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Mountaineer Commerical Scale Carbon Capture and Storage (CCS) Project

The Final Technical documents all work performed during the award period on the Mountaineer Commercial Scale Carbon Capture & Storage project. This report presents the findings and conclusions produced as a consequence of this work. As identified in the Cooperative Agreement DE-FE0002673, AEP's objective of the Mountaineer Commercial Scale Carbon Capture and Storage (MT CCS II) project is to design, build and operate a commercial scale carbon capture and storage (CCS) system capable of treating a nominal 235 MWe slip stream of flue gas from the outlet duct of the Flue Gas Desulfurization (FGD) system at AEP's Mountaineer Power Plant (Mountaineer Plant), a 1300 MWe coal-fired generating station in New Haven, WV. The CCS system is designed to capture 90% of the CO{sub 2} from the incoming flue gas using the Alstom Chilled Ammonia Process (CAP) and compress, transport, inject and store 1.5 million tonnes per year of the captured CO{sub 2} in deep saline reservoirs. Specific Project Objectives include: (1) Achieve a minimum of 90% carbon capture efficiency during steady-state operations; (2) Demonstrate progress toward capture and storage at less than a 35% increase in cost of electricity (COE); (3) Store CO{sub 2} at a rate of 1.5 million tonnes per year in deep saline reservoirs; and (4) Demonstrate commercial technology readiness of the integrated CO{sub 2} capture and storage system.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Assessment of the Mechanical Stress Improvement Process for Mitigating Primary Water Stress Corrosion Cracking in Nickel Alloy Butt Welds in Piping Systems Approved for Leak-Before-Break

In recent years, operating experience has shown that Alloy 82/182/600 materials used in reactor coolant system (RCS) pressure boundaries of pressurized water reactors (PWRs) are susceptible to primary water stress corrosion cracking (PWSCC). Cracking can initiate at the inside surface of these materials, in part, because of tensile residual stresses introduced by welding. These materials are present in piping systems that were approved by the U.S. Nuclear Regulatory Commission (NRC) for leak before-break (LBB) before PWSCC was found in RCS dissimilar metal butt welds. The identification of PWSCC led to concerns regarding the potential effect of this degradation on existing LBB analyses. In response to these concerns, the NRC Office of Nuclear Regulatory Research initiated a program entitled, “PWSCC in Leak-Before-Break Systems,” and a follow-on program entitled, “Degradation in Extremely Low Probability of Rupture (xLPR) Systems.” Under these programs, Pacific Northwest National Laboratory (PNNL) is assessing the various strategies being used by industry to manage potential or existing PWSCC in susceptible welds in piping systems approved for LBB. The commercial nuclear power industry has implemented strategies to manage potential or existing PWSCC at Alloy 82/182 dissimilar metal welds (DMW) in PWRs. One general strategy consists of management by a combination of mitigation plus inspection, where several mitigation techniques have been used by industry. The other general strategy is to manage potential PWSCC by inspection alone. At the request of the NRC, the American Society of Mechanical Engineers (ASME) took actions to develop improvements to the existing Code requirements to address the potential for PWSCC in Class 1 PWR piping butt welds fabricated with Alloy 82/182 weld materials. The ASME developed Code Case N-770, “Alternative Examination Requirements and Acceptance Standards for Class 1 PWR Piping and Vessel Nozzle Butt Welds Fabricated with UNS N06082 or UNS W86182 Weld Filler Material With or Without Application of Listed Mitigation Activities, Section XI, Division 1.” It was realized that the Code Case needed to be revised to address specific examinations such as welds with a design life of less than 10 years and post-weld preservice surface examinations. In general, the revised Code Case (N-770-1) has requirements for inspection of unmitigated as well as mitigated Alloy 82/182 RCS butt welds. As such, specific inspection requirements for welds mitigated by the Mechanical Stress Improvement Process (MSIP®), the subject of this technical letter report (TLR), are contained in the Code Case. The NRC incorporated ASME Code Case N-770-1 by reference into §50.55a (76 FR 36232, p. 36278) in June 2011.

