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DOE OSTI2022

The Demand for a Domestic Offshore Wind Energy Supply Chain

In March of 2021, the Biden-Harris Administration established a National Offshore Wind Target to install 30 GW by 2030. This ambitious goal was not only intended to help reduce dependencies on fossil fuels, but also represents an opportunity to establish a new and sustainable industry in the United States. The announcement referenced the potential benefits of establishing a domestic supply chain, including the opportunity for existing suppliers to produce thousands of components while creating tens of thousands of jobs over the course of the decade. This vision by the Biden-Harris Administration aligns with the perspective of the offshore wind industry. At a Leadership 100 event hosted by the Business Network for Offshore wind in 2019, offshore wind developers and manufacturers identified the need for a roadmap outlining a pathway to a domestic supply chain as the top priority facing the industry. Building up domestic manufacturing capabilities will not only energize local industries but can potentially de-risk individual project by reducing reliance on importing resources from European or Asian markets. Although establishing a domestic supply chain will require significant investment, it has the potential to create substantial benefits throughout the industry and, by extension, on the decarbonization goals of the United States. This study characterizes the challenges and opportunities facing the growth of a domestic supply chain industry and evaluates the potential benefits that could be achieved through the creation of the supply chain. This report is the first of a two-part series which will describe the full supply chain roadmap and the associated benefits; the current report focuses on the high-level deployment, workforce, and component requirements that need to be met to achieve the National Offshore Wind Target. We will present: 1. A deployment pipeline that demonstrates the pathway to 30 GW, the associated demand for major fixed-bottom and floating offshore wind components (turbines, foundations, cables, substations), and the vessel and port requirements to support these installation activities. 2. A series of sensitivity analyses showing how the demand for components, ports, and vessels changes for different technology pathways and availability of the global supply chain. 3. An estimate of the total number of jobs that would be required to support these deployment scenarios under varying levels of assumed domestic content. 4. A comprehensive list of the Tier 1, 2, and 3 components (finished components, subassemblies, and subcomponents) required to construct fixed-bottom and floating offshore wind projects. 5. A discussion of critical path components that represent a significant challenge, bottleneck, or risk for a future domestic supply chain.

17 WIND ENERGY↗

DOE OSTI2022

Plasma Ignition and Combustion Stabilization Technology to Improve Flexible Operation, Reliability and Economics of an Existing Coal-Fired Boiler

GE Steam Power, Inc. (GE) proposed to improve reliability, flexibility, and economics of an existing coal-fired power plant by applying a new advanced technology developed by GE, a plasma-assisted pulverized fuel firing system. The objective of this program is to demonstrate the achievement of lower load by improved flame stabilization and therefore lower operating costs in a full-scale field installation at coal-fired electric utility. GE’s Plasma Ignition and Combustion Stabilization System is designed to operate continuously to support low load operation. With the plasma on, the flame will be attached and stable, removing the firing system as a limitation to low load operation. In addition, GE’s exclusively from ABENZ company licensed AC based technology has a 90+% system efficiency compared to all other systems at which are DC and operate with ~75% efficiency. Plant operating costs are lowered by eliminating use of expensive support fuel as well as the ability to operate at lower loads. The utilities’ ability to better match the demand curve will result in significant savings. Maintenance is lower for an AC system than a DC system as it operates at lower current. This eliminates the need for a demineralized cooling water system and provides longer electrode life which translates into both material and labor savings. It is the objective of GE to not only demonstrate the additional low load achievable with a plasma system after best achievable tuning, sensor and software approach has been exhausted, but also the increased stability of the flame at all loads with plasma assistance as well as cost savings at all low loads using plasma instead of oil. Upon successful completion of this project, GE will have sufficient field experience to rapidly deploy the Plasma Technology. The project objectives were achieved through the implementation of plasma ignitor technology at PacifiCorp Hunter Station Unit 3. A plasma ignitor system was retrofitted on ten wall-fired burners, Mill 3-4 combustion system. The Plasma Ignitors installed at Hunter proved that this GE technology is a direct and complete replacement for the original oil ignitors. The Hunter Unit 3 burner management system allows the plasma system to be used in all applications that originally required oil to be burned. This includes any time the Mill 3-4 is started or stopped for any reason including boiler starts, load changes, and low load support.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2022

Residential Solar-Adopter Income and Demographic Trends: 2021 Update [Slides]

