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At least 433 records · Page 24

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DOE OSTI2025

Operation of helium sub-atmospheric multistage cryogenic centrifugal compressor trains: Part 2 – Transient modeling and pump-down path selection

Low-pressure conditions required for operation of helium cryogenic systems below the normal boiling point (i.e. 4.2 K) are established through a transient process, commonly referred to as ‘pump-down’. This process is defined as the transition from pressures above atmospheric conditions to the saturation pressure which corresponds to a specified operational temperature. The FRIB 2 K system consists of five cryogenic centrifugal compressors which are operated in series. Historically, the pump-down process path has been established through empirical methods and system operator experience. Investigation into the pump-down process at FRIB aimed to develop a pump-down methodology which relies on theoretical model predictions rather than empirically developed process paths. Ensuring stable operation during the pump-down process involved application of a centrifugal compressor performance prediction model, which is described in Part 1 of this paper. Compressor performance maps can be directly used to evaluate the stability of a selected pump-down path and anticipate the overall reliability of the selected path. In conjunction with the compressor performance maps, a system pressure model was developed to estimate the transient pressure response during the pump-down process. Lastly, an explicit equation was developed to establish a mass flow rate profile for the pump-down process. Implementation of the presented methodology (including the developed models) allows for the system operator to determine a continuous pump-down path which maintains compressor stability while conforming to overall system capabilities. Altogether, the methodology presented has resulted in simplification of transient pump-down operations and increased the reliability, stability and efficiency of the pump-down process.

Compressor train control↗

DOE OSTI2024

Enhancing Short-Term Flexibility through Characterization of HVDC Transmission Systems

Efficient power grid operation hinges on maintaining safety and reliability through adaptable system flexibility standards. However, in a future power grid characterized by extensive renewable energy integration, conventional system flexibility and predetermined requirements may falter under extreme conditions. This paper addresses the formidable challenge of sustaining secure and dependable power grid operations under these circumstances, emphasizing the role of controllable high voltage direct current (HVdc) transmission systems in amplifying overall system flexibility and tackling operational complexities. To quantitatively assess short-term flexibility and its associated economic benefits from HVdc within specific regions, we propose a Power Flow Distribution Factors (PTDFs) based approach. This methodology takes into account both dispatchable generators and HVdc systems, pinpointing their contributions. Through an analysis of the Western Electricity Coordinating Council (WECC) system, we demonstrate the practical application of this approach to scrutinize the impacts of existing and future HVdc lines.

Operational Flexibility, Multi-terminal HVdc, tran↗

DOE OSTI2024

Extraordinary frequency stabilization by resonant nonlinear mode coupling

Here, we show that a self-sustained oscillator with a frequency-selective element operating with two nonlinearly coupled modes can achieve a level of frequency stability well beyond that available using single-mode operation. The system of interest consists of a self-sustained oscillator based on a nonlinear primary mode that is coupled via an internal resonance to a passive secondary mode. Analysis of a generic model for this resonance with both additive and multiplicative noises reveals that the stability improvements accrue from two sources: (i) nonlinear frequency veering in the primary mode, a classical analogue to quantum-level repulsion, that eliminates amplitude-to-frequency noise conversion; and (ii) phase cleaning of the oscillator through an intrinsic phase constraint arising from synchronization of the modes. This latter effect can significantly reduce the effects of intrinsic frequency fluctuations of the primary mode, which are not accessible by any known strategy using single-mode operation. The theoretical predictions are supported by experimental measurements of a microelectromechanical systems-based oscillator that demonstrate a reduction in oscillator line width of several orders of magnitude. This approach offers a means of optimizing frequency stability in self-sustained oscillators, which has direct implications for applications in timekeeping and sensing.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Effect of pyrolysis operating conditions on the catalytic co‐pyrolysis of low‐density polyethylene and polyethylene terephthalate with zeolite catalysts

