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At least 415 records · Page 23

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↗

Case study on the novel permitting and authorization of PacWave South, a US grid-connected wave energy test facility: Development, challenges, and insights

Marine energy (i.e., energy from waves, tides, currents, and rivers) in the United States is a nascent industry. In particular, permitting processes—an uncertainty for industry advancement that can be costly and time consuming to navigate—have rarely been tested and used for marine energy. The novelty of the marine energy industry and utilization of open ocean permitting processes that were not originally developed for marine energy have led to extensive efforts to gain consensus amongst state and federal regulatory agencies to authorize marine energy projects. In 2021, Oregon State University successfully completed permitting of a wave energy test facility, called PacWave South, off the coast of Oregon, which is designed to advance wave energy research and development. This article documents the multi-year process that Oregon State University used to receive federal and state authorization for a pre-permitted commercial-scale grid connected facility by detailing the development of the test facility, management of uncertainty and challenges, and key decisions. The PacWave South case study provides insights for the larger marine energy community as the industry advances towards commercialization.

16 TIDAL AND WAVE POWER↗

Adaptive Power System Emergency Control using Deep Reinforcement Learning

Power system emergency control is generally regarded as the final safety net for grid security and resiliency. Existing emergency control schemes are usually designed off-line based on either the conceived “worst” case scenarios or a few typical operation scenarios. These schemes are facing significant adaptiveness and robustness issues as increasing uncertainties and variations occur in modern electrical grids. To address these challenges, for the first time, this paper proposes a novel adaptive emergency control scheme using deep reinforcement learning (DRL), by leveraging the high-dimensional feature extraction and non-linear generalization capabilities DRL has for complex systems with high-dimensional variations. Furthermore, an open-source platform named DeepGrid has been designed for the first time to assist the DRL development and benchmarking processes in power system emergency control. Details of the platform, DRL, and emergency control schemes that use dynamic braking or under-voltage load shedding are presented. Extensive case studies performed in both two-area four-machine system and IEEE 39-Bus system have demonstrated the excellent performance and robustness of the proposed schemes.

Deep reinforcement learning, emergency control, lo↗

A Stochastic Reduced-Order Model for Statistical Microstructure Descriptors Evolution

Integrated computational materials engineering (ICME) models have been a crucial building block for modern materials development, relieving heavy reliance on experiments and significantly accelerating the materials design process. However, ICME models are also computationally expensive, particularly with respect to time integration for dynamics, which hinders the ability to study statistical ensembles and thermodynamic properties of large systems for long time scales. To alleviate the computational bottleneck, we propose to model the evolution of statistical microstructure descriptors as a continuous-time stochastic process using a non-linear Langevin equation, where the probability density function (PDF) of the statistical microstructure descriptors, which are also the quantities of interests (QoIs), is modeled by the Fokker–Planck equation. In this work, we discuss how to calibrate the drift and diffusion terms of the Fokker–Planck equation from the theoretical and computational perspectives. The calibrated Fokker–Planck equation can be used as a stochastic reduced-order model to simulate the microstructure evolution of statistical microstructure descriptors PDF. Considering statistical microstructure descriptors in the microstructure evolution as QoIs, we demonstrate our proposed methodology in three integrated computational materials engineering (ICME) models: kinetic Monte Carlo, phase field, and molecular dynamics simulations.

97 MATHEMATICS AND COMPUTING↗

Optimization of WAAM Process to Produce AUSC Components with Increased Service Life

