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At least 37 records · Page 2

Cyber Resilient Flexible Alternating Current Transmission Systems (XFACTS)

This report summarizes the activities conducted under the DOE-OE funded project DEOE0000897, Cyber Attack Resilient Flexible AC Systems – XFACTS. Hitachi Energy (HE), in collaboration with ABB Inc. (ABB), Bonneville Power Administration (BPA), University of Illinois at Urbana-Champaign (UIUC), Iowa State University (ISU), and University of Idaho (UI) pursued the development of a system of defense for Flexible Alternating current Transmission Systems against cyber-attacks (XFACTS). A FACTS substation enhanced with XFACTS defense mechanisms will be capable of mitigating cyberattacks especially those that seek to control electrical parameters like voltage or current and interrupt the power flow in AC lines. It empowers existing FACTS controllers and associated intelligent electronic devices to detect and mitigate malicious intents to depress system voltages, destabilize power flows, trip AC circuit breakers, corrupt currents, and voltages, even if the malicious commands and the measurements have correct syntax. The XFACTS functions utilize the physics of active power electronic systems, control and protection, electric power engineering principles, and state estimation to bring more in-depth cyber defense closer to the protected FACTS substation devices.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Hydrogen Storage for Flexible Fossil Fuel Power Generation: Integration of Underground Hydrogen Storage with Gas Turbine (Final Report)

As the nation continues to encourage, through market structures and financial incentives, the proliferation of intermittent renewable electricity, how to optimize the ever-changing electric grid and identify means to retain and improve resilience, while ensuring continued reductions in GHG emissions, will be critical. According to Bloomberg, wind & solar generated 10.5% of US electricity in 2020 and that percentage continues to grow. In support of expanding renewable energy use, and to address its intermittent nature, this project will develop the Hydrogen Storage for Flexible Fossil Fuel Power Generation platform that is dispatchable, reliable, repeatable and have the ability to produce zero or negative carbon power while interfacing with geology capable of CO2 and hydrogen storage. GTI Energy (GTIE) and team members Illinois State Geological Survey (ISGS), Mitsubishi Heavy Industries America (MHIA), Ameren Illinois, Hexagon Purus, and the Low Carbon Resources Initiative (LCRI) completed a Phase I Conceptual Study under contract DE-FE0032012 for Hydrogen Storage for Flexible Fossil Fuel Power Generation: Integration of Underground Hydrogen Storage with Gas Turbine. The Hydrogen Storage for Flexible Fossil Fuel Power Generation platform addresses the intermittent nature of the expanding use of Variable Renewable Energy (VRE) generation. The low cost of the electricity (COE) generated results in greater dispatch and more operation at higher power levels (higher efficiency), fewer short intervals, and fewer start/stop cycles. The reliable, resilient system can produce zero carbon power and store hydrogen. It will demonstrate hydrogen storage in geologic formations like those used in natural gas underground storage thus enabling large scale storage of hydrogen in sedimentary strata across the United States rather than in geographically restricted salt caverns. The Phase I study confirmed the system is feasible and generates power at lower cost than other low carbon approaches. The demonstration defines the pathway for broad commercial application and will accelerate the development of larger systems suitable for centralized utility scale electricity production. The study advanced the maturity of the H 2 storage-based system with flexible power generation by completing a Pre-FEED study (Phase II). The Pre-FEED focused on the selected Energy Farm on the University of Illinois Urbana-Champaign (UIUC) site that includes above ground and underground hydrogen storage, low-carbon hydrogen production (GTI’s Compact Hydrogen Generator, CHG) with underground CO2 sequestration, and a 40-MW class gas turbine. The Pre-FEED addressed the entire system and its interconnection to the natural gas and electric grid and mitigation of key risks, such as storage behavior, load-following, and system operation. During Phase 1 of the project, the team completed key tasks, which moved the entire demonstration project, specific components and approaches closer to commercialization. These Phase I Accomplishments include: Completing System Requirements Review; Completing System Layout and Modeling - Heat & Mass Balance and Process Flow Diagram; Completing modelling of 9 turbine performance cases; Evaluating rock strata for underground storage of hydrogen and sequestration of carbon dioxide; Completing initial modelling of underground storage of hydrogen and withdrawal with evaluation of loss and water production; Identifying roadable storage for above ground hydrogen storage; Identifying existing electrical infrastructure for receiving/delivering electricity; Identifying existing gas supply infrastructure for receiving natural gas; Document concept design/development plans in required reports. Conclusions: The 12-month Feasibility study in Phase I study was completed and confirmed the system is feasible and generates power at lower cost than other low carbon approaches and even lower cost than the reference NGCC plant without carbon capture when taking advantage of 45Q carbon credits. The study enabled the fidelity of the concept to be improved and allowed identification of the requirements for the system. Defining the individual system and component requirements was performed via the system requirements review with the whole team. These requirements were then incorporated into and iterated with our Heat & Mass Balance process model and process flow diagrams were generated to reflect the overall system. This information was then used to complete the TEA and show economic feasibility. Large scale non-salt geologic storage of hydrogen is an enabling technology for a hydrogen-fired turbine that can be retrofitted into large-scale electric generating units (EGU). Our demonstration will include 428 MWh or ~4 hours full load of hydrogen storage (above and underground). Carbon capture inherent to the CHG process can capture 90% CO 2 (with upgrades to >98%). This system provides a COE of 23% savings relative to an NGCC with a post combustion amine system. Our proposed storage system decouples carbon capture and hydrogen production from power production; therefore, we expect our proposed system’s efficiency and variable COE to be superior resulting in overall higher dispatch and reduced deep cycling. Our demonstration will be full to multi-day hydrogen storage and has the potential for longer (seasonal) duration commercially. The demonstration defines the pathway for broad commercial application and will accelerate the development of larger systems suitable for centralized utility scale electricity production.

