Search NASA⌕ Search

SEARCH · Search NASA

Results for “pilot program”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 595 records · Page 33
All sourcesNASA NTRSDOE OSTI
DOE OSTI2015

Rapid Conditioning for the Next Generation Melting System

This report describes work on Rapid Conditioning for the Next Generation Melting System under US Department of Energy Contract DE-FC36-06GO16010. The project lead was the Gas Technology Institute (GTI). Partners included Owens Corning and Johns Manville. Cost share for this project was provided by NYSERDA (the New York State Energy Research and Development Authority), Owens Corning, Johns Manville, Owens Illinois, and the US natural gas industry through GTI’s SMP and UTD programs. The overreaching focus of this project was to study and develop rapid refining approaches for segmented glass manufacturing processes using high-intensity melters such as the submerged combustion melter. The objectives of this project were to 1) test and evaluate the most promising approaches to rapidly condition the homogeneous glass produced from the submerged combustion melter, and 2) to design a pilot-scale NGMS system for fiberglass recycle.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2014

Ion Implantation with in-situ Patterning for IBC Solar Cells

Interdigitated back-side Contact (IBC) solar cells are the highest efficiency silicon solar cells currently on the market. Unfortunately the cost to produce these solar cells is also very high, due to the large number of processing steps required. Varian believes that only the combination of high efficiency and low cost can meet the stated goal of $1/Wp. The core of this program has been to develop an in-situ patterning capability for an ion implantation system capable of producing patterned doped regions for IBC solar cells. Such a patterning capable ion implanter can reduce the number of process steps required to manufacture IBC cells, and therefore significantly reduce the cost. The present program was organized into three phases. Phase I was to select a patterning approach and determine the patterning requirements for IBC cells. Phase II consists of construction of a Beta ion implantation system containing in-situ patterning capability. Phase III consists of shipping and installation of the ion implant system in a customer factory where it will be tested and proven in a pilot production line.

14 SOLAR ENERGY↗
DOE OSTI2023

Conclusions from 3 years of continuous capture plant operation without exchange of the AMP/PZ-based solvent at Niederaussem – insights into solvent degradation management

A many times heard mantra of solvent degradation management in amine-based post combustion capture is “keep the solvent clean” to minimize solvent consumption. It is assumed that the amine losses would decrease by the removal of metals, degradation products, and reactive trace components which are captured from the flue gas, like NO 2 (as potentially driving components of the amine degradation besides dissolved O 2 ). However, this theoretical hypothesis – based on results from laboratory experiments typically generated with fresh amines – disregards the complexity of the solvent matrix, interaction of potential metal catalysts with degradation products and oxidizing agents, and specific chemical requirements which must be fulfilled before a degradation mechanism can proceed. Degradation of the solvent CESAR1 (aqueous solution of 3.0 molar 2-amino-2-methylpropan-1-ol (AMP) and 1.5 molar piperazine (PZ)) is investigated in a unique long-time test campaign (testing time up to now 40 months; 24/7 operation) without replacement of the solvent inventory at the capture pilot plant at the lignite-fired power plant in Niederaussem. Three solvent management strategies with different effect mechanisms are investigated and evaluated: (a) removal of only anionic compounds and trace elements (within 75 days solvent inventory treated two times) and anionic as well as cationic compounds and trace elements (114 days, inventory treated four times) from the solvent by ion exchange, (b) adsorptive removal of trace elements from the solvent by active carbon in 35% of the operating time, and (c) removal of >80% NO 2 by flue gas pretreatment with thiosulfate/sulfite solution (dosing for 2,000 h). The results of the testing program clearly show that “solvent cleanliness” is not a well-defined parameter and that results from laboratory tests, tests without fully representative industrial flue gasses, and short-term testing of monoethanolamine cannot be generalized for other solvents and industrial application. Furthermore, these results showcase that specific degradation management considering solvent, capture plant and flue gas quality is reasonable. Overshooting efforts for solvent management are contra-productive and produce unnecessary waste streams, efficiency losses and costs.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Development of a Pre-Combustion CO 2 Capture Process Using High-Temperature PBI Hollow-Fiber Membranes

