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DOE OSTI2025

Binder Jet Additive Manufacturing of Silicon Carbide Solar Reactor (CRADA Report)

Achieving high powder packing density is critical in binder jet additive manufacturing (BJAM), as it directly influences the final part density, mechanical properties, and sintering behavior. Multi-modal powder blends, which combine particles of different sizes, have been explored as a strategy to optimize packing efficiency and minimize defects. In this study, bimodal and trimodal powder blends were obtained by mixing silicon carbide powder in three different sizes. These results show that increased powder density is achievable with bimodal powder blends but is reduced in trimodal blends, and it was found that a 13% increase in the powder tap density was achieved using a bimodal blend of powder. The powder size distribution of the bimodal blend was measured at various stages during binder jet additive manufacturing and, no measurable powder separation occurred even after eight prints. Overall, this study shows limited advantage to trimodal powder blends but good promise for trimodal blends for increasing printed density while maintaining reusability in the binder jet process.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2025

Develop an efficient and cost-effective novel anaerobic digestion system producing high purity of methane from diverse waste biomass

This project focuses on developing an advanced, intensified anaerobic digestion system aimed at transforming the treatment and conversion of organic wastes into valuable products, specifically renewable natural gas. The motivation for this research stems from the limitations of conventional anaerobic digestion technologies, which often face challenges such as long retention times, high operational costs, and incomplete organic material degradation. The new technology called Intensified Versatile Anaerobic Digestion (IVAD), is developed to address these challenges by incorporating innovative reactors and processes that enhance the overall efficiency and output of anaerobic digestion. The significance of this project lies in its potential to revolutionize waste management practices and waste biomass utilization. The IVAD system integrates a hyperthermophilic anaerobic acidification reactor, a hydrothermal treatment (HTT) unit, and both thermophilic and mesophilic methanogenic reactors. This combination enables a higher rate of organic breakdown and energy recovery, resulting in faster processing times, reduced reactor sizes, and lower operational costs compared to traditional systems. Key data include an increase in methane productivity to 1.18 m 3 /m 3 /day, a significant improvement compared to the baseline technology’s 0.64 m 3 /m 3 /day. Additionally, the IVAD system achieves a 45% reduction in levelized cost of energy (LCOE), down to $\$$10.04/MMBTU, and an energy return on investment (EROI) of 3.19, representing an 87% increase over baseline levels. Technical and economic analyses highlight that the IVAD system significantly reduces hydraulic retention time (HRT) and solid retention time (SRT). The HRT for the HTT reactor can be reduced from 1 hour to 0.5 hours, while decoupling SRT from HRT in the anaerobic acidification reactor (AAR) allows for further reductions. These design optimizations lead to smaller reactor volumes, cutting down equipment and construction costs. Despite these advancements, energy consumption remains comparable to conventional methods due to a novel heat recovery strategy, enhancing overall process productivity. The system also achieves in-situ CO 2 removal and ammonia stripping features, resulting in biogas with a methane purity level of 75%, and produces high-quality nitrogen fertilizer as an additional by-product. Public benefits of the IVAD system are substantial, contributing to sustainable waste management and renewable energy production. By providing a scalable solution that can be adopted by dairy farms and similar agricultural operations, the IVAD system helps reduce waste, produce renewable natural gas (RNG) suitable for transportation fuel, and generate fertilizer, supporting a circular economy. This project plays a role in achieving broader environmental objectives by mitigating greenhouse gas emissions and promoting energy independence. Additionally, it offers a pathway for farmers to lower operational costs while adopting practices that are both environmentally sustainable and economically advantageous.

