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DOE OSTI2020

Development of a clostridia-based cell-free system for prototyping genetic parts and metabolic pathways

Gas fermentation by autotrophic bacteria, such as clostridia, offers a sustainable path to numerous bioproducts from a range of local, highly abundant, waste and low-cost feedstocks, such as industrial flue gases or syngas generated from biomass or municipal waste. Unfortunately, designing and engineering clostridia remains laborious and slow. The ability to prototype individual genetic part function, gene expression patterns, and biosynthetic pathway performance in vitro before implementing designs in cells could help address these bottlenecks by speeding up design. Unfortunately, a high-yielding cell-free gene expression (CFE) system from clostridia has yet to be developed. Here in this paper, we report the development and optimization of a high-yielding (236 ± 24 μg/mL) batch CFE platform from the industrially relevant anaerobe, Clostridium autoethanogenum. A key feature of the platform is that both circular and linear DNA templates can be applied directly to the CFE reaction to program protein synthesis. We demonstrate the ability to prototype gene expression, and quantitatively map aerobic cell-free metabolism in lysates from this system. We anticipate that the C. autoethanogenum CFE platform will not only expand the protein synthesis toolkit for synthetic biology, but also serve as a platform in expediting the screening and prototyping of gene regulatory elements in non-model, industrially relevant microbes.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2023

PV Inverter Systems Enabled by Monolithically Integrated SiC based Four Quadrant Power Switch (4-QPS) [BiDFET]

The purpose of this project was to develop a new breed of Power Conversion Systems (PCS) for PV integration that is enabled by the newly developed 4-Quadrant Single Die SiC Power Semiconductor Switches (4-QPS) or also referred to as “Bidirectional FET (BIDFET)”. This work includes semiconductor die development, advanced packaging, converter design, development, and testing of 4-QPS enabled hardware prototypes at 1 kW (for single phase residential application) and 10 kW (for three phase commercial application). The BiDirectional Field-Effect Transistor (BiDFET) can enable circuit topologies requiring four-quadrant switches, that were earlier designed using discrete combinations of MOSFETs, IGBTs, GaN HEMTs, and PiN diodes. The monolithic nature of the BiDFET allows lower device count, smaller switch volume, lower inductance, and simpler packaging, and hence more reliable and commercially viable implementation in power electronics converters. The matrix converter topologies, now feasible using BiDFETs, can eliminate the bulky and unreliable dc link capacitors or inductors required for conventional voltage-source or current-source converters in ac–ac and ac–dc applications. The 1.2 kV BiDFET has the potential to disrupt all the applications utilizing 1.2 kV switches, including electric vehicle (EV) drivetrain, bidirectional EV chargers, industrial motor drives, solid-state transformers, datacenter power supplies, elevator drives, dc microgrids, energy storage grid integration, solid-state breakers, etc.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2024

MultiGreen: A multiplexing architecture for GreenGate cloning

Genetic modification of plants fundamentally relies upon customized vector designs. The ever-increasing complexity of transgenic constructs has led to increased adoption of modular cloning systems for their ease of use, cost effectiveness, and rapid prototyping. GreenGate is a modular cloning system catered specifically to designing bespoke, single transcriptional unit vectors for plant transformation—which is also its greatest flaw. MultiGreen seeks to address GreenGate’s limitations while maintaining the syntax of the original GreenGate kit. The primary limitations MultiGreen addresses are 1) multiplexing in series, 2) multiplexing in parallel, and 3) repeated cycling of transcriptional unit assembly through binary intermediates. MultiGreen efficiently concatenates bespoke transcriptional units using an additional suite of level 1acceptor vectors which serve as an assembly point for individual transcriptional units prior to final, level 2, condensation of multiple transcriptional units. Assembly with MultiGreen level 1 vectors scales at a maximal rate of 2*⌈ log 6 n ⌉+3 days per assembly, where n represents the number of transcriptional units. Further, MultiGreen level 1 acceptor vectors are binary vectors and can be used directly for plant transformation to further maximize prototyping speed. MultiGreen is a 1:1 expansion of the original GreenGate architecture’s grammar and has been demonstrated to efficiently assemble plasmids with multiple transcriptional units. MultiGreen has been validated by using a truncated violacein operon from Chromobacterium violaceum in bacteria and by deconstructing the RUBY reporter for in planta functional validation. MultiGreen currently supports many of our in-house multi transcriptional unit assemblies and will be a valuable strategy for more complex cloning projects.

