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DOE OSTI2025

Discrepant wear behavior of carbon nanotubes (CNTs) and dispersant in four-ball unidirectional and ball-on-flat reciprocating sliding tests

Carbon nanotubes (CNTs), basically rolled graphene sheets, have been studied lately as oil additives in the literature. However, we observed discrepant impact of CNTs on wear protection from two common tribological tests, four-ball unidirectional sliding and high frequency reciprocating rig (HFRR) ball-on-flat reciprocating sliding. To gain a stable suspension and dispersion of the CNTs in the oil, the CNT surface was functionalized with a phenyl ligand and a dispersant, polyisobutylene succinimide (PIBSI), was added. In the four-ball test, PIBSI alone failed to protect the surface but the CNTs effectively reduced the wear loss. The observations in the HFRR test however were the opposite: the PIBSI alone provided strong wear reduction but the CNTs had no positive impact. Here, such a discrepancy was hypothetically attributed to the different wear protection mechanisms by the PIBSI and CNTs which responded distinctively under different testing conditions. Additional unidirectional and reciprocating sliding tests with matching Hertzian contact pressures were able to validate the hypothesis. Worn surface morphological examination and tribofilm chemical analysis further supported the proposed wear mechanisms. Fundamental understanding gained in this study provides insights into the potential benefits and limitations of using CNTs in lubrication.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Stabilizing a strongly nonlinear structure through shaker dynamics in fixed frequency voltage control tests

Bifurcations are commonly encountered during force controlled swept and stepped sine testing of nonlinear structures, which generally leads to the so-called jump-down or jump-up phenomena between stable solutions. There are various experimental closed-loop control algorithms, such as control-based continuation and phase-locked loop, to stabilize dynamical systems through these bifurcations, but they generally rely on specialized control algorithms that are not readily available with many commercial data acquisition software packages. A recent method was developed to experimentally apply sequential continuation using the shaker voltage that can be readily deployed using commercially available software. By utilizing the stabilizing effects of electrodynamic shakers and the force dropout phenomena in fixed frequency voltage control sine tests, this approach has been demonstrated to stabilize the unstable branch of a nonlinear system with three branches, allowing for three multivalued solutions to be identified within a specific frequency bandwidth near resonance. Recent testing on a strongly nonlinear system with vibro-impact nonlinearity has revealed jumping behavior when performing sequential continuation along the voltage parameter, like the jump phenomena seen during more traditional force controlled swept and stepped sine testing. Here, this paper investigates the stabilizing effects of an electrodynamic shaker on strongly nonlinear structures in fixed frequency voltage control tests using both numerical and experimental methods. The harmonic balance method is applied to the coupled shaker-structure system with an electromechanical model to simulate the fixed voltage control tests and predict the stabilization for different parameters of the model. The simulated results are leveraged to inform the design of a set of experiments to demonstrate the stabilization characteristics on a fixture-pylon assembly with a vibro-impact nonlinearity. Through numerical simulation and experimental testing on two different strongly nonlinear systems, the various parameters that influence the stability of the coupled shaker-structure are revealed to better understand the performance of fixed frequency voltage control tests.

42 ENGINEERING↗

DOE OSTI2022

Validation of material models for puncture of 7075-T651 aluminum plate

Plate puncture simulations are challenging computational tasks that require advanced material models including high strain rate and thermal-mechanical effects on both deformation and failure, plus finite element techniques capable of representing large deformations and material failure. The focus of this work is on the material issues, which require large sets of experiments, flexible material models and challenging calibration procedures. In this study, we consider the puncture of 12.7 mm thick, 7075-T651 aluminum alloy plates by a cylindrical punch with a hemispherical nose and diameter of 12.7 mm. The plasticity and ductile failure models were isotropic with calibration data obtained from uniaxial tension tests at different temperatures and strain rates plus quasi-static notched tension tests and shear-dominated tests described here. Sixteen puncture experiments were conducted to identify the threshold penetration energy, mode of puncture and punch acceleration during impact, The punch was mounted on a 139 kg mass and dropped on the plates with different impact speeds. Since the mass was the same in all tests, the quantity of interest was the impact speed. The axis and velocity of the punch were perpendicular to the plate surface. The mean threshold punch speed was 3.05 m/s, and the mode of failure was plugging by thermal-mechanical shear banding accompanied by scabbing fragments. Application of the material models in simulations of the tests yielded accurate estimates of the threshold puncture speed and of the mode of failure. Time histories of the punch acceleration compared well between simulation and test. Remarkably, the success of the simulations occurred in spite of even the smallest element used being larger than the width of the shear bands.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Emissions mitigation technology for advanced water-lean solvent-based CO 2 capture processes