The report describes income, demographic, and other socio-economic trends among U.S. residential rooftop solar adopters. The report is based on data for roughly 1.9 million residential rooftop solar systems installed through 2019, representing 82% of all U.S. systems. With its unique size, geographic scope, and level of detail, this report is intended to serve as a foundational reference document for policy-makers, industry stakeholders, and researchers. Key findings include the following: Solar adopters generally skew towards higher incomes, though that trend continues to diminish over time. Solar adopter incomes vary considerably and encompass many low-to-moderate income (LMI) households. Solar-adopter incomes are consistently higher for systems paired with battery storage, for host-owned systems, and for systems installed on single-family homes. Solar adopters differ from the broader U.S. population in terms of a variety of other demographic and socioeconomic measures. State-level comparisons indicate that solar-adopters tend to live in neighborhoods with relatively high non-Hispanic White and Asian populations, and with relatively low Hispanic and Black populations. In conjunction with the report, Berkeley Lab has published an updated accompanying set of online data visualizations that allow users to further explore the underlying data. Berkeley Lab is also offering related analytical support to states, local agencies, and other organizations on issues related to solar adoption among low-to-moderate income households.

14 SOLAR ENERGY↗

DOE OSTI2022

Assessment of the Electrical Substation-Grid Testbed with Inside/Outside Devices and Distributed Ledger Technology

The electrical substation-grid testbed was created to integrate the GOOSE and/or DNP (Distributed Network Protocol) messages with time synchronized sources and Distributed Ledger Technology (DLT). The objective was to study the impact of faults and cyber-events at an electrical substation with inside (protective relays) and outside (power meters) substation devices. The electrical substation-grid testbed was based on the design of a 34.5/ 12.47 kV electrical substation (sectionalized bus configuration) with two power transformers, connected to radial power lines and load feeders. The electrical substation-grid testbed was installed at 252 lab space (Advanced Power System Protection), Grid Research Integration and Deployment Center (GRID-C), Oak Ridge National Laboratory. This testbed was created for Task 5, DarkNet project. The electrical substation-grid testbed was created to simulate fault and/or cyber events that could potentially result in damage to the electrical infrastructure. In addition, tests were run that are usually not allowed to be performed in an operational electrical power grid, because these test scenarios could trip breakers and/or generate fault situations that could potentially damage equipment. The number of tests performed in the electrical substation-grid testbed were executed in a better way than in a real electrical substation and/or power grid, because multiple tests could be run in a short period of time, and complex permits, and safety/ schedule restrictions like in a real electrical substation environment were not needed. The electrical substation-grid testbed was created using real measurement, communication, and protection devices that are used by electrical utilities, to have same conditions that we could observe in a real power grid or electrical substation. The electrical substation-grid testbed was based on using a real time simulator and expansion box with amplifiers that were wired to electrical substation-grid devices. This hardware-in-the-loop (HIL) was provided by protective relays, power meters, ethernet switches, remote terminal units, synchronized timing network clock, DLT devices, workstations, and servers. This report includes the design, installation, and assessment of the electrical substation-grid testbed that was similar to an operational electrical substation, integrating the power system protection, communication, and control systems. The results for the electrical substation-grid testbed were based on:• verifying the analog signals for protective relays and power meters, • observing the synchronized time source frame at devices, • authenticating the GOOSE (IEC 61850) and DNP messages from power meters and protective relays, and • verifying the trip conditions of protective relays at fault tests with the power system fault event detection, using DLT devices. For future work, the electrical substation-grid testbed with protective relays and power meters, using DLT and synchronized time source from DarkNet, will be used to study the impact of cyber-events at inside and outside substation devices. Advanced algorithms for detecting cyber-events produced by non-desired protective relay settings will be studied, to improve the detection and reliability of protection, control, and communication systems at power grids.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2022

Solar Automated Permit Processing Software for Distributed PV (Cooperative Research and Development Final Report, CRADA Number CRD-19-00825)

NREL and its project partners built and commercialized the novel Solar Automated Permitting Processing Plus (SolarAPP+) software platform that delivers instant residential rooftop solar permits. The tool provides installers with a standard portal for entering permit information for residential solar systems across all Authorities Having Jurisdiction (AHJs) using SolarAPP+, thereby providing a streamlined plan review form, transparency into permitting timelines, and required specifications. The project has proven to reduce permitting timelines from as many as 20 business days to zero, delivering solar projects faster in the four participating AHJs using the platform. Streamlining permitting timelines, all else equal, results in consumers installing their systems and reducing their electricity bills faster. The continued expansion of SolarAPP+ features and adoption nationwide will expand the benefits of the SolarAPP+ beyond the current user base.

