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Boardman, Richard D.

Publications and source records attributed to Boardman, Richard D..

17 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Technoeconomic Analysis of Kraft Pulp Mill Integration with an Advanced Nuclear Reactor

This study focuses on post-combustion capture and oxy-fuel combustion for the boilers at the mill, as well as steam integration with the nuclear power plant. The primary goal of the research outlined in this report is to design, analyze, and document the integration of industrial-scale HTGR with a reference Kraft Pulp Mill. The purpose is to deliver reliable, cost-effective, and sustainable clean energy alternatives while reducing CO2 emissions. Specifically, this study focuses on 6 different scenarios that include carbon capture equipment and some of them use nuclear power to meet the heat and electricity needs of the reference plant. Also, 2 of these scenarios are created while also producing clean hydrogen through integrated High-Temperature Steam Electrolysis (HTSE). This report offers a detailed techno-economic assessment of different scenarios for a Kraft Pulp Mill, including an analysis of tax credits (section 45V, 45Q, and 48E) provided by the Inflation Reduction Act (IRA) of 2022. The evaluation explores the potential economic benefits and challenges of incorporating different configurations, including nuclear energy, into Kraft Pulp Mill operations, with particular attention to energy efficiency, economic implications, and environmental impact. By assessing both the technical feasibility and economic viability, this analysis aims to identify existing gaps and propose solutions for the successful implementation of nuclear integration. The findings are intended to provide valuable insights for stakeholders considering the adoption of advanced nuclear reactors in the pulp and paper industries.

08 HYDROGEN↗
DOE OSTI2024

Technical and Economic Assessment and Gap Analysis of Advanced Nuclear Reactor Integration with a Reference Methanol Synthesis Plant

Efforts continue to identify the most-economic methods to decarbonize several sectors of the United States (U.S.) economy. Industrial processes such as synfuel synthesis and high value commodity chemicals rely heavily on energy-dense and easily stored and transported fossil fuels, which power and feed their operations. Steam methane reforming (SMR) is a widely used process for producing methanol. In this process, methane (CH 4 ) from natural gas (NG) reacts with steam (H 2 O) over a catalyst at high temperatures (700-1,000°C) to produce syngas, a mixture of hydrogen (H 2 ) and carbon monoxide (CO). The syngas is then converted into methanol (CH 3 OH) through a second catalytic reaction. This method is known for being an efficient and commonly employed pathway for industrial methanol production. The high-temperature heat needed for SMR, which is currently used in the natural-gas-to-methanol process, cannot be supplied by small modular nuclear reactor (SMNR) direct heating; the temperatures required for the SMR process exceed those of the main steam produced by near-market high-temperature gas reactors (HTGRs). For the conventional methanol process, this leaves possible nuclear-integration opportunities that include: (1) blending nuclear hydrogen into the SMR NG fuel, or (2) assessing alternative synthesis routes leveraging nuclear capabilities and steam electrolysis outputs. In the reference methanol plant, SMR provides the methanol-synthesis reactor with H 2 and co. In Case (2), the state-of-the-art reverse water gas shift (RWGS) pathway achieves the same, sourcing carbon from an industrial CO 2 source.

08 HYDROGEN↗
DOE OSTI2024

Technical and Economic Assessment and Gap Analysis of Advanced Nuclear Reactor Integration with a Reference Oil Refinery