This technical final report submitted to DOE/NETL presents all the research activities performed during the entirety of DE-FE0031660 project-Emissions Mitigation Technology for Advanced Water-Lean Solvent-Based CO 2 Capture Processes which spans from October 2018 through March 2022. RTI International has been conducting studies from fundamental and operational aspects to reduce the overall amine emissions from the advanced Water-Lean Solvent (WLS) systems, specifically RTI’s Non-Aqueous Solvent (NAS). This technical final report will highlight the key findings from project which align closely to the project objectives which are: Identify the contribution of vapor loss, entrainment, and aerosols to the overall emissions of water-lean systems; Determine the significance of CO 2 capture system operating parameters to the amine emissions; Develop an emissions model based on critical operating parameters; Evaluate the effectiveness of emissions mitigation devices to reduce the amine emissions to <1 ppm under flue coal-fired flue gas; and, Determine the contribution of the ECTs to the overall CO 2 capture cost. The following are the key findings based on numerous tests using both lab-scale setups and parametric testing performed at RTI’s Bench-scale Gas Absorption System (BsGAS). During the BP1, the aerosol generation system and monitoring equipment were installed at BsGAS to produce and determine the aerosol characteristics during the NAS CO 2 capture process. The aerosol produced by this setup produced aerosols with the peak diameter and concentration of 50 micron and 1.2E10 7 cm -3 , respectively. These particle sizes and concentrations are matched to those observed in the actual coal-fired power plant flue gases and expected to be found at the absorber inlet of the CO 2 capture system. Over 1,300 hours of parametric testing have been conducted to evaluate the impact of the aerosols and operating conditions during the CO 2 capture with NAS on the overall amine emissions in the treated flue gas. At the worse condition tested, the presence of the aerosols in the flue gas could increase the overall emissions by 10X compared to the baseline emissions from NAS’s vapor pressure. CO 2 capture rate was found to be a main factor impacting the overall emissions as well as aerosol size and concentrations in the absorber off-gas. The higher CO 2 capture rate, the higher amine emissions in the treated gas. The temperature difference between the temperature bulge seen in the absorber and the water wash temperature also impacts the particle growth where the larger the temperature difference, the more amine emissions from aerosols in the treated gas. The majority of the aerosols did not grow substantially in the system, and the particle concentrations remained nearly constant between the absorber inlet and wash outlet. Only a small portion of the particles were found to grow significantly. The high efficiency demister with mesh size of 5-10 micron can be installed to remove a portion of the aerosols from the gas stream leaving the water wash. Overall, these results from parametric testing have established the emission baseline and validate our assumption on the need of emission control technologies (ECT) in order to minimize the emissions from the baseline NAS CO 2 capture process. Over 2,000 of BsGAS operating hours was used to investigate a handful of process improvements which led to a selection of the vital few changes that effectively control the amine emissions. These process improvements are lime-coated-filters for absorber gas inlet, advanced demister at the top of the absorber, a second water wash with amine recovery unit were designed, installed, and tested at BsGAS at the end of BP1. The result showed that the NAS CO 2 capture process with these additional emission control devices could lower the amine emission in the treated gas to about 1 ppm using a simulated coal-fire flue gas stream. The main contributor in lowering the amine emission came from the second water wash with amine recovery unit where the amine concentration in the scrubbing water was kept below 2 wt% through a continuous amine removal via an adsorbent bed, resulting in a low amine vapor pressure. The adsorbent bed was regenerated via a direct steam regeneration and the recover amine was returned to the absorber to minimize wastewater and makeup amine. A flue gas generation system was designed and installed during the first half of BP2 to support the emission testing using a real coal-derived flue gas. The system is capable of generating both coal- and natural gas- derived flue gases with the composition of the gaseous species highly resemble to that of the power plant flue gases. The particulates detected in the coal-derived flue gas showed the mean diameter of 1 micron. The CO 2 capture operating was then proceed using the real coal-derived flue gas where the amine