14 SOLAR ENERGY↗

DOE OSTI2022

Thermocouple Testing in Support of the AGR-5/6/7 Experiment

This report documents thermocouple testing performed in IRC Lab C-15 over a period of seven years. This testing supported selection and characterization of the thermocouple set used in the AGR-5/6/7 experiment. The following summary was taken directly from the report. Temperature measurement is a challenging aspect of very high temperature irradiation experiments because commonly used high-temperature commercial thermocouples such as platinum-rhodium (Types S, R, and B) and tungsten-rhenium (Type C), suffer dramatic drift because of neutron-induced transmutation. As a result, these types of thermocouples, which are used routinely for industrial temperature measurements outside of reactors, are used only in very special circumstances for reactor experiments. Conversely, because of their low neutron cross-sections, Type N thermocouples are affected to only a limited extent by neutron irradiation. However, the use of these nickel-based thermocouples is limited when the temperature exceeds 1050°C due to drift arising from minor alloying elements migrating from the thermocouple's metal sheath to the thermoelements. This change in the composition of the thermo-elements results in significant decalibration of the signal. The issues described above were recognized during the early planning stages of the final AGR experiment (designated AGR-5/6/7), and a thermocouple furnace testing program was performed over a seven-year period (2014-2019, 2021) to first select and then characterize the best thermocouple set for the high temperature regions of the AGR-5/6/7 irradiation experiment. The calculated temperature range of the AGR-5/6/7 experiment was 600–1500°C. For temperatures below 1000°C standard Type N thermocouples were deemed adequate. The furnace testing campaign identified two thermocouple types suitable for measuring temperatures above 1000°C, a Mo/Nb thermocouple developed at INL called HTIR-TC, and a Type N thermocouple developed by Cambridge University (called herein Cambridge Type N), which featured a custom high nickel alloy sheath. One of the original goals of the furnace testing program was to identify a thermocouple capable of low drift operation near the peak temperature expected in AGR-5/6/7, i.e., about 1400°C. The HTIR-TC design appeared promising in this regard, however a manufacturing difficulty proved to be a barrier and instead the furnace testing focused on drift performance at 1250°C. The manufacturing difficulty was that the Nb sheaths of the HTIR-TCs experienced extreme embrittlement when heat treated at 1600°C or greater. Heat treatment is needed to stabilize the emf output of this TC type, and the higher the heat treatment temperature the higher the peak temperature of stable operation. Because of the sheath embrittlement the heat treatment temperature had to be lowered to 1450°C resulting in a stable operating temperature of about 1250°C. One of the successes of the furnace testing program was identification of a shortcoming in the heat treatment procedure that had been traditionally used in the production of HTIR-TCs. The shortcoming was that the entire heated length of the HTIR-TC sensor was not being heat treated, but rather only the part of the sensor expected to experience temperatures above 1000°C. The problem manifested itself when the thermocouples were removed from the heat treat furnace and placed in another furnace with a different geometry, their indicated temperatures would be widely scattered, but mostly in the negative direction. The solution was to heat treat the entire heated length of the sensor. Since the deepest immersion depth in the AGR-5/6/7 experiment was about 40 inches, a heat treatment length of 48 inches was used. After this change was implemented, thermocouples which were moved into a new environment with a different temperature profile (i.e., a different furnace), produced accurate temperature measurements. Although assembly of the AGR-5/6/7 experiment was completed in September of 2017 (and irradiation begun in 2018), furnace testing of thermocouples continued in 2018 and 2019. The main purpose of this testing was to establish very long-term drift characteristics of the HTIR and Cambridge Type N thermocouples installed in the experiment. Representative thermocouples from the same lots as those installed in the AGR-5/6/7 experiment were used. Additionally, thermocouples of different designs, (particularly variations on the HTIR-TC design) were "piggy-backed" on this testing program to provide insights for instrumenting future very high temperature irradiation experiments. This two-year testing program demonstrated that HTIR-TCs and Cambridge Type N TCs could operate at 1250°C for up to 10,000 hrs (and in some cases longer) while experiencing negative drifts on the order of 2-4°C/1000 hrs. This performance was considered acceptable given the extreme operating environment the sensors faced.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2022

