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DOE OSTI2021

Controlled Pyrolysis: A Robust Scalable Composite Recycling Technology

The reinforced composites industry is facing significant challenges in handling the scrap composite material from automobile manufacturing, the wind turbine industry, and others. The fibers in the material, whether they be carbon, glass, or other materials have commercial value if they can be recovered successfully. Successfully means the fibers are clean with no sizing or other binders and have adequate strength and physical properties that would allow them to be economically reprocessed into valuable product. The composites recycling project was an industry-collaborative effort to develop a composite recycling technology using controlled pyrolysis. Through the recycling of scrap and end-of-life (EOL) cured composite materials, this pilot study was intended to create a business case by realizing a cost-effective means for recycling EOL and production scrap composite materials, ultimately reducing the volume of composite materials destined for landfill. The project was led by the Institute for Advanced Composites Manufacturing Innovation (IACMI), the American Composites Manufacturers Association (ACMA), Oak Ridge National Laboratory (ORNL), Continental Structural Plastics (CSP) a Teijin Group Company, CHZ Technologies, and A. Schulman with support from Owens Corning, John Deere, General Electric (GE), Ashland LLC, and Plastics Europe (CEFIC). The team studied and tested CHZ Technologies’ controlled pyrolysis system, known as the Thermolyzer TM , which operates on a scalable basis to convert organic polymer materials into a clean synthesis gas and char containing the recoverable carbon and glass fiber reinforcement. The recoverable energy contained in the input polymers creates the synthesis gas that can be used to provide heat to the Thermolyzer TM primary reactor in a sustainable manner. That is, once the Thermolyzer TM is started with a small amount of external natural gas, the synthesis gas that is created from the polymers will continue to operate the burners so long as feedstock is supplied. The reinforcing fiber materials remaining in the solid phase char were separated and cleaned for re-use in other polymer systems based on the retained properties of the fibers. The study created reports (attached in the appendix) on the Mass and Energy Balances, syngas analytics, VOC assessment, yield analysis and other analytics necessary for a Techno-Economic Analysis (TEA) to quantify the economic impact of the recovery and sustainable re-use of the carbon and glass fibers. The process consisted of 4 steps: Selection of 4 samples of cured composite waste materials from project partners interested in materials recycling and recovering the reinforcing fibers for best case re-use. The materials included glass fiber (GF) polyester/vinyl ester automotive SMC from CSP, GF epoxy balsa/PVC foam wind blades from GE, carbon fiber (CF) epoxy wind blade laminated spar caps from GE, and GF/CF epoxy hybrid assembly from John Deere. Processing the waste composite samples into 1-2” shreds. Packaging the shredded composites into bulk sacks on international shipping pallets for shipment to KUG in Forst (Lausitz), Germany. Pyrolysis of the shredded composites under controlled conditions designed for each polymer system. Collecting samples of the gas and char for analysis. Shipping the char containing the CF/GF back to the US for the next steps of testing the fibers and developing protocols for sustainable re-use of the fibers in composite applications.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Field Emission Analysis in SRF Cavities for PIP-II Using GEANT4

Field emission (FE) remains a key limitation to achieving optimal performance and reliability in superconducting radiofrequency (SRF) cavities used in accelerator cryomodules. Addressing this challenge requires a detailed understanding of the generation and transport of FE-induced radiation; however, the absence of standardized measurement protocols complicates comparisons across different testing stages and facilities. This work presents initial steps toward a quantitative, systematic framework for analyzing FE-induced radiation using Geant4 simulations. We model four cavity types to be deployed in Fermilab’s Proton Improvement Plan-II (PIP-II) linac - HB650, LB650, SSR2, and SSR1 - to investigate radiation signatures and their dependence on emission conditions. By integrating simulation results with radiation diagnostics, our goal is to identify probable emission sites, enhance diagnostic accuracy, and optimize detector placement. Ultimately, this approach seeks to inform cavity preparation, assembly, and testing procedures, enabling the delivery of FE-free SRF cryomodules for PIP-II.

