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DOE OSTI2025

Autonomous Nanoparticle Synthesis Guided by In Situ Multiscale Structural Characterization

Autonomous synthesis platforms promise rapid exploration of vast parameter spaces; yet, integrating in situ structural characterization in closed-loop synthesis optimization remains challenging. We demonstrate a realization of such a closed-loop platform coupled with a droplet-flow microreactor, in situ X-ray scattering methods (SAXS/WAXS), and Gaussian process optimization to synthesize citrate-reduced Au nanoparticles with targeted characteristics. The system efficiently explored ∼19,000 synthesis recipes through 365 experiments, achieving precise control over size (4–60 nm) and polydispersity (σ < 0.11) across large citrate/gold ratios, exceeding traditional synthesis boundaries (1–10). Beyond confirming classical Turkevich–Frens trends, partial-dependence analysis revealed strong nonlinear coupling among precursor, citrate, and pH effects. Combining quantitative SAXS/WAXS analysis with electron microscopy characterization, we uncovered that crystallite size (d c ) and particle size (d) follow d c = 0.18d + β, where synthesis chemistry controls the intercept β while maintaining a universal slope. This parallel-band structure enables independent tuning of crystallite domain size at fixed particle diameter through a combination of chloride, gold precursor, citrate, and pH contributions (cross-validated Spearman ρ = 0.7 ± 0.1). High-resolution electron microscopy shows multiple lattice-fringe orientations within single particles, directly confirming polycrystalline domains and the ability to tune d c at the fixed d. The platform’s validation includes indistinguishable static versus flowing measurements, stable droplet transport at 100 °C, and <5% run-to-run variation, establishing a robust framework for mapping and controlling multiscale nanoparticle structure across expansive chemical spaces. In conclusion, the developed closed-loop platform can be applied to a borad range of nanosyntheis processes.

77 NANOSCIENCE AND NANOTECHNOLOGY↗

DOE OSTI2024

An Experimental Setup for Mechanical Vibration Analysis Using VLC

This study explores the potential applications across various domains, including earthquake detection and warning systems, where the system’s sensitivity to ground vibrations can contribute to early seismic event detection. Additionally, the study paves the way of developing applications of VLC/T in mechanical vibration and stability analysis of engines and platforms, offering insights into structural integrity and performance optimization. These multifaceted applications underscore the adaptability and potential of VLC/T systems in diverse fields, heralding advancements in sensing, communication, and security technologies. To achieve this, in this study, Peak to Average Power Ratio (PAPR) is proposed to represent the impact of mechanical shocks and vibrations generated by several weights dropped onto the platform with which the receiver is fixed. Even though non-contact measurement methodology is preferred for various reasons, the proposed measurement campaign obtains the data in contact form; however, the system and signal model proposed in this study could easily be extended into non-contact form. Considering the fact that the proposed measurement campaign employs off-the-shelf products, it is cost-effective and very scalable.

Yilmaz, Ahmet Mucahit↗

DOE OSTI2020

The potential of quantum annealing for rapid solution structure identification

Abstract The recent emergence of novel computational devices, such as quantum computers, coherent Ising machines, and digital annealers presents new opportunities for hardware-accelerated hybrid optimization algorithms. Unfortunately, demonstrations of unquestionable performance gains leveraging novel hardware platforms have faced significant obstacles. One key challenge is understanding the algorithmic properties that distinguish such devices from established optimization approaches. Through the careful design of contrived optimization tasks, this work provides new insights into the computation properties of quantum annealing and suggests that this model has the potential to quickly identify the structure of high-quality solutions. A meticulous comparison to a variety of algorithms spanning both complete and local search suggests that quantum annealing’s performance on the proposed optimization tasks is distinct. This result provides new insights into the time scales and types of optimization problems where quantum annealing has the potential to provide notable performance gains over established optimization algorithms and suggests the development of hybrid algorithms that combine the best features of quantum annealing and state-of-the-art classical approaches.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2023

