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DOE OSTI2024

Bubble Mass Transport Measurement in the Large-Scale Test Loops at Oak Ridge National Laboratory

Molten salts are complex fluids that incorporate multi-phase behavior depending on the chemistry and the physical properties of the entrained components. These components include the carrier salt, the actinide fuel, and fission, activation, and corrosion products, the concentrations of which depends on the burnup history of the salt. Radionuclide transport from the salt into the cover gas / off-gas system depends on volatility as predicted by thermochemistry, but data from the Molten Salt Reactor Experiment (MSRE) conducted in the late 1960s suggest that bubble formation and transport are also important. Anomalously high fractions of noble metals were found in the off-gas system and were attributed to transportation with parent salt aerosols and their association with rising noble gas bubbles. The prediction of such phenomena requires coupled neutronic, thermal hydraulic, and chemical equilibrium calculations, the framework of which is being developed within the Nuclear Energy Advanced Modeling and Simulation (NEAMS) program supported by the US Department of Energy (DOE) Office of Nuclear Energy (NE). However, separate effects tests and models of experiments using tools such as SAM and Thermochimica can guide model developers through important processes. Conversely, model development guides the choice of experiments and systems to provide data that are relevant for validation. This report describes several experiments that tracked gas transport in molten salts, ranging from small-scale systems to large-scale loops. Gas transportation in a molten salt, LiCl-KCl, has been studied using the shadowgraph technique. Sensors such as residual gas analysis, Raman spectroscopy, and laser-induced breakdown spectroscopy have been tested for off-gas measurements. These data were used to interpret how the gases move through the upstream salt / cover gas and the interface between them. Differential pressure measurements were able to detect individual gas bubbles as they popped at the liquid–gas interface. Salt aerosols were collected on a cascade impactor. Their formation was also observed directly via the shadowgraph method, and most of these aerosols were launched ballistically into the cover gas. Fine mists could also be observed. Convection currents through the salt were visualized and can be used to calculate the thermophysical properties of the salt itself. The apparatuses described in this report and in a previous work (McFarlane et al. 2023) have been commissioned and are available for use in making further measurements of salt/surrogate fission product behavior. Novel approaches using neutron imaging are planned for the study of fluoride salts, which cannot be contained in quartz, so shadowgraph visualization is not available. Bubble transport in convective flow and in a slow-moving salt column are planned. The mobile laser-induced breakdown spectroscopy (LIBS) system is available for several applications, including iodine capture in a molten hydroxide scrubber, H2 transport though molten salts to complement Raman analysis, and online tracking of salt aerosol generation, transport, and deposition. This report summarizes the findings from FY24 and the plans for FY25. The work completes milestone M2AT-24OR0702013 of the DOE-NE Advanced Reactor Technology, Molten Salt Reactor Campaign, DOE-NE-5.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

In Situ Soil Moisture and Thaw Depth Measurements Coincident with Airborne SAR Data Collections, Seward Peninsula, Alaska, 2019

The in-situ soil moisture and thaw depth measurements provided in this dataset were collected coincident with airborne overflights of L- and P-band SAR instruments at the Teller and Kougarok NGEE Arctic study sites on the Seward Peninsula, Alaska. Field measurements and flights were conducted in August 2019 as a collaboration between the NASA ABoVE Project's Airborne SAR Campaign and the NGEE Arctic Project. ABoVE protocols for establishing field measurement plots were followed. NGEE Arctic plots for the ground-based measurements are located at existing study sites where SAR data would also add value to current monitoring and characterization efforts of the NGEE Team. The ground-based data will be used by ABoVE to analyze, calibrate and validate the remote sensing products. This dataset follows the format and collection guidelines of the collaboration effort in 2017. Contained in this dataset are *.csv (including data dictionaries), .zip, .kml, .jpgs, .py, and .pdf files.The Next-Generation Ecosystem Experiments: Arctic (NGEE Arctic), was a research effort (with some overlap with Covid-19 pandemic) to reduce uncertainty in Earth System Models by developing a predictive understanding of carbon-rich Arctic ecosystems and feedbacks to climate. NGEE Arctic was supported by the Department of Energy's Office of Biological and Environmental Research. The NGEE Arctic project had two field research sites: 1) located within the Arctic polygonal tundra coastal region on the Barrow Environmental Observatory (BEO) and the North Slope near Utqiagvik (Barrow), Alaska and 2) multiple areas on the discontinuous permafrost region of the Seward Peninsula north of Nome, Alaska. Through observations, experiments, and synthesis with existing datasets, NGEE Arctic provided an enhanced knowledge base for multi-scale modeling and contributed to improved process representation at global pan-Arctic scales within the Department of Energy's Earth system Model (the Energy Exascale Earth System Model, or E3SM), and specifically within the E3SM Land Model component (ELM).

