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DOE OSTI2024

Electrochemically Regenerated Solvent for Direct Air Capture with Co-generation of Hydrogen at Bench-scale

The goal of this final project report is to summarize the work conducted on project DE-FE0032125. In accordance with the Statement of Project Objectives (SOPO), the University of Kentucky Institute for Decarbonization and Energy Advancement (UK IDEA) (Recipient) developed an intensified process to capture CO 2 from ambient conditions (415 ppm CO 2 ). The process combines low-temperature solvent-aided membrane capture with electrochemically-mediated solvent regeneration to simultaneously capture ambient CO 2 while regenerating the solvent. The technology employs only two primary units, a regenerator and an absorber/contactor, while generating high purity hydrogen as a co-product that can be sold, used for energy storage, or cost-saving depolarization of the direct air capture (DAC) system during the grid peak demand, allowing for flexible operation. Since the technology is powered directly by DC electricity, it can seamlessly tie in with power sources like solar cells without the need for AC/DC converters, therefore allowing for a remote operation to further mitigate greenhouse gas generation toward deploying a negative carbon emissions technology that is completely decoupled from the carbon emissions from the power source for the DAC unit. The completion of the project results in significant progress toward the Department of Energy’s (DOE’s) goal of advancing lab and bench-scale DAC systems to a sufficient maturity level that can justify their continued scale-up through the verification testing of the electrochemically regenerated solvent system for DAC with co-generation of hydrogen at bench-scale. The technology addressed the complexities of incumbent DAC systems by demonstrating at ambient conditions (1) low gas-side pressure-drop facile CO 2 capture via an intensified membrane absorber with in-situ regenerated hydroxide as capture solvent, (2) multi-functional electrochemical regenerator for hydroxide regeneration, CO 2 concentration and hydrogen production at less than 3 V, and (3) stable DAC performance including >90% capture with air influent at the CFM scale. The data from this project enables the completion of Techno-Economic Analysis (TEA) and Life Cycle Assessment (LCA). TEA and LCA demonstrate the potential of the proposed electrochemical solvent-based process to be a viable DAC option. The analysis did not identify any obvious concern for the bench-scale operation and no apparent barriers to implementing UK IDEA carbon capture and solvent regeneration system at a larger scale.

08 HYDROGEN↗

DOE OSTI2021

Out of the Lab: 3D Printing on Non-Ideal Surfaces

In this work, coaxial direct ink writing is utilized to print sensitive or encapsulated materials onto heterogeneous and rough substrates. By enclosing the core fluid within a rigid ceramic shell, continuity is maintained even when printing on substrates traditionally considered challenging. This work presents the development of a coaxial ceramic direct ink writing system and investigates co-flow dynamics through microfluidic principles. A specially designed coaxial nozzle enables the co-extrusion of an alumina shell, with indium-tin-oxide inks serving as the core material. This approach allows the fabrication of core-shell ceramic structures suitable for future high-temperature applications on rough surfaces. The colloidal inks are tailored to achieve the necessary rheological properties and sintering performance. Additionally, flow simulations, guided by microfluidic co-flow principles, are employed to define the processing parameters for coaxial printing, ensuring precise control over the core-shell architectures. Physical modeling is further applied to study core deformation and eccentricity. These simulations are experimentally validated, supporting the successful deposition of coaxial ceramic features on heterogeneous, high-temperature ceramic substrates.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2026

Enabling microbial electrolysis cell scale-up via electrochemistry-, hydrodynamic-, and microbial ecology-informed framework

