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DOE OSTI2019

Performance Metric for Cementitious Waste Form Inventory Release in the Integrated Disposal Facility

This report describes work supporting Phase 1 of the 2018 Department of Energy (DOE) Office of River Protection’s (ORP) Grand Challenge recipient proposal “Cementitious Immobilization of Treated LAW and Ancillary Benefits to Risk Reduction in Cross Site Transfer”. Phase 1 was to establish a performance metric for grout leachability against which laboratory leach data (as observed diffusivities) can be assed, followed by a comparison of historical test data against this metric. Historically, advancements in the cementitious (grout) waste form performance have been made over the last 40 years, with the majority of progress achieved within the past 8 years as part of the Washington River Protection Solutions, LLC testing program. This report presents a summary of that effort relevant to the Hanford Site.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2016

Transactive Control of Commercial Building HVAC Systems

This document details the development and testing of market-based transactive controls for building heating, ventilating and air conditioning (HVAC) systems. These controls are intended to serve the purposes of reducing electricity use through conservation, reducing peak building electric demand, and providing demand flexibility to assist with power system operations. This report is the summary of the first year of work conducted under Phase 1 of the Clean Energy and Transactive Campus Project. The methods and techniques described here were first investigated in simulation, and then subsequently deployed to a physical testbed on the Pacific Northwest National Laboratory (PNNL) campus for validation. In this report, we describe the models and control algorithms we have developed, testing of the control algorithms in simulation, and deployment to a physical testbed. Results from physical experiments support previous simulation findings, and provide insights for further improvement.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2026

Findings from Large Bench-Scale Testing of Denitration Electrolyzers for the EDCGe Project

This report highlights the key findings and outcomes relevant to the processability of waste supernatant at Hanford using a denitration electrolyzer. The Electrosynthesis Company issued a Phase 1 report to the Savannah River National Laboratory (SRNL), summarizing the evaluation of large bench-scale denitration electrolyzers to support the electrochemical denitration and caustic generation (EDCGe) project. The Electrosynthesis Company’s report (attached as Appendix A) provides insights into the initial steps required to implement an electrolyzer system at Hanford. Phase 1 experiments focused on validating the denitration electrolyzer’s performance, operating parameters, and reaction products. The robustness of the electrochemical denitration process was demonstrated by two electrolyzer flow cell systems (a 100 cm 2 ElectroCell MP and a 150 cm 2 NESI NS01 cell), both of which achieved significant nitrate and nitrite removal (>50%) with a current efficiency of ~95% for both systems. Higher current densities (500 mA cm –2 ) improved nitrate and nitrite removal rates compared to lower current densities (333 mA cm –2 ), while maintaining a current efficiency of ~94%. The NS01 cell achieved a nitrate species removal rate of ~0.41 mol h –1 at 5 kA m –2 (equiv. to 500 mA cm –2 ). The primary reaction product was ammonia (NH 3 ), constituting 78.3–91.6% of the products (excluding OH – formation). NH 3 was predominantly retained in the catholyte liquid phase rather than being off-gassed. Additionally, the NS01 cell reported an NH 3 generation rate of ~0.36 mol h –1 at 5 kA m –2 . Other gas formation included ~7% N 2 , ~7% H 2 , and trace amounts of N 2 O. The estimated power requirement (extrapolated from the 0.015 m 2 cell data) for a full-scale denitration electrolyzer is approximated to be ~1.6 MW (DC-only) to treat 50% of nitrate and nitrite in a waste stream and generates ~2.1 kmol h –1 of NH 3 with an initial concentration of 4 M NO 3 – /NO 2 – at 300 gal h –1 . Simulated waste containing aluminate, carbonate, oxalate, and halogens exhibited no adverse effects on denitration performance. A preliminary experiment comparing alkaline anolyte (5 M NaOH) with a nickel based anode to acidic media (2 M H 2 SO 4 ) with a DSA-O 2 anode showed a lower operating voltage and generated less H 2 than the acid media. Maintaining a stable 5 M OH – concentration in the anolyte through periodic additions of caustic did not significantly impact denitration performance. This operational mode will be required for long-term experiments. All the experiments demonstrated that electrochemical denitration is a promising approach for treating nitrate and nitrite in simulated waste streams, achieving significant conversion and robustness across varying experimental conditions and electrochemical cell configurations. Lastly, the ability to generate a nearly pure NH 3 stream may prove advantageous for processing at other locations within the Hanford site.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2024