Efforts to identify the most-economic methods to decarbonize several sectors of the U.S. economy are underway. Industrial processes such as crude-oil refining rely heavily on energy-dense and easily stored and transported fossil fuels for powering their operations. Refineries use large amounts of energy, primarily derived from fossil sources to separate crude-oil components, break down heavier hydrocarbons into lighter compounds, remove impurities, reform hydrocarbon molecules, and generate steam and electricity for pumps and compressors and other various auxiliary systems. Crude-oil refining operations such as distillation, cracking, desulfurization, reforming, utilities systems and some offsite facilities collectively account for most of the energy consumption. Other operations such as hydrocracking or hydrotreating also require hydrogen for developing hydrogenation reactions which involve substantial heating to keep the reactors at high-temperature and pressure levels. All heat and energy demands are typically provided by natural gas (NG), oil, or other fuels, which makes refinery industry one of the most-difficult sectors to decarbonize. Nuclear power is a viable and energy-dense source of clean electricity, heat, and hydrogen to provide the large, sustainable energy supply that the refining industry demands. The U.S. Department of Energy’s (DOE’s) Integrated Energy Systems (IES) program is working to perform research and development, design, economic siting, and risk analysis. This state-of-the-art work will enable the first on-site demonstrations and commercial deployments of advanced small modular nuclear reactors (SMNRs) integrated with industries such as chemical production, refining, iron and steel making, and more. IES seeks to demonstrate the ability of advanced nuclear reactors to meet the heat and power demands of these industries while reducing carbon emissions in a sustainable and cost-competitive way. The primary objective of this research effort is to analyze industrial-scale SMNR integration intended to decarbonize refining facilities. The foreseen outcome is the provision of reliable, cost-competitive, and sustainable clean energy, alongside a reduction of carbon emissions. Specifically, the focus of this work lies on meeting the reference facilities’ heat and electricity demands with nuclear power while also supplying clean hydrogen via integrated high-temperature steam electrolysis (HTSE). This report presents a comprehensive technical and economic assessment of the integration of advanced nuclear reactors into a reference refinery, leveraging financial incentives from the Inflation Reduction Act (IRA). The evaluation aims to explore the potential economic benefits and challenges associated with incorporating advanced nuclear reactors into refinery operations, particularly in terms of energy efficiency, economic implications and environmental impact. By examining both the technical feasibility and economic viability, this analysis seeks to identify existing gaps and propose solutions for successful nuclear integration implementation. The findings are intended to provide valuable insights for stakeholders considering the adoption of advanced nuclear reactors in the refining sector. A refinery reference-plant was developed, using an open-source refinery model, Petroleum Refinery Lifecycle Inventory Model (PRELIM) and expert assessment, as a base case for comparison with various nuclear integration options. The capacity of 100 kbd/day (KBD) of heavy crude-oil feed was selected to represent a general coking-type refinery with deep conversion capabilities (incorporating heavy-oil upgrading with FCC, coking, and associated hydrotreating process units), using a heavy crude-oil feed, which represents about 70% of U.S. refineries configurations. A summary of all cases considered in this study is shown in Table 1.

13 HYDRO ENERGY↗
DOE OSTI2023

Comparison of Energy Storage and Arbitrage Options for Nuclear Power

Nuclear power is the most reliable source of clean energy and plays a crucial role in decarbonization efforts and national energy security. Achievement of Net-Zero targets depends on the deployment of new Nuclear Power Plants (NPPs) – both advanced reactors and large-scale Light-Water Reactors (LWRs) – as well as continuing operations at existing LWR plants. The Light-Water Reactor Sustainability (LWRS) program seeks to extend the lifetime of existing NPPs and improve their economic performance through research into plant modernization, Flexible Plant Operation and Generation (FPOG), risk-informed systems analysis, materials research, and physical security. The FPOG pathway investigates alternative revenue streams for LWRs. When electricity prices are driven low by an oversupply of renewable energy, steam and electricity from an NPP can be used to make value-added products while taking advantage of the low energy price; alternatively, this cheap energy can be stored chemically, electrically, or thermally, and used to regenerate-generate electricity at a later time when energy demand, and therefore the wholesale price of electricity, is higher in an economic concept called arbitrage. The purpose of this report is to investigate energy storage technologies that can store 500 MW of electricity from an LWR for a wide spectrum of durations.

13 HYDRO ENERGY↗
DOE OSTI2023

Greenhouse gas emissions embodied in the U.S. solar photovoltaic supply chain

Abstract Solar photovoltaic (PV) electricity is considered to be an important source of electricity generation in the quest for net-zero carbon emissions. However, the growth of solar electricity is creating both increased material demands and increased greenhouse gas (GHG) emissions from silicon and PV manufacturing (also referred to as embodied GHG emissions of solar electricity). Here we analyze the silicon and solar PV supply chain for the United States (U.S.) market and find that the embodied GHG emissions of solar PV panel materials (such as silicon), manufacture, logistics, and installation in the U.S. given the current supply chain are 36 g CO 2 e kWh −1 of solar electricity generated. Eighty-five percent of the embodied GHG emissions are from PV panel production processes in China and other Asia–Pacific countries. Moving the silicon and PV manufacturing to the U.S. would reduce the embodied GHG emissions of solar electricity by 16% from its current level, primarily because of the lower GHG emission intensity of the U.S. electrical grid and the lower GHG emissions for aluminum electrolysis in North America. Future scenario analysis shows that by 2030, with the U.S. PV domestic supply chain and its decarbonized grid electricity and aluminum production, as well as improving PV conversion efficiency, the embodied GHG emissions of solar electricity in the U.S. will be reduced to 21 g CO 2 e kWh −1 .

