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DOE OSTI2023

Advanced Monitoring and Control in the ANL METL Facility Using an Engineering Digital Twin

The potential benefits of using an engineering digital twin to achieve greater autonomy for monitoring and control functions in advanced reactors was investigated for the Mechanisms Engineering Test Loop (METL) liquid sodium facility at Argonne National Laboratory. The METL sodium purification system served as a representative system as it requires significant human in-the-loop interaction to accomplish its design function. The objective was to demonstrate how real-time operation could be automated while preserving oversight of the operator for ensuring that the system design functions are met. A digital twin model of the purification system was developed for both the cold trap purification loop and plugging meter diagnostic loop using information from the METL piping and instrumentation diagram (P&ID). Automated monitoring and diagnosis of component degradation in the METL facility was demonstrated in tests using the PRO-AID health monitoring software with the digital twin model incorporated in the library of components. Component failures were introduced and were successfully diagnosed in real time. These tests serve to demonstrate an advanced monitoring capability able to differentiate sensor degradation from component degradation, to generate a rank ordering of probabilities of different failure mechanisms that serves to circumvent the false alarm problem with current anomaly detection methods, and how facility monitoring can be transformed from anomaly detection to identification of a specific fault. Automated control of the purification system was demonstrated through simulations that exercised a model predictive controller designed using the digital twin model. Results of these simulations compared favorably with experimental data showing very good reference tracking response with negligible overshoot. In conclusion, these pilot tests and simulations successfully demonstrated the use of a digital twin for improved automation of monitoring and control. It was shown how the digital twin enables switching between control modes from cold trap operation where impurities are removed to plugging meter operation where impurity concentrations are measured.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

IER-484 CED3b Report: AFRRI ER1 Dosimetry Characterization

This report presents the preliminary work for IER 484, the characterization of the leakage radia tion field from the TRIGA reactor at the Armed Forces Radiobiology Research Institute (AFRRI). The purpose of the dose characterization is to establish the reference dose needed to execute a NAD inter-comparison exercise. During the week of August 20th, a team from Lawrence Livermore National Laboratory (LLNL), Sandia National Laboratory (SNL), and Institut de Radioprotection et de Sûreté Nucléaire (IRSN) performed various measurements in AFRRI’s TRIGA ER1 (Exposure Room 1) with Passive Neutron Spectrometer (PNS) spheres and nuclear accident dosimeters (NADs) mounted on Bottle Manikin Absorption (BOMAB) phantoms (to simulate doses received by people) and additional NADs mounted on aluminum plates (to simulate doses in free air). Without Atomic Weapons Establishment (AWE), LLNL became responsible for measuring the neutron spectrum using PNS spheres. SNL is responsible for providing photon dose data. LLNL, SNL, and IRSN each deployed their own NADs, which will be compared to the reference dose measured. Final characterization of the dose field based on analyzed data will be presented in the CED4a report.

42 ENGINEERING↗

DOE OSTI2024

Exhibit D Scope of Work and Technical Specifications MOX Rod Reduction

PROJECT/PROGRAM GOALS AND OBJECTIVES: The Los Alamos National Laboratory (LANL), here after referred to as the CONTRACTOR, plans to provide NQA-1 service and support for the disposition of PF-4 basement inventory of Areva fuel rods. These fuel rods need to be reduced in length for proper shipping and disposition. The objective of this acquisition is to enter into an agreement with a SUBCONTRACTOR that shall provide expertise, materials, input for procurement of specialized tooling to be identified, and mockups for size reduction and FS65 disposition. Handling and size reduction of the Areva rods would take place at LANL. Physical work at LANL will be performed by the CONTRACTOR’s field execution team, portions of this work will have expertise provided by the SUBCONTRACTOR. As cited below via an add alternative and supplemental site visit(s) to LANL the CONTRACTOR may request the SUBCONTRACTOR to ship the necessary transportation, handling and packaging equipment at the SUBCONTRACTOR’s location to the CONTRACTOR’s facility for size reduction activities at LANL by the CONTRACTOR’s self-perform field execution team. In addition, the SUBCONTRACTOR shall provide subject matter expertise to CONTRACTOR personnel cutting the mockup Areva Fuel Rod at LANL as a rehearsal prior to CONTRACTOR cutting the actual MOX Fuel Rod if this add alternative is exercised.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

