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DOE OSTI2019

Fuel Fabrication Facility Study for FCF HALEU

Nuclear energy technology developers seek to bring to market new advanced reactor designs and new light water reactor fuel designs, many of which would deploy fuel made from uranium with 235 U enrichment ranging from 5% to 19.75%. There is currently no commercial supply of uranium in this enrichment range, which is higher than used in today’s light water reactors but still lower than the safeguards limit of 20% 235 U. This limitation is a barrier to development of demonstration of these new nuclear energy technologies. As a means to address this near-term need, DOE and Idaho National Laboratory (INL) has considered how the HALEU product from sodium-bonded spent fuel treatment in the INL Fuel Conditioning Facility (FCF), located at the Materials and Fuels Complex (MFC), might be provided and fabricated into some of the new fuel designs. The evaluation presented in this report addresses the potential establishment of two types of fuel fabrication capability at INL, represented generically as a ceramic-type (or pellet-type) fuel fabrication line and a metallic fuel fabrication line. Because the FCF HALEU feedstock contains residual transuranic contamination and a relatively small amount of residual fission products, fabrication with that material is necessarily performed inside of engineered confinement barriers, such as gloveboxes, which would be filled with inert gas for most of the fuel types considered. The throughput rate of the fabrication lines envisioned is 2.5 metric tons of HALEU fuel per year, which is judged to be sufficiently representative of engineering-scale. Space in three existing buildings was identified for consideration in this study of pre-conceptual equipment layouts. The scope and nature of the work needed to prepare each of the three buildings for each type of fuel fabrication was identified (though not in engineering detail), and three-dimensional models of envisioned fabrication equipment were laid out in each of the buildings to assess adequacy of space. The study concluded that either type of fuel fabrication line can feasibly be installed and operated in either of the three buildings. However, each of the three buildings presents different challenges in preparation, due to accommodating current missions that would need to be relocated or necessary decontamination and decommissioning work to free-up space for fuel fabrication, or due to complications of accessibility. Rough order-of-magnitude (ROM) cost estimates for preparing buildings begin at $10M ( 20%/+50%) and would increase with increased complexity of building modifications. The cost of fabrication equipment and gloveboxes is roughly estimated to be $21M (-20%/+50%) for a metallic fuel fabrication line and $27M (-20%/+50%) for a ceramic/intermetallic fuel fabrication line. Nominal operating costs are estimated to be $7M per year (in 2019 dollars), increasing from lower amounts needed as the operating crew is being assembled and trained.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2019

Final Report: Development of High Light Output Plastic Scintillating and Wavelength-Shifting Fibers

Scintillating plastic optical fibers have increasingly been used as radiation detectors in nuclear and high energy physics research since they were first made in 1965. It is proposed to make fibers which are at least a factor of 2 brighter and thereby improve detection efficiency, spatial resolution and energy resolution. When radiation strikes existing plastic scintillator only the singlet excited states rather than the triplet excited states are used to produce scintillation light. This means only 25% of the deposited energy is available to produce scintillation light. Utilization of phosphorescent molecules should therefore drastically improve the light output. This process has been called “triplet harvesting” and has been successfully demonstrated in improving the light output of “Organic Light Emitting Diodes, OLEDs”. The objective of this proposal is to produce a bright scintillating fiber using triplet harvesting and a light output time constant of a few nanoseconds. In addition, an increase in the light containment will be achieved by using a new low refractive index cladding material. In Phase 1, polystyrene plastic material will be used. Organo-metallic phosphorescent and conventional dyes will be dissolved in the plastic to demonstrate both the desired brightness and fast decay time. Photophysical properties will be measured. Scintillating fiber will be made. Commercial benefits of this new material include providing improved detection of rare events such as the HIGGS BOSON at the billion dollar high energy facilities. and monitoring stored radioactive material. The new material will also play an important role in making improved imaging detection facilities for protecting civilians and facilities against CBRN-E threats. In addition, the resolution will be improved for medical brachytherapy. The results of selected organic dyes dissolved in a polystyrene matrix performing as scintillating samples are presented. The proposed organo-metallic phosphorescent dyes were not used due to lengthy synthesis times and cost. Rather, an attempt was made to harvest triplet energy from polystyrene using appropriately wavelength-matched dyes. Samples studied include films and blocks. Fibers were not manufactured as a suitable set of dyes was not determined.

