accordance with IEEE 1547-2018 Std

Distributed Energy Resources (DER) with smart inverters are becoming more prevalent as the need for renewable energy and grid stability increases. An important challenge arises when considering that inverterbased generation methods contribute less current during faults, rendering traditional overcurrent protection unsatisfactory. DERs have fault ride-through requirements when operating in high or low voltage, outlined by IEEE Std. 1547-2018. Faults cause the voltage to reach abnormal steady state magnitudes, depending on the fault resistance and fault type. There are several high voltage and low voltage ride-through zones defined by IEEE Std. 1547-2018. Each zone’s ride through duration decreases as the applicable voltage measurement, i.e., the phase RMS voltage, deviates from its nominal value. This presentation demonstrates the implementation of IEEE Std. 1547-2018 high and low voltage ridethrough grid support functions using a preexisting RSCAD model, discussing the challenges presented during this process. The implemented controls monitor the filtered phase voltages to have a more accurate reading of the applicable voltages. The controls sense the duration that the applicable voltage remains in a specific zone. The breaker trips and ceases energization to the grid when the duration is exceeded. The standard allows the operator to adjust the ride-through times and voltage zones from the default settings. These ranges are implemented into the runtime, which acts as the operator’s SCADA. The results show the accuracy of the voltage measurements, which remain within the IEEE Std. 1547-2018 for all cases.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2023

Beyond Price Taker: Conceptual Design and Optimization of Integrated Energy Systems Using Machine Learning Market Surrogates

Future electricity generation systems must be optimized to provide flexibility that counteracts the variability of non-dispatchable renewable energy sources and ensures the reliability and safety of critical infrastructure, including the electric grid. The current state-of-the-art is to co-optimize the design and operation of integrated energy systems (IES) treating historical or predicted time-series electricity prices as fixed parameters. Recent literature has shown the limitations of this price taker assumption, which neglects how IES optimization decisions influence market outcomes. As such, this paper proposes a new optimization formulation that uses machine learning surrogate models, trained from a library of annual market operation simulations, to embed IES market interactions into the co-optimization problem directly. Using a thermal generator example built in the open-source IDAES computational environment, we show that the price taker approach routinely over-predicts annual revenues by 8% or more compared to a validation simulation, where the proposed approach has a typical relative error of 1% or less.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

Waste management strategies for military-generated waste in the United States

Sustainable and energy efficient municipal solid waste (MSW) management is vital for the health and performance of deployed soldiers, as they play an important role in the safety and dignity of a country. As the United States targets net-zero carbon-free emission goals, research and development are essential to surpassing current practices for management of MSW at military installations, both at home and abroad. To achieve this, it is important to act upon and implement the policies and instructions set by government agencies such as the Environmental Protection Agency (EPA), the Department of Energy (DOE), and the Department of Defense (DoD). Understanding the composition of waste and disposal methods that are in use at military installations is a crucial step to success. Here, the authors show this through analyzed data from trusted sources, such as government agencies, reports, magazines, journals, and other publications on MSW management techniques. By defining these challenges, possible solutions can be better understood for improved management of MSW at military installations in the United States. Finally, an integrated approach with deployable units capable of waste-to-energy technology using waste reduction, diversion, and recycling strategies shows to be an effective pathway for MSW conversion into energy and other useful products.

09 BIOMASS FUELS↗

DOE OSTI2026

Scale-Up of Electrode Coating and Flow-Field for Commercial Hydrogen Peroxide Electrolyzer: Cooperative Research and Development Final Report, CRADA Number CRD-17-00687

Hydrogen peroxide is currently produced at central chemical plants via the anthraquinone oxidation process. This process produces environmental pollutants that are costly to remediate, requires hazardous long distance shipping of highly concentrated peroxide (50% or 70%), and necessitates extra handling costs related to storage and dilution. Peroxygen Systems, Inc. (PSi) is developing breakthrough technology for on-site hydrogen peroxide production. PSi’s on-site on-demand electrolyzer can reduce the cost of producing hydrogen peroxide by 50%, while also completely eliminating the cost and safety issues associated with shipping and handling of high concentration hydrogen peroxide. The challenge for PSi is scaling. To support the next step toward commercialization (customer pilot tests), scaling the prototype into larger single cells and 20-40 cell stacks is required. In addition to internal hardware and flow-field design efforts at PSi, NREL will address three critical problems for this scale-up effort: (1) demonstrating a large scale roll-to-roll (R2R) process to coat uniform electrode materials for 100 cm2 and 500 cm2 stack testing, (2) demonstrating an in-line diagnostic to achieve better electrode quality control, and (3) performing in situ cell/stack testing to better understand and optimize the performance of the flow field design.

28 EE - Advanced Manufacturing Office (EE-5A)↗

DOE OSTI2021

Concentrating Rare Earth Elements in Coal mine drainage Using Coal Combustion Products through Abandoned Mine Land Reclamation

