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At least 487 records · Page 27

Manufacturing Cost Levelization Model – A User’s Guide

The Manufacturing Cost Levelization Model is a cost-performance techno-economic model that estimates total large-scale manufacturing costs for necessary to produce a given product. It is designed to provide production cost estimates for technology researchers to help guide technology research and development towards an eventual cost-effective product. The model presented in this user’s guide is generic and can be tailored to the manufacturing of any product, including the generation of electricity (as a product). This flexibility, however, requires the user to develop the processes and process efficiencies that represents a full-scale manufacturing facility. The generic model is comprised of several modules that estimate variable costs (material, labor, and operating), fixed costs (capital & maintenance), financing structures (debt and equity financing), and tax implications (taxable income after equipment and building depreciation, debt interest payments, and expenses) of a notional manufacturing plant. A cash-flow method is used to estimate a selling price necessary for the manufacturing plant to recover its total cost of production. A levelized unit sales price ($ per unit of product) is determined by dividing the net-present value of the manufacturing plant’s expenses ($) by the net present value of its product output. A user defined production schedule drives the cash-flow method that determines the levelized unit price. In addition, an analyst can increase the levelized unit price to include a gross profit margin to estimate a product sales price. This model allows an analyst to understand the effect that any input variables could have on the cost of manufacturing a product. In addition, the tool is able to perform sensitivity analysis, which can be used to identify the key variables and assumptions that have the greatest influence on the levelized costs. This component is intended to help technology researchers focus their research attention on tasks that offer the greatest opportunities for cost reduction early in the research and development stages of technology invention.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Method development for thermal analyses testing on Reillex HPQ resin using the advanced reactive system screening tool (ARSST)

Reillex™ HPQ resin was developed by Los Alamos Laboratory and Reilly Industries Inc. in an effort to increase safety and process efficiency during the recovery and purification of plutonium. Ionac™ A-641, another strong base macroporous anion exchange resin used in the nuclear industry, was known to undergo a runaway reaction in hot nitric acid solutions. Because of this, an extensive amount of thermal analyses testing on the Reillex™ HPQ resin in SRNL was performed in 1999-2001 prior to use. A report on the thermal stability qualification of the Reillex™ HPQ resin in 8M (35%) and 12M (53%) HNO 3 was reported in 2000. In 2001, the reactivity of Reillex™ HPQ resin in 14.4M (64%) HNO 3 was evaluated. In January of 2001, thermal stability scoping tests were performed on irradiated Reillex™ HPQ resin in 14.4M (64%) HNO 3 (as a worst case scenario) and the results sent to Fauske and Associates to calculate a rupture disk size for the HB-Line resin column. A technical report by Fauske and Associates was issued in February 2001 recommending a 2.0” vent line with a rupture disk set pressure of 60 psig. This calculation was based on ARSST thermal analyses scoping tests at SRNL in which 4 grams of dried resin and 6.0 grams of 64% nitric acid in a 10 gram test cell, produced a maximum pressure rate (dP/dt) of 720 psi/min (12 psi/sec) and a maximum temperature of 250 °C. In 2015, a new batch of Reillex™ HPQ resin was manufactured by Vertellus Industries. A test sample of the resin was sent to SRNL to perform acceptance and qualification thermal stability testing using the ARSST. During these tests, method development was performed to ensure that a representative resin to acid ratios were used while running the tests in the ARSST. Fauske and Associates recommended to either use a full test cell representative of the HB-Line column or a 10 gram sample in the test cell that was representative of the ratios of resin to nitric acid in the actual HB-Line column. An observation was made during method development testing that the 4 grams of resin to 6 grams of 64% acid ratio used in 2001 to determine the rupture disk size did not entirely wet the resin and was not representative of the actual HB-Line column. The results of this study raised questions as to whether the ratio of 4 grams of resin to 6 grams of 64% nitric acid recommended by Fauske and Associates in 2001 was the correct ratio.