07 ISOTOPE AND RADIATION SOURCES↗

DOE OSTI2019

CSP Systems Analysis - Final Project Report

The CSP Systems Analysis project was a three-year effort supporting the Concentrating Solar Power (CSP) Subprogram within the Solar Energy Technologies Office of the U.S. Department of Energy (DOE). The goal of the CSP Systems Analysis project was to provide timely and accurate CSP cost data to the DOE and predict performance and cost for emerging technologies that may impact research directions and industry investment. The project consisted of six, mostly independent tasks. Major accomplishments over the three-year period of performance were as follows. The NREL team maintained current cost estimates for CSP technologies by annual updates to the cost input parameters within NREL's System Advisor Model (SAM). SAM is a performance and cost simulation software that includes technology models for the primary CSP technologies. During the period from 2016 to 2018, the estimated cost within SAM's default CSP molten-salt power tower technology dropped from 13.0 to 11.1 cent/kWh (real dollars without incentives). Power cycle models for the supercritical carbon dioxide (sCO2) Brayton Cycle were developed and made an option within SAM's molten-salt power tower model. These models were subsequently used to evaluate the cost reduction potential of alternative salts. The partial-cooling model was found to provide the greatest cost-reduction potential due to its combination of efficiency and temperature differential across the turbine and thermal energy storage (TES) system. These studies were documented in two journal articles. NREL's optical modeling software SolTrace and SolarPILOT were made more versatile and released as open-source software to the CSP community. These tools help researchers and developers to model and optimize the optical performance of CSP collector systems. The new features were highlighted in a recorded webinar that can be accessed from the NREL SAM website. New models for solar-thermal systems, that is, applications for solar industrial process heat, were developed, validated, and installed within SAM. The analysis includes a 2018 review of linear collectors in the market that are tailored for solar process heat applications. In 2018 the NREL team also developed an annual simulation for a direct steam generation system integrated with a latent-heat TES system. This analysis was submitted for journal publication. The NREL team continued to support the exchange of information and development of CSP guidelines within the international CSP community of SolarPACES. Much of the work under this project was presented at SolarPACES, including the development of a modeling checklist to help CSP stakeholders standardize the models used for estimating CSP performance and cost. The CSP Systems Analysis project also supported DOE requests for tracking and reporting programmatic targets for the CSP Subprogram.

14 SOLAR ENERGY↗

DOE OSTI2018

Analysis of Microgrid Locations Benefitting Community Resilience for Puerto Rico

An analysis of microgrids to increase resilience was conducted for the island of Puerto Rico. Critical infrastructure throughout the island was mapped to the key services provided by those sectors to help inform primary and secondary service sources during a major disruption to the electrical grid. Additionally, a resilience metric of burden was developed to quantify community resilience, and a related baseline resilience figure was calculated for the area. To improve resilience, Sandia performed an analysis of where clusters of critical infrastructure are located and used these suggested resilience node locations to create a portfolio of 159 microgrid options throughout Puerto Rico. The team then calculated the impact of these microgrids on the region's ability to provide critical services during an outage, and compared this impact to high-level estimates of cost for each microgrid to generate a set of efficient microgrid portfolios costing in the range of 218-917M dollars. This analysis is a refinement of the analysis delivered on June 01, 2018.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2019

Enabling Staged Pressurized Oxy-Combustion: Improving Flexibility and Performance at Reduced Cost

