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At least 397 records · Page 22

Lattice Structured Lightweight Structural Materials

The development of lightweight structural materials is crucial for enhancing the performance and deployment feasibility of fission batteries. This study aims to produce lightweight structural materials whose strength-to-weight ratios exceed those of current widely used structural materials. To achieve this, advanced modeling and simulation tools were employed to design lattice structures with different lattice parameters and different lattice types. A process was successfully developed for transforming lattice-structured models into Multiphysics Object Oriented Simulation Environment (MOOSE) inputs. Finite element modeling (FEM) was used to simulate the uniaxial tensile testing of the lattice-structured parts to investigate the stress distribution at a given displacement. The modeling results showed that the lattice-structured sample displayed a lower Young’s modulus in comparison to the solid material; the increase in solid shell thickness and blend radius enhances the mechanical performance; and the effect of unit cell size on macro scale stress is minimal. Tensile testing was conducted on the solid and lattice-structured materials fabricated by laser powder bed fusion (LPBF) additive manufacturing. The experimental results agreed well with the model prediction. The approach of using modeling as a guiding tool for preliminary material design can significantly save time and cost for new material development.

lightweight material↗

Modeling Tool Development and Validation for Solar Industry Process Heat Using Particle Thermal Energy Storage

U.S. industry sectors used 26.2 quadrillion Btu and accounted for 33% of total energy consumption in 2021 according to the Energy Information Agency. Industrial process heat accounts for 70% of industrial energy use with application temperatures ranging from 60 degrees -1100 degrees C. Industry processes, heavily relying on fossil fuels of cheap coal or natural gas, differ widely in operating conditions and load requirements which makes them difficult to standardize and imposes great challenges in decarbonization. Industry processes require reliable energy supply and vary widely in temperature ranges. Storing energy from renewable sources is necessary to improve reliability and to mitigate renewable intermittency when replacing carbon fuel-based heat supplies to achieve energy savings and reduce emissions. To this end, we have developed a particle-based thermal energy storage (TES) technology using low-cost and highly stable silica sand as a storage medium. The economic and performance-based analysis is key for renewable energy sources to reliably supply industry process heat and ultimately displace fossil fuels for decarbonization. The diversified industrial processes need case-by-case analysis and design. Therefore, an adaptive modeling tool is key for renewable power with energy storage to meet industry demands. Thus, a modeling tool to simulate a solar industry process heat system using the particle TES has been developed using the object-oriented equation-based language Modelica and the commercial platform of Modelon Impact. The Modelica-based software tool provides a general simulation environment for the design of reliable solar energy sources integrated with TES for various industrial process applications at different temperatures for economic competence with fossil fuels such as coal and natural gases. It uses both customized and standard component modeling modules in Modelon libraries for the flexibility to be adapted to a specific energy demand application. The particle TES system establishes a uniform energy supply platform with an efficient heat exchanger and particle thermal energy reservoir integrated with renewable powers. The particle TES system can provide a wide temperature range and can have a large storage temperature difference that increases storage energy density; therefore, it can be an adaptable energy storage system integrated with renewable power to supply 24/7 heat for industry decarbonization.

concentrated solar thermal↗

Appendix Q: Recommendations for Developing Molecular Assays for Microbial Pathogen Detection Using Modern In Silico Approaches

We describe the use of in silico approaches to improve the process of molecular assay development and reduce time and cost by utilizing available databases of whole genome pathogen sequences combined with modern bioinformatics and physical modeling tools. Well-characterized assays are needed for accurately detecting pathogens in environmental and patient samples and also for evaluation of the efficacy of a medical countermeasure that may be administered to patients. The polymerase chain reaction (PCR) remains the gold standard for pathogen detection due to the simplicity of its instrumentation, low cost of reagents, and outstanding limit of detection (LOD), sensitivity, and specificity. However, creation of such PCR assays often involves iterations of design, preliminary testing, and thorough validation with clinical isolates and testing in relevant matrices, which can be time consuming, costly, and result in suboptimal assays. Since formal validation (e.g., for Emergency Use Authorization [EUA] or Food and Drug Administration [FDA] licensure) of an infectious disease assay can be very expensive and can require extensive time of development, having a well-designed assay up front is a critical first step. Yet, many assays described in the literature utilized limited design capabilities and many initially promising assays fail the validation process, resulting in increased costs and timelines for successful product development. While the computational approaches outlined in this document by no means obviate the need for wet lab testing, they can reduce the amount of effort wasted on empirical optimization and iterative redesigns and also guide validation studies. The proposed computational approaches also result in higher performing assays with better sensitivity, specificity, and lower LOD and reduce the possibility of assay failure due to signature erosion. To provide clarity, an extensive glossary of defined terms is provided.