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2016

Development and Validation of an Acid Mine Drainage Treatment Process for Source Water

Throughout Northern Appalachia and surrounding regions, hundreds of abandoned mine sites exist which frequently are the source of Acid Mine Drainage (AMD). AMD typically contains metal ions in solution with sulfate ions which have been leached from the mine. These large volumes of water, if treated to a minimum standard, may be of use in Hydraulic Fracturing (HF) or other industrial processes. This project’s focus is to evaluate an AMD water treatment technology for the purpose of providing treated AMD as an alternative source of water for HF operations. The HydroFlex™ technology allows the conversion of a previous environmental liability into an asset while reducing stress on potable water sources. The technology achieves greater than 95% water recovery, while removing sulfate to concentrations below 100 mg/L and common metals (e.g., iron and aluminum) below 1 mg/L. The project is intended to demonstrate the capability of the process to provide AMD as alternative source water for HF operations. The second budget period of the project has been completed during which Battelle conducted two individual test campaigns in the field. The first test campaign demonstrated the ability of the HydroFlex system to remove sulfate to levels below 100 mg/L, meeting the requirements indicated by industry stakeholders for use of the treated AMD as source water. The second test campaign consisted of a series of focused confirmatory tests aimed at gathering additional data to refine the economic projections for the process. Throughout the project, regular communications were held with a group of project stakeholders to ensure alignment of the project objectives with industry requirements. Finally, the process byproduct generated by the HydroFlex process was evaluated for the treatment of produced water against commercial treatment chemicals. It was found that the process byproduct achieved similar results for produced water treatment as the chemicals currently in use. Further, the process byproduct demonstrated better settling characteristics in bench scale testing. The field testing conducted in the second project budget period demonstrated the ability of the HydroFlex technology to meet industry requirements for AMD water chemical composition so that it can be used as source water in HF activities. System and operational improvements were identified in an additional series of confirmatory tests to achieve competitive cost targets. Finally, the application of the HydroFlex process byproduct in produced water treatment was demonstrated, further supporting the commercial implementation of the technology. Overall, the project results demonstrate a path to the economic treatment of AMD to support its increased use as source water in HF, particularly in regions with limited local freshwater availability.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2011

High Temperature Integrated Thermoelectric Ststem and Materials

The final goal of this project is to produce, by the end of Phase II, an all ceramic high temperature thermoelectric module. Such a module design integrates oxide ceramic n-type, oxide ceramic p-type materials as thermoelectric legs and oxide ceramic conductive material as metalizing connection between n-type and p-type legs. The benefits of this all ceramic module are that it can function at higher temperatures (> 700 C), it is mechanically and functionally more reliable and it can be scaled up to production at lower cost. With this all ceramic module, millions of dollars in savings or in new opportunities recovering waste heat from high temperature processes could be made available. A very attractive application will be to convert exhaust heat from a vehicle to reusable electric energy by a thermoelectric generator (TEG). Phase I activities were focused on evaluating potential n-type and p-type oxide compositions as the thermoelectric legs. More than 40 oxide ceramic powder compositions were made and studied in the laboratory. The compositions were divided into 6 groups representing different material systems. Basic ceramic properties and thermoelectric properties of discs sintered from these powders were measured. Powders with different particles sizes were made to evaluate the effects of particle size reduction on thermoelectric properties. Several powders were submitted to a leading thermoelectric company for complete thermoelectric evaluation. Initial evaluation showed that when samples were sintered by conventional method, they had reasonable values of Seebeck coefficient but very low values of electrical conductivity. Therefore, their power factors (PF) and figure of merits (ZT) were too low to be useful for high temperature thermoelectric applications. An unconventional sintering method, Spark Plasma Sintering (SPS) was determined to produce better thermoelectric properties. Particle size reduction of powders also was found to have some positive benefits. Two composition systems, specifically 1.0 SrO - 0.8 x 1.03 TiO2 - 0.2 x 1.03 NbO2.5 and 0.97 TiO2 - 0.03 NbO2.5, have been identified as good base line compositions for n-type thermoelectric compositions in future module design. Tests of these materials at an outside company were promising using that company's processing and material expertise. There was no unique p-type thermoelectric compositions identified in phase I work other than several current cobaltite materials. Ca3Co4O9 will be the primary p-type material for the future module design until alternative materials are developed. BaTiO3 and rare earth titanate based dielectric compositions show both p-type and n-type behavior even though their electrical conductivities were very low. Further research and development of these materials for thermoelectric applications is planned in the future. A preliminary modeling and optimization of a thermoelectric generator (TEG) that uses the n-type 1.0 SrO - 1.03 x 0.8 TiO2 - 1.03 x 0.2 NbO2.5 was performed. Future work will combine development of ceramic powders and manufacturing expertise at TAM, development of SPS at TAM or a partner organization, and thermoelectric material/module testing, modeling, optimization, production at several partner organizations.