NORTH DAKOTA CARBONSAFE PHASE III: SITE CHARACTERIZATION AND PERMITTING OF GEOLOGIC STORAGE OF CARBON DIOXIDE

The Energy & Environmental Research Center (EERC), in partnership with Minnkota Power Cooperative Inc. (Minnkota), SLB, and Computer Modelling Group Ltd. (CMG), supported wide-scale deployment of carbon capture and storage (CCS) as part of the U.S. Department of Energy (DOE) National Energy Technology Laboratory Carbon Storage Assurance Facility Enterprise (CarbonSAFE) Initiative Phase III. This phase included the acquisition, analysis, and development of information to fully characterize two storage complexes to demonstrate viable storage resources for commercial volumes of CO2 (defined by DOE as a minimum of 50 million tonnes [MMt] of CO2 within a 30-year period) (National Energy Technology Laboratory, 2024). Phase III also involved the preparation, submission, and approval of North Dakota underground injection control (UIC) Class VI storage facility permits (SFPs)—required precursors to applications for Class VI injection well permits. The presumed viability of commercial-scale CCS, situated adjacent to Minnkota’s Milton R. Young Station (MRYS), is validated by Minnkota’s continued pursuit of Project Tundra—an initiative to build the world’s largest lignite-based CCS project in central North Dakota (www.projecttundrand.com). Project Tundra comprises two scopes of work, Tundra Capture (installation of postcombustion CO2 capture at MRYS) and Tundra SGS (secure geologic storage). The efforts of North Dakota CarbonSAFE Phase III, Site Characterization and Permitting, supported Tundra SGS. Extensive site-specific characterization activities included a successful multimeasurement geophysical approach and drilling a stratigraphic test well (J-ROC 1, subsequently renamed Liberty-1) adjacent to MRYS. Core collection and analyses, downhole testing and fluid sampling, and geophysical logging were performed on J-ROC 1 and on a nearby stratigraphic test well (known as J-LOC 1), which was drilled, cored, and tested under a complementary project funded by the North Dakota Lignite Research Program. The injection tests performed on J-LOC 1 positively impacted the CarbonSAFE project, resulting in fewer proposed injection wells and significant construction, operations, and monitoring cost savings. The characterization data collected and analyses performed were integrated into geologic models, and successive numerical simulations were run to determine CO2 plume extent and subsurface pressure buildup associated with the planned CO2 injection rate of nearly 4 MMt per year. The latter doubles the CarbonSAFE Initiative goal with an estimated 100 MMt of CO2 stored in 20 years. Application of the U.S. Environmental Protection Agency’s (EPA’s) method for estimating the Class VI Rule area of review (AOR) to the overpressurized Broom Creek Formation inspired an alternative method of calculation, called risk-based AOR delineation. This peer-reviewed method was applied for the first time during the storage facility-permitting process. The two SFP applications submitted in 2021 successfully resulted in North Dakota Industrial Commission (NDIC) orders in 2022 authorizing the creation of the storage facility areas and amalgamation of pore space as well as establishing financial responsibility requirements. After approval of the SFPs, Minnkota filed in 2022 applications for permits to reenter the J-ROC 1 well and to drill two new wells—all with the intended purpose to become Class VI injection wells. To establish eligibility under the Internal Revenue Code for Section 45Q tax incentives, a monitoring, reporting, and verification (MRV) plan was prepared and submitted by Minnkota to EPA in 2022, resulting in the first such plan approved in North Dakota. Also in 2022, under the National Environmental Policy Act (NEPA), Minnkota prepared and submitted an environmental information volume (EIV) describing the proposed CCS project and associated potential environmental impacts. Based on the EIV, DOE determined that the proposed construction project required an environmental assessment, and Minnkota submitted the first draft in 2023 and a revised draft in 2024. Both submissions were followed by a public comment period. Subsequently, DOE issued a finding of no significant impact (FONSI) on September 13, 2024. A successful outreach program, strongly based in the production, presentation, and dissemination of informational material, fostered an environment to aid stakeholders in making informed decisions regarding the planned project. Opportunities for public input were provided at various steps along the way, including at county planning and zoning meetings, before and during the SFP administrative hearing, and during environmental assessment public comment periods. In addition, land/pore space owners and mineral owners had various points of contact, including granting access rights, securing pore space leasing, and mineral owner notifications. Based upon the successful storage facility permitting issued by NDIC, approval of the MRV plan by EPA, and receipt of a FONSI under the NEPA, Minnkota is continuing its pursuit of Project Tundra. In December 2023, the Office of Clean Energy Demonstrations under its Carbon Capture Demonstrations Projects Program announced funding for the capture system (Office of Clean Energy Demonstrations, 2023) and a proposal for CarbonSAFE Phase IV: Construction funding was submitted in March 2024 for the storage project. A go/no-go decision to proceed with construction and operations in the Broom Creek Formation is anticipated in 2024. References National Energy Technology Laboratory, CarbonSafe Initiative, https://netl.doe.gov/carbon-management/carbon-storage/carbonsafe (accessed August 2024). Office of Clean Energy Demonstrations, 2023, OCED selects three projects in CA, ND, and TX to reduce harmful carbon pollution, create new economic opportunities, and advance carbon reducing technologies, December, www.energy.gov/oced/articles/oced-selects-three-projects-ca-nd-and-tx-reduce-harmful-carbon-pollution-create-new (accessed August 2024).