59 BASIC BIOLOGICAL SCIENCES↗

Plasma-Assisted Surface Nitridation of Proton Intercalatable WO 3 for Efficient Electrocatalytic Ammonia Synthesis

Electrocatalytic nitrogen reduction (eNRR) offers a green pathway for the production of NH 3 from N 2 and H 2 O under ambient conditions. Transition metal oxynitrides (TMO x N y ) are among the most promising catalysts but face challenges in achieving a high yield and faradaic efficiency (FE). This work develops a hybrid WO x N y /WO 3 catalyst with a unique heterogeneous interfacial complexion (HIC) structure. This design enables in situ generation and delivery of highly active hydrogen atoms (H*) in acidic electrolytes, promoting nitrogen hydrogenation and the formation of nitrogen vacancies (Nv) on the WO x N y surface. This significantly enhances the selectivity of eNRR for NH 3 synthesis while suppressing the hydrogen evolution reaction (HER). A simple two-step fabrication process─microwave hydrothermal growth followed by plasma-assisted surface nitridation─was developed to fabricate the designed catalyst electrode, achieving an NH 3 yield of 3.2 × 10 –10 mol·cm –2 ·s –1 with 40.1% FE, outperforming most TMN/TMO x N y electrocatalysts. Multiple control experiments confirm that the eNRR follows an HIC-enhanced Mars–van Krevelen (MvK) mechanism.

Catalysts↗

Development of a modeling toolbox for CORC cable performance evaluation

One critical, yet currently unknown aspect in the development process of CORC® cables is how current sharing around defects impact the overall performance of a cable design. Within the scope of this project, a simulation framework has been developed that is specialized on the quenching behavior and temperature rise around cable defects.

42 ENGINEERING↗

The FEWSION for Community Resilience (F4R) Process: Building Local Technical and Social Capacity for Critical Supply Chain Resilience

Local business leaders, policy makers, elected officials, city planners, emergency managers, and private citizens are responsible for, and deeply affected by, the performance of critical supply chains and related infrastructures. At the center of critical supply chains is the food-energy-water nexus (FEW); a nexus that is key to a community’s wellbeing, resilience, and sustainability. In the 21st century, managing a local FEW nexus requires accurate data describing the function and structure of a community’s supply chains. However, data is not enough; we need data-informed conversation and technical and social capacity building among local stakeholders to utilize the data effectively. There are some resources available at the mesoscale and for food, energy, or water, but many communities lack the data and tools needed to understand connections and bridge the gaps between these scales and systems. As a result, we currently lack the capacity to manage these systems in small and medium sized communities where the vast majority of people, decisions, and problems reside. This study develops and validates a participatory citizen science process for FEW nexus capacity building and data-driven problem solving in small communities at the grassroots level. The FEWSION for Community Resilience (F4R) process applies a Public Participation in Scientific Research (PPSR) framework to map supply chain data for a community’s FEW nexus, to identify the social network that manages the nexus, and then to generate a data-informed conversation among stakeholders. F4R was piloted and co-developed with participants over a 2-year study, using a design-based research process to make evidence-based adjustments as needed. Results show that the F4R model was successful at improving volunteers’ awareness about nexus and supply chain issues, at creating a network of connections and communication with stakeholders across state, regional, and local organizations, and in facilitating data-informed discussion about improvements to the system. In this paper we describe the design and implementation of F4R and discuss four recommendations for the successful application of the F4R model in other communities: 1) embed opportunities for co-created PPSR, 2) build social capital, 3) integrate active learning strategies with user-friendly digital tools, and 4) adopt existing materials and structure.