Additive manufacturing has the potential to revolutionize industrial hardware and unlock efficiency gains through the fabrication of geometries and architectures not possible by conventional processing. Wire Arc Additive manufacturing (WAAM) process is a class of directed energy deposition process enabling higher build rate and allowing custom wire feedstock allowing spatial variation of microstructure. The larger spot size and lower speed creates a larger melt pool, reducing residual stress and often time creating directional/columnar microstructure for Ni-superalloy. The use of flexible platform provides freedom in deposition strategy, which can accommodate complex substrates, including feature addition onto existing structures, non-flat layers, and repair methods. However, the certification of the final component needs to match the strength requirement. Hence, the quality of the component produced is stringently monitored to avoid buildup of residual stress, cracks, porosity and to reduce detrimental segregated phases commonly observed during alloy solidification. Simulation plays a huge role in predicting the melt pool dimension and can be used to optimize the process parameter. Similar development is also required to perform physics-based modeling of microstructural development in WAAM that can predict the microstructural features during solidification and can be used to optimize the process more effectively. To move toward this goal, Raytheon Technologies Research Center together with Siemens worked to create a set of computational tools to control the process parameters, enable on-line measurements and acquisition with feedback to the optimized process parameters, and eventually track material evolution through each step of the additive process. Computational fluid dynamics is used for accurate prediction and calibration of the thermal field during WAAM process. and phase field models for microstructure evolution as a function of processing parameters to establish a connection between additive parameters and the final microstructure. Here we report cellular automata (CA) model development to predict the dendritic microstructure evolution with surface and bulk nuclei for single track and multiple layers. The CA model was developed to account for secondary element addition and predict segregation, local melting, and latent heat release as well as prediction of Euler angles from orientation information and validated against experiments. This framework was utilized to tailor spatially-varying composition in a part by appropriately controlling the microstructure evolution during the additive process. Functionally graded Haynes 282 alloy with high Cr content at the surface was tested for oxidation and mechanical properties. An advanced physics-based reaction-diffusion model predicting the simultaneous creation of chromium oxide and alumina is developed and validated to extend life expectancy of the WAAM manufactured high temperature part. A machine-learning data-driven framework establishing the process-structure relationship from a dataset of real microstructure images and corresponding process history data has been developed and implemented in the NX Siemens design system. The digital twin configuration along with the tool path generation enabled prediction of WAAM component buildup time and the techno-economic analysis provided a favorable option for all 4 cases with 15-40% cost reduction.

33 ADVANCED PROPULSION SYSTEMS↗

Small Hydropower Interconnection: Decision Support Tool User Guide

The Small Hydropower Interconnection Decision Support Tool is designed to provide specific information to small hydropower developers about the interconnection process. Developers follow this user guide to understand the general process; the Small Hydropower Interconnection Tool accompanies this user guide and provides specific knowledge of the processes and costs pertinent to specific locations.

13 HYDRO ENERGY↗

AMPPED LDRD: Advanced Models of the Physics & Phenomena of Electrical Discharge.

This Laboratory Directed Research and Development (LDRD) project aimed at addressing an unmet need for physics-based models that enable prediction of electrical breakdown in the presence of high voltage gradients and real-world environments. This project focused on understanding coupled plasma-surface feedback phenomena critical to electrical discharge processes and design of breakdown voltages, breakdown times, and breakdown paths. New secondary electron emission and coupled plasma-surface measurement methods and models were developed. Highly reproducible discharge experiments were developed to provide current-voltage data as a function of time, and methods were developed to condition electrodes for predictable discharge. To assess plasma-surface feedback mechanisms, new surface physics capabilities, including measurement systems for local and global photoemission yield and ion-induced secondary electron emission yield were developed. Discharge models were developed to incorporate these yields for predicting discharge behavior to understand influence of surface physics on discharge current and time evolution, and methods to accelerate these simulations were demonstrated. A key finding was that the initiation process of a non-vacuum discharge appears highly dependent on photoemission at the cathode. Advanced diagnostics were developed, including spatial electrical field imaging, spectroscopy of plasmas, and high-speed imaging of discharge event s in metal and dielectric environments. These diagnostics and improved electrical models are a step toward enabling quantitative design margins, assurance of safety architectures, and implementation of novel materials and technologies for wide ranging energy and electronics applications.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Therapeutic Targeting of LIF Overcomes Macrophage-mediated Immunosuppression of the Local Tumor Microenvironment