03 NATURAL GAS↗

DOE OSTI2025

Binder jet additive manufacturing of silicon carbide solar reactor

36 MATERIALS SCIENCE↗

DOE OSTI2023

20 kV Gallium Nitride pn Diode Electro-Magnetic Pulse Arrestor for Grid Reliability (Final Scientific/Technical Report)

This project developed vertical Gallium Nitride (GaN) pn diodes under two main thrusts: (1) A focus on relatively higher-voltage devices for use as fast EMP arrestors to protect the electric grid; and (2) A focus on a Foundry effort to establish the manufacturability of relatively lower voltage devices. For the first thrust, the aim was to develop devices that go into avalanche breakdown to clamp the voltage across sensitive grid equipment subject to voltage transients induced by electromagnetic pulses (EMPs). Devices with breakdown voltages exceeding 6.5 kV were achieved, and breakdown times shorter than 1 ns were demonstrated, which is sufficiently fast to protect against the fast component of an EMP-induced signal. Key challenges included the epitaxial growth of thick (50 µm or more), low-doped (low 10 15 cm -3 range) GaN layers comprising the drift regions of the diodes, as well as the design and fabrication of edge termination structures (step-etched junction termination extensions) to prevent premature breakdown. Midway through the project, an additional emphasis was put on large-area, high-current devices, and forward currents of approximately 400 A were achieved in composite devices towards the end of the project. Experimental and theoretical studies of impact ionization and avalanche ruggedness were also conducted. For the second thrust (the Foundry), the focus was primarily on 1.2-kV-class devices, although towards the end of the project outstanding results on 3.3-kV class devices were also achieved. The aim of the Foundry was to develop a high-yield, reliable, and economic vertical GaN pn diode process. The Foundry conducted characterization of incoming epitaxial material and correlated this information with the yield and performance of fully processed devices. Wafer maps of diode characteristics such as forward and reverse current as well as capacitance-voltage curves were measured using auto-probing. Several mask sets comprising different-area devices as well as multiple edge termination designs (implanted junction termination extensions, guard rings, and combinations thereof) were studied, and machine-learning-based approaches were utilized to analyze the data. Packaging and reliability efforts were also undertaken for the Foundry diodes, which are necessary for a viable commercial process.

20KV↗

DOE OSTI2025

Development of Niobium-based alloys for Turbine Applications: 20/CJ000/08/09 (ULTIMATE Phase I project)

Current Ni-based alloys used in turbine blade applications are operating at 1100°C which is approximately 90% of the solidus of Ni-based alloys. Further increases in temperature can be achieved only through the use of alloys with higher solidus temperatures such as refractory alloys which include Mo, Nb, W, Ta alloys. Niobium has a unique combination of physical properties that include a high melting point (2468°C), lowest density (8.57 g/cc), and the lowest modulus amongst refractory alloys, a good thermal conductivity that increases from 45 W/mK at room temperature to 62 W/mK at 1093°C, good ductility with fabricability using traditional techniques, high strength, good creep resistance, and general chemical inactivity. Hence niobium alloys offer many advantages for use at the desired temperature of 1300°C. One of the major deterrents to the use of niobium and its alloys at high temperatures is achieving good oxidation resistance. In addition, achieving balanced properties of room temperature strength, ductility, fracture toughness, high temperature strength, and creep resistance required for 1300°C operation at a density of 9 g/cm 3 is extremely challenging since the addition of W which is a potent strengthener increases the density of the alloy. This project seeks to enable the development of a tri-layered turbine blade that can operate continuously at 1300°C with the core of the turbine blade providing good creep resistance, the second layer providing improved oxidation resistance over the core layer, and the third layer being an environmental barrier providing oxidation resistance. The objective of this Phase 1 project was to use computational modeling and advanced characterization tools to develop two classes of Nb alloys which could be used as the core layer and the transition layer.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Theoretical Modeling of Reactor Relevant Conditions for Plasma Jet Driven Magneto-Inertial Fusion

The Charger Advanced Power and Propulsion Laboratory (CAPP), a laboratory within the Propulsion Research Center (PRC) at the University of Alabama in Huntsville (UAH) is working with Los Alamos National Laboratory (LANL). to develop models and inform on promising paths for high gain magneto-inertial fusion (MIF) conditions. This report provides a framework for identifying promising conditions for achieving ignition in plasma-jet-driven magneto-inertial fusion (PJMIF)[1]. As proposed, for the first part of the contract, UAH proposes to develop a gain over unity set of stagnation conditions to provide a state of plasma conditions to achieve to set long terms goals for the PJMIF program. Specifically, UAH will model PJMIF stagnation conditions to include radiation, heat transfer, two temperature energy equations, fusion reactivity and nonlocal fusion product deposition, but no hydrodynamics for these purposes. These calculations will use a stationary plasma model to reduce simulation complexity—focusing on a DT target at 10 keV. Subsequent work will include a DD plasma layer acting as an afterburner. UAH will assume an initial magnetic field without any consideration of the topology, just assume a field strength, most likely scaled with consideration of the local hall parameter. This effort will inform the team on the tradeoff between mass, peak target field, etc and the achievable gain.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2025

