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DOE OSTI2024

Monitoring Helium Cryogen Usage with iFix Software at IB1 Test Facility

At the IB1 facility of the Applied Physics and Superconducting Technology Directorate within the Cryogenic Division at Fermilab, liquid helium is essential to the testing activities. The test stands used require large amounts of Helium to test the thermal and superconducting cavities and magnets. The liquid helium that enters the test stand is monitored through a series of valves and controls to determine the start and stop for monitoring time. There are 3 phases of cryogen usage that must be considered for each stand, cooldown, warming and overnight mode. With a new system in place, cold hour tracking will be more objective and precise within each test stand ensuring better calculations for user s fees that will provide funding for the replenishment of helium and continual operation at IB1.

Trillo, Angelica↗

DOE OSTI2024

A Full-scale Demonstration of Pressurized Water Reactor Core Design Optimization using Multi-Cycle Optimization Methodology

The U.S. nuclear sector encounters a difficulty in upholding essential safety standards while also securing economic viability for continued operation. Safety stands as a pivotal factor across all facets of operations within light-water reactor nuclear power plants. Achieving economic feasibility alongside safety can be facilitated through the utilization of a risk-informed framework, exemplified by the ongoing development within the Risk-Informed Systems Analysis Pathway under the auspices of the U.S. Department of Energy's LWRS Program. This initiative advocates for a diverse array of research and development endeavors aimed at optimizing both safety and economic efficacy within nuclear power plants, particularly pertinent as many plants contemplate second license renewals. The Risk-Informed Systems Analysis Pathway has two main goals: deploy methodologies and technologies that better represent safety margins and cost and safety factors and develop advanced applications that enable cost-effective plant operation. This report assesses the potential for resolving multi-cycle plant reload challenges through real-world scenarios utilizing the Plant ReLoad Optimization (PRLO) framework. This framework offers reactor core design developers analytic tools of reactor safety and fuel performance with the assistance of artificial intelligence (AI) to enhance core design solutions. Multi-objective genetic algorithm alongside acceleration techniques is explored as an enabling technology for improving fuel efficiency while upholding safety thresholds. The demonstration of multi-cycle core design optimization is performed. This report investigates the practical application of the PRLO platform in addressing real-world core design challenges, supporting AI efforts, and contrasting outcomes with those derived from heuristic or conventional algorithms.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

Brochure on the 2024 ASCR Workshop on Analog Computing for Science

Analog computing fundamentally differs from digital by representing data with fully continuous physical quantities, such as voltages, probabilities, chemical concentrations, or light intensities, rather than encoding values in discrete binary states. While digital computing has historically excelled in precision, scalability, and noise resistance, newer analog approaches are gaining interest for their potential to dramatically improve energy efficiency and processing speed. Analog systems can inherently solve mathematical problems through their physical behavior and offer distinct advantages in scenarios where continuous operations are more effective than Boolean logic.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2024

Evaluating Utility Costs Savings and Resilience: A Case Study in Port Arthur, Texas

This study evaluates the techno-economic feasibility of integrating solar photovoltaics (PV), battery energy storage systems (BESS), and generators to enhance both cost savings and resilience in critical community facilities in Port Arthur, Texas. Using NREL's REopt model, we analyze four facilities: the Golden Triangle Empowerment Center (GTEC), Lamar State College (LSC), Port Arthur Independent School District (PAISD), and Port Arthur Transit (PAT). A key aspect of the analysis is the incorporation of the Value of Lost Load (VoLL) and microgrid upgrade costs to assess the hidden value of resilience during grid outages. While standalone PV scenarios show moderate cost reductions and a 10-15% decrease in CO2 emissions, the inclusion of resilience measures with BESS and generators significantly increases system costs. However, the hidden value of resilience - quantified through avoided outage costs - leads to a substantial improvement in financial outcomes, resulting in positive Net Present Value (NPV) at many sites. The study demonstrates that resilient solar and storage systems offer both economic and resilience benefits, particularly for underserved communities, by balancing energy savings and enhanced operational continuity during outages.