25 ENERGY STORAGE↗
DOE OSTI2024

The need for carbon-emissions-driven climate projections in CMIP7

Abstract. Previous phases of the Coupled Model Intercomparison Project (CMIP) have primarily focused on simulations driven by atmospheric concentrations of greenhouse gases (GHGs), for both idealized model experiments and climate projections of different emissions scenarios. We argue that although this approach was practical to allow parallel development of Earth system model simulations and detailed socioeconomic futures, carbon cycle uncertainty as represented by diverse, process-resolving Earth system models (ESMs) is not manifested in the scenario outcomes, thus omitting a dominant source of uncertainty in meeting the Paris Agreement. Mitigation policy is defined in terms of human activity (including emissions), with strategies varying in their timing of net-zero emissions, the balance of mitigation effort between short-lived and long-lived climate forcers, their reliance on land use strategy, and the extent and timing of carbon removals. To explore the response to these drivers, ESMs need to explicitly represent complete cycles of major GHGs, including natural processes and anthropogenic influences. Carbon removal and sequestration strategies, which rely on proposed human management of natural systems, are currently calculated in integrated assessment models (IAMs) during scenario development with only the net carbon emissions passed to the ESM. However, proper accounting of the coupled system impacts of and feedback on such interventions requires explicit process representation in ESMs to build self-consistent physical representations of their potential effectiveness and risks under climate change. We propose that CMIP7 efforts prioritize simulations driven by CO2 emissions from fossil fuel use and projected deployment of carbon dioxide removal technologies, as well as land use and management, using the process resolution allowed by state-of-the-art ESMs to resolve carbon–climate feedbacks. Post-CMIP7 ambitions should aim to incorporate modeling of non-CO2 GHGs (in particular, sources and sinks of methane and nitrous oxide) and process-based representation of carbon removal options. These developments will allow three primary benefits: (1) resources to be allocated to policy-relevant climate projections and better real-time information related to the detectability and verification of emissions reductions and their relationship to expected near-term climate impacts, (2) scenario modeling of the range of possible future climate states including Earth system processes and feedbacks that are increasingly well-represented in ESMs, and (3) optimal utilization of the strengths of ESMs in the wider context of climate modeling infrastructure (which includes simple climate models, machine learning approaches and kilometer-scale climate models).

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2013

Enterprise SRS: Leveraging Ongoing Operations To Advance Nuclear Fuel Cycles Research And Development Programs

The Savannah River Site (SRS) is repurposing its vast array of assets to solve future national issues regarding environmental stewardship, national security, and clean energy. The vehicle for this transformation is Enterprise SRS which presents a new, radical view of SRS as a united endeavor for ''all things nuclear'' as opposed to a group of distinct and separate entities with individual missions and organizations. Key among the Enterprise SRS strategic initiatives is the integration of research into facilities in conjunction with on-going missions to provide researchers from other national laboratories, academic institutions, and commercial entities the opportunity to demonstrate their technologies in a relevant environment and scale prior to deployment. To manage that integration of research demonstrations into site facilities, The Department of Energy, Savannah River Operations Office, Savannah River Nuclear Solutions, the Savannah River National Laboratory (SRNL) have established a center for applied nuclear materials processing and engineering research (hereafter referred to as the Center). The key proposition of this initiative is to bridge the gap between promising transformational nuclear fuel cycle processing discoveries and large commercial-scale-technology deployment by leveraging SRS assets as facilities for those critical engineering-scale demonstrations necessary to assure the successful deployment of new technologies. The Center will coordinate the demonstration of R&D technologies and serve as the interface between the engineering-scale demonstration and the R&D programs, essentially providing cradle-to-grave support to the research team during the demonstration. While the initial focus of the Center will be on the effective use of SRS assets for these demonstrations, the Center also will work with research teams to identify opportunities to perform research demonstrations at other facilities. Unique to this approach is the fact that these SRS assets will continue to accomplish DOE's critical nuclear material missions (e.g., processing in H-Canyon and plutonium storage in K-Area). Thus, the demonstration can be accomplished by leveraging the incremental cost of performing demonstrations without needing to cover the full operational cost of the facility. Current Center activities have been focused on integrating advanced safeguards monitoring technologies demonstrations into the SRS H-Canyon and advanced location technologies demonstrations into K-Area Materials Storage. These demonstrations are providing valuable information to researchers and customers as well as providing the Center with an improved protocol for demonstration management that can be exercised across the entire SRS (as well as to offsite venues) so that future demonstrations can be done more efficiently and provide an opportunity to utilize these unique assets for multiple purposes involving national laboratories, academia, and commercial entities. Key among the envisioned future demonstrations is the use of H-Canyon to demonstrate new nuclear materials separations technologies critical for advancing the mission needs DOE-Nuclear Energy (DOE-NE) to advance the research for next generation fuel cycle technologies. The concept is to install processing equipment on frames. The frames are then positioned into an H-Canyon cell and testing in a relevant radiological environment involving prototypic radioactive materials can be performed.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2019