Science & Technology - Other Topics↗

DOE OSTI2022

Topical Group on Application and Industry Community Engagement Frontier Snowmass 2021 (Summary Report)

HEP community leads and operates cutting-edge experiments for the DOE Office of Science which have challenging sensing, data processing, and computing requirements that far surpass typical industrial applications. To make necessary progress in the energy, material, and fundamental sciences, development of novel technologies is often required to enable these advanced detector and accelerator programs. Our capabilities include efficient co-design, which is a prerequisite to enable the deployment of advanced techniques in a scientific setting where development spans from rapid prototyping to robust and reliable production scale. This applies across the design spectrum from the low level fabrication techniques to the high level software development. It underpins the requirement for a holistic approach of innovation that accelerates the cycle of technology development and deployment. The challenges set by the next generation of experiments requires a collaborative approach between academia, industry and national labs. Just a single stakeholder will be unable to deliver the technologies required for the success of the scientific goals. Tools and techniques developed for High Energy Physics (HEP) research can accelerate scientific discovery more broadly across DOE Office of Science and other federal initiatives and also benefit industry applications.

43 PARTICLE ACCELERATORS↗

DOE OSTI2024

Design, Fabrication, and testing of Direct Air Capture Sorbent modules to increase understanding of trade-offs in pressure drop and capture efficiency

Conference presentation for the work entitled “Design, Fabrication, and testing of Direct Air Capture Sorbent modules to increase understanding of trade-offs in pressure drop and capture efficiency”. In recent years, there has been a growing interest in Direct Air Capture (DAC) of CO2. This technology is gaining attention as a method to enhance the reduction of atmospheric greenhouse gases (GHGs), particularly when used alongside other decarbonization strategies. The route for efficient and net carbon negative DAC is challenging because CO2 in the atmosphere is highly diluted (~400ppm). This work, utilizing 3D printing capabilities for rapid prototyping, presents application-based findings on the design, fabrication, and testing of DAC module form factors that house solid sorbents. The work leverages an experimental rig that can achieve air throughput and velocities approaching that which are anticipated for commercial scales. The tradeoffs of pressure drop, footprint and capture efficiency are discussed for different orientations of a NETL patented sorbent material.

Riley, Jarrett↗

DOE OSTI2024

In‐operando thermal transport characterization of moving particle bed heat exchanger

The project aimed to develop modulated photothermal radiometry (MPR) for conducting in-operando measurements of thermal transport in moving particle bed heat exchangers (MPBE) located at Sandia National Laboratory (SNL). The plan was to initially conduct lab-scale measurements on a 1-meter-long particle channel at UCSD, followed by in- operando measurements at SNL on a 20 kWth MPBE prototype built for this project, and if time permitting, potential final deployment on SNL’s 1 MWth G3P3 MPBE. The first two goals were successfully achieved but due to changes with commissioning timeline of the G3P3 MPBE, in-operando measurements on the G3P3 MPBE could not be conducted. The measurement campaigns have resulted in some promising results and the MPR tool has been handed over to trained SNL personnel for future use. MPR measurements on UCSD’s 1-meter-long particle channel showed a peculiar length dependence of the particle bed thermal conductivity and near-wall thermal resistance. The bed thermal conductivity increased, and the near-wall thermal resistance decreased, with increasing distance from the channel inlet, both eventually reaching a plateau. This was found to be due to hydrostatic pressure screening by the channel walls, known as the “Janssen effect”, and is the first experimental study on its role in granular heat transfer. A 20 kWth small-scale MPBE prototype, the first of its kind with 3 mm particle channels and 2 mm sCO2 plates, was designed and manufactured by Vacuum Process Engineering (VPE) for this project. This MPBE prototype was installed in SNL’s HEX test stand and the MPR tool was integrated into the test stand for in-operando measurements. Several modifications have been made to the MPR setup for facile installation and easy operation at SNL. Measurements with Carbo HSP40/70 particles were conducted with various particle and sCO2 temperatures and flow rates. Further, apart from regular MPBE operation, fault scenarios such as plate warping, particle stagnation, and choking were also detected and MPR showed excellent sensitivity to the detection of such conditions. Through the course of this project, MPR has evolved from a sensitive laboratory technique to a rugged industrial tool with various applications in high temperature measurements and diagnostics.

