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Plug into NREL's Resilient CUBE

Designed for mobility and flexibility, NREL's Consolidated Utility Base Energy (CUBE) is a hybrid power generation system that converts energy from different sources - solar panels, batteries, diesel generators, and host grid power - into tactical electricity, improving the efficiency and reliability of power for the military's forward operating bases. By reducing dependence on diesel generators, the CUBE also helps reduce the number of soldiers, sailors, airmen and marines shipping fuel across dangerous territory.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Land-Based Wind Energy Siting: A Foundational and Technical Resource

This land-based wind energy siting resource was created by the U.S. Department of Energy Wind Energy Technologies Office’s WINDExchange initiative and presents foundational information about land-based utility-scale wind energy that local decision makers can use when making community decisions about wind energy development. Consolidated, accessible, and easy to understand, this information resource focuses on land-based wind energy from the community perspective and examines siting-related impacts and mitigation strategies. Other impacts and strategies exist, such as those related to economics, climate, health, water, emissions, and waste; however, they are not covered in this resource. For more information on economic considerations, see the “Land-Based Wind: Economic Development Guide” and “Advancing the Growth of the U.S. Wind Industry: Federal Incentives, Funding, and Partnership Opportunities.” The intended audience for this guide is county-level decision officials, as they are often responsible for approving both wind energy ordinances and applicable permits needed for wind energy development. This guide may also provide relevant information to decision makers from other government jurisdictions and interested community members.

17 WIND ENERGY↗

Port Technical Assistance Program: A Proposed Initiative to Support U.S. Ports Through Energy Innovation

This document highlights the crucial importance of the maritime sector within the United States (U.S.) economy, serving as a key node for trade and global goods transportation. U.S. ports are currently grappling with challenges posed by rising shipping demands, the health impacts of diesel fuel reliance, and the technology adoptions of global trade partners due to increasing environmental regulations. This document proposes forming a technical assistance program, led by Pacific Northwest National Laboratory (PNNL), to help U.S. ports transition to sustainable energy solutions that not only improve environmental and community outcomes, but also enhance resilience to unexpected weather events and reduce pressure on local utilities. Coordinated by PNNL, this initiative would offer a web-based platform of consolidated resources and tools for comprehensive strategic planning and cost-benefit analysis. It also seeks to establish a collaborative network between ports and national laboratories to facilitate the sharing of best practices. The document suggests that optimizing resource allocation and providing tailored support could be achieved through strategic categorization of ports within this network, with relevant attributes and examples detailed in the report. The anticipated benefits of such a program could include increased efficiency and cost savings in port operations and the advancement of scientific innovation via alternative energy research. Also, it could enhance economic growth and competitiveness in international trade by enabling ports to meet shipping demands and develop resilient critical infrastructure through informed, long-term strategies.

33 ADVANCED PROPULSION SYSTEMS↗

Clear Sky Toolkit: Decision Support User Guide

The Clear Sky Decision Support Template is a Microsoft Excel-based resource that enables users to screen and prioritize critical facilities for the addition of solar + storage. The Decision Support Template consolidates and streamlines the most relevant resources from the emergency management discipline, the electric utility sector, and national energy research institutions to assist in further site analysis and decision-making. The Decision Support Template is intended for use by local government and private sector decision-makers who aim to mitigate the effects of power outages on critical infrastructure, understand the potential for deploying photovoltaic (PV) and storage solutions on critical facilities, and align emergency management planning processes and utility needs with community resilience objectives. The Decision Support Template is divided into five modules that provide a structured, step-by-step approach users can follow and apply to unique circumstances. This process guides a more thorough and accurate assessment of a site's potential to accommodate a solar + storage system, provide grid benefits to utilities, and support community resilience and disaster mitigation for the broader region. After identifying potentially viable and preferred sites for solar + storage using the Decision Support Template, users should conduct a more detailed evaluation and consultation with a solar professional.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Shear Assisted Processing and Extrusion (ShAPE) of Plastics: Recycling and Remolding