Peck, Wesley↗

DOE OSTI2016

Preliminary irradiation effect on corrosion resistance of zirconium alloys - 2016-0067

In order to improve the composition and structure of zirconium alloys, it is important to know how changes in their structure-phase state under irradiation affect various properties, including corrosion. In this work, autoclave corrosion tests were carried out on fuel cladding samples made of zirconium-niobium and zirconium-niobium-tin-iron alloy systems. All samples were preliminarily irradiated in a BOR-60 nuclear reactor at a fluence of 2 X10{sup 26} m{sup -2} (E>0.1 MeV). The autoclave tests of irradiated and unirradiated samples were performed at 350 deg. C for 240 days in distilled water containing 10 ppm lithium and 1,600 ppm boron. The irradiation of all alloys resulted in a significant change in their initial structure-phase state. The content of niobium in b-niobium-phase precipitates was reduced from 80 % to - 90 % to 50 % to - 60 %. Iron atoms from the Laves-phase particles were diffused into a matrix, and their lattice transformed from hexagonal close-packed to body-centered cubic. An average size of the transformed second-phase precipitates in the irradiated alloys increased relatively to an average size of the initial precipitates. Elongated radiation-induced precipitates (RIPs) with an average length up to 7 nm were formed in all alloys under irradiation. In comparison with the unirradiated state, irradiation reduced the corrosion of zirconium-niobium alloys, and this effect became more apparent with increased niobium content in the alloy. For zirconium-niobium-tin-iron alloys, irradiation led to more severe corrosion, mostly because of increasing tin content. Niobium content increased up to 2.37 %, and iron content decreased up to 0.18 % in the alloys, contributing to higher corrosion resistance. An interconnection between the niobium/(tin + iron) alloying parameter, quantity of nanometric precipitates formed therein under irradiation, and their corrosion performance has been suggested. (authors)

36 MATERIALS SCIENCE↗

DOE OSTI2022

Advanced Characterization of Fuel-cladding Chemical Interaction between U-10Zr Fuel and HT9 Cladding Tested in Fast Flux Test Facility