14 SOLAR ENERGY↗

DOE OSTI2026

Prototype Development, Testing, and Modeling for a Solar Light-Trapping Planar-Cavity Particle Receiver

Many applications for concentrating solar thermal power (CSP) technologies of high efficiency power cycles or thermochemical processes require higher operating temperatures and alternative heat transfer media. Inert solid particles for next-generation CSP and reactive gas and/or solid media for solar thermochemical processes are common options; however, these have significantly lower heat transfer capabilities than thermal oil, molten salt, or molten metal media. Conventional solar receivers operating temperatures >700 degrees Celsius face challenges including thermal performance and thermal-mechanical issues. To overcome these limitations, we have developed a novel light-trapping, planar-cavity receiver (LTPCR) that can heat solid-phase media within an enclosed receiver while maintaining a high aperture solar flux concentration for high efficiency. This paper presents progress on design, fabrication, and testing of a 100 kWt prototype receiver to demonstrate the LTPCR operability and its commercial feasibility.

14 SOLAR ENERGY↗

DOE OSTI2025

A compact low-level RF control system for advanced concept compact electron linear accelerator

A compact low-level RF (LLRF) control system based on RF system-on-chip (RFSoC) technology has been designed for the Advanced Concept Compact Electron Linear-accelerator (ACCEL) program, which has challenging requirements in both RF performance and size, weight, and power consumption (SWaP). The compact LLRF solution employs the direct RF sampling technique of RFSoC, which samples the RF signals directly without any analog upconversion and downconversion. Compared with the conventional heterodyne based architecture used for the LLRF system of a linear accelerator (LINAC), the elimination of analog mixers can significantly reduce the size and weight of the system, especially with LINAC requiring a larger number of RF channels. Based on the requirements of ACCEL, a prototype LLRF platform has been developed, and the control schemes have been proposed. The prototype LLRF system demonstrated magnitude and phase fluctuation levels below 1% and 1° on the flattop of a 2 μs RF pulse. The LLRF control schemes proposed for ACCEL are implemented with a prototype hardware platform. In conclusion, this paper will introduce the new compact LLRF solution and summarize a selection of experimental test results of the prototype itself and with the accelerating structure cavities designed for ACCEL.

Liu, C. [SLAC National Accelerator Laboratory (SLA↗

DOE OSTI2026

Prototype Development, Testing, and Modeling for a Solar Light-Trapping Planar-Cavity Particle Receiver (LTPCR)

14 SOLAR ENERGY↗

DOE OSTI2024

Proof-of-Concept for Sensor Modeling in MOOSE for the Design of Autonomous Nuclear Reactor Control

Autonomous operation is essential for the deployment of microreactors and fission batteries, both in terrestrial and space applications. However, prototypes of microreactors and fission batteries do not exist yet, and even the design space has not been narrowed down conclusively, making the instrumentation and control system design difficult. For this reason, there is a need for flexible computational capabilities to create a numerical stand-in of potential microreactor and fission battery designs. The latter can be used to design and test control strategies to support autonomous operations. In this paper, we describe the initial implementation of a pluggable sensor system for the easy implementation of realistic sensor models in the multiphysics object-oriented simulation environment (MOOSE) framework. This new capability will enable MOOSE users to create a numerical stand-in of microreactors and fission batteries, ultimately allowing them to easily test new control algorithms, and instrumentation strategies for advanced systems in the design phase