Progress and Challenges in Absorber and Interface Fabrication of Polycrystalline CdTe Photovoltaics

Polycrystalline thin-film CdTe device efficiency of over 19% has been achieved at Colorado State University using a highly repeatable and scalable sublimation process. Record efficiency for research scale CdTe photovoltaics has been reported to be over 22% and highest reported module efficiency is over 18% by First Solar Inc. Use of Se alloying with CdTe to form a lower band-gap CdSexTe1-x (CST) alloy has led to higher devices efficiencies with better current collection. Recent materials characterization has revealed that Se may be responsible for more than just reduction of band-gap. With CdCl2 treatment Cl is known to very effectively passivate defects at CdTe grain boundaries. Recent materials and electrical characterization have shown that Se has a very similar behavior to Cl at the grain boundaries of polycrystalline CdTe. These include Se decorating the grain boundaries like Cl in the diffusion region between CST and CdTe while cross-section cathodoluminescence maps show substantially higher signal intensity in regions with Se. Double heterostructures fabricated using CdSeTe with Al2O3 as a passivating oxide have been measured to have several hundred nanosecond bulk recombination lifetime. These films were also measured to have surface recombination velocity of under 100 cm/s. These results among others emphasis that Se also helps in passivation of grain boundaries. High absorber quality may help in mitigating the voltage deficit that has traditionally been the largest limiting factor in CdTe photovoltaics in achieving efficiency closer to Shockley-Queisser limit. In addition to graded absorber devices and double heterostructures, replacing the traditional Cu doping with more advanced group V doping is an important research effort that maybe critical for future improvements in device efficiency. Nitrogen, Phosphorous, Arsenic and Antimony doping has been investigated by several research groups. Advanced co-sublimation hardware developed at Colorado State University provides researchers with a unique capability of depositing films for group V doping with Cd overpressure. Such deposition under Cd overpressure causes formation of CdV which is known to be favorable for incorporation of group V dopant and activation. Utilizing the high absorber and interface quality material and higher doping, efforts are in progress to fabricate polycrystalline devices with open-circuit voltage over 1V and device efficiency over 24%.

Munshi, Amit↗
DOE OSTI2011

Detection and Production of Methane Hydrate

This project seeks to understand regional differences in gas hydrate systems from the perspective of as an energy resource, geohazard, and long-term climate influence. Specifically, the effort will: (1) collect data and conceptual models that targets causes of gas hydrate variance, (2) construct numerical models that explain and predict regional-scale gas hydrate differences in 2-dimensions with minimal 'free parameters', (3) simulate hydrocarbon production from various gas hydrate systems to establish promising resource characteristics, (4) perturb different gas hydrate systems to assess potential impacts of hot fluids on seafloor stability and well stability, and (5) develop geophysical approaches that enable remote quantification of gas hydrate heterogeneities so that they can be characterized with minimal costly drilling. Our integrated program takes advantage of the fact that we have a close working team comprised of experts in distinct disciplines. The expected outcomes of this project are improved exploration and production technology for production of natural gas from methane hydrates and improved safety through understanding of seafloor and well bore stability in the presence of hydrates. The scope of this project was to more fully characterize, understand, and appreciate fundamental differences in the amount and distribution of gas hydrate and how this would affect the production potential of a hydrate accumulation in the marine environment. The effort combines existing information from locations in the ocean that are dominated by low permeability sediments with small amounts of high permeability sediments, one permafrost location where extensive hydrates exist in reservoir quality rocks and other locations deemed by mutual agreement of DOE and Rice to be appropriate. The initial ocean locations were Blake Ridge, Hydrate Ridge, Peru Margin and GOM. The permafrost location was Mallik. Although the ultimate goal of the project was to understand processes that control production potential of hydrates in marine settings, Mallik was included because of the extensive data collected in a producible hydrate accumulation. To date, such a location had not been studied in the oceanic environment. The project worked closely with ongoing projects (e.g. GOM JIP and offshore India) that are actively investigating potentially economic hydrate accumulations in marine settings. The overall approach was fivefold: (1) collect key data concerning hydrocarbon fluxes which is currently missing at all locations to be included in the study, (2) use this and existing data to build numerical models that can explain gas hydrate variance at all four locations, (3) simulate how natural gas could be produced from each location with different production strategies, (4) collect new sediment property data at these locations that are required for constraining fluxes, production simulations and assessing sediment stability, and (5) develop a method for remotely quantifying heterogeneities in gas hydrate and free gas distributions. While we generally restricted our efforts to the locations where key parameters can be measured or constrained, our ultimate aim was to make our efforts universally applicable to any hydrate accumulation.