Polyethylene (PE) and polypropylene (PP) are often disposed as mixed plastic wastes. The challenges in recycling and upcycling these mixed polyolefin wastes lie in the difficulty in separating individual constituents in a cost-effective and scalable manner. Direct recycling the mixed PE and PP wastes in conventional melt-phase extruders typically result in a product with poor properties and low added value, because of immiscibility, phase separation, and lack of crystallinity. Friction extrusion (FE), a solid phase processing technique that has successfully extruded metal matrix composites with desired end products, has never been utilized to address the issue of recycling mixed plastic wastes. In this study, FE was performed on single-stream low-density polyethylene (LDPE), single-stream PP and mixed-stream LDPE+PP. Consolidated filaments of 2.5 mm diameter were extruded from different precursors. The thermal, infrared, and microscopic properties of extruded filaments were measured to evaluate the effects of FE process on the structure of recycled polymers. Meanwhile, the energy efficiency of FE was estimated based on extrusion rates and compared with conventional melt extrusion processes.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Illinois Basin Regional DAC Hub TA-1: Feasibility (Phase-0) (Final Scientific/Technical Report)

The overall objective of this project was to complete a feasibility study for a Regional Direct Air Capture (DAC) Hub that encompasses Illinois, Indiana, and Kentucky. The geographic construct of this hub was based on the Illinois Basin – a geological area where at least seven (7) geological storage studies were conducted. The Hub was designed to assure a capacity to capture, store, and utilize at least 1,000,000 metric tons (tonnes) of CO2 from the atmosphere annually 1 metric tonnes per annum (MTA), starting from an initial capacity of 200,000 tonnes of CO2 per annum (KTA). The Hub also included:(1) clean energy providers to supply renewable energy to the DAC units; (2) geological storage facilities to inject and sequestrate the captured CO2; (3) CO2 utilization facilities that would uptake the captured CO2 and convert it into products; and (4) small business organizations that would assist in workforce development efforts for the region. This closeout report consolidates the tasks undertaken and accomplished as deliverables for the project. The project team had successfully completed all required tasks of phase 0a, confirming that the project is feasible based on the preliminary conceptual designs and operational requirements of the DAC systems. Of particular interest, the hub ownership structure was identified and was implemented in follow on projects that would transition the hub infrastructure to a build/operate phase.

36 MATERIALS SCIENCE↗

A Business Case Evaluation of Gas Switching Reforming (GSR) Technology: A Promising Technology for Natural Gas Reforming with Integrated CO2 Capture

Hydrogen is essential in the transition to sustainable energy, and developing low-carbon production methods is a key research focus. Traditional steam methane reforming (SMR) dominates the hydrogen industry but contributes substantially to CO2 emissions. In response, Gas Switching Reforming (GSR) has emerged as a novel process that integrates carbon capture and utilizes process heat more efficiently. Unlike other reforming methods, GSR consolidates oxidation and reduction reactions within a single reactor, which minimizes external energy inputs and simplifies scaling. Like conventional steam methane reforming (SMR), GSR can be integrated with water-gas shift and pressure swing adsorption units for pure hydrogen production. This work presents a comprehensive business case analysis of GSR technology based on experimental results in Technology Readiness Level 3, Life Cycle Assessment (LCA) and Techno-Economic (TEA) evaluation incorporating ASPEN Plus process modeling considering different configurations and energy scenarios. The TEA incorporates data from kinetic experiments from various catalysts to evaluate the GSR process under various conditions. The goal of this work is to evaluate GSR’s potential to serve as a low-carbon alternative to SMR, focusing on global warming potential and additional impact categories to evaluate a wide spectrum of environmental impacts. Comparative assessments were conducted with SMR, chemical loop reforming (CLR), and proton exchange membrane (PEM) electrolysis to explore trade-offs across environmental metrics. The environmental impact assessment of this work encompasses the entire hydrogen production lifecycle from raw material extraction to plant decommissioning, using a cradle-to-gate boundary. Preliminary findings highlight that GSR, when integrated with low-carbon energy sources, could significantly reduce environmental impacts, making it a promising candidate for low-carbon hydrogen infrastructure. The insights from this business case evaluation aim to guide industry in scale-up and commercialization of this promising clean energy technology.

03 NATURAL GAS↗

Software-defined Networking for Energy Delivery Systems (SDN4EDS): An Architectural Blueprint (Final Report)

This is the initial version of a reference for suppliers and energy companies of all sizes to deploy networks based on software-defined networking technology (SDN) to improve reliability, reduce cyber security attack surface, and facilitate mitigation of adversarial behavior. It is a living document and will progress over the life cycle of the Software-Defined Networking for Energy Delivery Systems (SDN4EDS) project. Version 2 of this report provides information on the Red Team tabletop assessment performed against the initial reference architecture. Version 3 of this report updates the reference architecture with lessons learned from the Red Team tabletop assessment, as well as provides additional details for the use cases. It also provides information on the decision process that could be used by an organization when considering deploying SDN in their environment. The final version of this report consolidates all the interim reports generated by the project into a final report. It also draws from PNNL’s experience in deploying SDN to make recommendations on how SDN could be deployed in a utility environment, and provides rationale for those decisions allowing individual utilities to make risk-based and knowledge-based decisions on how to best deploy SDN in their own environment