MSIP↗

Safety and Regulatory Issues of the Thorium Fuel Cycle

Thorium has been widely considered an alternative to uranium fuel because of its relatively large natural abundance and its ability to breed fissile fuel (233U) from natural thorium (232Th). Possible scenarios for using thorium in the nuclear fuel cycle include use in different nuclear reactor types (light water, high temperature gas cooled, fast spectrum sodium, molten salt, etc.), advanced accelerator-driven systems, or even fission-fusion hybrid systems. The most likely near-term application of thorium in the United States is in currently operating light water reactors (LWRs). This use is primarily based on concepts that mix thorium with uranium (UO2 + ThO2), add fertile thorium (ThO2) fuel pins to LWR fuel assemblies, or use mixed plutonium and thorium (PuO2 + ThO2) fuel assemblies. The addition of thorium to currently operating LWRs would result in a number of different phenomenological impacts on the nuclear fuel. Thorium and its irradiation products have nuclear characteristics that are different from those of uranium. In addition, ThO2, alone or mixed with UO2 fuel, leads to different chemical and physical properties of the fuel. These aspects are key to reactor safety-related issues. The primary objectives of this report are to summarize historical, current, and proposed uses of thorium in nuclear reactors; provide some important properties of thorium fuel; perform qualitative and quantitative evaluations of both in-reactor and out-of-reactor safety issues and requirements specific to a thorium-based fuel cycle for current LWR reactor designs; and identify key knowledge gaps and technical issues that need to be addressed for the licensing of thorium LWR fuel in the United States.

LWR Fuel↗

Development of a Solar Heat and Power Co-Generation System. Final Report, CRADA No. TC02152.0

Final Report, CRADA No. TC02152.0. Date Technical Work Ended: October 28, 2013. This was a collaborative effort between Lawrence Livermore National Security, LLC as manager and operator of Lawrence Livermore National Laboratory (LLNL) and Tassajara Technologies, Inc. (TTI), to develop, fabricate and demonstrate a Solar Heat and Power Co-generation System. The technical objectives of this CRADA were to engineer, design and build a prototype Solar Thermal Process Heat and Power Demonstration System that would be suitable for use at the Arc of Hilo food processing facility. This would be accomplished in two phases. The first phase would entail the building of a prototype at Tassajara facilities. Base design parameters, including the subsystem interactions that would produce reliable performance at the lowest cost per watt of energy generated with the desired balance of power and heat to meet the requirements of the designated food processing applications from Arc of Hilo, would be provided by LLNL. The data and design development would be integrated into the second phase engine prototype and solar thermal system that would be built and delivered, with interface requirements to the Miko Building. This project was originally designated as an eight (8) month project. However, it was ultimately extended by an additional thirty-five (35) months, for total project duration of forty-three (43) months.

14 SOLAR ENERGY↗

Development of a Solar Heat and Power Co-Generation System. Final CRADA Report

Final Report CRADA No. TC02152.0 Date Technical Work Ended: October 28, 2013. This was a collaborative effort between Lawrence Livermore National Security, LLC as manager and operator of Lawrence Livermore National Laboratory (LLNL) and Tassajara Technologies, Inc. (TTI), to develop, fabricate and demonstrate a Solar Heat and Power Co-generation System. The technical objectives of this CRADA were to engineer, design and build a prototype Solar Thermal Process Heat and Power Demonstration System that would be suitable for use at the Arc of Hilo food processing facility. This would be accomplished in two phases. The first phase would entail the building of a prototype at Tassajara facilities. Base design parameters, including the subsystem interactions that would produce reliable performance at the lowest cost per watt of energy generated with the desired balance of power and heat to meet the requirements of the designated food processing applications from Arc of Hilo, would be provided by LLNL. The data and design development would be integrated into the second phase engine prototype and solar thermal system that would be built and delivered, with interface requirements to the Miko Building.

14 SOLAR ENERGY↗

Characterization of the Sulfur-Saturated Melt Versions of the HFG1 Study Glasses

The U.S. Department of Energy (DOE) is responsible for building the Hanford Tank Waste Treatment and Immobilization Plant (WTP) at the Hanford Site in Washington to remediate 55 million gallons of radioactive waste that is temporarily stored in 177 underground tanks. The Office of River Protection (ORP) has requested that the Savannah River National Laboratory (SRNL) contribute to current glass studies to support successful startup of the WTP, due to SRNL’s recognized capabilities and expertise for glass waste form development. As part of this effort, the Pacific Northwest National Laboratory (PNNL) is developing, batching, and fabricating simulated high-level waste (HLW) glasses to generate the associated property data needed to validate or identify areas of potential characterization improvements in the current glass property/ composition models. Currently, the models cover only a small fraction of the waste compositions projected in the Hanford tank farm; therefore, the models must be expanded to include high fluoride compositions to successfully complete the WTP mission. SRNL support of this work is defined in the Task Technical and Quality Assurance Plan (TTQAP). This report provides results from the chemical analyses of a series of sulfur-saturated melt (SSM) versions of simulated nuclear waste glasses fabricated at PNNL. The glasses were selected as part of a broader study of the influence of glass composition on chemical durability, sulfur retention, and other properties. The glasses were designated the High Fluoride Glasses-1 (HLG1).

