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DOE OSTI2019

Experimental Investigation of a Novel High Energy Density Mobile Sorption–based Thermal Battery

Around 20% of the total primary energy use in the United States is for thermal demands of buildings, such as space cooling, dehumidification, and space heating. Low-grade geothermal energy is abundant and could effectively satisfy these thermal demands. However, low-grade geothermal energy is underused because geothermal fluids have an energy density too low to justify transportation between the existing resources and buildings. The mobile sorption-based thermal battery (MSTB) system was thus developed to store the low-temperature heat using three-phase (vapor-liquid solution-solid crystal) sorption technology with a much higher energy density than a geothermal fluid provides. The energy density of an MSTB is over 6 times that of conventional hot water, enabling economical long-distance transport of low-temperature heat for thermal end uses. This can alleviate peak demand on the electricity grid by offsetting space-conditioning loads, improving the reliability and resilience of US energy systems. High energy density, fast crystallization, and crystal dissolution of the sorption material are critical to the viability and performance of the MSTB system. Therefore, the design and operation of MSTB systems must ensure effective generation and dissolution of the salt crystals inside the MSTB. To achieve this target, this study developed a prototype MSTB and its testing apparatus, and experimentally investigated the prototype MSTB. The crystallization and dissolution performance were also theoretically defined and quantified. The experimental results showed that the prototype MSTB was able to achieve an energy storage density of 903.0 kJ/kg and a maximum discharge rate of 1.3 kW. This study proves the feasibility and high performance of the MSTB concept, which is helpful to further study and development of the MSTB system.

Wang, Lingshi↗

DOE OSTI2020

Hydrothermally carbonized biomass formed via reactive twin-screw extrusion

A biomass-derived thermosetting polymer material being a product of processing a biomass feed material via a twin screw extruder having a length extending between an inlet and an outlet. Hot water from a water heater is injected into at least one inlet along the length of the twin screw extruder, the at least one inlet generally corresponding with a pressure boundary within the twin screw extruder. A pressure-sustaining valve is connected between the length of the twin screw extruder and the outlet, with the valve being adjusted to produce the biomass-derived thermosetting polymer material.

09 BIOMASS FUELS↗

DOE OSTI2020

Deep Retrofits for Multifamily: Experiences in Scaling to Zero Energy: Preprint

Zero net energy (ZNE) buildings are needed to reverse the growing trend of increasing energy consumption. But to make dramatic changes, existing buildings must be renovated at scale. In addition, the building stock must be electrified so that its energy needs could be met by renewable generation. Such aggressive goals often mean very high custom design and capital construction costs. Suitable options for comprehensive envelope retrofits can be too expensive to be practical, and electrification requires upgrades to building-level electrical infrastructure. This paper is a case study of eight projects—primarily multifamily residential—that strived for zero-energy, all-electric retrofits. The design teams were challenged to create solutions that could be replicated at scale, showing decreasing costs with broader adoption. Key technologies considered in designing cost-effective, scalable solutions include industrialized prefabricated retrofit components, modular HVAC solutions, and innovative domestic hot water systems. We trace the progress toward the goals set and examine the choices made by the teams as they encountered technical, logistical, and cost barriers. We also discuss financial challenges for multifamily retrofits, provide guidance for incentives, and examine procurement processes for design services and technologies.

ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATION↗

DOE OSTI2020

Transforming New Multifamily Construction to Zero: Strategies for Implementing Energy Targets and Design Pathways: Preprint

Creating zero energy (ZE) mid- to high-rise multifamily buildings represent significant challenges in the design world. Tenants often take responsibility for some of the utilities and are responsible for consumption of some of the largest end uses: hot water and plug loads. Furthermore, designers can experience risk in creating new sets of details and recommending new strategies to reach aggressive EUI targets. To assist in a more streamlined and successful design approach to ZE multifamily buildings, five major professional societies and experts from the multifamily space created a Zero Energy Advanced Energy Design Guide (AEDG) for multifamily buildings based on data driven results coupled with actual design experiences and case studies. Pathways to achieve ZE design were established including whole building energy use intensity targets coupled with details on how to achieve success in implementing individual efficiency measures. The guidance strives to overcome design barriers and this paper provides an overview of the recommended process to achieve ZE or ZE-ready status, along with details on selecting energy targets, and strategy pathways to achieve the targets.