Fuel cladding chemical interaction (FCCI) can greatly accelerate the cladding failure. However, due to the limited space in a fuel cladding assembly, it is historically challenging to gain an mechanistical understanding of the formation mechanism of FCCI and its influence on fuel and cladding performance. With the imminent need to qualify U-10Zr based metallic fuel cladded by HT-9 for advanced reactors demonstration project, it is of vital importance to use advanced characterization method to study FCCI in a unprecedent detailed manner and gain better mechanism understanding of FCCI. Mechanistic Fuel Failure (MFF) series of prototypic fuel elements irradiated in FFTF [1, 2] provides the best samples to study FCCI since the MFF-series assemblies had an axial fuel height the same as proposed length by industry partners. Jason et al. [3] has performed preliminary post-irradiation examination on a MFF fuel pin sample, which was extracted from the HT9 cladded U-10at.%Zr MFF-3 pin MFF-3 pin (#193045) at an axial location of X/L = 0.98. This sample has a peak burnup of 5.7 at.% and peak inner cladding temperature (PICT) of around 615 °C during in-core testing. Scanning electron microscope examination has identified visible FCCI region on more than half of the HT9 circumference [3]. The most striking feature are grain boundary attacking by apparently lanthanides (Lns) rich phase. However, SEM cannot provide accurate assessment of phase and concentration of grain boundary phases and prevented a better understanding of the formation mechanism of such attach. This study, by pairing transmission electron microscope (TEM) characterization and atom probe tomography (APT) techniques with in-situ micro-tensile testing in scanning electron microscope (SEM), aims at gaining in-depth understanding on the formed FCCI region. The identified FCCI region roughly consists of multilayers as illustrated in Figure 1 (c). The main findings are: (1) layer-B shows observable lanthanides (Lns) infiltration along grain boundaries and mechanical softening due to FCCI- and irradiation-induced microstructural and microchemistry changes, particularly the recovery of martensitic lath structure and dissolution of pre-existing M23C6 together with the formation of coarsened Laves phases, (Fe, Cr)2(Mo, W); (2) layer-C is Fe depleted but Lns significantly enriched, becoming very brittle; (3) layer-D is mainly composed of UFe2 and Lns; (4) three FCCI-induced intermetallic U-Fe-Zr phases, ? (Fe0.5Zr0.32U0.18), e (Fe0.3Zr0.4U0.3), ? (Fe0.06Zr0.23U0.71), were identified near layer-E; (5) the ? (Fe0.5Zr0.32U0.18) phase was characterized to be a face centered cubic (FCC) crystal structure. These results will help to better understanding the governing mechanism of FCCI and facilitating the development of theoretical model for assessing the performance of metallic fuel and cladding integrity.

36 MATERIALS SCIENCE↗

DOE OSTI2016

Dependence of the critical temperature in overdoped copper oxides on superfluid density

The physics of underdoped copper-oxide superconductors, including the pseudogap, spin and charge ordering, and their relation to superconductivity 1-3 , is intensely debated. The overdoped side is perceived as simpler, with strongly-correlated fermion physics evolving smoothly into the conventional Bardeen-Cooper-Schrieffer (BCS) behavior. Pioneering studies on a few overdoped samples 4-11 indicated that the superfluid density was much smaller than expected, but this was attributed to pair-breaking, disorder, and phase separation. Here, we test this conjecture by studying how the magnetic penetration depth λ and the phase stiffness ρs depend on temperature and doping, scanning densely the entire overdoped side of the La 2-x Sr x CuO 4 (LSCO) phase diagram. We have measured the absolute values of λ and ρs to the accuracy of ±1% in thousands of cuprate samples; the large statistics reveals clear trends and intrinsic properties. The films are quite homogeneous; variations in the critical temperature (T c ) within a film are very small (< 1 K). At every doping, ρs(T) decreases linearly with temperature. The T c (ρ s0) dependence is linear but with an offset, (T c - T 0 ) ∝ ρs0 where T0 ≈ 7 K, except very close to the origin where Tc ∝ √ρ s0. This scaling law defies the standard BCS description, posing a challenge to theory.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2018

Effect of Strain Rate on the Plastic Deformation and Fracture of 90W-7Ni-3Fe Alloy Prepared by Liquid-Phase Sintering