Front-End Engineering Design for Piperazine with the Advanced Stripper

This Department of Energy (DOE) funded project was executed with the goal of preparing a Front-End Engineering Design (FEED) for the capture and compression of 90% of the CO2 that would normally be emitted from an existing natural gas combined cycle (NGCC) plant. The FEED focused on the application of the piperazine advanced stripper (PZAS) process at Mustang Station of the Golden Spread Electric Cooperative (GSEC), which consists of two gas turbines with common heat recovery steam generator (HRSG). The University of Texas at Austin (UT) served as the prime contractor, and subcontracted AECOM Technical Services and Trimeric Corporation to support FEED development. This project team has worked together to advance PZAS for more than a decade. ExxonMobil, Chevron, and Total provided project co-funding. The objectives of this work included: 1. To advance engineering design such that a comprehensive estimate for the total installed cost of a full-scale PZAS CO2 Capture Plant with CO2 compression can be developed on an existing NGCC power plant. a. These detailed costs can also be used to qualify PZAS and other related second generation (2G) amine scrubbing processes for use on cogeneration facilities in refineries and chemical plants that use gas turbines with HRSGs to produce steam. b. These detailed costs will help qualify 2G amine scrubbing for use on NGCC power plants and establish a more accurate baseline cost to be used as a target by other capture technologies. 2. To provide cost details to be used in the economic optimization of the process features of PZAS and other 2G amine scrubbing processes. 3. To provide DOE with a more detailed understanding of carbon capture costs in a commercial application, enabling DOE to better design its R&D program to improve the economics for carbon capture. 4. To provide the host site and cost share partners with the information necessary to determine whether a commercial project to capture and use CO2 for enhanced oil recovery (EOR) or for sequestration can be justified (when accounting for the 45Q tax credit). A key component of the FEED is the estimated total installed cost, which provides a basis for the likely capital investment necessary to implement the PZAS carbon capture process at this location and scale. In combination with the included economic analysis, which accounts for potential revenue from the produced CO2, potential avenues to profitability are explored. The major findings of the FEED are as follows: The Mustang Station PZAS CO2 Capture Plant estimated total project cost of $698 MM of which $384 MM was direct costs. The annual operating costs were $32.6 MM. The total investment for a PZAS facility at Mustang Station is $725 MM. This estimate includes owner’s cost of $25 million and a contingency of $110 MM. • The study estimated the CO2 capture plant at Mustang Station would generate CO2 at $110/tonne for EOR, assuming a 12% IRR (internal rate of return) and an 85% capacity factor. For CO2 storage, the same case would achieve a 12% IRR at about $114/tonne. At a capacity factor of 52%, the storage and EOR cases would break even when carbon is priced ~$150/tonne. The economic analysis determined that the capacity factor and utility pricing, among other variable factors, had a significant effect on the economics and will need additional studied. • The energy penalty of the PZAS plant would be about 46 MW in connected power and 35 MW in operating load. The natural gas requirement (for the Gas Boiler package) would be about 354 MMBTU/hr. • The FEED revealed no major risks in process maturity. However, some areas were outlined for further engineering during detailed design, which included the Gas Boiler system, general arrangement and site layout, air coolers, schedule development, and optimization of the process for higher CO2 removal. • If PZAS were to be implemented at another host site, additional opportunities for cost reduction for would include cost reduction through use of cooling water and steam extraction.

03 NATURAL GAS↗

DOE OSTI2022

US HL-LHC Accelerator Upgrade Project (MQXFA Final Design Report)

The MQXFA Quadrupole magnets will be installed in High Luminosity LHC to form the Q1 and Q3 inner triplet optical elements in front of the interaction points 1 (ATLAS) and 5 (CMS). A pair of MQXFA units is assembled in a stainless steel helium vessel, including the end domes, to make the Q1 Cold Mass or the Q3 Cold Mass. The US HL LHC Accelerator Upgrade Project* is responsible for the design, manufacturing and test of the Q1/Q3 Cold Masses and the complete MQXFA magnets. CERN provides the cryostat components and is responsible for integration and installation in HL LHC. The MQXFA quadrupoles have 150 mm aperture, 4.2 m magnetic length, nominal gradient of 132.2 T/m, and coil peak field of 11.3 T. They use Nb_3Sn conductor and a support structure made of segmented aluminum shells pre-loaded by using bladders and keys. This report presents the final design of the MQXFA quadrupole magnets.

43 PARTICLE ACCELERATORS↗

DOE OSTI2022

Upgrade of Core Conduction Cooldown Test Facility Control System

The CCCTF was designed and installed at ORNL in the 1990s for high-temperature gas-cooled reactor accident simulation. It is located within a modular hot cell housed in the IFEL facility. In 2008 and 2009, modifications were made to the CCCTF in preparation for AGR safety testing. A new airlock was designed and installed to better support periodic exchange of the fission product deposition cups while maintaining the fuel at safety test temperature, and modifications were made to add routines to the existing user interface software for computer-controlled automation of the He sweep gas flow and liquid nitrogen supply to the 85Kr cold traps. However, the furnace control hardware and software remained essentially unchanged. At the conclusion of the AGR-1 and AGR-2 PIE campaigns, continued use of the CCCTF was in question because of the gradual obsolescence of the hardware and software used to control the furnace and ancillary systems that make up the CCCTF. Therefore, an effort was undertaken to replace all the obsolete components with new hardware and update the software to increase system reliability and ensure this capability’s maintenance for future research and fuel qualification efforts. The modifications included creating a new National Instruments (NI) LabVIEW-based control system with a graphical user interface (GUI).

