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DOE OSTI2022

Triton Field Trials - Changes in Habitats, a Literature Review of Monitoring Technologies

Marine energy devices are installed in highly dynamic environments and have the potential to affect benthic and pelagic habitats around them. Regulatory bodies often require baseline characterization and/or post-installation monitoring to determine whether changes in these habitats are being observed. However, a great diversity of technologies is available for surveying and sampling marine habitats. Selecting the most suitable instrument to identify and measure changes in habitats at marine energy sites can become a daunting task. We conducted a thorough review of journal articles, survey reports, and grey literature to extract information about the technologies used, the data collection and processing methods, and the performance and effectiveness of these instruments. We examined documents related to marine energy development, offshore wind farms, oil and gas offshore sites, and other marine industries around the world over the last 20 years, as well as national and international guidelines for surveying habitats around offshore activities. A total of 120 different technologies were identified across six main habitat categories: seafloor, sediment, infauna, epifauna, pelagic, and biofouling. The technologies were organized into 12 broad technology classes: acoustic, corer, dredge, grab, hook and line, net and trawl, plate, remote sensing, scrape samples, trap, visual, and others. Visual was the most common and the most diverse technology class, with applications across all six habitat categories. Sampling designs varied considerably among the reviewed studies but transect was the predominant design for surveying seafloor, epifauna, and pelagic habitats. The most common data analyses were univariate and multivariate statistical analyses aimed at calculating and comparing biodiversity indices, characterizing faunal assemblages or sediment classes, or modeling the distribution of animals related to abiotic parameters. Technologies and sampling methods adaptable and designed to work efficiently in energetic environments have greater success at marine energy sites. In addition, sampling designs and statistical analyses should be carefully thought through to identify differences in faunal assemblages and spatiotemporal changes in habitats.

16 TIDAL AND WAVE POWER↗
DOE OSTI2023

Representation of Fossil Power Generation Technologies in NREL’s Annual Technology Baseline

This presentation was delivered at the Energy Economics USAEE/IAEE North American Conference on November 7, 2023. The presentation highlights support provided by the National Energy Technology Laboratory (NETL) on the development of National Renewable Energy Laboratory's (NREL) Annual Technology Baseline (ATB). The ATB documents transparent, normalized technology cost and performance assumptions using public sources. NETL's role in the development was to provide NREL with performance and cost data for select fossil-based technology classes. The ATB was released in June 2023.

Hackett, Gregory↗
DOE OSTI2026

DUNE: Michel Electron Selection with SPINE

This poster details the evaluation of a Michel electron selection algorithm centered on the neural network-based software SPINE (Scalable Particle Imageing with Neural Embeddings). The algorithm was developed and calibrated using simulated data from the SBND (Short-Baseline Neutrino Detector) experiment before being applied to simulated data from DUNE (Deep Underground Neutrino Experiment).

Wilson, Dante [U. Colorado, Boulder]↗
DOE OSTI2022

Zero Liquid Discharge and Water Reuse in Recirculating Cooling Towers at Power Facilities: Review and Case Study Analysis

Zero liquid discharge (ZLD) systems installed at power facilities with the primary purpose of meeting water discharge regulations have the added benefit of providing high quality effluent that can be reused in the facility. This paper provides a review of water use in power sector recirculating cooling towers and a baseline assessment of on-site water reuse at natural gas combined cycle (NGCC) power facilities. Two NGCC facilities with reverse-osmosis (RO) or brine-concentrator processes followed by evaporation ponds were selected as case studies; data from these facilities were used to quantify the water, energy, and cost implications of implementing conventional and emerging ZLD technologies. At one case study facility, model results show that implementation of ZLD would reduce water withdrawals by 18%, which is less than savings associated with implementation of dry cooling but comparable to current efforts to reduce water withdrawals by increasing cycles of concentration. Implementation of ZLD using high-recovery RO resulted in a doubling of the levelized cost of water (LCOW). LCOW increased more when a brine concentrator was used. For both case studies, the ZLD system using high-recovery RO required less than 0.1% of a facilitiy's annual electricity generation and the ZLD system using a brine concentrator process required less than 0.8%. Additionally, increasing the evaporation pond area to minimize required ZLD system recovery rates and reduce system electricity costs does not reduce the LCOW. Instead, the LCOW increases because less water is recovered and more water is lost to evaporation. Furthermore, if water availability decreases or water competition/cost increases, facilities may be incentivized to maximize water recovery from ZLD systems.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

