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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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DOE OSTI2020

A Replacement Cold Neutron Guide System for HFIR (Conceptual Design Report)

The design of a replacement cold neutron guide system for the High Flux Isotope Reactor (HFIR) is presented. The proposed six-channel design uses the latest technologies and is optimally designed to account for operational and site constraints. These include the design of the cold source and the beam tube, the size and shape of the penetrations in the reactor confinement boundary, and the shape and orientation of the guide hall. The existing user instruments are a macromolecular diffractometer (IMAGINE), an IMAGING station, two small-angle neutron scattering (SANS) instruments (Bio-SANS and GP-SANS), and a cold triple-axis spectrometer (C-TAX). These instruments will all be reinstalled at end-of-guide positions with improved performance, and a position for a new high-performance neutron spin echo instrument will be created. The proposed guide design requires an extension to the guide hall toward the south. The calculated flux gain for a typical experiment is between a factor of 1.3 and 3 for all instruments, with the exception of the C-TAX instrument, which stands to gain a factor of >30 in flux at the sample. The new guide system will also offer additional performance gains, such as an increase in Q-range on Bio-SANS. The stated performance gains do not take into account any potential performance gains resulting from renewal and realignment of the guide system. The design of the guide system in the common sections up to about 25 m from the source is considered to be complete and ready for engineering design, while the designs of the instrument-specific guides are in some cases still a work in progress. The present report describes the current status of those designs.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2025

FRMAC Laboratory Analysis Manual Volume 1, Revision 0

The Federal Radiological Monitoring and Assessment Center (FRMAC) is an operational center, available on request by the Department of Homeland Security (DHS) to respond to nuclear and radiological incidents as described in the National Response Framework (NRF). Under the Federal Interagency Operational Plan for Response and Recovery’s Nuclear/Radiological Annex, the U.S. Department of Energy (DOE) has the responsibility to maintain the operational readiness of the FRMAC during the emergency phase of an event. FRMAC is initially established and managed by the Nuclear Emergency Support Team (NEST) and serves as an interagency operations center with representatives from various federal, state, and local radiological response organizations. The purpose of the FRMAC is to assist state, local, tribal, and territorial governments (SLTT) in their mission to protect the health and well-being of their citizens with: • Verified radiation measurements. • Interpretations of radiation distributions based on Environmental Protection Agency (EPA), Food and Drug Administration (FDA), or local Protective Action Guidelines (PAGs). • Characterization of overall radiological conditions. Once a declaration to respond to a radiological emergency has been made, the National Nuclear Security Administration (NNSA) Headquarters will coordinate the response in consultation with the cognizant NNSA Regional Coordinating Office (RCO). Each of the eight RCOs maintain a 24-hour response capability for radiological emergencies that may occur in states served by its region. When a FRMAC is established, it operates under the parameters of the Incident Command System (ICS), as defined in the National Incident Management Systems (NIMS) construct. The Consequence Management Home Team (CMHT) will be activated immediately during normal business hours (Pacific Time Zone), and within two hours otherwise. The Consequence Management Response Team (CMRT) is prepared for deployment within six hours after activation. Along with the assets, FRMAC provides an operational framework for coordinating of all federal off-site radiological monitoring and assessment activities during a response to a radiological emergency to support the coordinating agency and SLTT governments. Potential radiological emergencies that fall within FRMAC vary widely in terms of the area affected, the nature of the contamination, and the scope of the government’s response. Detonation of a nuclear device, accidental release of radiation from a nuclear power plant, and a terrorist threat are just a few of the many possible scenarios FRMAC must be prepared to address. Through all this, supporting the state, local, and tribal organizations in the protection of the public remains the primary goal of the federal response.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

Hyper Suprime-Cam Legacy Archive

Abstract We present the launch of the Hyper Suprime-Cam Legacy Archive (HSCLA), a public archive of processed, science-ready data from the Hyper Suprime-Cam (HSC). HSC is an optical wide-field imager installed at the prime focus of the Subaru Telescope and has been in operation since 2014. While ∼1/3 of the total observing time of HSC has been used for the Subaru Strategic Program (SSP), the remainder of the time is used for Principal Investigator (PI)-based programs. We have processed the data from these PI-based programs and make the processed, high-quality data available to the community through HSCLA. The current version of HSCLA includes data taken in the first year of science operation, 2014. We provide both individual and coadd images as well as photometric catalogs. The photometric catalog from the coadd is loaded to the database, which offers a fast access to the large catalog. There are other online tools such as an image browser and an image cutout tool and they will be useful for science analyses. The coadd images reach 24–27th magnitudes at 5σ for point sources and cover approximately 580 square degrees in at least one filter with 150 million objects in total. We perform extensive quality assurance tests and verify that the photometric and astrometric quality of the data is good enough for most scientific explorations. However, the data are not without problems and users are referred to the list of known issues before exploiting the data for science. All the data and documentations can be found at the data release site, 〈https://hscla.mtk.nao.ac.jp/〉.