The overall objective of this project was to evaluate the advantages of transformational polybenzimidazole (PBI) polymer hollow-fiber membrane (HFM)-based, carbon dioxide (CO 2 ) capture and purification technology at bench-scale using an actual coal-derived syngas stream from a coal gasification facility. The project was carried out over two budget periods. The technical objectives in Budget Period 1 (BP1) included preparing HFs and modules and upgrading the available skid for field testing. The technical objectives for BP2 were to field-test the skid unit with actual coal-derived syngas from an oxygen-blown gasifier to obtain performance data, update the Techno-Economic Analysis (TEA) that would assist with future process scale-up, and provide information on the design of a small pilot-scale test unit. The goal was to advance the PBI-HFM CO 2 capture and gas separation system for pre-combustion applications beyond second-generation economic performance predictions and make progress toward meeting overall fossil energy performance goals of CO 2 capture with 95% CO 2 purity at a cost of electricity (COE) 30% less than baseline capture approaches. The research program was designed with progressive technical tasks leading to both dynamic and steady-state testing of the PBI-HFM skid with actual coal-derived syngas. The work plan was to: (1) fabricate sufficient Generation-2 (GEN-2) fibers for module fabrication; (2) upgrade the fiber skid to accommodate large fiber modules for bench-scale field testing; (3) conduct dynamic and steady-state testing with coal-derived syngas from an oxygen-blown gasifier and obtain system performance data; (4) perform a TEA and environmental, health, and safety (EH&S) assessment; (5) update the State-Point Data Table, Technology Gap Analysis (TGA), and Technology Maturation Plan (TMP); (6) uninstall and return the test skid to the Recipient’s facilities; and (7) submit a Final Report that describes the results and analysis of the project research effort.

03 NATURAL GAS↗
DOE OSTI2018

Net-baryon diffusion in fluid-dynamic simulations of relativistic heavy-ion collisions

A hybrid (hydrodynamics + hadronic transport) theoretical framework is assembled to model the bulk dynamics of relativistic heavy-ion collisions at energies accessible in the Beam Energy Scan (BES) program at the Relativistic Heavy-Ion Collider (RHIC) and the NA61/SHINE experiment at CERN. The system's energy-momentum tensor and net baryon current are evolved according to relativistic hydrodynamics with finite shear viscosity and non-zero net baryon diffusion. Our hydrodynamic description is matched to a hadronic transport model in the dilute region. With this fully integrated theoretical framework, we present a pilot study of the hadronic chemistry, particle spectra, and anisotropic flow. Phenomenological effects of a non-zero net-baryon current and its diffusion on hadronic observables are presented for the first time. Furthermore, the importance of the hadronic transport phase is also investigated.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2025

BOPTest As a Platform for Building Controls and Grid-Interactive Buildings Workforce Training

Building automation and controls are becoming increasingly complex with the emergence of Grid Integrated Efficient Buildings (GEBs) as well as new highly efficient sequences of operation and data-driven control schemes. However, there remains a significant gap in hands-on training opportunities for building operators and technicians to gain practical experience with advanced control systems in a low-risk environment. This paper presents BOPTEST (Building Optimization Performance Test) as a suitable platform for workforce training in building controls and GEB technologies. BOPTEST provides a suite of standardized building simulation test cases with a REST API, real-time control interfaces through BACnet, semantic models connecting users to building data, and built-in calculation of control metrics and performance indicators. The platform enables trainees to interact with virtual buildings using industry-standard protocols while learning how to implement and innovate control strategies. The training platform is designed to offer a structured and interactive learning experience for building engineers, helping them effectively develop, learn, and retain skills in fault identification, troubleshooting, and correction. The workflow is divided into three main phases: 1) Setup, 2) Exercise, and 3) Review, each comprising specific activities performed by either the instructor or the student. Initial pilot training sessions have yielded positive feedback from instructors and participants and demonstrates that BOPTEST effectively fills an industry need for a low-risk training resource via simulation of real building control systems, allowing trainees to gain practical experience before working in the field. The platform's ability to provide immediate performance feedback while maintaining familiar industry interfaces makes it particularly suitable for workforce development programs. This work provides a replicable model for leveraging building simulation in control education and training.