The Development of Catalysts for Upgrading of Pyrolysis Vapor for Refinery Feedstocks and Intermediates (CRADA Final Report)

Catalytic fast pyrolysis (CFP) is a versatile technology platform to convert biomass into fungible hydrocarbon transportation fuels and chemical co-products. Key technical barriers to reaching this goal include increasing the product yields and achieving the desired fuel properties for gasoline, diesel, and jet range fuels or blendstocks that would be suitable for introduction into existing refinery unit operations. Overcoming these barriers will require durable catalysts that are effective at upgrading and stabilizing biomass pyrolysis vapors. Towards these goals, this CRADA leveraged NREL experience as a leader in biomass pyrolysis research and Johnson Matthey's (JM) experience as a leader in the production of advanced catalytic materials. The scope spanned CFP catalyst development, characterization, multi-scale reaction testing, and computational modeling. CRADA benefits to DOE, Participant, and U.S. Taxpayer: Assists laboratory in achieving programmatic scope, Uses the laboratory’s core competencies. The purpose of this CRADA was to develop and deploy catalysts for biomass CFP to help achieve cost-competitive biofuels and bio-based products. This was accomplished through a close collaboration between biomass conversion researchers at NREL and catalyst development researchers at JM. Summary of Research Results: Focus Area 1. Foundational research on catalytic conversion and deactivation: Key interactions between pyrolysis vapors and heterogeneous catalysts were probed through catalyst characterization, model compound reaction testing, and atomistic-scale computational modeling. Catalyst development focused on multifunctional materials, which include zeolites, oxides, carbides, and nitrides. Computational modeling identified reaction mechanisms and elucidated surface chemistry to test hypotheses regarding mechanisms of deoxygenation, coupling, cracking, dehydration, coke formation, hydrogen transfer, and aromatic ring reactions. This information was used to design multifunctional catalysts to increase product yields, control product selectivity, and reduce deactivation during CFP and downstream processing steps. The results served to increase fundamental understanding of key catalyst attributes and durability features for the upgrading of biomass pyrolysis vapors. Model compound experiments confirmed the importance of metal-acid bifunctionality for the deoxygenation of lignin-derived phenolic species under hydrodeoxygenation conditions. This insight led to the development of catalysts such as Pt/TiO2 and Mo2C, which were confirmed as high-performing materials during subsequent bench-scale experiments using biomass-derived pyrolysis vapors. This focus area also led to the identification of important catalyst deactivation mechanisms associated with the deposition of inorganic contaminants such as potassium. The molecular-level insight from model compound experiments and computational modeling, shown in Figure 1, informed the development of regeneration procedures that have been shown to be effective for restoration of > 90% of initial catalyst activity. This understanding has subsequently been translated to other catalyst systems, including zeolite materials that can be operated without requirements for co-fed hydrogen.

09 BIOMASS FUELS↗

DOE OSTI2023

20 kV Gallium Nitride pn Diode Electro-Magnetic Pulse Arrestor for Grid Reliability (Final Report)