Digital Twin for Optimizing Real-time Economy of the Integrated Energy Systems

Economic and safe operation of integrated energy systems (IES) requires real-time optimization (RTO) of the control and actions conducted on each system component. In this regard, digital twins (DTs), which consist of a physical system, a virtual system, and the data communication that occurs between the two, are essential for effective RTO. Through the data warehouse, the virtual system is constantly updated with real-time data from the physical system, and functions as the model in the optimization framework. The reduced-order model of the dynamic process model in the virtual system is used in the optimization framework. The optimization results are then returned, via the data warehouse, as control actions to the physical system. This work demonstrates the software capabilities of DT assets for an IES in the context of preparing a DT for an experimental system comprised of Idaho National Laboratory (INL)’s Thermal Energy Delivery System and battery system. For the virtual demonstration, the DTs encompass (1) a physical system, including the Modelica models of the Thermal Energy Delivery System and the battery system; (2) virtual optimization via the Optimization of Real-Time Capacity Allocation (ORCA) platform; and (3) the open-source data warehouse software DeepLynx. This work assesses the performance of ORCA, which utilizes a reduced-order model built using the Risk Analysis Virtual Environment (RAVEN) and trained on the Modelica models and real-time data pipeline through the graph database hosted in DeepLynx. The proposed optimization workflow will be an RTO model based on DTs and the data they generate.

25 ENERGY STORAGE↗

DOE OSTI2022

Intersections of Disadvantaged Communities and Renewable Energy Potential: Data Set and Analysis to Inform Equitable Investment Prioritization in the United States

Renewable energy development can bolster local economies through job creation, local tax revenues, and reduced energy costs; however, communities most in need of economic development and employment opportunities often see lower levels of renewable energy deployment. We sought to identify areas where disadvantaged community indicators and high generation potential from cost-effective renewable energy opportunities intersect and deployment could lead to economic development and job creation. This presentation will highlight several of our findings. This research and the associated county-level data set are intended to inform national- and state-level energy-related assistance programs, economic development efforts, and infrastructure programs seeking to prioritize investments in disadvantaged communities.

community energy planning↗

DOE OSTI2026

Toward Lithium Recovery Using Modular (and Membraneless) Phase Separation and Extraction (MPSE) Technology with Ionic Liquid (IL) Solvents: Effect of Coatings

In this work, a single-channel slope-plate Modular and Membrane-less Phase Separation and Extraction (MPSE) device was fabricated using 3D printing. The slope-plate was designed with an insertable glass slide to enable surface modification with coatings. Self-assembled monolayers (SAMs) and perfluoropolyether (Zdol) coatings were applied to tailor surface wettability and enhance phase separation. Using a model biphasic system of water and hexadecane, both coatings significantly improved the separation efficiency compared to the uncoated device by promoting selective wetting. Building on these results, lithium extraction from a simulated saline solution was investigated using 1-ethyl-3-methylimidazolium bis(trifluoromethylsulfonyl)imide ([EMIM][NTf₂]) as the ionic liquid (IL) extractant. The IL effectively extracted Li⁺ from the aqueous phase in bulk extraction, demonstrating its potential for lithium recovery. However, the low interfacial tension between the IL and aqueous phases posed challenges for phase separation. The application of SAM and Zdol coatings effectively mitigated this issue. Overall, integrating tailored surface chemistry with the slope-plate MPSE design shows great promise as an efficient and scalable platform for studying liquid–liquid separation and optimizing ionic liquid–based extraction processes for lithium recovery from saline sources.

3D printing↗

DOE OSTI2022

AbBERT: Learning Antibody Humanness via Masked Language Modeling

Understanding the degree of humanness of antibody sequences is critical to the therapeutic antibody development process to reduce the risk of failure modes like immunogenicity or poor manufacturability. We introduce AbBERT, a transformer-based language model trained on up to 20 million unpaired heavy/light chain sequences from the Observed Antibody Space database. We first validate AbBERT using a novel “multi-mask” scoring procedure to demonstrate high accuracy in predicting complementary determining regions—including the challenging hypervariable H3 region. We then demonstrate several uses of AbBERT at various points along the antibody design process. AbBERT enhances in silico antibody optimization via deep reinforcement learning by utilizing its learned embeddings as additional observations during optimization. Within a larger computational antibody design platform, AbBERT has been successfully applied as an additional design objective, where it displays strong correlations with computational tools predicting antibody structural stability. Finally, mutant antibody sequences that have been scored as unfavorable by AbBERT have shown corresponding low yields when expressed in cells. These use cases demonstrate the power of language modeling within computational antibody design.