Introduction: The staged pressurized oxy-combustion (SPOC) process, developed by Washington University in St. Louis (WUSTL), is an oxy-combustion carbon capture technology that employs a steam power cycle to generate electricity. As with atmospheric-pressure oxy-combustion processes, carbon dioxide (CO 2 ) capture rates of 90% or higher can be achieved. The staged-combustion approach of the SPOC process, when operated at elevated gas pressure, allows for near elimination of flue gas recycle (FGR) and leads to significant improvements in efficiency and reduced costs. The primary goal of this project was to investigate the potential for SPOC for flexible operation beyond the capabilities of conventional coal-fired power plants, particularly those employing carbon capture and storage (CCS). Oxy-combustion differs from conventional coal combustion in that the combustion of coal is carried out using oxygen as opposed to air. The resultant flue gas is a mixture of primarily CO 2 and water, greatly simplifying CO 2 capture. As SPOC does the oxy-combustion process under pressure, it is higher efficiency and lower cost than atmospheric oxy-combustion. The project was led by the Electric Power Research Institute, Inc., with the assistance of WUSTL, Doosan Babcock (DBL – boiler plant original equipment manufacturer), and Air Liquide (AL – air separation experts). The specific objectives of the project were to: (1) Evaluate the SPOC concept and develop a risk-based approach to the heating surface layout ensuring that performance (gas and steam side), manufacturing, transportation, and plant erection considerations were fully accounted for in the system design. (2) Improve the technology to ensure its performance and cost potential are substantially better than today’s baseline pulverized coal power plant with post-combustion capture (PCC) or atmospheric oxy-combustion, and show progress toward performance commensurate with projected commercial operation, including 90% or more CO 2 capture. (3) Address critical technology gaps and improving overall system performance for the technology. (4) Perform combustion tests at scale under commensurate pressure to the commercial operating system validate combustor and advance the SPOC combustion modeling tools that will facilitate full-scale design. Combustion Testing: Testing was initially carried out at atmospheric pressure with methane to ensure that all systems were correctly operating. Following this, the testing then proceeded to moderate pressure operation at 4 bara, where different stoichiometric conditions were used across an extended heat input range, showing that a stable flame could be maintained. Testing then proceeded at 10 and 15 bara where it was shown that the ignition system needed to be replaced at these operating conditions. When testing recommenced, a similar stable flame shape was achieved, without any methane support, and the full 100 kWth coal oxy-combustion was demonstrated. Heat flux measurements showed 400 kW/m 2 (0.126 MMBtu/hr-ft 2 ) from the flame, within the 450 kW/m 2 (0.142 MMBtu/hr-ft 2 ) preferred limit defined by DBL for the full-scale design case. Carbon monoxide and carbon-in-ash measurements showed that complete combustion was possible with ultra-low excess oxygen at 1 vol % in the product flue gas. This allowed the full-scale models to be calculated based on this level of excess oxygen, improving the performance of the system as lower feed oxygen is produced in the air separation unit (ASU), saving auxiliary power. Full-Scale Design: The full-scale design is sized to deliver 550 MWe net electrical power output to allow direct comparison with the National Energy Technology Laboratory (NETL) baseline cases using the same Montana Powder River Basin (PRB) fuel. The cases used for direct comparison are: Case S12A (supercritical [SC] coal without CO 2 capture), Case S12B (SC coal with PCC at 90% CO 2 capture, and Case S12F (atmospheric oxy-combustion SC coal with 90% CO 2 capture). The SPOC stages were configured to be identical arrangements, allowing for a more straightforward design, construction, and control strategy. Each stage consists of two PVs, the first being the combustor PV module and the second being the convective PV module. The combustor module is the tallest vessel, with local coal feeding equipment and the burner FGR and oxygen plenums at the top and ash management at the bottom. The combustor module is effectively an open cross section with membrane tubes around the circumference – this unobstructed slender profile ensures that the relatively slower burnout mechanism needed for the low-speed turbulent mixing burner can proceed unimpeded and that molten ash will not attach to any surfaces at an angle to the predominant flue gas flow. The steam turbine used in the SPOC design is essentially the same unit utilized in the atmospheric oxy-combustion case except the degree of heat recovery possible allows the low-pressure (LP) feedwater heater train to be eliminated. This is a result of being able to capture the latent heat of evaporation of the moisture produced in the combustion (normally lost to the stack). The SPOC system outperforms the NETL atmospheric oxy-combustion baseline case by 3.3% points and the PCC case by 7.5% points. This performance increase is mainly a result of the improved heat recovery possible from the product flue gas and from the reduced auxiliary power consumption from the ASU and the CO 2 compression and purification unit over the atmospheric equivalent. The combined improvement in boiler efficiency and reduction in the steam turbine heat rate resulted in a net improvement in the overall plant efficiency by 0.61%, to 35.6% on a HHV basis. This relatively small improvement in plant efficiency between sub-bituminous and bituminous coals shows the value of useful moisture latent heat recovery offered by the SPOC system when using low rank fuels. Flexibility and Turndown: The SPOC system has inherent high turndown capabilities because of a demonstrated high range of combustion stability and the ability to bypass stages, thereby reducing steam generation rates proportionally without altering firing rates in operating stages. ASU units do not generally offer significant turndown opportunities as they are limited by the performance of the compression plant. The baseline SPOC design has a 2-train ASU configuration, needed to be able to meet the 10,500 tonnes per day duty, that can deliver efficient turndown points between 85–100% load with both trains operating, and at 45–50% load with a single train operating. Outside these operating points, the flexibility and efficiency are limited and may be uncompetitive at loads below 45% as the ASU systems are unable to turndown beyond 85% for the base case and 70% for the flexible case. The ASU cold box for the flexible case was designed to operate at loads between 40-100%, below this operating range the purity of the produced oxygen cannot be guaranteed, resulting in additional load for the CPU equipment. The additional power consumption of these cases yields an uneconomic operating condition with poor efficiency when operating at low loads such as 25% and 12%. To address this flexibility constraint, AL evaluated how the ASU configuration could be altered to deliver efficient oxygen supply over the load range. This involved integrating the compressor duties across both ASU trains into a shared duty arrangement with multiple compressors, strategically sized to deliver the duty required across all load ranges between 40–100% by enabling different combinations of the main air compressors and the booster air compressors. The oxygen purity cannot be guaranteed below 40% load for each train – the power consumption at 25% and 12% loads were estimated based on the multi-compressor configuration at maximum turndown as these load cases were not considered in the flexible ASU design. With a different cold box configuration, i.e. number of trains, the entire load range could be delivered within oxygen purity specifications. Although there is a small efficiency reduction at full load, there are significant improvements in overall plant performance during low-load operation. The exact ASU configuration needed will therefore be dependent on the expected operating profile of the unit. Economic Analysis: Cost estimates for the baseline and the flexible cases were developed using NETL baseline case data for common BOP items and an Association for the Advancement of Cost Engineering International Class 5 (conceptual/screening study) assessment of key components unique to the SPOC system. The capital, operating, and maintenance costs were assessed along with the first-year power cost, levelized cost of electricity, and CO 2 captured and avoided cost for the SPOC cases were compared against the relevant NETL baseline cases in January 2019 dollars. Both SPOC cases achieve a lower cost that the alternative NETL baseline cases (with the flexible SPOC case being slightly higher than the baseline SPOC case due to the compounded impact of higher capital costs and lower efficiency at full load). The SPOC cases deliver a lower cost of CO 2 avoided than the NETL baseline cases due to greater efficiency in generating low-carbon power. However, the cost of CO 2 captured is higher because the higher efficiency of the SPOC process generates less CO 2 , hence less needs to be captured, resulting in a high capital cost being shared over a reduced CO 2 quantity. The flexible ASU adds 1.6% overall to the plant cost in comparison to the baseline case, but the efficiency improvements at loads below 50% are significant. Subsequently, depending on the plant load-profile expectation, the flexible ASU would be beneficial if the plant spends a significant portion of its operating life below 50% load. This kind of operating profile is likely to be required for all fossil plants when more renewable electricity generators are installed on the local grid, particularly solar power that can be predicted ahead of time, allowing for appropriate pricing signals to be incorporated into the diurnal cycle. R&D Recommendations: SPOC, while a promising technology, is a relatively recent concept and, as such, operability issues of combustor design and steam-side integration for such systems at a scale relevant to commercial deployment have not been evaluated. WUSTL has conducted extensive small pilot-scale (100 kWth) research to understand and advance pressurized oxy-combustion processes, including investigation of combustion and flame characteristics, radiative heat flux, burner operability, turn down, char burnout, ash characteristics, water-wash column operation, etc. for pressurized oxy-combustion systems. Nonetheless, at this stage in the development of the SPOC process, what is needed is a large-scale pilot plant that can serve to study pressurized oxy-combustion systems and components at a scale commensurate with the maturity of the technology. A scale of 10 MWth, which includes steam-side integration and two stages would yield essential information with respect to heat transfer characteristics both in the radiative and convective sections of the pressure vessels, and the ability to operate the fuel staging process. In addition, while modeling results indicate that combustion and flame characteristics improve with scale, direct studies of the combustor at this scale will ensure that the models can be relied upon for scale up to commercial scale. Furthermore, a detailed analysis must be performed to understand the scaling aspects of key components and systems.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2019