Microbial electrolysis cells (MECs) can produce green hydrogen while removing organic contaminants from liquid waste streams by leveraging the metabolic activity of electroactive microorganisms. Despite their potential in a sustainable, circular economy, large-scale MECs that can treat relevant volumes of wastewater have failed to deliver performance proportional to their lab-scale counterparts. The reason behind this lower performance at scale remains unclear. Here, in this study, we developed a combined electrochemistry-, hydrodynamic-, and microbial ecology-informed framework to analyze and optimize MEC performance during scale-up, enabling accurate quantification of major limitations and the identification of strategies to overcome them, ultimately facilitating equivalent performance at scale. Applying this framework to the scale-up of a zero-gap MEC from 9 cm 2 electrode area to 100 cm 2 electrode area, resulted in similar maximum current densities in a 100 cm 2 MEC (21.7 ± 1.1 A/m 2 ) compared to a 9 cm 2 system (25.1 ± 2.7 A/m 2 ), as well as equivalent hydrogen production rates of 69.3 L/L-d (100 cm 2 ) and 67.7 ± 2.4 L/L-d (9 cm 2 ). COMSOL flow dynamics simulations were used to scale up the reactor configuration without negatively affecting electrolyte velocity and distribution in the cell, minimizing the increase in internal resistances during scale-up (11.7 ± 0.5 mΩm 2 at 9 cm 2 ; 19.7 ± 1.3 mΩm 2 at 100 cm 2 ). Microbial community structures were assessed at both scales using high-throughput sequencing, highlighting the differences of populations across electrode dimensions and operational parameters. The framework presented here accelerates the development of effective strategies toward the scale-up of MECs by furthering the understanding of how electrochemical, hydrodynamic, and microbial ecology parameters change as the reactor dimension is increased. Ultimately, this approach contributes to advancing electrochemical biotechnology toward practical deployment in energy-efficient wastewater treatment systems.

Flow path↗

DOE OSTI2025

Implementation of a turbine farm model into the Energy Exascale Earth System Model for investigation and quantification of global climate impacts

Although there has been widespread deployment of wind farms in the United States, and plans to continue deployment into the future, the complete effects of wind farms on Earth systems are not well understood. The work performed here has incorporated wind farm models into the Energy Exascale Earth System Model (E3SM) capable of simulating the effects of extracting momentum from the atmospheric flow field using power generating wind farms. This new capability will allow scientists to quantify the impacts of wind farm induced changes on Earth systems by exploiting E3SM’s ability to couple atmospheric, oceanic, and biogeochemical (BGC) models on a global scale and monitor precipitation levels, extreme weather events, soil moisture content and jet stream location over decades-long time periods. This tool will be used to inform decision making on wind farm citing and will contribute to the Lab’s ability to assess energy technology impacts on the environment and evaluate the trade-offs between energy infrastructure investments and their impacts on natural systems.

17 WIND ENERGY↗

DOE OSTI2019

Component Testing Supporting SHINE Medical Technologies

SHINE is going to be implementing a tritium gas processing system to support their Mo-99 work. They have requested that the Hydrogen Process Group of SRNL does some required testing on the system components before startup. The lab plans on conducting both seismic and valve testing. Test Plan: - Testing 10 1C valves 750,000 cycles or until failure; - Testing intervals will be every couple thousand; - 1C valves will have metal stem tips instead of Polymer due to being in a tritium prone area; - Hope that the valves will still have enough force to create a sufficient seal with metal stem tips; - Goal is for a more cost and space efficient alternative to the 5C valves. Status: - Received half the parts, waiting on the other half due to long procurement times; - Waiting on the LabVIEW program which will perform the testing. Path Forward: - R and DE to change out the stem tips (July 2018); - Assemble Manifold (July 2018); - Perform Testing (August 2018); - Report (September 2018). Since SRNL does not own a shaker table, the test will be conducted at a facility like the NTS Facility in Huntsville, Alabama. Test Plans: - Leak Testing; - Use LabVIEW to monitor for leaks before, during and after seismic testing with an Electronic Pressure Transducer; - If leak is detected, sniff for location using Helium Leak Detector; - Connector Testing; - Use LabVIEW to test for electrical continuity before, during and after seismic testing; - If a connectors continuity is interrupted, further testing will be performed; - Each Pin in faulty connector will be testing to determine specific location of disruption. Path Forward: - Pick a Qualified Vender for testing (July 2018); - Procure the connector plugs (July 2018); - Send components and test plan to facility for testing (August 2018); - Perform Testing (August-September 2018); - Report Results (September 2018)

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2025

Aerogel with Unparalleled Performance and Cost-Effectiveness for All Insulation Needs (CRADA Final Report)

