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DOE OSTI2023

Developing VSC-HVDC Oscillation Damping Control Constraints in Unit Commitment

High-voltage direct current (HVDC) systems within the existing power grids will play a pivotal role in enabling high share of renewable power integration and transportation electrification. There is a need for transmission planning models to accurately capture the impact of VSC-HVDC oscillation damping control on the system planning and model the constraints in the security constrained unit commitment (SCUC) problem. In this paper, the SCUC problem in a hybrid DC-AC grid considering damping on electromechanical inter-area oscillation is studied. An electromechanical oscillation-driven transmission capability constraints are derived from system swing equation and incorporated into the SCUC. Multiple system damping control scenarios are set based on the extracted plausible bounds of damping coefficient and inertia constant to linearize the nonlinear expressions. The SCUC problem with proposed constraints is tested on the Reliability Test System Grid Modernization Lab Consortium (RTS-GMLC) via PLEXOS. The impact of the proposed constraints on regional generation, inertia, power flow, annual system cost, and renewable energy curtailment are fully assessed.

damping control↗

DOE OSTI2021

Digital data provenance for the power grid based on a Keyless Infrastructure Security Solution

In this work a data provenance system for grid-oriented applications is presented. The proposed Keyless Infrastructure Security Solution (KISS) provides mechanisms to store and maintain digital data fingerprints that can later be used to validate and assert data provenance using a time-based, hash tree mechanism. The developed solution has been designed to satisfy the stringent requirements of the modern power grid including execution time and storage necessities. Its applicability has been tested using a lab-scale, proof-of-concept deployment that secures an energy management system against the attack sequence observed on the 2016 Ukrainian power grid cyberattack. The results demonstrate a strong potential for enabling data provenance in a wide array of applications, including speed-sensitive applications such as those found in control room environments.

Sebastian Cardenas, David J.↗

DOE OSTI2024

Vertical z-axis discontinuous carbon fibers for improved lightning strike performance of continuous fiber-reinforced polymer composites

Effective lightning strike protection for critical aerospace and wind applications requires high electrical conductivity to dissipate current efficiently. However, polymer matrix composites face a challenge due to their inherently insulating nature. While conventional carbon fiber-reinforced composites (CFRP) exhibit electrical conductivity in the planar direction, achieving through-thickness conductivity remains an ongoing challenge. In this work, we have undertaken the fabrication of CFRP interleaved with vertically oriented carbon fibers (Z-fiber) to impart higher electrical conductivity along the thickness direction. Two Z-fiber composite variations are prepared: Z-1 with a single layer of Z-fiber and Z-5 with five interleaved layers and compared with no Z-fiber layer (Z-0) composite. The composite panels were subjected to lab-scale lightning strike tests with a current magnitude of 100 kA. To emulate real-world service conditions, an aerospace-grade paint coating was applied to the composite laminates. Comparative analysis shows Z-1 reduces damage diameter to ∼22 mm compared to Z-0 (∼26 mm), while Z-5 exhibits the least damage (∼16.7 mm), confirmed by optical microscopy. Z-5 demonstrates nine times higher through-thickness electrical conductivity than Z-0, reducing electrical anisotropy substantially. Thermal-electric finite element damage modeling predicts surface damage within 6% of experimental values for both Z-0 and Z-5 composites. Flexural tests post-lightning reveal Z-5 retains 66% flexural strength and 86% modulus, significantly better than Z-0, which retains less than 40% for both properties. This study highlights the efficacy of Z-fiber composites in lightning strike protection, offering improved through-thickness conductivity and mechanical property retention.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Development of Helium Vessel Welding Process for SNS PPU Cavities

The Spallation Neutron Source Proton Power Upgrade cavities are produced by Research Instrument with all the cavity processing done at vendor sites with final chemistry applied to the cavity to be electropolishing. Cavities are delivered to Jefferson Lab, ready to be tested. One of the tasks to be completed before the arrival of production-ready PPU cavities is to develop a robust helium vessel welding protocol. We have successfully developed the process and applied it to three six-cell high beta cavities. Here, we present the summary of RF results, welding process development, and post helium vessel RF results.