Paul, Lazlo↗
DOE OSTI2025

BOPTEST as a Platform for Building Controls and Grid-Interactive Buildings Workforce Training

Building automation and controls are becoming increasingly complex with the emergence of Grid Integrated Efficient Buildings (GEBs) as well as new highly efficient sequences of operation and data-driven control schemes. However, there remains a significant gap in hands-on training opportunities for building operators and technicians to gain practical experience with advanced control systems in a low-risk environment. This paper presents BOPTEST (Building Optimization Performance Test) as a suitable platform for workforce training in building controls and GEB technologies. BOPTEST provides a suite of standardized building simulation test cases with a REST API, real-time control interfaces through BACnet, semantic models connecting users to building data, and built-in calculation of control metrics and performance indicators. The platform enables trainees to interact with virtual buildings using industry-standard protocols while learning how to implement and innovate control strategies. The training platform is designed to offer a structured and interactive learning experience for building engineers, helping them effectively develop, learn, and retain skills in fault identification, troubleshooting, and correction. The workflow is divided into three main phases: 1) Setup, 2) Exercise, and 3) Review, each comprising specific activities performed by either the instructor or the student. Initial pilot training sessions have yielded positive feedback from instructors and participants and demonstrates that BOPTEST effectively fills an industry need for a low-risk training resource via simulation of real building control systems, allowing trainees to gain practical experience before working in the field. The platform's ability to provide immediate performance feedback while maintaining familiar industry interfaces makes it particularly suitable for workforce development programs. This work provides a replicable model for leveraging building simulation in control education and training.

Paul, Lazlo↗
DOE OSTI2017

Commercialization of an Atmospheric Iron-based CDCL Process for Power Production: Phase II

This project is focused on supporting the use of coal for power production through the continued development of the Coal Direct Chemical Looping (CDCL) technology. The objective of the program is to evaluate the commercial viability of the CDCL technology. This report describes the results of Phase II of the project up to the date of the period of performance as listed above. The Phase II objectives are to reduce the technology gaps associated with the oxygen-carrier properties, coal conversion, and reducer design of the CDCL process. During this project, a 250 kWth CDCL pilot unit was designed, fabricated, installed and subsequently tested to demonstrate critical components. The pilot unit simulates actual design concepts envisioned for the commercial unit. The knowledge gained from laboratory and pilot-scale testing is used to refine the commercial plant design and cost analyses.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2018

Analysis of Radiolytically Generated Gases in Mini-AMORE Experiment

Argonne National Laboratory (Argonne) is assisting one of the potential domestic Mo-99 producers, SHINE Medical Technologies, as part of the National Nuclear Security Administration’s (NNSA) Office of Material, Management, and Minimization (M 3 ) program in the development of a domestic Mo-99 production pathway that does not use highly enriched uranium (HEU). The process proposed by SHINE would produce Mo-99 by neutron-induced fission of a low enriched uranium (LEU) solution as uranyl sulfate in a subcritical assembly. As part of the development effort, Argonne is undertaking the AMORE (Argonne Molybdenum Research Experiment) project, which is essentially a pilot facility for all phases of Mo-99 production, recovery, and purification. Mini-AMORE is a part of the AMORE experiment where 2 mL samples of uranyl sulfate solution are inserted in the dry well of the AMORE target solution vessel.

07 ISOTOPE AND RADIATION SOURCES↗
DOE OSTI2014

Energy Management in Small Commercial Buildings: A Look at How HVAC Contractors Can Deliver Energy Efficiency to this Segment

While buildings smaller than 50,000 sq ft account for nearly half of the energy used in US commercial buildings, energy efficiency programs to-date have primarily focused on larger buildings. Interviews with stakeholders and a review of the literature indicate interest in energy efficiency from the small commercial building sector, provided solutions are simple and low-cost. An approach to deliver energy management to small commercial buildings via HVAC contractors and preliminary demonstration findings are presented. The energy management package (EMP) developed includes five technical elements: benchmarking and analysis of monthly energy use; analysis of interval electricity data (if available), a one-hour onsite walkthrough, communication with the building owner, and checking of results. This data-driven approach tracks performance and identifies low-cost opportunities, using guidelines and worksheets for each element to streamline the delivery process and minimize the formal training required. This energy management approach is unique from, but often complementary to conventional quality maintenance or retrofit-focused programs targeting the small commercial segment. Because HVAC contractors already serve these clients, the transaction cost to market and deliver energy management services can be reduced to the order of hundreds of dollars per year. This business model, outlined briefly in this report, enables the offering to benefit the contractor and client even at the modest expected energy savings in small buildings. Results from a small-scale pilot of this approach validated that the EMP could be delivered by contractors in 4-8 hours per building per year, and that energy savings of 3-5percent are feasible through this approach.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2019