36 MATERIALS SCIENCE↗

Ethanol from Agriculture for Arkansas and America

The purpose of this project was to develop technology that would facilitate production of sugars from agricultural residues to enable biofuels and biobased product manufacturing. Our primary technology is to use genetic engineering to put bacterial and fungal cellulase genes into corn kernels, using the grain as the production system for the enzymes. At the beginning of this DoE funded program, we were producing two cellulases—E1 endocellulase from a bacterium found in a hot spring at Yellowstone National Park, and CBH I exocellulase from a wood rot fungus. Our team developed several new regulatory sequences (promoters) that increased enzyme protein accumulation in two kernel compartments (embryo and endosperm). We were also able to capitalize on the diverse genetics of corn to increase protein accumulation. High oil germplasm in particular was instrumental in this increase. A second task in the program was to produce enzymes and proteins that enhanced the activity of the E1 and CBH I enzymes. Our team produced CBH II, from the same wood rot fungus at a level that enabled highly enhanced deconstruction activity of E1 and CBH I in a synergistic manner. We analyzed an additional protein, expansin from cucumber that was expressed in the maize grain expression system. This protein had been previously shown to enhance cellulase activity (D. Cosgrove, Penn State University), and required a large-scale production platform. Our team showed that the corn production system allows industrial amounts of active expansin to be harvested from the grain. One of the challenges of any new production system is to maximize recovery of active ingredient from the raw materials at a cost compatible with its final use. Our team showed that low pH extraction of grain solubilized the enzymes without contamination of native corn protein and active product could be concentrated through ultrafiltration. The final outcomes of this project were the following: 3 cellulase enzymes and the synergistic protein expansin produced at high levels in corn grain, new promoters and combinations of promoters to enhance protein accumulation in grain, application of unique germplasm pools to enhance protein accumulation, and highly efficient processing enabling cost-effective production of cellulases that are highly active in biomass deconstruction.

09 BIOMASS FUELS↗

High power ring methods and accelerator driven subcritical reactor application

High power proton accelerators allow providing, by spallation reaction, the neutron fluxes necessary in the synthesis of fissile material, starting from Uranium 238 or Thorium 232. This is the basis of the concept of sub-critical operation of a reactor, for energy production or nuclear waste transmutation, with the objective of achieving cleaner, safer and more efficient process than today’s technologies allow. Designing, building and operating a proton accelerator in the 500-1000 MeV energy range, CW regime, MW power class still remains a challenge nowadays. There is a limited number of installations at present achieving beam characteristics in that class, e.g., PSI in Villigen, 590 MeV CW beam from a cyclotron, SNS in Oakland, 1 GeV pulsed beam from a linear accelerator, in addition to projects as the ESS in Europe, a 5 MW beam from a linear accelerator. Furthermore, coupling an accelerator to a sub-critical nuclear reactor is a challenging proposition: some of the key issues/requirements are the design of a spallation target to withstand high power densities as well as ensure the safety of the installation. These two domains are the grounds of the PhD work: the focus is on the high power ring methods in the frame of the KURRI FFAG collaboration in Japan: upgrade of the installation towards high intensity is crucial to demonstrate the high beam power capability of FFAG. Thus, modeling of the beam dynamics and benchmarking of different codes was undertaken to validate the simulation results. Experimental results revealed some major losses that need to be understood and eventually overcome. By developing analytical models that account for the field defects, one identified major sources of imperfection in the design of scaling FFAG that explain the important tune variations resulting in the crossing of several betatron resonances. A new formula is derived to compute the tunes and properties established that characterize the effect of the field imperfections on the transverse beam dynamics. The results obtained allow to develop a correction scheme to minimize the tune variations of the FFAG. This is the cornerstone of a new fixed tune non-scaling FFAG that represents a potential candidate for high power applications. As part of the developments towards high power at the KURRI FFAG, beam dynamics studies have to account for space charge effects. In that framework, models have been installed in the tracking code ZGOUBI to account for the self-interaction of the particles in the accelerator. Application to the FFAG studies is shown. Finally, one focused on the ADSR concept as a candidate to solve the problem of nuclear waste. In order to establish the accelerator requirements, one compared the performance of ADSR with other conventional critical reactors by means of the levelized cost of energy. A general comparison between the different accelerator technologies that can satisfy these requirements is finally presented. In summary, the main drawback of the ADSR technology is the high Levelized Cost Of Energy compared to other advanced reactor concepts that do not employ an accelerator. Nowadays, this is a show-stopper for any industrial application aiming at producing energy (without dealing with the waste problem). Besides, the reactor is not intrinsically safer than critical reactor concepts, given the complexity of managing the target interface between the accelerator and the reactor core.