Abstract In this study, the catalytic (co‐)pyrolysis of low‐density polyethylene (LDPE) and polyethylene terephthalate (PET) with HZSM‐5 and HY zeolite catalysts was conducted in a micro‐pyrolysis reactor coupled to a two‐dimensional gas chromatography system. Pyrolysis operating conditions, such as the pyrolysis temperature, the catalyst to feedstock (CF) ratio, and the LDPE:PET ratio, were varied. It was found that for the co‐pyrolysis of LDPE and PET, HZSM‐5 led to higher yields of C2‐C4 olefins and monoaromatic products. Lower CF ratios increased the yield of C2‐C4 olefins for LDPE pyrolysis, but decreased benzene yield for PET pyrolysis, concomitant with an increased yield in benzoic acid. A lower temperature of 400°C which was sufficient for the pyrolysis of LDPE, led to incomplete conversion of PET. Surface response diagrams were used to visualize the impact of the various pyrolysis operating conditions on the yield of C2‐C4 olefins and BTEX, which serve as target products for the circular economy.

Okonsky, Sean Timothy↗

DOE OSTI2024

Report on Initial Sodium Testing on the Thermal Hydraulic Experimental Test Article (THETA) (Fiscal Year 2024 Final Report)

The Thermal Hydraulic Experimental Test Article (THETA) is a facility that is used to develop sodium components and instrumentation as well as to acquire experimental data for validation of reactor thermal hydraulic and safety analysis codes. The facility simulates nominal thermal hydraulic conditions as well as protected/unprotected loss of flow accidents in a sodium-cooled fast reactor (SFR). High fidelity distributed temperature profiles of the developed flow field may be acquired with Rayleigh backscatter based optical fiber temperature sensors. The facility was designed in partnership with systems code experts to tailor the experiment to ensure the most relevant and highest quality data for code validation. THETA is comprised of a traditional primary coolant and secondary coolant system. The primary system is submerged in the pool of sodium and consists of a pump, electrically heated core, intermediate heat exchanger, and connected piping and thermal barriers (redan). The secondary system, located outside of the sodium pool, consists of a pump, sodium to air heat exchanger, and connected piping and valves. In fiscal year 2023, thermal stratification tests were completed with the primary system online, while the secondary system was being constructed [1]. These tests had shown that the core barrel and intermediate heat exchanger (IHX) outlet required increased thermal insulation. The THETA primary system was removed from METL, cleaned, thermal insulators installed, and then inserted into METL Test Vessel 4. At the time of this writing the THETA primary and secondary system are operational. During this fiscal year 100+ hours of testing was completed to characterize thermal hydraulic phenomena associated with steady state and transient conditions in a pool type liquid metal cooled reactor. A majority of the testing campaign was completed to satisfy the experimental data acquisition requirements for the GAIN Voucher with Oklo, CRADA 2021-21121. THETA is still operational at the time of this publication and future testing is planned for fiscal year 2025. Work is underway to publish existing and future data to an online database to facilitate collaboration with SFR engineers looking to validate their systems code or computational fluid dynamics models.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

New opportunities in produced water management: A market-based approach to produced water trading

Produced water (PW) is a byproduct of oil and gas (O&G) production. Obtained alongside the more valuable energy products, PW is usually characterized by high levels of salinity and often contains many contaminants (chemicals, soluble and insoluble oil, organics, etc.) making it unsuitable for release without substantial treatment. Couple this with the fact that PW is typically obtained at multiple times the rate of oil or gas, and the added transport, treatment, and disposal costs become a serious challenge for operators. These realities have led to ad-hoc practices including cooperation between industry competitors to recycle, share, or otherwise mitigate PW costs. The National Energy Technology Laboratory (NETL) in partnership with the Ground Water Protection Council (GWPC) is pursuing novel technology solutions to address PW issues that complement or improve ad-hoc practices adopted by operators. In this paper, we observe that well-established market management practices used in electrical power generation have natural analogues in the PW supply chain. These parallels open up a new line of research where we view PW management as a market equilibrium problem, and explore solutions that foster active and data-based collaboration among operators through market structures similar to power markets, with the ultimate objective of improving PW management costs and recycling rates. Here, we make a case for our observations, present a PW market clearing optimization model that shows how such a market system could operate in the O&G space, and provide an illustrative case study for demonstration.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2026