14 SOLAR ENERGY↗
DOE OSTI2022

Production of Fischer-Tropsch Synfuels at Nuclear Plants

A case study analysis was performed to evaluate nuclear-powered synthetic fuel production in the midwestern United States (U.S.). A Fischer-Tropsch (FT) fuel synthesis plant design was used as the basis for the analysis. The FT plant design was configured to produce a product slate consisting of diesel fuel, jet fuel, and motor gasoline blend stocks from carbon dioxide (CO 2 ) and hydrogen (H 2 ) feedstocks. The CO 2 feedstock for the FT plant was assumed to be sourced from biorefineries in the region around a Midwest light water reactor (LWR) nuclear power plant (NPP). The analysis specifies that power from the LWR is used to produce H 2 via high-temperature steam electrolysis and to operate the FT synfuel production plant. Capital costs were estimated for the FT plant while capital costs for the electrolysis plant were based on previous Idaho National Laboratory (INL) studies. In addition to labor and maintenance costs for the FT and electrolysis plants, operating costs also include the costs for CO 2 feedstock transport. An analysis was performed to determine the cost of transporting CO 2 from the distributed biorefinery sources to the centralized fuel synthesis plant as a function of the synfuel plant capacity and corresponding CO 2 demand. The primary revenue streams are associated with sales of the synthetic fuel products. The synthetic fuel products will likely follow the same market trends as the conventional fuel products. The synfuel price data was thus based on projections made by the U.S. Energy Information Administration (EIA) 2021 Annual Energy Outlook (AEO) for conventional fuel products minus federal and state taxes, as well as marketing and distribution costs. The economic analysis also considered cases that included and excluded revenues from the 2022 Inflation Reduction Act (IRA) clean hydrogen production tax credit (PTC) of $\$ $3.00/kg for the first ten years of operation. The economic analysis calculated the net present value (NPV) for cases involving steady-state synfuel production for comparison with the NPV for a business-as-usual case in which NPP continues to sell only electric power to the grid. A synfuel production “Reference Case” was considered in addition to sensitivity cases in which the plant capacity, electricity price, and synthetic fuel product prices were perturbed. The synfuel production Reference Case considered a scenario in which the electrolysis and synfuel plants utilized a combined electrical load of 1000 megawatt electrical (MWe) from the LWR with the balance of the LWR power output being sold to the electric grid. The economic analysis suggests that the synfuel production Reference Case evaluated in this analysis would lead to considerable economic potential for near-term deployment of a nuclear-based synfuel production plant. Specifically, the economic analysis suggests that the deployment of a 1000 megawatt (MW) nuclear-powered synfuel plant could result in a NPV increase of approximately $\$ $1.7 billion for a case with no clean synfuel price premium relative to conventional petroleum fuels when accounting for the additional revenues from the 2022 IRA clean hydrogen PTCs of $\$ $3/kg. Sensitivity analysis was performed to evaluate the effect of perturbation of selected model input parameters on the NPV for the synfuel production Reference Case. The sensitivity analysis indicates that the plant capacity has the largest impact on the differential NPV, with a smaller synfuel production capacity resulting in a decrease in revenue when a larger fraction of the power from the NPP is sold to the grid and a smaller fraction of the power is used to produce synthetic fuel products. The synfuel product pricing has the next largest impact on the differential NPV, with lower synfuel prices resulting in decreased NPV from decreased synfuel sales revenue while higher synfuel prices result in increased NPV from increased synfuel sales revenue. Electricity pricing has a smaller effect on the NPV than the fuel sales price since, in the Reference Case, most of the energy from the NPP is used for synfuel production and a smaller amount of the system revenues are associated with electrical power sales. However, the electricity price sensitivity does indicate that the Synfuel Integrated Energy System (IES) would have a greater NPV than the business-as-usual case (e.g., grid power sales only) when electricity market prices are low, suggesting that synfuel production could provide a strategy for decreasing the economic risks to NPPs posed by a loss of revenues attributed to falling electricity market prices.