Design and Manufacturing of High Performance, Reduced Charge Heat Exchangers

Air-to-fluid heat exchangers (HXs) play a critical role as the main heat transfer component in Heating, Ventilation, Air-Conditioning, and Refrigeration (HVAC&R) systems. However, their airside thermal resistance significantly inhibits their overall performance. Furthermore, these HXs must be continually more compact to meet the latest refrigerant charge limits to reduce emissions. Recent literature suggests that traditional HX geometries (e.g., round or flat tubes with fins), have reached their limits, and more sophisticated shape- and topology-optimized designs are required to achieve the next jump in performance. This research sheds light on the next generation of air-to-refrigerant HXs and aims to address several practical issues to commercialization such as novelty challenges (improved performance for significant charge reduction; modeling expertise & time investment), manufacturing challenges (non-round tube manufacturing; tube-header integration; product qualification, e.g., burst pressure testing, extreme operational environment, etc.), and operational challenges (flow maldistribution, fouling & wetting, noise & vibration). For example, a >20% improvement on one (or more) HX-level performance metrics (e.g., envelope volume, airside pressure drop, face area, capacity, refrigerant charge, weight, cost, etc.) must be achieved before a HX design is considered for commercialization. We present a new, comprehensive and experimentally validated air-to-refrigerant HX optimization framework with simultaneous thermal-hydraulic performance and mechanical strength considerations for novel, non-round, shape- and topology-optimized tubes capable of optimizing single and two-phase HX designs for any refrigerant choice and performance requirement with significant engineering time savings compared to conventional design practices. The framework was exercised for a wide range of applications and refrigerants, resulting in HXs which achieved greater than 20% improved performance, 20% reductions in size, and 25% reductions in refrigerant charge. To enable non-round tube bundle use in next generation HVAC&R equipment, novel manufacturing techniques were investigated, including the development of conventional manufacturing methods for small diameter, non-round tubes and novel tube-header integration strategies. In total, ten HX prototypes were manufactured, nine using conventional methods directly attributed to this project and one using advanced additive manufacturing methods. The five-year manufacturing feasibility of the proposed HXs was found to have a good outlook. The non-round tube HX simulated performance was validated through comprehensive experimental testing, including nine in-house component-level tests, one independent component-level test at an industry partner laboratory, and in-house system-level tests of using a commercially-available, residential packaged A/C unit which was retrofitted with a non-round tube prototype HX. It was found that HX designs proposed by the new framework can successfully predict experimental thermal-hydraulic performance within ±10-20% the first time with no manual design changes, eliminating the need for time-consuming and expensive prototyping efforts. This work will accelerate design and time to market for next generation HXs while simultaneously facilitating industry transition to new refrigerants at lower charge.

42 ENGINEERING↗

DOE OSTI2023

The 2021 Blind PVPMC Modeling Intercomparison

This document provides the instructions for participating in the 2021 blind photovoltaic (PV) modeling intercomparison organized by the PV Performance Modeling Collaborative (PVPMC). It describes the system configurations, metadata, and other information necessary for the modeling exercise. The practical details of the validation datasets are also described. The datasets were published online in open access in April 2023, after completing the analysis of the results.

14 SOLAR ENERGY↗

DOE OSTI2024

Development of a Sulfur Tolerant CHG Process [Abstract]

The goal of this project is to overcome CHG catalyst sulfur poisoning to enable commercially viable CHG processing of HTL aqueous waste streams with reasonable catalyst turn-over rates. If successful, several of the following objectives will be achieved. (1) Identification and confirmation of the efficacy of sulfur-tolerant catalyst for the conversion of soluble organics in HTL aqueous byproduct to methane or hydrogen. (2) Demonstration of long-term stability of sulfur tolerant catalysts. (3) Identification and exercise of a means to produce larger quantities of the promising catalyst (i.e., sufficient catalyst for a CHG system with a through put of 10 to 20 L/h of aqueous byproduct) (4) Demonstration of the technical feasibility of a novel sulfur removal process and approach for scale up and application.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2024