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2025

Scaled-up fabrication of durable and porous adsorbent-coated minichannels on aluminum for CO 2 separation

A method was developed to fabricate zeolite 13X adsorbent-coated minichannels on aluminum for CO₂ adsorption applications in this study. It emphasizes the innovative use of aluminum as a substrate, which offers airtight assembly, paving the way for highly efficient adsorption systems. An optimized coating process was developed using a slurry of Zeolite 13X, yeast, sugar, and xanthan gum, resulting in durable and highly porous layers that enhance CO₂ capture performance. A PETG peeler was designed to remove the top layer of the yeast-engineered adsorbent coatings, revealing a super porous and foamy structure. The teeth of the peeler were designed and fabricated for high repeatability and rapid prototyping. Breakthrough experiments were conducted on the scaled-up adsorbent bed using gas mixtures of 80% CO₂, 20% N₂, and 20% CO₂, 80% N₂ to represent different industrial scenarios. The performance of the bed was evaluated at flow rates of 160 and 190 cm³ min -1 using a Raman Laser Gas Analyzer (RLGA), demonstrating stable adsorption without degradation across multiple cycles. Computational modeling of integral transport phenomena under the chosen experimental conditions was pursued using gPROMS ProcessBuilder™, and the modeling results were compared with those from the tests for adsorption time, which resulted in an error margin of 2% to 9% for the breakthrough time, confirming the easy reproducibility of the design through modeling. This research advances CO₂ capture technologies by providing an effective and scalable solution for producing aluminum-based adsorbent coated beds, supporting industrial carbon capture efforts.

CO2 capture↗

DOE OSTI2020

Sodium Ion Expansion Power Block for Distributed CSP

The Sodium Ion Expansion Power Block for Distributed CSP was a three-plus-one-year effort under the Concentrating Solar Power: Advanced Projects Offering Low LCOE Opportunities (CSP: APOLLO) funding program within the U.S. Department of Energy Solar Energy Technologies Office. The primary objective of this project is to develop a dual-stage modular sodium thermal electrochemical converter (Na-TEC) heat engine power block, which can be potentially integrated with either a small-scale dish solar or large-scale heliostats and parabolic trough CSP. Na-TEC is a heat engine that generates electricity through the isothermal expansion of sodium ions. The Na-TEC is a closed system that can theoretically achieve conversion efficiencies above 45% when operating between thermal reservoirs at 1150 K and 550 K. However, thermal designs have confined previous single-stage devices to thermal efficiencies below 20%. To mitigate some of these limitations, we consider dividing the isothermal expansion into two stages; one at the evaporator temperature (1150 K) and another at an intermediate temperature (650 K –1050 K). This dual-stage Na-TEC takes advantage of regeneration and reheating, and could be amenable to better thermal management. In light of this, we first designed and developed a thermo-electrochemical model, and thermodynamically demonstrated how the dual-stage device can improve the efficiency by up to 8% points over the best performing single-stage device. We also established an application regime map for the single- and dual-stage Na-TEC in terms of the power density and the total thermal parasitic loss. Moreover, a thermal design of an axisymmetric dual-stage Na-TEC is developed to guide the scale-up and fabrication of sub-components of prototype module. A reduced-order finite-element model is used in conjunction with a Na-TEC thermodynamic model that was developed to determine the total parasitic heat loss of this dual-stage design. A number of simplifications are applied in the reduced-order model to decrease the computational time while maintaining acceptable accuracy. According to this analysis, a maximum efficiency of 29% and a maximum power output of 125 W can be achieved. Ultimately, we were able to demonstrate thermal efficiency improvements of the Na-TEC heat engine from 19% up to 40.3%, in a dual-stage (non-optimized) prototype module that we designed, fabricated, and tested with high temperature stage at 923 K. Furthermore, a cost-performance analysis for this improved dual-stage design was carried out for distributed-CSP systems. A high-level techno-economic analysis (TEA) explores four scenarios where a Na-TEC is used as the heat engine for a distributed-CSP system. Overnight capital cost and levelized cost of electricity (LCOE) are estimated for a system lifetime of 30 years, revealing that overnight capital costs in a range from $3.57 to $17.71 per We are feasible, which equate to LCOEs from 6.9 to 17.2 cents/kWh e -1 . This analysis makes a significant contribution by concurrently quantifying the efficiency and unit costs for a range of multistage configurations, and demonstrating that a Na-TEC may be a promising alternative to Stirling engines for distributed-CSP systems at residential scale of 1–5 kW e .