10 SYNTHETIC FUELS↗
DOE OSTI2022

Plan for Scaling Up Hydrogen Production with Nuclear Power Plants

The United States (U.S.) Department of Energy’s (DOE’s) Light Water Reactor Sustainability (LWRS) Program Flexible Plant Operations and Generation (FPOG) Pathway is developing options to help U.S. nuclear power plants (NPPs) better integrate with intermittent wind and solar capacity and the recent surge of natural gas power generation. Research is focusing on improving NPP flexibility through hybrid production of electricity and other products, such as hydrogen (H 2 ) and energy storage for the purpose of shifting power production to a later time. In the case of H 2 production, the clean electrical and thermal power from an NPP can be used to split water using electrolysis. This report outlines the opportunity for NPPs to participate in a first-of-akind (FOAK) commercial nuclear H 2 project intended to bring industry partners together to create regional clean H 2 hubs. The Bipartisan Infrastructure Law (BIL) will fund at least one hub up to $1.25 billion as federal cost share totally no less than 50% to execute a nuclear H 2 project. The report discusses the set of activities that are now underway or that are planned for completion by the FPOG Pathway to reduce the economic, technical, regulatory, and safety risks of these projects. DOE cross-program activities are being coordinated to ensure success in the timeframe allowed by the BIL. Figure ES-1 shows the approximate schedule of coordinated research and development (R&D) and pilot demonstration projects leading up to the first commercial nuclear H 2 production project. Execution of this plan requires DOE and industry collaboration. DOE research accomplishments are being provided to the electric utilities or industries looking to participate in the H 2 hub proposal and project execution process.

08 HYDROGEN↗
DOE OSTI2022

Developing a low-cost renewable supply of hydrogen with high-temperature electrochemistry

Abstract Producing inexpensive hydrogen using electricity to split water or to extract hydrogen from hydrocarbon compounds is a two-sided coin: one side is obtaining and exploiting low-cost, emissions-free energy sources while the opposite side is establishing low-cost robust, durable, and efficient materials for the conversion processes. This article explores the materials needed for water splitting electrolysis, electrochemical abstraction of hydrogen from light alkanes, and looping thermal-chemical reaction processes that typically form and then dissociate an acid compound in a two- or three-step process. The focus is on the R&D needs of materials that are used for high-temperature electrochemistry, focusing on solid-oxide, ion-conducting cell materials sets (SOECs). To exploit the availability of low-cost electricity, these materials must stand up to cyclic operations. They also must be durable for years of service to reduce operating and maintenance costs, and they must achieve high conversion efficiencies to avoid large, energy-intensive recycle loops. Graphical abstract

Boardman, Richard D.↗
DOE OSTI2022

High Temperature Steam Electrolysis Process Performance and Cost Estimates

Technology readiness levels (TRLs) of electrolysis systems have dramatically increased in recent years as the interest in clean hydrogen production and decarbonization of transportation, industrial and other sectors increases across the globe. This is especially true of high temperature steam electrolysis (HTSE) / solid oxide electrolysis cell (SOEC) systems which show promise of much higher system efficiencies than other more developed electrolysis technologies. This possibility of higher efficiencies of HTSE / SOEC systems has been previously assumed to be theoretically possible but in recent years it has become less theoretical and more realistic as an increasing amount of suppliers complete lab and pilot tests showing very promising results. Research in the areas of manufacturing techniques, material selection, electrode and electrolyte compositions, and balance of plant size and integration continues at a fast pace as an increasing number of suppliers both internationally and domestically become involved. The advantages of HTSE become more pronounced when HTSE is coupled with nuclear power plants (NPPs). This is because thermal energy produced by the nuclear reactor can be used in a series of heat transfer loops and heat exchangers to vaporize HTSE feedwater, which drastically improves the economics of the process. Idaho National Laboratory (INL) has been very involved in the research and modeling of HTSE systems for a number of years, in collaboration with other national laboratories, academia, and industry stakeholders both on the hydrogen production as well as the hydrogen demand side. The modeling completed over the years on a large variety of projects has led to a wealth of knowledge at INL including in the area of the technoeconomic assessment (TEA) of HTSE systems. TEAs include process modeling of the HTSE systems to calculate system energy requirements and equipment sizing, followed by estimation of capital and operating costs to enable calculation of the levelized cost of hydrogen (LCOH). The TEA work performed has produced incremental improvements and tuning of the methods, assumptions, models, and results of the analyses as well as providing some opportunities for validating these results. The purpose of this document is to record the current baseline HTSE analyses led by INL to show the current status of assumptions and costs of these systems. Given the rapid development of this technology, the variety of suppliers entering the space, and the increasing attention government and industry are giving to such systems, this document may be updated on a periodic basis with updated analysis and assumptions. This document compiles various analyses results and approaches completed over a period of years into a single document to be used as a baseline going forward. It represents what the INL HTSE analysis group assumes to be the internal best estimate of the current operation, costs, and landscape of the HTSE industry state of the art capability for current SOEC technology in an Nth-of-a-Kind (NOAK) plant, which in this study is defined as existence of the manufacturing capacity to support previous deployment of N = 100 count of 25 MWe modular HTSE blocks (with modular equipment component cost reductions specified as following a 95% learning curve). That said, This is a public document and as such so no proprietary data was used or included in this report. There may be HTSE suppliers that have performance specifications, and cost estimates, and test data that differ from the analysis presented in this document. This document is meant to be a best conservative estimate of the technology and not an absolute reference.