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2022

Assessing the New Home Market Opportunity: Case Study and Cost Modeling for Solar and Storage in 2030

In 2020, the United States had a cumulative 19 gigawatts (GWdc) of residential solar photovoltaic (PV) capacity. A growing percentage of these solar installations are paired with battery storage, up from 0.1% in 2015 to 8.1% in 2020. Some states are considering or have already adopted policy mandates to require solar and storage systems. The cost of installing residential solar and battery storage projects remains a barrier to widespread adoption nationwide. For example, the cost of a typical residential retrofit solar and storage system ranges from $\$ 26,153$ to $\$ 37,909$, which is 38% to 100% higher than a standalone PV system.

14 SOLAR ENERGY↗

DOE OSTI2022

An Architectural Survey of the REECo Maintenance Compound, Area 6, Nevada National Security Site, Nye County, Nevada

The U.S. Department of Energy (DOE), National Nuclear Security Administration Nevada Field Office (NNSA/NFO) plans to install a 26.45-mile-long 138-kilovolt (kV) transmission line on the Nevada National Security Site (NNSS) in Nye County, Nevada. This new transmission line will upgrade the electrical transmission system and provide reliable power between Mercury Switching Station in Area 23 and the U1a Facility in Area 1. The proposed upgrade to the power transmission system constitutes an undertaking subject to review under Section 106 of the National Historic Preservation Act (NHPA) (54 United States Code [USC] § 306101) and its implementing regulations, 36 Code of Federal Regulations (CFR) Part 800. A portion of this new transmission line will cross the western perimeter of the Reynolds Electrical and Engineering Company (REECo) Maintenance Compound located in Area 6 of the NNSS. This compound with its trade shops, storage sheds, and yards served as a general construction facility that supported nuclear testing activities on the NNSS from 1967 to 1992. Although three architectural resources in the compound have previously been recorded and evaluated for the National Register of Historic Places (NRHP), other resources within it have not, nor has the compound been recorded and evaluated as a potential district. The State Historic Preservation Officer (SHPO) concurred with NNSA/NFO’s determination that the unevaluated REECo Maintenance Compound will be adversely affected by the proposed undertaking (Reed 2021). The NNSA/NFO, in consultation with the SHPO, then developed the Memorandum of Agreement DE-GM58-22NA25553 between the U.S. Department of Energy and the Nevada State Historic Preservation Officer Regarding Installation of a 138-kilovolt Transmission Line from the Mercury Switching Station to the U1a Facility and the Removal of the Historic 138-kilovolt Transmission Line from the Mercury Switching Station to the U1a Facility in Areas 1, 3, 5, 6, and 23 of the Nevada National Security Site, Nye County, hereafter referred to as the MOA. This architectural survey report was prepared in accordance with MOA Stipulation III.B. It describes the origins, history, layout, and functions of the REECo Maintenance Compound during the Cold War and identifies contributing and noncontributing resources. The report defines a district boundary based on archival research and the field survey and concludes with an appendix that presents digital color images of the compound with descriptions and a map key showing image viewpoints and directions. Although none of the architectural resources are recommended individually eligible, the district evaluation concludes the REECo Maintenance Compound is eligible as a historic district for listing in the NRHP under the Secretary of the Interior’s Significance Criteria A and C at the local level. The historic district retains all seven aspects of integrity and conveys its significance under the abovementioned criteria.

138 kV↗

DOE OSTI2021

Commercial Building Fenestration Market Study

This study characterizes and assesses the U.S. commercial fenestration market. It analyzes a groundbreaking amount of data that will ultimately support an estimate of national savings potential of energy efficient fenestration products in commercial applications to demonstrate the benefits of efficient façade and fenestration systems. This study provides data and analysis on: commercial fenestration market and fenestration selection process, installed commercial fenestration stock across the U.S. and fenestration sales estimates, and current commercial building fenestration codes and market trends of installation to or above code.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2022

Utility-Scale Solar, 2022 Edition: Empirical Trends in Deployment, Technology, Cost, Performance, PPA Pricing, and Value in the United States [Slides]