Muons Inc Master CRADA with Annex A for Magnetron Development

Modern CW or pulsed superconducting accelerators of megawatts beams require efficient RF sources controllable in phase and power. It is desirable to have an individual RF power source with power up to hundreds of kW for each Superconductive RF (SRF) cavity. For pulsed accelerators the pulse duration in millisecond range is required. The efficiency of the traditional RF sources (klystrons, IOTs, solid-state amplifiers) in comparison to magnetrons is lower and the cost of unit of RF power is significantly higher. Typically, the cost of RF sources and their operation is a significant part of the total project cost and operation. The magnetron-based RF sources with a cost of power unit of 1-3 dollars per Watt would significantly reduce the capital and operation costs in comparison with the traditional RF sources. This arouses interest in magnetron RF sources for use in modern accelerators. A recently developed kinetic model describing the principle of magnetron operation and subsequent experiments resulted in an innovative technique producing the "stimulated" generation of magnetrons powered below the self-excitation threshold voltage. The magnetron operation in this regime is stable, low noise, controllable in phase and power, and provides higher efficiency than other types of RF power sources. It allows operation in CW and pulse modes (at large duty factor). For pulsed operation this technique does not require pulse modulators to form RF pulses. It also looks as a promising opportunity to extend magnetron life time.

43 PARTICLE ACCELERATORS↗

DOE OSTI2019

Enabling 10mol/kg Swing Capacity via Heat Integrated Sub-ambient Pressure Swing Adsorption

This project focused on the development of a post-combustion CO 2 capture technology for coal-fired power stations. The core concept of the technology was the combination of an adsorption-based separation with combustion flue gas cooling, compression followed by heat and power recovery. The key features of the adsorption unit (which captures and purifies the CO 2 ) are the use of high flow fiber-based adsorption systems that incorporate materials that manage the significant amounts of heat released during the adsorption separation. The adsorbent material utilized was a hybrid organic-inorganic material (a metal-organic framework) that had the proper combination of separation selectivity and CO 2 capture capacity. In this case, record-setting, process-relevant CO 2 capture capacities (approximately 8-10 mol of CO 2 per kg of adsorbent “swing capacities”) were observed in experimental measurements of the adsorptive separation. The experimental work was accompanied by detailed multi-level simulation works, which investigated the molecular mechanism for the high CO 2 capture efficiencies, the heat and mass transport dynamics within the separation system, and the process-level integration of the various systems associated with the technology. Overall, the analysis conducted in this work indicates that this technology can potentially reach CO 2 capture costs as low as 40-50 dollars/tonne with capital costs of 250M-400M dollars for the 550 MW e basecase established by the National Energy Technology Laboratory.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2019

Final Report for Industrial Base Cybersecurity Initiative (IBCI) Project (FY2019)