Dhakal, P.↗

DOE OSTI2021

Simulation Studies on the Interactions of Electron Beam with Wastewater

The manufactured chemical pollutants, like 1,4 dioxane and PFAS (per- and polyfluroralkyl substances), found in the underground water and/or drinking water are challenging to be removed or biodegraded. Energetic electrons are capable of mediating and removing them. This paper utilizes FLUKA code to evaluate the beam-wastewater interaction effects with different energy, space and divergence distributions of the electron beam. With 8 MeV average energy, the electron beam exits from a 0.0127 cm thick titanium window, travels through a 4.3 cm distance air and a second 0.0127 cm thick stainless water container window with 2.43 cm radius, and finally is injected into the water area, where the volume of water is around 75 cubic cm. The distribution parameters of the electron beam are from the GPT (General Particle Tracer) simulations for UITF (Upgraded Injector Test Facility) in Jefferson lab. By varying the distributions, several measurements including the dose (or energy deposition) distribution, electron fluence, photon fluence are scored and compared. Taking the comparisons into consideration, this paper is aiming to find better electron beams for the wastewater irradiation.

Li, X.↗

DOE OSTI2022

Cavity Qualification and Production Update for SNS-PPU Cryomodules at Jefferson Lab

The Proton Power Upgrade (PPU) project at Oak Ridge National Lab’s Spallation Neutron Source (SNS) currently being constructed will double the proton beam power capability from 1.4 to 2.8 MW by adding seven cryomodules, each containing four six-cell high-beta (β = 0.81) superconducting radio frequency cavities. Research Instruments, located in Germany, built and processed the cavities at the vendor site, including electropolishing as the final active chemistry step. Twenty-eight cavities for seven cryomodules and an additional four cavities for a spare cryomodules were delivered to Jefferson Lab and first qualification tests were completed on all cavities as received from the vendor. The performance largely exceeded the requirements on quality factor and accelerating gradient. Here we present the status of initial cavity qualification tests, rework on unqualified cavities and final cavity qualification with helium vessel prior to installation in cryomodules. In addition, an update on cryomodule production is presented.

Dhakal, P.↗

DOE OSTI2021

Simulation Studies on the Interactions of Electron Beam with Wastewater

Li, X.↗

DOE OSTI2021

Electron beam irradiation of 1,4 dioxane

Electron beam irradiation produces both, reducing and oxidizing species which facilitate the reduction of contaminants found in water and wastewater. To investigate the impact of electron beam on 1,4-dioxane, a widely used solvent which has been declared as a probable human carcinogen by the U.S. Environmental Protection Agency, a beamline was designed and commissioned at the Upgraded Injector Test Facility at Jefferson Lab. Here, wastewater samples can be irradiated with a beam energy up to 10 MeV and a beam current of up to 100 nA. Beam acceleration is achieved by two superconducting radio-frequency cavities cooled by liquid helium in a cryomodule. A beam spot with a diameter of ~5 cm was produced at the target location using a pair of raster coils. Electron beam irradiation studies were performed using 1,4-dioxane in two different matrices, de-ionized water and secondary effluent wastewater, and for two concentrations, 10 microg/L and 100 microg/L. The concentration of 1,4-dioxane after irradiation was measured as a function of dose.

Li, Xi↗

DOE OSTI2024

American-Made Geothermal Geophone Prize: Ultra-High Temperature Seismic Tool for Geothermal Wells Summary Report

This work was conducted in support of the American Made Geothermal Prize. The following data summary report presents the testing conducted at Sandia National Labs to validate the performance of the Ultra-High Temperature Seismic Tool for Geothermal Wells. The goal of the testing was to measure the sensitivity of the device to seismic vibrations and reliability of the instrument at elevated temperatures. To this end, two tests were conducted: 1) Ambient Temperature Seismic Testing, which measured the response of the tool to a sweep of frequencies from 1 to 1000 Hz, and 2) Elevated Temperature Survivability Testing which measured the voltage response of the device at 225°C over a month-long testing window. The details of the testing methodology and summary of the tests are presented herein.