Berkeley Lab’s “Utility-Scale Solar, 2022 Edition” provides an overview of key trends in the U.S. market, with a focus on 2021. Highlights of this year’s update include: -A record of nearly 12.5 GWAC of new utility-scale PV capacity came online in 2021, bringing cumulative installed capacity to more than 51.3 GWAC across 44 states. -90% of all new utility-scale PV capacity added in 2021 uses single-axis tracking. -Median installed project costs declined to $\$1.35$/WAC (or $\$1.02$/WDC) in 2021. -Project-level capacity factors vary widely, from 9% to 35% (on an AC basis), with a sample median of 24%. The report explores drivers of this variation. -Utility-scale PV’s LCOE fell to $\$33$/MWh in 2021 ($\$27$/MWh if factoring in the federal investment tax credit, or ITC). -PPA prices have largely followed the decline in solar’s LCOE over time, but have recently stagnated and even moved slightly higher. Prices from a sample of recent contracts average around $\$20$/MWh (levelized) in the West and $\$30-40$/MWh elsewhere in the continental US. In 2021, solar’s average market value (defined in the report to include only energy and capacity value) rose by 55% to $\$47$/MWh and exceeded average wholesale prices in 13 of the 17 balancing authorities analyzed. -Adding battery storage is one way to increase the value of solar. Our public data file tracks metadata and PPA prices from 67 PV+battery hybrid projects that are already online or that have secured offtake arrangements. -At the end of 2021, there were at least 674 GW of utility-scale solar power capacity within the interconnection queues across the nation, 284 GW of which include batteries. For more information, and to explore related interactive data visualizations, go to utilityscalesolar.lbl.gov.

14 SOLAR ENERGY↗

DOE OSTI2022

Advanced Ceramic Membranes/Modules for Ultra Efficient Hydrogen (H2) Production/Carbon Dioxide (CO2) Capture for Coal-Based Polygeneration Plants: Fabrication, Testing, and CFD Modeling

Inorganic membrane-based systems are a promising technology for precombustion CO2 capture with simultaneous H2 production. State-of-the-art packages for high temperature and pressure service consist of multiple tube membrane bundles prepared in a "candle filter" configuration, in which the membrane tubes are open at one end and sealed at the other. This configuration is used for practical reasons, specifically the need to minimize problems due to thermal expansion mismatch between the ceramic tube bundle and the steel housing. However, the primary technical problem with the candle filter format for commercial-scale installations is the inability to purge the tube side (typically the permeate side), a feature that is crucial for high H2 recovery. In this study, the focus is to design and fabricate the first dual-end open full ceramic multiple tube membrane bundle that enables tube side (permeate) purge for gas separation applications. An additional key feature of this design is the simplified module layout, as the membrane bundles can be installed end-to-end with tube side (permeate) flow directly from one bundle to the next. This layout simplifies the membrane to housing seals and yields significant improvement in membrane packing density. Detailed focus areas in our studies include: (i) Materials development and preparation of the tube-to-tube sheet potting for the dual-ended bundle; (ii) the sealing and optimal module configuration design to minimize membrane stress upon module mounting; (iii) the demonstration, via the fabrication of CMS and Pd-alloy membranes supported on full-size, dual-ended ceramic support bundles, of the first example of a purgeable ceramic membrane and module; and (iv) development of a CFD model of the membrane module for calculation of feed flow distribution, and for use in scale-up, and capital cost estimating. The CFD model was validated using experimental data with the multi-tubular membrane system, employing He/N2 as a model gas mixture (surrogate for H2/CO2), and has been shown to be quite accurate. Employing the model, we are able to study the effects of operating pressure and temperature, feed and sweep gas flow rates, and the choice of membrane tube configuration on system performance.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2023