Information security issues impact all manufacturing sectors and are particularly troublesome when designs for advanced weapons systems are lost via attacks that propagate through the relatively unprotected lower tiers of the nation's supply chains. The US Manufacturing Industrial Base (MIB) consists of suppliers and distributors that range in size from large prime contractors with extensive cybersecurity resources to small shops with little or no in-house information technology capabilities. The acquisition and maintenance of the technologies, systems, and financial resources needed to assure secure collaborations can be an overwhelming challenge for many manufacturers yet the cost of poor cybersecurity practices can lead to the compromise of national security information worth hundreds of millions of dollars. The Department of Defense Manufacturing Industrial Base Policy organization and the Department of Energy, Energy Efficiency and Renewable Energy Advanced Manufacturing Office have chartered the Los Alamos National Laboratory (LANL) and the Oak Ridge Y-12 National Security Complex (Y-12) to design, develop, and demonstrate a Manufacturing Threat Evaluation Wargaming System (MTEWS). The MTEWS concept is based on the use of a virtual model of the computer networks and cybersecurity protocols used across the MIB that will be continuously updated to reflect the dynamic threat environment. The MTEWS cyber-physical test range will demonstrate a prototype wargaming system that analyzes the impact of new and existing cybersecurity threats while also providing the information needed to sustain the integrity of the MIB supply chains. A long-term goal is the establishment of an enduring national manufacturing operations center that proactively responds to the continuously changing attacks that threaten the MIB and US national security. LANL and Y-12 have formed an Industrial Base Cybersecurity Initiative Team (IBCI), consisting of partners from the public, private and academic sectors, that is developing the MTEWS. To date, most of the project tasks have been centered on the technologies required to create a representative model of the MIB because this is a foundational element for the entire project. Modeling activities at the University of North Carolina at Charlotte (UNC Charlotte) have demonstrated a VMware-based prototype system that can accommodate a network model with up to 350 nodes and includes features such as the option to incorporate network scanning information when building the model and the ability to down select the elements of duplicative networks to a statistically significant subset that avoids redundantly duplicating network configurations. Broad Ordering Agreements have been established with UNC Charlotte and the University of West Florida (UWF) that support a variety of cybersecurity for manufacturing tasks and wide-spread endorsement has been received from government, industry and academia sectors concerning the IBCI goals and technical direction.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗

DOE OSTI2019

Development of thinned silicon sensors on 8” wafers (CRADA FRA-2015-0015 Final Report)

Sensors fabricated from high resistivity, float zone, silicon material have been the basis of vertex detectors and trackers for the last 30 years. The areas of these devices have increased from a few square cm to >200 m 2 for the existing CMS tracker. CMS and ATLAS upgrades will each require more than 200 m 2 of silicon and the CMS High Granularity Calorimeter (HGC) will require more than 600 m 2 . Cost and complexity of assembly of these devices is related to the area of each module, which in turn is set by the area of the silicon sensors. A move from 4” and 6” wafers (the only sizes currently available) to 8” diameter in volume production has the potential for savings of tens of millions of dollars in the detector upgrade programs at the Large Hadron Collider (LHC) and future experiments. In addition to large area, the devices must be radiation hard, which can be achieved by the use of sensors thinned to 200 microns or less. The combination of wafer thinning and large wafer diameter is a significant technical challenge, and is the subject of this work.

43 PARTICLE ACCELERATORS↗

DOE OSTI2020

Cost of saving natural gas through efficiency programs funded by utility customers: 2012–2017

This study estimates the cost of saving a therm of natural gas from energy efficiency programs funded by utility customers during the period 2012 to 2017. Berkeley Lab researchers compiled and analyzed efficiency program data reported by investor-owned utilities and other program administrators in a dozen states representative of the four U.S. Census regions — Arkansas, California, Connecticut, Iowa, Massachusetts, Michigan, Minnesota, New Jersey, New York, Oklahoma, Rhode Island and Utah. Depending on the year, the dataset accounts for about 50 percent to 70 percent of annual national spending on natural gas efficiency programs. The estimated cost of saving natural gas during the study period is $0.40 per therm. The analysis also includes estimates of the program administrator cost of saved energy for three core sectors for natural gas: commercial and industrial, residential, and low-income households. It aggregates these sectors to provide regional and national values. Our metrics include savings-weighted averages, unweighted medians, and interquartile ranges (25th and 75th percentiles) of the levelized program administrator cost of saving gas, in constant 2017 dollars. In addition, the study analyzes cost trends during the study period, finding that average program costs trended downward. The U.S. Department of Energy’s Building Technologies Office supported this work.

03 NATURAL GAS↗

DOE OSTI2019

Basic Research Needs Workshop on Compact Accelerators for Security and Medicine: Tools for the 21st Century, May 6-8, 2019

Accelerator-based radiation sources are ubiquitous tools for imaging and treatment in the fields of medicine and security that save millions of lives, impact billions of dollars of commercial goods annually, and fulfill a critical role in US national security. Today’s commercially available accelerator technology has fallen significantly behind the state-of-the-art. Advancing and transferring state-of-the-art compact accelerator technology into broader use holds the promise of achieving greater control, power, and automation, which can significantly enhance society’s ability to sense and control the world around us. The Workshop identified a wealth of opportunities to advance these technologies from today’s commercial baselines, largely based on half-century old developments, by employing emerging concepts in charged particle acceleration and radiation generation and detection, along with modern ways of thinking about and utilizing developments in systems engineering, advanced materials, supply chain management, manufacturing, advanced computation, energy storage, and artificial intelligence.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2020