Bioinformatics↗

DOE OSTI2025

Noise-aware circuit compilations for a continuously parameterized two-qubit gateset

State-of-the-art noisy-intermediate-scale quantum processors are currently implemented across a variety of hardware platforms, each with their own distinct gatesets. As such, circuit compilation should not only be aware of but also deeply connect to the native gateset and noise properties of each. Trapped-ion processors are one such platform that provides a gateset that can be continuously parameterized across both one- and two-qubit gates. Here we use the Quantum Scientific Computing Open User Testbed to study noise-aware compilations focused on continuously parameterized two-qubit 𝑍⁢𝑍 gates (based on the Mølmer-Sørensen interaction) using $\scriptsize{SUPERSTAQ}$, a quantum software platform for hardware-aware circuit compiler optimizations. We discuss the realization of 𝑍⁢𝑍 gates with arbitrary angle on the all-to-all connected trapped-ion system. Then we discuss a variety of different compiler optimizations that innately target these 𝑍⁢𝑍 gates and their noise properties. These optimizations include moving from a restricted maximally entangling gateset to a continuously parameterized one, swap mirroring to further reduce the total entangling angle of the operations, focusing the heaviest 𝑍⁢𝑍 angle participation on the best-performing gate pairs, and circuit approximation to remove the least impactful 𝑍⁢𝑍 gates. We demonstrate these compilation approaches on the hardware with randomized quantum volume circuits, observing the potential to realize a larger quantum volume as a result of these optimizations. Using differing yet complementary analysis techniques, we observe the distinct improvements in system performance provided by these noise-aware compilations and study the role of stochastic and coherent error channels for each compilation choice.

Noise↗

DOE OSTI2022

Maximizing Archimedes spiral packing density area

In this paper, we experimentally demonstrate a broadband Archimedes spiral delay line with high packing density on a silicon photonic platform. This high density is achieved by optimizing the gap between the adjacent waveguides (down to sub-micron scale) in the spiral configuration. However, care must be taken to avoid evanescent coupling, the presence of which will cause the spiral to behave as a novel type of distributed spiral resonator. To this end, an analytical model of the resonance phenomenon was developed for a simple spiral. Moreover, it is demonstrated that this distributed spiral resonator effect can be minimized by ensuring that adjacent waveguides in the spiral configuration have different propagation constants ( β ). Experimental validations were accomplished by fabricating and testing multiple spiral waveguides with varying lengths (i.e., 0.4, 0.8, and 1.4 mm) and separation gaps (i.e., 300 and 150 nm). Finally, a Linear Density Figure of Merit (LDFM) is introduced to evaluate the packing efficiency of various spiral designs in the literature. In this work, the optimum experimental design with mitigated resonance had a length of 1.4mm and occupied an area of 60 × 60µm, corresponding to an LDFM of 388km -1 .

42 ENGINEERING↗

DOE OSTI2025

Spatio-spectral quantum state estimation of photon pairs from optical fiber using stimulated emission

Developing a quantum light source that carries more than one bit per photon is pivotal for expanding quantum information applications. Characterizing a high-dimensional multiple-degree-of-freedom source at the single-photon level is challenging due to the large parameter space as well as limited emission rates and detection efficiencies. Here, we characterize photon pairs generated in optical fiber in the transverse-mode and frequency degrees of freedom by applying stimulated emission in both degrees of freedom while detecting in one of them at a time. This method may be useful in the quantum state estimation and optimization of various photon-pair source platforms in which complicated correlations across multiple degrees of freedom may be present.