emission was controlled to be about 0-3 ppm for the total run time of about 200 hours. Similar testing was conducted with natural gas-derived flue gas and the result showed a highly amine emission of 30 ppm under the total run time of 200 hours. The Principal Component Analysis (PCA) and the Partial Least Squares Projection to Latent Structures (PLS) techniques were applied to the parametric testing data to derive a multivariate statistical model. The model was validated and trained with half of the data collected, and the predictive ability of the model was evaluated using the remaining half of the data. The resulting empirical model was capable of predicting the overall emissions from the NAS process without the ECTs with ±15% accuracy (average absolute deviation, AAD) in BP1. As more emission data were obtained under the real coal-flue gas in the BP2, the model incorporated these new set of data to reflect the final process configuration, operating parameters, and amine emission. This results in the updated empirical model predicting the amine emission from the NAS CO 2 capture process with 84% goodness-of-fit (R 2 ), 85% predictability (Q 2 ), and 15% AAD. The study evaluates the use of RTI’s Non-Aqueous Solvent technology for 90% CO 2 capture from a net 650 MWe pulverized coal power plant, downstream of the flue-gas desulfurization unit. The captured CO 2 has a purity of > 95% CO 2 , and is dried, compressed to 15.3 MPa (2,215 psia), ready for sequestration. The analysis uses Case B12B from the DOE Baseline study on Bituminous Coal, Revision 4 where the Cansolv CO 2 capture plant is replaced by the RTI CO 2 Capture plant. The CO 2 capture plant has been sized to capture >90% CO 2 from flue gas derived from a net 650 MWe supercritical pulverized coal power plant. The CO 2 capture plant is equipped with emission control technologies that limits the amine emissions to < 1 ppm. Two different cases were evaluated for the technoeconomic study. The key difference between the two cases is the regenerator pressure. In Case 1, the regenerator operates at 0.195 MPa (28.3 psia), whereas in Case 2, the regenerator pressure is 0.44 MPa (64 psia) thus removing the need for the first stage of compression of the eight-stage compression train. Results from the TEA are compared against the DOE reference cases for SCPC plant with and without CO 2 Capture (Case B12A and Case B12B of the DOE Baseline study, respectively). Case 2 with CO 2 regeneration at higher pressure results in the lower cost of CO 2 capture. The total capital cost of the capture process has been estimated using 2018 dollars in Aspen Process Economic Analyzer and was estimated to be $579 MM. The capture plant operation leads to a total parasitic power loss rate of 96 MWe, resulting in a decrease in pulverized coal power plant efficiency of 7.8% points. The resulting cost of electric power increases from 64.4 mills/kWh, for no capture, to 97.5 mills/kWh, with 90% capture, an increase of 51% in the COE. The cost of capturing 90% CO 2 was estimated to be $38.2/tonne-CO 2 , and meets the DOE target of $40/t-CO 2 . Emission control technologies (ECT) investigated in this project includes a second water wash with use of activated carbon beds for removal of amine from the wash water prior to recirculation in the water wash. These ECT allow operation of the CO 2 capture plant with < 1 ppm amine emissions with the treated flue gas and contributes to $2.4/t-CO 2 captured. Amine emissions derived from thermal and oxidative degradations were investigated under this project along with the emissions derived from aerosols for the NAS system. The thermally degraded of the lean NAS showed less than 4% decreased of the original total amine content in the NAS at 150 °C while the result obtained at 120 °C showed no drop in total amine content, suggesting that thermal degradation of the NAS is minimal. These results also suggested that the thermally degraded species are not likely formed and contributed to the emissions due to the low regeneration temperature of the NAS at 90-105 °C. The oxidative degradation, on the other hand, could become problematic as some of these oxidative degraded species were observed during the NAS-5 testing at National Carbon Capture Center (NCCC) and SINTEF in our previous project. The rapid screening of selected inhibitors suggested that oxidative degradation of NAS can be suppressed using thiol containing compounds in amounts of at least 1 mol%. The detailed mechanistic degradation pathway was conceived for a specific amine used in NAS formulation during BP2. he reduction of the nitrosamines caused by the NO x present in the flue gas was also examined. The study suggested that the thermo-chemical treatment of the NAS solvent would be a more effective and economically viable compared to removing NO x at the DCC.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2022