Developing Platinum-Group-Metal-Free Catalysts for Oxygen Reduction Reaction in Acid: Beyond the Single Metal Site

This project is to develop M (x) -N-C catalysts with dense multiple metal center (MMC) sites to meet the DOE 2025 activity target of 0.044 mA/cm 2 at 0.9 V IR-free ., as well as other goals such as durability. We have made important contributions to both catalyst development and fundamental understandings of the active sites in M-N-C catalysts in this project. We successfully made M (x) -N-C catalysts with some multiple metal center (MMC) sites by combining ionothermal carbonization with chemical vapor deposition (CVD). These catalysts, however, are not as active as the most active single-atom Fe-N-C catalysts made by the similar CVD process, owing likely to the low site density and the presence of inorganic Fe species such as iron carbides and nanoparticles. The most significant accomplishments we achieved in this project are: (1) we unraveled the formation pathway of Fe-N 4 sites during pyrolysis step-by-step and identified the trans-metalation mechanism, in collaboration with Deborah Myers and her colleagues at Argonne National Laboratory (ANL); (2) inspired by this finding, we pioneered the CVD synthesis of M-N-C catalysts (M = Mn, Fe, and Co), in which the Fe-N-C catalyst by CVD demonstrated an ORR activity of 33 mA/cm 2 at 0.9 V in H 2 -O 2 proton exchange membrane fuel cells (PEMFCs), very close to the ultimate goal of 35 mA/cm 2 of our project. This catalyst is the first Fe-N-C catalyst that contains only D1 sites without the D2 sites; whereas D1 and D2 sites have been always identified by Mossbauer in previous Fe-N-C catalysts. This finding helps to understand what the D1 and D2 sites are and their roles in catalyzing the ORR. (3) by improving the mass transport of the carbon matrix prior to the CVD process, the revised Fe-N-C catalyst made by CVD delivered a maximum power density of 0.53 W/cm 2 in H 2 -air PEMFCs. The improvement strategy was partly inspired by the computational modeling work by Adam Weber from LBNL, the Co-PI of this project, by developing, coding, and exercising a continuum level model of transport phenomena within a PGM-free catalyst layer. The model demonstrated that local resistances combined with limited site density of the PGM-free catalyst can result in limiting currents and poor polarization performance. The model also gave design guidance for impact of ECSA and overall catalyst-layer thickness. However, both Fe-N-C and Co-N-C catalysts developed by CVD showed poor durability in PEMFCS, in comparison with the traditional M-N-C catalysts synthesized via regular pyrolysis process. Consequently, we did not achieve the proposed durability targets. Despite so, we believe the FeNC-CVD catalysts with the poor durability and D1 sites only provides an excellent platform to understand the degradation mechanism of Fe-N-C in PEMFCs, the most important challenge in the development of M-N-C catalysts.

08 HYDROGEN↗

DOE OSTI2022

Heartbeat: Detecting Malware by Periodic Power Signal Injection and Monitoring

Rootkits and other stealthy malware attempt to conceal their presence on a computer by making changes to the host computer’s operating environment. ORNL’s Heartbeat technology detects these changes, and thus the malware itself. Heartbeat operates by directly monitoring the DC power consumption of the computer while a set of operations, the “heartbeat,” is executed periodically. These operations exercise parts of the operating system that are common targets of malware tampering. The power consumption during these heartbeat events is monitored and then compared to a previously learned baseline, with any significant deviation detected and analyzed. This technology has been tested and validated in a laboratory environment, and ORNL is currently seeking a deployment partner to allow for further in-context development and testing of this technology.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2024

Central Asia Seismic Hazard Assessment (CASHA): A Probabilistic Seismic Hazard Assessment for Kazakhstan, Kyrgyzstan and Tajikistan