Abstract Purpose: Leukemia inhibitory factor (LIF) is a multifunctional cytokine with numerous reported roles in cancer and is thought to drive tumor development and progression. Characterization of LIF and clinical-stage LIF inhibitors would increase our understanding of LIF as a therapeutic target. Experimental Design: We first tested the association of LIF expression with transcript signatures representing multiple processes regulating tumor development and progression. Next, we developed MSC-1, a high-affinity therapeutic antibody that potently inhibits LIF signaling and tested it in immune competent animal models of cancer. Results: LIF was associated with signatures of tumor-associated macrophages (TAM) across 7,769 tumor samples spanning 22 solid tumor indications. In human tumors, LIF receptor was highly expressed within the macrophage compartment and LIF treatment drove macrophages to acquire immunosuppressive capacity. MSC-1 potently inhibited LIF signaling by binding an epitope that overlaps with the gp130 receptor binding site on LIF. MSC-1 showed monotherapy efficacy in vivo and drove TAMs to acquire antitumor and proinflammatory function in syngeneic colon cancer mouse models. Combining MSC-1 with anti-PD1 leads to strong antitumor response and a long-term tumor-free survival in a significant proportion of treated mice. Conclusions: Overall, our findings highlight LIF as a therapeutic target for cancer immunotherapy.

Oncology↗

Tunable Permanent Magnet Quadrupole Operating at Cryogenic Temperatures for Accelerators

The project objective is to develop a compact and tunable quadrupole using Electron Energy Corporation (EEC)’s PM materials for cryogenic accelerator applications. To achieve this objective, EEC and SLAC National Accelerator Laboratory (SLAC) will collaborate to develop a cost-effective quadrupole and optimize the conventional manufacturing process. Based on previous experience, EEC designed an innovative field adjustment capability using tuning magnets which is able to achieve all the requirements for SLAC’s cold copper collider (C3 ) application. These novel ideas enable us to develop a compact and tunable quadrupole magnet superior to the current designs. Our approach is to leverage EEC's over 50 years of experience in magnet manufacturing and SLAC’s beamline test capabilities.

42 ENGINEERING↗

2024 OES-Environmental 2024 State of the Science Report, Chapter 5: Stakeholder Engagement for Marine Renewable Energy

Stakeholder engagement is a critical piece of any new development project that affects public or private interests. Effective, thoughtful engagement and participatory activities early in the planning process of a project can help planners and project developers understand local concerns, adjust designs to avoid negative environmental impacts, select the best site for a project, answer questions, reduce delay, enhance opportunities and benefits, and build support for a project (Cuppen et al. 2016; Portman 2009; Wiersma & DevineWright 2014). On the other hand, cursory or inadequate engagement that is viewed as “checking the box” or tokenism is unlikely to be effective, and can result in project failures, diminished trust, strong opposition, or costly, drawn-out processes (Butcher & MacLennan 2020; Garard & Kowarsch 2017; Gill & Rand 2022; Jolivet & Heiskanen 2010; Pizzi et al. 2021; Sterling et al. 2017).

16 TIDAL AND WAVE POWER↗

Start-up of Silo 130 Waste Retrieval at La Hague: first Step Towards Reducing Legacy Inventory - 20020