Addressing Nuclear I&C Modernization Through Application of Techniques Employed in Other Industries

This research focuses on presenting advancements that have been made by non-nuclear I&C OT vendors and potential savings that could be realized by their optimized nuclear industry application. To promote understanding and to bound the initial scope for this effort, a pilot vendor and an associated pilot implementation were chosen as an integrated, presentation example for illustration. This integrated example is unique in that a utility in the United States (Duke Energy) engaged a traditional non-nuclear vendor (Honeywell Process Solutions) to install a non-safety, Distributed Control System (DCS) in four of its nuclear units. Duke Energy is currently exploring performing a “technology refresh” of these installed systems as part of a program to address digital obsolescence. This research presents techniques developed by distributed control system vendors to enable such upgrades and potential methods to employ them in a nuclear industry context. The objectives of such an effort are to minimize the utility cost both to refresh the systems and to put the systems into a repeatable refresh cycle for future obsolescence management. This will enable the utility to maximize the benefits of expanded use of their DCS as part of a larger plant strategy to eliminate obsolete I&C systems, reduce Operating and Maintenance (O&M) costs, and improve operational performance through digitalization.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Static actuator-sharing algorithm for concurrent control of multiple plasma properties

Simultaneous regulation of multiple properties in next-generation tokamaks like ITER and fusion pilot plant may require the integration of different plasma control algorithms. Such integration requires the conversion of individual controller commands into physical actuator requests while accounting for the coupling between different plasma properties. This work proposes a tokamak and scenario-agnostic actuator-sharing algorithm (ASA) to perform the above-mentioned command-request conversion and, hence, integrate multiple plasma controllers. The proposed algorithm implicitly solves a quadratic programming (QP) problem formulated to account for the saturation limits and the relation between the controller commands and physical actuator requests. Since the constraints arising in the QP program are linear, the proposed ASA is highly computationally efficient and can be implemented in the tokamak plasma control system in real time. Furthermore, the proposed algorithm is designed to handle real-time changes in the control objectives and actuators’ availability. Nonlinear simulations carried out using the Control Oriented Transport SIMulator illustrate the effectiveness of the proposed algorithm in achieving multiple control objectives simultaneously.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2019

X-Ray Phase Contrast Imaging of Liquid Film and Spray Development Inside an Aircraft Engine Swirler

Modern aircraft engines combine liquid fuel and air using an intricate flow device with many fuel and air flow passages. To date, the process by which the fuel atomizes within this swirler set has not been examined directly due to optical access limitations. In this work, high-speed X-ray phase-contrast imaging of a liquid spray inside a gas turbine engine swirler geometry is presented. Measurements were carried out at the 7-BM beamline of the Advanced Photon Source at Argonne National Laboratory using the high-energy broadband X-ray beam. The synchrotron X-ray source provides the necessary photon energy and flux to capture time-resolved fluid phenomena within the confines of the relevant geometry while liquid and air are flowing. Spray nozzle hardware and geometries were provided by the National Jet Fuels Combustion Program (NJFCP), allowing for characterization of the spray using a commercially relevant configuration. Modified swirlers were three-dimensional printed with acrylic to improve imaging access while maintaining influential internal features. Water was used as a surrogate fluid for these studies to demonstrate the visualization capabilities. The experiments were conducted at atmospheric exit pressure conditions with a pressure drop of 6% across the swirler. High-speed imaging of the pilot spray cone revealed sheet breakup several millimeters downstream of the orifice exit, upon interaction with the radial assist air flow. These droplets and ligaments were observed to impinge on the inner filming surface of the swirler and flow toward the exit while developing a tangential flow. Under these conditions, the liquid film grows up to several hundred microns in thickness on the filming surface, and subsequently forms ligaments up to several millimeters in length before breaking up. This work demonstrates the capability of X-ray diagnostics in visualizing liquid flows within solid geometries of technical relevance. Furthermore, the spatial quantification of filming flows and liquid interaction with the swirler air provides validation data for modeling of the multiphase flows and surface interactions within the swirler.

