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DOE OSTI2024

Contactless Production Testing of Silicon Solar Cells

Critical cost reductions in silicon solar cells are made by minimizing silver usage in their metal contacts. The reason why is both clear and unavoidable—silver is not only expensive, but also a potential limiting resource for scale-up (the PV industry alone used 10.3 % of the global silver supply in 2020 [1]). The result is solar cells with vanishing electrical contact area that are extremely difficult to test prior to module manufacture, when they must be sorted for quality to maximize power output and reliability of the subsequent modules. This project developed a new measurement instrument that enables the transition to solar cells with very low silver content, including cell designs with both minimal busbars and no busbars at all to electrically contact. The resulting instrument at project completion demonstrated the ability to sort cells with comparable—or better—results than existing technology. Compared to existing cell-test instruments, the new tool has minimal contacting requirements, which lowers the maintenance costs and use of consumable parts. We demonstrated innovative, yet pragmatic, solutions for reporting a comprehensive set of measurement results useful for both cell sorting (going forward in the line for module manufacture) and process control (looking backward in the line to identify cell manufacturing issues from wafer to cell-test). In addition to the traditional current-voltage characterization at cell test—short circuit current, open-circuit voltage, power, efficiency and fill factor—the new tool maintains all the advanced parameter characterization of our existing product line such as a substrate doping measurement, carrier recombination (lifetime) analysis, and surface recombination analysis.

14 SOLAR ENERGY↗

DOE OSTI2024

The Single Event Error (SEE) test and analysis of the CMS Endcap Timing Layer readout chip

The ETROC2, the first full size and full functionality prototype chip for the CMS Endcap Timing Layer readout, is strategically designed to meet the SEE immunity requirements of detector operation with the low power constraint. The triplicated periphery and pixel I2C configuration registers are designed with self-correction feature. The pixel readout control is centralized in the global readout and fully triplicated. The pixel readout is not triplicated, instead protected with power-efficient one-bit correction Hamming code. The TMR protection of the on-pixel threshold calibration can be turned off allowing the detection of the beam spot during the beam test by checking the bit-flips of the internal memory cells. In the initial proton beam test in January 2024, the chip readout process did not hang throughout the tests. The Hamming code correction strategy works because the error corrected TDC data were observed in the data frames. The error-injection simulation is performed to analy ze the small number of bit-flips in the configuration registers. We also performed SEE testing with a heavy ion beam in April and the data analysis is ongoing. The detailed design on the SEE immunity and the testing as well as simulation results will be presented, including follow-up SEE testing results in May and June 2024.

Gong, Datao↗

DOE OSTI2023

Heat Exchanger Intensification Through Powder Processing and Enhanced Design (HIPPED)

High intensity, supercritical CO 2 heat exchangers capable of operating at temperatures between 800 and 1100 ˚C and pressures greater than 80 bar are considered a critical component for high efficiency power generation and a range of next-generation industrial processes. A novel heat exchanger concept was proposed in this project. The proposed concept involved a plate-type architecture with three-dimensional fins, called twisted s-shaped fins, that capitalize on additive manufacturing. Four manufacturing processes were studied to realize the complex envisioned design: press and sinter of metallic powders, directed energy deposition, laser powder bed fusion, and a novel powder bed process involving a photoreactive polymer called SEAM (scalable expeditious additive manufacturing), that later was developed at MSU. The team was able to manufacture subscale heat exchangers using laser powder bed fusion (LPBF) and SEAM. The team settled on using SEAM as a final manufacturing approach due to its very low cost. The SEAM-manufactured heat exchanger, however, when tested under pressure, exhibited leaks and the process still requires further development beyond the timeline of the project. To support the heat exchanger design and testing, the team developed a new high temperature flow loop allowing testing under high temperature and pressure. Computational modeling of the heat exchanger was also performed for the twisted s-shaped fins and the computations were validated with experimental data. The new twisted fins resulted in enhanced heat transfer and reduced pressure drop. To further minimize pressure drop in the plate heat exchanger, the team also developed a simplified model for flow maldistribution in the manifolds, providing a new tool for designers that eliminates the need for complex CFD calculations. A technoeconomic analysis was also developed to contrast SEAM with LPBF, this tool indicated that SEAM is several times less costly and offer significant promises as a rapid low cost additive manufacturing process for metallic systems.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2024