Tanaka, Masayuki↗
DOE OSTI2025

Phase II Field Demonstration at Lansing Smith Generating Plant, Southport, Florida (Final Report)

The Final Technical Report: Field Test Design and Pressure Management Strategies for Phase II Field Demonstration of Optimal Pressure Control, Plume Management, and Produced Water Strategies presents the culmination of multi-year efforts under the U.S. Department of Energy’s Brine Extraction and Storage Test (BEST) program, led by EPRI in partnership with Gulf Power at the Plant Smith site near Panama City, Florida. The project was designed to evaluate and demonstrate the technical feasibility of managing subsurface pressures and fluid movement associated with large-scale CO₂ injection, using low-salinity water as a proxy fluid. Through a combination of field injection testing, reservoir modeling, and optimization studies, the research team developed and refined active and passive brine extraction strategies aimed at controlling injection-induced pressure buildup, mitigating risks of fault activation, and managing plume migration. The field demonstration incorporated a new injection well (TIW-2), a new monitoring/extraction well (TEMW-A), and an existing well (TIW-1) repurposed for passive pressure relief. Complementary geophysical monitoring was designed to track plume development and evaluate the effectiveness of pressure management strategies. The report details the integrated workflow encompassing wellfield development, regulatory permitting, model calibration, and survey design. It includes a comprehensive electromagnetic (EM) modeling and inversion study used to develop a cost-effective, time-lapse geophysical monitoring plan capable of imaging the evolving low-salinity plume within the highly saline Lower Tuscaloosa formation. Reservoir simulation results guided the design of the 17-month injection program and the timing of active extraction to maintain formation pressures below a hypothetical fault reactivation threshold. Supporting analyses evaluated potential injectivity risks related to clay fines migration and geochemical incompatibility, identifying practical mitigation measures such as salinity and pH control. The final design recommends a series of crosswell EM surveys—conducted before, during, and after injection—as the most effective and economical approach for plume imaging, supplemented by continuous downhole pressure and flow monitoring. Collectively, the study provides a field-ready framework for cost-effective pressure management and monitoring in support of future CO₂ storage projects.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2020

PORFLOW modeling of Vadose zone flow and transport for the E-area intermediate level vault

In support of the E-Area Performance Assessment, a two-dimensional model of water flow and radionuclide transport through the E-Area Intermediate Level Vault (ILV) and local vadose zone has been developed using the PORFLOWTM software. The purpose of the model is to calculate flux to the water table for radionuclides eluted from the ILV during its operational life, the period of institutional control, and times following site closure. Results of model calculations will be used by a three-dimensional PORFLOW model of transport through the aquifer to determine radionuclide concentrations at a hypothetical 100 meter well and at the site boundary where contaminated groundwater could be assessed by members of the public following site closure. While newly developed, the model structure closely follows that used in the 2008 PA while incorporating a refined computational mesh, updated material properties for the vadose zone soil and vault concrete, revised infiltration rates, and new solid-liquid distribution coefficients. The model also addresses degradation of concrete hydraulic properties by blending soil and concrete water retention curves over a 500 year period. That is, the hydraulic properties of ILV concrete start out as fresh concrete at the time of site closure and degrade to soil properties over a 500 year time period. This approach has not been used previously in E-Area PA’s. The model has been used to calculate water flow through the ILV vadose zone and, on a trial basis, transport of a limited number of radionuclides from the waste region inside the ILV to the water table. Figure ES-1 provides a view of the model and an example of water flow after the concrete has substantially degraded. Figure dimensions are in centimeters. The red area in the left hand side figure is the waste disposal region within the ILV. Colored bands in the figures indicate different soil and concrete regions. Figure ES-2 shows a calculation of flux to the water table (mol/yr) for U-234 and its one-year half-life decay chain (U-234 → Th-230 → Ra-226 → Pb-210). Pb-210 flux is too small to show on the same scale used for Th-230 and Ra-226 in Figure ES-2. The model has also been used to make a preliminary evaluation of the release of tritium from TPBAR disposal containers that will be place in the ILV. A separately calculated tritium release rate as a function of time was used as a source in the PORFLOW model. The TPBAR disposal schedule and tritium release rate differ from the values used in the 2008 PA. Results from these initial trial runs are compared to calculations made for the 2008 PA ILV analysis. In brief, a new PORFLOW model of flow and transport through the ILV vadose zone has been developed and tested. The model is ready to be used for PA calculations.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2023