43 PARTICLE ACCELERATORS↗

Manufacturing Technology Development for Visible Color Filters

Sandia National Laboratories (SNL) and Rockwell Collins Inc. (RCI) developed new metallic filters for separating red, green, and blue channels. These designs were not based on traditional absorptive dye layers. This technology is well-established, but difficult to change from pixel to pixel as pixels shrink in size and increase in number. These films are also quite lossy: throwing away needed light in low-light applications. The SNL-RCI technology investigated metal plasmonic filters. These patterns are a single thin layer and the metal pattern may be changed from one pixel to the next simply by varying the metal pattern shape or dimensions. This allows adjacent pixels to view different colors with an efficient processing method and without loss of as much loss as the dye technology.

36 MATERIALS SCIENCE↗

Big Area Additive Manufacturing (BAAM) Materials Development and Reinforcement with Advanced Composites

Additive manufacturing (AM) by extrusion deposition is rapidly developing as an energy efficient process that greatly reduces development time for new products including vehicle structures. Development of reinforced thermoplastic compounds that are specifically tailored to the AM process and possess the properties necessary for engineering structures is currently underway. This project focused on developing a fundamental understanding of printability by performing a number of polymer characterization tests, initial printability screenings, and basic mechanical property determinations for a number of compounds. Structural evaluations of more complex printed articles were also performed in order to build a database of mechanical performance for validation of structural simulations planned for Phase II. Included in the structural tests were components that were reinforced using a number of methods including over-wrapping with dry fabric and resin infusing to form an advanced composite having the shape of the 3D printed structure. The results indicate a number of factors that affect printability of materials, and initial structural analysis shows that the data generated will be useful for model validation.

36 MATERIALS SCIENCE↗

Weapon Systems Risk-Assessment Tool Review

To anticipate, and potentially mitigate, future problems in aging weapon systems, four unique riskassessment techniques were analyzed, including root-cause analysis tools, six-sigma problemsolving approaches, and lean six-sigma tools. Identifying the most efficient process, or tool, is crucial for successful application to current and future weapon systems, subsystems, and components. The following processes were reviewed: Fault Tree Analysis, Failure Modes and Effects Analysis, Bow-Tie Analysis, and Hazard and Operability Study. A systematic assessment was performed to determine the most desirable method, and included investigating qualitative versus quantitative characteristics, scope, process durations, advantages, and limitations. Presented results will outline the study findings and further illustrate a capacity to identify future issues and/or concerns, and ultimately, reduce risk.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗

Residential Solar Adoption Timelines and Impacts from the COVID-19 Pandemic

In this study we evaluate PII and other PV adoption timelines from 2017-2021. We use project-level data collected by the National Renewable Energy Laboratory (NREL) for the Solar Time-Based Residential Analytics and Cycle Time Estimator (SolarTRACE). Additionally, we conducted a survey of 171 AHJs about their experiences, challenges, and process changes during the first 18 months of the COVID-19 pandemic. The survey findings were supplemented with follow up interviews with 5 AHJs from 4 states. We find that the pandemic moderately increased the duration and variability of pre-install timelines (contract signing to install), particularly in the permit review phase (permit submit to approval). In contrast, post-install timelines (install to final utility interconnection) continued to decline during the pandemic. The net result is that overall project timelines (contract signing to final interconnection) continued to decline during the pandemic. Our findings suggest that AHJs and installers faced challenges throughout the pandemic but ongoing improvements in PII processes - particularly post-install processes - more than offset these challenges. Furthermore, the pandemic may have catalyzed or accelerated a widespread adoption of online/electronic permitting, among other process efficiency improvements.