03 NATURAL GAS↗
DOE OSTI2022

Versatile Heat Transfer Module

Development of micro-reactors that can be easily transported to remote areas for civilian or military applications is an immediate focus of U.S. nuclear industry and therefore is being pursued by multiple reactor vendors (e.g. HolosGen LLC, Westinghouse, Ultra Safe Nuclear Corporation, URENCO, etc.) and actively supported by DOE-NE, DOE-ARPA-E and by the Department Of Defense (DoD). Very-high-temperature gas-cooled (VHTR) and heat pipe cooled reactor technologies are regarded as promising concepts for microreactors applications since they enable compact power conversion systems and display beneficial inherent safety features. Development of microreactors with enhanced performance must be supported by innovations in nuclear technologies. Several technologies being developed by the microreactor industry are being revisited with material technologies developed at the Argonne National Laboratory (ANL). Innovative high-temperature compatible solutions are developed to enable advanced thermal-spectrum microreactor designs featuring improved neutronics performance at high-temperature operating conditions to enable high thermal efficiency and economic competitiveness. This report focuses on the Versatile Heat Transfer Module (VHTM) technology that is developed at ANL for heat-transfer in thermal-spectrum microreactors. This technology is built on a liquid alkali metal heat pipe concept while leveraging advanced nuclear material technologies for high-temperature applications at reduced neutronic penalty with potential improvement in inherent safety behavior. The VHTM can be applied to design high-temperature thermal-spectrum microreactor systems with reduced size, weight, uranium enrichment, or increased lifetime. The INFINIT technology deriving from the VHTM enables design of a highly compact long-life microreactor concept for fission surface power (FSP). Demonstration of multiphysics modeling capability was also completed to showcase the added inherent safety benefits obtained with this concept. The VHTM technology remain at an early development stage with low Technology Readiness Level and Manufacturing Readiness Level. The current demonstration of these technologies has focused on manufacturing capability, on performance of the hydrogen diffusion barrier under thermal cycling, while radiation tolerance demonstration is planned. The next step of the demonstration plan will be the assembly of miniature VHTM for high-temperature testing, which can be used as a prototype for future pilot scale demonstration. Such research is critical to pursue development of these technologies that have the clear potential to significantly improve the performance of currently investigated micro-reactors systems.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2012

Novel Non-Vacuum Fabrication of Solid State Lithium Ion Battery Components

The purpose of this Cooperative Research and Development Agreement (CRADA) between Oak Ridge National Laboratory (ORNL) and Planar Energy Devices, Inc. was to develop large-scale electroless deposition and photonic annealing processes associated with making all-solid-state lithium ion battery cathode and electrolyte layers. However, technical and processing difficulties encountered in 2011 resulted in the focus of the CRADA being redirected solely to annealing of the cathode thin films. In addition, Planar Energy Devices de-emphasized the importance of annealing of the solid-state electrolytes within the scope of the project, but materials characterization of stabilized electrolyte layers was still of interest. All-solid-state lithium ion batteries are important to automotive and stationary energy storage applications because they would eliminate the problems associated with the safety of the liquid electrolyte in conventional lithium ion batteries. However, all-solid-state batteries are currently produced using expensive, energy consuming vacuum methods suited for small electrode sizes. Transition metal oxide cathode and solid-state electrolyte layers currently require about 30-60 minutes at 700-800°C vacuum processing conditions. Photonic annealing requires only milliseconds of exposure time at high temperature and a total of <1 min of cumulative processing time. As a result, these processing techniques are revolutionary and highly disruptive to the existing lithium ion battery supply chain. The current methods of producing all-solid-state lithium ion batteries are only suited for small-scale, low-power cells and involve high-temperature vacuum techniques. Stabilized LiNi x Mn y Co z Al 1-x-y-z O 2 (NMCA) nanoparticle films were deposited onto stainless steel substrates using Planar Energy Devices’ streaming process for electroless electrochemical deposition (SPEED). Since successful SPEED trials were demonstrated by Planar Energy Devices with NMCA prior to 2010, this high-voltage (i.e. 5 V) cathode material was the focus of the project. ORNL had also shown in prior work that photonic annealing can be used to anneal conventionally coated cathode metal oxide structures into the active crystalline phase. Planar Energy Devices also had demonstrated SPEED with solid electrolyte layers consisting of LiGaAlSPO 4 prior to the start of the project.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2017