Westwood Aerogel investigated the reproducible production of an ambiently or electromagnetic spectrum assisted drying of extremely porous aerogel materials. Traditional aerogel processing is limited by low throughput and scalability due to supercritical drying. Westwood Aerogel’s advanced manufacturing process enables commercialization and deployment at scale, making aerogel materials more accessible to a range of industries and applications. We focused on shifting from the lab scale environment to manufacturing prototypes. The initial manufacturing model is based on the float glass process, which is the industry standard for glass window production, and the paper drying process. By incorporating an ambient drying process a continuous line model can be used from start to finish. The project team worked to develop a continuous manufacturing system to scale-up and reduce costs while maintaining the lightweight and insulative properties of aerospace-grade aerogel. While aerogels are extremely insulative, lightweight, and thin materials (making them ideal insulators across application spaces), high costs and stagnant innovation have hampered their wider adoption. Traditional manufacturing of aerogel requires supercritical extraction of pore fluid to obtain highly insulating materials, which is an energy intensive batch process and limits aerogel production output. Westwood Aerogel’s proprietary ambient drying process enables the continuous production of highly insulative aerogel materials without the use of supercritical extraction.

36 MATERIALS SCIENCE↗

DOE OSTI2020

A New Family of Proton‐Conducting Electrolytes for Reversible Solid Oxide Cells: BaHf x Ce 0.8− x Y 0.1 Yb 0.1 O 3− δ

Abstract Reversible solid oxide cells based on ceramic proton conductors have potential to be the most efficient system for large‐scale energy storage. The performance and long‐term durability of these systems, however, are often limited by the ionic conductivity or stability of the proton‐conducting electrolyte. Here new family of solid oxide electrolytes, BaHf x Ce 0.8− x Y 0.1 Yb 0.1 O 3− δ (BHCYYb), which demonstrate a superior ionic conductivity to stability trade‐off than the state‐of‐the‐art proton conductors, BaZr x Ce 0.8− x Y 0.1 Yb 0.1 O 3− δ (BZCYYb), at similar Zr/Hf concentrations, as confirmed by thermogravimetric analysis, Raman, and X‐ray diffraction analysis of samples over 500 h of testing are reported. The increase in performance is revealed through thermodynamic arguments and first‐principle calculations. In addition, lab scale full cells are fabricated, demonstrating high peak power densities of 1.1, 1.4, and 1.6 W cm −2 at 600, 650, and 700 °C, respectively. Round‐trip efficiencies for steam electrolysis at 1 A cm −2 are 78%, 72%, and 62% at 700, 650, and 600 °C, respectively. Finally, CO 2 H 2 O electrolysis is carried out for over 700 h with no degradation.

Murphy, Ryan↗

DOE OSTI2024

Negative Medium-Voltage Direct Current Discharges in Air under Simulated Sub-Atmospheric Pressures for All-Electric Aircraft

The increase in the global temperature due to greenhouse gas emissions is a major concern to the world. To achieve the goal of zero emissions by 2050 in the USA the practical realization of all-electric vehicles, particularly all-electric aircraft (AEA), is important. For the design of electrical power systems (EPSs) in all-electric aircraft, a bipolar medium-voltage direct current (MVDC) system of ±5 kV is being investigated. However, several challenges manifest when using such voltages in a low-pressure environment. One of the main challenges is the partial discharge (PD) behavior of the insulation. It is important to study the PD behavior of the insulation by simulating the aviation environment in the lab. This work aimed to study the partial discharge behavior of air under a negative DC voltage in a needle-to-plane electrode geometry by simulating the aviation pressures in the lab. The partial discharge inception voltage (PDIV) and the breakdown voltage (BDV) show an obvious pressure-dependent variation. Regression analysis was performed to better understand the relationship between the PDIV and pressures. Plots were drawn for the average discharge current at each voltage step until breakdown. This paper’s findings can provide valuable insight into the design of EPS for an AEA. To the best of our knowledge, such a study has not been carried out to date.

air discharge↗

DOE OSTI2025

U.S. Efforts in Support of Examinations at Fukushima Daiichi - September 2024 Meeting Notes