Complete the Design, Cost Estimate, Assembly Plan, and Operating Instructions for a Bench-Scale Packed-Bed Tubular Methanol Catalyst Testing System

This report details the design of a test stand that converts carbon dioxide and hydrogen into methanol via a two-step process. The first step is a reverse water-gas shift reaction, carried out at 600°C and 25 bar to reduce carbon dioxide to carbon monoxide, and the second is a synthesis reaction that forms methanol at 260°C and 75 bar. The purpose of the system is to test catalysts for each of these steps. The test stand produces approximately 1.5 gallons of crude methanol (methanol mixed with water) per day, and recycles unreacted syngas for increased efficiency. At peak recycle, the stand is expected to consume 0.29 cylinders per day of carbon dioxide and 1.43 cylinders per day of hydrogen. It is planned to be built next to the Blue Star electrolysis unit in the Energy Systems Laboratory (ESL) and includes future plans of acquiring hydrogen from that stand rather than gas cylinders. At this phase of research, three key documents have been produced, as summarized in Table 1. These documents are primarily intended to describe the system and its operation, demonstrate that selected components are appropriate for the intended application, identify potential hazards, safeguards, and mitigation strategies, and ensure that the system is designed to appropriate standards. The body of the report and its appendices provide a narrative of the work completed in FY25. The parts required to build the test stand will be procured and assembled in FY26. Testing will be conducted in the final quarter.

10 - SYNTHETIC FUELS↗

DOE OSTI2026

Reliable Protection for an Inverter-Based Resources Dominant Grid: Technology Development and Field Demonstration

The project aimed to address the challenges posed by the rapid growth of inverter-based resources (IBR) such as solar, wind, and battery storage, which have fundamentally changed fault behavior, system strength, and protection performance in bulk power systems. Traditional protection schemes, designed for synchronous generator-dominated grids, are inadequate under high IBR penetration. Overall, the project materially advances protection modeling and simulation capabilities needed to maintain reliable grid protection under high IBR penetration. The results build utility confidence in operating power systems safely and reliably across a wide range of generation mixes, supporting grid modernization goals.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2024

Quantitative local state of charge mapping by operando electrochemical fluorescence microscopy in porous electrodes

We introduce operando quantitative electrochemical fluorescence state of charge mapping (QEFSM), a non-invasive technique to study operating electrochemical systems along with a new design of optically transparent microfluidic redox flow cells compatible with the most demanding optical requirements. QEFSM allows quantitative mappings of the concentration of a particular oxidation state of a redox-active species within a porous electrode during its operation. In this study, we used confocal microscopy to map the fluorescence signal of the reduced form of 2,7-anthraquinone disulfonate (AQDS) in a set of multistep-chronoamperometry experiments. Calibrating these images and incorporating an analytical model of quinhydrone heterodimer formation with no free parameters, and accounting for the emission of each species involved, we determined the local molecular concentration and the state of charge (SOC) fields within a commercial porous electrode during operation. With this method, electrochemical conversion and species advection, reaction and diffusion can be monitored at heretofore unprecedented transverse and axial resolution (1 μm and 25 μm, respectively) at frame rates of 0.5 Hz, opening new routes to understanding local electrochemical processes in porous electrodes. Here, we observed pore-scale SOC inhomogeneities appearing when the fraction of electroactive species converted in a single pass through the electrode becomes large.

