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DOE OSTI2021

High-Resolution 3D Acoustic Borehole Integrity Monitoring (Research Performance Progress Report Q2 2021)

Real-time, in-situ, high spatial resolution (sub-cm) imaging of the near-borehole environment would revolutionize wellbore diagnostics and integrity assessment by direct observation of defects. It is becoming increasingly apparent, that better understanding of the near-wellbore environment is required to meet the safety and operational needs in challenging environments such as those present in subsurface energy extraction (geothermal) and storage (CO2 sequestration) applications. Therefore, it is important to have a more robust ability to image the near-borehole and reliably detect defects. It was proposed to further develop and improve our advanced 3D imaging system to evaluate casing defects (e.g. corrosion) and cement quality in either open- or cased-borehole with the ultimate goal to develop a commercially deployable technology. The system consists of a unique acoustic source (LANL) and advanced inversion techniques for image processing (LANL, ORNL). This system will provide comprehensive borehole integrity monitoring with improved resolution over existing techniques. As an application of this imaging system, we will characterize the effectiveness of next-generation wellbore completion technology (NETL, SNL), and will demonstrate that, unlike current technology, the proposed approach can successfully characterize foamed cements.

15 GEOTHERMAL ENERGY↗

DOE OSTI2021

Top 13 Blendstocks Derived from Biomass for Mixing-Controlled Compression-Ignition (Diesel) Engines: Bioblendstocks with Potential for Decreased Emissions and Improved Operability

Reducing the impacts of medium- and heavy-duty (MD/HD) ground transportation can be enabled by fuel-engine combinations that use lower compression ignition liquid fuels and reduce criteria pollutant emissions. Fuels and blendstocks combined with advanced engine technologies could reduce the cost of ownership and the emission of pollutants, including soot, nitrogen oxides (NOx) and greenhouse gases (GHGs), from MD/HD vehicles. This report describes the evaluation and screening of MD/HD mixing-controlled compression ignition (MCCI) biofuel candidates for further development and commercialization. The report is aimed at 1) biofuel researchers looking to better understand options to reduce criteria pollutant and GHG emissions while maintaining efficiency and meeting requirements for engine operability and 2) engine researchers who want to evaluate biofuels that meet diesel fuel properties for their impact on conventional and advanced diesel combustion strategies.

09 BIOMASS FUELS↗

DOE OSTI2021

Report Q3FY21 - High-Resolution 3D Acoustic Borehole Integrity Monitoring

Real-time, in-situ, high spatial resolution (sub-cm) imaging of the near-borehole environment would revolutionize wellbore diagnostics and integrity assessment by direct observation of defects. It is becoming increasingly apparent, that better understanding of the near-wellbore environment is required to meet the safety and operational needs in challenging environments such as those present in subsurface energy extraction (geothermal) and storage (CO 2 sequestration) applications. Therefore, it is important to have a more robust ability to image the near-borehole and reliably detect defects. It was proposed to further develop and improve our advanced 3D imaging system to evaluate casing defects (e.g. corrosion) and cement quality in either open- or cased-borehole with the ultimate goal to develop a commercially deployable technology. The system consists of a unique acoustic source (LANL) and advanced inversion techniques for image processing (LANL, ORNL). This system will provide comprehensive borehole integrity monitoring with improved resolution over existing techniques. As an application of this imaging system, we will characterize the effectiveness of next-generation wellbore completion technology (NETL, SNL), and will demonstrate that, unlike current technology, the proposed approach can successfully characterize foamed cements.

42 ENGINEERING↗

DOE OSTI2022

High-Resolution 3D Acoustic Borehole Integrity Monitoring (Final Report)

42 ENGINEERING↗

DOE OSTI2021

Concentric Ring Gas Atomization Die Design for Optimized Particle Production

In partnership with Linde plc (formerly Praxair, Inc.), Ames Laboratory will further develop and commercialize its concentric-ring high pressure gas atomization (CR-HPGA) gas-die technology with a goal to improve the precision of metal powder production in a desired size range and quality. The successful commercialization of this technology could reduce production cost of metal powders and improve reliability of this industrial process, increasing specialty alloy powder availability for new applications and adoption into additive manufacturing and multiple materials sectors. The project scope is to [1] utilize AMES compressible gas flow and melt break-up models to explore a wide swath of parameter space available for the CR-HPGA technology, identifying the most promising gas-die designs for fabrication, [2] verify and optimize the new gas-die design, fabricate it and select preferred operating parameters by gas-only flow imaging and aspiration pressure measurements, down-selecting gas compositions and atomization parameters for full scale testing, [3] perform pilot-scale atomization trials with Al and/or Cu alloys of a new CR-HPGA gas-die at selected parameters, [4] evaluate gas-die performance by comparing resulting powder size distribution and powder quality attributes with equivalent powders made by conventional close-coupled HPGA technology, and [5] assess (through Praxair partnership) reduction in operational costs of new CR-HPGA gas-die through the use of an inert gas recovery/recycling system. In partnership with Praxair, Inc., the team, led by Ames Laboratory senior metallurgist Iver Anderson, intend to demonstrate the performance of an optimized CR-HPGA gas-die design in a pilot scale atomizer and better understand the design and operational controls to increase overall benefits for precision metal powder production.