15 GEOTHERMAL ENERGY↗

DOE OSTI2024

Distributed Wind Monitoring Best Practices

Accessible performance and operational data have been identified as a key enabler for distributed wind energy industry advancement. While utility-scale wind turbines benefit from reliable and continuous supervisory control and data acquisition (SCADA)-based monitoring platforms, monitoring of the U.S. fleet of distributed wind (DW) turbines has been more inconsistent, unreliable, and sometime difficult to access. Without fleet monitoring data, the industry will never understand and thus work to improve turbine under-performance and reliability issues. For the DW industry to scale up, attract investors, and boost credibility, fleetwide monitoring must be robust and reliable, select data must be made accessible to stakeholders, and the data must be in a format useful to users. To help move the industry toward a more standardized, accessible stream of monitoring data, this distributed wind monitoring best practices report attempts to cover topics including key monitoring channels, hardware, communication strategies, and accessibility. Strategic engagement with DW original equipment manufacturers (OEMs), service providers, lab and university researchers, testing organization, certification bodies, end users and solar photovoltaic (PV) monitoring experts has enabled a better understanding of the current state-of-the-art of monitoring and aided in articulating this set of best practices that will guide OEMs toward harmonized monitoring strategies, aimed at a future goal of achieving accessible performance and operational data for the entire fleet of U.S. distributed wind turbines.

17 WIND ENERGY↗

DOE OSTI2021

Dynamic Inverter Characterization for Modeling

The goal of the project was to develop data to be used for modeling the dynamic characteristics of smart inverters. The inverters were tested in both a lab setting, and a subset was deployed in residential homes for longer term data collection during real-world use.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2026

Pilot Development Progress to Demonstrate Electric Thermal Energy Storage (ETES) Using Low-Cost Particles

The rapid growth of future energy demand increases the need to economically store electrical energy over durations up to several days in long-duration energy storage (LDES) applications. LDES can reduce the grid stress for improving the resilience of the grid. The integration of renewable power and storage has several significant and positive impacts including expanding the renewable energy portion of electricity generation, meeting peak-load demand, and coordinating supply and demand. Several energy storage approaches including mechanical, chemical and electrochemical methods are currently deployed or under development. However, LDES requirements pose unique challenges for scalability, energy capacity, and cost. Thermal energy storage (TES) has the ability to store a large capacity of energy with improved site flexibility compared to incumbent LDES technologies (i.e., pumped hydro) and has attracted significant interest. Our development in TES technology using solid particles as the storage medium has shown feasibility and potential in serving LDES purposes. Particle TES has various advantages over commercialized molten nitrate salt TES and has emerged as a promising storage technology originating from Generation 3 concentrating solar power (CSP) development. Stable, inexpensive silica sand produced in the Midwestern U.S. was identified as a suitable storage medium and has been validated through lab heating and cycling tests. We have successfully developed particle TES for bidirectional electric energy storage to broaden the applications for TES beyond CSP technologies and into standalone electric-thermal energy storage (ETES) systems. Key component designs and performance were verified with prototype testing and model simulations. The ETES system uses high-temperature, low-cost particle thermal energy storage coupled with a unique pressurized fluidized bed heat exchanger that supports a high-efficiency, air-Brayton combined power cycle. At times of low energy demand or high renewable production, an electric particle heater heats large quantities of solid particles to high temperatures in excess of 1100 degrees C. The particles are stored in internally insulated silos. At times of high electricity demand, the hot particles are gravity-fed through the heat exchanger where stored thermal energy is transferred to the power cycle working fluid to drive the gas turbine power generation system, thereby converting the thermal energy back into electricity for the grid. The cold particles leaving the heat exchanger are returned to the storage silos by a well-insulated particle conveyor. This ETES technology using particle TES can be sited anywhere and is predicted to be economic and efficient. Moreover, this ETES technology could be co-located with a retired coal or gas plant to leverage existing power generation and grid infrastructure. Our work has focused on the development of each of the key components (e.g., the electric particle heater, particle storage silos, and the particle-to-gas pressurized fluidized bed heat exchanger) through conceptual designs, prototype testing, and computational modeling. These developments demonstrate technological feasibility and are an important step towards the next phase of development of this promising LDES technology. This presentation will show the progress in developing a pilot demonstration of the ETES system on a commercially relevant scale.