42 ENGINEERING↗

DOE OSTI2024

Hydrogen, Methane, Brine Flow Behavior, and Saturation in Sandstone Cores During H 2 and CH 4 Injection and Displacement

Large-scale underground hydrogen storage (UHS) is a critical component in the emerging hydrogen economy. Knowledge of multiphase flow behavior involving hydrogen in storage reservoir formations is crucial to characterizing hydrogen transport properties and essential for the deliverability and storage operations of UHS. There are still many gaps in fully understanding hydrogen–methane–brine multiphase phase flow that require further investigation. In this work, H 2 and CH 4 were injected through brine-saturated sandstone cores using a tri-axial core holder system fitted with flow rate meters and pressure transducers, while the effluent gas concentrations were analyzed using an online micro gas chromatograph. Brine displacement, permeability, and gas breakthrough curves were measured. We studied the flow behavior of hydrogen and methane in sandstone cores through testing brine displacement by gas injection and comparing the hydrogen displacement of methane with the methane displacement of hydrogen. We also tested the differences between horizontal and vertical flow in brine displacement. The results showed that brine displacement was more efficient in a core with higher permeability and porosity, resulting in a higher initial gas saturation. A higher gas injection rate brought about faster gas breakthrough measured by pore volume and sharper concentration curves. Hydrogen did not exhibit abnormal flow in the sandstone when the flow was horizontal and downward vertical. Gas overriding was observed in brine displacements when the flow was horizontal, with hydrogen showing this behavior more profoundly compared to methane. Downward vertical gas injection induced higher efficiency brine displacement compared to horizontal displacement and resulted in a higher initial gas saturation in the sandstone cores. These findings address critical knowledge gaps regarding gas flow patterns and displacement behaviors during hydrogen injection and recovery phases in UHS facilities using methane as the cushion gas. The insights from this research offer valuable guidance for optimizing UHS systems, ensuring operational efficiency, and advancing sustainable energy solutions in alignment with decarbonization goals.

08 HYDROGEN↗

DOE OSTI2026

Design, Manufacturing, and Installation of DIII-D Lower Hybrid Current Drive Outer Wall Waveguides and Expandable Vacuum Interface

High field side lower hybrid current drive (HFS LHCD) is promising method for efficient, off axis current drive. To operate this system, development of an expandable combination radio frequency (RF) and vacuum interface was necessary to allow the long (~2 m) waveguides to thermally expand with respect to the DIII-D 0 degree R-1 port extension without damage to the waveguide or excessive force on the vacuum seals which was previously observed when baking the waveguides during operations that were installed in 2024. Design of a custom bellows assembly with RF feedthrough that allows >20mm of waveguide thermal expansion is presented. Fabrication of this bellows assembly required simultaneously vacuum brazing multiple 304 stainless steel flanges to an oxygen free high conductivity copper waveguide section which required significant manufacturing development.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2025

Fermilab's Transition to Token Authentication

Fermilab is the first High Energy Physics institution to transition from X.509 user certificates to authentication tokens in production systems. All the experiments that Fermilab hosts are now using JSON Web Token (JWT) access tokens in their grid jobs. Many software components have been either updated or created for this transition, and most of the software is available to others as open source. The tokens are defined using the WLCG Common JWT Profile. Token attributes for all the tokens are stored in the Fermilab FERRY system which generates the configuration for the CILogon token issuer. High security-value refresh tokens are stored in Hashicorp Vault configured by htvault-config, and JWT access tokens are requested by the htgettoken client through its integration with HTCondor. The Fermilab job submission system jobsub was redesigned to be a lightweight wrapper around HTCondor. The grid workload management system GlideinWMS which is also based on HTCondor was updated to use tokens for pilot job submission. For automated job submissions a managed tokens service was created to reduce duplication of effort and knowledge of how to securely keep tokens active. The existing Fermilab file transfer tool ifdh was updated to work seamlessly with tokens, as well as the Fermilab POMS (Production Operations Management System) which is used to manage automatic job submission and the RCDS (Rapid Code Distribution System) which is used to distribute analysis code via the CernVM FileSystem. The dCache storage system was reconfigured to accept tokens for authentication in place of X.509 proxy certificates. As some services and sites have not yet implemented token support, proxy certificates are still sent with jobs for backwards compatibility, but some experiments are beginning to transition to stop using them.