Design and Evaluation of Environmental Barrier Coatings for Protection of Ceramic Matrix Composites in Hydrogen-Based Turbines

This presentation at the 2024 FECM Spring Project Review Meeting summarizes ongoing work at NETL aimed at enabling the use of ceramic matrix composite (CMC) materials in next-generation high-efficiency power generation turbines fueled by hydrogen, natural gas, or other fuels. The work broadly involves three aspects (1) phase-field damage modeling of CMCs and the environmental barrier coatings (EBCs) used to protect them (2) computational design of new and improved EBCs and (3) performance testing of EBCs using a novel gas turbine combustion simulation rig developed at NETL. An overview on current status and next steps for each aspect of the project are presented.

ceramic matrix composite (CMC)↗

DOE OSTI2024

Microstructure Optimization and Novel Processing Development of ODS Steels for Fusion Environments (Final ARPA-E Report)

This project aimed to develop scalable, cost-effective fabrication of high-performance, oxide- dispersion-strengthened (ODS) steel using advanced manufacturing methods (AMMs) for fusion blanket-breeding applications. Gas atomization reaction synthesis (GARS) enables the synthesis of precursor ODS steel powders without prolonged mechanical alloying. This process creates a chromium (Cr)-enriched surface oxide with yttrium/titanium (Y/Ti)-enriched intermetallics in powder interiors. GARS powders were consolidated to >99% of the theoretical density using a first-of-a-kind shear assisted processing and extrusion (ShAPE) and laser-based powder bed fusion (L-PBF) AM processes. These processes led to ODS steels containing a high-density of nano-oxide dispersoids that enhance high-temperature mechanical properties. Such scalable, cost-effective fabrication of ODS steels can enable efficient power conversion cycles (=40%) at operating temperatures beyond 900 K in future fusion power plants.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Accelerators for HEP: Challenges and R&D

Particle accelerators are arguably the most effective tools for the particle physics research. The physics needs continuously push us to invent novel ways to increase energy and improve performance of accelerators, reduce their cost and make them more power efficient. Here we briefly overview three main families of modern and future accelerators for HEP – high intensity accelerators for neutrino research, particle factories for the electro-weak physics and Higgs studies, and post-LHC energy frontier colliders – and discuss corresponding ongoing or planned accelerator R&D topics and objectives.

43 PARTICLE ACCELERATORS↗

DOE OSTI2022

Challenges of Future Accelerators for Particle Physics Research

For over half a century, high-energy particle accelerators have been a major enabling technology for particle and nuclear physics research as well as sources of X-rays for photon science research in material science, chemistry and biology. Particle accelerators for energy and intensity Frontier research in particle and nuclear physics continuously push the accelerator community to invent ways to increase the energy and improve the performance of accelerators, reduce their cost, and make them more power efficient. The accelerator community has demonstrated imagination and creativity in developing a plethora of future accelerator ideas and proposals. The technical maturity of the proposed facilities ranges from shovel-ready to those that are still largely conceptual. At this time, over 100 contributed papers have been submitted to the Accelerator Frontier of the US particle physics decadal community planning exercise known as Snowmass’2021. These papers cover a broad spectrum of topics: beam physics and accelerator education, accelerators for neutrinos, colliders for Electroweak/Higgs studies and multi-TeV energies, accelerators for Physics Beyond Colliders and rare processes, advanced accelerator concepts, and accelerator technology for Radio Frequency cavities (RF), magnets, targets and sources. This paper provides an overview of the present state of accelerators for particle physics and gives a brief description of some of the major facilities that have been proposed, their perceived advantages and some of the remaining challenges.