42 ENGINEERING↗

DOE OSTI2021

Cooperative Research and Development Agreement between National Energy Technology Laboratory and Nuionic Technologies (Canada) Inc. [Abstract]

The National Energy Technology Laboratory (NETL) and NuIonic will collaborate in the development and commercial scaling of low-temperature and pressure ammonia synthesis using microwaves. Ammonia is one of the largest used chemicals in the world and is currently manufactured with a high temperature and pressure Haber-Bosch process. The current economical production scale of ammonia using Haber-Bosch (HB) synthesis is too large for the deployable scale of renewables (from 1 to 150 MW). Scaling down a HB process to 170,000 ton/year would increase production costs by a factor of 2-3. This collaboration will facilitate the deployment of a non-HB process for ammonia production that can directly interface and provide storage for intermittent renewable energy.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2022

Workshop on Materials & Manufacturing for Marine Energy Technologies (Summary Report: October 5, 2021)

The U.S. Department of Energy’s Water Power Technologies Office (WPTO) enables research, testing, development, and commercialization of emerging technologies to advance marine energy, as well as next-generation hydropower and pumped storage systems, for a flexible, reliable grid. This report summarizes the results of a WPTO-sponsored public workshop held virtually on October 5, 2021.

13 HYDRO ENERGY↗

DOE OSTI2022

Reversible Solid Oxide Fuel Cell Systems for Energy Storage and Hydrogen Production

FuelCell Energy (FCE) studied the performance, design, and economics of a reversible solid-oxide fuel cell/electrolyzer integrated with a natural gas-based electricity generation plant and used as an energy storage system. Increased market penetration of renewable energy is challenging for operators of fossilbased plants which are not suited for quick turndown and ramp-up. Process simulations studies show that with utilization of waste heat from the power plant, a high roundtrip efficiency (RTE) around 70% is possible, providing excellent market potential for this energy storage technology, potentially providing improved economics and lifetime for such power plant. The market potential and economics as a function of production volume are analyzed in detail. FCE is continuing the development and commercialization of its solid oxide technology.

08 HYDROGEN↗

DOE OSTI2023

COLLABORATIVE DEVELOPMENT PROJECTS - PHOTONIC MEMORY CONTROLLER MODULE (P-MCM)

As computational density for high-performance computing and big-data services continues to scale, performance scalability of next generation computing systems is becoming increasingly constrained by limitations in memory access, power dissipation and chip packaging. The processor-memory communication bottleneck, a major challenge in current multicore processors due to limited pin-out and power budget, presents a detrimental scaling barrier to data-intensive computing. A consortium team of small businesses and leading researchers that includes experts from photonics processor-memory architecture, III/V photonic laser design/fabrication, silicon photonics design/fabrication, photonics packaging and assembly, and FPGA-based high-performance memory controller IP development – to collaboratively develop a commercialization path for a Photonic Memory Controller Module (P-MCM).

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2024

Grid Optimization Competition Challenge 3 Problem Formulation

This report contains the problem formulation for the Grid Optimization (GO) Competition Challenge 3. The Grid Optimization Competition is run by a team of researchers from a number of organizations, including the sponsor Advanced Research Projects Agency - Energy (ARPA-E), lead organization Pacific Northwest National Laboratory (PNNL), and technical contributors from Los Alamos National Laboratory (LANL), National Renewable Energy Laboratory (NREL), Texas A&M University (TAMU), Georgia Institute of Technology (GT), University of Wisconsin (UW), and others. The GO Competition poses challenge problems in the field of power grid management, invites entrants to develop solvers for these problems, invokes the solvers on a set of problem instances using common hardware, ranks the solvers according to their performance, and awards prizes according to the rankings. The overall goal of the GO Competition is to spur innovative research on high impact and computationally challenging problems in power grid management from initial development through commercial deployment. Complete information about the GO Competition can be found online at [2]. The webpage covers previous Challenges, rules, timeline, registration information, data formats, scoring methods, computational platform information, information on supported solvers and languages, sponsor information, frequently asked questions, administrator contact information, publicly available problem instances, computer code for reading and evaluating problem and solution data, a sandbox for testing solvers, and a solver submission interface, results, and publications.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2022

Developing an Ultra-Compact, Topology-Optimized Heat Exchanger using Additive Manufacturing