03 NATURAL GAS↗

FEED Study of CarbonCapture Inc DAC and CarbonCure Utilization Technologies Using United States Steel’s Gary Works Plant Waste Heat (Final Report)

The University of Illinois at Urbana-Champaign (UIUC) led this project to produce a front-end engineering design (FEED) study of an advanced Direct Air Capture and Utilization System (DACUS) system that can remove a minimum of 5,000 tonnes/yr net of carbon dioxide from air (based on cradle-to-gate LCA) and utilizing the CO 2 to produce low carbon intensity ready mix concrete. The designed system, if built, would be larger than any currently existing Direct Air Capture (DAC) collector in the U.S. Such carbon capture technologies are critical to meeting the goals of the DOE’s program to accelerate climate-critical technology. In addition to the power sector, industrial facilities for the manufacture of steel and cement/concrete are among the major sources of anthropogenic CO 2 . DAC is a promising new technology for reducing CO 2 , a potent greenhouse gas, in the atmosphere but is expensive, in part due to the energy required to adsorb and desorb captured CO 2 during cycles. By integrating CarbonCapture Inc. (CCI) DAC modules at United States Steel's Gary Works (USS) and utilizing the site's waste heat, energy, and location this project evaluates the feasibility of utilizing the captured CO 2 and the logistics of transportation. CarbonCapture Inc. has developed an innovative DAC system using novel adsorbents to cost-effectively capture CO 2 . The captured, liquified gas will be trucked to ready-mix concrete plants within the region, the closest of which is approximately 3.5 miles away, where CarbonCure will inject it into concrete during the mixing process at the facilities. The carbon dioxide reacts with concrete, mineralizing into calcium carbonate (CaCO 3 ), permanently locking the greenhouse gas into the matrix of the building material. This FEED study demonstrated a full CO 2 value chain for DACUS from industrial facilities. It also provided a means for Visage Energy Corp. (Visage) to assess the impact of this holistic approach on job creation, regional economic impact, and environmental justice. The project team also included Sargent & Lundy (S&L) to provide the constructability review and costing of the integration of the DAC with the steel plant. Ecotek Engineering USA, LLC designed the outside battery limit (OSBL) infrastructure to connect the DAC and the plant. Activities performed during the project included: (1) Project Management Plan; (2) Technology Maturation Plan (TMP); (3) Initial Workforce Readiness Plan; (4) Workforce Readiness Plan; (5) Front-End Engineering Design (FEED) Study; (6) Project Design Basis; (7) Hazards and Operability (HAZOP) Study; (8) Constructability Review; (9) Project Cost Assessment; (10) Logistics Analysis of CO 2 Transportation to the Utilization Site; (11) Business Case Analysis; (12) Life Cycle Analysis (LCA); (13) Environmental Health and Safety (EH&S) Analysis; (14) Environmental Justice Analysis; and (15) Economic Revitalization and Job Creation Outcomes Analysis. This report provides a summary of the outcomes and results of the project, which was performed between Oct. 1, 2022, through Sept. 30, 2024.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