Energy Northwest - Horn Rapids Solar and Storage: An Assessment of Battery Technical Performance

Chartered in 1957 as a joint action agency of the state, Energy Northwest (ENW) is a consortium of 27 public utility districts and municipalities across Washington state. ENW takes advantage of economies of scale and shared services to help utilities run their operations more efficiently and at lower cost, to the benefit of more than 1.5 million customers. ENW develops, owns, and operates a diverse mix of electricity generating resources, including hydro, solar, and wind projects – and the Northwest’s only active nuclear energy facility. These projects provide enough reliable, affordable, and environmentally responsible energy to power more than a million homes each year, and that carbon-free electricity is provided at the cost of generation. The agency continually explores new generation projects to meet its members’ needs. In 2017, as part of the second round of funding from the Washington state Clean Energy Fund, the Washington State Department of Commerce granted up to $3 million in matching funds to develop an estimated $6.5 million project that deployed a 4-MW, 20-acre solar generating array of photovoltaic (PV) panels coupled with a 1 MW/5.5 MWh lithium-iron-phosphate battery energy storage system (BESS) in Richland, Washington. The combination of PV and BESS will provide a predictable, renewable generating source and will also serve as a training ground for solar and battery technicians throughout the nation. The City of Richland will purchase the power from the project and utilize the benefits of the energy storage. The project provides Washington state with its first opportunity to integrate a large-scale solar and storage facility into its clean mix of hydro, nuclear, and wind resources. This first-of-its-kind facility combines solar generation with battery storage and technician training. In 2019, Pacific Northwest National Laboratory (PNNL) worked with ENW to assess the integrated PV and BESS in representative use cases that could benefit the City of Richland. Between March and May 2022, extensive testing was conducted, and the results were used to assess the technical performance of the BESS subjected to actual field operations. Both reference performance and use case tests were performed: (A) Reference performance tests assess the general technical capabilities of the BESS, such as energy capacity, round-trip efficiency (RTE), ramp rate, and signal tracking capability. These are the first tests performed (baseline), and they are repeated after use case tests (post cycle). A standardized U.S. Department of Energy (DOE) energy storage performance protocol was used to characterize the BESS, including representative duty cycle profiles, test procedure guidance, and calculation guidance for determining key characteristics. (B) Use case tests examine the performance of the BESS for specific use cases using duty cycles developed by PNNL in collaboration with ENW. Five use cases were selected for testing: 1) demand charge reduction, 2) load shaping, 3) transmission charge reduction, 4) Volt-VAR service, and 5) outage mitigation. The use case duty cycles were developed based on utility and site-specific characteristics in addition to the technical characteristics and physical capabilities of the BESS. Use case tests were performed between the baseline and post cycle tests. This report describes the BESS and its components, presents testing and performance analysis results, and shares key insights and lessons learned from this project. Outcomes of the tests and analyses will help ENW understand the performance of the Horn Rapids BESS in its current state and design appropriate operational strategies for this and other BESSs over the long term.

14 SOLAR ENERGY↗
DOE OSTI2023

LA100 Equity Strategies. Chapter 11: Truck Electrification for Improved Air Quality and Health

The LA100 Equity Strategies project integrates community guidance with robust research, modeling, and analysis to identify strategy options that can increase equitable outcomes in Los Angeles' clean energy transition. This report focuses on truck electrification as a means to improve air quality and health in traffic and air quality disadvantaged communities. It also identifies potential strategies to more equitably distribute air quality benefits from electrification of trucks, defined here as heavy-duty vehicles over 8,500 pounds (lbs) gross vehicle weight. Specifically, NREL analyzed 1) baseline air pollutant emissions, 2) emissions reductions associated with incremental increases in electrification of three types of heavy-duty trucks in 2035, and 3) resultant changes to air pollutant concentrations for selected census tracts along major roadways in disadvantaged and non-disadvantaged communities for comparison. In addition, NREL analyzed the impact of estimated pollutant concentrations on several health effects and the distribution of those health effects by disadvantaged community status. NREL's analysis is complemented by a University of California Los Angeles (UCLA) analysis of air quality benefits from transportation electrification, which included light-duty vehicles (Chapter 15) and evaluated regional air-quality changes across Los Angeles. Research was guided by input from the community engagement process, and associated equity strategies are presented in alignment with that guidance.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2022