97 MATHEMATICS AND COMPUTING↗

Software-defined Networking for Energy Delivery Systems (SDN4EDS): An Architectural Blueprint (Final Summary Report)

This is the initial version of a reference for suppliers and energy companies of all sizes to deploy networks based on software-defined networking technology (SDN) to improve reliability, reduce cyber security attack surface, and facilitate mitigation of adversarial behavior. It is a living document and will progress over the life cycle of the Software-Defined Networking for Energy Delivery Systems (SDN4EDS) project. Version 2 of this report provides information on the Red Team tabletop assessment performed against the initial reference architecture. Version 3 of this report updates the reference architecture with lessons learned from the Red Team tabletop assessment, as well as provides additional details for the use cases. It also provides information on the decision process that could be used by an organization when considering deploying SDN in their environment. The final version of this report consolidates all the interim reports generated by the project into a final report. It also draws from PNNL’s experience in deploying SDN to make recommendations on how SDN could be deployed in a utility environment, and provides rationale for those decisions allowing individual utilities to make risk-based and knowledge-based decisions on how to best deploy SDN in their own environment. This summary report provides a higher-level overview of the project reports. Readers interested in additional detail, including results of the Red Team assessments and the final configuration, are encouraged to read the full final report.

97 MATHEMATICS AND COMPUTING↗

How To Determine and Verify Operations and Maintenance Savings in Energy Savings Performance Contracts

Operations and maintenance (O&M) savings frequently occur in energy savings performance contracts (ESPCs). During FY 2022, 37% of reported annual cost savings for projects awarded under the U.S. Department of Energy (DOE) ESPC indefinite delivery indefinite quantity (IDIQ) contracts and in the performance period were due to O&M or other energy- and/or water-related cost savings, with the balance (63%) from utility cost savings (i.e., energy or water cost savings). Sometimes the energy- and water-related cost savings are acknowledged and included in payments within ESPCs; other times, for various reasons, they are not. As presented in this guide, FEMP recommends including energy- and water-related cost savings that are O&M (including related repair and replacement) savings in the financial aspects of an ESPC, to the extent such savings can be documented. Inclusion of these savings will help augment project scopes and/or lower interest costs (by shortening financing terms). However, there is a burden of proof as to what constitutes acceptability in O&M savings that needs to be carefully considered and documented in individual projects. Beyond promoting a key tenet used in U.S. federal performance contracting—that savings must be from actual budgets and therefore based on the level of O&M that is actually occurring, not what should have been performed—FEMP also recommends good practice in establishing and documenting O&M baselines, formulating the rationale for baseline adjustments during the performance period, and conducting ongoing verification activities. This document concludes with five examples of how O&M savings may be handled, in situations ranging from the partial displacement of O&M contracts to consolidation and “virtualization” of servers in data centers. A key theme that permeates this guide is the importance of thoroughly documenting all conditions and assumptions used in the development of and accounting for O&M costs and savings throughout the ESPC life cycle, from baseline-setting to measurement and verification (M&V) of the savings during each year of the performance period. Doing so not only prevents internal claims of non-performance (especially in the case of staff turnover during the contract term), but also simplifies ordering agency and energy service company (ESCO) response in the event of scrutiny from oversight organizations, such as government audits. While this guide focuses on federal ESPCs, it may also be applicable when O&M savings are included in utility energy service contracts (UESCs) and non-federal ESPCs.

Voss, Phil↗

Friction-based recycling: an evaluation of friction extrusion for fabricating Ti-6Al-4 V wire fabricated from machining chip feedstock

Abstract Titanium and its alloys are used in aviation and automobile industries due to their remarkable strength to weight ratio, but machining loss commonly is high with ~ 80 wt% of the material being converted to scrap. Recycling post-consumer Ti scrap directly into solid bulk products is a potential solution for repurposing valuable material. Further, eliminating fresh Ti sponge during recycling might lead to lower energy and greenhouse gas emissions. In this study, a solid-phase process known as friction extrusion was utilized to recycle Ti-6Al-4 V machining chips into solid wires which could be used as feedstock in additive manufacturing. The friction consolidation technique was first used to convert chips with varying degrees of oxygen content into solid billets for its use as feedstock material in subsequent friction extrusion. The extrudates were fabricated above the beta transition temperature, which was achieved by selecting the rotation rate and feed rate, to process the billets near 1000 °C using a tungsten-lanthana extrusion die. This work presents the first occurrence of friction extruded titanium alloy wires. The effect of friction extrusion on microstructural features, tensile properties, and texture are reported. Overall, the friction extrusion method is capable of directly recycling Ti-6Al-4 V scrap into extruded wire.