CMB-S4 Instrument Modeling and Development for CMB-S4

During this thirteen month award, we focused on two main tasks relevant to the development of the CMB-S4 project: (1) The refinement of sensitivity models and use of those to optimize the instrument design, and (2) the final development and testing a cryogenic blackbody calibrator prototype, of which we then produced three copies for CMB-S4's detector testing systems at FNAL, SLAC and UIUC.

47 OTHER INSTRUMENTATION↗

Genome-scale Design and Engineering of Non-model Yeast Organisms for Production of Biofuels and Bioproducts

The overall goal of this project was to develop genome-scale design and engineering tools for two non-model yeast organisms including Rhodotorula toruloides and Issatchenkia orientalis to produce high-levels of fatty acids-derived products and organic acids, respectively. The project was performed between 9/15/2017 and 9/14/2024 (the last two-years were no-cost extensions). The team consisted of Huimin Zhao (Lead PI) and Christopher Rao (Co-PI) from the University of Illinois at Urbana-Champaign (UIUC), Costas Maranas (Co-PI) from the Pennsylvania State University, Joshua Rabinowitz (Co-PI) and Martin Wuhr (Co-PI) from Princeton University, and Yasuo Yoshikuni (Co-PI) from the DOE Joint Genome Institute. The team has made great progress in both tool development and fundamental understanding of these two non-model yeasts. In total, there were 40 research publications (one of them is still under review) and one patent application as well as numerous oral presentations.

60 APPLIED LIFE SCIENCES↗

FEED Study of Carbon Capture Inc. DAC and CarbonCure Utilization Using United States Steel's Gary Works Waste Plant

The University of Illinois Urbana-Champaign (UIUC) is spearheading a front-end engineering design (FEED) study of a Direct Air Capture and Utilization System (DACUS) that can remove 5,000 tonnes/yr net CO2 from ambient air, utilizing it in the production of concrete. The designed system, if built, would be larger than any currently existing DAC collector. Such carbon negative technologies are critical to meeting the goals of the DOE’s program to accelerate climate-critical technology. DAC is a promising new technology for reducing the greenhouse gas in the atmosphere but is expensive, partly due to the energy required to capture and then release CO2 during the process. By integrating CarbonCapture Technologies Inc. DAC collector at United States Steel's Gary Works and utilizing steel plant's waste heat, energy, and location so energy & transportation costs can be minimized. CarbonCapture has developed an innovative DAC system using novel adsorbents to cost- effectively capture CO2. The captured, liquified CO2 will be trucked to ready-mix concrete plants across Illinois, Indiana, & Wisconsin, where CarbonCure will inject it into concrete during the mixing process. The carbon dioxide reacts with concrete, mineralizing into calcium carbonate (CaCO3), sequestering the CO2 into the concrete, and reducing the amount of cement, the manufacturing of which is among the major sources of CO2 emissions. This FEED study demonstrates a full CO2 value chain for DACUS from industrial facilities. It also provided an opportunity to assess the impact of this holistic approach on job creation, regional economic impact, and environmental justice.

Carbon management, ccus, carbon capture, utilizati↗

INFUSE:FLARED (Final Technical Report)

This report summarizes the final outcomes of the INFUSE:FLARED collaboration between Tokamak Energy (TE), the University of Illinois Urbana-Champaign (UIUC), and the Department of Energy (DOE). The project aimed to experimentally determine and model the pumping, absorption, and separation behavior of deuterium in flowing liquid lithium under gas and plasma exposure conditions. The work supports the development of lithium-based plasma-facing components (PFCs) and tritium management strategies for next-generation fusion plants.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