14 SOLAR ENERGY↗

DOE OSTI2025

Lessons Learned: Summary of Insights From the HERO WEC and Waves to Water Deployments Between 2022 and 2024

In 2020, a team from the National Renewable Energy Laboratory (NREL) partnered with the East Carolina University Coastal Studies Institute to develop a small, modular, wave-powered point absorber desalination prototype. That prototype, known as the hydraulic and electric reverse osmosis wave energy converter (HERO WEC), was intended to de-risk the installation activities planned for the Waves to Water Prize sponsored by the Water Power Technologies Office. The NREL team was given approximately 18 months to design, build, bench test, and deploy the HERO WEC prototype. Since the initial HERO WEC development, it has been used for two in-lab test programs and three ocean deployments. The first in-lab test program focused on ensuring that the overall operation of the device occurred as expected and on validating the operation of safety systems such as pressure relief valves or electrical breakers for load mitigation. The second in-lab test program was the first time the NREL team leveraged NREL’s large-amplitude motion platform to characterize the performance of the HERO WEC. Of the three in-water deployments, the first deployment was effectively an installation and recovery practice with no meaningful wave activity during the time that it was installed. The second deployment was a 2-week effort that enabled both the electric and hydraulic configurations of the device to be in the water for approximately 5 days each. This deployment was also the first time that the team had the opportunity to perform a drivetrain swap on the Coastal Studies Institute research vessel. The third deployment had to be split into two separate installations due to minor damage incurred from the WEC spinning during the initial installation. This report summarizes the deployments, the challenges encountered with each deployment, and the lessons learned for future work.

16 TIDAL AND WAVE POWER↗

DOE OSTI2025

Novel Light Detectors for Directional MeV scale DM Detectors

The search for sub-GeV dark matter requires novel detector development due to the small expected ionization signal and large backgrounds, many of which still need to be well-modeled. For this reason, to unambiguously detect dark matter, a detector must be able to determine the directionality of the incoming particles so that the daily modulation of the rate can be used to confirm a dark matter signal. This can be accomplished by combining anisotropic scintillating crystals, such as trans-Stilbene, as a detector target, with an optically-sensitive Skipper CCD as a readout. I will present on my work over the past six months developing the first prototype of this detector, including optical testing of the trans-Stilbene and design of the detector. This work will lead to characterization of the CCDs and deployment of the first prototype later this year.

Hoch, Nora [MIT]↗

DOE OSTI2020

SAMPA Based Streaming Readout Data Acquisition Prototype

We have assembled a small-scale streaming data acquisition system based on the SAMPA front-end ASIC. The 32-channel SAMPA chip was designed for the high-luminosity upgrade of the ALICE Time Projection Chamber (TPC) detector at the CERN Large Hadron Collider. The goals of the prototype system are to determine if the SAMPA chip is appropriate for use in detector systems at Jefferson Lab, and to gain experience with the hardware and software required to deploy streaming data acquisition systems in nuclear physics experiments. The 800 channel system is composed of components used in the ALICE TPC data acquisition upgrade. Five front-end cards (FEC) support five SAMPA chips each. SAMPA data streams on an FEC are concentrated into two high-speed (4.48 Gb/s) serial data streams by a pair Gigabit Transceiver ASICs (GBTx). These ten streams (44.8 Gb/s) are transmitted from the FECs over fibers to a PCIe based readout unit. The FPGA engine on the readout unit compresses data for transmission to a server via 100 Gb ethernet. Components on the FECs are radiation tolerant. High data rates can be handled. The system is by design scalable and thus provides a functional prototype for high-rate streaming readout at Jefferson Lab and the future Electron Ion Collider. We have made fundamental measurements (noise, linearity, time resolution) on the SAMPA ASIC. We have also coupled the readout system to a small Gas Electron Multiplier (GEM) detector and have studied its response to cosmic rays. A beam test of the system is planned.