Rare earth elements (REEs) (including scandium, yttrium and a group of 15 lanthanides) are often considered to be critical components in the productions of renewable energy hardware, electric vehicles, health care and military equipment, and consumer electronic products. The demand of REEs has been projected to be growing at an annual rate of 5-9% in the next 25 years. In 2011, the global demand of total rare earth oxides (REOs) was estimated to be approximately 105,000 tons, which is expected to grow to 210,000 tons by 2025. China overwhelmingly dominates the current worldwide rare earth productions but has strategically restricted its exports, causing significant instability for the global market. In response to the increasing demand for REEs and the supply dominance of China, identifying alternative sources of REEs has become a critical issue for the United States and other countries. Coal, coal ash, and coal mine drainage (CMD) are considered to be the alternative sources of REEs. In the U.S., high REE concentrations have been reported to be closely associated with coal deposits, including the Appalachian Basins. When surface and/or groundwater come in contact with geologic strata containing sulfide minerals exposed by coal mining, the accelerated oxidation of sulfide minerals in the presence of ferric iron and/or oxygen can produce sulfuric acid. The process promotes the weathering of REE-bearing rocks and minerals in the host geologic strata. Compared to average river water and seawater, the concentrations of REEs can be orders of magnitude higher in CMD. In this study, we demonstrated a trap-extract-precipitate (TEP) process that can effectively recover REEs from CMD. The three-stage TEP process uses alkaline industrial by-products to capture REEs from CMD and then applies an extraction/precipitation procedure to produce a feedstock that can be economically processed to produce marketable rare earth oxides. The alkaline industrial by-products tested in this study include the residual from a water softening process (DRWP sludge) and two types of stabilized flue gas desulfurization materials (sFGDs). sFGD material is a mixture of lime (CaO) and two coal combustion by-products, calcium sulfite FGD by-product and fly ash. The objectives of this study are to (1) validate the effectiveness and feasibility; (2) determine mechanisms controlling the rare earth recovery, (3) quantify the associated economic and environmental benefits, and (4) evaluate the full-scale application. To achieve these objectives, tasks to be carried out in this proposed project are organized into three phases. In the first phase, the research team collaborated with Ohio Department of Natural Resources, American Electric Power, The Wilds (a nonprofit wildlife conservation organization), and a private landowner to carry out field investigations aimed to screen and evaluate the seasonal changes of rare earths in the CMD discharges that have high recovery potentials. Next, the recovery of REEs from CMD was tested using a series of lab-scale column and batch tests under, respectively, percolation and completely mixed conditions. Results obtained from these lab-scale studies show that all three tested solids are very effective in retaining REEs. Over 98% of the CMD REEs that contacted the solids were captured before the solids exhausted their neutralization capacities. We also determined an extraction process using a non-acid, organic ligand extraction solution that can effectively remobilize the retained REEs from the spent solids (over 90%). The REE concentrate (>7.5 wt. % of total REEs) is then formed in an aeration process. The TEP process uses environmentally benign industrial by-products and a naturally-occurring organic ligand to mitigate CMD and recover REEs. Techno-economic analysis (TEA) and life-cycle assessment (LCA) was carried out in the third phase. The engineering-economic costs and net energy, net CO2 emissions, and water and other requirements were investigated to understand the economic and environmental implications of this process. This work uses mass and energy balances from laboratory-scale experiments to estimate the economic costs and environmental impacts. The results suggest that passive treatment systems that use DRWP sludge are preferred over those that use sFGD material, because of lower economic costs ($89,300/yr with a unit cost of $86/gT-REE vs. $89,800/yr, or $278/gT-REE) and improved environmental performance across all indicators from two different impact assessment methods. These differences are largely attributable to the larger capacity of DRWP sludge in the passive treatment application. We envision this TEP process can be integrated with abandoned mine land (AML) reclamation to create an approach that can add economic incentives for AML reclamation, remediate CMD discharge, and eliminate public safety hazards and threats to local environment and ecological systems posed by AMLs. It can restore lands and communities that are adversely impacted by legacy mining.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2024

Precision Agriculture using Networks of Degradable Analytical Sensors (PANDAS) (Final Technical Report)

Precision agriculture, where sensing of soil, environment and crop conditions are used to precisely synchronize inputs (such as water and fertilizer) to crop needs enhances input use efficiency. This can improve yields and farm profitability while mitigating environmental losses, improving soil carbon content and substantially decreasing energy use for food, feed and fuel crops. Unfortunately, farmers are not yet able to harness the full potential of these management technologies as there is a lack of available management information, and there is therefore a need for sensors that are able to economically measure spatio-temporal variability in soil and crop properties of extremely heterogeneous farm fields precisely at high resolution and at low cost. Real-time, in-situ monitoring of agricultural soil conditions is today carried out using devices that limit the total number of nodes that can be used economically to typically one per acre or less. Higher spatio-temporal resolution sensing would enable more precise agricultural input optimization, with significant benefits to the farmer and the environment. In order to address this issue, this project focused on developing additively manufactured, biodegradable, soil sensors with predicted costs of < $\$$1 per unit to monitor crop inputs (such as water and fertilizer) that predictably, harmlessly degrade away into the soil when no longer needed. These sensor nodes should be easy to place, accurately and continuously monitor soil and crop conditions for an entire season, be read remotely using existing farm equipment, require no ongoing maintenance, not impede farm operations and produce no persistent waste. This approach could enable a >100× increase in information density over current solutions for precision farming of row and other crops, and lead to significant reductions in input energy use and provide increased yield for biofuel crops. Over the course of this project the team at the University of Colorado Boulder, University of California Berkeley, and Colorado State University/Kansas State University investigated a wide range of printable biodegradable electronic materials and sensor designs for determining soil moisture and soil nitrate concentration. These efforts expanded the available materials set for printed soil degradable electronic materials, particularly for conductors, enabling high conductivity and stability. Printed soil moisture and nitrate sensors with suitable sensitivity and selectivity were developed and characterized. Low power and passive wireless electronic systems were integrated with the soil sensors, and testing was carried out with completed sensors to understand their functionality under agricultural conditions. Additionally, other sensor types enabled by the biodegradable materials set created during this project, such as soil microbial activity sensors, were also developed and demonstrated. Project outputs include 10 peer reviewed publications, 4 patent applications, 21 technical presentations, 3 PhD thesis, 10 media reports, 8 additional grants worth over $\$$6M, and the formation of 3 start-up companies.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