In this study, the effect of the strain rates on the plastic deformation behavior and fracture mechanism of 90W-7Ni-3Fe heavy alloy prepared by liquid-phase sintering was investigated. Stress–strain tests were carried out in tensile and compression under quasi-static condition with the strain rate ranging from 10{sup −3} to 1 s{sup −1}. Dynamic test was examined using a compression split Hopkinson bar at strain rates ranging from 1000 to 1700 s{sup −1} in order to evaluate the effects of high strain rate on dynamic plastic deformation behavior. Quasi-static tests results show that the strength and hardness of this alloy increase with increasing strain rate. Results indicate that the as-sintered 90W-7Ni-3Fe heavy alloy has obvious strain-hardening characteristic under tensile or compression deformation under quasi-static condition. At this time, strain hardening is the main factor. Nevertheless, strain-hardening and strain-softening behaviors of the specimens occur simultaneously under dynamic compression condition. The effect of compressive stress on the work hardening is more obvious. A strong relevance of work-hardening effect on strain rate is also found. And the fracture mode of quasi-static and dynamic compression samples is also different.

36 MATERIALS SCIENCE↗

DOE OSTI2017

Statistical Analysis of CO 2 Exposed Wells to Predict Long Term Leakage through the Development of an Integrated Neural-Genetic Algorithm

The objective of this project is to develop a computerized statistical model with the Integrated Neural-Genetic Algorithm (INGA) for predicting the probability of long-term leak of wells in CO 2 sequestration operations. This object has been accomplished by conducting research in three phases: 1) data mining of CO 2 -explosed wells, 2) INGA computer model development, and 3) evaluation of the predictive performance of the computer model with data from field tests. Data mining was conducted for 510 wells in two CO 2 sequestration projects in the Texas Gulf Coast region. They are the Hasting West field and Oyster Bayou field in the Southern Texas. Missing wellbore integrity data were estimated using an analytical and Finite Element Method (FEM) model. The INGA was first tested for performances of convergence and computing efficiency with the obtained data set of high dimension. It was concluded that the INGA can handle the gathered data set with good accuracy and reasonable computing time after a reduction of dimension with a grouping mechanism. A computerized statistical model with the INGA was then developed based on data pre-processing and grouping. Comprehensive training and testing of the model were carried out to ensure that the model is accurate and efficient enough for predicting the probability of long-term leak of wells in CO 2 sequestration operations. The Cranfield in the southern Mississippi was select as the test site. Observation wells CFU31F2 and CFU31F3 were used for pressure-testing, formation-logging, and cement-sampling. Tools run in the wells include Isolation Scanner, Slim Cement Mapping Tool (SCMT), Cased Hole Formation Dynamics Tester (CHDT), and Mechanical Sidewall Coring Tool (MSCT). Analyses of the obtained data indicate no leak of CO 2 cross the cap zone while it is evident that the well cement sheath was invaded by the CO 2 from the storage zone. This observation is consistent with the result predicted by the INGA model which indicates the well has a CO 2 leak-safe probability of 72%. This comparison implies that the developed INGA model is valid for future use in predicting well leak probability.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2018

Final Scientific / Technical Report: Enabling Technologies for Heavy-Duty Vehicles – Cummins 55BTE