What’s in My Toolkit? A Review of Technologies for Assessing Changes in Habitats Caused by Marine Energy Development

Marine energy devices are installed in highly dynamic environments and have the potential to affect the benthic and pelagic habitats around them. Regulatory bodies often require baseline characterization and/or post-installation monitoring to determine whether changes in these habitats are being observed. However, a great diversity of technologies is available for surveying and sampling marine habitats, and selecting the most suitable instrument to identify and measure changes in habitats at marine energy sites can become a daunting task. We conducted a thorough review of journal articles, survey reports, and grey literature to extract information about the technologies used, the data collection and processing methods, and the performance and effectiveness of these instruments. We examined documents related to marine energy development, offshore wind farms, oil and gas offshore sites, and other marine industries around the world over the last 20 years. A total of 120 different technologies were identified across six main habitat categories: seafloor, sediment, infauna, epifauna, pelagic, and biofouling. The technologies were organized into 12 broad technology classes: acoustic, corer, dredge, grab, hook and line, net and trawl, plate, remote sensing, scrape samples, trap, visual, and others. Visual was the most common and the most diverse technology class, with applications across all six habitat categories. Technologies and sampling methods that are designed for working efficiently in energetic environments have greater success at marine energy sites. In addition, sampling designs and statistical analyses should be carefully thought through to identify differences in faunal assemblages and spatiotemporal changes in habitats.

16 TIDAL AND WAVE POWER↗
DOE OSTI2026

Demonstration and performance of an online data selection algorithm for liquid argon time projection chambers using MicroBooNE

The MicroBooNE detector is a liquid argon time projection chamber (LArTPC) that produces three-dimensional images of particle interactions using ionization charge collected by anode wire plane arrays and scintillation light collected by a light detection system. In addition to testing long-standing experimental neutrino anomalies and performing measurements of neutrino interactions with argon nuclei using the Fermilab Booster Neutrino Beam, MicroBooNE aims to develop methodologies for rare beyond the Standard Model and off-beam physics searches. Looking ahead to the upcoming Deep Underground Neutrino Experiment (DUNE), with MicroBooNE serving as a valuable testbed, achieving high sensitivity and livetime for off-beam physics while satisfying data processing and storage constraints will require data-driven, intelligent, and online or real-time data selection techniques. These techniques are essential for reducing data rates and preserving rare signals with high accuracy. In this paper, we describe a fast data selection algorithm suitable for online execution to identify electrons from stopping cosmic ray muons in the MicroBooNE detector utilizing ionization charge information, and present its performance. This represents the first demonstration of online data selection in a LArTPC using real data and charge information exclusively and provides an important proof-of-principle for applying such techniques to other LArTPC experiments such as the Short-Baseline Near Detector and DUNE.

Abratenko, P. [Tufts U. (main)]↗
DOE OSTI2024

User Impressions and Gait Analysis of Exoskeleton Device Usage in Generalized Tank Farm Activities

Tank farm workers involved in nuclear cleanup activities perform physically demanding tasks, typically while wearing heavy personal protective equipment (PPE). Exoskeleton devices have the potential to bring considerable benefit to this industry but have not been thoroughly studied in the context of nuclear cleanup. In this paper, we examine the performance of exoskeletons during a series of tasks emulating jobs performed on tank farms while participants wore PPE commonly deployed by tank farm workers. The goal of this study was to evaluate the effects of commercially available lower-body exoskeletons on a user’s gait kinematics and user perceptions. Three participants each tested three lower-body exoskeletons in a 70-min protocol consisting of level treadmill walking, incline treadmill walking, weighted treadmill walking, a weight lifting session, and a hand tool dexterity task. Results were compared to a no exoskeleton baseline condition and evaluated as individual case studies. The three participants showed a wide spectrum of user preferences and adaptations toward the devices. Individual case studies revealed that some users quickly adapted to select devices for certain tasks while others remained hesitant to use the devices. Temporal effects on gait change and perception were also observed for select participants in device usage over the course of the device session. Here, device benefit varied between tasks, but no conclusive aggregate trends were observed across devices for all tasks. Evidence suggests that device benefits observed for specific tasks may have been overshadowed by the wide array of tasks used in the protocol.