Remediation of 130 mSv/hr. Soil Contamination Under a Hot Cell - 17301

Department of Energy (DOE) contractor CH2M HILL Plateau Remediation Company (CH2M) is currently engineering a system to safely remove and dispose of highly contaminated soil underneath Building 324 located adjacent to the Columbia River on the Hanford Site in Washington State. Cleaning up the waste site will allow for the eventual demolition of the building, which is a top priority for DOE and CH2M due to the proximity of the Columbia River and City of Richland. Building 324 at Hanford was originally constructed in 1966 and was operated for a number of years serving various missions. One of the missions involved development of treatment processes for liquid high activity waste. As of result of one particular mission, liquid high activity waste was spilled in one of the building's hot cells (known as 'B' Cell) and the liquid leaked from a breach in a sump and through construction joints in the hot cell floor and into the soil. Sampling efforts using borehole technology revealed significant under-building contamination with dose rates measuring has high as 130 mSv/hr (13,000 R/hr.). The Hanford Federal Facility Agreement and Consent Order (Tri-Party Agreement) between the Washington State, Department of Ecology (Ecology), the U.S. Environmental Protection Agency and the DOE has established a 2021 milestone for demolition and removal of the Building 324. Before building demolition can be undertaken, the highly contaminated soil must be removed from beneath the hot cell while the hot cell structure remains in place to provide shielding and containment during the soil remediation. CH2M will fabricate and install remotely operated equipment that will remove debris and grout in the cell, the floor of the hot cell, and the contaminated soil beneath the hot cell and package that soil for disposal. To ensure that the structure remains intact and does not shift during soil removal, support for the building structure must also be constructed as a prerequisite for the planned work. CH2M will use a full-scale mock-up of the Building 324 B Cell and airlock area to assist in the testing of the remotely operated equipment and the training of the soil removal team in a contamination-free environment to ensure efficient and safe performance of the challenging work of the project. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2020

Subtask 1.3 – Integrated Carbon Capture and Storage for North Dakota Ethanol Production

The Energy & Environmental Research Center (EERC), in partnership with Red Trail Energy, LLC (RTE), a North Dakota ethanol producer; the North Dakota Industrial Commission (NDIC) Renewable Energy Program (REP); and the U.S. Department of Energy (DOE), conducted a feasibility and implementation study for a commercial carbon capture and storage (CCS) effort. This subtask provided technical support and developed recommended practices of how small-scale industrial CO2 emitters (<1,000,000 tonnes of CO2 emitted annually) may economically deploy CCS. The 64-million-gallon dry mill RTE ethanol facility, emitting an average 180,000 tonnes of CO2 annually, was the subject of the case study. The positive outcome of this research, which shows technical and economic potential for ethanol–CCS in North Dakota, has resulted in RTE acquiring an approved Permit to Drill on December 2, 2019, for a stratigraphic test well in early 2020, a necessary step toward a North Dakota CO2 Storage Facility Permit (SFP) for the RTE CCS effort. Outcomes include 1) validating the Broom Creek Formation as a regional target for CCS, 2) determining the full carbon life cycle of an industrial fuel production facility with CCS, 3) developing a field implementation plan (FIP) for small-scale CCS, and 4) determining the validity and pathway for using CCS to meet low-carbon fuel (LCF) standards. The technical team included the EERC, RTE, Trimeric Corporation, Schlumberger Carbon Services, and Computer Modelling Group (CMG). Findings from activities conducted November 2016 – May 2020 are summarized as follows. Several key steps have been accomplished toward validating the Broom Creek Formation as a CO2 injection and storage target at the RTE CCS site, including verification of the presence and structure of sandstone layers that may comprise the potential CO2 storage reservoir and the several thousand feet of overlying confining zone. Work included site characterization using existing data, interpretation of seismic data within the study area, and geologic modeling simulation of CO2 injection. Interpreted results estimate 3000 feet of confining zone between the Broom Creek Formation (storage target) and the lowermost underground source of drinking water (e.g., the Fox Hills Formation). The thickness of the Broom Creek injection target varies 230–420 ft within the survey area. Results were used to inform the location of a stratigraphic test well and associated characterization test program. No impediments were identified within the targeted CO2 storage complex that would prevent the project from moving forward. A stratigraphic test well is the next step to validate these results and to acquire remaining data necessary to develop a North Dakota CO2 SFP application. The EERC generated full carbon life cycle estimates for CCS integration with the RTE ethanol facility. Results indicated that an average 40% reduction in CO2 emissions is possible through CCS implementation. Approximately half of the carbon in the overall life cycle for a dry mill ethanol plant is generated through the fermentation process and emitted to the atmosphere; this is the CO2 stream targeted for CCS. The remaining carbon is attributed to corn feedstock farming (diesel, fertilizer), energy for fuel processing (natural gas, electricity), and transportation (diesel) of the fuel product. Life cycle carbon estimates are also affected by the anticipated energy consumption of a potential capture facility, which depend on the type of CO2 product generated. For example, a 30%–40% net CO2 emission reduction is estimated if a liquefied CO2 facility were incorporated compared to a 40%–50% net CO2 reduction if a supercritical “injection-grade” CO2 product is generated; i.e., more energy is required to further refine the CO2 stream, affecting the full carbon life cycle estimates. A CCS FIP was developed and initiated at the RTE CCS site, resulting in the development of several guidance documents: a CO2 Capture Process Design Package, a North Dakota CO2 geologic Storage Permits Template, and a Public Outreach Package for CCS in North Dakota. General FIP components include CO2 capture system, pipeline and well designs; monitoring, verification, and accounting (MVA) plans; geologic characterization and testing programs; and permitting and outreach plans. Vendor bids were also acquired for the CO2 liquefaction facility. Near-surface characterization (groundwater and soil gas sampling) and geologic characterization (seismic survey) were initiated to inform development of a UIC Class VI-compliant MVA plan compliant with a North Dakota CO2 SFP. Designs (well and geologic testing) were completed for a stratigraphic test well compliant with a North Dakota CO2 SFP. In addition, the outreach plan was executed, including community open houses, meetings with city/county/state officials, and development of public materials. Although other entities continued to mature incentive programs in 2019–2020, California and the Internal Revenue Service (IRS) currently provide the most advanced economic opportunities for CCS integrated with fuel production. The California Low-Carbon Fuel Standard (LCFS) adopted a CCS Protocol in January 2019, allowing submittal of a design-based pathway (DBP) application for an approved temporary (not certified) carbon intensity value for a fully engineered facility. An ethanol–CCS DBP application to the California LCFS Program (officially approved February 28, 2020) was developed to show that the RTE CCS effort meets LCFS requirements. The approved DBP provides confidence to advance the project and supports potential investments. Other entities continue to mature incentive programs. The IRS issued guidance in February 2020 that addresses the definition of beginning of construction and revenue procedure on partnerships for the Enhancement of Carbon Dioxide Sequestration Credit (a.k.a. Section 45Q) CCS tax credit program; the IRS anticipates issuing further guidance on issues such as secure geologic storage, utilization qualifications, and recapture of claimed credits. Maturing incentive programs coupled with workable permitting regulations provide confidence to advance CCS projects in North Dakota and support financial investment to proceed with designing, constructing, and implementing CCS projects at small-scale fuel production facilities. The largest hurdles for CCS implementation at small-scale industrial systems are often business/economic-related (i.e., not technical). Market uncertainty already exists for agriculture-based alternative fuels such as corn ethanol, for which production has increased by ~33%, and prices have correspondingly lowered since 2015. Passing the Section 45Q tax credit program improves economic feasibility for CCS but may require external investors for a small business to achieve maximum benefits. Public–private partnerships with NDIC and DOE have resulted in foundational technical and regulatory knowledge, growing stakeholder confidence, and a pathway to implementation that enables similar industrial CCS projects in the region to advance. This subtask was funded through the EERC–DOE Joint Program on Research and Development for Fossil Energy-Related Resources Cooperative Agreement No. DE-FE0024233. Nonfederal funding was provided by NDIC and RTE. The authors would also like to thank CMG, ESRI, IHS, Neuralog, and Schlumberger for allowing the use of their software packages in support of this work.