43 PARTICLE ACCELERATORS↗

DOE OSTI2022

Scientific challenges to characterizing the wind resource in the marine atmospheric boundary layer

Abstract. With the increasing level of offshore wind energy investment, it is correspondingly important to be able to accurately characterize the wind resource in terms of energy potential as well as operating conditions affecting wind plant performance, maintenance, and lifespan. Accurate resource assessment at a particular site supports investment decisions. Following construction, accurate wind forecasts are needed to support efficient power markets and integration of wind power with the electrical grid. To optimize the design of wind turbines, it is necessary to accurately describe the environmental characteristics, such as precipitation and waves, that erode turbine surfaces and generate structural loads as a complicated response to the combined impact of shear, atmospheric turbulence, and wave stresses. Despite recent considerable progress both in improvements to numerical weather prediction models and in coupling these models to turbulent flows within wind plants, major challenges remain, especially in the offshore environment. Accurately simulating the interactions among winds, waves, wakes, and their structural interactions with offshore wind turbines requires accounting for spatial (and associated temporal) scales from O(1 m) to O(100 km). Computing capabilities for the foreseeable future will not be able to resolve all of these scales simultaneously, necessitating continuing improvement in subgrid-scale parameterizations within highly nonlinear models. In addition, observations to constrain and validate these models, especially in the rotor-swept area of turbines over the ocean, remains largely absent. Thus, gaining sufficient understanding of the physics of atmospheric flow within and around wind plants remains one of the grand challenges of wind energy, particularly in the offshore environment. This paper provides a review of prominent scientific challenges to characterizing the offshore wind resource using as examples phenomena that occur in the rapidly developing wind energy areas off the United States. Such phenomena include horizontal temperature gradients that lead to strong vertical stratification; consequent features such as low-level jets and internal boundary layers; highly nonstationary conditions, which occur with both extratropical storms (e.g., nor'easters) and tropical storms; air–sea interaction, including deformation of conventional wind profiles by the wave boundary layer; and precipitation with its contributions to leading-edge erosion of wind turbine blades. The paper also describes the current state of modeling and observations in the marine atmospheric boundary layer and provides specific recommendations for filling key current knowledge gaps.

17 WIND ENERGY↗

DOE OSTI2021

Accelerator Technologies and Science: Progress and Outlook

For over half a century, high-energy particle accelerators play a key role and shape modern nuclear and particle physics, they are also the instruments at the forefront of research for material science and biology. The physics needs continuously push us to invent novel ways to increase energy and improve the performance of accelerators, reduce their cost and make them more power-efficient. Here we briefly overview the most notable accelerator facilities which recently became operational and are now employed for research in nuclear physics, basic energy sciences, neutrinos, high energy particle frontier. We also present upcoming and planned future facilities and outline their main goals, challenges, and required R&D. Focus will be given to the core accelerator technologies such as magnets, RF acceleration, and targets as we as leading beam physics developments such as beam cooling, colliding beams and plasma acceleration.

Shiltsev, Vladimir D.↗

DOE OSTI2021

Particle-based thermal energy storage systems

Methods and devices for long-duration electricity storage using low-cost thermal energy storage and high-efficiency power cycle, are disclosed. In some embodiments it has the potential for superior long-duration, low-cost energy storage.

Ma, Zhiwen↗

DOE OSTI2023

Particle-based thermal energy storage systems

Ma, Zhiwen↗

DOE OSTI2024

Intelligent Pixel Detectors: Towards a Radiation Hard ASIC with On-Chip Machine Learning in 28 nm CMOS

Detectors at future high energy colliders will face enormous technical challenges. Disentangling the unprecedented numbers of particles expected in each event will require highly granular silicon pixel detectors with billions of readout channels. With event rates as high as 40 MHz, these detectors will generate petabytes of data per second. To enable discovery within strict bandwidth and latency constraints, future trackers must be capable of fast, power efficient, and radiation hard data-reduction at the source. We are developing a radiation hard readout integrated circuit (ROIC) in 28nm CMOS with on-chip machine learning (ML) for future intelligent pixel detectors. We will show track parameter predictions using a neural network within a single layer of silicon and hardware tests on the first tape-outs produced with TSMC. Preliminary results indicate that reading out featurized clusters from particles above a modest momentum threshold could enable using pixel information at 40 MHz.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2025