14 SOLAR ENERGY↗

DOE OSTI2024

Photovoltaic Cable Jackets: A Comparison of Representative Products Using Combined-Accelerated Stress Testing [Slides]

Photovoltaic (PV) cables facilitate the distribution of electricity collected from modules to the energy grid. Durable cabling enables continuous operation of PV installations, whereas cables with a lifetime less than the modules must be replaced - reducing electricity generation and adding to the operating expense. This study primarily focusses on the aging of the key cable types using the combined-accelerated stress testing (C-AST) protocol. Representative cables for utility, building, and control/auxiliary applications were examined. Cable jacket materials examined include: polyolefin, polyethylene, polyamide, poly(vinyl chloride), chlorinated polyethylene, thermoplastic elastomer, and ethylene propylene diene monomer rubber. Specimen characterizations applied include: optical microscopy, mechanical profilometry, instrumented indentation, scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), Fourier-transform infrared spectroscopy (FTIR), thermogravimetric analysis (TGA), and differential scanning calorimetry (DSC). A variety of performance and durability characteristics were observed, depending on the base material, polymer formulation, and jacket color. The results from C-AST are analyzed and discussed relative to a recent industry survey on electronic balance of system components in addition to a recent study where similar cables were aged using steady state ultraviolet weathering (International Electrotechnical Commission Technical Specification 62788-7-2). Recommendations are made for the screening, industry qualification, and service life prediction of PV cable jackets.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2025

ROTA-CAP™: An Intensified Carbon Capture System Using Rotating Packed Beds (Final Scientific/Technical Report)

GTI Energy and Carbon Clean Solutions Limited successfully designed, constructed, and operated an integrated ROTA-CAP carbon capture skid. ROTA-CAP™ is a process intensification technology, applied for post-combustion carbon capture, which utilizes the centrifugal forces generated from rotation of rotating packed beds as well as advanced solvents to achieve increased mass transfer rates 1-2 orders of magnitude higher than conventional columns while substantially decreasing footprint. The test skid, which consisted of a dual stage RPB absorber with external interstage cooling and a single stage RPB regenerator, was operated at capacities up to 0.5 tonne/day of CO 2 capture with flue gas concentrations ranging from 4% to 22% CO 2 by vol. CO 2 removal rates greater than 95% were achieved, with CO 2 product purity also exceeding 95% by vol. Over 1,600 hours of operation were accumulated throughout the project, including over 1,000 hours of operation of the with real flue gas containing at least 9.8% CO 2 by vol. The skid was operated continuously for 24 hours per day and 7 days per week over the course of 7 long-term test campaigns, with the campaigns ranging from approximately 2-4 weeks per campaign. A techno-economic analysis was performed, and a cost of capture of $\$$41.18/tonne CO 2 was calculated for the ROTA-CAP process, compared to $\$$45.75/tonne for a Cansolv-based process. These results show a cost reduction of approximately 10% compared to the Cansolv-based process. Although this still exceeds the target cost of capture of $\$$30/tonne specified for this project, GTI expects that the cost of capture can be further reduced through further optimization of the design and technology. GTI also performed an engineering design review to determine the scale-up potential of the technology, with the results of the preliminary assessment indicating that it appears to be feasible to scale up the RPB technology to 4,000 TPD. It was also determined that both horizontal and vertical rotor orientations are feasible, though there are mechanical advantages to the vertical orientation.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2025