Multi-Unit Dwelling Plug-in EV Charging Innovation Pilots (Final Report)

Nearly one-third of residences in the U.S. are multi-unit dwellings (MUDs), e.g., apartments and condominiums, and MUDs with five or more units account for approximately 45% of rental households. While 80% of EV charging takes place at home, less than 5% of home charging takes place at MUDs. With public electric vehicle (EV) charging still underdeveloped, lack of access to reliable home charging is a major barrier to EV adoption for MUD residents. Challenges to siting electric vehicle supply equipment (EVSE) at MUDs include the high upfront cost of EVSE installation, physical and/or electrical infrastructure constraints, a lack of clear incentives for property managers to invest in installing EV charging for tenants, and a limited number of EV charging service providers that offer solutions adapted to the unique needs of MUDs. Through award DE-EE0008473 from the U.S. Department of Energy’s Office of Energy Efficiency and Renewable Energy (EERE), Center for Sustainable Energy (CSE), Energetics, and Forth, along with a diverse team of partners, led a three-year project to address barriers to EV charging at MUDs by developing an online toolkit geared toward residents, homeowner associations (HOAs), and property managers. The project, referred to as Vehicle Charging Innovations – Multi-Unit Dwellings (VCI-MUD project), engaged stakeholders across the country to identify real and perceived barriers to EV charging at MUDs and explored innovative technologies that attempt to alleviate the identified barriers. Over the course of three and a half years, the project conducted 60 interviews with industry stakeholders, compiled findings in an easy-to-use toolkit, and disseminated the toolkit across national, regional, state, and local channels. Key findings and outcomes of the VCI-MUD project include: Identifying six primary barriers to the installation of EV charging at MUDs; Developing five fact sheets and eight case studies highlighting innovative charging solutions to address barriers, including real-world operational and financial data; Developing a user-friendly, online empowerment toolkit with five important points for “making your pitch” to support EV charging to assist residents, property managers, building managers, and HOAs explore options for MUD charging. The VCI-MUD online toolkit was designed with replicability in mind. It includes general tools and guides to evaluate EV charging demand, gauge readiness for EV charging installation, and develop actionable plans. The fact sheets and case studies highlight the diversity of emerging MUD EV charging solutions, featuring different geographic and structural installation scenarios and providing interested parties with a menu of options, rather than prescribing a one-size-fits-all solution. The following resources are included in the toolkit to provide MUD stakeholders with all the information needed to navigate EV charging installation at their MUD location: Empowerment Toolkit – Easy-to-read FAQ overview, stakeholder roles and responsibilities, and additional resources for MUD EV charging installations; Charging Basics – Glossary of terms and descriptions of charging features, installation and operating expenses; EV Charging Survey Templates – Resident-to-Resident, Property Manager-to-Resident and HOA-to-Resident template letters with pre-populated template questions; Technology Selection Tool – Charging barrier fact sheets and case study examples; Installation Checklist – Submittal document requirements for EVSE installations; MUD Building Self-Evaluation Survey – Self-guided evaluation of potential barriers to EV charging installation at MUD locations; Curbside Resources – Case studies and fact sheets for curbside charging options; Find a Certified Electrician – Approved list of certified EV charging installers; “Right-to-Charge” State Legal References – Legal requirements for charging equipment at MUD locations. The online toolkit was promoted extensively in the final six months of the project and will continue to be disseminated by the Clean Cities Coalitions and other partners after the end of the VCI-MUD project to encourage, support, and demonstrate viable solutions for vehicle charging infrastructure in MUDs.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