A New Process for Carbon Dioxide Conversion to Fuel

In this project, TDA developed a new mixed metal oxide-based sorbent that converts CO 2 (captured from coal fired power plant) to CO, which can then be combined with renewable H 2 generated by water electrolysis to produce different liquid fuels. TDA’s absorbent-based CO 2 conversion process uses a redox process, which splits the reverse water gas shift reaction steps into two stages: CO 2 reduction to CO and H 2 oxidation to H 2 O and eliminates the equilibrium limitations. The CO produced in the two-stage reactor system can then be further reacted with renewable H 2 to produce methanol, naphtha, diesel, or gasoline. We worked with the Gas Technology Institute (GTI) and Advanced Power & Energy Program (APEP) of University of California, Irvine (UCI) to design and develop the liquid fuel synthesis process that is built around this new material. We demonstrated the techno-economic viability of the new sorbent based redox process to convert CO 2 into synthesis gas by: 1) demonstrating continuous carbon dioxide reduction in a prototype test system for over 500 hours while converting up to 0.4 kg CO 2 /day. With the successful completion of the R&D effort, the technology is now ready for a larger pilot-scale demonstration and the technology readiness has been raised from TRL 3 to TRL 5. In collaboration UCI, we also completed a high-fidelity process design and economic analysis. The required selling price (RSP) for methanol (Case 1 H2-MeOH) is $\$$3.06/gal, naphtha and diesel (Case 2 H2-FT) are $\$$6.21/gal and $\$$8.91/gal, and for gasoline (Case 3 H2-MTG) is $\$$6.96/gal on a 2011 dollar basis. To put these costs in perspective, the recent (June 2020) U.S. price for methanol made from natural gas is about $\$$1.19/gal according to Methanex, a major methanol producer in North America. The recent (June 2, 2020) California prices for gasoline and diesel with California’s strict specifications are $\$$3.35/gal and $\$$3.73/gal according to the U.S. Energy Information Agency. On the other hand, it should be noted that the gasoline and diesel produced by the designs of Case 2 and Case 3 would be both nitrogen and sulfur free. These RSPs are based on a cost of imported electricity of $\$$64/MWh based on the low-end current wind generated electricity cost (Genevieve and Ramsden, Wind Electrolysis: Hydrogen Cost Optimization, Technical Report, June 2011, NREL/TP-5600-50408). This cost is by far the largest component of the variable costs used in computing the RSPs. The cost of the imported electricity has to approach zero for the RSP to be competitive for methanol produced in Case 1 and naphtha and diesel produced in Case 2 while the cost of electricity has to be less than $\$$10/MWh for gasoline produced in Case 3.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2020

2020 Exascale Computing Project Annual Meeting (Executive Summary Report)

The Exascale Computing Project (ECP) delivers specific applications, software products, and outcomes on DOE computing facilities. Integration across these elements for specific hardware technologies for exascale system instantiations is fundamental to ECP success. The outcome of the ECP is the delivery of a capable exascale computing ecosystem to provide breakthrough solutions addressing our most critical challenges in scientific discovery, energy assurance, economic competitiveness, and national security. This outcome is not a matter of ensuring more powerful computing systems. The ECP is designed to create more valuable and rapid insights from a wide variety of applications (“capable”), which requires a much higher level of inherent efficacy in all methods, software tools, and ECP-enabled computing technologies to be acquired by DOE laboratories (“ecosystem”). The ECP annual meeting provides a unique opportunity for the core technical expertise in the United States focused on achieving this next plateau of computational science and computing performance to engage in direct discussions on project execution. Face-to-face gatherings in technical communities like this are common and needed for the exchange of scientific ideas and technical performance. The ECP annual meeting stands apart from other technical conferences and meetings in the computing community as it is uniquely and solely focused on the execution of the ECP and the integration of technical activities leading to the creation of the exascale computing ecosystem for the future. The direct interaction of key critical technical staff, who are leaders in their respective fields, and the resulting give-and-take between software, applications, and hardware and the technical co-design therein, is unique and essential to the effective execution of the ECP. The first annual meeting was held in Knoxville, Tennessee, January 31 – February 2, 2017 and brought together, for the first time, a diverse collection of researchers from 16 DOE national laboratories as well as university computer and computational science researchers to discuss shared problems and joint solutions for the development of a capable exascale computing ecosystem. These interactions resulted in focused technical plans and an energized community centered on advances for ECP. The second annual meeting was held in Knoxville, Tennessee, February 5–9, 2018. It included 643 individual thought leaders and performers in application development, software research and deployment, and hardware research and integrators, all of whom are part of the multifaceted, billion dollar HPC community. This meeting provided a platform to discuss and disseminate numerous examples where researchers with common goals and synergistic solutions came together for the first time to deliver tangible results. Additionally, at the 2018 meeting, ECP researchers had the opportunity to digest all US HPC vendor R&D product roadmaps pointing to exascale – not only to learn how their research can play a role, but, more importantly, to influence those roadmaps to ensure successful delivery on DOE applications that will contribute to (if not solve) problems of national interest in national security, science, energy, and health, as well as growing security threats. The third annual meeting was held in Houston, Texas, January 14–17, 2019. With a 19% increase in the number of registrations (768 people), and the change in location, the third annual meeting was considered the most impactful of the three at the time. The new website provided a better platform for the dissemination of the content, the new venue as a meeting hotel instead of a conference center facilitated interactions and discussions after event hours, and the addition of an award-winning mobile event conference app (Whova) transformed dramatically the attendee experience at the event. This fourth annual meeting was held in Houston, Texas, February 3-7, 2020. This meeting had an increase in the number of attendees for a total of 824 people registered (782 attendees) and included numerous enhancements based on feedback and lessons learned from previous meetings, some of which are listed here: Improved quality of the sessions, their material and the whole program.; Had more industry participation and addition of external collaborators from overseas.; Published the full agenda earlier to better accommodate attendance and travel plans based on schedule.; Centralized all sessions in one venue.; Provided additional hotels and room blocks for the attendees.; Improved communication with the audience (links, material, directions, notifications, etc.) to go paperless.; Enhanced side meeting scheduling, management and user experience.; Made available additional space and tables for impromptu meetings and side discussions.; Improved IT and A/V solutions for speakers. In addition, our final survey captured the following points as opportunities for improvement in future meetings: consider a different meeting location that is more pedestrian friendly, reduce talks during working meals to allow more collaboration and informal time, adapt the agenda to acknowledge attendees from different timezones, consider recording some of the tutorials and/or sessions to share broadly with the HPC community, have a larger poster room, provide additional power strips, and improve the WiFi.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2019