54 ENVIRONMENTAL SCIENCES↗

Sustainable hydrogen manufacturing via renewable-integrated intensified process for refueling stations

The widescale consumer adoption of hydrogen fuel cell electric vehicles (HFCEVs) is currently hindered by the high cost of small-scale hydrogen generation and the lack of extensive hydrogen refueling infrastructure. Natural gas-based hydrogen is cheaper when produced in large volumes but is also associated with high CO 2 emissions. To counter these challenges, we propose a hybrid approach where both natural gas and renewables are integrated in a synergistic manner using a dynamic process intensification technology that can be deployed on-site for meeting local demands of refueling stations. The technology is based on sorption enhanced steam methane reforming (SE-SMR) that utilizes a combination of reaction with in-situ CO 2 adsorption for enhancing process modularity, productivity and efficiency thereby outperforming conventional SMR at small scale. We develop a mixed integer linear programming (MILP)-based optimization framework for simultaneous design and scheduling of the SE-SMR process. The simultaneous optimization provides a synergistic combination whereby the renewables allow sustainable hydrogen manufacturing and the dynamic SE-SMR allows optimal use of the intermittency of the renewables. The U.S. nationwide analysis indicates that for futuristic renewable prices and a hydrogen production capacity of 2 ton/day, hydrogen can be produced at 50% less cost compared to the current cost of small-scale hydrogen generation. Finally, the city-wise analysis with varying hydrogen demand shows that even with just 5% HFCEV market penetration level, hydrogen production cost less than $3/kg can be obtained at small scales across the United States with even cheaper hydrogen for large cities.

08 HYDROGEN↗

Low-Cost Sulfur Thermal Storage for Solar Industrial Process Heat Applications

Industrial process heat (IPH) is one of the largest energy demands in U.S., representing about 10% of all domestic energy consumption. Fuel costs to generate this industrial process heat are generally a top three cost for industry, a major component in American manufacturing competitiveness. Roughly 60% of US IPH demand (about 6,500 TBtu annually) falls in the medium-temperature range of 100–250 °C. While concentrated solar thermal (CST) technologies can provide a cost-effective source of heat in this temperature range, solar intermittency limits their adoption in industries that operate 24/7. Element 16 Technologies, Inc. developed a low-cost sulfur thermal energy storage (TES) technology to bridge this gap by capturing excess solar heat during the day and dispatching it reliably during non-solar hours. The core innovation is the use of sulfur, an abundant, industrial waste byproduct that costs ten times less than molten salt used in commercial TES systems. The overall goal of the project was to advance the design and development of molten sulfur TES to a manufacturing-relevant prototype stage for solar industrial process heat applications, while establishing and validating a realistic pathway to commercial success. Key tasks included corrosion and mechanical durability testing to identify cost-effective materials, design investigations using physics-based simulation tools, techno-economic evaluations of system lifetime costs, and pilot-scale testing for performance verification. Corrosion testing of steel alloys under cyclic molten sulfur conditions showed that austenitic stainless steels in the 300 series performed particularly well, with no structural degradation of welds or joints. Thermal cyclic testing of pilot sulfur TES units up to 1.5 MWh quantified charge/discharge rates, heat losses, round-trip efficiency and validated the system's capability to operate effectively under intermittent charging conditions. A techno-economic model, informed by sulfur TES performance model validated using pilot test data, showed that hybrid solar+sulfur TES+NG boiler systems are economically competitive with incumbent natural gas boilers for multiple locations in the southwest US. In summary, this project established molten sulfur TES as a technically viable pathway to improve economic competitiveness of American manufacturing by lowering the cost of solar industrial process heat.

14 SOLAR ENERGY↗

Final Report – Cooperative Research and Development Agreement between National Energy Technology Laboratory and Praxair, Inc.

Praxair and DOE-NETL entered into a collaborative research and development agreement (CRADA) in March 2019 to evaluate economic viability of chemical looping processes for hydrogen, CO, and syngas production in comparison to state-of-the-art conventional processes. Praxair had developed process configurations for producing hydrogen and CO using chemical looping processes. NETL had modeling and system design experience for the chemical looping reactor system. The goal for NETL is to provide performance and design information regarding the chemical looping portion of a potential commercial plant. Praxair’s goal is to evaluate chemical looping processes and try to identify a process that can be commercially relevant within a few years. A key to success for the program will be to develop a chemical looping reactor system that enables significant capital cost reduction and performance improvement for the overall process. This report describes chemical looping-based CO production process, chemical looping reactor system and oxygen carrier material as well as summary of technoeconomic analysis results. Also included in the report are a list of assumptions that were used for designing the chemical looping plant and a list of areas for further study required to validate some of these assumptions in future efforts. The initial goal was to design two chemical looping plants. Case 1 would produce 1 MM scfd Hydrogen from NG, and Case 2 would co-produce hydrogen and 5 MM scfd CO from NG. However, later in the collaboration, it was decided to drop Case 1 as Case 2 process already included hydrogen production.