Tank farm↗
DOE OSTI2022

Illustrating galaxy–halo connection in the DESI era with illustrisTNG

ABSTRACT We employ the hydrodynamical simulation illustrisTNG to inform the galaxy–halo connection of the Luminous Red Galaxy (LRG) and Emission Line Galaxy (ELG) samples of the Dark Energy Spectroscopic Instrument (DESI) survey at redshift z ∼ 0.8. Specifically, we model the galaxy colours of illustrisTNG and apply sliding DESI colour–magnitude cuts, matching the DESI target densities. We study the halo occupation distribution (HOD) model of the selected samples by matching them to their corresponding dark matter haloes in the illustrisTNG dark matter run. We find the HOD of both the LRG and ELG samples to be consistent with their respective baseline models, but also we find important deviations from common assumptions about the satellite distribution, velocity bias, and galaxy secondary biases. We identify strong evidence for concentration-based and environment-based occupational variance in both samples, an effect known as ‘galaxy assembly bias’. The central and satellite galaxies have distinct dependencies on secondary halo properties, showing that centrals and satellites have distinct evolutionary trajectories and should be modelled separately. These results serve to inform the necessary complexities in modelling galaxy–halo connection for DESI analyses and also prepare for building high-fidelity mock galaxies. Finally, we present a shuffling-based clustering analysis that reveals a 10–15 ${{\ \rm per\ cent}}$ excess in the LRG clustering of modest statistical significance due to secondary galaxy biases. We also find a similar excess signature for the ELGs, but with much lower statistical significance. When a larger hydrodynamical simulation volume becomes available, we expect our analysis pipeline to pinpoint the exact sources of such excess clustering signatures.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2025

Design of Novel Hot Gas Component for Gas Turbine Engines Enabled by Materials and Additive Manufacturing Process Development

This CRADA project was the result of a project award under FOA-DOE-0001980. The overarching FOA project team consisted of researchers from Carpenter Technology Corporation (CTC), Solar Turbines Incorporated (Solar), Pennsylvania State University (PSU), University of California-Santa Barbara (UCSB), and Oak Ridge National Laboratory (ORNL). Evaluations were conducted on two high-γ’ superalloys that were designed by CTC and the UCSB. One alloy named GammaPrint-700 (GP-700) is a cobalt-base superalloy. The other alloy named GammaPrint-1100 (GP-1100) is a nickel-base (Ni-base) superalloy. PSU provided expertise and experimental testing of the thermal performance of AM micro-cooling architectures. ORNL provided expertise with the AM superalloy materials characterization and AM processing science. Solar provided turbine component design expertise. The focus of this CRADA report is to document the efforts between ORNL and CTC towards the development of superalloys designed for AM. The project goal was to use an AM processable high-temperature superalloy and design for Additive Manufacturing (DfAM) techniques to design an efficient turbine component (i.e. a turbine tip shoe) with enhanced cooling features that can only be fabricated through additive manufacturing (AM). The efficiencies of existing combined heat and power (CHP) engines are capped by both component design and materials limitations. However, AM of a tip shoe component from a γ’strengthened superalloy offers the design flexibility to increase the efficiency and power of an industrial gas turbine. This project brought about advancements in the DfAM tip shoe design space and in the area of high temperature superalloys processable through laser powder bed fusion (LPBF) AM. State of art computation design tools were utilized to optimize unique cooling features into a tip shoe component design. A two-prong materials development approach was taken to support development of the AM tip shoe geometry. The first approach centered on investigating the processability and the appropriate process science for the industry standard high-γ’ nickel-base (Ni-base) superalloy Mar-M247. This superalloy is typically cast and considered non-weldable by traditional welding standards. In the course of this work, the alloy was not deemed feasible for process scale-up due to significant cracking issues during printing. The second approach focused on the development and evaluation of a novel cobalt-base superalloy, GammaPrint™-700 (GP-700 and a Ni-base superalloy, GammaPrint™-1100 (GP-1100) designed to mitigate the significant AM processing issues with Mar-M247. The processability of these two alloys were investigated through electron beam melting (EBM) binder-jet AM (BJAM), and LPBF as a risk mitigation for manufacturability. To be considered a candidate material for down-selection to proceed to fullscale AM tip shoe engine testing trials, the high temperature creep rupture strength was required to achieve at a minimum, a Larsen Miller Parameter (LMP) increase of 10.9% over the baseline material LPBF AM Hastelloy X.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Final Search for Short-Baseline Neutrino Oscillations with the PROSPECT-I Detector at HFIR