Dykstra, Dave [Fermilab] (ORCID:0000000326539015)↗

DOE OSTI2024

NMPC for Mode-Switching Operation of Reversible Solid Oxide Cell Systems

Solid oxide cells (SOCs) are a promising dual-mode technology that generates hydrogen through high-temperature water electrolysis and generates power through a fuel cell reaction that consumes hydrogen. Reversible operation of SOCs requires a transition between these two modes for hydrogen production setpoints as the demand and price of electricity fluctuate. Moreover, a well-functioning control system is important to avoid cell degradation during mode-switching operation. In this work, we apply nonlinear model predictive control (NMPC) to an SOC module and supporting equipment and compare NMPC performance to classical proportional integral (PI) control strategies, while ramping between the modes of hydrogen and power production. While both control methods provide similar performance in many metrics, NMPC significantly reduces cell thermal gradients and curvatures (mixed spatial-temporal partial derivatives) during mode switching. A dynamic process flowsheet of the reversible SOC system was developed in the open-source, equation-based IDAES modeling framework. Our IDAES dynamic simulation results show that NMPC can ramp the SOC system between hydrogen and power production targets within short mode-switching times. Moreover, NMPC can comply with operating limits in the SOC system more effectively than PI, and only NMPC can directly enforce user-specified limits for mixed spatial-temporal partial derivatives of temperature. This allows for management of the trade-off be-tween operating efficiency and cell degradation, which is dependent on these temperature curvatures.

Li, Mingrui↗

DOE OSTI2026

Universal Optimization and Tighter Fidelity Bounds for Approximate Quantum Error Correction

Approximate quantum error correction (AQEC) not only dictates the performance of discrete- and continuous-variable quantum error correction codes but also serves as a unifying framework across various physical disciplines. Identifying the optimal recovery channel to maximize the entanglement fidelity via standard semidefinite programming is computationally bottlenecked by the exponentially growing number of Kraus operators with system size, rendering large-scale optimization prohibitive. While analytical near-optimal maps exist, they typically work only when the Knill-Laflamme conditions are nearly satisfied. In this Letter, we establish an efficient framework by leveraging the duality between recovery and environment decoupling. This framework yields a tighter analytical lower bound on entanglement fidelity than the conventional limit set by the transpose channel. Furthermore, by exploiting the decayed weights of noise Kraus operators, we introduce a framework based on principal component analysis to reduce the dimension. In thermal loss channels where the weights decay exponentially, our approach achieves a 33-fold computational speedup while maintaining rigorous accuracy. Our approach enables high-precision optimization for AQEC codes that were previously intractable due to the curse of dimensionality.

Wu, Jing [Fermilab] (ORCID:0000000249460732)↗

DOE OSTI2026

Hydrogen applications in airport operations: a review using the Port Authority of New York and New Jersey as an illustrative airport system

Airports combine aircraft propulsion, ground operations, stationary power systems, and fuel logistics in ways that make emissions reduction technically and operationally complex. Existing studies often assess hydrogen applications in these areas separately, limiting understanding of the shared infrastructure, safety, and operational constraints that shape airport deployment. This review evaluates hydrogen across three airport-relevant operational domains: aviation propulsion, ground support equipment and vehicles, and stationary power systems. Within aviation propulsion, the review examines sustainable aviation fuel production and hydrogen-powered aircraft as two distinct hydrogen-relevant pathways. The Port Authority of New York and New Jersey is used as an illustrative airport system to relate the literature to a real operating context. Drawing on peer-reviewed studies, technical reports, demonstration projects, and public operational information, the review also includes screening-level calculations of hydrogen demand and potential CO 2 e reductions for selected applications. The findings show that hydrogen's role is highly application-specific. Near-term opportunities are strongest where hydrogen serves as a low-carbon process input, supports selected high-utilization ground equipment, or contributes to resilient stationary power-system configurations. Hydrogen-powered aircraft remain a longer-term option because storage, fueling infrastructure, certification, cost, and NO x management continue to constrain deployment. Across all domains, infrastructure readiness, fuel logistics, safety requirements, and leakage management emerge as recurring determinants of viability. Future research should focus on cross-domain infrastructure planning, comparative assessment of hydrogen against alternative pathways, improved treatment of leakage and non-CO 2 effects, and clearer safety and regulatory frameworks for airport deployment.