This project developed vertical Gallium Nitride (GaN) pn diodes under two main thrusts: (1) A focus on relatively higher-voltage devices for use as fast EMP arrestors to protect the electric grid; and (2) A focus on a Foundry effort to establish the manufacturability of relatively lower-voltage devices. For the first thrust, the aim was to develop devices that go into avalanche breakdown to clamp the voltage across sensitive grid equipment subject to voltage transients induced by electromagnetic pulses (EMPs). Devices with breakdown voltages exceeding 6.5 kV were achieved, and breakdown times shorter than 1 ns were demonstrated, which is sufficiently fast to protect against the fast component of an EMP-induced signal. Key challenges included the epitaxial growth of thick (50 um or more), low-doped (low 10 15 cm -3 range) GaN layers comprising the drift regions of the diodes, as well as the design and fabrication of edge termination structures (step-etched junction termination extensions) to prevent premature breakdown. Midway through the project, an additional emphasis was put on large-area, high-current devices, and forward currents of approximately 400 A were achieved in composite devices towards the end of the project. Experimental and theoretical studies of impact ionization and avalanche ruggedness were also conducted. For the second thrust (the Foundry), the focus was primarily on 1.2-kV-class devices, although towards the end of the project outstanding results on 3.3-kV-class devices were also achieved. The aim of the Foundry was to develop a high-yield, reliable, and economic vertical GaN pn diode process. The Foundry conducted characterization of incoming epitaxial material and correlated this information with the yield and performance of fully processed devices. Wafer maps of diode characteristics such as forward and reverse current as well as capacitance-voltage curves were measured using auto-probing. Several mask sets comprising different-area devices as well as multiple edge termination designs (implanted junction termination extensions, guard rings, and combinations thereof) were studied, and machine-learning-based approaches were utilized to analyze the data. Packaging and reliability efforts were also undertaken for the Foundry diodes, which are necessary for a viable commercial process.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2025

S&TR July-August: Beyond Ignition

On December 5, 2022, Lawrence Livermore’s National Ignition Facility achieved the first-ever successful positive-gain ignition shot. This scientific advance, heralded worldwide, required a multidecadal effort to synthesize physics theory, laser technologies, computation and diagnostic capabilities, as well as engineering, materials development, and other inputs. The question, “Can ignition be achieved?” had been answered. Since then, the Laboratory has answered the question, “Can we do it again?” with additional ignition shots at increasing yield. Now Lawrence Livermore researchers ask, “Can we improve ignition outcomes?” for the benefit of the Stockpile Stewardship Program. Interrelated articles presenting the Laboratory’s ignition science, the role of supercomputing in achieving ignition, the evolution of diagnostic instruments to measure ignition data, and the ambitious steps required to realize a fusion energy future lead to one answer: “Yes, we can.”

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2023

Automated Air Sealing Demonstration: Denver Federal Center Building 40

This project aimed to demonstrate building airtightness achieved by automated air sealing in a commercial building setting. The automated air sealing demonstrated in this project uses a modified blower door to pressurize and distribute the sealing aerosol to achieve the required building airtightness. To demonstrate this technology, Building 40 at the Denver Federal Center, a federally owned campus under the jurisdiction, custody and control of the U.S. General Services Administration (GSA), was selected for testing (Figure 2). This building is currently undergoing several retrofit projects, including increasing insulation, installing high-performance windows, and adding advanced equipment, control systems, and automated air sealing. This demonstration project involved installing automated air sealing and measuring the improvements in the building's airtightness. The automated air sealing was installed over two days by AeroBarrier, the vendor. An external blower door test contractor measured the airtightness of the demonstration space before and after air sealing. The new airtightness value and the percentage increase in airtightness were used to evaluate the energy savings potential of automated air sealing. These airtightness values were used to compute the energy savings and CO 2 emissions reduction for different climate zones, building types, and initial airtightness conditions. In addition, the heating, ventilation and air conditioning (HVAC) load reduction attributable to the reduced building air leakage was studied. This study included research to determine the cost and time reduction of automated air sealing. Finally, the automated air sealing performance was evaluated qualitatively using a focus group discussion that included GSA and Bristol, the general contractor. The installation has shown the demonstration site, with a floor size of 4,462 ft 2 , air leakage has reduced by more than 50% in less than 7 hours, including preparation, site sealing, and cleanup. The performance objectives were classified as quantitative or qualitative based on the evaluation metrics used to assess the project’s success. The key performance objectives for this project were the level of airtightness achieved, the time and cost required to perform the sealing, and the HVAC load reduction attributable to air sealing. Table 1 shows the quantitative performance objectives.