Early Research in Load-Following Management for HPC-Nuclear Integration

With the rising demand for high performance computing (HPC) and artificial intelligence (AI) systems, maintaining a stable and efficient power supply is increasingly critical. The HPC team at Idaho National Laboratory is spearheading efforts to seamlessly integrate HPC systems with nuclear reactors. This lightning talk explores one early strategy for managing power fluctuations using software-defined controls. To effectively harness nuclear reactors for power generation, control mechanisms are essential to address the slow load-following capabilities of reactors, which are typically around 5% per minute. While this rate is sufficient for many uses, large HPC systems can experience rapid power consumption changes by tens of megawatts when jobs start or stop running. A reactor could overproduce power and match the peak power rating for the HPC system, however when the system is not running a job or a job unexpectedly stops, the load-following of the system would be affected leading to power being wasted and the likelihood of power transient occurrences increases. Controlling the increase or decrease of power consumption on these systems at the same rate as the load-following of reactors is one piece of the puzzle to properly utilizing nuclear reactors as a power source for HPC systems.

97 - MATHEMATICS AND COMPUTING↗

DOE OSTI2024

Degradation of Poly- and Perfluoroalkyl Substances (PFAS) in Water via High Power, Energy-Efficient Electron Beam Accelerator

The goal of the 2-year workplan was to see if electron beam (EB) could be used to break down a sub-set of the larger chemical family of per and polyfluoroalkylated substances (PFAS) in an energy efficient and economical manner when compared to conventional water treatment technologies. Year one (Y1) work focused on sample EB treatment work in the Fermi National Accelerator Laboratory’s (FNALs) Accelerator Applications Demonstration and Development (A2D2) EB accelerator. While there are reportedly thousands of types of PFAS, for the point of most of the work herein, a small subset was examined, typically perfluorooctane sulfonate (PFOS) and perfluorooctanoate (PFOA). PFOA and PFOS are two of the most well studied PFAS and are studied for baseline evaluations and are considered most useful. The work from Y1 provided information about the optimal operating parameters and additives to use when treating PFOS and PFOA via EB. The data were then used to see where in a water treatment system an EB accelerator would be best suited to treat PFAS. A conventional water treatment technology, GAC, was then compared to e-beam treatment technology with respect to energy and costs for treatment. In year two (Y2), several conventional e-beam accelerator designs, and FNAL’s developmental compact SRF accelerator design, were evaluated for their suitability in PFAS treatment, from an energy efficiency and cost standpoint. Several EB parameters were evaluated and optimized for the removal of PFOA and PFOS from water at normal pressure and temperature, measured as total PFAS removal. Under the optimized test conditions both PFOA showed complete destruction to inorganic fluoride, and PFOS to inorganic fluoride and sulfate, with mass balance. The effect on PFAS removal relative to solution pH, total EB dose, EB dose rate, dissolved oxygen concentration (DO), temperature, and initial PFAS concentration were evaluated. In general, PFOA was easier to destroy than PFOS. Degradation products, typically observed under less-than-optimal EB conditions, provided insight to degradation mechanisms. Products were identified to rule out possible deleterious biproduct formation. The water radiolysis radical reaction kinetics with PFOS and PFOA were not dependent on the initial concentration over 5-orders of magnitude from 2 μg/L to 20 mg/L. This is thought to be because there was an overabundance of the reactive water radiolysis radicals relative to PFAS molecules and largely attributed to aqueous electrons. The reaction rates appeared to be diffusion limited. Testing at higher concentrations (100-200 mg/L) showed a decrease in removal efficiency, suggesting alternative kinetics, possibly second order rates, at higher concentrations. In all, we successfully defined a set of optimal EB parameters to treat PFOA and PFOS at concentrations of 20 mg/L in water with destruction efficiencies near 100%. We further tested the optimized EB parameters with other types of PFAS, including shorter and longer fluorocarbon chain homologs of PFOA and PFOS, and PFAS with alternative functional groups such as sulfonamides. Based on our results EB can be optimized as an effective destructive technology for removing PFAS from water. The conditions optimized for PFOA and PFOS were less effective with ultra-short fluorocarbon compounds like TFMS, PFES, PFPS and PFBS, and likely require re-optimization of parameters to them. In all, it