Kim, Dong Beom (ORCID:0000000346887375)↗

DOE OSTI2021

Smart Labs Final Report Summer 2021

The Smart Labs Project at Los Alamos National Laboratory (LANL) is an initiative derived from The University of California, Irvine and is part of the Department of Energy’s (DOE) Better Buildings Challenge. These carbon abatement strategies aim to reduce energy consumption of laboratories while also maintaining health and safety requirements. Smart Labs designs incorporate seven key principles which are: digital control systems, demand-based ventilation, low power-density demand-based lighting, exhaust fan discharge velocity optimization, pressure drop optimization, fume hood flow optimization, and commissioning with automated cross-platform fault detection. As the ALDCP Smart Labs team for the summer of 2021, the scope of the project is to determine the energy savings within building 03-1698 (Material Science Laboratory - MSL). Over the past couple of years, the Sustainability Group has been adding Smart Labs upgrades into the MSL building and the summer team would like to understand the impact made for the overall energy consumption/demand and safety for the building, determine the overall return on investment (ROI), and recommend more Smart Labs upgrades that can be added to the MSL building. The goal is to enable the UI FOD (Utilities and Infrastructure Facility Operation Division) to promote more Smart Labs projects in the future and further the reputation LANL and DOE facilities have of being leading examples of developers of high performing buildings.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2021

Open-Loop Control of Adjustable Tuned Mass Dampers for Floating Wind Turbine Platforms: Preprint

Floating offshore wind turbines have several advantages over their land-based counterparts, including access to stronger, more consistent winds and proximity to population centers. However, increased costs from the platform have been a challenge inhibiting their widespread adoption. New damping technologies with tunable target frequencies and damping ratios promise a greater degree of control over platform motions, allowing hulls to be designed smaller and reducing the overall cost of the turbines. In this work, a control strategy is proposed for these adjustable tuned mass dampers (TMDs). A frequency-domain model of the system is developed, from which response amplitude operators (RAOs) for the platform's rigid-body modes can be obtained for different natural frequencies and damping ratios of the dampers. Using these RAOs, and JONSWAP spectrums of operational and extreme sea states, the performance of the various damper settings are compared by evaluating the standard deviation of a rigid-body motion of interest (platform pitch or heave). By finding the optimal damper setting for a range of representative design load cases (DLCs), a lookup function is made to return the damper target frequency given the peak period of the sea state. To determine the current sea state, we propose a simple estimator that uses wave measurements (e.g., from a measurement buoy) to determine the peak period and significant wave height. The significant wave height is determined using the statistics of the past 100 seconds of wave elevation information and the peak period is computed using a frequency locked loop. Initial results show that we can use these estimated values to control the TMD natural frequency with an open loop controller. The controlled system is tested in a range of environmental conditions determined by the International Electrotechnical Commission design load cases (DLCs), which include normal and extreme wind and wave models. In these tests, we compare the performance of 4 cases: (1) no TMD, (2) a constant TMD based on the worst case DLC, (3) a controlled TMD based on known wind and wave environments, and (4) a real-time controlled TMD using estimated wind and wave environments. The effect of hull-based TMD control is also compared to changes in traditional wind turbine control via blade pitch.

control↗

DOE OSTI2022

A Unified Testing Platform to Mature Blockchain Applications for Grid Emulation Environments

Blockchain technology is a relatively novel technology that can be used to develop more decentralized, autonomous and tamper-evident solutions. A feature that can aid Transactive Energy Systems to reach their goals by enabling individual actors to communicate and reach consensus with other participants in a more decentralized fashion. However, technical barriers to evaluate and adopt this type of technology within the electrical domain still exist. To facilitate this task, BLOSEM Unified Testing Platform (UTP), a DOE-sponsored, multi-lab effort intends to accelerate the development of solutions by offering a common set of reusable services that can be used to interconnect existent grid tools with blockchain services. UTP is intended to serve as development platform that can provide application engineers with the technical means to evaluate potential blockchain solutions, by enabling them to concentrate on the actual application functionalities while at the same time abstracting the connectivity and performance measurement tasks. The use of BLOSEM UTP is further demonstrated by implementing two potential use cases that are intended to validate both the feasibility of implementing these applications as blockchain-based solutions while also demonstrating the features provided by UTP.

blockchain co-simulation↗

DOE OSTI2022

Growth Optimization and Device Integration of Narrow‐Bandgap Graphene Nanoribbons