Bat Smart Curtailment: Efficacy and Operational Testing

Curtailment, or blanket curtailment, is a leading method to mitigate the impacts to bats from operating wind turbines. Although this strategy results in considerable decreases in bat fatalities, it also results in decreased energy production. In 2019, Natural Power was awarded funding by the Department of Energy to assess the readiness of the informed smart curtailment technology, EchoSense (formerly referred to as Detection and Active Response Curtailment, [DARC]). The research undertaken by this project expands the understanding of alternative methods, known as smart curtailment, to maintain a reduction in bat fatalities while simultaneously recovering lost energy associated with blanket curtailment. The overall project was composed of three major tasks; Task 1 was focused on cybersecurity compliance of the EchoSense system in accordance with the North American Electric Reliability Corporation Critical Infrastructure Protection (“NERC CIP”) standards, Task 2 assessed the mechanical loads exerted on turbines when operating under a smart curtailment regime, and Task 3 assessed the efficacy of the EchoSense system at an operational wind farm. Regarding Task 1, an external review by the National Renewable Energy Laboratory determined that the EchoSense system did not create any new cybersecurity weaknesses and was compliant with the NERC CIP standards. As a result of this process, Natural Power developed some best practices (10.1) for wind- wildlife technology developers. In conjunction with the National Renewable Energy Laboratory, the results (10.2) of the loads testing demonstrated that the periodic curtailment and release of turbines by the EchoSense system did not have any detrimental impact on the mechanical components of a wind turbine (Task 2). During the late summer to fall of 2020 and 2021, Natural Power demonstrated that the use of the EchoSense smart curtailment system resulted in no significant difference in bat fatalities compared to blanket curtailment with cut-in speeds at 6.9 m/s (2020) and 5.0 m/s (2021) while resulting in a significant difference in decreased lost energy (Task 3). This translates to an average of 41% (2020) and 56% (2021) reduction in per turbine energy loss compared to blanket curtailment. The reduction in energy loss that would have been achieved by EchoSense curtailment compared to blanket curtailment, if applied across all 69 turbines, is roughly equivalent to having an additional turbine on site. These results are notable for finding a balance between the environmental impact of wind energy and the economic feasibility in energy production associated with mitigating that impact. https://www.naturalpower.com/us/expertise/service/engineering-operations/echosense

17 WIND ENERGY↗
DOE OSTI2026

matsim-agents v1.0

matsim-agents is a multi-agent AI framework for atomistic materials simulation and discovery. It orchestrates large language models (LLMs), machine-learned interatomic potentials (MLIPs), and DFT codes into a single agentic loop running on laptops and DOE leadership-class supercomputers. MULTI-AGENT ORCHESTRATION A LangGraph state machine with three nodes: a Planner that converts a natural-language research objective into structured tasks; an Executor that dispatches atomistic tools and loops until the queue is empty; and an Analyst that summarizes results into a human-readable report. State is checkpointed after every step and human-in-the-loop gates can be inserted at any edge. HYPOTHESIS-DRIVEN DISCOVERY CHAT An interactive REPL (matsim-agents chat) that couples LLM dialogue with atomistic simulation. Chemical formulas are automatically detected in conversation turns and trigger a full crystal-phase exploration: structure generation → relaxation → stability scoring → result injection back into the conversation, creating a closed hypothesis-refinement loop. CRYSTAL PHASE ENUMERATION Given a composition, the phase explorer enumerates prototypes by stoichiometry: elemental (fcc/bcc/hcp/sc/diamond), binary 1:1 (rocksalt/CsCl/zincblende/ wurtzite/fluorite/rutile), ternary 1:1:3 (cubic perovskite), ternary 1:2:4 (perovskite + spinel), quaternary 1:1:2:6 (Fm-3m double perovskite). 2-D prototypes (graphene, h-BN, MoS2 2H/1T) and multilayer stacking are also supported via --include-2d and --num-layers. SUPERCELL GENERATION AND SITE DECORATION Auto-tiling to a minimum atom count (--min-atoms), explicit NxNxN tiling (--supercell), symmetry-distinct site decorations (--n-orderings), and isotropic lattice-scale sweeps (--lattice-scales) for volume bracketing. MLFF RELAXATION AND STABILITY SCORING HydraGNN (multi-headed GNN) drives structure relaxation via ASE with FIRE, BFGS, or BFGSLineSearch. Stability output: delta-E/atom ranking across phases and a max-residual-force dynamical-stability proxy. Other MLIPs (MACE, NequIP, Orb) can be plugged in through the same interface. DFT BACKENDS Quantum ESPRESSO pw.x and VASP 6.6 are first-class labellers. Both have validated GPU builds and SLURM/PBS launchers for three DOE platforms: Frontier (AMD MI250X, ROCm), Aurora (Intel PVC, oneAPI), Perlmutter (NVIDIA A100, CUDA). QE produces ~100 binaries (pw.x, ph.x, epw.x, ...). VASP supports scf, relax, vc-relax, and vc-relax-shape run types. ACTIVE-LEARNING LOOP matsim-agents al run CONFIG.yaml drives an iterative HydraGNN-DFT loop: MD generates candidates → ensemble/MC-dropout uncertainty selects the most informative → DFT labels them in parallel inside one allocation → dataset grows → HydraGNN retrains → repeat. DFT backend is a single YAML toggle (dft.backend: vasp | qe). LLM-generated seed structures are supported (no curated POSCAR library needed). Config uses ${VAR}, ${VAR:-default}, ${VAR:?msg} shell-style substitution for cross-user/cross-site portability. LLM BACKENDS Ollama (local, default), vLLM (HPC multi-GPU serving), OpenAI, Anthropic, HuggingFace Transformers+Accelerate. Selected at runtime via flag or env var with no code changes. HPC PORTABILITY Same Python entry points run on Frontier (ROCm 7.2), Aurora (oneAPI), and Perlmutter (CUDA 12). DFT and ML stacks are never co-loaded in the same shell; they couple through the scheduler and filesystem. Advanced multi-node launchers (serve, discovery-chat, single-relaxation, active-learning, QE warm-start) are provided for all three platforms. CODABENCH COMPETITION BUNDLE A self-contained benchmark: 159 atomistic test structures across 11 material classes, 5 tasks (formation energy, forces, ML relaxation, AI-DFT relaxation, phase stability ranking), public/private leaderboard split (30/70), and four ready-to-run baselines: MACE-MP-0, HydraGNN, UMA, AllScAIP.