Bayham, Samuel↗

Autonomous Fueling System for Heavy-Duty Fuel Cell Electric Trucks

The motivation for this project stemmed from the challenges associated with rapidly refueling heavy-duty hydrogen fuel cell electric trucks (FCETs). Current manual refueling processes for fast refueling involve large, heavy equipment (e.g., hoses three times heavier than standard) and pose ergonomic risks and potential for equipment damage. The goal was to develop and test an autonomous fueling system to improve ergonomics, enhance safety, increase equipment durability through design improvements, and potentially speed up the fueling process. This project aimed to add to the understanding of autonomous systems in the context of heavy-duty hydrogen refueling, evaluating the technical effectiveness of potential concepts. A successfully developed system would benefit the public by facilitating the adoption of zero-emission heavy-duty transport, reducing reliance on manual labor for a physically demanding task, and potentially improving the safety and efficiency of hydrogen refueling infrastructure. The major accomplishment during the project's active period was the completion of the system-level architecture task. This involved establishing a detailed list of system requirements covering interfaces, environmental conditions, regulatory compliance, industry standards, safety, security, performance capabilities, and optional features. Five key use cases for the autonomous system were also identified. However, due to internal restructuring at Nikola, the necessary resources could not be allocated to continue the project. Consequently, Nikola opted to discontinue the project. The award was mutually terminated by Nikola and the DOE.

08 HYDROGEN↗

A Novel Algorithm for CAD to CSG Conversion in McCAD

Modeling and simulation lie at the heart of the design process of any nuclear application. An accurate representation of the radiation environment ensures not only the feasibility of new technologies, but it also aids in operation, maintenance, and even decommissioning. With increasingly complex designs, high-fidelity models have become a necessity for design maturity. McCAD has been under development for many years at Karlsruhe Institute of Technology (KIT) to facilitate the process of generating suitable models for nuclear analyses. In this paper, an overview of the major advances in the new version of the code is presented. A novel conversion algorithm has proven to be robust in significantly reducing the processing time to generate radiation transport models, making it easier to iterate on design details. A first-of-a-kind capability to generate hierarchical void cells is also discussed with preliminary analysis showing performance gains for particle tracking.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Advancing Agrivoltaic Modeling With ADAM

Designing an agrivoltaic system presents a complex set of tradeoffs around PV system configuration, resulting performance, agricultural needs, and system economics. Developing tools for agrivoltaic analysis can assist system designers when making decisions related to these tradeoffs. We are developing the Agrivoltaics Design and Analysis Model (ADAM) as a free, publicly available web tool for agrivoltaics economics analysis. Features of ADAM include automated calculations for available agrivoltaic cropland, user-friendly configuration changes, inter-row irradiance calculations, and integrated economic modeling of energy and non-energy revenues. We will discuss the iterative process of agrivoltaic tool development including tradeoffs between accuracy and uncertainty, feature prioritization, and ease of use driven by our multi-disciplinary stakeholder design process. Finally, we will share modeling results from existing agrivoltaics systems as a preliminary case study.