Assessing the Impact of Effective Thermal Conductivity on Gas-cooled Reactor Transients in RELAP5-3D

High-temperature gas-cooled reactors (HTGRs) are a relatively mature advanced reactor concept that are of interest to industry and government for near-term deployment. These systems feature passive safety through low power density, coated particle fuels, and large graphite volumes that lead to slow heatup. In loss of flow transients, cooldown is achieved through conduction and radiation heat transfer. In prismatic block-type reactors, such as the mHTGR-350, the presence of coolant holes and fuel compacts alters the flow of heat through the blocks. To capture this effect in systems codes like RELAP5-3D, relationships for effective thermal conductivity (ETC) must be used to appropriately degrade the thermal conductivity. This work presents an assessment of the impact of ETC on performance of block-type gas-cooled reactors in a pressurized conduction cooldown (PCC) and depressurized conduction cooldown (DCC) transients. Models for PCC and DCC with bulk material thermal conductivity and ETC were run for both the mHTGR-350 and the High-Temperature Test Facility (HTTF) to determine the impact of ETC on transient performance.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2023

Opinion: A critical evaluation of the evidence for aerosol invigoration of deep convection

Deep convective updraft invigoration via indirect effects of increased aerosol number concentration on cloud microphysics is frequently cited as a driver of correlations between aerosol and deep convection properties. Here, we critically evaluate the theoretical, modeling, and observational evidence for warm- and cold-phase invigoration pathways. Though warm-phase invigoration is plausible and theoretically supported via lowering of the supersaturation with increased cloud droplet concentration in polluted conditions, the significance of this effect depends on substantial supersaturation changes in real-world convective clouds that have not been observed. Much of the theoretical support for cold-phase invigoration depends on unrealistic assumptions of instantaneous freezing and unloading of condensate in growing, isolated updrafts. When applying more realistic assumptions, impacts on buoyancy from enhanced latent heating via fusion in polluted conditions are largely canceled by greater condensate loading. Many foundational observational studies supporting invigoration have several fundamental methodological flaws that render their findings incorrect or highly questionable. Thus, much of the evidence for invigoration has come from numerical modeling, but different models and setups have produced a vast range of results. Furthermore, modeled aerosol impacts on deep convection are rarely tested for robustness, and microphysical biases relative to observations persist, rendering many results unreliable for application to the real world. Without clear theoretical, modeling, or observational support, and given that enervation rather than invigoration may occur for some deep convective regimes and environments, it is entirely possible that the overall impact of cold-phase invigoration is negligible. Substantial mesoscale variability of dominant thermodynamic controls on convective updraft strength coupled with substantial updraft and aerosol variability in any given event are poorly quantified by observations and present further challenges to isolating aerosol effects. Observational isolation and quantification of convective invigoration by aerosols is also complicated by limitations of available cloud condensation nuclei and updraft speed proxies, aerosol correlations with meteorological conditions, and cloud impacts on aerosols. Furthermore, many cloud processes, such as entrainment and condensate fallout, modulate updraft strength and aerosol–cloud interactions, varying with cloud life cycle and organization, but these processes remain poorly characterized. Considering these challenges, recommendations for future observational and modeling research related to aerosol invigoration of deep convection are provided.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2024

Water foraging with dynamic roots in E3SM; The role of roots in terrestrial ecosystem memory on intermediate timescales (Final Technical Report)

Terrestrial ecosystems can show sustained responses to stress events that may last for years after the initial perturbation. This phenomenon is referred to as legacy or memory and it emerges from a set of ecosystem processes that are poorly captured by Earth System and Land Surface Models. Consequently, these models struggle to predict the impact that extreme climate events have on surface energy, carbon and hydrological exchange once a stressor such as drought has relaxed or in response to repeated exposure to stress. In this project, we set out to test how the addition of dynamic root profiles in land surface models impact the capacity for Earth System Models, such as the Department of Energy’s E3SM, to capture realistic legacy effects. Observations have shown that vegetation shifts their root profiles during stress events to forage for water and these altered root profiles may take years to relax back to the initial state. We hypothesized that the alteration of the belowground root structures may be a source of terrestrial ecosystem legacy that is missing from models. To test this idea we undertook three core activities. (1) We developed a global-scale analysis of the impact of dynamic roots on ecosystem legacy building from a recently developed dynamic root module. (2) We developed new root dynamics in the DOE’s Energy Land Model (ELM) that allowed not only root profiles to shift their profile but also simultaneously alter carbon allocation to fine root pools. We then tested the impact of these new dynamics with intensive sensitivity analysis at four long-term AmeriFlux sites. (3) We undertook detailed isotopic analysis of tree rings from these AmeriFlux sites to assess ecophysiological and ecohydrological legacy to stress events that can be used to benchmark the sensitivity experiments with ELM. From these core activities, we report the following key findings. Firstly, on a global scale, the addition of dynamic roots led to chronically water-stressed ecosystems recovering faster to climate stress while wetter ecosystem showed enhanced legacy. This is because across ecosystems, stress events were almost universally associated with water shortages that led to the development of deeper root profiles. These deeper root profiles proved beneficial for recovery from drought stress. While the root dynamics did not universally improve the modeled representation of legacy it showed complex transient dynamics that emerge from the addition of dynamic roots. Secondly, the sensitivity analysis illustrated long term shifts in rooting depths away from the prescribed default profile suggesting that initializing of root profiles could benefit from spin-up simulations that converge on locally optimized root profiles. In addition, by enabling dynamic allocation some of the sites predicted unrealistically low allocation to roots (and high allocation to leaves). While these changes did not dramatically alter modeled gross primary productivity, they illustrated that without more sophisticated root processes in models, there is little penalty to dramatically disinvest in roots. Thirdly, the isotopic analysis of tree rings showed highly distinct legacy responses across species and sites. For example, T. canadensis showed reduced transpiration the year after stress events illustrated by sustained elevated $\delta^{18}$O. In contrast, A saccharum displayed elevated $\delta^{13}$C associated with reduced stomatal conductance in response to the previous years’ stress event. These geochemical signatures of legacy were present despite tree growth returning to normal the year after the stress. The results show the importance of species-level dynamics in legacy that are absent in modeling that assumes common traits within plant functional types. In summary, the work here established new avenues to explore root dynamics in models while illustrating how additional root processes are needed before dynamic carbon allocation can be implemented. Lastly, this project provided mentorship to a postdoctoral fellow, training for an early career scientist and multiple undergraduate students recruited from a minority serving institution.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2020