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Global Cost and Weight Evaluation of Fuselage Side Panel Design Concepts

This report documents preliminary design trades conducted under NASA contracts NAS1 18889 (Advanced Technology Composite Aircraft Structures, ATCAS) and NAS1-19349 (Task 3, Pathfinder Shell Design) for a subsonic wide body commercial aircraft fuselage side panel section utilizing composite materials. Included in this effort were (1) development of two complete design concepts, (2) generation of cost and weight estimates, (3) identification of technical issues and potential design enhancements, and (4) selection of a single design to be further developed. The first design concept featured an open-section stringer stiffened skin configuration while the second was based on honeycomb core sandwich construction. The trade study cost and weight results were generated from comprehensive assessment of each structural component comprising the fuselage side panel section from detail fabrication through airplane final assembly. Results were obtained in three phases: (1) for the baseline designs, (2) after global optimization of the designs, and (3) the results anticipated after detailed design optimization. A critical assessment of both designs was performed to determine the risk associated with each concept, that is the relative probability of achieving the cost and weight projections. Seven critical technical issues were identified as the first step towards side panel detailed design optimization.

Polland, D. R.↗

Technical Assessment of the National Full Scale Aerodynamic Complex Fan Blades Repair

This report describes the principal activities of a technical review team formed to address National Full Scale Aerodynamic Complex (NFAC) blade repair problems. In particular, the problem of lack of good adhesive bonding of the composite overwrap to the Hyduliginum wood blade material was studied extensively. Description of action plans and technical elements of the plans are provided. Results of experiments designed to optimize the bonding process and bonding strengths obtained on a full scale blade using a two-step cure process with adhesive primers are presented. Consensus recommendations developed by the review team in conjunction with the NASA Ames Fan Blade Repair Project Team are provided along with lessons learned on this program. Implementation of recommendations resulted in achieving good adhesive bonds between the composite materials and wooden blades, thereby providing assurance that the repaired fan blades will meet or exceed operational life requirements.

Young, Clarence P., Jr.↗

1999 NASA High-Speed Research Program Aerodynamic Performance Workshop: High Lift - Volume 2

The High-Speed Research Program sponsored the NASA High-Speed Research Program Aerodynamic Performance Review on February 8-12, 1999 in Anaheim, California. The review was designed to bring together NASA and industry High-Speed Civil Transport (HSCT) Aerodynamic Performance technology development participants in areas of: Configuration Aerodynamics (transonic and supersonic cruise drag prediction and minimization) and High-Lift. The review objectives were to: (1) report the progress and status of HSCT aerodynamic performance technology development; (2) disseminate this technology within the appropriate technical communities; and (3) promote synergy among the scientist and engineers working HSCT aerodynamics. The HSR AP Technical Review was held simultaneously with the annual review of the following airframe technology areas: Materials and Structures, Environmental Impact, Flight Deck, and Technology Integration Thus, a fourth objective of the Review was to promote synergy between the Aerodynamic Performance technology area and the other technology areas within the airframe element of the HSR Program. This Volume 2/Part 1 publication presents the High-Lift Configuration Development session.

Hahne, David E.↗

6 K Cryocooler Program

The report summarizes experimental and theoretical work on an Oxford type Stirling Cycle mechanical precooler operating in the temperature range of 13-20 degrees Kelvin. It includes measurements of the thermal losses of particle regenerators made from lead, and rare earth and rare earth alloys in an operating three stage cryocooler. A 6 K hybrid cooler is designed using the technical information gathered on regenerator performance.