Probabilistic seismic hazard assessments (PSHA) underpin the calculation of earthquake loads in most building codes around the world. In Central Asia, the building codes are slowly being updated to incorporate some of the contemporary concepts of seismic hazard representation. There is also a regional desire to coordinate hazard assessments and building code modernization. However, some challenges remain. Expertise in the region related to seismic hazard assessments is still largely compartmentalised, requiring a significant amount of training and capacity building in seismic hazard assessment related topics. In addition, there are vast amounts of seismic data (bulletin and waveforms), both from analogue and digital eras, that the region’s countries stored but until recently did not use or share among themselves or with the broader seismological community around the world. Finally, after the collapse of the Soviet Union in the 1990s, many of the countries’ seismic networks suffered a major setback with the lack of attention and budget to update existing equipment and installation of new instruments. In order to address these issues, the United States Department of Energy through Lawrence Livermore National Laboratory (LLNL) initiated a project in 2016 to engage and train local scientists in Central Asia to install new equipment, to enhance the quality of seismic monitoring and reporting, to improve and harmonise the regional earthquake catalogue, and to conduct national probabilistic seismic hazard assessments using the new and improved datasets. To achieve the seismic hazard assessment related goals, a series of workshops were held in Almaty, Kazakhstan; Bishkek, Kyrgyzstan; and Dushanbe, Tajikistan from 2016 until 2020. During the time that the COVID-19 pandemic restricted travel, workshops continued online (22 online workshops were hosted in two years). Finally, in May 2022, an in-person workshop in Istanbul, Turkey brought together all project participants along with civil engineers engaged with building code activities in their respective countries, providing a platform to discuss the implementation of the hazard models into updates of building codes in each country, as well as to discuss model parameters, sensitivity analyses and model results in terms of hazard maps, uniform hazard spectra and hazard deaggregations. The workshops were a combination of lectures and hands-on exercises, and included international participation as well as local scientists and engineers. The workshops served several purposes, including training, coordination of data collection, interactions between local earth scientists and engineers, and brainstorming and knowledge exchange among local and international experts. This report outlines the new earthquake catalogue compilation effort and the PSHA project undertaken in Kyrgyzstan, Tajikistan, and Kazakhstan as part of this initiative. The southern part of this region is tectonically active with moderate to high levels of both shallow crustal seismic activity and occurrence of deeper earthquakes under the Hindu Kush and Pamir mountain ranges. Deeper earthquakes also occur near southwestern Kazakhstan, under the eastern Greater Caucasus and Caspian Sea. Large portions of central and northern Kazakhstan, on the other hand, are in stable continental regions with low levels of seismic activity. This study systematically compiles and improves all available data on local seismicity, active faults, and ground motion attenuation characteristics of the region; and builds a framework to enable a contemporary PSHA to be carried out with the engagement of local scientists. While the project was regional, the seismic hazard assessments are primarily driven by the countries’ own national preferences and understanding of data collection, interpretation, and validation of results.

58 GEOSCIENCES↗

DOE OSTI2024

Jackson County Community Solar Modeling Results [Slides]

Jackson County, via the U.S. Department of Energy's Communities LEAP (Local Energy Action Program) requested support on the topic of Community Solar in their area. NREL completed a technical and financial modeling exercise to determine the potential for developing community solar in the region. The analysis performed determined that the current policy and economic environment, in large part due to Illinois's Solar For All program, is advantageous to the deployment and growth of community solar in Illinois. Across all 6 scenarios modeled, including current minimum and maximum financial incentives, the economics yielded positive net present values for both the project owner and its subscribers. The analysis shown in this presentation is only one of the first steps in deploying community solar and suggests Jackson County should pursue next steps. Such actions could include refining project economics, partnering with local utilities, policy makers, and developers to identify potential projects and outreach opportunities, and educating and engaging community members.