advanced energy design guide↗

DOE OSTI2021

Development of Integrated Mechanical Pods

This presentation highlights early wins, updated progress, and upcoming developments on ‘national-scale shared development platform’ for rapid prototyping, testing and validation of various integrated Mechanical Pod solutions and form factors. Such pod solutions consist of a set of all-electric heat pump mechanical equipment that have integrated functionalities through built-in controls, with heating, cooling, hot water, ventilation (including energy recovery), electrical management, and battery storage within a single package. The presentation draws inspiration from the success of bathroom pods in the US modular construction industry, UK’s efforts with unitizing mechanical systems as ‘utility cupboards’, and VEIC’s early wins in design-build of all-electric Mechanical Pod solutions in Vermont. The presentation includes researchers and partners involved with NREL in Design for Manufacturing and Assembly (DfMA), Virtual Design and Construction (VDC), and digital twin based process optimization modeling of integrated Mechanical Pod solutions. The presentation aims to highlight early wins from such a platform and how various physical and virtual tools are currently being employed as part of NREL’s ongoing multi-year project funded by US DOE. Streamlined procurement, coordination, installation, and O&M of Mechanical Pods such that the majority of work is delegated to the off-site modular factory implies monetary savings. Such a seemingly basic shift in location of the construction process leads to great reduction in complexity, first cost, lead time, and waste, and greater opportunities for innovative compartmentalization and integration of mechanical systems appropriately sized for each apartment or hotel guest room. However, past studies on unitized combination systems show that high installation costs, maintenance issues, challenges with system integration, limitations in existing electrical infrastructure, and lack of architecturally appealing solutions are key barriers. NREL and partners aim to address key barriers through DfMA approach, rapid prototyping and testing, and digital twin process optimization modeling. The presentation is also a call for interested entities to partner with NREL as part of the national-scale development platform, help drive both product and process innovation, and encourage open source sharing of learnings. Learning objectives include (1) learn about the vision of national-scale shared development platform for process-product innovation on integrated mechanical pod solutions and how to get involved, (2) gain an understanding of the components of an all-electric, high performance home, design characteristics and equipment included in an all-electric mechanical pod, integration of mechanical systems within a modular factories’ assembly line, and the system’s commissioning, operation and maintenance. The pre-planning and coordination with the factory and sub-contractors are also highlighted, (3) gain an understanding of using process modeling tools to quantify resource-constrained performance of operations (such as integration of energy efficiency strategies) to manufacture modules of varying design, (4) gain insights on virtual design, rapid prototyping, and emulated testing of various form factors across different climatic conditions. The need for such preliminary testing with open source sharing of learnings will also be highlighted.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2022

Draft Environmental Impact Statement for Proposed Energy Conservation Standards for Manufactured Housing

This draft environmental impact statement (EIS) analyzes the impacts related to DOE’s proposed energy conservation standards for manufactured homes. DOE’s proposed energy conservation standards are based on the 2021 International Energy Conservation Code (IECC) and relate to the building thermal envelope; air sealing; installation of insulation; duct sealing; heating, ventilation and air conditioning (HVAC); service hot water systems; mechanical ventilation fan efficacy; and heating and cooling equipment sizing. The draft EIS evaluates DOE’s proposed action (energy conservation standards tiered based the manufacturers retail list price), alternatives to the proposed action (including energy conservation standards tiered based on size of the manufactured home and untiered standards), and a no action alternative. The draft EIS presents analysis of impacts related to (1) energy resources; (2) air resources (including greenhouse gases, climate change, ambient air quality and indoor air quality); (3) health and safety; (4) socioeconomics; and (5) environmental justice.