Gully, Willy↗

A Model-Driven Visualization Tool for Use with Model-Based Systems Engineering Projects

Model-Based Systems Engineering (MBSE) promotes increased consistency between a system's design and its design documentation through the use of an object-oriented system model. The creation of this system model facilitates data presentation by providing a mechanism from which information can be extracted by automated manipulation of model content. Existing MBSE tools enable model creation, but are often too complex for the unfamiliar model viewer to easily use. These tools do not yet provide many opportunities for easing into the development and use of a system model when system design documentation already exists. This study creates a Systems Modeling Language (SysML) Document Traceability Framework (SDTF) for integrating design documentation with a system model, and develops an Interactive Visualization Engine for SysML Tools (InVEST), that exports consistent, clear, and concise views of SysML model data. These exported views are each meaningful to a variety of project stakeholders with differing subjects of concern and depth of technical involvement. InVEST allows a model user to generate multiple views and reports from a MBSE model, including wiki pages and interactive visualizations of data. System data can also be filtered to present only the information relevant to the particular stakeholder, resulting in a view that is both consistent with the larger system model and other model views. Viewing the relationships between system artifacts and documentation, and filtering through data to see specialized views improves the value of the system as a whole, as data becomes information

relational databases↗

Deep Borehole Field Test Specifications

This report documents conceptual design development for the Deep Borehole Field Test (DBFT), mainly the test packages (not containing waste) and the system for demonstrating emplacement and retrieval of those packages in the Field Test Borehole (FTB). For the DBFT to have demonstration value, it must be based on conceptualization of a deep borehole disposal (DBD) system for specific waste forms. This document therefore describes a current reference DBD concept, and analyzes key design options for disposal, to guide selection of options for the DBFT. The most important of these options is the emplacement mode, i.e. whether packages are emplaced using a wireline or a string of drill pipe (with a drill rig). This choice is analyzed using cost and risk models, in Sections 5 and 6. Other emplacement mode options are also identified and discussed. The reference DBD concept and the analysis of waste packaging and emplacement options, are used to develop requirements and assumptions for the DBFT and to recommend DBFT specifications. Design issues are identified, and priorities are developed for further conceptual design development and additional engineering analysis, anticipating future design activities. Conceptual design development is part of a process that proceeds in three stages: 1) conceptual design including feasibility studies; 2) preliminary design that includes technical and cost information necessary for final design; and 3) final design sufficient for fabrication or construction. The DBFT engineering demonstration will follow such an evolution. Whereas design evolution typically begins with bench-scale and pilot-scale investigations proceeding to conceptual, preliminary, and final designs, the DBFT can proceed directly to design because of extensive previous work and published literature on scientific drilling, characterization methods, waste packaging and handling, industrial deep-hole drilling and construction, and downhole operations. Hence it is anticipated that this report will lead to completion of conceptual design, then preliminary and final design, fabrication and testing, and demonstration of waste emplacement in a deep borehole.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Final Technical Report

The research summarized here has the goal of developing a fundamental understanding of how catalysts work. These materials are demonstrably essential to our daily life, from the cars we drive to the clothes we wear. Our Center advances the science behind how we prepare, analyze, and describe catalysts. This has been identified by one of the documents guiding Federal research objectives (Directing Matter and Energy: Five Challenges for Science and the Imagination): “Major challenges in heterogeneous catalysis are to more clearly define the nature of the active sites, to engineer at the molecular level catalysis with designed properties in three dimensions, and to create new catalysts for new transformations.” This directly addresses this objective.

10 SYNTHETIC FUELS↗

Expert and operator perspectives on barriers to energy efficiency in data centers

Abstract It was last estimated in 2016 that data centers (DCs) comprise approximately 2% of total US electricity consumption. However, this estimate is currently being updated to account for the massive increase in computing needs due to streaming, cryptocurrency, and artificial intelligence (AI). To prevent energy consumption that tracks with increasing computing needs, it is imperative we identify energy efficiency strategies and investments beyond the low-hanging fruit solutions. In a two-phased research approach, we ask: What non-technical barriers still impede energy efficiency (EE) practices and investments in the data center sector, and what can be done to overcome these barriers? In particular, we are focused on social and organizational barriers to EE. In Phase I, we performed a literature review and found that technical solutions are abundant in the literature, but fail to address the top-down cultural shifts that need to take place in order to adapt new energy efficiency strategies. In Phase II, reported here, we interviewed 16 data center operators/experts to ground-truth our literature findings. Our interview protocols focus on three aspects of DC decision-making: procurement practices, metrics and monitoring, and perceived barriers to energy efficiency. We find that vendors are the key drivers of procurement decisions, advanced efficiency metrics are facility-specific, and there is convergence in the design of advanced facilities due to the heat density of parallelized infrastructure. Our ultimate goals for our research are to design DC decarbonization policies that target organizational structure, empower individual staff, and foster a supportive external market.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

CRADA Number NFE-19-07867 with Neptune Fluid Flow Systems (CRADA Final Report)

Neptune Fluid Flow Systems is a rising engineering firm with a technology focus in improving cryogenic sample preparation for cryogenic-transmission electron microscopy (cryo-TEM) studies. To advance the R&D of its innovative cryogenic preparation method, Neptune has teamed up with the Center for Nanophase Materials Science (CNMS) at Oak Ridge National Laboratory (ORNL) to achieve the following aims: (1) validate the technical feasibility of CryoSheet sample prep method, (2) design, fabricate and test the cryo-stage support, and (3) experiment and achieve success with the novel sample preparation method on different soft matters.