Abstract The electronic, optical, and magnetic properties of graphene nanoribbons (GNRs) can be engineered by controlling their edge structure and width with atomic precision through bottom‐up fabrication based on molecular precursors. This approach offers a unique platform for all‐carbon electronic devices but requires careful optimization of the growth conditions to match structural requirements for successful device integration, with GNR length being the most critical parameter. In this work, the growth, characterization, and device integration of 5‐atom wide armchair GNRs (5‐AGNRs) are studied, which are expected to have an optimal bandgap as active material in switching devices. 5‐AGNRs are obtained via on‐surface synthesis under ultrahigh vacuum conditions from Br‐ and I‐substituted precursors. It is shown that the use of I‐substituted precursors and the optimization of the initial precursor coverage quintupled the average 5‐AGNR length. This significant length increase allowed the integration of 5‐AGNRs into devices and the realization of the first field‐effect transistor based on narrow bandgap AGNRs that shows switching behavior at room temperature. The study highlights that the optimized growth protocols can successfully bridge between the sub‐nanometer scale, where atomic precision is needed to control the electronic properties, and the scale of tens of nanometers relevant for successful device integration of GNRs.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Initial Characterization and Optimization of the Liquid Sampling-Atmospheric Pressure Glow Discharge Ionization Source Coupled to an Orbitrap Mass Spectrometer for the Determination of Plutonium

Plutonium measurements are essential to the nuclear forensics and safeguards community. The liquid sampling-atmospheric pressure glow discharge (LS-APGD) microplasma ionization source coupled with an Orbitrap mass spectrometer is a proven platform for uranium isotope ratio determinations. Here, this work expands the LS-APGD-Orbitrap platform capabilities by reporting the first-ever analysis of plutonium with the LS-APGD and the first-ever measurement of elemental plutonium with an Orbitrap mass spectrometer. This coupling has the potential to dramatically reduce the complex sample manipulations required for traditional analysis techniques employed for actinide isotope ratio determinations. As a first step toward the goal of simultaneous uranium and plutonium isotope ratio determinations, the initial characterization and optimization of the platform for the detection of plutonium are reported. Collision-induced dissociation modality settings were optimized to reduce water-related and other molecular clusters containing plutonium, maximizing 242 Pu 16 O 2 + responses. A design of experiments study was conducted to optimize the discharge conditions of the dual-electrode LS-APGD toward the responsivity of 242 Pu 16 O 2 +. The measurement sensitivity was determined from a Pu response curve, yielding a limit of detection of 10 fg (absolute) of total analyte when data was collected and processed with a Spectroswiss FTMS Booster X2 data acquisition system. Additionally, plutonium and uranium were measured in a simultaneous acquisition, and each analyte remained unaffected by the other. It is believed that the LS-APGD-Orbitrap platform could be a valuable addition to the nuclear forensics’ toolbox and, indeed, other scientific disciplines and regulatory communities in which rapid, high-resolution plutonium determinations are paramount.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2018

Industrial Scale Demonstration of Smart Manufacturing, Achieving Transformational Energy Productivity Gains