Friction Extrusion↗

Damaged Fuel in the United States

Over the years of commercial nuclear power plant operations in the United States (U.S.), many fuel assemblies have lost the capability to perform all of their desired functions. These assemblies have lost the capability to be handled, stored, or transported to meet regulations resulting in them being classified as damaged fuel. The causes of these failed assemblies are diverse and plant-specific. The majority of these failed assemblies are contained in a damaged fuel can that will be used in conjunction with a storage and/or transportation system. The storage and transportation systems have a limit on how many slots can be filled with damaged fuel cans. A damaged fuel can is generally a stainless steel container that confines damaged SNF and is closed on its end by screened openings. These screened openings allow gaseous and liquid media to escape but minimize the dispersal of gross particulate material. Out of an abundance of caution a few reactors have loaded high burnup fuel into damaged fuel cans. Damaged fuel is not licensed for storage or transport in the U.S., because the regulations for storage and transport do not specify exactly how to classify damaged fuel. Instead the regulations license/certify packages that specify approved contents. Damaged fuel must be included in the approved contents to be a viable option. In many cases damaged SNF is encapsulated in a damaged fuel can to ensure it can confine gross fuel particles, debris, and or damaged assemblies to a known volume within a loaded cask. This damaged fuel can may then be utilized in the same way as an assembly in a storage and transportation design system. Some storage cask systems utilize top and bottom plugs to confine debris in damaged fuel. The most recent domestic documentation on damaged SNF was performed by the U.S. Energy Information Administration (EIA) and used data from U.S. reactors concluding in June 30th 2013 to produce Form GC-859, “Nuclear Fuel Data Survey”. Based on this form there were 136,821 boiling water reactor (BWR) spent nuclear fuel (SNF) assemblies and 104,647 pressurized water reactor (PWR) SNF assemblies for a total of 241,468 SNF assemblies in the U.S. Out of these 241,468 SNF assemblies, 4,521 assemblies were classified as failed. Some assemblies were also disassembled and the fuel rods or pieces of fuel rods were combined together to make a consolidated assembly. A consolidated assembly may include damaged fuel, or it could have been consolidated as part of a demonstration project. The GC-859 data includes 2,550 consolidated assemblies containing between 0 and 264 whole fuel rods. These consolidated assemblies could be placed in single assembly canisters and stored in the spent fuel pool. For dry storage and transportation, a single assembly canister is generally placed in a damaged fuel can. In addition to the consolidated assemblies, 2,391 uncanistered fuel rod pieces exist, which were removed from 494 assemblies.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

INTERFUEL: FAST -- Fueling Center and EVSE Reporting Process Changes

This presentation presents an overview of coming changes to how federal agencies with motor vehicles will submit required information about fueling centers and electric vehicle supply equipment (EVSE) inventory through the Federal Automotive Statistical Tool (FAST). Historically, information covering these two areas has been provide during two separate data submissions, but is now being consolidated and simplified into a single submission due by December 15 of each year. The presentation provides background on the process, a re-cap of how the information is currently submitted, and describes the new approach for organizations to submit the required information. This presentation is intended for delivery via WebEx/GoToMeeting at the July 8, 2020 meeting of the DOE-sponsored INTERFUEL working group. FAST is a web-based information management tool developed by INL and funded by GSA's Office of Government-wide Policy and DOE's Federal Energy Management Program.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Community Solar Consolidated Billing: An Exploration of Implementation and Alternatives [Slides]

This presentation is an abridged version of the report it is based on that presents an analysis of the considerations, costs, and benefits surrounding the implementation of utility consolidated billing in community solar programs while also exploring alternatives to achieve similar benefits in its absence. Consolidated billing simplifies the billing process for customers by combining all charges and credits associated with electricity service and community solar subscriptions into a single bill. The potential benefits of consolidated billing implementation include increased transparency, improved customer experience, and ultimately increased retention rates and decreased subscriber acquisition costs. Currently, community solar subscribers often receive two separate bills - one from the utility and one from a third-party community solar provider - potentially causing confusion. Consolidated billing seeks to resolve this by offering a unified bill, which, while beneficial to numerous stakeholders, presents administrative, technical, and financial hurdles that utilities and program administrators must address.