ABBOTT, David↗

DOE OSTI2021

University of Missouri Research Reactor LEU Fuel Element Flow Test Conceptual Design—Hydraulic Reactor Design Parameters

The University of Missouri-Columbia Research Reactor (MURR®) is one of five U.S. high performance research reactors (USHPRR), plus one critical facility, that actively collaborates with the National Nuclear Security Administration (NNSA) Material Management and Minimization(M 3 ) Reactor Conversion Program to convert to the use of low-enriched uranium (LEU, < 20 wt.% U-235) fuel. A new type of LEU fuel with very high density, based on an alloy of uranium and 10 weight percent molybdenum (U-10Mo), is expected to allow the conversion to LEU of USHPRR that have been found unable to be converted with previously qualified uranium silicide-aluminum (U 3 Si 2 -Al) dispersion fuel. MURR has been working with the USHPRR Reactor Conversion (RC) Pillar at Argonne National Laboratory to perform fuel element design and fuel cycle performance analyses, steady-state thermal hydraulics safety analyses, and accident safety analyses in preparation for the conversion of MURR and to support a preliminary Safety Analysis Report (SAR) for conversion to LEU fuel. This work is performed in preparation for the flow test campaign that will be conducted by the USHPRR RC Pillar. The purpose of the hydraulic performance evaluation of the MURR LEU fuel element designed by the RC Pillar is to test a prototypic commercially fabricated LEU fuel element to determine whether any failure modes are observed or predicted in the fuel element, including significant deformations such as plate bending, twisting, or plate detachment from the side plate under selected safety-basis limits for reactor hydraulic conditions. To support the design of the flow test for MURR LEU fuel element hydraulic performance evaluation, design parameters for hydraulic testing of the LEU fuel element are laid out in this report.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2021

Accident Tolerant Fuel Test 2B (ATF-2B) Irradiation Test Report

A fully prototypic testing platform for testing new accident tolerant fuel (ATF) designs for light water reactors has been established in the center flux trap of Idaho National Laboratory’s advanced test reactor (ATR). The irradiation experiment named ATF-2 has completed 7 cycles of prototypic steady state irradiation irradiating 41 test pins to burnups as high as 30 MWd/kgU. Irradiation conditions have been maintained via the loop 2a pressurized water coolant loop and have been monitored through in-situ instrumentation during each cycle. Power and fast neutron flux histories of each of the 41 test pins has been calculated using a combined MCNP, and ORIGIN methodology to provide accurate and reliable power histories on a per pin basis.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

Two-Stage Cryogenic HEMT-Based Amplifier for Low-Temperature Detectors

To search for dark matter candidates with masses below $\mathcal{O}$ (MeV), the SPLENDOR (Search for Particles of Light dark mattEr with Narrow-gap semiconDuctORs) experiment is developing novel narrow-bandgap semiconductors with electronic bandgaps on the order of 1–100 meV. In order to detect the charge signal produced by scattering or absorption events, SPLENDOR has designed a two-stage cryogenic HEMT-based amplifier with an estimated charge resolution approaching the single-electron level. A low-capacitance (~ 1.6 pF) HEMT is used as a buffer stage at T = 10 mK to mitigate effects of stray capacitance at the input. The buffered signal is then amplified by a higher-capacitance (~ 200 pF) HEMT amplifier stage at T = 4 K. Importantly, the design of this amplifier makes it usable with any insulating material—allowing for rapid prototyping of a variety of novel detector materials. Here, we present the two-stage cryogenic amplifier design, preliminary voltage noise performance, and estimated charge resolution of 7.2 electrons.

47 OTHER INSTRUMENTATION↗