The Cummins 55% BTE (55BTE) program has completed the planned technical work on the project. This work includes the planned engine system demonstration in pursuit of the goal of demonstrating a peak system brake thermal efficiency (BTE) of 55%. The engine system included a high efficiency diesel engine integrated with a state-of-the-art waste heat recovery (WHR) system and an advanced aftertreatment system capable of meeting the current emissions standards. While the ultimate program goal of 55% BTE was not fully achieved due to hardware issues during the final testing phase, the program demonstrated a significant increase in reported engine system BTE for a heavy duty sized engine. The previous demonstrations in the Department of Energy funded SuperTruck 1 programs ranged between 50% - 51% BTE. The Cummins 55% BTE program demonstrated 54% BTE. Additionally, the program established a revised path-to-target showing how the system could be improved to reach the ultimate program goal of 55% BTE with some minor modification to the engine system. The changes in the revised path-to-target were unable to be completed during the course of this program due to time and money constraints placed on the program. The program’s goals were challenging in both scope and timing. Although the program’s goal can be simply stated in terms of demonstrating a system efficiency of 55%, the achievement of a heavy-duty diesel engine capable of full torque curve operation, adequate transient performance, low emissions and high brake thermal efficiency (>51% BTE) had not been previously demonstrated in a heavy-duty engine. The closest efforts to date included the SuperTruck 1 programs referenced earlier. The program made several advancements in all system areas. The combustion system was re-designed for a shorter combustion duration and lower in-cylinder heat loss. This was achieved through optimization of the fuel injection rate shape, number of spray holes, piston bowl shape, compression ratio, piston oil cooling, heat flow through the piston and in-cylinder charge motion. The air handling system was re-designed to provide cooled EGR at virtually no pumping penalty. This was achieved through implementation of a dual loop EGR system, reduction of EGR system pressure drop, and implementation of advanced turbocharger efficiency technologies. The engine friction and parasitic signature was dramatically reduced by the program through adoption of variable flow pumps, advanced rings and coatings, rollerized valvetrain, adoption of low viscosity lubricants and reduction in cylinder line bore distortion. The aftertreatment system was optimized through use of low dP substrates and an ammonia gas injection system. The WHR system development included the use of a dual-entry turbine and a mixed charger cooler. Finding and implementing these solutions in a short two-year program at the budgeted funding provided the greatest challenge for the program.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2018

Remote Off-grid Microgrid Design Support Tool (ROMDST) - An Optimal Design Support Tool for Remote, Resilient, and Reliable Microgrids Phase II - Final Report

The objective of the project is to develop an advanced optimization-based design support tool for AC or DC microgrids in remote locations, where utility grids may not be accessible. The mathematical model and the interface are being developed such that multiple design objectives and criteria/constraints can be easily enabled or disabled, to deliver a flexible tool relevant to a large, diverse user base, and to facilitate future feature developments. The new tool delivered by this project leverages the team’s extensive expertise in the development, testing, deployment, and commercialization of the state-of-the-art Distributed Energy Resources Customer Adoption Model (DER-CAM) – which is the foundation for the new tool. Phase I of the project leverages the microgrid design and decision support tool DER-CAM. Key Phase I developments include the following adaption to the DER-CAM model: a) AC or DC microgrid architectures, b) multiple economic objectives (e.g. single customer vs community vs utility perspective), c) constraints on fuel availability (e.g. total fuel available during outage periods), d) active and reactive power flow constraints for normal and N-1 contingency cases, e) component part load efficiencies (e.g. power electronic devices), and f) interactive data visualization capabilities (e.g. design topology elements). A component library including components’ default technical and economical characteristics was also developed. In Phase II, the project is focused on tool testing and validation, use for real-world microgrid designs, and outreach. Fully developing this tool will have the following impacts: 1) optimal off-grid microgrid designs that replace existing back of the envelope or non-optimal calculations, reducing capital costs and risk of microgrid deployment; 2) removing barriers to microgrid assessments by lowering microgrid soft costs, as the tool is freely usable; 3) reliable and resilient designs that reduce the cost of critical load shedding due to component outages.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2019

Remote Off-grid Microgrid Design Support Tool (ROMDST) - An Optimal Design Support Tool for Remote, Resilient, and Reliable Microgrids (Phase II, Final Report)

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2024

Design and Evaluation of Environmental Barrier Coatings for Protection of Ceramic Matrix Composites in Hydrogen-Based Turbines

This presentation at the 2024 FECM Spring Project Review Meeting summarizes ongoing work at NETL aimed at enabling the use of ceramic matrix composite (CMC) materials in next-generation high-efficiency power generation turbines fueled by hydrogen, natural gas, or other fuels. The work broadly involves three aspects (1) phase-field damage modeling of CMCs and the environmental barrier coatings (EBCs) used to protect them (2) computational design of new and improved EBCs and (3) performance testing of EBCs using a novel gas turbine combustion simulation rig developed at NETL. An overview on current status and next steps for each aspect of the project are presented.