The PROSPECT experiment is designed to perform precise searches for antineutrino disappearance at short distances (7–9 m) from compact nuclear reactor cores. This Letter reports results from a new neutrino oscillation analysis performed using the complete data sample from the PROSPECT-I detector operated at the High Flux Isotope Reactor in 2018. The analysis uses a multiperiod selection of inverse beta decay neutrino interactions with reduced backgrounds and enhanced statistical power to set limits on electron neutrino disappearance caused by mixing with sterile neutrinos with 0.2–20 eV 2 mass splittings. Inverse beta decay positron energy spectra from six different reactor-detector distance ranges are found to be statistically consistent with one another, as would be expected in the absence of sterile neutrino oscillations. The data excludes at 95% confidence level the existence of sterile neutrinos in regions above 3 eV 2 previously unexplored by terrestrial experiments, including all space below 10 eV 2 suggested by the recently strengthened Gallium Anomaly. The best-fit point of the Neutrino-4 reactor experiment’s claimed observation of short-baseline oscillation is ruled out at more than 5 standard deviations.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2022

Measurements of the groomed and ungroomed jet angularities in pp collisions at $ \sqrt{s}$ = 5.02 TeV

The jet angularities are a class of jet substructure observables which characterize the angular and momentum distribution of particles within jets. These observables are sensitive to momentum scales ranging from perturbative hard scatterings to nonperturbative fragmentation into final-state hadrons. We report measurements of several groomed and ungroomed jet angularities in pp collisions at $\sqrt{s}$ = 5.02 TeV with the ALICE detector. Jets are reconstructed using charged particle tracks at midrapidity (|η| < 0.9). The anti-$k_T$ algorithm is used with jet resolution parameters R = 0.2 and R = 0.4 for several transverse momentum $p^{ch jet}_{T}$ intervals in the 20–100 GeV/c range. Using the jet grooming algorithm Soft Drop, the sensitivity to softer, wide-angle processes, as well as the underlying event, can be reduced in a way which is well-controlled in theoretical calculations. We report the ungroomed jet angularities, λ α , and groomed jet angularities, λ α,g , to investigate the interplay between perturbative and nonperturbative effects at low jet momenta. Various angular exponent parameters α = 1, 1.5, 2, and 3 are used to systematically vary the sensitivity of the observable to collinear and soft radiation. Results are compared to analytical predictions at next-to-leading-logarithmic accuracy, which provide a generally good description of the data in the perturbative regime but exhibit discrepancies in the nonperturbative regime. Moreover, these measurements serve as a baseline for future ones in heavy-ion collisions by providing new insight into the interplay between perturbative and nonperturbative effects in the angular and momentum substructure of jets. They supply crucial guidance on the selection of jet resolution parameter, jet transverse momentum, and angular scaling variable for jet quenching studies.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2024