MacDonell, Margaret↗

DOE OSTI2022

NCSU Industrial Assessment Center

Renewable energy technologies are becoming more attractive and gaining more attention as the world becomes increasingly aware of the negative impacts of global warming and greenhouse gas (GHG) emissions. Two such emerging technologies are geothermal heat pumps (GHP) and solar thermal heating which can be used for heating and cooling of buildings. GHP systems are a well-studied technology that have been proven to be more efficient than traditional air-source heat pumps for space conditioning of buildings. Solar thermal heating has become more common as a way to heat domestic hot water (DHW) in homes, but the two technologies are not often combined. This study presents the findings of combining an open-loop GHP with 100 ft2 of flat plate solar thermal panels and a 5,655-gallon sensible water storage tank for space heating and DHW heating needs of a residential home in Bozeman, MT, USA. The goal of this system was to use energy from the solar panels and storage tank first to decrease pumping energy from the GHP well. The open loop system was designed to be a backup system to the solar thermal panels and sensible storage tank. An actual home was modeled to determine potential energy and cost savings of such a system compared to a traditional propane boiler. Then, a case study was performed on the installed system from January to June 2021. Results obtained from April 2nd to June 5th, 2021 indicated that the combination system supplied all necessary heat, and that heat was supplied from the thermal storage tank 55% of the time. This represents a savings of 330 kWh of energy and $36 compared to operating just the open loop geothermal system. From April 2nd to June 5th the combination system consumed a total of 2,510 kWh of energy and cost $274 to operate. Based on data obtained, there is significant potential for energy savings compared to a propane boiler, however only small potential for cost savings.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2022

The Complexity and Challenges of Irradiation-Induced Phase Instability Phenomenon in Nuclear Power Plant Components

High energy irradiation by neutrons or ions of metastable austenitic 300-series steels appears to initiate formation of bcc-phases with different morphology and elemental composition compared to that of retained ferrite. Extensive formation of specific Fe-rich ferrite was observed on the grain boundaries of annealed Russian steel 12Cr18Ni10Ti, an analog of AISI 321, after irradiation in the center-core region of sodium-cooled BN-350 fast reactor (SFR) doses up to 57 dpa at ~1×10-6dpa/sec. The ferrite fraction determined from scanning electron microscopy (SEM) closely matched the magnetic fraction determined using a ferritscope confirmed by X-ray diffraction analysis and selected area diffraction patterns. Chemical composition of the secondary phases was determined by energy dispersive X-ray analysis using transmission electron microscope, showing Fe-rich ferrite domains. Fe-ion irradiation (2.3 MeV) was used to study the accumulation of ferrite and martensite phases at higher dpa rates. The very high etchability of these ferrite particles in alcohol-based solutions may signal a very high etching in hot water, leading to accelerated intergranular cracking, especially upon long-term exposure during extended plant lifetimes.

D a, Merezhko↗

DOE OSTI2022

Low-Carbon District Heating: Performance Modeling of Hybrid Solar, Heat Pump, and Thermal Storage Systems for District Thermal Energy in the United States

District heating requires thermal energy in the temperature range of 40 degrees C - 120 degrees C. Typically, the thermal energy input for these systems has largely been met through fossil energy. However, the temperature range is low enough that it presents an opportunity for low-carbon technologies such as solar thermal and electrified thermal generators like heat pumps to decarbonize the heat generation. In this paper, a heat pump model was applied to estimate the performance and economics of a real-world low-carbon district heating substation. This system is comprised of a flat plate solar collector field paired with a mechanical vapor compression heat pump and hot water thermal storage, augmented by gas-fired boilers. Plant data was used to tune the model and estimate the system's benefits in terms of both standard financial metrics (IRR and payback), and environmental metrics, including avoided CO2 emissions. The model is subsequently employed to estimate the technical and economic potential of solar + heat pump + ther-mal storage hybrid systems as retrofits for district heating systems in eight US Markets.

district heating↗

DOE OSTI2022

Modeling and Experiments on a Dedicated Outdoor Air System Using Liquid Desiccant Heat and Mass Exchangers