ceramic matrix composite (CMC)↗

DOE OSTI2022

Experimental Studies of Low-Load Limit in a Stoichiometric Micro-Pilot Diesel Natural Gas Engine

While operating at light loads, diesel pilot-ignited natural gas engines with lean premixed natural gas suffer from poor combustion efficiency and high methane emissions. This work investigates the limits of low-load operation for a micro-pilot diesel natural gas engine that uses a stoichiometric mixture to enable methane and nitrogen oxide emission control. By optimizing engine hardware, operating conditions, and injection strategies, this study focused on defining the lowest achievable load while maintaining a stoichiometric equivalence ratio and with acceptable combustion stability. A multi-cylinder diesel 6.7 L engine was converted to run natural gas premix with a maximum diesel micro-pilot contribution of 10%. With a base diesel compression ratio of 17.3:1, the intake manifold pressure limit was 80 kPa(absolute). At a reduced compression ratio of 15:1, this limit increased to 85 kPa, raising the minimum stable load. Retarding the combustion phasing, typically used in spark-ignition engines to achieve lower loads, was also tested but found to be limited by degraded diesel ignition at later timings. Reducing the pilot injection pressure improved combustion stability, as did increasing pilot quantity at the cost of lower substitution ratios. The lean operation further reduced load but increased NOx and hydrocarbon emissions. At loads below the practical dual-fuel limit, a transition to lean diesel operation will likely be required with corresponding implications for the aftertreatment system.

03 NATURAL GAS↗

DOE OSTI2018

Pipe Overpack Container Fire Testing: Phase I II & III.

The Pipe Overpack Container (POC) was developed at Rocky Flats to transport plutonium residues with higher levels of plutonium than standard transuranic (TRU) waste to the Waste Isolation Pilot Plant (WIPP) for disposal. In 1996 Sandia National Laboratories (SNL) conducted a series of tests to determine the degree of protection POCs provided during storage accident events. One of these tests exposed four of the POCs to a 30-minute engulfing pool fire, resulting in one of the 7A drum overpacks generating sufficient internal pressure to pop off its lid and expose the top of the pipe container (PC) to the fire environment. The initial contents of the POCs were inert materials, which would not generate large internal pressure within the PC if heated. POCs are now being used to store combustible TRU waste at Department of Energy (DOE) sites. At the request of DOE’s Office of Environmental Management (EM) and National Nuclear Security Administration (NNSA), starting in 2015 SNL conducted a series of fire tests to examine whether PCs with combustibles would reach a temperature that would result in (1) decomposition of inner contents and (2) subsequent generation of sufficient gas to cause the PC to over-pressurize and release its inner content. Tests conducted during 2015 and 2016 were done in three phases. The goal of the first phase was to see if the PC would reach high enough temperatures to decompose typical combustible materials inside the PC. The goal of the second test phase was to determine under what heating loads (i.e., incident heat fluxes) the 7A drum lid pops off from the POC drum. The goal of the third phase was to see if surrogate aerosol gets released from the PC when the drum lid is off. This report will describe the various tests conducted in phase I, II, and III, present preliminary results from these tests, and discuss implications for the POCs.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2017

Status of the Development of Superconducting Undulators for Storage Rings and Free Electron Lasers at the Advanced Photon Source

Development of superconducting undulator (SCU) technology continues at the Advanced Photon Source (APS). The experience of building and successful operating the first short-length, 16-mm period length superconducting undulator SCU0 paved the way for a 1-m long, 18-mm period device— SCU18-1— which has been in operation since May 2015. The APS SCU team has also built and tested a 1.5-m long, 21-mm period length undulator as a part of the LCLS SCU R&D program, aimed at demonstration of SCU technology availability for free electron lasers. This undulator successfully achieved all the requirements including a phase error of 5° RMS. Our team has recently completed one more 1-m long, 18-mm period length undulator— SCU18-2— that is replacing the SCU0. We are also working on a helical SCU for the APS. The status of these projects will be presented.