A New Plasma Radar Concept for Simultaneous Magnetic and Density Measurements

An innovative, compact 288GHz interferometer has been fabricated, tested, installed and successfully demonstrated on the LAPD-U magnetized plasma at UCLA. The system takes advantage of frequency modulated (FM) radar techniques to deliver a compact heterodyne system. In addition, the reflected power from the source is taken advantage of to eliminate the need for additional quasi-optical components. Electron density in LAPD-U plasma has recently been increased substantially thereby requiring a higher frequency/shorter wavelength interferometer to avoid deleterious refractive effects. This system satisfies those needs. The system uses a 96GHz varactor tuned Gunn oscillator which passes to a passive tripler. This tripler has ~3% conversion efficiency. The 288GHz radiation is then coupled to free space using a so-called dual-mode or Pickett horn. The output 288GHz beam is then coupled to an aspheric lens manufactured from low-loss, high-density polyethylene. This lens is employed to collimate the emerging beam. Small axial adjustment of the lens position can also be used to create a slowly focusing beam so as to optimize the measured signal. In addition, up-down or side-to-side adjustment of the lens can be utilized to steer the beam vertically or horizontally – again to optimize alignment. The propagating beam passes through a beam splitter and then through a water-free, bubble-free fused quartz window into the LAPD-U vacuum vessel. The beam-splitter is a thin sheet of G10 which reflects a small fraction of the incident power (~5 %) towards a zero-bias detector optimized for the frequency range from 220 to 300GHz. Note that waveguides at this frequency have dimensions of ~0.9mm x 0.45mm and so have very large conductive losses. This drives the use of quasi-optical propagation. The detector requires no DC bias and is very responsive (> 1V/mW into 1MΩ). Radiation is coupled to the detector via a similar lens-horn arrangement used for the launch. This reflected beam acts as the local oscillator or reference millimeter-wave beam for the detector. The remainder of the launched source beam then enters the LAPD-U vacuum vessel and passes through the plasma at the mid-plane until reaching the opposing port which is closed off with an aluminum flange. This flange is used as a mirror to retroreflect the incident 288GHz beam back along its path. The retroreflected beam exits the input port but does NOT couple directly into the zero-bias detector. Instead, the majority of the return power continues towards the 288GHz source. As mentioned above the transmitted beam enters the source a second time. This would appear undesirable. However, at these frequencies multipliers are highly non-linear elements which results in a significant portion of the return beam (~20%) re-emerging from the multiplier and horn and then coupling via the G10 beam-splitter to the zero-bias detector. This approach eliminated the need for a second quasi-optical beam-splitter. The system is extremely compact measuring approximately 28 inches x 20 inches. The above did not explain how heterodyne operation was achieved. As mentioned above the Gunn oscillator is able to be varactor tuned. This allows a low voltage to be applied to control the operating frequency of the Gunn oscillator. During heterodyne operation a sawtooth shaped voltage is applied to the varactor at 750kHz using an 80MHz Arbitrary Waveform Generator (AWG). This voltage changes the Gunn frequency linearly during the up-sweep which is then reset abruptly at the sawtooth crash to be immediately followed by another linear sweep. Passage through the 288GHz multiplier triples the frequency change experienced by the electromagnetic wave. These frequency changes are small – tens of megahertz. This FM radar approach results in the launched electromagnetic wave frequencies at the detector for the reference and plasma wave to be different. The approximately 10 ns delay propagation delay for the plasma beam results in the local oscillator and plasma beams NOT having an identical frequency – there is in fact a fixed difference frequency. The frequency tuning level of the Gunn oscillator is then adjusted so that there is ONE cycle of this difference frequency during each linear ramp. During the sawtooth crash or downward re-sweep this one cycle replays in reverse but on a very fast timescale. The process then repeats. Low-pass filtering eliminates the fast re-sweep to leave a pure sine wave heterodyne signal. When the plasma is present it introduces a phase delay in the sine wave (caused by the extremely small Doppler shift resulting from the optical path length change). Of course, to measure this phase change we need a reference. This is simply obtained from an arbitrary waveform generator which provides a synchronized output pulse train which again is low pass filtered to obtain a 750kHz sinusoidal voltage reference for the interferometer. The interferometer was installed on LAPD-U where it has worked reliably and has established that electron densities exceeding 1x10 13 cm -3 are routinely achieved. In addition, the system sensitivity was able to easily observe density fluctuation at frequencies up to 50kHz. FM Radar techniques have enabled a full demonstration of a compact, sensitive, high frequency (288GHz/1mm) heterodyne interferometer.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2022

Remote Deployment and Setup of VOLTTRON Instances

The goal of this project is to increase the pool of people who can install and configure applications in the Intellimation platform. This will be accomplished with a joint development effort between Intellimation and PNNL to create a set of services to simplify the process for the onsite client as well as the Intellimation staff at a centralized location. Intellimation’s tagging capability, hosted in their cloud, will be leveraged to create an autoconfiguration process for selected PNNL applications such as Intelligent Load Control and AIRCX. The results of the configuration process will be sent to Intellimation field units which host the applications locally. This will allow these applications to be configured remotely and with greatly reduced effort on the part of Intellimation staff. Consequently, this will enable a greater usage of these applications and greater impact to energy efficiency than would be possible without this effort. The use of these newly developed services would allow Intellimation to reduce the cost of installation and allow them to offer the service to new and existing clients.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2022