14 SOLAR ENERGY↗

DOE OSTI2024

LENS: Learning Enabled Network Synthesis

RTRC and UMD have developed novel machine learning based methods under the ARPA-E DIFFERENTIATE program for rapid acceleration of hypothesis generation in complex architecture design spaces involving both discrete choices of component inclusion and interconnection and continuous parametric decisions. The project named Learning Enabled Network Synthesis (LENS) further demonstrated the developed methods on challenging electrical power converter design problems by identifying the most suitable circuit topologies and simultaneously selecting the most appropriate components to achieve optimized design of power converter with improved performances. We demonstrated that LENS could enable exploration of very large design space of circuit topologies and components by addressing the limitations of conventional design process in non-linear, high switching speed, multi-dimensional power converter design and optimization. The key innovation developed in LENS is the seamless integration of statistical learning and logical reasoning techniques and building on the individual strengths of these techniques for rapid hypothesis discovery. The main component of LENS comprises of: 1) Graph Reasoning Engine (GRE) to enforce composition rules that rapidly reject all discrete architectures that are composed incorrectly and generates an adaptive database of feasible designs which can be used by ML modules, 2) Graph Generative Learning module which is a deep neural network based generative model for graph architectures which can enable design space exploration beyond the dataset generated by the GRE, 3) Graph Reduced Order Model (ROM) for graph domains for accelerating computation of output metrics, and 4) Active learning and Rule Discovery module for sample efficient learning and extracting logical rules from the learned ML models which will be integrated in the GRE to enhance the filtering effectiveness. LENS approach can be applied to any design domains where designs can be represented as multi-attribute graphs. The LENS team integrated the various technical innovations listed above into an optimization pipeline and exercised the optimization pipeline on the converter design problem. The LENS project demonstrated that the developed AI/ML technologies can be used to generate novel converter circuits >45x faster than experts on chosen use-cases. This can enable faster design space exploration and identification of new designs which are not considered by experts due to the increasing design space complexity. This has significant potential impact on the public and energy needs of the country. It is currently estimated that 30% of all electrical powers generated passes through power converters. The future estimate is that 80% of all power generated would be passing through converters. LENS fills a critical gap in this space since by accelerating the design process the designers would be able to generate more efficient converters which can lead to significant energy savings for the country.

42 ENGINEERING↗

DOE OSTI2024

Graph Analytics for CEBAF Operations

We report on the progress achieved during a 2-year Laboratory Directed Research and Development (LDRD) project titled “Graph Analytics for CEBAF Operations”. The objective of this project is to leverage deep learning on graph representations of CEBAF’s injector beamline in order to create a tool for improving the efficiency of beam tuning tasks. Specifically, we use graphs to represent the injector beamline at any arbitrary date and time and invoke a graph neural network (GNN) to extract a low-dimensional, informative representation that can be visualized in two-dimensions. By analyzing years of operational data from the CEBAF archiver, good and bad regions of parameter space can be identified. The goal is to exercise this framework as a real-time tool to aid beam tuning, which represents the dominant source of machine downtime.

43 PARTICLE ACCELERATORS↗

DOE OSTI2024

USAID Haiti Training Session #1: Engage Orientation [Slides]

Welcome to Engage! Engage is a capacity expansion modeling tool supported by the National Renewable Energy Laboratory and based on the Calliope open-source capacity expansion model developed by the ETH Zurich University, maintained at the TU Delft University. Engage is an accessible (free, open-access, web-hosted) and flexible web-based energy system planning application for rapid multiple-energy-form energy system scenario exploration. Its cloud-based, collaborator-sharable data model, intuitive interface and visualization capabilities facilitate collaboration and communication among teams, with experts, and among diverse stakeholder groups exploring energy system implications at from district to national-scale models. This training series was developed under USAID to empower Haitian stakeholders to explore modeling scenarios in Engage to develop a Haiti Energy Master Plan. This training series includes a general overview of how Engage works along with tailored exercises that target Haiti's specific energy needs, such as modeling the capacity expansion of the bulk power system, fuel scarcity challenges, the development of microgrids, and the economic viability of transmission strategies. See NREL/PR-7A40-89366 for the French translation of this document.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2024

USAID Haiti Training Session #2: Introduction to Engage [Slides]