was determined that from a cost and energy efficiency standpoint, EB would be best applied to waste streams with relatively high concentrations of PFOS and PFOA and is not as cost effective as GAC treatment for removing low concentrations of PFAS from water. Higher concentrations of PFAS can be found in the wastewater of conventional treatment processes such as RO and IE and therefore EB may be used to supplement such treatment technologies. Some real-world IE regeneration wash water and RO reject water containing higher concentrations of PFAS and obtained from pilot scale industrial wastewater treatment system at a fluorochemical manufacturing facility, showed that EB could remove PFAS from such types of wastewaters. The IE regenerant wash water appeared to be the most efficient of the two types of wastewaters tested. However, some further optimization of the EB parameters for the specific PFAS types present in those wastewaters may be required. Also, the effects of co-present TOC and mineral salts should be considered during such optimization efforts. From the experimental Y1 results it was seen that the aqueous electron drives degradation of the PFAS. In a hypothetical water treatment skid using EB for PFAS destruction the parameters of the system should be optimized to promote aqueous electron production. Before EB treatment, the PFAS should be preconcentrated when possible, the pH should be raised to pH 10 or higher to enhance aqueous electron production, and the water should be nitrogen purged to remove dissolved oxygen to minimize aqueous electron scavenging. An excel spreadsheet was created that calculates optimal conditions based on inlet PFAS concentration and desired outlet concentration, by optimizing the accelerator power, dose rate, water treatment rate, pH and dissolved oxygen levels to reach the desired endpoint. Given this information on accelerator operating conditions five different EB accelerator systems were compared. One EB system was a continuous-wave, linear superconducting accelerator being designed at Fermilab. Three other EB systems (IMPELA at 5% and 25% duty factor and the ILU-14) were normal conducting pulsed linear accelerators. The fifth system was an IBA Rhodotron which is a normal conducting, circular, continuous-wave accelerator. The accelerator efficiency (% of the incoming power that is used in water treatment) was the dominating factor in accelerator choice. The radio frequency (RF) power supply and the accelerator design (superconducting versus warm technology) drive the accelerator efficiency. The IBA Rhodotron was seen to be the most energy efficient commercially available technology with a wall-plug (total) power efficiency of 43% at 400 kW. The Fermilab design, with a prototype for a different application currently being fabricated, was the most energy efficient at 55% when driven by a Klystron RF power supply and as high as 77% when powered by a magnetron. As the Fermilab design was the most energy efficient by approximately 10-30%, further design work was done on the accelerator and beam delivery system specific to the destruction of PFAS in water. The Fermilab design is unique from industrial accelerators in that is superconducting. Superconducting technology allows for the acceleration of electrons without losses. The accelerator must be cooled to below the point where it is superconducting and is operated around 4 degrees Kelvin. The bulk of the design work for the accelerator is on making the accelerator as energy efficient as possible so that it does not require liquid helium and can be cooled with conduction cooling via cryocoolers. Final design work resulted in an EB accelerator that would operate at minimally 200 kW and 10 MeV. Prototype construction would cost $\$ $7.8 million dollars when driven by a Klystron power supply. A second version of the same accelerator would cost $\$ $5.5 million dollars when driven by a magnetron that is still under development. The commercially available 300 kW IBA Rhodotron cost was estimated at approximately $\$ $9 million. While it is hard to directly compare, an operational GAC system used by 3M for groundwater treatment capital cost (2022 dollars) was estimated to cost $\$ $3.3 million. While the capital expense of the EB accelerator systems was higher than GAC, the accelerator EB treatment would result in destruction of the PFAS and not just sequestration of PFAS to form a new waste stream that requires further treatment or disposal. The operating cost to destroy the PFAS via 400 kw EB system was less than $\$ $1000/kg of PFAS destroyed when treating at a 20 mg/L PFAS concentration, compared to GAC with operating costs that calculated at $\$ $27,530 per kg of PFAS sequestered when treating 100 μg/L PFOA and PFOS combined concentration.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2024

Power Layout Design of a GaN HEMTs-Based High-Power High-Efficiency Three-Level ANPC Inverter for 800 V DC Bus System