Information obtained from Fukushima Daiichi Nuclear Power Station (Daiichi) is required to inform future Decontamination and Decommissioning (D&D) activities, improving the ability of the Tokyo Electric Power Company Holdings, Incorporated (TEPCO Holdings) to characterize potential hazards and to ensure the safety of workers involved with cleanup activities. This information also has important implications for the safety and operation of U.S. Commercial nuclear power plants. A collaborative U.S. and Japanese effort was initiated in 2014 by the Department of Energy Office of Nuclear Energy to identify Daiichi examination needs and evaluate recent Daiichi examination data to address these needs. This document summarizes information presented at and findings, action items, and recommendations by U.S. and Japanese experts in reactor safety and plant operations during the September 2024 Forensics Effort meeting. Significant safety insights were obtained in several areas: system and component performance, radionuclide surveys and sampling, debris end-state location, combustible gas effects, and plant operations and maintenance. In addition to reducing uncertainties and knowledge gaps in severe accident modeling progression, these insights continue to be used to assess whether additional updates are needed in guidance for severe accident prevention, mitigation, and emergency planning. Furthermore, Daiichi-related activities, such as code modeling improvements and analysis, testing, and new technology deployment efforts, have the potential to offer additional safety and economic benefits to the operating fleet and new light water reactor (LWR) and non-LWR designs.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2025

Notes on Bayliss Taper for Monopulse Radar

A radar system’s antenna characteristics are fundamental to its performance. A principal defining feature of an antenna’s performance are its often problematic sidelobes. Often in monopulse antenna topologies, the emphasis has been on the sum channel sidelobes at the expense of difference channel sidelobes. Edward Bayliss published a paper detailing a design procedure for managing the difference channel sidelobes. The resulting aperture taper now is identified by his name. This report analyzes his taper derivation, and resulting performance attributes, after which some implementation comments are rendered.

42 ENGINEERING↗

DOE OSTI2024

Performance Study of CXL Memory Topology

This paper presents a comprehensive evaluation of the performance impact of various Compute Express Link (CXL) memory topologies, with a particular emphasis on CXL switches, in the context of High- Performance Computing (HPC) and Large Language Model (LLM) inference workloads. Our study unveils significant performance variations across different topologies, demonstrating that certain configurations yield superior performance for specific workloads. These findings underscore the critical importance of tailored topol- ogy selection in optimizing system performance. Additionally, we address the inherent challenges associated with integrating CXL switches, including overhead considerations and routing complex- ities. Our research highlights the necessity for thorough evalua- tion methodologies to fully leverage CXL technology’s potential in contemporary computing environments. These insights provide valuable guidance for system architects and data center operators in designing and optimizing CXL-based infrastructures for diverse workload requirements.

CXL, memory, Artificial Intelligence (AI), HPC↗

DOE OSTI2024

High Efficacy Validation of Hydride Mega Tanks at the ARIES Lab (HEVHY METAL)

The High Efficacy Validation of Hydride Mega Tanks at ARIES Lab (HEVHY METAL) project will advance materials-based hydrogen storage technologies by large-scale demonstration and identification of deployment pathways. This includes demonstrating how two metal hydride HY2MEGA subsystems are installed with megawatt-scale green hydrogen infrastructure; validating its performance via rates, capacities, and efficiencies; and investigating supply and demand side techno-economics.

ARIES↗

DOE OSTI2023

High Efficacy Validation of Hydride Mega Tanks at ARIES Lab (HEVHY METAL)

ARIES↗

DOE OSTI2018

Toroidal merger simulations for the JLEIC bunched beam electron cooler ring

The bunched beam electron cooler ring for the Jefferson Lab Electron-Ion Collider (JLEIC) requires a merger system to transport magnetized electron beams of two different energies to the same energy recovery linac (ERL) beamline. The system is especially challenging compared to existing mergers for ERL or hadron cooling applications (as at COSY) due to the small separation in energy between the two beams; for the JLEIC bunched beam cooler, the two beam energies may only differ by a factor of 4. An additional complication is the use of a magnetized beam. A toroidal merger system is studied using G4Beamline/GEANT4. Preservation of the quality of the low energy beam from the injector is especially vital for efficient cooling performance and compatibility with the ERL. Effects of the toroidal system on transverse and longitudinal emittances of the magnetized beams, as well as space charge effects, are presented and discussed.