Sforzo, Brandon A.↗
DOE OSTI2016

INTEGRATION OF PANDA WORKLOAD MANAGEMENT SYSTEM WITH SUPERCOMPUTERS

Abstract The Large Hadron Collider (LHC), operating at the international CERN Laboratory in Geneva, Switzerland, is leading Big Data driven scientific explorations. Experiments at the LHC explore the funda- mental nature of matter and the basic forces that shape our universe, and were recently credited for the dis- covery of a Higgs boson. ATLAS, one of the largest collaborations ever assembled in the sciences, is at the forefront of research at the LHC. To address an unprecedented multi-petabyte data processing challenge, the ATLAS experiment is relying on a heterogeneous distributed computational infrastructure. The ATLAS experiment uses PanDA (Production and Data Analysis) Workload Management System for managing the workflow for all data processing on over 140 data centers. Through PanDA, ATLAS physicists see a single computing facility that enables rapid scientific breakthroughs for the experiment, even though the data cen- ters are physically scattered all over the world. While PanDA currently uses more than 250000 cores with a peak performance of 0.3+ petaFLOPS, next LHC data taking runs will require more resources than Grid computing can possibly provide. To alleviate these challenges, LHC experiments are engaged in an ambitious program to expand the current computing model to include additional resources such as the opportunistic use of supercomputers. We will describe a project aimed at integration of PanDA WMS with supercomputers in United States, Europe and Russia (in particular with Titan supercomputer at Oak Ridge Leadership Com- puting Facility (OLCF), Supercomputer at the National Research Center Kurchatov Institute , IT4 in Ostrava, and others). The current approach utilizes a modified PanDA pilot framework for job submission to the supercomputers batch queues and local data management, with light-weight MPI wrappers to run single- threaded workloads in parallel on Titan s multi-core worker nodes. This implementation was tested with a variety of Monte-Carlo workloads on several supercomputing platforms. We will present our current accom- plishments in running PanDA WMS at supercomputers and demonstrate our ability to use PanDA as a portal independent of the computing facility s infrastructure for High Energy and Nuclear Physics, as well as other data-intensive science applications, such as bioinformatics and astro-particle physics.

De, K↗
DOE OSTI2018

Photovoltaic Manufacturing Consortium (PVMC) – Enabling America’s Solar Revolution

The U.S. Photovoltaic Manufacturing Consortium (US-PVMC) is an industry-led consortium which was created with the mission to accelerate the research, development, manufacturing, field testing, commercialization, and deployment of next-generation solar photovoltaic technologies. Formed as part of the U.S. Department of Energy's (DOE) SunShot initiative, and headquartered in New York State, PVMC is managed by the State University of New York Polytechnic Institute (SUNY Poly) at the Colleges of Nanoscale Science and Engineering. PVMC is a hybrid of industry-led consortium and manufacturing development facility, with capabilities for collaborative and proprietary industry engagement. Through its technology development programs, advanced manufacturing development facilities, system demonstrations, and reliability and testing capabilities, PVMC has demonstrated itself to be a recognized proving ground for innovative solar technologies and system designs. PVMC comprises multiple locations, with the core manufacturing and deployment support activities conducted at the Solar Energy Development Center (SEDC), and the core Si wafering and metrology technologies being headed out of the University of Central Florida. The SEDC provides a pilot line for proof-of-concept prototyping, offering critical opportunities to demonstrate emerging concepts in PV manufacturing, such as evaluations of innovative materials, system components, and PV system designs. The facility, located in Halfmoon NY, encompasses 40,000 square feet of dedicated PV development space. The infrastructure and capabilities housed at PVMC includes PV system level testing at the Prototype Demonstration Facility (PDF), manufacturing scale cell & module fabrication at the Manufacturing Development Facility (MDF), cell and module testing, reliability equipment on its PV pilot line, all integrated with a PV performance database and analytical characterizations for PVMC and its partners test and commercial arrays. Additional development and deployment support are also housed at the SEDC, such as cost modeling and cost model based development activities for PV and thin film modules, components, and system level designs for reduced LCOE through lower installation hardware costs, labor reductions, soft costs and reduced operations and maintenance costs. The progression of the consortium activities started with infrastructure and capabilities build out focused on CIGS thin film photovoltaics, with a particular focus on flexible cell and module production. As marketplace changes and partners objectives shifted, the consortium shifted heavily towards deployment and market pull activities including Balance of System, cost modeling, and installation cost reduction efforts along with impacts to performance and DER operational costs. The consortium consisted of a wide array of PV supply chain companies from equipment and component suppliers through national developers and installers with a particular focus on commercial scale deployments (typically 25 to 2MW installations). With DOE funding ending after the fifth budget period, the advantages and disadvantages of such a consortium is detailed along with potential avenues for self-sustainability is reviewed.