Liquid desiccants can provide efficient dehumidification but have yet to see widespread adoption. Most systems studied previously use natural gas-combustion to heat and regenerate the desiccant, and a central chiller plant or cooling tower for removing the heat of absorption. Here we present modeling and experimental results on a novel packaged air conditioner integrating liquid-desiccant heat and mass exchangers with a vapor compression cycle. The packaged system does not need cold or hot water from a central plant or cooling tower and is suitable for rooftop unit air conditioners. The system uses the evaporator to cool the liquid desiccant that is absorbing moisture from the air, and the condenser to heat the liquid desiccant to regenerate it. Efficiency is improved by reducing the load on the evaporator for a given supply-air dewpoint. This paper presents the measured dehumidification efficiency for a 10- ton packaged air conditioner, focusing on dehumidifying ventilation air. The paper also presents a numerical model to predict the outlet conditions and dehumidification efficiency, which we compare with the measured data.

air conditioning↗

DOE OSTI2023

Subsurface Characterization for Evaluating Geothermal Resource Potential from Existing Oil and Gas Wells in Tuttle, Oklahoma: Preprint

Oil and gas (O&G) wells often encounter co-produced hot water, possibly suitable for geothermal direct-use applications. The City of Tuttle is located on the eastern part of the Anadarko sedimentary basin in Oklahoma with high heat-in-place potential and recovery capability at depth. This study aims at demonstrating the potential of geothermal energy production for direct-use applications in two public schools and 250 nearby houses in Tuttle via repurposing existing O&G wells. In this scope, geochemistry, geology, and borehole log data were collected and incorporated into a 3D conceptual subsurface model. A digital elevation model (DEM) was used to represent the study area topography with four O&G wells. In addition, hydrogeochemical characteristics of the geothermal fluid and scaling potential were analyzed using ternary diagrams and chemical ratios to develop mixing models. The subsurface geology model indicated that the study area primarily consists of Permian to Mississippian Sandstone and Limestone formations, implying a porosity ranging between 12% and 22%, and a permeability up to 3.90E-14 m2 in certain reservoir levels. The reservoir temperature is expected to be ranging between 80 degrees C to 95 degrees C around 3 km depth with an average temperature gradient of 22.8 degrees C/km. Chemical geothermometers also estimated the reservoir temperature as 90 degrees C. Findings of the chemical model demonstrated that the geothermal fluid is Sodium-Potassium-Chloride-Sulfate type and possibly mixed with shallow groundwater resulting in higher Ca and Mg concentrations and lower Na/K ratio implying lower calcite scaling. These results comprehensively characterize the potential of geothermal resources in the study area and imply that geothermal energy production by repurposing existing O&G wells is suitable for low-temperature direct-use applications.

GEOTHERMAL ENERGY↗

DOE OSTI2023

Resource Characterization to Estimate Potential for Electricity Co-Production at Blackburn Oil Field, Nevada

The U.S. Department of Energy estimates that an annual average of 25 billion barrels of hot water are produced from oil and gas wells within the United States. The thermal energy available in the co-produced water stream is usually discarded, as the produced waters are considered an inconvenience by the operators and are disposed of using injection wells. However, utilizing organic Rankine cycle (ORC) generators, a vast amount of thermal energy can be captured and converted into electricity (albeit at relatively low efficiency due to the low temperatures). The National Renewable Energy Laboratory (NREL), in collaboration with Transitional Energy and Grant Canyon Oil & Gas, evaluated the feasibility of geothermal co-production of electricity by utilizing existing oil wells in Blackburn oil field in Nevada. The once prolific Blackburn oil field is located in Pine Valley, approximately 45 miles east-southeast of Elko, Nevada. Currently, the wells targeting the highly fractured Devonian Nevada dolomite reservoir are operating at a water cut ratio of more than 99%, with individual fluid (oil and water) production rates reaching 7.4 L/s (4,021 BBL/day). Analysis of publicly available data showed that the combination of the suitable wells' maximum historical production rates reached 22.90 L/s. The production from these wells occurs naturally and the wells are choked (and even shut down) by the operator to mitigate excessive water production, indicating a strong reservoir recharge and future opportunity to increase the water production for geothermal electricity generation. The main goal of this study was to evaluate the productivity of the existing wells, the performance of the reservoir, the surface network, and the operational constraints in order to achieve 1 MWe of electricity production from the field's water production. Utilizing the GEOPHIRES tool, we have determined that a twofold to threefold increase in the total fluid production, compared to the historical production under artificial restraint (choke), is required to reach a 1-MWe net target output for a low-temperature ORC system with air-cooled condensers. Lower flow rates would be required when utilizing water-based condensers instead of air-cooled condensers. However, that would require a constant supply of cold water, which may be challenging given the arid environment of the project site.