25 ENERGY STORAGE↗

DOE OSTI2026

Robust Heat-Flux Sensors for Coal-Fired Boiler Extreme Environments

In this project, robust heat-flux measurement systems were developed. The heat-flux sensors utilize thermoelectric effects to directly transduce the heat-flux inputs to analog electrical voltage signals. They were constructed from dedicated materials that can withstand temperatures of at least 1000°C and maintain adequate performance at these conditions for prolonged periods of time. The proposed approaches took into account numerous considerations, including system cost, sensor head resilience, sensor footprint, data accuracy, response time, and maintenance requirements. Through modern thermoelectric materials design, methodical materials selection and rigorous testing in materials characterization labs and medium-scale fire research facilities, we have demonstrated functioning laboratory prototypes, upon which one could base industrial heat-flux sensing platforms capable of operating in the challenging high-temperature, corrosive environments of the boilers of coal-fired power plants. A distributed sensor array for heat-flux measurements throughout the furnace water-wall, the superheater area and the economizer coils can provide critical data for the power plant control systems to increase efficiency, improve safety and reduce down times. For example, the combined heat-flux sensor/control systems can contribute to the optimization of burner and boiler operations under flexible loads, the optimization of heat-exchange conditions and overall reduction of heat rate and emissions, the prediction of imminent overheating conditions, and the optimization of the soot-blowing protocols.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2020

BACKFLIP Project: Determination of BACKsheet Material Properties: A Comparison of Market-Benchmark Technologies to Novel Non-Fluoro-Based Co-Extruded Backsheet Materials and Their Correlation and Impact on PV Module Degradation Rates

Quantifying degradation rate of backsheets will help procuring materials for 30+ years. Today most backsheets on the market have a laminated PET core; polyolefin materials may provide better properties for backsheets (barrier to water, mechanical properties through UV and hydrolytic environments, etc.). End-of-life regulations may require fluorine-free backsheet products in future global markets. Parametrized equation predicting the service life of backsheets, and validated by both lab and outdoor extensive testing. Technical and commercial confidence to the entire value chain: from backsheet and module manufacturers to the downstream community (IPP, banks, developers) that materials of higher quality can help reduce finance costs, therefore driving down LCOE. A fast track PV module market adaptation for novel high-quality materials, such as co-extruded polyolefin-core backsheets, by obtaining unbiased durability data.

14 SOLAR ENERGY↗

DOE OSTI2020

Thermal Storage Performance of a Dual-Purpose Underground Thermal Battery for Shaping the Electric Demand of Buildings

A dual-purpose underground thermal battery (DPUTB) integrates a ground heat exchanger with underground thermal energy storage. It can be installed in shallow boreholes (less than 6 m deep) and thus is less expensive than the conventional ground heat exchangers. The thermal energy storage can be used to shave or shift the electric load for meeting the thermal demands of a building. The charging and discharging performance of a lab-scale DPUTB were tested. The test results show that the DPUTB can be fully charged within 4 h and can provide 34 W cooling continuously for 2.5 h with a supply water temperature below 14°C. A small amount of phase-change material significantly increased the thermal storage capacity.