Sy, Amy V.↗

DOE OSTI2020

Bat Impact Minimization Technology: An Improved Bat Deterrent for the Full Swept Rotor Area of Any Wind Turbine

The growth in the number of wind turbine generators has led to a significant number of fatal interactions with bat species. The need to reduce the number of bat fatalities while minimizing power losses is the greatest conservation challenge for wind energy development in parts of the country, according to the American Wind Wildlife Institute. Technological solutions that can also allow turbines to operate normally would generate the maximum electricity and avoid financial losses. Bats use echolocation to perceive their surroundings by listening to features of echoes from their high frequency vocal signals reflecting from targets. In this project, Frontier Wind built on previous research demonstrating that ultrasonic noise can mask echolocation and act as a repellent or deterrent to bat flight activity. Whereas the initial study only broadcast ultrasonic transmissions from the center of the turbine, the Strike Free™ system developed for this project extended the ultrasonic coverage to the entire area swept by the turbine blades. Frontier Wind designed the system components and their integration and then tested them in the lab and in the field at Pattern Energy’s Hatchet Ridge Wind Facility near Redding, California. The researchers used an acoustic model to determine the optimal configuration of transmitters along the blades to provide sound transmission coverage across the turbine rotor swept area volume. The custom ultrasonic transmitters were designed specifically for the echolocation frequencies of the four main bat species that have been shown to have died at Hatchet Ridge, although the transmitters can be customized for different frequencies as needed in other geographic locations. The Strike Free™ system shows promise for reducing bat fatalities, and the path to commercialization requires further testing to validate and optimize performance in the field.

17 WIND ENERGY↗

DOE OSTI2025

Long-Term Photovoltaic System Performance in Cold, Snowy Climates

As countries around the world transition towards renewable energy, there is increasing interest in using photovoltaic (PV) technologies to help decarbonize northern and alpine communities due to their scalability and affordability. However, a barrier to large-scale adoption of PV in cold climates is long-term performance uncertainty under snowfall, freeze-thaw cycles, low temperatures, and high winds. In this work, we provide a comprehensive review of published silicon degradation rates in cold Koppen-Geiger climate classifications of Dfb (humid continental), Dfc (subarctic), and ET (tundra). We first analyze the system degradation rates of three subarctic ground-mounted photovoltaic sites in North America using the RdTools year-on-year method: an Al-BSF double-axis tracking site in Fairbanks, Alaska (65degrees N); a PERC and silicon heterojunction bifacial vertical and south-tilted site in Fairbanks, Alaska; and a PERC south-facing fixed-tilt site in Fort Simpson, Northwest Territories (62degrees N). Degradation rates of these newly analyzed sites vary between -0.4%/year and -1.5%/year. Combining these data with previously reported cold climate degradation rates, we show that the distribution of cold climate degradation peaks at -0.1%/year to -0.2%/year but has a large tail with rates above -0.5%/year. The average reported cold climate degradation rate is -0.45%/year, whereas the median value is -0.33%/year. These results suggest that despite frequent freeze-thaw cycles and potential exposure to high wind and snow loads, PV systems in cold climates tend to degrade slower than PV systems in warmer climates. The limited sample size of reported degradation rates in cold climates (27) motivates the need for further data acquisition and monitoring efforts as new technologies are deployed.

14 SOLAR ENERGY↗

DOE OSTI2017

Pilot-Scale Silicone Process for Low-Cost Carbon Dioxide Capture. Final Scientific/Technical Report