Blackburn↗

DOE OSTI2023

Thermo-Hydrological Modeling of Thermal Energy Storage in a Depleted Oil Reservoir

Thermal energy storage in oil and gas reservoirs leverages the existing surface and subsurface infrastructure, which can pave the way for economic production of geothermal energy. Existing studies on geothermal energy storage are focused mostly on the use of aquifers with more homogeneous rock and fluid properties. Coupling of heat and fluid flow in a multiphase-multicomponent system, such as an oil reservoir, is imperative especially if existing oil field assets need to be repurposed as required for a sustainable energy transition. The objective is to model the subsurface thermo-hydrological processes associated with reservoir performance and operational sustainability. The model evaluates formation pressure and temperature within the reservoir and at the injection/production wells during multiple charge and discharge cycles. Hot water (approximately 200 degrees C) heated by Concentrating Solar Power (CSP) at high pressure is injected into the existing oil reservoir for storage and produced as thermal energy for power generation, which will be accompanied by enhanced oil recovery. To demonstrate the coupled fluid and heat flow during the injection/production cycle in the subsurface reservoir, TOUGH3 (developed by Berkeley Lab) is used to simulate the thermo-hydrological (TH) processes in a multiphase, multicomponent system. Two well geometries are considered within the reservoir grid: 1) a single-well huff-n-puff system (same well is used for injection and production), and 2) an isolated injection-production well doublet. Seasonal charge and discharge cycling are implemented based on the scheduling specified in the model input file. The model reports pressure, temperature, enthalpy, liquid fluxes, heat fluxes, pore velocities, and changes in porosity & permeability due to temperature and pressure variations during the cyclic Reservoir Thermal Energy Storage (RTES) operations. The results from the simulations can be used to optimize the operational parameters (such as well spacing and injection/production rates) and round-trip efficiency for surface power-plants coupled with thermal energy storage over time. They can also serve as important inputs for levelized cost of storage estimations. The research will help to design and integrate surface renewable energy sources, such as concentrating solar power (CSP), with RTES to help balance out power supply and demand on the grid.

CSP↗

DOE OSTI2023

Subsurface Characterization for Evaluating Geothermal Resource Potential from Existing Oil and Gas Wells in Tuttle, Oklahoma

gas wells↗

DOE OSTI2024

Evolution of a Geological Model for Co-Producing Electricity at the Blackburn Oil Field, Nevada: Preprint

Oil fields characterized by significant proportions of hot water in the reservoir offer a unique opportunity for geothermal energy co-production and utilization. Development of an accurate geological model is essential in understanding the subsurface. However, this is a challenge at the preliminary stages of resource assessment when data on the subsurface parameters and subterranean fault network is scarce. Our focus in this paper is to explore a methodology for developing an accurate conceptual geological model of the complexly faulted reservoir at the Blackburn Field, Nevada, to create a numerical simulation that will eventually be used to assess the potential of co-producing electricity. There are four steps to the evolution of this model: (1) collection of public data and research on the geological setting of the system; (2) digitization of seismic time-interpretation and cross-sections to create the most representative model of the subsurface; and (3) creation of a natural-state numerical model to simulate the thermal gradient through the subsurface. Utilizing publicly available data of the geological system and Leapfrog conceptual modeling software, we refined a preliminary model to be more representative of the subsurface geology of an active geothermal exploration stage project. The conceptual geological model developed has been imported into VOLSUNG reservoir modeling software to create a natural-state model, further characterizing the Blackburn Field reservoir's thermal gradient. In the future, new seismic data will be utilized to further evolve the conceptual geological model for numerical simulations.