42 ENGINEERING↗
DOE OSTI2014

Development of low-cost technology for the next generation of high efficiency solar cells composed of earth abundant elements

The development of renewable, affordable, and environmentally conscious means of generating energy on a global scale represents a grand challenge of our time. Due to the “permanence” of radiation from the sun, solar energy promises to remain a viable and sustainable power source far into the future. Established single-junction photovoltaic technologies achieve high power conversion efficiencies (pce) near 20% but require complicated manufacturing processes that prohibit the marriage of large-scale throughput (e.g. on the GW scale), profitability, and quality control. Our approach to this problem begins with the synthesis of nanocrystals of semiconductor materials comprising earth abundant elements and characterized by material and optoelectronic properties ideal for photovoltaic applications, namely Cu2ZnSn(S,Se)4 (CZTSSe). Once synthesized, such nanocrystals are formulated into an ink, coated onto substrates, and processed into completed solar cells in such a way that enables scale-up to high throughput, roll-to-roll manufacturing processes. This project aimed to address the major limitation to CZTSSe solar cell pce’s – the low open-circuit voltage (Voc) reported throughout literature for devices comprised of this material. Throughout the project significant advancements have been made in fundamental understanding of the CZTSSe material and device limitations associated with this material system. Additionally, notable improvements have been made to our nanocrystal based processing technique to alleviate performance limitations due to the identified device limitations. Notably, (1) significant improvements have been made in reducing intra- and inter-nanoparticle heterogeneity, (2) improvements in device performance have been realized with novel cation substitution in Ge-alloyed CZTGeSSe absorbers, (3) systematic analysis of absorber sintering has been conducted to optimize the selenization process for large grain CZTSSe absorbers, (4) novel electrical characterization analysis techniques have been developed to identify significant limitations to traditional electrical characterization of CZTSSe devices, and (5) the developed electrical analysis techniques have been used to identify the role that band gap and electrostatic potential fluctuations have in limiting device performance for this material system. The device modeling and characterization of CZTSSe undertaken with this project have significant implications for the CZTSSe research community, as the identified limitations due to potential fluctuations are expected to be a performance limitation to high-efficiency CZTSSe devices fabricated from all current processing techniques. Additionally, improvements realized through enhanced absorber processing conditions to minimize nanoparticle and large-grain absorber heterogeneity are suggested to be beneficial processing improvements which should be applied to CZTSSe devices fabricated from all processing techniques. Ultimately, our research has indicated that improved performance for CZTSSe will be achieved through novel absorber processing which minimizes defect formation, elemental losses, secondary phase formation, and compositional uniformity in CZTSSe absorbers; we believe this novel absorber processing can be achieved through nanocrystal based processing of CZTSSe which is an active area of research at the conclusion of this award. While significant fundamental understanding of CZTSSe and the performance limitations associated with this material system, as well as notable improvements in the processing of nanocrystal based CZTSSe absorbers, have been achieved under this project, the limitation of two years of research funding towards our goals prevents further significant advancements directly identified through pce. improvements relative to those reported herein. As the characterization and modeling subtask of this project has been the main driving force for understanding device limitations, the conclusions of this analysis have just recently been applied to the processing of nanocrystal based CZTSSe absorbers -- with notable success. We expect the notable fundamental understanding of device limitations and absorber sintering achieved under this project will lead to significant improvements in device performance for CZTSSe devices in the near future for devices fabricated from a variety of processing techniques