14 SOLAR ENERGY↗

Challenges and Advances in Aqueous Processing of Corn Stover Pellets into High Concentration Slurries

Significant progress has occurred in developing combined enzyme hydrolysis and fermentation technologies for transforming lignocellulosic feedstocks into ethanol and other bioproducts. Various routes described in the literature show that low carbon footprint processes efficiently convert the cellulose and hemicellulose fractions of pretreated corn stover, wood chips, and sugarcane bagasse to sugars and to ethanol.Combinations of different pretreatments at high or low pH or in liquid hot water, followed by enzyme hydrolysis and fermentation or direct conversion of cellulose to ethanol (i.e., by consolidated bioprocessing)have been demonstrated. These successes have brought the need to preparing the feedstock – before it enters the biorefinery – into focus. This paper summarizes recent developments in liquefying corn stover,before pretreatment, so that slurries with yield stresses below 200 Pa are obtained and a “pumpable” corn stover slurry results at initial solids loadings of up to 300 g/L. The manner in which corn stover pellets are combined with water and enzyme in an agitated bioreactor is described, and properties that define slurry behavior are presented. Implications on biorefinery operations are explained in terms of particle properties and the preprocessing of corn stover as well as the team approach used to obtain these results.

Wassgren, Carl↗

Laser 3D printing of highly compacted protonic ceramic electrolyzer stack

Solid oxide electrolysis cells (SOECs) for H 2 production is a core technology for H2@scale. However, its conventional manufacturing methods adapted from the manufacture of solid oxide fuel cells (SOFC) need high cost, especially for small-volume production. The emerging laser 3D printing (L3DP) technology with computer-aided 3D printing and computer-controlled laser processing can fulfill layer-by-layer digital shaping and rapid in-situ consolidating feedstock into complicated geometries. L3DP, a promising additive manufacturing (AM) technology, has achieved significant success in manufacturing plastic and metal parts, which is currently attracting considerable attention for the cost-effective, rapid, and flexible manufacturing of heterogeneous multilayered ceramic devices (e.g., SOECs, SOFCs, and solid-state batteries). It is believed that the L3DP can integrate the advantages of selective consolidation of heterogeneous layers, accurate control of layer microstructures, high processing heat efficiency, high processing speed, high stack compactness, high stack design flexibility, and low stack sealing area for cost-effective, rapid, and flexible manufacturing of SOECs to meet DOE’s electrolyzer target.

08 HYDROGEN↗

A New Vehicle-to-Vehicle Communication System: Visual-Enhanced Cooperative Traffic Operations

The advent of Connected and Autonomous Vehicles (CAVs) has highlighted the necessity for robust communication systems between vehicles and their environment. This study introduces a novel vehicle-to-vehicle (V2V) communication system, termed the Visual-Enhanced Cooperative Traffic Operations (VECTOR) system. The VECTOR system addresses the need for robust communication by converting dynamic data (including velocity and yaw angle data) into binary code, which is displayed on an LED panel mounted on the top of the vehicle. Following vehicles detect this panel and decode the information using a camera, implementing a visual-based communication method. VECTOR system employs a comprehensive five-module process. Initially, polynomial fitting techniques are applied to velocity data over fixed time intervals using third-degree polynomials, with validation via R² and MSE metrics. The second module converts velocity and yaw angle data into binary form, thereby enhancing detection and processing efficiency. The third module focuses on improving detection stability across various environmental conditions to enhance traffic safety. The fourth module decodes the binary data back into trajectory information, ensuring the fidelity of velocity and yaw angles. The final module integrates eco-control through the VECTOR system, employing advanced control algorithms to minimize energy consumption in CAVs. Experimental evaluations conducted using a modified CAV test platform based on the Lincoln MKZ demonstrate the feasibility and efficiency of the VECTOR system, achieving a 75% R-squared accuracy rate in replicating original velocity data. This methodology not only highlights potential applications but also underscores significant implications for advancing CAV technology.

Ma, Ke↗

Advanced Data Management for the Wastewater Industry

This information sheet discusses the technology pillar Advanced Data Management as a pathway toward improving wastewater infrastructure sustainability and resiliency. To supplement existing literature on current technologies and policies for improving resiliency at wastewater treatment plants (WWTPs), this document aims to accomplish the following: • Summarize key technologies such as Supervisory Control and Data Acquisition (SCADA), digital twins, and smart sensors • Summarize relevant cybersecurity measures and data management tools available for WW utilities • Summarize advances in sensing and monitoring technologies • Serve as a comprehensive (though not exhaustive) repository for data management for wastewater utilities The Advanced Management Technical Information Sheet should be viewed as a general guide to established best practices for the water and wastewater sector when considering implementing energy capture and energy- or process-efficient technologies. Further details are presented in the SWIFt Technology Information Sheet Series for accompanying Technology Pillars.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Development of in-situ polymerized intrinsically conductive resin and low-cost carbon pigments offering high conductivity for sensing, EMI shielding and lighting protection