G2Aero Database of Airfoils - Curated Airfoils

This dataset contains a curated set of 19,164 airfoil shapes from various applications and the data-driven design space of separable shape tensors (PGA space), which can be used as a parameter space for machine-learning applications focused on airfoil shapes. We constructed the airfoil dataset in two main stages. First, we identified 13 baseline airfoils from the NREL 5MW and IEA 15MW reference wind turbines. We reparameterized these shapes using least-squares fits of 8-order CST parametrizations, which involve 18 coefficients. By uniformly perturbing all 18 CST coefficients by +/-20% around each baseline airfoil, we generated 1,000 unique airfoils. Each airfoil was sampled with 1,001 shape landmarks whose x-coordinates followed a cosine distribution along the chord. This process resulted in a total of 13,000 airfoil shapes, each with 1,001 landmarks. In the second phase, we gathered additional airfoils from the extensive BigFoil database, which consolidates data from sources such as the University of Illinois Urbana-Champaign (UIUC) airfoil database, the JavaFoil database, the NACA-TR-824 database, and others. We undertook a thorough pre-processing step to filter out shapes with sparse, noisy, or incomplete data. We also removed airfoils with sharp leading edge and those exceeding our threshold for trailing edge thickness. Additionally, we thinned out the collection of NACA airfoils-- parametric sweeps of NACA airfoils with increasing thickness and camber present in BigFoil database-- by selecting every fourth step in the parameter sweeps. Finally, we regularized the airfoils by reparametrizing them with an 8-order CST parametrization (with 1,001 shape landmarks with x coordinated following cosine distribution along the chord) and removing airfoils with high reconstruction errors. This data pre-processing resulted in a set of 6,164 airfoils. In total, our curated airfoil dataset comprises 19,164 airfoils, each with 1,001 landmarks, and is stored in the curated_airfoils.npz file. Using this curated airfoil dataset, we utilized the separable shape tensors framework to develop a data-driven parameterization of airfoils based on principal geodesic analysis (PGA) of separable shape tensors. This PGA space is provided in PGAspace.npz file.

airfoils↗

DarkNESS: A skipper-CCD NanoSatellite for Dark Matter Searches

The Dark matter Nanosatellite Equipped with Skipper Sensors (DarkNESS) deploys a recently developed skipper-CCD architecture with sub-electron readout noise in low Earth orbit (LEO) to investigate potential signatures of dark matter (DM). The mission addresses two interaction channels: electron recoils from strongly interacting sub-GeV DM and X-rays produced through decaying DM. Orbital observations avoid attenuation that limits ground-based measurements, extending sensitivity reach for both channels. The mission proceeds toward launch following laboratory validation of the instrument. A launch opportunity has been secured through Firefly Aerospace's DREAM 2.0 program, awarded to the University of Illinois Urbana-Champaign (UIUC). This will constitute the first use of skipper-CCDs in space and evaluate their suitability for low-noise X-ray and single-photon detection in future space observatories.

Alpine, Phoenix [Illinois U., Urbana (main)] (ORCI↗

Multi-layered Resilient Microgrid Networks

Distribution grid resilience, especially when the grid is under high penetration of Distributed Energy Resources (DER), e.g. PV and energy storage, is essential to ensure the quality of electric power services. The resiliency aspect is particularly important for critical loads that typically include hospitals, police/fire stations, and national security facilities. Networks of multiple interconnected reconfigurable microgrids help to increase renewable energy penetration and may be used as basic building blocks for implementing future resilient power grids. However, this integration requires additional layers of communications, both horizontal and vertical, which may substantially increase the potential cyber attack surfaces as well as escalate risks for wide-spread malfunctions of automation systems. The Mulit-layered Resilient Microgrid Networks project is an industry-academic collaboration between ABB, Duke Energy and the University of Illinois at Urbana-Champaign (UIUC) that has developed and demonstrated a cyber-physical resilient control and communication architecture for deployment of multiple microgrid networks, as well as retrofitting the existing distribution grids by increasing DER penetration levels.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Cyber-physical Resilient Interoperable Microgrid Networks

The paper presents the results of an industry-academic collaboration between ABB, Duke Energy and the University of Illinois at Urbana-Champaign (UIUC) that has developed and demonstrated a cyberphysical resilient control and communication architecture for deployment of multiple microgrid networks, as well as retrofitting the existing distribution grids by increasing DER penetration levels.