Traditional heat exchanger designs have relied on a plate-fin architecture, assembled in a crossflow configuration. These HX designs are limited in their maximum allowable temperature and, therefore, efficiency. More advanced designs, such as those containing counter-flow, microtube cores, can yield higher efficiencies, but generally require complex headers. The design of such headers is usually determined based on user experience rather than on rigorous design tools, which can lead to lossy architectures; conventional headers can generate up to 50% of the total pressure loss through the HX. Furthermore, the consequences of manufacturing techniques are rarely considered during the design phase. Our team has developed an ultra-compact, topology-optimized heat exchanger capable of operating in environments with temperatures and pressures up to 800°C (1472°F) and 250 bar (3626 psi), respectively. Throughout the program, the team leveraged extensive additive manufacturing research and experience in supercritical carbon dioxide (sCO 2 ) power generation experience to develop and commercialize the technology. The final power density numbers for the subscale and full-scale heat exchangers are >15 kW/kg and >50 kW/L, which includes the core and the headers. The team has involved the RTX business units, notably Collins Aerospace, in discussions for commercializing the technology.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2024

OSU/NETL/Sandia/LBNL IDAES (CRADA Final Report)

The objective of this CRADA is to facilitate the cooperation among the Ohio State Univesity and the collaborators for the Institute for the Design of Advanced Energy Systems (IDAES). The goal is to develop, validate, and use a suite of process models based on the Ohio State's Fe-based coal direct chemical looping (CDCL) combustion process. This collaboration will provide Ohio State with a greater fundamental understanding of their chemical looping process, will help to improve the process efficiency, and will thus enable a greater probability of developing a commercial success. This collaboration will provide the IDAES team with detailed real-world process data to validate and demonstrate the effectiveness of its toolset.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2025

Technical and Commercial Assessment of a Newly Developed Secondary Reflector Design for Linear Fresnel Technology (CRADA Final Report)

Under the CRADA Contractor and Participant will develop competitive low-cost CSP collector technology for the renewable process heat market.

14 SOLAR ENERGY↗

DOE OSTI2025

Membrane-based Ionic Liquid Absorption System for Ultra-Efficient Dehumidification and Heating

The project team – comprising the University of Florida (UF), GTI Energy, and Modine Manufacturing – sought to develop a highly efficient heat-powered absorption cycle with combined dehumidification and heat pumping. This DOE-supported project advanced the technology from a TRL of 3 to 6, culminating in the development of a 1,000 CFM system. Key innovations implemented in the system addressed the low efficiency, size, cost, and reliability challenges of conventional absorption cycles. Specifically, the system was enabled by: (1) a semi-open cycle that allowed simultaneous dehumidification and heat recovery, (2) non-crystallizing ionic liquids (ILs) that enabled “double-effect” operation at elevated temperatures without the need for costly control equipment, (3) a compact membrane-based absorber that confined the IL and directly cooled it to achieve low dew points, and (4) a novel, highly integrated desorber–condenser assembly that reduced size, weight, and cost. The technology was developed with commercial HVAC applications in mind, particularly for separate sensible and latent cooling (SSLC), an innovation aimed at achieving independent and more efficient humidity control.

42 ENGINEERING↗

DOE OSTI2025

Infrared Cloud Imager Instrument Intercomparison Report

The Infrared Cloud Imager Instrument Intercomparison was a guest instrument deployment by NWB Sensors to the U.S. Department of Energy’s Atmospheric Radiation Measurement (ARM) User Facility observatory on the Southern Great Plains (SGP) between May 18 and December 12, 2023. NWB Sensors is a company that has developed a commercially available infrared cloud imager (ICI). The ICI provides radiometrically calibrated, full-sky images of the downwelling infrared radiance in the 7.3-14 µm band. In addition, it provides cloud radiance as the residual between the observed radiance and the modeled cloud-free radiance as well as derived cloud products. The instrument is used in applications that require consistent detection of clouds across day and night. For more information, consult the instrument's webpage. The primary goal of the deployment was to validate the radiometric accuracy of the ICI. The ICI uses a proprietary calibration method to convert the raw data from its infrared camera into downwelling radiance. Unlike similar instruments, the system does not have an onboard blackbody calibration standard. Instead, NWB Sensors characterizes each ICI camera individually in an environmental chamber while looking at a blackbody standard. The resulting (proprietary) calibration is used operationally in the instrument and has been demonstrated to be stable over long periods. To validate the radiometric products from the ICI, an intercomparison between the ICI data products and those from ARM’s atmospheric emitted radiance interferometer (AERI) was made. The AERI is a best-in-class instrument for measuring downwelling infrared radiance (Gero et al. 2025). A weighted integration of the AERI’s spectral radiances across the ICI’s camera response was performed. The resulting radiance (herein called the AERI radiance) was directly compared to the zenith radiance concurrently observed by the ICI. The results of these comparisons are reported in the next section of this report.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2025