GE Global Research has developed, over the last 8 years, a platform of cost effective CO 2 capture technologies based on a non-aqueous aminosilicone solvent (GAP-1m). As demonstrated in a previous funded DOE project (DE-FE0007502), the GAP-1m solvent has increased CO 2 working capacity, lower volatility and corrosivity than the benchmark aqueous amine technology. The current report describes the cooperative program between GE Global Research (GE GRC), and the National Carbon Capture Center (NCCC) to design, construct, and operate a pilot-scale process using GAP-1m solvent to demonstrate its performance at 0.5 MWe. (i) Performance of the GAP-1m solvent was demonstrated in a 0.5 MWe pilot with real flue gas for over 900 hrs. of operation using two alternative desorption designs: a Continuous Stirred Tank Reactor (CSTR), and a Steam Stripper Column (SSC). The CSTR is a one-stage separation unit with reduced space requirements, and capital cost. The alternative is a multi-stage separation column, with improved desorption efficiency. Testing the two desorber options allowed us to identify the most cost effective, and space efficient desorber solution. (ii) CSTR Campaign: The CSTR desorber unit was designed, fabricated and integrated with the pilot solvent test unit (PSTU), replacing the PSTU Steam Stripper Column at NCCC. Solvent management and waste water special procedures were implemented to accommodate operation of the non-aqueous solvent in the PSTU. Performance of the GAP-1m solvent with the CSTR was demonstrated for over 500 hrs. while varying temperature of the desorption (230 – 265 oF), solvent circulation rate (GAP-1m : CO 2 (molar) = 1.5 – 4), and flue gas flow rates (0.2 – 0.5 MWe). Solvent carry-over in the CO 2 product was minimized by maintaining water content below 5 wt.%, and desorption pressure at 7 psig. CO 2 capture efficiency achieved was 95% at 0.25 MWe (GAP-1m : CO 2 = 4 (molar), 230 oF desorption), and 65% at 0.5 MWe (GAP-1m : CO 2 (molar) = 1.5, 248 oF). Solvent loss was dominated by thermal degradation of the rich solvent. (iii) Steam Stripper Column Campaign: Higher expected cost of the solvent vs. aqueous amines makes solvent management a top priority to maintain the low cost for the process. During the testing of the GAP-1m solvent with the CSTR, thermal degradation of the rich solvent was found to be the main mechanism in solvent loss. Small amounts of water in the working solution were found to be an effective way to enable steam stripping, thereby lowering desorption temperature, and hence reducing thermal degradation. Steam stripping also increased working capacity by 30% due to a more efficient desorption. The concept was first tested in a glass stripping column (lab scale, GE GRC), optimized in a continuous bench scale system (2 kWe, GE GRC), and demonstrated in a 0.5 MWe PSTU at NCCC. No special system modifications were required to the PSTU to accommodate the testing of the non-aqueous GAP-1 solvent with the regenerator column. SSC was found to be more robust towards solvent entrainment (H 2 O < 35 wt.%). 90 – 95% CO 2 capture efficiency was achieved under stoichiometric conditions at 0.5 MWe (235 oF desorption, 2 psig and 19 wt. % H 2 O). Both CO 2 capture efficiency and specific duty reached optimum conditions at 18 wt.% H 2 O. Low amine degradation (< 0.05 wt.%/day) was recorded over 350 hrs. of operation. Controlled water addition to GAP-1m solvent decreased the desorption temperature, thermal degradation, and improved the CO 2 working capacity due to more efficient absorption and desorption processes. Under these conditions, the GAP-1m solvent exhibited a 25% increased working capacity, and 10% reduction in specific steam duty vs. MEA, at 10 oF lower desorption temperature. (iv) Techno-economic Analysis: The pilot-scale PSTU engineering data were used to update the capture system process models, and the techno-economic analysis was performed for a 550 MW coal fired power plant. The 1st year CO 2 removal cost for the aminosilicone-based carbon-capture process was evaluated at $48/ton CO 2 using the steam stripper column. This is a 20% reduction compared to MEA, primarily due to lower overall capital cost. CO 2 cost using the CSTR desorber is dominated by the economics of the solvent make-up. The steam stripper desorber is the preferred unit operation due to a more efficient desorption, and reduced solvent make-up rate. Further reduction in CO 2 capture cost is expected by lowering the manufacturing cost of the solvent, implementing flowsheet optimization and/or implementing the next generation aminosilicone solvent with improved stability and increased CO 2 working capacity.

0.5 MW Pilot↗

DOE OSTI2025

Jacobian-based model diagnostics and application to equation oriented modeling of a carbon capture system

It can be difficult to identify the specific variables or equations responsible for convergence issues in large mathematical programming models. The Institute for the Design of Advanced Energy Systems Integrated Platform (IDAES-IP) contains a tool to identify poorly scaled constraints and variables by searching for rows and columns of the Jacobian matrix with small L2-norms. A singular value decomposition is then performed to identify degenerate sets of equations and remaining scaling issues. Here, this work presents a flowsheet developed for post-combustion carbon capture using a monoethanolamine (MEA) solvent system as a case study. This work takes the reader through the entire process of model diagnostics and reformulation, from a basic introduction to the mathematics behind these model diagnostics to the reformulations necessary to make the model numerically robust, including a significantly modified enhancement factor model.

IDAES↗