08 HYDROGEN↗
DOE OSTI2021

A Technical and Economic Assessment of LWR Flexible Operation for Generation and Demand Balancing to Optimize Plant Revenue

With increased penetration of subsidized variable renewable energy (VRE) resources and competition from low natural gas prices, existing light water reactor (LWR) nuclear power plants (NPPs) are struggling to remain economically competitive. This work examines the potential economic competitiveness of various thermal energy storage (TES) technologies when coupled directly or indirectly with a NPP. To highlight their relative economic competitiveness, we contrast several energy storage solutions in stochastic dispatch optimization. We leverage data from recent work analyzing a range of TES technologies with varying capital costs, performance, and technology readiness level (TRL) to establish our case. We explore inserting these technologies into an electricity market with existing nuclear generation and large projected variable renewable energy (VRE) penetration. Although these technologies' projected capital costs may make them unlikely candidates in their current state, this analysis demonstrates a high-fidelity techno-economic analysis of energy storage. Furthermore, as the projected cost of energy storage technologies evolves, this analysis sets a precedent for similar future investigations. One region with projected trends that may be unfavorable for existing nuclear capacity is the New York Independent System Operator (NYISO) market. New York state’s baseload generation has been historically provided by fossil-fired and nuclear assets. However, amid economic pressures from subsidized VREs and low natural gas prices, the state has recently deactivated Indian Point nuclear power plant units 2 and 3. Furthermore, the state plans to meet its zero-emission generation target by 2040 by replacing fossil-fired capacity with significant investments in VRE resources like wind and solar photovoltaic (PV) and battery storage. Increased intermittent resource penetration lowers the baseload power requirement, adding further economic pressure to the state’s three remaining NPPs still in operation. With three NPPs still in operation in New York, this work analyzes potential economic benefits to NPPs on the New York grid when directly or indirectly coupled with various TES technologies. This work requires two modeling steps to analyze the potential economic benefits of various system configurations of the TES directly or indirectly coupled with nuclear. First, this analysis leverages capacity expansion modeling by experts at the Electric Power Research Institute (EPRI). Using their deterministic capacity expansion model, U.S. Regional Economy, Greenhouse Gas, and Energy (US-REGEN), EPRI analysts evaluated the capacity and generation evolution of the New York state energy market under four projection scenarios. These four projection scenarios were developed to represent the potential evolution of the capacity and generation in NYISO from 2015 to 2050 under various economic, technology, and policy constraints. The results from these capacity expansion models are then used as boundary conditions in the second modeling step. The second modeling step uses the Holistic Energy Resource Optimization Network (HERON) for a set of stochastic techno-economic analyses (STEAs) to investigate the potential increase in the economic viability of various configurations of the TES. With no current capacity expansion capabilities, HERON takes the data generated from US-REGEN for 2050 to generate synthetic load, solar, and wind data. Then HERON economically optimizes the capacity and dispatch of the various TES configurations. The potential economic benefit is the differential net present value (NPV) of the TES configurations from the no-TES baseline. As a stochastic techno-economic analysis package, HERON introduces uncertainty into the economic metrics, while US-REGEN trades resolution for reduced computational complexity. Using HERON also allows the modeling of direct thermal coupling, a feature not common in capacity and dispatch models. As expected, with high capital costs, the costs of introducing energy storage for all the technologies considered outweighed the potential economic benefit of this strategy for flexible plant operation. The benefit of this analysis is primarily in demonstrating a workflow that examines innovative solutions to increase NPP revenue via TES coupling. HERON’s stochastic capacity and dispatch optimization process used in this work has proven an effective tool in observing and evaluating the impact of introducing storage technologies in a grid energy system.