While many U.S. manufacturing operations utilize optimization for individual unit processes, smart manufacturing (SM) systems that integrate manufacturing intelligence in real time across an entire production operation are rare in large companies and virtually nonexistent in smaller organizations. One example of an area where SM systems can be applied is in the management of waste heat. A smart system that not only seeks to recover waste heat, but also to use energy more efficiently, is a more cost-effective approach because energy use, waste energy loss and product output are optimized together. The overall objective of this project was to develop an industry-accepted SM Platform that enables smart systems by accelerating and lowering the cost of development and implementation scales for use in diverse sets of manufacturing industry sectors, manufacturing operations and company sizes. Specifically, the project (1) designed and demonstrated the application of a prototype SM Platform for two diverse commercial test beds, (2) demonstrated at one and estimated for the other test bed the potential reduction in waste heat generation, and (3) worked with leading automation vendors to catalyze low-cost commercialization of the technology developed. The Smart Manufacturing Application and Data Platform (SM Platform) developed during this project is an innovative approach that marries IT virtualization technologies with operational data and modeling system requirements to construct a ready-to-go platform for enabling sensor – data – modeling – actuation systems, driven by real-time plant data and performance metrics. This SM Platform allows manufacturing organizations, regardless of their industry or size, to assemble new operational systems at a much lower cost, optimizing process knowledge and improving energy productivity by integrating with existing process control and automation systems. Also developed during this project is a methodology for developing energy productivity metrics that use real-time process information and provide comparisons for potential, practical, and actual performance, as well as examples and the methodology for provisioning of an Energy Dashboard that displays alternatives to optimize energy use within specific business contexts aimed at helping improve energy productivity and reduce emissions in U.S. manufacturing. The SM Platform designed utilizes current manufacturing, operational and IT industry standards. The platform can be used to expedite sensor – data – model – actuation system development and deployment in a cloud-based environment using a novel end-to-end workflow as a service capability that is already integrated with data connection, ingestion, and contextualization services. In addition, the methodology for development of energy productivity metrics and reusable application templates called Toolkits have been defined so that they can be tailored to a specific business situation. The project’s two test beds, one in a hydrogen production plant and the other in a forging, heat treatment, and machining operation, utilize sensor-driven modeling, measurement, and simulation systems. In these two test beds, the implementation of these as a comprehensive system has made it possible for energy productivity to be managed in real-time throughout the plant and enterprise using an energy dashboard. The development pathway to direct machine actuation was articulated. During the first year, the project team developed the most highly instrumented steam-methane reformer (SMR) in the U.S. using infrared cameras and thermocouples. Real-time data are streamed to high fidelity and reduced-order models for analysis. A high fidelity CFD model, parallelized in the SM Platform cloud environment, was demonstrated for operational use. This is the first real-time operational productivity system of a steam methane reformer using both high fidelity and data-driven models together in a real time situation to balance natural gas flow to the reformer tubes. An infrared camera system was developed and shown to outperform thermocouples in coverage, accuracy, reliability, and cost effectiveness for use in a high temperature, harsh environment. A forging, heat-treating, machining line operation test bed includes new instrumentation for data capture analysis, modeling, and simulation and will be integrated into SM Platform workflows so that business performance can be managed in real-time. Composable metrics were developed using the SM Platform to drive improvements in energy productivity, environmental performance, safety, asset management, costs, and overall operations. A major focus of the SM systems developed was optimization of energy productivity at the enterprise level, which resulted in reductions in waste heat generation for the two project test beds. Reductions in the waste heat generated will result in greater energy savings than will waste heat recovery due to inefficiencies in the heat transfer process. For the SMR test bed an efficiency improvement of 1 – 2% with a corresponding waste heat reduction of 5% were demonstrated. It should be noted that the test bed SMR unit had an efficiency of more than 90% as compared to 70 to 80% efficiencies of most SMR units. So implementation of similar SM systems at typical SMR units could yield more than 15 to 25% waste heat reductions. Similarly the forging, heat-treating, machining line operation test bed is a DOE AMO Platinum Level Superior Energy Performance plant with a much higher than typical overall operating efficiency. For this test bed heat integration using recuperators is estimated to result in fuel savings of 15.9% due to waste heat recovery compared to the base case without recuperators with negligible changes in part exit conditions. This results in an 18.9% energy efficiency improvement. The project team estimates that broad multi-sector adoption of the developed technology could reduce waste heat generation by an amount equivalent to 1.3% of total U.S. energy use. This waste heat reduction is associated with 69 million tons reduction in annual carbon dioxide emissions. Other potential benefits include reducing process times, solid and liquid wastes, environmental impacts, and water use. It is estimated that this investment has an anticipated payback period of less than one year in energy-intensive applications. The SM Platform could also reduce the costs of deploying SM systems by 50% in manufacturing operations. Commercialization of the SM Platform will require significant cross-industry collaboration and technology provider market changes. Steps taken toward commercialization included 1) analyzing savings from deployment of the SM Platform and 2) holding SM Platform workshops, webinars, and conferences with targeted individual industry segments, with a focus on small and medium-sized organizations. An upgraded community website has been established as a portal for accessing and distributing information. Most importantly, the SM platform enabling technology developed during this project and its commercialization will continue, evolve and expand under the Clean Energy Smart Manufacturing Innovation Institute (CESMII).