08 HYDROGEN↗

DOE OSTI2024

The Lithuania 100% Renewable Energy Study - Interim Results: Electricity System Scenarios for 2030 [Slides]

Lithuania's Energy Vision aims to achieve self-sufficiency in electricity generation by 2035 and transition to 100% renewable energy as soon as possible while maintaining affordability, reliability, and energy security. The Lithuania Energy Agency (LEA) is partnering with the National Renewable Energy Laboratory (NREL) to conduct the Lithuania 100% Renewable Energy Study (Lithuania 100) to provide evidence-based analysis for development of Lithuania's National Energy Independence Strategy. The Lithuania 100 Study leverages unique tools and capabilities of NREL to provide rigorous technical analysis of clean energy policies to achieve 100% renewable energy, and assess impacts on electricity grid operations, hydrogen system development, electricity distribution networks, air quality, and human health outcomes. The study is supported by a stakeholder committee chaired by the Ministry of Energy of Lithuania and implemented by four technical working groups. This report provides highlights of key interim results from modeling of Lithuania's near-term electricity grid through the year 2030. Results show that Lithuania has sufficient renewable energy potential, flexible generation capacity, and interconnection with neighboring European Union countries to reliably meet projected 2030 electricity demand with 100% renewable energy. A range of scenarios were modeled, each of which achieves at least 100% renewable energy in electricity, on average over the year, by 2030. Potential demands for hydrogen across industrial and transportation sectors were also evaluated, as well as the cost of hydrogen produced in Lithuania by 2030.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2025

Modernizing to an AI-Ready Control System

The Accelerator Controls Operations Research Network (ACORN) project will modernize the accelerator control system and upgrade power supplies to enable future operations of the Fermilab Accelerator Complex with megawatt proton beams. By focusing on MLOps, ACORN enables full integration of AI into the control system to allow safe and reliable improvements to accelerator beam operations.

43 PARTICLE ACCELERATORS↗

DOE OSTI2025

Techno-Economic Viability of Flexible Dispatch of Unconventional Geothermal Systems

Flexible geothermal operations could boost project returns through the allocation of improved power purchase agreements and/or exploitation of power price arbitrage opportunities. In this study, we investigated the techno-economic feasibility of variable flow rate control and time-of-day pricing in closed-loop geothermal systems. We considered U-shaped multilateral system configurations and modeled a variety of technical system parameters. These designs were simulated using a slender-body theory (SBT) model for transient heat transfer and fluid flow. This subsurface model was integrated into the flexible geothermal economic model (FGEM) tool to evaluate the overall flexible geothermal system techno-economics. Future hourly ambient temperature conditions were based on the Sup3rCC dataset. Published datasets were used for future hourly wholesale electricity prices. We analyzed four operating strategies: 1) baseload operation, 2) seasonal dispatch (high flow rate during summer and nominal flow rate during the rest of the year), 3) net generation maximization by varying flow rate to maximize net power output, and 4) revenue maximization by varying flow rate to maximize revenue. We ran all four scenarios for a multiloop configuration with 12 lateral passes, 7-km vertical depth and 87-km total drilling length. Furthermore, we assumed a 60 degrees C/km geothermal gradient and ambient temperature and wholesale electricity prices for New Mexico as a typical state location. The nominal flow rate was set to 80 kg/s. When considering drilling costs of $1,000/m and a discount rate of 7%, the generation maximization scenario resulted in the lowest levelized cost of electricity (LCOE) of ~$150/MWh. When considering project return on investment (ROI), defined as lifetime net income divided by upfront capital costs, all flexible operation scenarios performed better than the base case scenario. The highest ROI of 80% was obtained with the revenue maximization scenario. With drilling costs of $200/m and a discount rate of 5%, the generation maximization scenario resulted in LCOE of $49/MWh.

flexible geothermal↗