Wijethunga, Sajini [Fermilab] (ORCID:0000000287659↗

DOE OSTI2026

Field Emission Analysis in SRF Cavities for PIP-II Using GEANT4

Wijethunga, Sajini [Fermilab] (ORCID:0000000287659↗

DOE OSTI2022

Systems and methods for distributed authentication of devices

A lightweight, fast, and reliable authentication mechanism compatible with the 5G D2D ProSe standard mechanisms is provided. A distributed authentication with a delegation-based scheme avoids repeated access to the 5G core network key management functions. Hence, a legitimate user equipment device (e.g., a drone) is authorized by the cellular network (e.g., 5G cellular network) via offering a proxy signature to authenticate itself to other drones. Test results demonstrate that the protocol is lightweight and reliable.

Akkaya, Kemal↗

DOE OSTI2025

Quick-and-Easy Validation of Protein–Ligand Binding Models Using Fragment-Based Semiempirical Quantum Chemistry

Electronic structure calculations in enzymes converge very slowly with respect to the size of the model region that is described using quantum mechanics (QM), requiring hundreds of atoms to obtain converged results and exhibiting substantial sensitivity (at least in smaller models) to which amino acids are included in the QM region. As such, there is considerable interest in developing automated procedures to construct a QM model region based on well-defined criteria. However, testing such procedures is burdensome due to the cost of large-scale electronic structure calculations. Here, we show that semiempirical methods can be used as alternatives to density functional theory (DFT) to assess convergence in sequences of models generated by various automated protocols. The cost of these convergence tests is reduced even further by means of a many-body expansion. We use this approach to examine convergence (with respect to model size) of protein–ligand binding energies. Fragment-based semiempirical calculations afford well-converged interaction energies in a tiny fraction of the cost required for DFT calculations. Two-body interactions between the ligand and single-residue amino acid fragments afford a low-cost way to construct a “QM-informed” enzyme model of reduced size, furnishing an automatable active-site model-building procedure. This provides a streamlined, user-friendly approach for constructing ligand binding-site models that needs neither a priori information nor manual adjustments. Extension to model-building for thermochemical calculations should be straightforward.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2023

Behavior of contaminants and simulant fission products in the advanced chlorination process

The University of Tennessee, Knoxville and Oak Ridge National Laboratory have completed proof-of principle testing on an advanced sulfur-based zirconium and aluminum chlorination process for the recovery of Zr or Al from spent fuel claddings and purification of the products. This process could be used to recover hafnium-free nuclear-grade zirconium for reuse or disposal as low-level waste. Testing showed that even non-optimized reaction protocols could produce zirconium product streams from simulated irradiated fuel with purities >90%. The chlorination process was tested on representative fission product species that would be found in Advanced Test Reactor fuel (ATR). First, fission product generation was determined through modeling and simulation of the ATR. The generation of fission products was used to selected contaminants and potentially volatile fission product simulants for laboratory testing. The goal is to identify which species may react with the sulfur-chlorine reagents and be transported into the advanced chlorination off-gas.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2022

Evaluation of the Reliability of Passive Infrared (PIR) Occupancy Sensors for Residential Indoor Lighting