14 SOLAR ENERGY↗
DOE OSTI2014

Recovery Act: Oxy-Combustion Technology Development for Industrial-Scale Boiler Applications. Task 4 - Testing in Alstom's 15 MW th Boiler Simulation Facility

Alstom Power Inc. (Alstom), under U.S. DOE/NETL Cooperative Agreement No. DE-NT0005290, is conducting a development program to generate detailed technical information needed for application of oxy-combustion technology. The program is designed to provide the necessary information and understanding for the next step of large-scale commercial demonstration of oxy combustion in tangentially fired boilers and to accelerate the commercialization of this technology. The main project objectives include: Design and develop an innovative oxyfuel system for existing tangentially-fired boiler units that minimizes overall capital investment and operating costs; Evaluate performance of oxyfuel tangentially fired boiler systems in pilot scale tests at Alstom’s 15 MWth tangentially fired Boiler Simulation Facility (BSF); Address technical gaps for the design of oxyfuel commercial utility boilers by focused testing and improvement of engineering and simulation tools; Develop the design, performance and costs for a demonstration scale oxyfuel boiler and auxiliary systems; Develop the design and costs for both industrial and utility commercial scale reference oxyfuel boilers and auxiliary systems that are optimized for overall plant performance and cost; and, Define key design considerations and develop general guidelines for application of results to utility and different industrial applications. The project was initiated in October 2008 and the scope extended in 2010 under an ARRA award. The project is scheduled for completion by April 30, 2014. Central to the project is 15 MWth testing in the BSF, which provided in-depth understanding of oxy-combustion under boiler conditions, detailed data for improvement of design tools, and key information for application to commercial scale oxy-fired boiler design. Eight comprehensive 15 MWth oxy-fired test campaigns were performed with different coals, providing detailed data on combustion, emissions, and thermal behavior over a matrix of fuels, oxy-process variables and boiler design parameters. Significant improvement of CFD modeling tools and validation against 15 MWth experimental data has been completed. Oxy-boiler demonstration and large reference designs have been developed, supported with the information and knowledge gained from the 15 MWth testing. This report addresses the results from the 15 MWth testing in the BSF.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2014

Recovery Act: Oxy-Combustion Technology Development for Industrial-Scale Boiler Applications

Alstom Power Inc. (Alstom), under U.S. DOE/NETL Cooperative Agreement No. DE-NT0005290, is conducting a development program to generate detailed technical information needed for application of oxy-combustion technology. The program is designed to provide the necessary information and understanding for the next step of large-scale commercial demonstration of oxy combustion in tangentially fired boilers and to accelerate the commercialization of this technology. The main project objectives include: • Design and develop an innovative oxyfuel system for existing tangentially-fired boiler units that minimizes overall capital investment and operating costs. • Evaluate performance of oxyfuel tangentially fired boiler systems in pilot scale tests at Alstom’s 15 MWth tangentially fired Boiler Simulation Facility (BSF). • Address technical gaps for the design of oxyfuel commercial utility boilers by focused testing and improvement of engineering and simulation tools. • Develop the design, performance and costs for a demonstration scale oxyfuel boiler and auxiliary systems. • Develop the design and costs for both industrial and utility commercial scale reference oxyfuel boilers and auxiliary systems that are optimized for overall plant performance and cost. • Define key design considerations and develop general guidelines for application of results to utility and different industrial applications. The project was initiated in October 2008 and the scope extended in 2010 under an ARRA award. The project completion date was April 30, 2014. Central to the project is 15 MWth testing in the BSF, which provided in-depth understanding of oxy-combustion under boiler conditions, detailed data for improvement of design tools, and key information for application to commercial scale oxy-fired boiler design. Eight comprehensive 15 MWth oxy-fired test campaigns were performed with different coals, providing detailed data on combustion, emissions, and thermal behavior over a matrix of fuels, oxyprocess variables and boiler design parameters. Significant improvement of CFD modeling tools and validation against 15 MWth experimental data has been completed. Oxy-boiler demonstration and large reference designs have been developed, supported with the information and knowledge gained from the 15 MWth testing. The results from the 15 MWth testing in the BSF and complimentary bench-scale testing are addressed in this volume (Volume II) of the final report. The results of the modeling efforts (Volume III) and the oxy boiler design efforts (Volume IV) are reported in separate volumes.