Spent Crystalline Silicotitanate Storage Study

Washington River Protection Solutions is working to support initial production of immobilized low-activity waste (LAW) by feeding Hanford tank supernate from tank farms to the Hanford Waste Treatment and Immobilization Plant (WTP) LAW Facility. This goal incorporates the design of a Tank-Side Cesium Removal (TSCR) system, which filters tank waste supernate to remove suspended solids and then removes Cs by processing it through crystalline silicotitanate (CST) ion exchange media manufactured by Honeywell UOP, LLC. The 137 Cs-depleted product is intended to be sent to the WTP for vitrification. The Cs-loaded CST columns will be stored indefinitely, with a goal of eventual CST removal and treatment. Thus, the spent CST needs to be recoverable. The testing described herein looks to potential upset process conditions where CST storage may be required before various rinse steps are completed. This study evaluated upset conditions at three sequential processing steps envisioned for TSCR (feed, 0.1 M NaOH rinse, water rinse), and in-column drying with compressed air (normal end step) to assess impacts on the nature of the CST bed. Testing was conducted at the small scale (12-mL bed volume); simulated AP-105 tank waste was used as the feed. Following process disruption, the CST bed was dried in place at 70 °C. Post-dried CST bed physical properties (angle of repose, penetration depth, particle morphological changes) were measured to evaluate how CST moved and flowed. The testing is intended to provide a preliminary assessment of issues that may arise from desiccation of CST with the indicated salt solutions in place. Since these were small-scale tests, the processing conditions will not match full scale conditions exactly; however, the tests do provide insight into the impact of stopping processing at an earlier step than normal. Except for the feed that was dried in-place, all other process stop-conditions showed the CST bed flowed well after drying. At this small scale, CST beds would not present an issue for retrievability. The feed that was dried in place had solidified into a rock-hard monolith with no movement possible. Samples had to be chipped from the surface.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2021

Comprehensive Assessment of On-And Off-Board Vehicle-To-Grid Technology Performance and Impacts on Battery and the Grid

This project defined, developed, and tested the open standards-based requirements, engineering design and system integration of on and off-vehicle Vehicle-to-Grid technologies both on the grid and on the PEV, to assess their effectiveness in implementing the use cases that create value for the grid, which in turn, can be passed on to the ratepayers and the PEV owners. The project comprised of three key categories of work and four key sub-areas of work. The three key categories were: On-Vehicle V2G, Off-Vehicle V2G, and impact of V2G operation on the battery capacity degradation. The four key sub-areas of work under each of these categories were: defining requirements, implementing the technology, performing system integration testing, and estimating the value of each of the grid services under specific assumptions, on a per-vehicle and on an aggregated basis. The technical implementation demonstrated the validity of standards-based approach to grid integration that led to interoperability, in addition to assessing the operational details with grid constraints imposed at the transformer level. The technology implementation also identified the subtle gaps in the standards definition to close the feedback loop on the accuracy of the standards as written, which are being implemented as revisions to the appropriate protocols. The battery impacts assessment developed a test cycle that the batteries from a real PHEV were subjected to for both the mobility-only and mobility with V2G specific energy cycling. While the battery impact results show a clear incremental degradation in response to additional throughput for V2G application purposes, the amount of additional kWh that can be made available without exceeding the end-of-life capacity definition of the battery at its 10-year warranty period was found to be significant. Given that the PEV battery being exercised during testing was a PHEV battery (smaller energy capacity), and 44% of its usable energy (i.e., SOC) was utilized daily for V2G applications, the EVs with much larger batteries will fare much better, either in terms of extracting more value in terms of incremental kWh for V2G, or in terms of relative incremental degradation of the capacity through the battery lifespan. Further, this battery was the second-generation Lithium-Ion chemistry circa 2015, which is at least two generations ago. Continual improvements in electrochemistry and manufacturing techniques as well as on-board capacity will enable the future batteries to provide even more energy for non-mobility-related services. Finally, the valuation of V2G energy services at the premise, distribution, and the ISO/market level was carried out for both the on-vehicle and off-vehicle cases, to understand both the GHG mitigation and operational efficiency improvements in quantitative terms. The analysis indicates that between $\$400$ and $\$1400$ per year of total value to the grid can be realized. When netted of costs to implement V2G either on or off-vehicle, the net value is available to be shared between the ratepayers and the EV owners. Over the life of the EV, therefore, this value becomes significant and can easily provide both ratepayer and EV owner benefits more than the cost of the equipment, either on or off-board, in addition to providing GHG mitigation benefits both on the grid and on the mobility sides. For these benefits to accrue, the key learnings from both the on- and off-vehicle V2G parts of the project indicate the need for at-scale demonstrations through involvement of real EV owners to validate both the technical feasibility, interoperability, as well as real grid benefits by performing extensive data collection and analysis. This will help inform the grid planners, the program designs, and tariff designers, as well as automotive and equipment manufacturers how best to create their products to maximize grid, ratepayer, and EV owner value.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2024