42 ENGINEERING↗

DOE OSTI2025

Efficient and Selective Chemical Transformations in Highly Charged and Confined Nanodroplets

The acceleration of chemical reaction rates and the increased product selectivity in microdroplets compared to that in bulk solutions has become a topic of increasing interest that has been extensively characterized by electrospray ionization mass spectrometry (ESI-MS). However, the sources of this acceleration and the detailed relationships between droplet properties and resulting reaction rate acceleration are still under debate. Moreover, droplet properties are governed by multiple interrelated experimental parameters, i.e., electrospray voltage, solution flow rate, etc., which makes it difficult and time-consuming to explore this diverse parameter space using traditional manual experimental or computational approaches. In this work, we developed an automated experimental platform integrating reactions in controlled charged microdroplet environments with ESI-MS characterization and sequential hybrid Bayesian modeling, as well as an optimal experimental design framework, to achieve multidimensional parameter optimization for higher reaction turnover rates, based on a model reaction of tetraethylenepentamine (TEPA) with carbon dioxide. With the current platform, we have achieved automated scans with a range of electrospray voltages and solution flow rates, and determined and optimized parameter settings to achieve increased reaction turnovers. We have also linked this platform to the underlying properties of droplets via a hybrid model incorporating physics, high-level theoretical calculations, and machine learning (ML) approaches. The autonomous platform is broadly applicable to a range of chemical reactions relevant to DOE’s mission in chemical separations, catalysis, and materials synthesis.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Application of Raman Spectroscopy to Determine Uranium Content in ADUN Solution

The work presented in this report is part of the ongoing efforts to address the nuclear material control and accounting needs for advanced reactor fuel fabrication facilities. This work was supported by the Materials Protection, Accounting, and Control Technologies (MPACT) program under the US Department of Energy Office of Nuclear Energy‘s Nuclear Fuel Cycle and Supply Chain program. The activities and engagements under the MPACT program are designed to support a robust US civilian nuclear energy enterprise. In the work described in this report, we supported MPACT objectives by developing measurement techniques that could be used for material accounting and process monitoring and by working with industry partners to identify existing gaps and areas for improvement. Oak Ridge National Laboratory has been working with commercial tristructural isotropic (TRISO) fuel fabricators such as Standard Nuclear to develop technology for rapid and cost-effective uranium content assessment. This work has focused on demonstrating advanced measurement techniques (e.g., Raman spectroscopy) that can be used for rapid, reliable, and cost-effective routine measurements of uranium content in feed solutions and liquid waste streams as well as for monitoring in-line process measurements and product streams. Specifically, this report explores techniques for accurately determining uranium content in acid-deficient uranyl nitrate (ADUN) solutions and detecting low uranium concentrations in ammonia solutions. Developing such measurement techniques will benefit TRISO fuel fabrication facilities, facilities involved in other parts of the fuel cycle that require online monitoring of aqueous solutions, and potentially molten salt fuel reactors. This work supports developing Raman spectroscopy procedures to determine uranium concentrations in ADUN solutions, which are used as feedstock in the sol–gel process for creating TRISO fuel. Some additional benefits of using Raman spectroscopy for uranium quantification in fabrication facilities include enabling online monitoring of the chemical process, which would provide near real-time feedback; eliminating the need for sample transfers, preparation, or dilution; providing nondestructive measurements; and user friendliness. In this fiscal year, FY25, we determined the identity of the unknown Raman band at approximately 853 cm−1 that was discovered in ADUN Raman spectra in FY24, created calibration curves and determined uranium concentrations of two ADUN solutions, and compared the Raman results to results obtained from inductively coupled plasma mass spectrometry and Davies–Gray titration. Furthermore, we have identified focus areas for experimentation in future fiscal years. A key result is that the accuracy of using Raman can provide accuracy comparable to destructive analysist techniques, With a well-developed calibration curve, using standards and a large number of samples (more than five samples), uncertainty on the order of 1%–3% is achievable. Given that the uncertainties achieved by Raman spectroscopy were on the order of the uncertainties achieved using ICP-MS, we conclude that with a well-developed procedure Raman spectroscopy can be used to determine uranium concentrations in ADUN solutions for NMC&A applications. The benefits of such an approach are that the time and effort will be less than that of comparable destructive analysis techniques, with approximately the same level of technical expertise. This will be attractive to operators of fuel fabrication facilities as it will lower costs and improve efficiencies.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