Lupo Pasini, Massimiliano [Oak Ridge National Labo↗
DOE OSTI2020

Enhancement of Optical Efficiency of CSP Mirrors for Reducing O&M Cost via Near-Continuous Operation of Self-Cleaning Electrodynamic Screens (EDS). Final Report

Over the past decade, techno-economical advancements in solar energy systems, particularly the improvement in the conversion efficiency of PV modules made with mono-crystalline silicon solar cells from 12% to 20%, as well as the cost reduction in manufacturing by a factor of about 10%, have made it possible to achieve a levelized cost of electricity (LCOE) in PV plants that is comparable to, or less than, the cost of deriving electricity from fossil fuels. Operating PV plants in mid-latitude sun-belt regions, where the solar irradiance level is highest, provides a high annual energy-yield (kWh/kWp) due to two factors: (1) the availability of predictable high solar irradiance throughout the year with the fewest interruptions in solar flux from clouds and rain, and (2) the increased conversion efficiency of crystalline solar cells, as recombination loss has decreased with increased intensity of the sunlight that illuminates the silicon solar cells. Semi-arid and desert regions, however, are plagued by high atmospheric dust concentrations and frequent sand storms. The deposition of a layer of dust on the optical surfaces of solar collectors such as PV modules and concentrating mirrors reduces the transmission efficiency of sunlight that actually reaches the solar cells or receivers, resulting in high energy-yield soiling loss. There are two major cost components to operating a solar plant: (1) installation costs, and (2) operation-and-maintenance (O&M) costs. There is no fuel cost; hence operating a solar plant in a semi-arid or desert region provides high returns on investment if soiling losses are mitigated via efficient cleaning methods and optimized cleaning frequency. If solar collectors are not cleaned, the accumulation of dust layers on solar collectors may cause the operation of such plants in arid regions to become economically unviable. Washing solar collectors with water and detergent, as is most commonly done now, is an efficient method for cleaning. The conventional approach in utility-scale solar plants is to use a large truck with a water tank and pump system for spraying deionized water on the surface of the solar collectors. Robotic cleaning with brushes, used for many solar plants, requires lesser water for cleaning. The water consumed using semi-automated cleaning of PV modules in utility-scale solar plants is approximately 2 liters/m 2 per cleaning cycle. The total optical surface area of the solar collectors in 1 TW-scale solar installation will be more than 3 × 109 m 2 ; hence an enormous amount of water be needed for cleaning. There simply is not enough fresh water in the sun-belt areas of the world for predicted cleaning needs. In solar power plants, the estimated cost of cleaning solar collectors includes expenses related to the equipment used, labor, cost of transportation of water, the energy required for cleaning, plus ancillary costs whereas the cost of water is not considered. The water used is obtained from sources located close to plant sites, unmindful of the environmental and societal impact as the power plants are oftentimes located in regions that face severe drought. This practice is very similar to the cost calculations in deriving the levelized cost of electricity (LCOE) in conventional power plants based on burning fossil fuel such as coal and gas, while disregarding the cost of climate change and health effects. Unless a water-free or low-water cleaning method is established, the expansion of solar plants may lose public support in areas suffering long intervals of drought. The goal of this research project has been the development and application of the Electrodynamic Screen (EDS) as a means for a water-free, scalable cleaning process applicable to solar-power installations, including rooftop applications. We describe here the development of an EDS film-based cleaning process as an emerging method for use on PV modules, parabolic troughs, and heliostats. This report aims to show the feasibility of integrating or retrofitting EDS films onto the optical surfaces of solar collectors (both PV and CSP) while maintaining high transmission or reflection efficiency. The cleaning action provided by the EDS film is an active method to remove dust deposits by electrodynamic force. Current lab-scale prototype EDS films, retrofitted onto solar panels and mirrors, have shown to be capable of maintaining optical transmission or specular-reflection efficiencies higher than 90% of initial values under clean conditions. The optical surfaces of solar collectors laminated with EDS films can remove more than 90% of deposited dust when the EDS is activated for less than two minutes. As an electrodynamic dust removal process, the EDS film-based method is designed primarily for the removal of dust in solar installations located in semi-arid and desert areas, where the atmosphere is often dry and dusty and rainfall is infrequent. While EDS film application minimizes water consumption and facilitates cleaning as frequently as needed, it has limitations in removing contaminants such as soot, organic pollutants deposited as fine films on the surface, and bird droppings. The dust