Long-Term field testing of the accuracy and HVAC energy savings potential of occupancy presence sensors in A Single-Family home

The energy-saving potential of occupancy-centric smart thermostats has been extensively explored in simulations but lacked field testing for energy savings quantification and sensor performance assessment in real buildings. This paper presents a long-term field study conducted in a single-family home in Texas, U.S. to evaluate the performance of occupancy-centric controls (OCC) of HVAC (heating, ventilation, and air-conditioning) system in terms of energy savings, sensor accuracy, and impact on electric peak demand. The test site was equipped with a commercial off-the-shelf (COTS) smart thermostat and multiple occupancy presence sensors for OCC implementation. Additionally, a sub-metering system was installed to monitor electricity consumption of various end-use equipment, including the HVAC system. A supplementary device was installed to track the ground-truth occupancy for the accuracy evaluation of the occupancy presence sensor. Scenarios of baseline and OCC controls were alternated weekly over the 20-month testing period. The results indicated an effective OCC execution, as evidenced by indoor temperature profiles. During the 2023 cooling season, OCC achieved total energy savings of 1,958 kWh, corresponding to a 17.6% energy savings ratio. Under certain conditions, daily HVAC energy savings reached as high as 17 kWh, with a savings ratio of 35%. Sensor performance showed an overall accuracy of 83.8%, a False Positive Rate (FPR) of 12.8%, and a False Negative Rate (FNR) of 47.4%. A key limitation was the sensor’s inability to detect stationary occupants during sleep, leading to a midnight FNR of nearly 100% and significantly compromising thermal comfort. Additionally, the implementation of OCC resulted in extended periods of high electricity demand on summer afternoons, affecting occupant’s thermal comfort and posing potential challenges to community-level grid operations if OCC were widely adopted. Furthermore, this study addresses a critical research gap by empirically investigating energy-saving potential and occupancy sensor performance in residential buildings. Through a comprehensive field-testing study, the research examines the interrelationship between sensor accuracy, energy savings, and thermal comfort, an area that has received limited attention in the current literature.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2026

EVs@Scale: NextGen Profiles EVSE Characterization 2025

As part of the U.S. DOE EVs@Scale consortium, the Next-Generation Profiles (NextGen Profiles [NGP]) project presents analysis and results from the characterization of high-power conductive and wireless charging infrastructure. High Power Charging equipment is capable of recharging electric vehicle traction batteries at power levels of 200KW and above. Electric Vehicle Service Equipment (EVSE) characterization involves testing over a wide range of DC charging currents and voltages during nominal and off-nominal conditions. This testing allows for a better understanding of the impact that high-power charging will have on the electric grid. A common set of standard test plans, procedures, and data requirements were applied to the characterization in this document with minor updates and improvements. This report covers all conductive characterization activities performed between October 2024 and September 2025 on the Delta Electronics 350KW Electric Vehicle Charging System, consisting of power cabinet model EIDN-U350KTA01 and dispenser model EIDD-U350SSUUAEG-350.Key Findings include: Output regulation, Efficiency and power factor, Load management, Grid Resilience, Smart Charge Management (SCM) performance, Thermal control system performance, Multi-port simultaneous charging performance, and Selected performance comparisons with other EVSEs characterized in the NextGen Profiles project. Hot and cold temperature testing was not conducted on the Delta 350KW due to laboratory limitations. Future research could include continued testing the Delta hardware under off-nominal temperature conditions including multi-port/multi-session simultaneous charge testing, in addition to collecting data on other high-power conductive chargers to augment.