14 SOLAR ENERGY↗

Climate Vulnerability Assessment and Resilience Planning for Idaho National Laboratory

Idaho National Laboratory’s (INL’s) mission is to discover, demonstrate, and secure innovative nuclear energy solutions, other clean energy options, and critical infrastructure. This INL’s Climate Vulnerability Assessment and Resilience Plan (VARP) was developed to enable and sustain that mission while ensuring the viability of operations considering expected climate change impacts. The VARP was developed according to the narrative requirements from the “Vulnerability Assessment and Resilience Planning Guidance, Version 1.2” document issued in February 2022. A prescribed process was used to identify mission-critical systems and components, determine historical and expected climate impacts, and develop resilient solutions. Experts from across INL, including operations staff, researchers, and climate scientists supplied input to the process. Analyses of climate modeling sources revealed that under scenarios of higher and lower greenhouse gas emissions (Representative Concentration Pathway (RCP) 4.5 and RCP 8.5), INL anticipates an increase in climate hazards, including drought, heat waves, wildfire, and precipitation. Increased frequency and duration of climatic hazards forecasts high impacts on certain mission-critical asset and infrastructure types. Utilizing the VARP Risk Assessment Tool, projected high climate hazard impacts across multiple asset and infrastructure types at the INL include energy generation and distribution systems, Site buildings, specialized or mission-critical equipment, and transportation and fleet infrastructure. Some of these mission-critical asset and infrastructure types maintain high adaptive capacity to climatic changes; however, others may need additional adaptive capacity to withstand increased frequency and duration of climate hazards. INL identified close to 300 resilient solutions that were consolidated into 11 solution categories to be tracked in the Department of Energy Sustainability Dashboard. The identified solutions are a starting point for future project development and analysis. These data are intended to inform decision makers on climate issues and potential solutions across INL and associated communities. The VARP is not intended to be a budget tool or project decision document on its own, but rather one of many tools used by decision makers to establish resilient priorities. This initial document provides the framework and foundation to resilient solutions. In the coming years, each solution needs to be fully developed, costed, and prioritized based on mission-critical risk and funding priorities.

54 ENVIRONMENTAL SCIENCES↗

An Integrated ML/AI Framework for Digitizing, Structuring and Searching DOE U-TRU-Fuels Data with Gap Analysis of Non-DOE Records

The U.S. Department of Energy (DOE) Advanced Fuels Campaign (AFC) is advancing transmutation fuel technologies to reduce long-lived radioactive waste by converting minor actinides into shorter-lived or stable elements through irradiation in sodium-cooled fast reactors. Key experiments such as AFC-1, AFC-2, FUels for the transmutation of Trans-URanium elements In phéniX (FUTURIX)-Fortes Teneurs en Actinides (FTA), and Experimental Breeder Reactor-II (EBR-II) X501 have provided fuel fabrication, irradiation, and performance data on various transuranic-bearing fuel forms. This report documents the creation of an artificial-intelligence assisted database, which has consolidated all DOE-owned data related to Transuranic (TRU)-bearing fuel experiments and stored across it across both the Idaho National Laboratory (INL) Nuclear Data Management and Analysis System and the INL high performance computing (HPC) infrastructure. A dedicated webpage, hosted on the INL HPC system, has been developed to support role-based access and data interaction. The database architecture allows researchers to navigate large, heterogeneous archives with far greater speed and accuracy than manual search and lays the foundation for future expansion into multimodal nuclear materials analysis environments. The database represents a major step towards a nationally integrated fuels database utilizing artificial intelligence tools.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