Basin and Range province↗

DOE OSTI2024

Modeling and Validation of a Residential Multi-Functional Variable Refrigerant Flow Heat Pump System with Heat Recovery

To bridge the existing gap in modeling the variable refrigerant flow heat pump systems with heat recovery (VRFHR), we developed a suite of dynamic VRFHR system models in Modelica. These models are specifically tailored for residential multi-functional VRFHR (MF-VRFHR) applications, including space conditioning and domestic hot water (DHW) heating, utilizing both the TIL library for HVAC equipment and the Buildings library for thermal load calculations. The development comprises essential component models, including the newly developed heat recovery unit (HRU), along with system models that integrate the heat pump system and building envelope. These system models accommodate various operational modes such as heating-only, cooling-only, and heating-recovery (including heating-dominant and cooling-dominant) modes. Furthermore, we propose an efficient optimization-based model calibration method that identifies critical model parameters while utilizing a small amount of data obtained from either real systems or manufacturer's specifications. We demonstrate the effectiveness of these models and the proposed calibration method for a MF-VRFHR system installed in Richland, WA. The developed models are calibrated and validated using data collected under different operational modes during both heating and cooling seasons. The results show that the models capture the system dynamics and achieve high accuracy, with the coefficient of the variation of the root-mean-square-error less than 15% for variables such as outdoor unit power consumption, compressor speed, space temperature and DHW temperature. The validated models serve as a reliable representation of the MF-VRFHR system, facilitating the development and validation of optimized controls needed to realize the full benefits of integrated heat pump systems. Future research will utilize these models to develop advanced controls and optimize system performance for improved energy efficiency and demand flexibility.

Modeling, Variable refrigerant flow (VRF) systems,↗

DOE OSTI2025

Residential Home Decarbonization Using Advanced Micro-CHP

An efficient micro-combined heat and power (CHP) prototype was developed to provide heat and electricity for single-family homes and light commercial buildings. The unit can be installed independently at the point of energy consumption. Consequently, it enables cost-effectively and flexibly matching heat and electrical loads, simplifying distribution and installation processes, and recovering and storing waste heat as hot water. The analyzed results show that the micro-CHP using natural gas as fuel achieves 10.68%–32.80% CO2 reduction in the selected five home applications. The potential effect of H2 on decarbonization of these home was also evaluated, finding that the micro-CHP using a blended fuel with H2 and natural gas can further reduce CO2 emissions. However, the 50% CO2 reduction in the micro-CHP requires at least 70%–90% of H2 in the blend with natural gas. Overall, the micro-CHP technology demonstrates a solid potential to accelerate micro-CHP adoption in residential and light commercial markets, thereby promoting broader micro-CHP acceptance and use in the future for building decarbonization.

Gao, Zhiming [ORNL] (ORCID:0000000271397995)↗

DOE OSTI2020

Recent Progress to Understand and Improve Zeolite Stability in the Aqueous Medium

The work reviewed here attempts to summarize the growing literature on zeolite stability in hot liquid water. This required to first establish the nature, structure and interactions of the active sites in Brønsted and Lewis acidic microporous materials in the presence of liquid water. This understanding was then transferred to zeolite stability and catalyst deactivation. While early results correctly established Si–O–Si hydrolysis as the dominant pathway compared to the Si–O–Al hydrolysis observed in steaming, it also focused extensively on the positive role of framework and extra-framework Al in stabilizing zeolites. However, stability was instead found to more directly correlate with the number of internal structural defects and intraporous water concentration. Stabilization protocols for Brønsted acidic zeolites are described in detail. In the case of Lewis acidic zeolites, their inherent hydrophobic behavior (Si/M >100) makes them more resistant towards water, however, issues such as reversible carbonaceous species formation as well as irreversible metal leaching and fouling remain. Finally, we summarize the most important factors in designing robust and efficient zeolite catalysts made to withstand hot liquid water.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