42 ENGINEERING↗
DOE OSTI2021

Depowering of Batteries to Reduce Cost of Ownership

(1) Executive Summary: End of life batteries (EOLBs) present a cost and safety liability for their owners and stakeholders. This is due flammability, energy, and power with EOLBs. Current approaches include cumbersome, expensive packaging, specialized shipping, regulated storage, and they are responsible for over half of the cost of recycling. They all expensively and inadequately address symptoms. OnTo has developed and proven a simple way to resolve the problem systemically, through depowering of lithium-ion batteries (and most any battery other than lead). The low-cost process removes flammability, power, and energy in EOLBs through non-toxic chemical processing. The opportunity for commerce of inert scrap is at least $5 billion greater than the commerce in hazardous scrap, all made possible through OnTo’s technology for efficiency and safety. (2) Depowering Improves Safety and Decreases Cost of Battery Ownership: OnTo’s depowering technology will remove half of the cost of EOLB management and recycling. Without this technology, EOLB recycling will always be a liability. EOLB is hazardous due to inherent flammability of electrolyte and lithium. The shipping and commerce of EOLBs is costly and dangerous all along the chain of custody from owner, dealership/shop, shipper, second-life sorter, (shipper again), and finally to the destination facility recycler. OnTo’s depowering service renders inert most any EOLB packs, modules, and cells. The technology uses a brief, non-toxic treatment applicable to most any chemistry. The industry needs a safe, simple, modular, and inexpensive method to render EOLBs as inert scrap. OnTo’s deactivation system is scalable to the needs of any customer along the EOLB chain of custody. (3) Evidence of Successful Depowering: Untreated batteries will catch fire and explode under abuse conditions such as heat or crush. Slide 2 below shows that untreated batteries will blow-up and expel their internal components with heating, after OnTo’s depowering treatment, the same battery is inert with the same heat treatment (Fig. 7 in the slide). Depowering also removes electrolyte reactivity, eliminating the production of HF and other toxins (Fig 6. in the slide) The depowering process is applicable to large, 26 Ah cells. Fig. 5 in the slide shows the removal of all the electrolyte from whole cells. Removal of flammable material from an EOLB contributes to the inert behavior. OnTo developed this technology through a project supported by the US Department of Energy EERE program, with partners including Seattle King County Metro Transit. While OnTo has generated evidence of successful depowering of batteries, in 2020, a follow-on voucher opportunity for third party analysis of depowered cells and materials was approved through CalTestBed. The expertise of the battery and materials research groups at Lawrence Berkeley National Laboratory will characterize these depowered cells to provide better understanding of the materials level changes in depowering. (4) Pilot Plant for Depowering EOLBs: Making the spoke work in hub-and-spoke While other companies are marketing the hub-and-spoke approach for recycling EOLBs, they rely on dangerous, expensive shredding methods with flimsy IP protection. OnTo offers the only patented, proven ability to depower EOLBs from most any chemistry – at half of the capital cost required for shredding, while eliminating the liability, danger, and waste streams inherent with shredding. The proposed commercial pilot facility is (5) OnTo Technology LLC Company: OnTo develops advanced battery recycling innovations that produce manufacturing quality electrode materials from recycled batteries. Their patented Cathode-healing™ and Deactivation/Depowering processes improve safety and reduce the cost of recycling. OnTo’s breakthrough technologies produce advanced materials for manufacturing batteries useful in applications from portable power to electric vehicles. Contact: Steve Sloop OnTo Technology LLC, 63221 Service Road, STE F, Bend, OR 97703, ssloop@onto-technology.com , 541-389-7897

deactivation↗