Miniaturized Magnetoelastic Sensor System

This article describes the design, assembly, and implementation of a hand-held, magnetic-field-based sensor system that can be adapted for a variety of sensing applications. The miniaturized system is based on Chemical Identification by Magneto-Elastic Sensing (ChIMES) technology, which uses three concentric solenoid coils to wirelessly interrogate a sensor body comprised of a response material coupled to a magnetoelastic wire. The response material expands when it encounters a target, imposing mechanical stress on the wire and altering its magnetic permeability. The sensor bodies are passive, requiring no external power source, and they are small, measuring about 15 mm in length and 3.0 mm in diameter. Up to four sensor bodies can be configured as an evenly-spaced linear array. The sensor system operates by applying a low-frequency, current-stabilized, filtered triangle wave to a uniform-density excitation coil to switch the magnetic domains within the wire. Further, the responses from the sensors are picked up by a detection coil as stress-induced changes in the Faraday voltage, and the strong magnetic field induced by the excitation coil in the detection coil is nullified by a cancellation coil reverse-wound in series with the detection coil. The responses of the sensors in an array are separated in time by a linear gradient dc biasing coil. The sensors can be interrogated through metallic and nonmetallic barriers. The signals from the detection coil and the excitation coil are digitized by a pair of bipolar analog-to-digital converters (ADCs). A Raspberry Pi single-board computer (SBC) and associated software perform data acquisition and control all aspects of the sensor system hardware. The program allows the user to select the number of sensors in the array, the type of signal that is being collected, and the number of samples to take. The program also allows for signal processing of the sensor data, such as baseline correction. The program can differentiate sensor peaks from each other and calculate the magnitude of each sensor response with less than 1% error. The data are then displayed along with a graph of the signal.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2020

Optimization of Archimedes Screw for Use in Hydroelectric Projects

In 2017, the Department of Energy’s (DOE) Water Power Technologies Office (WPTO) made federal funding available to several awardees to investigate and provide innovative technological solutions to reduce capital costs of installed hydroelectric facilities at non-powered dam’s (NPD’s) across the United States, while maintaining a high level of efficiency. Awardees were to develop specific technologies that showed promise of reducing installed capital cost (ICC) by at least 20% over a given baseline and maintain a water-to-wire efficiency of at least 80% at head levels of 50 feet or less and flows of 1000 cubic feet per second (cfs) or less. Canyon Hydro (Canyon) was selected as an awardee for this funding and worked to refine the implementation of the Archimedes screw turbine for use at these site conditions. Canyon and its project partners analyzed several dam inventory datasets to determine the most common head and flow range of current NPD’s in order to best select design conditions for a turbine that would perform successfully at common heads and flows. Computational Fluid Dynamic (CFD) analyses were conducted after site conditions had been selected to optimize the turbine geometry for efficiency. Through this effort we were able to estimate water-to-wire efficiency over a range of flows. Equipment design focused on concepts of modularity and pre-fabricated construction. These methodologies were used where possible to reduce costly on-site construction and shorten deployment timelines. Cost modeling was conducted with input from industry experts in general construction, pre-fabricated concrete construction, and composite fabrication. As a hydroelectric turbine manufacturer of 35 years, Canyon drew upon its own knowledge base in steel fabrication, water-to-wire component specification and ancillary systems to develop the remaining cost matrix for the project. As a result of these efforts, Canyon was able to present findings that indicated a modular Archimedes screw turbine system could be designed that reduced ICC by 23.9% and maintain a maximum water-to-wire efficiency of 82.3%, meeting the goals of the project.