Initial Characterization of the NREL Large-Amplitude Motion Platform

The Large Amplitude Motion Platform (LAMP) at NREL represents a significant advancement in the controlled testing of Wave Energy Converters (WECs) under laboratory conditions. Originally designed by E2M as a six-degree-of-freedom (DOF) Stewart platform for flight simulation, LAMP has been adapted by NREL to facilitate the mounting and evaluation of WECs. This adaptation enables dry testing of WECs using motion profiles similar to the ocean, facilitating the iterative design, testing, and validation of WEC performance prior to ocean deployments. This report presents the initial work completed to characterize LAMP, with particular emphasis on its stability and operational capabilities across various single and multi-degree-of-freedom (DOF) motion profiles. The report includes planned comparisons at three distinct mass payloads, aimed at assessing the platform's positional accuracy, frequency response, and endurance over extended runtime periods. These experimental tests are critical for establishing the platform's limitations and ensuring that the data generated during WEC validation is both accurate and reproducible. The outcomes of this study not only contribute to a deeper understanding of LAMP's capabilities but also lay the groundwork for future advancements in WEC testing methodologies. By providing robust and reliable performance data within a controlled laboratory setting, the findings are expected to significantly enhance the development and commercialization of marine energy technologies. This report presents the initial findings of the LAMP Characterization work and proposed steps to further understand and characterize LAMP. Data collected during this work can be found on MHKDR at: https://mhkdr.openei.org/submissions/602 Note that this report shares the measured/found instantaneous maximum operating range of LAMP. For most applications the maximum operating range cannot be used for system health and longevity. The operating range and capabilities of LAMP will be evaluated on a case-by-case basis, single-DOF position, velocity, and acceleration values presented in Table 4a-c, and Table 5 should be taken as instantaneous absolute maximum values. Future use of LAMP will likely be limited to smaller values.

16 TIDAL AND WAVE POWER↗

DOE OSTI2025

Visolis Microbial Chemical Intermediate Library Screening (CRADA Final Report)

Visolis is developing a commercial process for the bioproduction of a chemical intermediate, towards the derivative production of a portfolio of bio-based chemicals with large application potential, from drop-in commodity chemicals, to innovative specialty chemical offerings, to materials for multiple end markets and industries, which will ultimately benefit consumers and the public. Visolis already has several variants of a microbe that produce the chemical intermediate at distinct levels (i.e. high, medium, and low). They are currently pursuing transcriptomics analysis for some of these strains, towards a better understanding of the biology behind what makes certain strains perform better than others. There exist genome-scale library approaches for the microbe that could be used to screen gene disruption, overexpression, or repression candidates for perturbations to the production of the chemical intermediate. These approaches often reveal opportunities for further production improvement that are not otherwise accessible using hypothesis-driven metabolic engineering approaches. However, Visolis, while it could generate or procure such genome-scale libraries, does not have the automated strain engineering workflows required to screen thousands of variants, obtaining a production phenotype and a genotype for each. The purpose of this collaboration is to use LBNL and SNL capabilities to enable Visolis to effectively screen thousands of genome-scale library strain variants for phenotype/genotype relationships that will complement Visolis’ transcriptomic investigations.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2023

Tropical Red Macroalgae Cultivation with a Focus on Compositional Analysis

To create carbon efficient sources of bioenergy feedstocks and feedstuff for aquaculture and terrestrial livestock, it is critical to develop and commercialize the most efficient seaweed cultivation approach with a sustainable nutrient input supply. Here, we present data for a novel, onshore tropical macroalgae cultivation system, based on influent deep seawater as the nutrient and carbon sources. Two red algal species were selected, Agardhiella subulata and Halymenia hawaiiana, as the basis for growth optimization. Highest productivity in small-scale cultivation was demonstrated with A. subulata in the 10% deep seawater (64.7 µg N L−1) treatment, growing at up to 26% specific growth rate day−1 with highest yields observed at 247.5 g m−2 day−1 fresh weight. The highest yields for H. hawaiiana were measured with the addition of 10% deep seawater up to 8.8% specific growth rate day−1 and yields at 63.3 g fresh weight m−2 day−1 equivalent. Biomass should be culled weekly or biweekly to avoid density limitations, which likely contributed to a decrease in SGR over time. With a measured 30–40% carbon content of the ash-free dry weight (20–30% of the dry weight) biomass, this translates to an almost 1:1 CO2 capture to biomass ratio. The compositional fingerprint of the high carbohydrate content of both Agardhiella and Halymenia makes for an attractive feedstock for downstream biorefinery applications. By focusing on scaling and optimizing seaweed farming technologies for large-scale onshore farms, the opportunities for yield potential, adaptability to cultivation conditions, and meeting global sustainability goals through novel, carbon-negative biomass sources such as seaweed can be realized.

09 BIOMASS FUELS↗