On June 25, 2019, the first grapple of waste and debris was lifted from Silo 130, one of the most challenging legacy waste storage silos at La Hague. This was the achievement of more than ten years of studies and efforts focused on solving some very unique technical and safety challenges, and on designing an innovative, efficient solution. The waste is from de-cladding materials from past Gas-Cooled Reactor fuel reprocessing operations. It is an unsorted mixture of magnesium cladding pieces, graphite debris, and various other metallic waste types. These materials can be chemically reactive and therefore need specific dispositions for handling and storing. The building is more than 40 years old and does not meet modern standards. French safety authorities have required the silo to be emptied. After about three years of operation, the bulk of this waste will be removed and placed in safe storage, pending the selection of a final conditioning solution. Removal of bottom debris will then be possible. When finished, this operation will bring a conclusion to a significant legacy-related hazard on the site. The silo will then be available for final cleaning and de-activation. This paper will describe the technical, safety, and economical challenges, and the various decisions and optimizations that led to the definition of the process and technology to be implemented. Several innovative features were developed and implemented, in all sections of the project: project organization, progressive approach for the waste disposition strategy, light building design, customized and robust retrieval technology, processing technologies involving the most modern robotic and sorting techniques, storage method... Several of these first-of-a-kind innovative features have been developed and qualified specifically for this application, using the detailed qualification procedure specified for all La Hague projects. The facility was built in less than five years, overcoming various difficulties along the line. Commissioning is now finished with the combined efforts of the project, engineering, start-up, and operating teams assisted by dedicated suppliers. The facility is now ramping-up. The paper will also report on the commissioning and start-up of the facility and describe the first operational results. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Design, Construction, and Testing of 0.5-m, 18-mm Period Nb 3 Sn Superconducting Undulator Magnets

We report design and fabrication of a new Nb 3 Sn-based superconducting undulator (SCU) are underway at the Advanced Photon Source (APS) of Argonne National Laboratory in collaboration with Fermilab and Lawrence Berkeley National Laboratory. To develop a robust and reliable fabrication process, the magnet development consists of several steps. First, magnetic and mechanical simulations were performed to optimize the magnet design; then, the design matured further by fabricating and testing a series of very short prototypes, ~8 cm long with a period length of 18 mm. These short prototype studies were previously reported. Second, the design was scaled to an intermediate length of ~0.5 m. These two steps led to the final design of ~1.1–m-long magnets, which are currently being fabricated. The quench behavior of each 0.5-m-long undulator magnet, as well as undulator assemblies from these magnets, was studied. The first SCU magnet assembly did not meet the design specifications due to the breakdown of the insulation. With an improved design and fabrication process based on lessons learned, the second SCU assembly achieved the design undulator field of 1.2 T. The design was further optimized, and the third set of magnets was fabricated and successfully tested.

43 PARTICLE ACCELERATORS↗

U.S. Domestic Pebble Bed Reactor: Security-by-Design

U.S. nuclear power facilities face increasing challenges in meeting dynamic security requirements caused by evolving and expanding threats while keeping cost reasonable to make nuclear energy competitive. The past approach has often included implementing security features after a facility has been designed and without attention to optimization, which 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 both to develop a framework for the integration of security into the design phase of High Temperature Gas Reactors (HTGRs) that utilize pebble-based fuels and increase the use of modeling and simulation tools to optimize the design of physical protection systems. Specifically, this effort focuses on integrating security into the design phase of a model HTGR that meets current Nuclear Regulatory Commission (NRC) physical protection requirements and providing 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 HTGR facility. Physical protection elements such as sensors, cameras, barriers, and guard forces were added to the model based on best practices for physical protection systems. Multiple outsider sabotage scenarios were examined with four-to eight adversaries to determine security metrics. The results of this work will influence physical protection system designs and facility designs for U.S. domestic HTGRs. This work will also demonstrate how a series of experimental and modeling capabilities across the Department of Energy (DOE) Complex can impact the design of and complete Safeguards and Security by Design (SSBD) for SMRs. The conclusions and recommendations in this document may be applicable to all SMR designs.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