University Data Management Pilot Utilizing the Nuclear Research Data System

Background In 2022, the Office of Science and Technology Policy (OSTP) issued a memo that significantly reshaped the landscape of access to federally funded research. The memo mandated that all taxpayer-funded research be made available to the public without delay upon publication, without an embargo period, superseding the 2013 OSTP public access policy. This public access policy promotes transparency and the democratization of knowledge, ensuring that the fruits of scientific endeavors funded by federal agencies could be immediately accessed and built upon by scientists, educators, students, and the public at large. To implement the requirements of the OSTP guidance and DOE Public Access Plan, the Office of Nuclear Energy (NE) has implemented public access plan guidance and has identified several areas where better data management practices would further expand public access to important nuclear energy related scientific data, reports, and other technical products. Significant NE supported efforts are already underway for data management and public access to important nuclear energy related data.1 2 To address gaps in data management practices, and improve retention and accessibility of data, NE is actively exploring enhanced data management options utilizing its high-performance computing resources administered by its Nuclear Scientific User Facility Program. A newly piloted system, the Nuclear Research Data System (NRDS) acts as a portal for data collection and dissemination. Nuclear Energy University Program Research and Development Portfolio According to Web of Science, NEUP has produced 2,345 journal publication that have been cited more than 61,000 times3 and countless conference proceedings. These publications are publicly available through OSTI.gov and in the open literature. Additional scientific and technical products including project milestones that are not publications and NEUP project final reports are vetted through OSTI.gov and released once reviewed and approved by DOE. Since 2009, NEUP has awarded close to 1,000 different R&D projects in technical areas across the NE research programs. As of June 2023, 512 NEUP reports are publicly available on OSTI. The underlying data for projects is still held at universities, and data transfer, co-location, and dissemination has not occurred in a systematic way. NEUP data is currently accessible through myriad university-based data repositories, or through direct requests to PIs. The program identified this patchwork of repositories, or often lack of publicly available data, as a significant barrier to an organized, accessible, and comprehensive solution to sharing data with the larger nuclear energy community. Approach The goal of this pilot project is to establish a pathway to a consolidated long-term repository for NEUP project data. To accomplish this goal, the pilot strives to accomplish the following objectives: Establish data collection standards, including a standard set of required supplementary information to contextualize and support raw data files. Work with the HPC group collect and upload information and to modify the NRDS system, as needed, to support a standardized approach. Resolve potential barriers to successful roll out of an expanded data collection strategy, including modifying data management plan guidelines and establishing a document and data release process that accounts for potential intellectual property and/or export control concerns. Results Overall, the pilot was successful in collecting 8,982 raw and processes data files, 220 reports, 56 calibration files, and 5,931 other supplementary documents. Supplementary documents included experimental plans, methods, journal publications and conference proceedings, milestone reports, and final reports. Figure 2 shows the number of data sets and supplementary project information provided by each project. Projects has significantly different input, depending on experimental data produced and completeness of the datasets provided.

Data collection↗

Boride-based Ceramic Super-high Temperature Thermocouples in Harsh Environments (Final Scientific/Technical Report)

An electromotive force (emf) can be generated along a temperature gradient between the cold end and hot end of a thermoelectric material, termed the Seebeck effect. Based on the Seebeck effect, metallic alloys have been extensively employed to detect temperatures for centuries, named thermocouples. However, commercially available thermocouple alloys suffer from limitations, such as oxidation, chemical degradation, and poor long-term stability under high-temperature harsh environments. This DOE-funded project aimed to develop high-temperature, chemically tolerant thermocouples suitable for operation in extreme environments relevant to semiconducting thermoelectric materials. The research focused on boride-based semiconducting thermoelectric compounds as candidates for next-generation thermocouples with enhanced oxidation resistance, chemical stability, and thermal robustness under conditions representative of charcoal-fired electricity facilities. During the funded years, boride materials were synthesized using an arc-plasma technique under ambient air and argon atmospheres, enabling scalable and cost-effective production compared with conventional boride fabrication methods. The synthesized borides were processed into nanostructured powders, followed by consolidation into dense bulk materials using a spark plasma sintering (SPS) bottom-up approach. Comprehensive characterization was performed, including microstructural analysis, electrical transport measurements, and optical and thermal property evaluation. Both p-type and n-type boride electric legs were fabricated and integrated into boride-based thermocouples. The thermal and irradiation stabilities of the boride nanomaterials and bulk thermoelectric materials were systematically evaluated to assess suitability for long-term operation in harsh environments. Additionally, 12 students were broadly hands-on trained spanning the full research workflow, including word processing and technical editing (e.g., LATEX for manuscript and poster preparation), data collection and analysis (using Python and related libraries and hardware interfaces), sample preparation (including arc-plasma synthesis and spark plasma sintering), and advanced characterization techniques (such as X-ray diffraction, UV–vis spectroscopy, electron microscopy, differential thermal analysis (DTA), and Seebeck coefficient measurements, etc). Overall, this project demonstrated the feasibility of boride-based thermoelectric materials as durable high-temperature thermocouples, providing a promising pathway toward robust temperature sensing technologies aligned with DOE energy infrastructure and extreme-environment monitoring needs.

20 FOSSIL-FUELED POWER PLANTS↗