Latest Results from the ICARUS Experiment at the Short-Baseline Neutrino Program

The ICARUS Collaboration is now entering its fifth year of continuing operations of the 760-ton liquid argon T600 detector. The T600 was overhauled at CERN after operations at the LNGS underground laboratory in Italy and moved to its present location at FNAL - as part of the Short-Baseline Neutrino (SBN) program - where it successfully completed its commissioning phase in June 2022. At FNAL ICARUS collects neutrino interactions from both the Booster Neutrino Beam (BNB) and off-axis from the Main Injector Neutrino beam (NuMI). To date, ICARUS has accumulated approximately 5.2\times 10^{20} protons on target (POT) with the BNB and about 6.2\times 10^{20} POT with NuMI. Within the SBN program ICARUS will search for evidence of short-baseline oscillations, potentially explained by eV-scale sterile neutrinos, jointly with the Short-Baseline Near Detector (SBND). In addition, ICARUS is performing stand-along oscillation searches in disappearance mode and measuring neutrino cross sections on argon with both the BNB and NuMI beams. It is also performing searches for additional Beyond the Standard Model signatures. Preliminary results from the ICARUS experiment, using data from the BNB and NuMI neutrino beams, will be presented.

Hausner, Harry [Fermilab]↗

DOE OSTI2025

Latest Results from the ICARUS experiment at the Short-Baseline Neutrino Program

The ICARUS Collaboration is now entering its fifth year of continuing operations of the 760-ton liquid argon T600 detector. The T600 was overhauled at CERN after operations at the LNGS underground laboratory in Italy and moved to its present location at FNAL - as part of the Short-Baseline Neutrino (SBN) program - where it successfully completed its commissioning phase in June 2022. At FNAL ICARUS collects neutrino interactions from both the Booster Neutrino Beam (BNB) and off-axis from the Main Injector Neutrino beam (NuMI). Within the SBN program ICARUS will search for evidence of short-baseline oscillations, potentially explained by eV-scale sterile neutrinos, jointly with the Short-Baseline Near Detector (SBND). In addition, ICARUS is performing stand-along oscillation searches in disappearance mode and measuring neutrino cross sections on argon with both the BNB and NuMI beams. It is also performing searches for additional Beyond the Standard Model signatures. Preliminary results from the ICARUS experiment, using data from the BNB and NuMI neutrino beams, will be presented.

Farnese, Christian [Fermilab]↗

DOE OSTI2025

Dual-Comb Spectroscopy to Tethered Balloon System (DCS to TBS) Field Campaign Report

There is a critical need for the ability to detect, quantify, and attribute sources and sinks of greenhouse gases (GHGs) with high temporal and spatial resolution. Current methods are typically based on continuously operating near-surface point sensors or intermittent aerial/satellite observations. Dual optical frequency comb spectroscopy (“dual-comb spectroscopy”; DCS) is a laser-based technique that can bridge this sensing gap by providing high-precision, high-accuracy, and high-temporal-resolution detection and quantification of trace gases over kilometer-length scales, connecting local and regional observations. A single DCS system can also provide spatial resolution for source/sink attribution with the addition of a few minor optical elements, enabling cross-validation of other observations (e.g., Total Carbon Column Observing Network [TCCON], Orbiting Carbon Observatory [OCO-2/3], Greenhouse Gases Observing Satellite [GOSAT-1/2][).

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2025

Development of Niobium-based alloys for Turbine Applications: 20/CJ000/08/09 (ULTIMATE Phase I project)

Current Ni-based alloys used in turbine blade applications are operating at 1100°C which is approximately 90% of the solidus of Ni-based alloys. Further increases in temperature can be achieved only through the use of alloys with higher solidus temperatures such as refractory alloys which include Mo, Nb, W, Ta alloys. Niobium has a unique combination of physical properties that include a high melting point (2468°C), lowest density (8.57 g/cc), and the lowest modulus amongst refractory alloys, a good thermal conductivity that increases from 45 W/mK at room temperature to 62 W/mK at 1093°C, good ductility with fabricability using traditional techniques, high strength, good creep resistance, and general chemical inactivity. Hence niobium alloys offer many advantages for use at the desired temperature of 1300°C. One of the major deterrents to the use of niobium and its alloys at high temperatures is achieving good oxidation resistance. In addition, achieving balanced properties of room temperature strength, ductility, fracture toughness, high temperature strength, and creep resistance required for 1300°C operation at a density of 9 g/cm 3 is extremely challenging since the addition of W which is a potent strengthener increases the density of the alloy. This project seeks to enable the development of a tri-layered turbine blade that can operate continuously at 1300°C with the core of the turbine blade providing good creep resistance, the second layer providing improved oxidation resistance over the core layer, and the third layer being an environmental barrier providing oxidation resistance. The objective of this Phase 1 project was to use computational modeling and advanced characterization tools to develop two classes of Nb alloys which could be used as the core layer and the transition layer.