25 ENERGY STORAGE↗

DOE OSTI2022

Model for determining rupture area in Zircaloy cladding under LOCA conditions

The dispersal of nuclear fuel through a cladding rupture opening during a transient event is the primary safety concern preventing the United States nuclear industry from extending burnup beyond a peak rod average burnup of 62 GWd/tU. The majority of research thus far has prioritized understanding, or at a minimum prioritized quantifying, fuel fragmentation and pulverization as a function of burnup and to a lesser extent onset temperature. Early high burnup loss-of-coolant accident tests performed at the Halden Boiling Water Reactor evaluated the impact of relocation on cladding temperature, whereas historical and recent cladding burst tests focused primarily on generating data related to cladding balloon and burst timing. However, very little effort has been put forth to develop a relationship for determining the rupture opening dimensions for Zircaloy cladding tubes bursting during a simulated light water reactor loss-of-coolant accident. This is significant because high burnup loss-of-coolant accident data suggest dispersal could be limited by the size of the rupture opening or rupture dimensions, thereby minimizing the safety concern. Therefore, the purpose of this research is to build a database composed of all simulated loss-of-coolant accident data to develop an empirical model that conservatively captures the rupture opening dimensions and translates those dimensions to rupture area. Analysis of the experimental data indicates the rupture dimensions are strongly correlated to the peak balloon strain. This relationship is leveraged to develop a rupture length empirical correlation as a function of peak balloon strain and a rupture width empirical correlation as a function of rupture length. Outliers in the experimental data are identified and discussed. Finally, the rupture opening empirical model is presented in such a way for general implementation into high fidelity fuel performance codes or fuel performance codes used for safety analyses.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

Risk-based System Upgrade Planning for AOT-IC [Capstone Project]

The Accelerator Operations and Technology Instrumentation and Controls Group (AOT IC) at the Los Alamos Neutron Science Center (LANSCE) has established a comprehensive risk-based system upgrade planning strategy which has been utilized as a tool to prioritize system upgrade projects for the past several years. A challenge with the current system is that the group often lacks the data to quantify the probability and impact of system failures, so the group often relies instead on qualitative risk assessments as well as evaluations of a potential upgrade project’s alignment with group strategy and vision to prioritize projects. A proposed framework to enable quantitative risk probability and impact assessments has been developed and tested on three pilot systems chosen to broadly represent the types and conditions of equipment used by the group. The proposed framework incorporates availability data gathered from the LANSCE control room logbooks and the LANSCE work control system, as well as a system health evaluation which is conducted from a variety of resources to assess the probability of equipment failure. The impact of system failure is viewed from the perspective of impact on mission and schedule, where spares status, system documentation status, and the functional distribution of deployed systems are used to quantify these impacts.

43 PARTICLE ACCELERATORS↗

DOE OSTI2022

A Multi-Model Framework for Assessing Long- and Short-Term Climate Influences on the Electric Grid

Climate change influences many aspects of the electric grid, but prior work and industry practices often ignore the potential effects of changing climate, or they only consider a single effect or individual effects in isolation. Challenges vary with each grid and include adapting to long-term trends such as changing temperature and precipitation or shorter-term events such as drought or storms that could increase in frequency or intensity. Here we present a multi-model framework designed to analyze the effects of long and short-term climate impacts in combination. This framework couples capacity expansion and production cost models with hydrologic models and future climate scenario data to analyze alternative climate and energy futures at high spatial, temporal, and process resolutions. Furthermore, we constructed and evaluated the results of a suite of simulated scenarios exploring climate impacts on capacity investment and stress-tested the resulting future infrastructures using hourly dispatch modeling under alternative drought and load conditions. We demonstrate the approach through a case study of the U.S. Western Interconnection, where climate impacts depend on interactions between temperature-induced load, water availability for hydropower, technology competitiveness, and demand flexibility. Changes in 2038 generating capacity range from -8.5-16.6 GW, and changes in 2038 transmission capacity range from -1-2 GW. Capacity increases are driven by higher load from higher temperatures, while capacity reductions can be achieved in scenarios with higher future hydropower availability and increased demand flexibility. Scenarios requiring additional capacity cost an additional $\$5$-$\$17$ billion (discounted) from 2018 to 2038; however, scenarios with capacity reductions cost $\$1$-$\$18$ billion less. Stress tests on four 2038 infrastructures demonstrated that the identified systems were able to serve at least 99.999% of load and 99.96% of reserves. However, drought and unexpected high-load conditions can result in reduced capacity to respond to contingency events we did not model. Although these results are system and scenario specific, they highlight the importance of considering multiple climate change impacts simultaneously in long-term planning efforts and demonstrate a multi-model, multiscale approach that can be flexibly applied to any system and set of climate change concerns.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2020

Evaluation of Multi-cell Failure Propagation

Failure propagation testing is of increasing interest to the designers and end users of battery systems. One of the chief difficulties, however, is choosing an appropriate initiation method to perform the test. Single cell abuse testing is typically used to initiate thermal runaway but this can involve a large amount of additional energy injected into the system. It is assumed that this will have some impact on the behavior of a propagating thermal runaway event, but there is little data available as to how significant this would be. Further, it is ultimately difficult to develop viable propagation tests for compliance and public safety activities without better knowledge of how test methods will impact the results. This work looks at propagating battery failure with a variety of chemistries, formats, configurations and initiation methods to determine the level of significance of the chosen initiation method on the test results. We have ultimately found while there is some impact on the detailed results of propagation testing, in most cases other factors, particularly the energy density of the system play a much greater role in the likelihood of a propagation event consuming an entire battery. We have also provided some guidelines for test design to support best practices in testing.