Solid-state lighting (SSL) technologies have penetrated the general illumination market in recent years, largely replacing conventional technologies such as incandescent and fluorescent lighting. Most of the initial excitement about light-emitting diode (LED) sources for SSL devices focused on their energy savings potential resulting from vast improvements in source efficiency and luminous efficacy compared with conventional illumination products. More recently, the focus has shifted toward other aspects of lighting application efficiency, namely intensity effectiveness and spectral efficiency, because of the ease of controlling both the light intensity of LEDs with drive voltage and the color properties of the LED-based illuminators. To capitalize on the energy savings of increased intensity effectiveness and spectral efficiency, a lighting control system (LCS) is often used. While the current penetration of LCSs is relatively modest, it is anticipated that lighting controls (i.e., connected lighting, controls and LED and conventional lighting) could have an installed penetration as higher as 46% by the year 2035, saving an additional 1.3 quads of energy. Despite the large energy savings that can be gained from using LCSs, standard test methods for evaluating sensors employed in LCSs and reliability data of the LCSs and their components are generally lacking. The National Electrical Manufacturers Association (NEMA) developed the only standard, NEMA WD 7-2011 (R2016), to test occupancy and motion sensor performance (herein referred to as “the NEMA protocol”). In a previous U.S. Department of Energy (DOE) effort, some concerns of the NEMA protocol were identified (e.g., strict height and weight limits on test subjects, large amounts of manual effort, sometimes inconsistent repeatability). During the current work, a consistent detection length test (DLT) and a Robotic Sensor Evaluation System (RoboSES) were developed to alleviate some of these concerns. RoboSES acts as a human surrogate by using thermal pads on a mannequin and a remote-controlled mobile base to test a sensor’s field of view (FOV). This report builds on the earlier DOE efforts to understand sensor technologies used in LCSs for general illumination. Specifically, this report describes the optimization of RoboSES, characterizes and establishes test methods to assess the reliability of multiple passive infrared (PIR) sensors, and reports the findings of robustness and reliability testing on two commercial PIR sensors intended for residential applications. The information presented in this report is gained from up to 4,000 hours (hrs) of accelerated stress tests (ASTs).

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2023

Polymerase chain reaction for the in vitro detection of the pESI plasmid associated with the globally circulating Salmonella Infantis outbreak strain

Abstract A globally circulating strain of Salmonella enterica serotype Infantis containing the pESI plasmid has increased in prevalence in poultry meat samples and cases of human infections. In this study, a polymerase chain reaction (PCR) protocol was designed to detect the pESI plasmid and confirm the Infantis serotype of Salmonella isolates. Primers were tested bioinformatically to predict specificity, sensitivity, and precision. A total of 54 isolates of Salmonella serotypes Infantis, Senftenberg, and Alachua were tested, with and without the pESI plasmid carriage. Isolates of 31 additional serotypes were also screened to confirm specificity to Infantis. Specificity, sensitivity, and precision of each primer were >0.95. All isolates tested produced the expected band sizes. This PCR protocol provides a rapid and clear result for the detection of the pESI plasmid and serotype Infantis and will allow for the in vitro detection for epidemiological studies where whole-genome sequencing is not available.

McMillan, Elizabeth A. (ORCID:000000027503514X)↗

DOE OSTI2021

Cell-level reliability testing procedures for CIGS photovoltaics

The reliability of photovoltaics is commonly studied at the module level. Many reliability problems originate from module attributes, such as metal interconnections to cells, junction boxes. However, significant work in reliability can also be done prior to module design. Testing for reliability earlier in the research cycle increases the probability of avoiding common module reliability problems before cell changes are implemented on a large scale. Cell-level reliability studies can thus lower the rates of module failures in the field and provide confidence to investors that new technologies will perform as advertised. This report summarizes how we investigated three reliability concerns in Cu(In,Ga)Se 2 (CIGS) photovoltaics at the cell level: metastability, shading-induced damage, and potential-induced degradation (PID). We find that examining these concerns required developing robust measurement protocols including the fabrication of novel testing structures. This information will allow readers to incorporate sound metrics for investigating reliability phenomena and aid their studies of cell and module reliability improvements.

14 SOLAR ENERGY↗

DOE OSTI2023

Results from an International Interlaboratory Study on Light- and Elevated Temperature-Induced Degradation (LETID) in Solar Modules

This presentation reports recently submitted results from an international interlaboratory comparison study on light- and elevated temperature-induced degradation (LETID) on crystalline silicon photovoltaic (PV) modules. A large global network of PV module manufacturers and PV testing laboratories collaborated to design a protocol for LETID detection, and screen a large and diverse set of prototype modules for LETID. We summarize the range of observed degradation and provide initial conclusions on the reproducibility of results across labs. In LETID-sensitive modules, both open-circuit voltage (VOC) and short-circuit current (ISC) degrade by a roughly similar magnitude. We observe, as do previous studies, that LETID affects each cell in a module differently. An investigation of the potential mismatch losses caused by nonuniform LETID degradation found that mismatch loss is insignificant compared to the direct LETID-related losses. We summarize the conclusions drawn from the study, provide an update on a forthcoming standard technical specification for LETID testing of PV modules (IEC TS 63342 ED1), and discuss unresolved questions and potential future work on LETID in PV modules.