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

Zero Emission Cargo Transport (ZECT) II Demonstration: South Coast Air Quality Management District (Final Report)

The South Coast Air Quality Management District (South Coast AQMD), California Air Resources Board (CARB) and Southern California Association of Governments (SCAG) — the agencies responsible for preparing the State Implementation Plan required under the federal Clean Air Act — have agreed that attainment of federal air quality standards for the region will require a transition to the broad use of zero and near-zero emission energy sources in cars, trucks and other equipment. Accordingly, the 2012 South Coast AQMD Air Quality Management Plan, the SCAG 2012 Regional Transportation Plan, and the “Vision for Clean Air: A Framework for Air Quality and Climate Control Planning” all identify the need to immediately enact a phasing in of zero and near-zero emission technologies to meet air quality goals. In 2014, South Coast AQMD was awarded grant funding under the US Department of Energy Zero Emission Cargo Transport (ZECT) II Demonstration program to develop and demonstrate zero-emission drayage trucks for goods movement operations between the Port of Los Angeles (POLA) and Port of Long Beach (POLB) near dock rail yards and warehouses: 1) development and demonstration of zero-emission fuel cell range extended electric drayage trucks and 2) development and demonstration of hybrid electric drayage trucks. The purpose of this project was to accelerate deployment of zero emission cargo transport technologies to reduce harmful diesel emissions, petroleum consumption and greenhouse gases in the surrounding communities along the goods movement corridors that are impacted by heavy diesel traffic and the associated air pollution. Between 2014 – 2024, six ZECT II zero-emission fuel cell drayage truck platforms, including fuel cell range extended and CNG hybrid trucks, were successfully designed, developed, integrated, built, tested, and demonstrated with drayage fleet operators in transportation corridors within areas of the South Coast AQMD jurisdiction in Southern California such as in and around POLA and POLB. Portable hydrogen refueling was deployed to support the fuel cell vehicles. The project had real-time improvement with on-going debugging and optimizations while the vehicles were under demonstration. All platforms demonstrated sufficient or excess power, torque, and energy to support 82,000lbs Gross Vehicle Weight Rating and gradeability to perform their daily duty cycles. Collectively, the trucks drove over 23,000 miles during their respective demonstration phases. The ZECT II project was the first of its kind to demonstrate the commercial viability that supported the additional technology breakthroughs for Class 8 zero emission trucks and validations as well as the regulatory basis for all the zero-emission regulation that we know today, such as the Innovative Clean Transit regulation, Advanced Clean Trucks and Clean Fleet regulations.

08 HYDROGEN↗

DOE OSTI2024

Multiphysics Design Optimization and Additive Manufacturing of Nuclear Components (Final CRADA Report - Executive Summary)

Westinghouse Electric Company (WEC) actively participated in the advancement of the nuclear fuel and reactor design space and requested the help of Oak Ridge National Laboratory (ORNL) in the creation of a new design tool set. This report details the creation of a collection of software tool sets that are linked together to collectively assist WEC design engineers in developing novel ideas outside the normal scope of traditional nuclear fuel and reactor design formulas. Specifically, Siemens HEEDS, a design space exploration and parametric optimization software, monitored and changed parameters in a collection of softwares to meet the team’s objective. The HEEDS parametric optimization method, SHERPA, was developed to control the Siemens NX CAD platform to adjust the native CAD of a hexahedral spacer grid. This new geometry can be used to execute a topological design optimization by the NX Topology software add-in. The resulting geometry is additively manufacturable. This topological optimization occurred twice—once on the spacer grid’s spring, and once on the dimple geometry. These new geometries were imported by Siemens’ STAR-CCM+, a multiphysics structural and fluid dynamic computational solver in which the spring geometry is deflected to match the rod insertion configuration. Along with the dimple geometry, this new deflected spring was used to complete a hydraulic assessment of a single-unit cell comprising one rod, one spring, and two dimples. The HEEDS SHERPA algorithm ranks the design based on the final mass of the unit cell and the hydraulic pressure drop performance. The ORNL team demonstrated the ability to use this software and provided engineering judgement to apply modern aerospace aerodynamic design. The effort has been focused on thinking outside the conventional design space and redesigning a spacer grid to perform beyond the WEC set objectives. Furthermore, the ORNL team also demonstrated that the HEEDS optimization routine can independently develop a design that meets the WEC design goals. Although these designs were at a low technology readiness level, their demonstration confirmed the team’s capability to create novel advanced nuclear concepts.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