Welcome to Engage! Engage is a capacity expansion modeling tool supported by the National Renewable Energy Laboratory and based on the Calliope open-source capacity expansion model developed by the ETH Zurich University, maintained at the TU Delft University. Engage is an accessible (free, open-access, web-hosted) and flexible web-based energy system planning application for rapid multiple-energy-form energy system scenario exploration. Its cloud-based, collaborator-sharable data model, intuitive interface and visualization capabilities facilitate collaboration and communication among teams, with experts, and among diverse stakeholder groups exploring energy system implications from district to national-scale models. This training series was developed under USAID to empower Haitian stakeholders to explore modeling scenarios in Engage to develop a Haiti Energy Master Plan. This training series includes a general overview of how Engage works along with tailored exercises that target Haiti's specific energy needs, such as modeling the capacity expansion of the bulk power system, fuel scarcity challenges, the development of microgrids, and the economic viability of transmission strategies. See NREL/PR-7A40-89369 for the French translation of this document.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2024

USAID Haiti Training Session #3: Capacity Expansion [Slides]

Welcome to Engage! Engage is a capacity expansion modeling tool supported by the National Renewable Energy Laboratory and based on the Calliope open-source capacity expansion model developed by the ETH Zurich University, maintained at the TU Delft University. Engage is an accessible (free, open-access, web-hosted) and flexible web-based energy system planning application for rapid multiple-energy-form energy system scenario exploration. Its cloud-based, collaborator-sharable data model, intuitive interface and visualization capabilities facilitate collaboration and communication among teams, with experts, and among diverse stakeholder groups exploring energy system implications from district to national-scale models. This training series was developed under USAID to empower Haitian stakeholders to explore modeling scenarios in Engage to develop a Haiti Energy Master Plan. This training series includes a general overview of how Engage works along with tailored exercises that target Haiti's specific energy needs, such as modeling the capacity expansion of the bulk power system, fuel scarcity challenges, the development of microgrids, and the economic viability of transmission strategies. See NREL/PR-7A40-89365 for the French translation of this document.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2024

Session de formation de l'USAID en Haiti n1: Orientation de l'outil Engage [Slides]

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2024

Session de formation de l'USAID en Haiti n2: Introduction a l'outil Engage [Slides]

Welcome to Engage! Engage is a capacity expansion modeling tool supported by the National Renewable Energy Laboratory and based on the Calliope open-source capacity expansion model developed by the ETH Zurich University, maintained at the TU Delft University. Engage is an accessible (free, open-access, web-hosted) and flexible web-based energy system planning application for rapid multiple-energy-form energy system scenario exploration. Its cloud-based, collaborator-sharable data model, intuitive interface and visualization capabilities facilitate collaboration and communication among teams, with experts, and among diverse stakeholder groups exploring energy system implications from district to national-scale models. This training series was developed under USAID to empower Haitian stakeholders to explore modeling scenarios in Engage to develop a Haiti Energy Master Plan. This training series includes a general overview of how Engage works along with tailored exercises that target Haiti's specific energy needs, such as modeling the capacity expansion of the bulk power system, fuel scarcity challenges, the development of microgrids, and the economic viability of transmission strategies. See NREL/PR-7A40-88836 for the English translation of this document.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2024

Seance de formation de l'USAID en Haiti n3: Expansion des capacites [Slides]

Welcome to Engage! Engage is a capacity expansion modeling tool supported by the National Renewable Energy Laboratory and based on the Calliope open-source capacity expansion model developed by the ETH Zurich University, maintained at the TU Delft University. Engage is an accessible (free, open-access, web-hosted) and flexible web-based energy system planning application for rapid multiple-energy-form energy system scenario exploration. Its cloud-based, collaborator-sharable data model, intuitive interface and visualization capabilities facilitate collaboration and communication among teams, with experts, and among diverse stakeholder groups exploring energy system implications from district to national-scale models. This training series was developed under USAID to empower Haitian stakeholders to explore modeling scenarios in Engage to develop a Haiti Energy Master Plan. This training series includes a general overview of how Engage works along with tailored exercises that target Haiti's specific energy needs, such as modeling the capacity expansion of the bulk power system, fuel scarcity challenges, the development of microgrids, and the economic viability of transmission strategies. See NREL/PR-7A40-88837 for the English translation of this document.

24 POWER TRANSMISSION AND DISTRIBUTION↗