Electrically conductive composites are emerging across diverse industries such as electronic, automotive, aerospace, advanced air mobility, biomedical, infrastructure, defense and security offering static charge dissipation, electromagnetic interference shielding, lighting protection, sensing, dicing, corrosion monitoring, etc. Conductivity enhanced composites provide several advantages compared to conventional metals including weight reduction, corrosion resistance, energy efficient processability, tunable properties and multifunctionality. Polymers are typically insulating in nature and require conducting filler for electron transport. However, dispersion and polymer-filler interphases are critical and often disrupt conducting pathways. Besides, conductive fillers such as graphene, carbon nanotube, MXene, silver nanowire, etc. are expensive, limiting their wide adoption in composite industry. On the other hand, a limited number of intrinsically conductive polymers are available among which polyaniline (PANI) has been widely studied due to its high conductivity, thermal and chemical stability. However, PANI is difficult to process and exhibits weak mechanical properties. In brief, there is a significant demand for electrically conductive polymer formulation with cost-effective conducting fillers that offer processability in scale to expand the market of conductivity enhanced materials.

Kumar, Vipin [Oak Ridge National Laboratory (ORNL)↗

Bacterial Bioleaching and Biorecovery for Biomining Unconventional Rare Earth Element Feedstocks

Bacterial metabolic interactions with rare earth elements (REEs) can be harnessed for biomining unconventional feedstocks like abandoned coal-mine drainage (AMD). Pennsylvania has ~500 AMD passive remediation systems that can precipitate REE rich solids. REEs include yttrium and the lanthanide series that are used in modern energy and technology. Bacteria that metabolically interact with REEs can be used for biomining in an affordable efficient process that does not require hazardous chemical additives. Currently, the microbial metal mechanisms that contribute to REE biorelease and biorecovery are poorly understood. Our work shows acidogenic bacterial isolates (Bacillus mycoides JR07 and Bacillus pseudomycoides KB7) successfully bioleach a mixed REE solution from AMD solids by their organic acid production and biofilm formation. Further, our work shows the potential for bacterial lanthanide-dependent enzymes to recover lanthanides from a mixed REE solution; here we have bacterial isolate Methylobacterium sp. B3 that can recover soluble lanthanum. Whole genome sequencing of Methylobacterium sp. B3 predict lanthanide-dependent methanol dehydrogenase XoxF. Understanding the microbial metabolism and genes involved in the REE release and recovery is crucial to optimize the biomining of AMD solids. Our work addresses the growing need to develop novel REE mining methods from unconventional feedstocks.

biogeochemistry↗

Investigation of Cutter–Woodchip Contact Pressure in a New Biomass Comminution System

A Crumbler ® rotary shear system was recently developed to process fuel-grade woodchips into feedstocks having more uniform particle sizes for improved flowability and higher thermochemical output yield than a traditional hammer mill. It represents a significant innovation in the state of the art of biomass comminution equipment. However, the milling unit has experienced significant abrasive wear of the feeding teeth and cutters when processing hard and dusty feedstocks, such as logging residue and corn stover. Here, we present initial simulation results from a finite-element stress analysis of the rotary shear, which is used to investigate the dynamics of interaction between the cutters and woodchips. This is the first step for optimizing the cutter design to improve the system lifetime and processing efficiency, thus reducing downtime and improving overall productivity.