Network Models of Active Degradation Mechanisms and Pathways for Service Life Prediction of Indoor and Outdoor PV Modules

ct: PV service lifetime prediction (SLP) enables accurate calculation of levelized cost of energy (LCOE), which is crucial to rationalizing PV investment and installation. However, SLP is challeging since PV reliability in the field is affected by many combined factors, including various environmental stresses and module quality. In order to map out the active degradation mechanisms and pathways that best resemble real world conditions, we introduce the framework of a study protocol and use network models fitted to data, to enable analysis and SLP of complex PV systems with multiple active degradation mechanisms. The study protocol is the experimental design, including module variants and different exposure conditions, selection of evaluation methods, time-series data acquisition and training of network models to these data. We present SLP of minimodules in the lab and PV systems in the field. For lab SLP, minimodules with 8 variants based on manufacturer, architecture, and encapsulation were prepared and aged in modified damp heat with or without full spectrum light exposure. Stepwise I-V and Suns-Voc data acquisition tracks changes in electrical properties including Rs,IV, Isc,IV, Vmp,PIV providing insights into power loss of minimodules. Network structural equation modeling (netSEM) was utilized to construct degradation pathway models that identify active degradation mechanisms and predict power loss over time. For field SLP, datastreams of Pmp values and I-V curve datastreams of two types of modules installed in three distinctly different Köppen-Geiger climate zones for 9 years were acquired. With power loss modes corresponding to uniform current loss (ΔPIsc), recombination (ΔPVoc), series resistance (ΔPRs), and current mismatch (ΔPImis) determined, the performance loss rates (PLR) were determined using PVplr. We show how to establish a study protocol framework to ensure appropriate parametric variations and valid data collection from the variants of your complex systems. Then the data-driven netSEM model fitting provides a comprehensive mapping of multiple active degradation mechanisms, and accurate service life prediction.

network model, degradation, photovoltaic, solar↗

DOE OSTI2022

Report Series: Finding of Effect and Mitigation Documentation for Building 23-W10, Mercury, Area 23, Nevada National Security Site, Nye County, Nevada

Finding of Effect: The U.S. Department of Energy (DOE), National Nuclear Security Administration Nevada Field Office (NNSA/NFO) plans to demolish Building 23-W10 in Mercury (Nevada State Historic Preservation Office [SHPO] Resource No. B15228), which is on the Nevada National Security Site (NNSS) in Nye County, Nevada (Figure 1). The purpose of the undertaking is related to the modernization of Mercury for future mission needs. The NNSA/NFO will implement this undertaking in accordance with the Programmatic Agreement between the National Nuclear Security Administration Nevada Field Office and the Nevada State Historic Preservation Officer Regarding Modernization and Operational Maintenance of the Nevada National Security Site, at Mercury in Nye County, Nevada, hereafter referred to as the Mercury PA. Building 23-W10, a supply warehouse, was installed in Mercury in 1962 (NNSS GIS Database) and served as a support facility for nuclear testing throughout much of the Cold War. It was likely produced during World War II (WWII) and previously installed at Camp Desert Rock. The town of Mercury and the immediate surrounding area have been formally determined eligible for listing in the National Register of Historic Places (National Register, NRHP) as the Mercury Historic District (MHD, SHPO Resource #D230) under Criteria A and C for their importance in supporting nuclear testing and scientific research from 1951 through 1992. Building 23-W10 was identified as a contributing element to the MHD in a 2018 architectural survey of the district (Reno et al. 2018) and recorded on a Nevada Architectural Resource Assessment (ARA) form (Reno et al. 2017). Building 23-W10 was also identified in Appendix C of the Mercury PA as a Category II contributing element. Category II properties are those that have several representatives in the MHD, such as warehouses, but may possess different engineering or architectural characteristics that distinguish them from other classes of similar elements. Building 23-W10 is a historic property for the purposes of compliance with Section 106 of the National Historic Preservation Act (NHPA) and subject to the stipulations of the Mercury PA. Mitigation: The purpose of this letter report is to support the mitigation of the demolition of Building 23-W10 (Nevada State Historic Preservation Office [SHPO] Resource No. B15228) in the Mercury Historic District (MHD, SHPO Resource #D230) at the Nevada National Security Site (NNSS) in Nye County, Nevada. The warehouse is considered contributing to the significance of the district both for its historic importance in relation to nuclear testing under Criterion A and as a part of the distinctive design and construction of the district under Criterion C. This submission is intended to comply with the stipulations in the Programmatic Agreement between the National Nuclear Security Administration Nevada Field Office and the Nevada State Historic Preservation Officer Regarding Modernization and Operational Maintenance of the Nevada National Security Site, at Mercury in Nye County, Nevada, hereafter referred to as the Mercury PA.

54 ENVIRONMENTAL SCIENCES↗