removal efficiency of the EDS is maximum at relative humidity RH is 40 to 50% and decreases at when RH > 65%. Many solar plant sites undergo diurnal and seasonal cycles of high ambient, early afternoon temperatures and an RH that reaches the dew point early in the morning. These variations in atmospheric conditions do not limit the operation of the EDS film. This report presents a brief review of the progress and the potential of EDS film technology for mitigating the impact of dust on solar collectors via water-free cleaning, as well as current technical challenges regarding efficiency and durability. Our experimental data on the performance of EDS films show that: (1) the dust-removal efficiency (DRE) can reach levels higher than 90%, (2) the specular reflectivity (SR) of EDS film-laminated second-surface mirrors reach levels in excess of 90%, (3) the specular reflectivity restoration (SRR) can exceed 90%, (4) the output-power restoration (OPR) of PV modules can exceed 95%, and (5) the optical transmission efficiency (TE) of the EDS films can be greater than 90%. Working with Sandia National Laboratories (NM), Corning Research and Development Corporation (NY), Eastman Kodak (NY), Tomark-Worthen Industries (NH), and EDS Chile SPA (Chile), we have produced EDS film-laminated PV modules and demonstrated their self-cleaning functions without requiring water. We have demonstrated that the operational range of EDS films will cover the expected ambient temperature of solar fields at RH cycling varying from 20 to 95% as long as the EDS films are activated in the RH range 20 to 50%. (Typical solar-field climates in deserts and semi-arid lands often reach near dew point in coastal areas.) Our experiments on the application of hydrophobic-fluorinated nanoparticle coatings on EDS film surfaces show that the EDS operational range can be extended to higher RH levels that approach the dew point. At Eastman Kodak, as one of our industrial partners, we were able to establish a process for manufacturing EDS films using flexographic printing of the electrodes onto transparent polymer films. This process utilizes an existing manufacturing line at Eastman Kodak that allows fabrication of medium-scale EDS films (26 cm × 30 cm). The manufacturing process has the capacity to produce EDS films at high production speeds. The medium-scale EDS films that have been printed at Kodak were evaluated in the lab at Boston University. The EDS films produced at Kodak were laminated at Tomark-Worthen using an industrial scale vacuum laminator to produce EDS film stacks, which can be affixed onto the optical surfaces of PV modules or concentrating mirrors. The EDS film stack consists of the EDS films that have Willow® Glass (WG) which has a thickness of 100 μm as the front surface. The WG sheets obtained from Corning Research and Development Corporation are customized in size and shape to cover the active area of the EDS films. The back surface of the EDS film stack is integrated onto the optical surface of the solar panel or mirror using optically clear adhesive (OCA) films or silicone adhesives. The OCA films (thickness 25 μm) are produced by 3M. The EDS film stacks have the architecture: WG/OCA/EDS Film/OCA/ over PV module or solar mirror. The power-supply units needed for activating the electrodes of the EDS film were designed and produced at Boston University. These power supply units provide three-phase, 1.2 kV voltage pulses at a very low current (micro-ampere) level and at a low frequency (≈ 5 Hz). The voltage pulses are applied to the electrodes in a sequence such that the train of pulses resembles a unidirectional traveling wave of electrical field on the surface of the EDS film. The dust particles on the surface become charged electrostatically and are levitated by the Coulomb force. The lateral sweeping action of the traveling electric field created by the three-phase voltages pulses then sweeps the dust off the surface. The energy consumed by the EDS electrodes is less than 0.2 Wh/m 2 /cleaning cycle, enabling energy-efficient restoration of output power (OPR) of PV module or specular reflectivity restoration (SRR) for solar mirrors. The EDS system consists of (1) an EDS film stack laminated onto the solar collectors, (2) connection of the EDS film to its power supply unit and (3) Interconnection of the power supply to PV modules or solar mirrors. Design, construction and assessment of field-testing units that have EDS stack laminated PV modules for evaluating the performance of the EDS films in solar fields is being carried out at BU. Our progress under this project, aimed at the advancement of EDS film technology, has reached DOE Technology Readiness Level (TRL) 6. Based on the extensive laboratory evaluations and limited field trials, as well as contacts with potential users, we believe that the technology has reached its commercial stage. We are conducting a cost analysis using the National Renewable Energy Laboratory (NREL) System Advisory Model (SAM) and are preparing for field trials of EDS films in different solar fields in the US, Chile, India and in the Middle East. A brief description of EDS film performance, construction and testing of the field-test unit, autonomous operation of the field-test unit for evaluating EDS performance in increasing energy yield, associated revenue savings, and water conservation is presented.