25 ENERGY STORAGE↗

DOE OSTI2023

Enhanced Hanford High-Fluoride Waste Glass Property Data Development: Phase 1

This study focused on investigating the effects of fluorine concentration on simulated high-level waste glass properties to eventually establish a fluorine limit (as a single-component or multiple-component constraint) for glass formulations for high-fluoride Hanford wastes. This is a first step to provide data to understand the impacts of changing flowsheets on the mission duration and extent. A test matrix of 20 high-fluoride glasses was generated, and the chemical compositions were measured. The following properties were measured and tested against current model predictions: crystal formation after centerline canister cooling, crystallinity as a function of temperature, density, viscosity, electrical conductivity, toxic leaching characteristics using the toxicity characteristic leach profile (TCLP), product consistency using the product consistency test (PCT), and SO 3 solubility. Overall, current models failed to adequately predict most of the properties, possibly due to differences in compositional space used to generate the models and the current test matrix. Additional work is needed to more accurately assess the impacts of high-fluoride wastes on Hanford processing, including additional data collection over a broader composition region and model development for the key models of interest such as PCT and TCLP.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2021

Observations of modal coupling due to bolted joints in an experimental benchmark structure

The goal of this paper is to present a set of measurements from a benchmark structure containing two bolted joints to support future efforts to predict the damping due to the joints and to model nonlinear coupling between the first two elastic modes. Bolted joints introduce nonlinearities in structures, typically causing a softening in the natural frequency and an increase in damping because of frictional slip between the contact interfaces within the joint. These nonlinearities pose significant challenges when characterizing the response of the structure under a large range of load amplitudes, especially when the modal responses become coupled, causing the effective damping and natural frequency to not only depend on the excitation amplitude of the targeted mode, but also the relative amplitudes of other modes. In this work, two nominally identical benchmark structures, known in some prior works as the S4 beam, are tested to characterize their nonlinear properties for the first two elastic modes. Detailed surface measurements are presented and validated through finite element analysis and reveal distinct contact interactions between the two sets of beams. The free-free test structures are excited with an impact hammer and the transient response is analyzed to extract the damping and frequency backbone curves. A range of impact amplitudes and drive points are used to isolate a single mode or to excite both modes simultaneously. Differences in the nonlinear response correlate with the relative strength of the modes that are excited, allowing one to characterize mode coupling. Each of the beams shows different nonlinear properties for each mode, which is attributed to the different contact pressure distributions between the parts, although the mode coupling relationship is found to be consistent between the two. Lastly, the test data key finding are presented in this paper and the supporting data is available on a public repository for interested researchers.

42 ENGINEERING↗

DOE OSTI2020

Improving Time Step Convergence in an Atmosphere Model With Simplified Physics: The Impacts of Closure Assumption and Process Coupling

Convergence testing is a common practice in the development of dynamical cores of atmospheric models but is not as often exercised for the parameterization of sub-grid physics. An earlier study revealed that the stratiform cloud parameterizations in several predecessors of the Energy Exascale Earth System Model (E3SM) showed strong time-step sensitivity and slower-than-expected convergence when the model's time step was systematically refined. In this work, a simplified atmosphere model is configured that consists of the spectral-element dynamical core of the E3SM atmosphere model coupled with a large-scale condensation parameterization based on commonly used assumptions. This simplified model also resembles E3SM and its predecessors in the numerical implementation of process coupling and shows poor time-step convergence in short ensemble tests. We present a formal error analysis to reveal the expected time-step convergence rate and the conditions for obtaining such convergence. Numerical experiments are conducted to investigate the root causes of convergence problems. We show that revisions in the process coupling and closure assumption help to improve convergence in short simulations using the simplified model; the same revisions applied to a full atmosphere model lead to significant changes in the simulated long-term climate. This work demonstrates that causes of convergence issues in atmospheric simulations can be understood by combining analyses from physical and mathematical perspectives. Addressing convergence issues can help to obtain a discrete model that is more consistent with the intended representation of the physical phenomena.

54 ENVIRONMENTAL SCIENCES↗