U.S. Fusion D-Li Neutron Irradiation Facility: Fusion Prototypic Neutron Source (FPNS) Technology Study

A primary engineering challenge for the realization of fusion energy involves the development of high-performance structural and plasma-facing materials with dimensional stability and resistance to neutron degradation of mechanical properties. The harsh fusion environment, including high levels of helium production and other transmutation products along with high operating temperatures, poses an extreme challenge for materials. Identifying materials that can withstand these conditions is a high priority for fusion energy research. Critical to resolving this gap in scientific understanding is developing a neutron source facility with the ability to mimic the extreme conditions in a fusion reactor. Working with the Department of Energy (DOE) Office of Fusion Energy Sciences (FES), Oak Ridge National Laboratory (ORNL) and the Virtual Laboratory for Technology (VLT) organized a workshop to discuss the need for a Fusion Prototypic Neutron Source (FPNS). [1] While there are a variety of uses for FPNS neutrons, the main driver of US interest is expanding the scientific understanding of materials degradation in the deuterium-tritium (D-T) fusion environment. FPNS will help build the scientific foundation required to enable design of a next step fusion device. Using specifications from previous projects as a guide, key parameters were agreed upon for a near term, moderate cost US facility that would be complementary to the more extensive plans of the International Fusion Materials Irradiation Facility (IFMIF). Types of facilities that could potentially meet those criteria were identified. A scoping study for three technologies was initiated to answer three critical questions: 1) Can the concept meet the key parameters, 2) What is the estimated cost, and 3) What is the estimated schedule. One approach selected for the scoping study is a D-Li stripping source similar to the design of the IFMIF but at a lower beam power and atomic displacement rate for cost and schedule reasons. The purpose of this report is to document the results of the D-Li stripping source option study, providing answers to the three questions. The approach to generating a fusion prototypic neutron source using a deuteron beam incident on a flowing lithium target has been studied for more than 40 years. As a result of the research and development recently executed primarily in Europe and Japan, the ability of this approach to meet key parameters (damage parameters, irradiation volume) outlined in the US workshop for a near-term, moderate cost fusion prototypic neutron source facility is not in doubt. The main question that must be answered is the cost of such a facility. As a result, a strong focus was placed on understanding alternatives for developing the facility and their relative costs. The project was broken into four components for the cost estimate: the ion source, accelerator, lithium target system, and conventional facilities. The cost of the accelerator is an important cost driver for the D-Li stripping concept. To fully understand the range of the accelerator cost, multiple alternatives were considered including normal conducting and superconducting linacs and the frequency of the radiofrequency quadrupole. Multiple previous design studies dating from 1989 through 2017 were examined (costs were escalated to 2019 dollars) and compared. After analysis, two options were selected for costing, one superconducting and one room temperature. We found similar project costs for the two accelerator options, on the order of $100M including design and project management but excluding contingency. Including everything except the conventional facilities, the estimate for the neutron source facility is estimated to be $220M without contingency. Additional significant costs for the facility are the conventional costs arising from the need to construct buildings for the accelerator and target facilities, bringing electrical power to the site including a new substation, and removing the heat from the facility using heat exchangers. While ORNL would oversee this work, much of the effort would be executed by contractors. Estimates for this effort was based on similar projects that are currently being executed at ORNL or were executed at ORNL in the recent past. The estimate for conventional facilities for the neutron facility is $173M without contingency, bringing the total project cost to $393M without contingency. With a 50% contingency, the estimated cost is $589M. The estimate range was established using guidance from the Association for the Advancement of Cost Engineering (AACE). Specifically, guidance from recommended practice 17R-97 provides insight on the expected accuracy range of estimates based on the degree of project definition and the position of the project in the stage-gate process or maturity timeline. An AACE Class 5 type estimate is appropriate for concept screening. The expected accuracy range includes a low end of -50% to -20% and a high end of +30% to +100% around the estimated cost. For the D-Li stripping neutron source, a -20% to +100% cost range was applied for a recommended cost range of $471M to $1,179M. Less emphasis was placed on determining the project schedule due to the fact that the project costs were large and may eliminate this option from consideration. The development of the accelerator facility may require on the order of five years without contingency. A more realistic schedule with contingency may be seven years. However, this estimate should be scrutinized in a preconceptual design activity if a more realistic estimate is needed. Finally, one lesson learned in this process is that the requirements for a near-term, moderate cost facility drives the alternative selection toward existing facilities and infrastructure. The D-Li stripping neutron source option requires a green field site due to the lack of existing buildings and infrastructure that can be reused for this effort. As a result, the conventional facilities costs are a significant fraction of the total facility cost. Other neutron source options where buildings, electrical power, and cooling infrastructure already exist may be able to meet the requirements for a near term, moderate cost facility.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2020