14 SOLAR ENERGY↗
DOE OSTI2021

Pilot-Scale Testing of an Integrated Circuit for the Extraction of Rare Earth Minerals and Elements from Coal and Coal Byproducts Using Advanced Separation Technologies

The primary objective of this project was to develop and demonstrate an integrated pilot-scale circuitry for recovering high-value rare earth elements (REEs) from coal and coal byproducts. The target performance was to produce a mixed REE product with content of at least two percent by weight on a dry mass basis in a cost-effective and environmentally benign manner. During the first nine months of the project period (Phase 2 Budget Period 2), pilot plant construction was completed including all field site startup activities such as permitting, engineering design, procurement/bidding, unit fabrication, site construction, equipment installation, module assembly, safety training, and circuit shakedown. During the remaining 21 months of project period (Phase 2 Budget Period 3), detailed field-testing activities were performed including feedstock sample collection and preparation, exploratory testing, circuit modification, detailed parametric study, and performance optimization. A detailed techno-economic analysis was performed based on the pilot plant testing findings which provided various scenarios for REE production. The project successfully accomplished the proposed target performance by producing mixed rare earth oxide (REO) with greater than 90% purity by weight in a continuous pilot scale operation from two distinctly different coarse refuse materials (i.e., West Kentucky No. 13 and Fire Clay coal seams), and at least three secondary sources (i.e., heap leach process and naturally formed acid mine drainage system). Project partners included the University of Kentucky, Virginia Tech, West Virginia University, Alliance Coal, Blackhawk Mining, Mineral Refining Company, and Mineral Separation Technologies. The pilot scale test facility was constructed at a former mining complex owned by Alliance Natural Resource Partners (Alliance Coal). The site was rehabilitated to accommodate the equipment installation, construction and fabrication, electrical power requirement, water line management and containment. The process units constructed and installed included X-ray sorting unit, crushing and grinding unit, physical separation unit, acid leaching unit, solvent extraction unit, and wastewater management unit. A rare earth mineral concentration unit was constructed as a standalone unit for flexible operation. A detailed environmental assessment and control plan was carried out to identify and quantify any potential impacts of the pilot-scale processing circuitry on the human and eco-system health and well-being. Corresponding mitigation strategies and control measures were provided. A conceptual flowsheet was developed to effectively remove thorium and uranium from high purity rare earth oxide mix or any potential radionuclide enriched stream. The two distinct feedstock materials were secured from the Blackhawk Mining Complex in eastern Kentucky where the Fire Clay (Hazard No. 4) seam is processed. The West Kentucky No. 13 (Baker) coarse refuse material was collected from an active process stream at an Alliance coal preparation plant located in western Kentucky. Characterization analysis indicated that both of feed materials generated from the two sources contained >300 ppm of TREEs on a dry whole mass basis which met the requirements for a qualified feed stock. The two feedstocks were further upgraded using a dual x-ray sorter to prepare the feed material for hydrometallurgical circuit. Thermal treatment on feed material prior to leaching was found to: 1) improve the leaching recovery of REEs, 2) increase the leaching kinetics, and 3) allow the leaching reaction to occur at lower acidity. Roasting at 600°C was selected as the pre-treatment condition for both West Kentucky No. 13 and Fire Clay coarse refuse material. Over 40% of leaching recovery was achieved by roasting West Kentucky No. 13 material having a top particle size of 3 mm in the pilot scale operation using 1.2M sulfuric acid leaching at 75OC. Initial pilot scale testing involved continuous operation of the pilot plant for 94 hours. The leaching unit was operated at solid-to-liquid ratio of 1 to 10 (w/v) using 0.5M sulfuric acid solution at a temperature of 75°C. The continuous solvent extraction circuit utilized rougher and cleaner units with DEHPA and TBP as the extractants. An innovative stripping circuit was developed to accumulate the REE concentration in the stripping solution to a level above 600 ppm. A bleed stream from the recycled strip solution was treated using oxalic acid precipitation which produced a high grade rare earth oxalate. The oxalate product was roasted to remove the oxalate which produced a rare earth oxide product having a purity greater 90%. Due to high concentrations of contaminant ions in the pregnant leach solution (PLS), a modified flowsheet was developed that involved pre-concentration of the REEs using multiple stages of precipitation and redissolution. The advantage of this process was improved removal of contamination before the downstream purification process and a significant cost reduction relative to the circuit that utilized the solvent extraction process. The modified circuitry included