14 SOLAR ENERGY↗

U.S. Domestic Small Modular Reactor Security by Design

U.S. nuclear power facilities face increasing challenges in meeting evolving security requirements caused by evolving and expanding threats while keeping cost reasonable to make nuclear energy competitive. The addition of security features after a facility has been designed and without attention to optimization (the past approach) can lead to cost overruns. Incorporating security in the design process can provide robust, cost effective, and sufficient physical protection systems. The purpose of this work is to develop a framework for the integration of security into the design phase of Small Modular Reactors (SMRs) and the use of modeling and simulation tools to optimize the design of physical protection systems. This effort will intend to integrate security into the design phase of a model SMR that meets current NRC physical protection requirements and provide advanced solutions to improve physical protection and decrease costs. A suite of tools, including SCRIBE3D, PATHTRACE and Blender were used to model a hypothetical generic domestic SMR facility. Physical protection elements such as sensors, cameras, portal monitors, barriers, and guard forces were added to the model based on best practices for physical protection systems. One outsider sabotage scenario was examined with 4-8 adversaries to determine security metrics. This work will influence physical protection system designs and facility designs for U.S. domestic SMRs. The purpose of this project is to demonstrate how a series of experimental and modeling capabilities across the Department of Energy Complex can impact the design of U.S. domestic SMRs and the complete Safeguards and Security by Design (SSBD) for SMRs.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Custom Equipment Development for Processing of Surplus Plutonium

Facilities and Material • Location: Savannah River Site K-Area, South Carolina • Plutonium designated as surplus is blended with adulterant material, re-packaged and shipped to WIPP in New Mexico • Currently one operational glovebox for downblending, facility modifications and construction of three additional glovebox lines in progress • Current operations are highly manual requiring full PPE and reader/worker steps

Krementz, Daniel [Savannah River National Laborato↗

Innovative rail transport of a supersized land-based wind turbine blade

Wind turbine blade logistic providers are being challenged with escalating costs and routing complexities as one-piece blade approach lengths of 75 m in various regions of the U.S. land-based market. New lower cost solutions are needed to enable further reductions in the levelized cost of energy (LCOE) and continued market expansion. In this paper, a novel method of using existing U.S. rail infrastructure to deploy 100-m, one-piece blades to U.S. land-based wind sites is numerically investigated. The study removes the constraint that blades must be kept rigid during transport, and it allows bending to keep blades within a clearance profile while navigating horizontal and vertical curvatures. Novel system optimization and blade design processes consider blade structural constraints and rail logistic constraints in parallel to develop a highly flexible, rail-transportable blade. Results indicate maximum deployment potential in the Interior region of the United States and limited deployment potential in other regions. The study concludes that innovative rail transportation solutions combined with advanced rotor technologies can provide a feasible alternative to segmentation and support continued LCOE reductions in the U.S. land-based wind energy market.

17 WIND ENERGY↗

Flattening the Radial Temperature Profile across the Transformational Challenge Reactor Core

The Transformational Challenge Reactor (TCR) program is demonstrating an agile development approach to advanced nuclear reactor design, which has traditionally utilized a linear design process. In leveraging artificial intelligence, additive manufacturing, advanced materials, and cutting-edge modeling and simulation, the TCR program aims to minimize the high cost and lengthy deployment timelines now standard in the nuclear industry. Within a relatively short period of time, a robust and mature advanced gas-cooled reactor was iteratively designed under the TCR program, using these cutting-edge technologies. The TCR is a 3 MWt gas-cooled microreactor fueled with uranium nitride (UN) tristructural isotropic (TRISO) fuel particles. Though manufactured via traditional means, these UN TRISO particles are loaded into additively manufactured silicon carbide (SiC) cans [4]. Once loaded with TRISO particles, the SiC cans are densified using a chemical vapor infiltration process. The additively manufactured SiC enables significantly more freedom in the design of the fuel form than could ever be achieved using traditionally manufactured SiC. The helium coolant, pressurized to 5 MPa, enters the core at 300°C and nominally exits it at 500°C. Typically, the most thermally limiting components in any reactor design are the fuel assemblies in the core center. To provide a wide thermal margin in these central fuel assemblies, the flow may be biased toward the center of the core to more effectively cool these fuel assemblies with more power deposition and flatten the core’s radial temperature distribution. An analytical fluid model of the TCR core was developed to explore methods for biasing the flow away from the cooler outer fuel assemblies and towards the hotter inner ones. Higher-fidelity models developed in STAR-CCM+ 2020.3.1, a computational fluid dynamics code, were then utilized to verify the analytical model’s findings.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Techno-economic design of a linear Fresnel reflector for industrial process heat