EXPERIMENTAL INVESTIGATION OF IMPACT AND ABRASION EROSIONS AT LOW VELOCITIES AND COMPARISON TO CFD SIMULATIONS

Wear and erosion damage of materials due to interaction of the surface with solid particles is a major issue in various industries. This phenomenon is common in mining, and oil and gas production, causing damages worth millions of dollars annually. Erosion is becoming a critical issue in renewable technologies as well such as concentrated solar thermal power (CSP) systems. In some CSP systems, solid particles can be used to absorb solar energy and enhance the heat storage. However, these particles may cause significant amount of wear to system components while falling down the power tower at high temperatures. This damage can be costly, and therefore, investigating solid particle erosion in CSP systems is of utmost importance. In collaboration with Sandia National Laboratories, the erosion durability of particle-based Generation 3 (GEN3) CSP system are being investigated both experimentally and numerically. In order to develop models to predict the life time of such systems, erosion under low temperature and low particle impact velocity conditions are investigated. Impact erosion and abrasion erosion experiments are conducted for low velocity and low temperature conditions for various candidate particles and containment materials. The impact erosion testing is conducted for three different containment material including Stainless Steel 316, special refractory material, and Inconel 740H with CARBOBEAD HSP 40/70 ceramic particles and UNIWEST 430 silica quartz erodent particles. All this data will enable us to better model the erosion behavior of these materials and provides a data base to investigate erosion at high temperatures experienced in CSP systems. At low temperatures and low velocities the softer refractory material exhibited greater erosion by an order-of-magnitude when compared to the harder Inconel 740H and Stainless Steel 316 materials. The overall erosion ratio for all the candidate materials was of the order of 10 -7 kg/kg. We also investigated wear in containment materials from sliding of particles over the surfaces at very low angles, also referred to as abrasion. For the velocities expected in a typical 1MW CSP plant, visible surface wear was noted, but the overall mass loss per unit surface area was found to be dependent on the hardness of the containment material tested. In this manuscript, we also present Computational Fluid Dynamics (CFD) simulations and erosion prediction of low velocity impact erosion. These results are compared with the experimental data to evaluate the ability of available erosion models for predicting erosion under these conditions.

14 SOLAR ENERGY↗

DOE OSTI2020

Simulation of Cross-Border Renewable Energy Trading in South Asia [Slides]

India's national renewable energy zones for wind power and solar photovoltaics (PV) could become regional green power resources if South Asian countries liberalize their rules for cross-border energy trading (CBET). Similarly, Nepal's wealth of hydropower could be more valuable to Nepal and its neighbors with greater market integration. These are the findings of a study by the U.S. National Renewable Energy Laboratory (NREL) that tested trading scenarios for wind power, solar power, and hydropower among Bangladesh, India, Nepal, and Sri Lanka. The NREL study found that wheeling power through India's interstate transmission system (ISTS) could be just as efficient operationally as building new high-voltage direct current (HVDC) lines from the renewable energy zones directly to the importing country. This means that CBET integration could substitute for new long-distance HVDC transmission - which could cost billions of dollars - while delivering to all participating countries the same benefits for renewable energy development and decarbonization.

13 HYDRO ENERGY↗

DOE OSTI2020

Addressing Soiling: From Interface Chemistry to Practicality

Natural soiling has reduced the energy output of photovoltaic (PV) systems since the technology was first used. Projecting even a small average annual soiling loss translates to billions of dollars in annual lost revenue worldwide. Production losses due to soiling can be very high in some locations, substantially increasing the levelized cost of electricity (LCOE) due to lost power production, increased operating and maintenance costs, and/or increased finance cost due to the uncertainty. Furthermore, although soiling has been discussed in the literature for more than 70 years, solutions to many problems are still needed. The National Renewable Energy Laboratory (NREL) is working with the PV industry to develop the tools/knowledge so that the effects of soiling can be predicted for different environmental conditions and cost-effective mitigation can be implemented. For this project, NREL performed a number of research and development tasks/subtasks in the following general areas to 1) predict PV module soiling losses based on environmental factors at a PV installation and from its energy production data, 2) quantitatively measure the adhesion forces to understand the physics enabling soiling, and 3) develop related standards on PV module coatings and artificial soiling. At the inception of the project, the PV industry considered these efforts to be the most important and immediate soiling issues that we could address to have the highest impact on LCOE. These focused efforts have led to outstanding accomplishments that have been communicated and very well received by the community.

14 SOLAR ENERGY↗

DOE OSTI2020

Cross-Border Electricity Trading and Renewable Energy Zones

14 SOLAR ENERGY↗