Ivanyushenkov, Y.↗

DOE OSTI2021

Development of Algal Biomass Yield Improvements in an Integrated Process (Final Report)

This project built on the success of Global Algae Innovations Algae Biomass Yield Phase 1 project to accelerate the commercialization of algal biofuels through development of an integrated, economical, photosynthetic, open raceway system to produce algal oil. Two parallel pathways to a biofuel were investigated. In the algal crude oil pathway, highlighted in blue, the dewatered algal biomass slurry is used as a feed to hydrothermal liquefaction to produce an algae crude oil and recycle aqueous stream. In the algal lipid oil pathway, highlighted in green, the algal biomass slurry is dried, and the oil is extracted to produce an algal lipid oil biofuel intermediate and a high protein algae meal co-product. Upgrading to drop-in fuels has been demonstrated for the biofuel intermediates in both pathways. Since the algal lipid oil pathway requires lipid accumulation, the productivity is generally lower than the algal crude oil pathway, but the required productivity for economical algal biofuel production is also lower because the coproduct value is greater. The outdoor cultivation was performed at the Kauai Algae Farm. The project team has expertise across the full breadth strain development, advanced algal cultivation, open raceway contamination control, CO 2 supply, harvesting, dewatering, extraction, hydrothermal liquefaction, technoeconomic analysis and life cycle analysis: Hildebrand laboratory at Scripps Institution of Oceanography – diatom strain development. Mayfield laboratory at UCSD - green algae strain development. TSD Management Associates- CO 2 supply, algal harvesting and dewatering, and algal drying and extraction. Qualitas - large-scale test site for algal harvesting technology. Texas A&M University - algal drying and extraction technology. Pacific Northwest National Laboratory - hydrothermal liquefaction technology. GE Water and Power - membrane technology. National Renewable Energy Laboratory - algal techno-economic analysis. Phase 1 of the project resulted in tremendous productivity and pre-processing improvements in an integrated, large-scale, low-cost cultivation and pre-processing process that moved algal technology closer to economic viability for biofuels than ever before. Phase 2 accomplishments further facilitate development of a commercial algal biofuel industry by adding: several top performing strains and strain development tools including breeding; open-pond cultivation innovations that achieved a 30% improvement in overall productivity, an 83% reduction in cost, and a 95% reduction in energy use relative to conventional technology; further improvements in harvesting that led to the Zobi harvester ® as a universal, economical, low energy, commercially available microalgae harvesting solution; breakthroughs in drying and extraction including a new low energy drying process and several new low energy extraction unit operations that together with the Zobi harvester ® achieve a 90% reduction in cost and 97% reduction in energy use relative to conventional technology. These improvements are sufficient to enable economical production of algae biofuel and protein meal co-product if the process were scaled up to a commercial-scale 5,000-acre algae farm.

09 BIOMASS FUELS↗

DOE OSTI2019

An Investigation of the Wear Performance of Aged Inconel 718 Superalloy by the Fuzzy Logic Approach

In this study, the effects of δ, γ′ and γ″ phases on the microstructure and wear behavior of Inconel 718 alloy, produced by powder metallurgy technique, were analyzed experimentally and a fuzzy logic model was developed for the weight loss prediction after the wear tests. Aging process was carried out in two stages: firstly at 720 °C for 8 h and then at 620 °C for 6-10 h. Wear tests were performed at five different sliding distances (400-2000 m) for 1 ms{sup −1} sliding speed under 30 to 60 N loads. Weight loss prediction model was developed by using fuzzy logic method. SEM images of Inconel 718 alloy aged for 6, 8 and 10 h at 620 °C show intermetallic precipitates formed around particle boundaries. XRD examinations showed orthorhombic δ (Ni{sub 3}Nb), BCT γ″ (Ni{sub 3}Nb), FCC γ′ Ni{sub 3}(Al,Ti) hexagonal Laves (Fe{sub 2}Nb) phases formed in the structure with the same chemical composition and different crystal lattice. Accurate estimates were obtained in the developed fuzzy logic model. It was illustrated that this fuzzy logic model can be used successfully for the prediction of weight loss in wear tests of Inconel 718 alloy that was produced by powder metallurgy method.

36 MATERIALS SCIENCE↗