25 ENERGY STORAGE↗
DOE OSTI2021

Technoeconomic assessment of hydrogen cogeneration via high temperature steam electrolysis with a light-water reactor

Increased electricity production from renewable energy resources, coupled with low natural gas (NG) prices, has caused existing light-water reactors (LWRs) to experience diminishing returns from the electricity market. This reduction in revenue is forcing LWRs to consider alternative revenue streams, such as introduction hydrogen production or desalination, to remain profitable. This paper performs a technoeconomic assessment (TEA) regarding the viability of retrofitting existing pressurized-water reactors (PWRs) to produce green hydrogen (H 2 ) via high-temperature steam electrolysis (HTSE). Such an integration would allow nuclear facilities to expand into additional markets that may be more profitable in the long term and eliminate CO 2 emissions from the hydrogen production process. Here, to accommodate such an integration, a detailed single market levelized cost of hydrogen (LCOH) and multimarket analyses were conducted of HTSE process operation, requirements, costing, and flexibility. Alongside this costing analysis, market analyses were conducted on the electric and hydrogen markets in the PJM interconnect. Utilizing a novel stochastic, dispatch optimization approach results suggest that a positive gain is achievable, and by operating in multiple markets, the nuclear facility can avoid the sale of electricity during times of low electricity market pricing, while maintaining the ability to capitalize on the high electricity market pricing. It should be noted that the analysis conducted is a differential cash flow analysis and, as such, does not present profit levels. LCOH analysis results demonstrate the potential exists to produce hydrogen at a cost as low as $1.20/kg. This price is lower than traditional steam methane reforming (SMR) allowing nuclear based hydrogen production to disrupt the existing hydrogen production market.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Methods and systems for syngas production and for efficient, flexible energy generation

Methods for producing syngas (e.g., H2 and CO) include introducing a stream comprising H2O and CO2 to a high-temperature co-electrolysis (HTCE) unit. A CO2 sweep gas is also introduced to the HTCE unit. Both H2O and CO2 are reduced in the HTCE unit to form the syngas and to form O2 that is swept away from the HTCE unit by the CO2 sweep gas, and the O2 and CO2 are then introduced to a combustion device (e.g., a gasifier), which may be configured to generate electrical power, as a result of combusting a carbonaceous fuel in the presence of the O2 and CO2. The HTCE unit is powered at least in part by power from an electricity-generating sub-system (e.g., at least one nuclear power plant). Related systems are also disclosed.

O'Brien, James E.↗
DOE OSTI2021

Exploring the structural uniformity and integrity of protonic ceramic thin film electrolyte using wet powder spraying

Thin protonic ceramic electrolyte contributes to lower ohmic resistance and enhances electrochemical performance of protonic ceramic electrochemical cells. However, manufacturing of large-scale thin electrolyte remains a challenge. Wet powder spraying is an attractive technique to deposit <10 µm thin electrolyte when advanced atomizing techniques and optimized spraying process are integrated. Here ultrasonic atomization is integrated in the wet powder spray technique to reduce the thickness of electrolyte. Moreover, a parametric study is conducted to optimize the wet powder spray process to deposit uniform and crack-free electrolyte film. It is illustrated that tuning of solid loading rates and spray passes can affect the morphology of the as-sprayed electrolyte film, enabling the structural compactness of the sintered electrolyte layer. To maintain chemical stability of the electrolyte layer during sintering, effect of sintering temperature is further investigated to produce a physically thin, structurally dense, and chemically homogeneous electrolyte layer. The protonic ceramic electrochemical cells fabricated with optimized spraying and sintering parameters demonstrate excellent performance under both fuel cell and electrolysis modes. In addition, the cells exhibit remarkable structural integrity during redox and long-term stability tests.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Process Heat for Chemical Industry