Design, Fabrication and Concept for the Surface Treatment of the SRF Cavity Prototype for the CLIC Damping Rings

The Compact Linear Collider (CLIC) Damping Rings (DRs) need to generate ultra-low emittance bunches to achieve high luminosity in CLIC. This requires many wiggler magnets with big energy loss which is compensated by the Radio Frequency (RF) system. The resulting strong beam loading transients lead to a challenging design for the RF system. A novel SRF cavity at 2 GHz with an ultra-low R/Q parameter of below 1 Ω is proposed to minimize the transient beam loading effects below acceptable level. The design and fabrication of the bulk Nb prototype based on turning from a single piece of Nb and EB welding is presented. Moreover, conceptual study of the system for cavity surface treatment to achieve the highest surface magnetic field which is the main goal of the prototype cold test is described as well. To enable excellent performance in this cavity, we plan to apply the 75/120C modified low temperature bake in combination with the cold electropolishing process. This surface treatment approach has been shown to consistently deliver high accelerating gradients and improved quality factors in TESLA-shaped 1.3 GHz SRF cavities. By adapting and implementing this process for the 2 GHz ultra-low R/Q design, we aim to maximize the achievable surface magnetic field while minimizing residual resistance and field emission. This treatment strategy will be critical for demonstrating that the cavity can meet the demanding performance requirements of the CLIC damping ring RF system under high beam loading conditions.

Bafia, Daniel P. [Fermilab]↗

DOE OSTI2026

Findings from Large Bench-Scale Testing of Denitration Electrolyzers for the EDCGe Project

This report highlights the key findings and outcomes relevant to the processability of waste supernatant at Hanford using a denitration electrolyzer. The Electrosynthesis Company issued a Phase 1 report to the Savannah River National Laboratory (SRNL), summarizing the evaluation of large bench-scale denitration electrolyzers to support the electrochemical denitration and caustic generation (EDCGe) project. The Electrosynthesis Company’s report (attached as Appendix A) provides insights into the initial steps required to implement an electrolyzer system at Hanford. Phase 1 experiments focused on validating the denitration electrolyzer’s performance, operating parameters, and reaction products. The robustness of the electrochemical denitration process was demonstrated by two electrolyzer flow cell systems (a 100 cm 2 ElectroCell MP and a 150 cm 2 NESI NS01 cell), both of which achieved significant nitrate and nitrite removal (>50%) with a current efficiency of ~95% for both systems. Higher current densities (500 mA cm –2 ) improved nitrate and nitrite removal rates compared to lower current densities (333 mA cm –2 ), while maintaining a current efficiency of ~94%. The NS01 cell achieved a nitrate species removal rate of ~0.41 mol h –1 at 5 kA m –2 (equiv. to 500 mA cm –2 ). The primary reaction product was ammonia (NH 3 ), constituting 78.3–91.6% of the products (excluding OH – formation). NH 3 was predominantly retained in the catholyte liquid phase rather than being off-gassed. Additionally, the NS01 cell reported an NH 3 generation rate of ~0.36 mol h –1 at 5 kA m –2 . Other gas formation included ~7% N 2 , ~7% H 2 , and trace amounts of N 2 O. The estimated power requirement (extrapolated from the 0.015 m 2 cell data) for a full-scale denitration electrolyzer is approximated to be ~1.6 MW (DC-only) to treat 50% of nitrate and nitrite in a waste stream and generates ~2.1 kmol h –1 of NH 3 with an initial concentration of 4 M NO 3 – /NO 2 – at 300 gal h –1 . Simulated waste containing aluminate, carbonate, oxalate, and halogens exhibited no adverse effects on denitration performance. A preliminary experiment comparing alkaline anolyte (5 M NaOH) with a nickel based anode to acidic media (2 M H 2 SO 4 ) with a DSA-O 2 anode showed a lower operating voltage and generated less H 2 than the acid media. Maintaining a stable 5 M OH – concentration in the anolyte through periodic additions of caustic did not significantly impact denitration performance. This operational mode will be required for long-term experiments. All the experiments demonstrated that electrochemical denitration is a promising approach for treating nitrate and nitrite in simulated waste streams, achieving significant conversion and robustness across varying experimental conditions and electrochemical cell configurations. Lastly, the ability to generate a nearly pure NH 3 stream may prove advantageous for processing at other locations within the Hanford site.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2026