degradation↗

DOE OSTI2024

Toward Wireless Smart Grid Communications: An Evaluation of Protocol Latencies in an Open-Source 5G Testbed

Fifth-generation networks promise wide availability of wireless communication with inherent security features. The 5G standards also outline access for different applications requiring low latency, machine-to-machine communication, or mobile broadband. These networks can be advantageous to numerous applications that require widespread and diverse communications. One such application is found in smart grids. Smart grid networks, and Operational Technology (OT) networks in general, utilize a variety of communication protocols for low-latency control, data monitoring, and reporting at every level. Transitioning these network communications from wired Wide Area Networks (WANs) to wireless communication through 5G can provide additional benefits to their security and network configurability. However, introducing these wireless capabilities may also result in a degradation of network latency. In this paper, we propose utilizing 5G for smart grid communications, and we evaluate the latency impacts of encapsulating GOOSE, Modbus, and DNP3 for transmission over a 5G network. The OpenAirInterface open-source library is utilized to deploy an in-lab 5G Core Network and gNB for testing with off-the-shelf User Equipment (UE). This creates an effective 5G test platform for experimenting with different OT protocols such as GOOSE. The results are validated by measuring two different Intelligent Electronic Devices’ contact closure times for each network configuration. These tests are also conducted for varying packet sizes in order to isolate different sources of network latency. Our study outlines the latency impact of communication over 5G for time-critical and non-critical applications regarding their transition toward private 5G-based OT network implementations. The conducted experiments illustrate that in the case of GOOSE packets, simple encapsulation may exceed the protocol’s time-critical nature, and, therefore, additional measures must be taken to ensure a viable transition of GOOSE to 5G services. However, non-critical applications are shown to be viable for migration to 5G.

42 ENGINEERING↗

DOE OSTI2024

Migration to WebDAV in Belle II Experiment

The usage of WebDAV protocol has become more and more popular within the physics experiments using grid middleware in the last decade, and today it represents a valid alternative to the GridFTP currently supported at best-effort level after the retirement of Globus Toolkit. Belle II experiment established the adoption of WebDAV protocol as the main protocol for data access and third-party-copy transfers, without relying on Storage Resource Manager interface (SRM). The migration process, carried on with continuous and gradual steps, has required a large effort to guarantee a smooth transition maintaining the production infrastructure fully operational. In this contribution we show the transition process, the tool of support developed to monitor step by step the status of third-party-copy support with WebDAV protocol by storages of the collaboration tested in both case pull and push, the strategy adopted to configure DIRAC and the solutions put in place for the corner cases. Finally, we will present some statistics of utilization and we will analyse the achieved results.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2022

Quantum Krylov subspace algorithms for ground- and excited-state energy estimation

Quantum Krylov subspace diagonalization (QKSD) algorithms provide a low-cost alternative to the conventional quantum phase estimation algorithm for estimating the ground- and excited-state energies of a quantum many-body system. While QKSD algorithms typically rely on using the Hadamard test for estimating Krylov subspace matrix elements of the form $\langle \phi_i|e^{-\widehat{H}τ}|\phi_j\rangle$, the associated quantum circuits require an ancilla qubit with controlled multiqubit gates that can be quite costly for near-term quantum hardware. In this paper, we show that a wide class of Hamiltonians relevant to condensed-matter physics and quantum chemistry contain symmetries that can be exploited to avoid the use of the Hadamard test. We propose a multifidelity estimation protocol that can be used to compute such quantities, showing that our approach, when combined with efficient single-fidelity estimation protocols, provides a substantial reduction in circuit depth. In addition, here we develop a unified theory of quantum Krylov subspace algorithms and present three quantum-classical algorithms for the ground- and excited-state energy estimation problems, where each algorithm provides various advantages and disadvantages in terms of total number of calls to the quantum computer, gate depth, classical complexity, and stability of the generalized eigenvalue problem within the Krylov subspace.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2022