24 POWER TRANSMISSION AND DISTRIBUTION↗

ALTRIOS - Advanced Locomotive Technology and Rail Infrastructure Optimization System

The Advanced Locomotive Technology and Rail Infrastructure Optimization System (ALTRIOS) is a unique, fully integrated, open-source software tool to evaluate strategies for deploying advanced locomotive technologies and associated infrastructure for cost-effective decarbonization. ALTRIOS simulates energy conversion and storage dynamics, locomotive and train dynamics, meet-pass planning (detailed train timetabling), and freight-demand-driven train scheduling in a Pareto optimization. Because new locomotives represent a significant long-term capital investment and new technologies must be thoroughly demonstrated before deployment, this tool provides guidance on the risk/reward tradeoffs of different technology rollout strategies. An open, integrated simulation tool will be invaluable for identifying future research needs and making decisions on technology development, routes, and train selection. ALTRIOS development is a collaboration between NREL, the University of Illinois Urbana-Champaign (UIUC) RailTEC, Southwest Research Institute (SwRI), and BNSF.

ADVANCED PROPULSION SYSTEMS,MATHEMATICS AND COMPUT↗

An open-source hybrid unstructured mesh - CAD fusion multiphysics analysis workflow in SALAMANDER

Plasma facing components in fusion devices will endure extreme neutron and heat fluxes. To facilitate their design using simulation tools, the open-source Fusion Module, Fusion ENergy Integrated multiphys-X (FENIX) framework is being developed to model these components with a high-fidelity multi-physics multi-dimensional approach. It can iteratively resolve couplings between all the physics at play, from neutron radiation, to thermomechanics, to near-wall plasma dynamics. This framework is based on the Multiphysics Object Oriented Simulation Environment (MOOSE), which is developed by a collaboration of US National Laboratories since 2008, for advanced nuclear, geomechanics simulations and other applications. FENIX couples numerous simulation tools, including OpenMC, the Tritium Migration Analysis Program v8, the NekRS CFD software, and most MOOSE modules. For the coupling of radiation transport and other physics, FENIX supports a hybrid workflow between Computer Assisted Design (CAD) and unstructured mesh geometries. The CAD can be generated from skinning the unstructured mesh, to enable a coarse geometry for efficient particle transport, but still resolving the local material compositions and temperature gradients. Neutron transport is performed using DAGMC on the CAD, and Cardinal, integrated in FENIX, maps tallied quantities, such as the heat deposition or the tritium generation rates, from a tally volumetric mesh to the other physics’ unstructured mesh. This coupling was exercised on a simplified tokamak geometry, coupling neutron transport with the heat conduction equation, and on a monoblock divertor problem, coupling additionally with tritium migration. Mesh convergence studies highlight the importance of the mapping conservativeness. Coupling with thermo-mechanics is further enabled by the generalization of the approach to moving meshes. The presentation will include these coupled analysis as well as an update on status of the FENIX framework.

70 - PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Retrofitting Holcim Ste. Genevieve Cement Plant with CO2 Capture Plant Using Air Liquide Cryocap™ FG Technology