Novel Method for Domestic Stable Isotope Production

This report presents the progress achieved on our chlorine isotope separation efforts in the CRADA #667 agreement. We used a microchannel distillation (MCD) packing structure to enrich HCl isotopes (H35Cl, H37Cl) and an isotachophoresis (ITP) separation to enrich ionic chloride species ( 35 Cl- and 37 Cl-). A 2 m tall MCD column was constructed and achieved 264 separation stages over several days, which is well above the goal of 50 stages outlined in the CRADA. The resulting height equivalent to a theoretical plate (HETP) was 0.76 cm. ITP tests were run ~ 24 hours and achieved a single-stage separation factor of 1.559.

07 ISOTOPE AND RADIATION SOURCES↗

DOE OSTI2025

Pushing the Boundaries of Coherence in Superconducting Quantum Systems at the SQMS Center for Computing, Sensing, and Metrology

This talk will highlight recent advances at the SQMS Center in understanding and mitigating decoherence in superconducting quantum systems, focusing on both transmon qubits and 3D superconducting cavities. I will present results from systematic studies of materials and devices, aimed at identifying key sources of loss: including two-level systems (TLS), quasiparticles, and other noise mechanisms. These studies span microwave loss characterization in materials such as niobium, tantalum, aluminum, and their native oxides, as well as substrate losses in silicon and sapphire. Using both qubits and cavities, we disentangle subsystem contributions to loss and develop a hierarchy of mitigation strategies. Through these efforts, we have achieved transmon coherence times exceeding one millisecond. I will also present investigations into quasiparticle dynamics, including bursts observed in qubits located above ground and in the Gran Sasso underground laboratory. Additional studies explore temperature dependence to distinguish between TLS and quasiparticle losses, and reveal that applying a magnetic field can reduce temporal T1 fluctuations in transmons. Building on these results, we demonstrate a record-coherence two-cell cavity-qudit system with coherence times exceeding 20 milliseconds. By leveraging sideband interactions and error-resilient protocols including measurement-based correction and post-selection, we achieve high-fidelity quantum state control. This includes preparation of Fock states up to N = 20 with fidelities over 95%, and two-mode entanglement with coherence-limited fidelities reaching 99.9% after post-selection. These achievements position the SQMS platform as a powerful foundation for scalable quantum information processing and high-dimensional qudit encodings. Finally, I will discuss how these ultra-coherent systems are being deployed in emerging quantum sensing applications, including dark matter searches and gravitational wave detection.

Roy, Tanay [Fermilab]↗

DOE OSTI2026

Higher Efficiency, Demand Flexible Refrigerator with On-Demand Micro-Vibrational De-icing Technology