42 ENGINEERING↗

Flowability of Crumbler Rotary Shear Size-Reduced Granular Biomass: An Experiment-Informed Modeling Study on the Angle of Repose

Biomass has potential as a carbon-neutral alternative to petroleum for chemical and energy products. However, complete replacement of fossil fuel is contingent upon efficient processes to eliminate undesirable characteristics of biomass, e.g., low bulk density, variability, and storage-induced quality problems. Mechanical size reduction via comminution is a processing operation to engineer favorable biomass flowability in handling. Crumbler rotary shear mill has been empirically demonstrated to produce more uniformly shaped particles with higher flowability than hammermilled biomass. This study combines modeling and experimentation to unveil fundamental understandings of the relation between granular particle characteristics and biomass flow behavior, which elucidate underlying mechanisms and guide selection of critical processing parameters. For this purpose, the impact of critical material attributes, including particle size (2–6 mm), particle shape (briquette, chip, clumped-sphere, cube, etc.), and surface roughness, on the angle of repose (AOR) of milled pine chips were investigated using discrete element method (DEM) simulations. Forest Concepts Crumbler rotary shear system is used to produce milled pine particles within the same size range considered in DEM simulations. AOR of different sets of these particles were measured experimentally to benchmark DEM results against experimental data. Specific energy consumption for the comminution of biomass with different particle size and moisture content are measured for technoeconomic analysis. Our results show that the smaller size (2 mm) of pine particle achieves better followability (i.e., smaller AOR) while the energy cost of comminution is significantly higher and bulk density is almost the same as the 6-mm pine particles. For the 2-mm particle size, Crumbles from veneer have better flow properties than Crumbles from chips. Contrarily, no significant difference was observed between the AOR of the two materials for the 6-mm particle size. Furthermore, from DEM simulations, mechanical interlocking between particles was found as a dominant factor in determining AOR of complex-shaped particles such as milled pine, which cannot be accurately captured by using simple particle shapes (e.g., mono-sphere) with a rolling resistance model. Conversely, clumped-sphere model alleviates this limitation without increasing computational cost significantly and can be used for accurate representation of biomass granular particles when simulating free-flow behavior.

09 BIOMASS FUELS↗

Building Analytics Tool Deployment at Scale: Benefits, Costs, and Deployment Practices

Buildings are becoming more data-rich. Building analytics tools, including energy information systems (EIS) and fault detection and diagnostic (FDD) tools, have emerged to enable building operators to translate large amounts of time-series data into actionable findings to achieve energy and non-energy benefits. To expedite data analytics adoption and facilitate technology innovation, building owners, technology developers, and researchers need reliable cost–benefit data and evidence-based guidance on deployment practices. This paper fulfills these needs with the energy use and survey data from a wide-ranging research and industry partnership program that covers thousands of buildings installed with analytics tools. The paper indicates that after two years of implementation, organizations using FDD tools and EIS tools achieved 9% and 3% median annual energy savings, respectively. The median base cost and annual recurring cost for FDD are USD 0.65 per square meter (m2) (USD 0.06 per square foot [ft2]) and USD 0.22 per m2 (USD 0.02 per ft2), and are USD 0.11 per m2 (USD 0.01 per ft2) and USD 0.11 per m2 (USD 0.01 per ft2) for EIS. The common metrics and analyses that are used in the tools to support the discovery of energy efficiency measures are summarized in detail. Two best practice examples identified to maximize the benefits of tool implementation are also presented. Opportunities to advance the state of technology include simplified data integration and management, and more efficient processes for acting on analytics outputs. Compared with previous efforts in the literature, the findings presented in this paper demonstrate the effectiveness of building analytics tools with the largest known dataset.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Cellulose Nanofibers as Rheological Modifiers to Improve Biomass Slurry Processing and Fermentation

This study investigates the enhancement of biomass slurry processability through the addition of rheological modifiers, focusing on carboxymethyl cellulose (CMC) and TEMPO-mediated oxidized cellulose nanofibrils (TCNF). Three sets of experiments were conducted to assess the effects of these additives on slurry processing and fermentation. Initial experiments evaluated the slurry extrudability, concluding that TCNF aids extrusion similarly to CMC. Subsequent experiments explored slurry viscosity reduction mechanisms, revealing that while CMC significantly reduced the viscosity, TCNF’s impact is negligible. Additionally, TCNF performed comparably to CMC in water retention tests across different conditions, which suggests that TCNF have potential as an effective additive for maintaining slurry fluidity at high solid concentrations through enhanced water retention. Lastly, both additives were investigated to ensure that they did not impact hydrolyzed biomass fermentation. The findings suggest that TCNF’s mechanisms differ from those of traditional water-soluble polymers like CMC, offering insights into novel approaches to improve the biomass processing efficiency and subsequent fermentation.

Jamieson, Zachary↗