36 MATERIALS SCIENCE↗

DOE OSTI2025

PV Reference Cells for Outdoor Use: Stability Over Four Years of Deployment

Photovoltaic (PV) reference cells are frequently used to evaluate the performance of PV power plants. They provide a measure of irradiance that strongly correlates with the electrical output of PV modules, which makes them very useful for detecting short-term anomalies or long-term degradation in PV power plant output. One very important quality is long-term stability. This report presents observations about the stability of a set of 22 commercial reference cells that have been in continuous operation for a period of four years at the Solar Radiation Research Laboratory (SRRL) site at the National Renewable Energy Laboratory (NREL). The 22 reference cells at the SRRL represent 10 different models from 6 manufacturers.

14 SOLAR ENERGY↗

DOE OSTI2025

A Zero-Emission Process for Direct Reduction of Iron by Hydrogen Plasma in a Rotary Kiln Reactor

This project’s goal was to demonstrate a hydrogen plasma (H-plasma)-rotary kiln process for reducing iron ore to iron as part of the steel manufacturing process. The H-plasma provides a greater thermodynamic driving force for reducing iron ores than thermal processes such as the DRI process, enabling lower reaction temperatures. We estimated that our process technology can reduce energy consumption by 45% compared to the blast furnace process and ~15% compared to the DRI process. Steel manufacturing produces about 1.8 tons of CO2/ton of steel with iron ore reduction accounting for about one-third of the CO2 produced in the overall manufacturing process. We estimated our process has the potential to reduce GHG emissions from ironmaking by 35% with today’s grid and by up to 88% with a future low-carbon grid while being cost competitive with the current blast furnace route. We demonstrated reduction of hematite and magnetite rich materials at temperatures from 600 to 800°C. We achieved 90-95% metallization on 100 gr samples in batch reduction experiments in the H-plasma rotary kiln furnace at 600-650°C. Attempts to perform tests in a continuous operation mode identified problems with the ore feed mechanism. We identified solutions but there was not time nor budget to correct these for this project

36 MATERIALS SCIENCE↗

DOE OSTI2025

A Zero-Emission Process for Direct Reduction of Iron by Hydrogen Plasma in a Rotary Kiln Reactor

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2025

2025 Atmospheric Radiation Measurement (ARM) Annual Report

ARM is a multi-laboratory, U.S. Department of Energy (DOE) Office of Science user facility and a key contributor to atmospheric research efforts. For more than 30 years, ARM has supported the DOE and Office of Science missions by providing atmospheric observations to enable scientific discovery, transform our understanding of the atmosphere, and evaluate and improve the accuracy of atmospheric models. ARM’s cutting-edge capabilities for scientists include continuously operating ground-based observatories, aerial observation platforms, and high performance computing.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2025

Portal Monitoring Considerations for Treaty Verification Applications

Portal monitoring is one method in a suite of options for treaty verification and can assist in verification of treaty accountable items (TAIs). Portal monitor technology spans a wide range of sensors, including radiation detectors, break-beams, or weight sensors. For radiation-detecting portal monitors, they are able to confirm absence / presence of a radiological signature and to track TAI direction of motion. Portal monitoring uses measurements from strategically placed sensors (e.g., radiation detectors) to record the entry or egress of TAIs. The implementation of portal monitoring relies on three key elements: perimeter definition, portal locations, and sensor technology, and can be implemented in either time-bound or continuous operations depending on what is permitted by the Treaty.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗

DOE OSTI2025

Latest Results from the ICARUS Experiment at the SBN Program

The ICARUS Collaboration is now entering its fifth year of continuing operations of the 760-ton liquid argon T600 detector. The T600 was overhauled at CERN after operations at the LNGS underground laboratory in Italy and moved to its present location at FNAL - as part of the Short-Baseline Neutrino (SBN) program - where it successfully completed its commissioning phase in June 2022. At FNAL ICARUS collects neutrino interactions from both the Booster Neutrino Beam (BNB) and off-axis from the Main Injector Neutrino beam (NuMI). To date, ICARUS has accumulated approximately $7.5\cdot 10^20$ protons on target (POT) with the BNB and about $6.2\cdot 10^20$ POT with NuMI. Within the SBN program ICARUS will search for evidence of short-baseline oscillations, potentially explained by eV-scale sterile neutrinos, jointly with the Short-Baseline Near Detector (SBND). In addition, ICARUS is performing stand-along oscillation searches in disappearance mode and measuring neutrino cross sections on argon with both the BNB and NuMI beams. It is also performing searches for additional Beyond the Standard Model signatures. Preliminary results from the ICARUS experiment, using data from the BNB and NuMI neutrino beams, will be presented.

Ricci, Alessandro Maria [U. Pisa (main); INFN, Pis↗

DOE OSTI2026

Boosting CO2R Performance of Ag Electrocatalysts by Sulfur-Doped Carbon Support

We find that S-doped carbon support can boost the CO2 reduction (CO2R) performance of Ag electrocatalysts. Firstly, surface science enabled electrocatalysis showed that Ag supported on S-doped highly oriented pyrolytic graphite (HOPG), a model electrocatalyst, demonstrated 100% higher CO turnover frequency (TOFCO = 3.6 ± 0.2 CO/atomAg/s) than that supported on S-free HOPG (TOFCO = 1.8 ± 0.2 CO/atomAg/s). Computational modeling based on density functional theory (DFT) revealed a more stabilized *COOH intermediate on Ag supported on S-doped carbon and thus a more favorable energetic pathway of CO2-to-CO, consistent with experimental results from the model electrocatalysts studies. Finally, this proof of concept was translated to the synthesis of powder electrocatalyst with 2 wt% Ag supported on S-doped carbon black, demonstrating > 40-fold high CO mass activity than a commercial Ag cathode with steady FECO ~ 96% at 100 mA/cm2 for 50 hours of continuous operation in a gas diffusion electrode (GDE) electrolyzer. For comparison, 2 wt% Ag supported on carbon black without S- doping showed a maximum FECO ~ 70% at 100 mA/cm2. This work demonstrates a successful bottom-up design of CO2R electrocatalysts guided by surface science enabled electrocatalysis.

CO2 conversion↗

DOE OSTI2026

Scalable Solar Fuels Production in A Reactor Train System by Thermochemical Redox Cycling of Novel Nonstoichiometric Perovskites

Hydrogen production via two-step thermochemical water splitting redox cycles using nonstoichiometric redox-active metal oxides has the potential to dramatically increase fuel production rates. At moderate-to-low water splitting temperatures, surface reaction kinetics co-limit the process. In such cases, stable and high surface area microstructures that allow exploitation of the full thermodynamic potential of the materials are essential as is tight thermal integration of the reactor module. This project’s goals were the development of novel nonstoichiometric perovskite oxides with high stability and favorable thermodynamic and kinetic properties, to optimize their microstructure for maximizing the fuel productivity, and to build a prototype reactor train system (RTS) comprising at least one reactor to meet specific performance targets: (1) capable of an in-house solar thermochemical hydrogen (STCH) productivity ≥ 12 mL g -1 for stable continuous operation ≥ 20 cycles; and (2) demonstration of scalable solar fuels production at practical solar reactor level in an industrial-scale concentrated solar tower (CST) using developed perovskites to achieve a hydrogen production rate ≥ 1 g h -1 .

08 HYDROGEN↗