The global cement manufacturing industry is a major contributor to carbon dioxide emissions. The International Energy Agency's "Net Zero Emissions by 2050 Scenario" identifies CCS as a major strategy for meeting that goal. This project is among the first attempts to transfer capture technology developed at coal-fired power plants to the cement industry. The main objective of the project is to execute and complete a front-end engineering and design (FEED) studies for commercial-scale, carbon capture projects that separates 95% of the total CO2 emissions at the Holcim (US) Ste. Genevieve cement manufacturing facility using Air Liquide’s Pressure Swing Adsorption system (PSA) assisted Cryocap™ technology. The Holcim Ste. Genevieve cement plant in Missouri, US, boasts one of the largest single cement production lines in the world, with a capacity of approximately 12,000 t/day. The plant currently uses traditional fuels, namely coal and petcoke. The captured CO2 will be pipeline and geological storage grade. The industrial host site emits approximately 3.0 million tonne CO2/yr. Air Liquide’s Cryocap™ technology has been developed over the last 18+ years for CO2 capture applications. It has been shown to be applicable to a variety of industrial applications (e.g., steel, cement, SMR, Fluidized Catalytic Crackers (FCCs)). Cryocap™ FG consists of a Pressure Swing Adsorption (PSA) unit coupled with a Cryogenic System. The PSA pre-concentrates the CO2 from the flue gas, while the cryogenic unit enables the CO2 purity to be increased to the desired level. The project team is led by the Prairie Research Institute at the University of Illinois at Urbana-Champaign. The tasks include: complete FEED study for retrofitting the industrial facility with a carbon capture system to support developing a detailed cost estimate; business case analysis outlining the anticipated revenue and credits if projects was built and operated; technoeconomic analysis (TEA) outlining how capture system achieves DOE capture goals; and life cycle (LCA) analysis demonstrating zero net carbon emissions. The FEED study was successfully completed. This includes completing the process basis of design; preliminary engineering; outside battery limits (OSBL) detailed engineering including a Zero Liquid Discharge (ZLD) wastewater treatment system; inside battery limits (ISBL) detailed engineering [1]. An overall project capital cost estimate within a -20%/+30% accuracy was developed. The major contributors to the Total Plant Cost (TPC), by system, are the costs associated with the Outside Battery Limit (OSBL) section of the plant which includes a new river water intake structure and a Zero Liquid Discharge (ZLD) system. By cost category, the major contributors to the TPC are equipment and subcontractor costs, followed closely by engineering, construction management, home office and contractor fees. The TEA has been created to reflect the findings of the project. It analyzes the economic performance of the Cryocap™ technology by reviewing the estimated capital costs, operating cost, and revenue. The Cost of Capture (COC) associated with the Cryocap™ technology for 95% CO2 capture, when considering NETL 2018 economic assumptions (42/58 debt/equity ratio, 5.15% interest on debt and 1.42% return on equity in real dollars) and 2022 economic assumptions (42/58 debt/equity ratio, 8.82% interest on debt and 4.90% return on equity in real dollars) was found to be much lower than that for the DOE-NETL’s base-line cases. The highest contributors to the COC are annualized capital expenditures (CAPEX) and electricity consumption which can be offset by using lower cost renewable sources. The LCA was conducted using OpenLCA which is an open-source software that is recommended by NETL. The database utilized for this study was a modified version of TRACI 2.1 (developed by the US. Environmental Protection Agency’s National Risk Management Research Laboratory and modified by NETL). The Cryocap™ FG technology does not consume fuels in significant quantities and does not utilize specialized chemical solvents subject to decomposition, such as those utilized in amine-based carbon capture systems. The Cryocap™ FG technology mainly utilizes electricity as its energy input; hence, its calculated emissions are mainly associated with the generation of electricity offsite and are dependent on the energy matrix of the grid at the time of project implementation. The water consumption impact of the Cryocap™ FG is mostly for makeup of the water lost by evaporation in the cooling tower; however, the carbon capture plant will be equipped with a ZLD system to avoid effluent streams and minimize water consumption. The successful construction and operation of this plant based on this study results will provide a means to demonstrate an economically attractive and transformational capture technology that can be used to retrofit existing plants and be deployed at new plants.

01 COAL, LIGNITE, AND PEAT↗

Industrial Carbon Capture from a Cement Facility Using the Cryocap™ FG Process

The objective of the project was to execute and complete front-end engineering and design (FEED) studies for commercial-scale, carbon capture projects that separate 95% of the total CO 2 emissions at an industrial facility, producing at least 100,000 metric tonnes/year of CO 2 for sequestration. The industrial facility selected is the Holcim (US) Ste. Genevieve cement manufacturing facility (the largest single kiln line in the world), while the carbon capture system selected is Pressure Swing Adsorption system (PSA) assisted Cryocap™ technology developed by Air Liquide. The industrial host site emits approximately 3 million tonnes CO 2 /year based on plant data from 2020-2022. The captured CO 2 will meet the requirements of transport (Pipeline Grade) and geological storage, and the geological storage facilities within 80 miles of the CO 2 source. The impact of the project on Environmental Justice and the regional economy was also analyzed.

01 COAL, LIGNITE, AND PEAT↗