36 MATERIALS SCIENCE↗

HPDF Data Catalog and Lakehouse Demo Heuristic Evaluation and Roadshow Feedback Reports

The December 2025 roadshow gathered rapid feedback from community members on the proof of concept AmSC/HPDF data lakehouse and catalog solution 1. This provided the opportunity to demonstrate our current state of progress and gather input on workflows and AI agents. We recognize that the proofs of concept interfaces (OpenMetadata and Goose) are not intended for our end users so we have captured feedback to keep in mind as additional technical and conceptual design work is undertaken.

97 MATHEMATICS AND COMPUTING↗

Energy Storage Annual Progress Report for FY15

The Energy Storage research and development (R&D) subprogram within the DOE Vehicle Technologies Office (VTO) provides support and guidance for projects focusing on batteries for plug-in electric vehicles (PEVs) in support of the EV Everywhere Grand Challenge. PEVs could have a significant impact on the nation's goal of reducing dependence on imported oil and gaseous pollutant emissions. The Energy Storage program targets overcoming technical barriers to enable market success, including: (1) significantly reducing battery cost; (2) increasing battery performance (power, energy, durability); (3) reducing battery weight and volume; and (4) increasing battery tolerance to abusive conditions such as short circuit, overcharge, and crush. The National Renewable Energy Laboratory (NREL) supports the VTO's Energy Storage program by evaluating the thermal performance of cells and packs, developing electrochemical-thermal models to accelerate the design cycle for developing batteries, investigating the behavior of lithium-ion batteries under abuse conditions such as crush, enhancing the durability of electrodes by coatings such as atomic layer deposition, synthesis of materials for higher energy density batteries, and conducting techno-economic analysis of batteries in various electric-drive vehicles. This report describes the progress made by NREL on the research and development projects funded by the DOE VTO Energy Storage subprogram in FY15.

25 ENERGY STORAGE↗

Quantum Materials at the Nanoscale - Final Report

The central aim of the Quantum Materials at the Nanoscale (QMN) cluster was to understand and control collective behavior involving the interplay of spins, orbitals, and charges, which governs many scientifically interesting and technologically important phenomena in numerous complex materials. Because these phenomena involve various competing interactions, and influence properties on many different length and energy scales in complex materials, tackling this important area of study motivated a collaborative effort that combined the diverse capabilities of QMN cluster experimentalists, the essential theoretical analysis provided by QMN cluster theorists, and the outstanding facilities and staff of the FSMRL. During the funding period 2007-2014, the DOE cluster grant for the Quantum Materials at the Nanoscale (QMN) cluster supported, at various times, 15 different faculty members (14 in Physics and 1 in Materials Science and Engineering), 7 postdoctoral research associates, and 57 physics and materials science PhD students. 41 of these PhD students have since graduated and have gone on to a variety of advanced technical positions at universities, industries, and national labs: 25 obtained postdoctoral positions at universities (14), industrial labs (2 at IBM), DOE national facilities (3 at Argonne National Laboratory, 1 at Brookhaven National Lab, 1 at Lawrence Berkeley National Lab, and 1 at Sandia National Lab), and other federal facilities (2 at NIST); 13 took various industrial positions, including positions at Intel (5), Quantum Design (1), Lasque Industries (1), Amazon (1), Bloomberg (1), and J.P. Morgan (1). Thus, the QMN grant provided the essential support for training a large number of technically advanced personnel who have now entered key national facilities, industries, and institutions. Additionally, during the period 2007-2015, the QMN cluster produced 159 publications (see pages 14-23), including 23 papers published in Physical Review Letters; 16 papers in Nature, Nature Physics, Nature Materials, or Nature Communications; 4 papers in Science, and 8 papers in Applied Physics Letters. In this report, we provide some key highlights of the collaborative projects in which the QMN cluster members have been involved since 2007.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