U.S. Domestic Microreactor Security-by-Design

U.S. nuclear power facilities face increasing challenges in meeting dynamic security requirements caused by evolving and expanding threats while keeping cost reasonable to make nuclear energy competitive. The past approach has often included implementing security features after a facility has been designed and without attention to optimization, which 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 both to develop a framework for the integration of security into the design phase of a microreactor and increase the use of modeling and simulation tools to optimize the design of physical protection systems. Specifically, this effort focuses on integrating security into the design phase of a model microreactor that meets current Nuclear Regulatory Commission (NRC) physical protection requirements and providing 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 microreactor facility. Physical protection elements such as sensors, cameras, barriers, and guard forces were added to the model based on best practices for physical protection systems. Multiple outsider sabotage scenarios were examined with four-to-eight adversaries to determine security metrics. The results of this work will influence physical protection system designs and facility designs for U.S. domestic microreactors. This work will also demonstrate how a series of experimental and modeling capabilities across the Department of Energy (DOE) Complex can impact the design of and complete Safeguards and Security by Design (SSBD) for microreactors. The conclusions and recommendations in this document may be applicable to all microreactor designs.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

U.S. Domestic Security-by-Design: On Site Response Force Strategies

U.S. nuclear power facilities face increasing challenges in meeting dynamic security requirements caused by evolving and expanding threats while keeping cost reasonable to make nuclear energy competitive. The past approach has often included implementing security features after a facility has been designed and without attention to optimization, which 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 both to develop a framework for the integration of security into the design phase of High Temperature Gas Reactors (HTGRs) that utilize pebble-based fuels and microreactors. Specifically, this effort focuses on integrating security into the design phase of a model HTGR and microreactor that meets current Nuclear Regulatory Commission (NRC) physical protection requirements and providing 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 HTGR facility and microreactor facility. Physical protection elements such as sensors, cameras, barriers, and onsite response forces were added to the model based on best practices for physical protection systems. Multiple outsider sabotage scenarios were examined with four-to-eight adversaries to determine security metrics. The results of this work will influence physical protection system designs and facility designs for U.S. domestic HTGRs and microreactors. This work will also demonstrate how a series of experimental and modeling capabilities across the Department of Energy (DOE) Complex can lead to efficient security systems that utilize an onsite response force. The conclusions and recommendations in this document may be applicable to all SMR designs.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

U.S. Domestic Molten Salt Reactor: Security-by-Design

U.S. nuclear power facilities face increasing challenges in meeting dynamic security requirements caused by evolving and expanding threats while keeping costs reasonable to make nuclear energy competitive. The past approach has often included implementing security features after a facility has been designed and without attention to optimization, which can lead to cost overruns. Incorporating security in the design process can provide robust, economical, and effective physical protection systems (PPS). The purpose of this work is both to develop a framework for the integration of security into the design phase of a molten salt reactor (MSR) and show how to effectively design a PPS with a reduced staffing headcount. Specifically, this work focuses on integrating PPS design features into a developed facility layout by making minor modifications to building structures. A suite of tools, including Scribe3D©, PathTrace©, and Blender©, were used to model a hypothetical, generic domestic MSR facility. Physical protection elements such as sensors, cameras, barriers, and responders were added into the model based on defending the hypothetical MSR facility against a hypothetical design basis threat (DBT). Multiple outsider sabotage scenarios were examined, with adversary team sizes ranging from 4–8 to determine security system effectiveness. The results of this work will influence PPS designs and facility designs for U.S. domestic MSRs. This work will also demonstrate how a series of experimental and modeling capabilities across the Department of Energy (DOE) complex can impact the design and completion of security-by-design (SeBD) for small modular reactors (SMRs). The conclusions and recommendations in this document may be applicable to all SMR designs.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

AEOLUS: Advances in Experimental Design, Optimal Control, and Learning for Uncertain Complex Systems

The AEOLUS Center is dedicated to developing a unified optimization-under-uncertainty framework for (1) learning predictive models from data and (2) optimizing experiments, processes, and designs governed by these models, all driven by complex, uncertain energy systems. AEOLUS addressed the critical need for principled, rigorous, scalable, and structure-exploiting capabilities for exploring parameter and decision spaces of complex forward simulation models---the so-called outer loop. This report summarizes the work done under DE-SC0021077 on (1) nonlocal models for solidification problems, (2) a multifidelity method for a nonlocal diffusion model, and (3) multifidelity Monte Carlo methods.

97 MATHEMATICS AND COMPUTING↗