Process heating with nuclear energy can reduce greenhouse gas emissions by reducing combustion of fossil fuels in fired heaters as steam boilers. Light water reactors can replace the majority of steam duties used by industry; however, high temperature processes such as steam methane reforming require advanced high temperature reactors. Here, guidance on matching the scale of nuclear reactors with specific industries is provided. Principles of heat transport, temperature boosting, and substitution for hot combustion gases are also discussed in this section.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Materials Challenges and Opportunities for Energy Generation, Conversion, Delivery, and Storage (Applied Energy Tri-Laboratory Consortium Workshop Report)

This report documents the outcomes of the Tri-Laboratory Materials Workshop that was held July 31 and August 1, 2019 to begin addressing the needs, opportunities, and challenges associated with the development, fabrication, and testing of the needed materials and components for integrated hybrid energy systems (i.e., incorporating nuclear, fossil, and renewables for electric and thermal applications). This was accomplished by assembling the research program leads and principal investigators at Idaho National Laboratory (INL), National Energy Technology Laboratory (NETL), and National Renewable Energy Laboratory (NREL), who support the research and development of new technology and system integration. The team then identified and prioritized key materials development needs. This effort was intended to enhance communications and synergy among the Tri-Lab partners. Advanced functional and structural materials are central to transformative energy technologies for energy generation, conversion, delivery, and storage. With that in mind, the workshop focused on identifying and assessing the foundational materials research needs at both the basic and applied levels. Materials challenges include the ability to withstand harsh environments, such as high temperatures and pressures, corrosion, oxidation, or irradiation while maintaining flexible mission profiles and long service lifespans. Advanced energy system material challenges and needs range from materials for the capture, upgrading/concentration, storage, and delivery of low-grade heat to materials for high temperature environments that involve liquid metals, molten salt, and very high temperature gas heat delivery and storage systems. Material improvements are needed for hybrid energy systems due to accelerated corrosion and stress-fatigue failure of materials and equipment, which results from increased frequency and amplitude of thermal, mechanical, and electrical cycling of systems components. Multifunctional materials are needed for high temperature solid-oxide fuel cells, advanced electrochemical reactors, and in-process separation. Relative to materials manufacturing, application of advanced additive and subtractive methods need to be understood to develop both thin-layer homogenous materials and materials of graded composition. Materials modeling and machine learning will be critical to accelerate the design and production of power electronics, and nuclear reactor materials and fuel, as well as to gain an understanding of beneficial materials phenomena or deleterious microstructure evolution. There is also a need for standardized models, computational structures, data reporting protocols and modeling tools across the three laboratories. This would allow consistent results, analysis, and data sharing. Combining computational capabilities between the three laboratories (e.g., hardware, software) would greatly increase computational capabilities and throughput. The workshop identified the need for laboratories to anticipate and address problems that will occur during scale-up. Laboratory work must connect with industry to ensure that research focuses on processes that are scalable and marketable. Industry input and perspective are essential to guide laboratory research to meet these requirements and deploy new technology in industrial demonstrations. Another aspect of scale-up is the integration of multiple systems since new challenges often arise at the subsystem interfaces. Establishing a scale-up manufacturing demonstration/pilot plant, potentially as an industrial user facility, would be beneficial to the laboratories and industry. That modular scale-up manufacturing demonstration/pilot plant would allow researchers to find and resolve interface problems that cannot be identified by focusing only on individual parts. Communication exchanges among the organizers, attendees, and workshop survey responses indicate that the workshop was successful in achieving its goal to identify key technology gaps and research needs. Strong positive feedback was received on the sharing of ideas, capabilities, talent, and passion to move forward on the materials-related action items.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Energy storage systems including thermal storage tanks

Energy storage systems include a heat source and a thermal energy storage system to store thermal energy produced by the heat source. The thermal energy storage system includes a first tank containing a first salt having a first melting temperature and a second tank containing a second salt having a second melting temperature. At least one input conduit is configured for transferring thermal energy from the heat source to the first tank and second tank. A first output conduit is in thermal communication with the first tank. A second output conduit is in thermal communication with the second tank. Additional energy storage systems include a heat booster positioned and configured to add thermal energy to a heated heat transfer fluid prior to reaching a tank containing at least one thermal storage material. Methods include transferring thermal energy from a thermal energy source to a plurality of thermal energy storage tanks.

McKellar, Michael G.↗