Multiple commutation paths exist for switching devices in a three-level active neutral point clamped (3L-ANPC) inverter operation based on the selected switching state and current direction. In addition, the capacitive coupling path of the nonswitching device is a key design aspect for enabling high voltage and high current operation of gallium nitride (GaN) switches in 3L-ANPC topology. A comprehensive study of the switching transient events of inner, outer, and clamping devices of 3L-ANPC is presented in this article. The commutation mechanisms for worst-case transient voltage overshoots (TVOs) are identified. A simplified equivalent circuit model is presented to determine the design criteria for the power layout structure's parasitic inductances. A power layout strategy satisfying the design criteria is then proposed using an insulated metal substrate power printed circuit board (PCB) to enable efficient high-power operation. The proposed design minimizes the commutation and capacitive coupling path inductances to 6 nH and 11.5 nH, respectively. This enables the fast switching operation of GaN HEMTs at 800 V dc, 36 A with a low TVO of 31% verified through experimental three-level double pulse test results. Experimental evaluation of a three-phase 3L-ANPC hardware prototype based on the proposed power layout shows 99% efficiency at 800 V, 9.5 kVA and 50 kHz switching frequency. The proposed design achieves a low case-to-ambient thermal resistance of 2.3 °C/W.

42 ENGINEERING↗

DOE OSTI2023

High-Efficiency Modular SiC-based Power-Converter for Flexible-CHP Systems with Stability-Enhanced Grid-Support Functions

This project seeks to develop a modular, scalable MV power converter featuring stability-enhanced grid-support functions for future grid-interface applications in flexible combined heat and power (F-CHP) cogeneration plants, being fully compliant with the IEEE Standard 1547, category B—for operation in local areas with high aggregated distributed energy resource (DER) penetration, and also with the IEEE standard for the specification of microgrid controllers, namely IEEE Std 2030.7, with the goal to enable F-CHP systems for both microgrid and standalone applications. Further, the proposed converter will use a modular circuit topology, the MMC, which is scalable both in voltage and current by interconnecting power-cell building blocks, thus flexibly suiting the needs of F-CHP systems in the 1–20 MWe range. Furthermore, the use of 10 kV SiC MOSFET devices will minimize the number of power-cells needed to operate in 2–13.8 kV MV distribution systems, but more importantly, they will render feasible a power conversion efficiency > 98 %, and a power density > 10 kW/l. This is highly relevant given that these are two key performance metrics that will further increase the value of F-CHP systems by shortening the time required to recover their investment costs.

14 SOLAR ENERGY↗

DOE OSTI2024

Extreme Efficiency 240 Vac to Load Data Center Power Delivery Topologies and Control

The research explored innovative new circuit topologies and power converter architectures for data center power delivery, from the 240 V ac voltage at the input of a server rack, down to the less than 1 V dc power supply of the latest microprocessors. The research pursued three parallel tracks to increase the power conversion efficiency and to reduce the overall size of the servers: 1) An innovative new ac-dc power converter topology which enables improved efficiency through use of a novel direct step-down topology, well suited for the popular 48V dc power distribution. 2) A new series-stacked power delivery approach for servers comprising a large number of similar loads, such as hard drives in storage servers. The approach greatly reduces the power conversion losses, and achieves efficiency well over 99%. 3) A new family of hybrid switched-capacitor power converters that enable improved efficiency and reduced size through the use of dense ceramic capacitors and new circuit topologies that leverage GaN and low-voltage Si transistor technology. Together, the accomplished research achieved the goal of reducing the power conversion losses in datacenters, thereby reducing greenhouse gas emissions, operating costs, and overall electricity consumption.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2024

Shape Optimization of Header Pipes in Power Plants for Enhanced Efficiency and Environmental Sustainability

In a power plant, the header pipe plays a pivotal role in optimizing the performance of diverse systems by serving as a central conduit for the collection and distribution of steam within the plant. This paper investigates the significance of header pipes within power plant setups, highlighting their critical influence on reliability, efficiency, and the performance of the power plant as a whole. The concept of shape optimization emerges as a crucial factor in power plant design and operation, with the potential to maximize performance while minimizing the use of materials. Shape optimization not only enhances efficiency but also contributes to reducing the environmental footprint of power plant installations. In this paper, we initially developed a methodology designed for optimizing header shapes with the primary goal of reducing the usage of costly new alloy materials and lowering the overall maintenance operation expenses. Secondly, we conducted a case study based on an authentic header sourced from an operational power plant.

20 FOSSIL-FUELED POWER PLANTS↗