A techno-economic model of a Concentrating Solar Thermal (CST) system using a Linear Fresnel Reflector (LFR) has been developed. LFRs can deliver process heat suitable for a range of industries, including food and beverage production. This model uses an adaptive algorithm to calculate the optimal secondary reflector shape given the geometry and optical properties of the rest of the system. A ray-tracing program is used to calculate optical efficiency over a wide range of longitudinal and transversal incidence angles and subsequently evaluate the annual efficiency at a given geographical location. A specific LFR design developed by Hyperlight Energy was modelled, and this industrial partner provided a detailed cost breakdown which was used as the basis of an economic model. Combining the technical and economic data facilitates the calculation of the Levelized Cost of Heat (LCOH). The influence of a number of parameters on the annual efficiency and LCOH is explored; notable parameters include the absorber height, the number, width, and spacing of the primary mirrors, the aim point, and the secondary reflector shape and width. By identifying an optimal combination of these parameters, we reduce the LCOH of the industry partner’s system design by 9.2%, from 14.4 $\$/MWh_{th}$ to 13.0 $\$/MWh_{th}$. In comparison, the LCOH of a natural gas boiler delivering the same annual quantity of heat is 29 $\$/MWh_{th}$, which indicates that LFRs can be a competitive heat source for industrial processes.

14 SOLAR ENERGY↗

Development of Self-Assembly Supports Enabling Transformational Membrane Performance for Cost-Effective Carbon Capture

This final technical report describes work conducted by Membrane Technology and Research, Inc. (MTR) for the U.S. Department of Energy (DOE), National Energy Technology Lab (NETL) on the development of membranes with transformational performance for carbon capture under award number DE-FE0031596. The work was performed from June 1, 2018 through May 31, 2024. For more than a decade, MTR has worked in partnership with DOE to develop an innovative membrane-based CO 2 capture process. This effort has included the first test of membrane modules with coal-fired flue gas at the Arizona Public Services (APS) Cholla plant in 2010; the accumulation of >11,000 hours of flue gas operation for Polaris modules on a bench-scale 1 tonne/day (TPD) system at the National Carbon Capture Center (NCCC); scale-up of first-generation (Gen-1) Polaris to a 20 TPD small pilot system, and successful operation of this system on a flue gas slipstream at NCCC and in integrated boiler testing at Babcock & Wilcox (B&W). Through continued development efforts, a second-generation (Gen-2) version of the Polaris membrane has been scaled-up to pilot production. This membrane offers 70% higher CO 2 permeance with similar selectivity to the base case Polaris. MTR also developed planar modules designed specifically for the low-pressure, high-volumetric flow rate process conditions of flue gas operation. These new modules have significantly lower pressure-drop values compared to the type originally used (spiral-wound modules), which results in significant energy savings. The goal of the work described in this report was to improve on the Polaris Gen-2 membrane with the ultimate aim to reduce the cost of carbon capture. The majority of the effort was to develop improved support membranes for the multi-layer composite structure of MTR’s Polaris membrane. Earlier work at MTR had identified the support structure as limiting membrane permeances, not because the support itself represents a permeation resistance, but because the distribution of pores at the surface of the support imposes a geometric restriction to diffusion in the layers above it. Support membranes were prepared from a range of polymers, including commercially available block copolymers and a custom synthesized block copolymer alternative. The best support membranes developed in this project reduced the geometric restriction by a factor of two to three. These supports then were used to produce Polaris composite membranes with improved permeances. The second topic was to create a high-selectivity version of the Polaris membrane. The high-selectivity version uses a novel selective polymeric material and high selectivities were confirmed in experiments at MTR. The material is not easily made into very thin films. Consequently, the permeances are significantly lower than the Polaris Gen-2 membrane. The utility of this membrane is therefore limited to the carbon dioxide purification step that produces liquid CO 2 . A Technical and Economic Analysis (TEA) was performed for a carbon capture system that uses both advanced membrane types. The TEA shows the novel advanced membranes reduce the cost of capture by 10%, from $63.32/tonne CO 2 to $56.90/tonne CO 2 (2022 USD). Most of the development work was carried out with laboratory-scale casting and coating equipment. A number, but not all, of the improvements identified have been implemented on commercial-scale manufacturing equipment. The focus of future work at MTR is to incorporate the advancements made into the Polaris membrane manufacturing process.

01 COAL, LIGNITE, AND PEAT↗