Refrigerator technology has advanced significantly over the last couple of decades. Today’s refrigerators use only about 25% of the energy that was required to power models built in 1975. Even as they continually improve efficiency to meet standards, refrigerators have increased in size by almost 20%, added energy-consuming features such as through-the-door ice, and provide more benefits than ever before. However, a few challenges and technology gaps are preventing further improvement of the demand responsiveness and efficiency of the refrigerators. One of the major technology gaps in existing refrigerators is their outdated de-icing process. When the evaporator generates frost, an old-fashioned resistive heating element melts the ice. Most refrigerators have a timed defrost cycle, rather than an active system that could monitor the state of the frost. In these systems, not only is the precious electricity used at its least efficient form of conversion (direct conversion of electricity to heat), but also all the latent heat associated with the ice is wasted during the melting process. On top of that, the refrigerator needs to work harder to pull the temperature down after defrosting, and, last but not least, the food quality is severely impacted by the temperature swings during the defrost cycle. According to a study, the EU alone wastes 89 million tons of food in the supply chain every year. Any temperature swing during defrosting (about 6F according to Emerson for low-temperature cases) can negatively impact the shelf life of meat and other products for multiple days. All these issues can happen during the peak demand time of the electric grid. Unlike the conventional systems, the proposed novel advanced micro-vibrational deicing process uses no heat for defrosting. Instead, it uses the micro vibrations generated by a piezoelectric or vibration-generating module to mechanically break ice from the heat exchanger almost instantaneously. The project titled “Higher Efficiency, Demand Flexible Refrigerator with On-Demand Micro-Vibrational De-icing Technology, performed by Ultrasonic Technology Solutions, LLC (UTS) of Knoxville, TN, in collaboration with Emerson (now Copeland), represents the final phase of a multi-year effort funded under the U.S. Department of Energy’s Building Technologies Office (BTO) BENEFIT FOA 2020. Initiated on October 1, 2021, and completed after a nine-month no-cost extension ending September 30, 2025, this project aimed to develop and validate a novel micro-vibrational mechanical defrosting system, achieving more than 25% improvement in defrosting energy efficiency over conventional baseline defrosting technologies. Over sixteen quarters, the project advanced from fundamental ice-mechanical characterization and prototype development to full-scale system integration and validation. Initial efforts established project management infrastructure and characterized ice adhesion properties, followed by the design and fabrication of early aluminum-based prototypes for resonance frequency testing. Subsequent quarters saw rapid technical progression, including the identification of optimal piezoelectric and motor-based vibration mechanisms, the demonstration of effective de-icing over 6x6-inch aluminum surfaces. The team achieved its Go/No-Go milestone by exceeding the 25% energy-efficiency improvement target—reaching up to 3,340% under optimized conditions—and later confirmed that motor-driven systems offered superior performance and energy efficiency compared to piezoelectric alternatives. Continued refinement led to the development of amplifier systems on printed circuit boards, improved control and instrumentation hardware, and integration into full-scale heat exchanger (HX) prototypes at both UTS and Copeland facilities. Multiple vibration-mounting studies and frost-growth experiments guided mechanical optimization and noise-mitigation strategies, achieving a 17.5 dB reduction in sound pressure level and verifying robust mechanical performance. Advanced analyses, including modal and harmonic simulations, established a quantitative understanding of vibrational behavior and de-icing efficiency across >1000 cm² systems. The final project phase successfully demonstrated scalable integration within reach-in and chest freezer prototypes, confirmed >25% efficiency improvements in large-area systems, and completed a comprehensive business model and scale-up strategy identifying electric defrost systems as the primary beachhead market. The culmination of this DOE-supported effort establishes micro-vibrational defrosting as a viable, high-efficiency, low-noise, and demand-flexible de-icing technology, paving the way for commercial deployment and broader application in next-generation refrigeration systems.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2026

Improvements to Stripping Foils in BTA

To achieve the desired charge state in the Alternating Gradient Synchrotron (AGS), there is a stripping foil in the Booster to AGS (BtA) transfer line. For light ions, such as p, d, and h, they are already fully stripped in the Booster, or ions such as O have few electrons to be stripped off, and a thin foil of aluminum is used. For medium weight ions, such as Zr and Ru, they use what foils are available which have been optimized for heavy and light ions at 100 MeV/u. This worked well in the Zr case which achieved a measured stripping efficiency of 87%, contrary to the Ru case which achieved a measured stripping efficiency of 63%. For the EIC early science, Ag is currently intended to be the first ion. Using our existing foils, this would, at best, yield a helium-like charge state with a theoretical stripping efficiency of 50%. To improve on this, two foils of Ti or Nb have been selected to provide optimal stripping efficiency of Ag, and other energetic medium ions, which can reach 90% efficiency to fully strip the Ag ions. For heavy ions, the Al+C or Al+Ni stripping foils (sandwich foils) are used to produce helium-like charge states. For high intensity operation of Au, the Al foil nears its melting point and, in some cases, has been severely damaged. To maximize foil lifetime, there is a maximum intensity per unit time in BTA dependent on the Booster and AGS timing configurations. To mitigate the risk of melting the Al, replacement foils that use Ti, Nb, or anodized Al have been evaluated for their improved thermal qualities. At the selected thicknesses, each foil has equivalent charge distributions before entering the C foil, and should provide the same stripping efficiency through the entire sandwich.

43 PARTICLE ACCELERATORS↗