Critical Barriers to Successful Implementation of Earth-Abundant, Mn-Rich Cathodes for Vehicle Applications and Beyond: The Effect of Particle Morphology

As the search for improved and next-generation cathodes continues, it is clear that a deeper understanding of synthesis–structure–electrochemical property relationships is of critical importance. The effects of primary and secondary particle morphologies on various transition metal oxides have been studied, but new findings are still being reported. To date, few studies have focused on the effects of particle morphologies on Li- and Mn-rich oxides (>50% Mn) and even fewer studies have focused on the influence over key properties such as electrode-level impedance. In this study, we report the effects of particle morphologies on the area-specific-impedance (ASI) and thermal behavior of Li- and Mn-rich oxides. Samples with a fixed, layered–layered–spinel (LLS), composition were synthesized with differing primary morphologies and tested under standardized, full-cell protocols. The results suggest that smaller primary particle size (i.e., higher surface area) leads to lower overall ASI, a delay in the increasing impedance at low states-of-charge (SOCs), and surprisingly, improved thermal behavior.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2023

Chemical contributions to silicon anode calendar aging are dominant over mechanical contributions

Silicon (Si) anodes are a promising candidate for increasing the energy density of lithium (Li)-ion batteries for electric vehicles. However, they have recently been identified as having poor calendar life that is insufficient for commercial needs, in addition to the well-known issue of their poor cycle life resulting from large volume expansion. Here, a specially designed protocol with variable rest periods between intermittent cycling is used to evaluate the impact of the mechanical disruption of Si and solid electrolyte interphase (SEI) from cycling on calendar aging measurements. Si was found to undergo more mechanical degradation during calendar aging with intermittent cycling than graphite. However, Si anode capacity fade was still dominated by time, especially for rest periods greater than or equal to 1 month between cycling. Postmortem dQ/dV half-cell analysis indicated this was mainly due to Li inventory loss and an increase in electrode resistance. Isothermal microcalorimetry further demonstrated that Si passivation is more disrupted than graphite passivation with intermittent cycling and suggested that there may be a chemical buildup of a detrimental species in the electrolyte, leading to a large spike in heat after the Si and SEI are disrupted by cycling.

25 ENERGY STORAGE↗

DOE OSTI2022

TEDS Test Plan for Performance Characterization of Packed-bed Thermal Energy Storage Unit

This report proposes a set of test plans for performance measurement and characterization of the packed-bed thermal energy storage (TES) unit for TEDS. The main goals of this test plan are three-fold: (i) support the high-fidelity data measurement for TEDS, (ii) characterize thermal and structural performance of the TEDS TES unit, and (iii) produce high quality validation-oriented data. To achieve the goals, it is first suggested to revisit the instrument calibration and data sampling protocols applied during the startup and commissioning tests of TEDS, based on the observation from the recent CFD validation study using the TEDS TES operational data. The uncertainty quantification of the thermal and hydraulic measurements is also suggested. Lastly, test matrices are provided for charge, discharge, and standby modes of the packed-bed TES unit, respectively, to characterize the thermal and structural performances during the envisioned TEDS operations.

25 ENERGY STORAGE↗

DOE OSTI2022

Bayesian optimized collection strategies for fatigue strength testing

Abstract A statistical framework is presented enabling optimal sampling and analysis of constant life fatigue data. Protocols using Bayesian maximum entropy sampling are built based on conventional staircase and stress step methods, reducing the requirement of prior knowledge for data collection. The Bayesian Staircase method shows improved parameter estimation efficiency, and the Bayesian Stress Step method shows equal accuracy to the standard method at larger step size allowing experimentalists to lessen concerns of loading history. Statistical methods for determining model suitability are shown, highlighting the influence of protocol. Experimental validation is performed, showing the applicability of the methods in laboratory testing.

36 MATERIALS SCIENCE↗

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↗