13 HYDRO ENERGY↗
DOE OSTI2021

2020 Cost Analysis of Hydropower Options at Non-Powered Dams

This report provides a cost analysis of potential hydropower development for representative non-powered dam (NPD) sites in the United States. The overarching objective is to support the establishment of a basis for evaluating progress towards improving the competitiveness of new hydropower development for electricity generation. The representative sites, herein referred to as “reference sites”, were selected from sites with detailed water resource data to support the cost analysis. Facility designs, capital costs, plant generation and efficiency profiles, capacity factors, and levelized costs of energy (LCOE) are presented for the sites under baseline and near-term innovation cases. The baseline case represents facility configurations using technologies that are already widely applied in the hydropower industry, whereas near-term innovations are technologies likely to reach wide acceptance within the next 5 to 10 years. Cost savings in the near-term relative to the baseline are discussed to illustrate the potential benefits to the hydropower industry from research and development (R&D) and adoption of these innovations. Medium- to long-term innovation options expected from ongoing private and government R&D efforts are also highlighted but are not quantified in this report because of a current lack of complete information on these options. The key findings of the cost analysis in this study imply that near-term innovations could reduce the baseline costs of hydropower development at US NPD sites. Thus, if remaining R&D issues with these near-term innovations can be resolved within the next 5 to 10 years, industry-wide adoption of these technologies and improved competitiveness of NPD hydropower development can be expected. Specific key findings of the analysis include the following: 1) Potential installed capacity at the NPD sites evaluated in this study vary from 200 kW to 70 MW, representing two orders of magnitude variation across nearly 20 sites; 2) Capital costs, not including development costs, for the sites evaluated in this study vary from $2,200/kW to $34,000/kW but are below $12,000/kW for most sites; 3) Baseline LCOE estimates for lake dams are from $79/MWh to $790/MWh with most sites under $400/MWh, whereas estimates for lock dams are from $134/MWh to $289/MWh with most sites under $200/MWh; 4) Reductions in capital cost per kilowatt under the near-term innovation case are from −77% to −14% for lake dams and −21% to −2.1% for lock dams (excluding one site with a 14% increase in per-kilowatt capital costs); 5) Combined changes in capital costs and capacity factors in the near-term case relative to the baseline lead to reductions in LCOE of −71% to −14% for lake dams and −21% to −14% for lock dams; 6) Overall, LCOE reductions lead to 8 of the 18 sites under the near-term case having LCOE values below $150/MWh compared with only 2 of 18 sites in the baseline case.

13 HYDRO ENERGY↗
DOE OSTI2025

Design of Novel Hot Gas Component for Gas Turbine Engines Enabled by Materials and Additive Manufacturing Process Development

This CRADA project was the result of a project award under FOA-DOE-0001980. The overarching FOA project team consisted of researchers from Carpenter Technology Corporation (CTC), Solar Turbines Incorporated (Solar), Pennsylvania State University (PSU), University of California-Santa Barbara (UCSB), and Oak Ridge National Laboratory (ORNL). Evaluations were conducted on two high-γ’ superalloys that were designed by CTC and the UCSB. One alloy named GammaPrint-700 (GP-700) is a cobalt-base superalloy. The other alloy named GammaPrint-1100 (GP-1100) is a nickel-base (Ni-base) superalloy. PSU provided expertise and experimental testing of the thermal performance of AM micro-cooling architectures. ORNL provided expertise with the AM superalloy materials characterization and AM processing science. Solar provided turbine component design expertise. The focus of this CRADA report is to document the efforts between ORNL and CTC towards the development of superalloys designed for AM. The project goal was to use an AM processable high-temperature superalloy and design for Additive Manufacturing (DfAM) techniques to design an efficient turbine component (i.e. a turbine tip shoe) with enhanced cooling features that can only be fabricated through additive manufacturing (AM). The efficiencies of existing combined heat and power (CHP) engines are capped by both component design and materials limitations. However, AM of a tip shoe component from a γ’strengthened superalloy offers the design flexibility to increase the efficiency and power of an industrial gas turbine. This project brought about advancements in the DfAM tip shoe design space and in the area of high temperature superalloys processable through laser powder bed fusion (LPBF) AM. State of art computation design tools were utilized to optimize unique cooling features into a tip shoe component design. A two-prong materials development approach was taken to support development of the AM tip shoe geometry. The first approach centered on investigating the processability and the appropriate process science for the industry standard high-γ’ nickel-base (Ni-base) superalloy Mar-M247. This superalloy is typically cast and considered non-weldable by traditional welding standards. In the course of this work, the alloy was not deemed feasible for process scale-up due to significant cracking issues during printing. The second approach focused on the development and evaluation of a novel cobalt-base superalloy, GammaPrint™-700 (GP-700 and a Ni-base superalloy, GammaPrint™-1100 (GP-1100) designed to mitigate the significant AM processing issues with Mar-M247. The processability of these two alloys were investigated through electron beam melting (EBM) binder-jet AM (BJAM), and LPBF as a risk mitigation for manufacturability. To be considered a candidate material for down-selection to proceed to full-scale AM tip shoe engine testing trials, the high temperature creep rupture strength was required to achieve at a minimum, a Larsen Miller Parameter (LMP) increase of 10.9% over the baseline material LPBF AM Hastelloy X.

99 GENERAL AND MISCELLANEOUS↗