Wang, Lingshi↗

DOE OSTI2022

Building Blocks for Secure and Prosperous Defense Critical Supply Chains: A Case Study from Microelectronics

Securing defense-critical supply chains, built on resilient and sustainable microelectronics fabrication and deployment, is a national imperative and one that requires an investment in basic and applied research, development, and deployment into industries in (and out of) the Defense Industrial Base (DIB). Critical next steps include the development of pilots for revolutionary concepts in a new formal verification model and the Cyber-Physical Passport (CPP) concept for chain of custody. Critical infrastructure leadership should take action with a sense of urgency. Working in conjunction with the Under Secretary for Acquisition and Sustainment, the Assistant Secretary of Defense for Research and Engineering should establish pilot programs with the Defense Advanced Research Projects Agency and the service labs to build and test both concepts in legacy and new system development.. Additionally, the Pentagon may be aware that an existing Manufacturing Innovation Institute is piloting, with the semiconductor industry, cyber innovations to provide verifiable security properties and guarantees of physical functions to build a more cyber secure, resilient and efficient micro-electronics supply chain.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2023

Integrated solid-state rapid thermo-cycling system

Techniques, systems, and devices are disclosed for implementing a portable lab system for PCR testing. An example method for operating an integrated thermal cycling system includes depositing samples into the integrated thermal cycling system that includes a thermal cycling device and an electronic interface. The thermal cycling device includes multiple wells to receive the samples to be thermally cycled, a thermoelectric cooling (TEC) element connected to the multiple wells, a substrate on which the TEC element is positioned, and a controller coupled to the TEC element. The multiple wells are positioned within the substrate that includes a thermally conductive ground positioned between adjacent wells. Supplying power to the integrated thermal cycling system, via the electronic interface, allows the multiple wells to exchange heat with the substrate and for each well to operate independently from other wells.

Beer, N. Reginald↗

DOE OSTI2020

Mechanical Properties of Permanent Foaming Fixatives for Deactivation and Decommissioning Activities

DOE-EM have identified an operational requirement for a fixative that can immobilize and/or encapsulate residual contamination in 3D void volumes (pipes, gloveboxes, waste containers, etc.) during D and D activities. Failure to safely and effectively immobilize residual contamination can: Put workers at risk, Contaminate the public and environment, Drive up operational costs. Commercial-off-the-shelf (COTS) polyurethane (PU) foams is one possible solution and is currently being investigated in collaboration with Savannah River National Lab (SRNL). Mechanical property testing will dictate how well PU foams can withstand physical stressors outlined in safety documents while immobilizing residual contamination. Results can provide a performance criteria for Section 5 of ASTM E3191: Standard Specification for Permanent Foaming Fixatives Used to Mitigate Spread of Radioactive Contamination. Polyurethanes consists of repeating units of urethanes which are produced from an exothermic reaction between a polyol (an alcohol with two or more hydroxyl groups in a molecule) and an isocyanate [2]. PUs consists of 3D cells that are formed by a blowing agent which is normally water. Water interacting with the isocyanate creates carbon dioxide and urea which contributes to cells' growth and expansion. The cross-linking between the polyol and isocyanate solidify the cell faces and walls. Micro scale properties that can influence mechanical properties include: Relative density (ratio between density of cellular material and density of the solid of which the cell walls are made of). Cells connectivity between edges and faces, and number of cells contact neighbors [3]. Whether a foam is open-celled or closed-celled. Closed-celled foams have a thin membrane that encloses each cell which can contribute to the stiffness of the foam. Incorporating fillers in the PU matrix like carbon-based nanoparticles in the form of expandable graphite (EG) can increase the thermal and mechanical performance [4]. When exposed to heat, EG produces a char layer that prevents heat and oxygen transfer which is known as intumescing. Mechanical performance is dependent on amount of EG loading since the cell sizes are linearly dependent on it. Overall, the rigid foams (I-R2) proved superior. SEM Analysis: I-R2 had the most consistent spherical sizes (average cell diameter: 489 μm), which enhance the relative density the most [5]. Tensile Testing Results: I-R2 experienced the largest breaking load (103.65 lbf) and stress (289.42 psi). I-R2 also had a higher Young's Modulus compared to R1 (2.99 ksi to 2.09 ksi). Compression Testing Results: I-R2 had the highest stress at 80% deflection (360.67 psi), load (1387.48 lbf) and modulus (3.92 ksi)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