processes involving leaching, multistage precipitation, redissolution, and oxalate precipitation followed by roasting of the oxalate product. The circuit produced a mixed REO that was 92.96% pure from the initial test. A detailed parametric test plan was carried out which involved varying key parameters including solids feed rate, acid flowrate, acid concentration, multistage precipitation pH, redissolution pH, oxalate precipitation dosage and pH. The response variables included REE recovery, contaminant recovery, REO product grade and overall chemical consumption. Test results indicated that the acid-to-solid ratio is the key parameter to leaching efficiency as performance deteriorated with an increase in solids concentration. The optimal pH determined for REE precipitation and redissolution was 6.5 and 2.5, respectively. Additional tests were conducted to further improve the flowsheet. Recirculating a portion of the PLS to the feed of the leach tanks improved the leaching performance by lowering the pH of the leaching system and reducing the contamination recovery by shortening the residence time. Moreover, the removal of Al prior to REE precipitation significantly reduced the oxalic acid consumption in the oxalate precipitation circuit. The modified circuit produced over 90% grade REO by weight from both West Kentucky No. 13 and Fire Clay coarse refuse material in pilot scale continuous test programs. A case analysis model was developed to project the REE and major contaminants concentration in each PLS stream based on the leaching condition, pH cut point, and oxalic acid dosage. A correlation was established using empirical and semi-empirical models. Using the models, chemical consumption required for each stage was predicted based on the projected performance of the hydrometallurgy circuit. After identifying the optimum conditions, validation tests were carried out for the treatment of both West Kentucky No. 13 and Fire Clay coarse refuse materials in the pilot plant. The actual circuit performance and chemical consumptions were very close to the model predictions. Other than the two coarse refuse sources, several secondary feedstocks were also tested in the pilot plant facility. A “heap leach” system was constructed using the coarse refuse material generated from cleaning the West Kentucky No. 13 seam coal. Using the two stage SX rougher and cleaner circuit, a concentrate with a grade >90% REO was produced while recovering >97% of the REEs from the heap leach PLS. Naturally generated acid mine drainage (AMD) from West Kentucky No.13 mine was processed using the multistage precipitation circuit in the pilot plant in a test conducted for a period of 32 hours. The final grade of the mix RE oxide produced from the AMD was 90.84% with an overall circuit recovery of 64%. The primary source of REE was the selective precipitation steps involving iron and aluminum rejection. The hydrophobic-hydrophilic separation (HHS) process was proven to effectively recover coal from fine waste materials. For REM recovery, the HHS process was able to produce concentrates at grades of approximately 1.8% REE on an ash basis; however, recovery values were typically low, <10%, under the optimal conditions determined in the laboratory-scale testing. Staged testing of the pilot-scale HHS process for coal recovery and semi-continuous laboratory testing for REM testing showed that a total concentration ratio of more than 15x was observed for the REM recovery process. A circuit simulation package was developed for REE extraction and purification using a spreadsheet-based platform (Microsoft Excel). The REESim circuit simulation package is configured to track the mass and volume flows of components passing through a series of unit operations specified and configured by the user. The mass rates can then be utilized by the user to determine important performance indicators such as product mass yields, concentrate purity levels, element-by-element recoveries, and so forth. The techno-economic analysis showed that the roasting and leaching operations were the most expensive capital items, each contributing approximately 30% to the total capital cost. One notable contributor to the high production costs was the low REE recovery observed in the pilot scale trials. The product basket price was shown to have a strong influence on the economic viability of the scenarios, with the scandium price being the most significant influencer. Operating cost was shown to be extremely sensitive to REE recovery, REE feed grade, and leaching acid consumption. An analysis of ten different scenarios for a 500 t/h commercial operation revealed that three were economically favorable, producing internal rates of return varying from 27.7% to 33.1% and payback periods of 4 to 5 years. The project successfully developed and demonstrated a process to recover REEs from coal and coal byproducts in a pilot-plant operation which consistently produced over 90% grade REO mix from varies types of feedstocks. Commercialization analysis showed that the technology readiness level successfully achieved TRL 6 at the end of the project and demonstrated the need and the potential for scaling the process to further advance the technologies toward the goal of providing a domestic supply of REEs at a commercial scale.

01 COAL, LIGNITE, AND PEAT↗