14 SOLAR ENERGY↗
DOE OSTI2016

Clemson University Wind Turbine Drivetrain Test Facility

In November of 2009, Clemson University was awarded a competitive grant from the U.S. Department of Energy to design, build and operate a facility for full-scale, highly accelerated mechanical testing of next-generation wind turbine drivetrain technologies. The primary goal of the project was to design, construct, commission, and operate a state-of-the-art sustainable facility that permits full-scale highly accelerated testing of advanced drivetrain systems for large wind turbines. The secondary goal was to meet the objectives of the American Recovery and Reinvestment Act of 2009, especially in job creation, and provide a positive impact on economically distressed areas in the United States, and preservation and economic recovery in an expeditious manner. The project was executed according to a managed cooperative agreement with the Department of Energy and was an extraordinary success. The resultant new facility is located in North Charleston, SC, providing easy transportation access by rail, road or ship and operates on an open access model such that it is available to the U.S. Wind Industry for research, analysis, and evaluation activities. The 72 m by 97 m facility features two mechanical dynamometer test bays for evaluating the torque and blade dynamic forces experienced by the rotors of wind turbine drivetrains. The dynamometers are rated at 7.5 MW and 15 MW of low speed shaft power and are configured as independent test areas capable of simultaneous operation. All six degrees of freedom, three linear and three rotational, for blade and rotor dynamics are replicated through the combination of a drive motor, speed reduction gearbox and a controllable hydraulic load application unit (LAU). This new LAU setup readily supports accelerated lifetime mechanical testing and load analysis for the entire drivetrain system of the nacelle and easily simulates a wide variety of realistic operating scenarios in a controlled laboratory environment. The development of these two dynamometer test rigs is the first significant achievement for the project. These test rigs embody a new manner of test due to the system configuration and completely new design with a free floating loading hub in the LAU. This project provided the catalyst for the advancement to this new test rig configuration that has been adopted by every significant wind turbine test rig constructed since the inception of this project. There are currently two different vendors supplying these new systems. Catalyzing this new design is the second major success of the project. With the increased market penetration of wind energy over the past decade, many regions and countries have developed specific electrical grid specifications and performance codes for large wind farms to ensure operational reliability and stability. These grid codes provide requirements for interconnection with the grid during low or high voltage phenomena, typically encountered during and after system fault events. Given the installed infrastructure of the Wind Turbine Drivetrain Testing Facility (WTDTF), a natural expansion of facility capability was to include the necessary equipment for performing fault ride-through evaluations of wind turbines to the Low Voltage Ride Through (LVRT) codes. Once the decision was made to expand the scope of the original grant into fault ride-through testing, it was clear that there are several markets, not just wind, which could benefit from this type of test and that simple fault ride-through testing could be extended into a broader scope of electrical testing capabilities. It was at this point that Clemson University was awarded a second grant to build a 15 MW Hardware-In-the-Loop (HIL) Grid Simulator in order to establish world class electrical testing capabilities to compliment the mechanical testing at the WTDTF. This third significant achievement resulted in the 15 MW HIL Grid Simulator as the corner stone of the Duke Energy eGRID Center and is collocated with the WTDTF in the SCE&G Energy Innovation Center at the new Facility in North Charleston, SC, USA. Before the eGRID was completed, it was recognized that the ability to test solar farm equipment was but a small step away thru the addition of enhanced equipment to provide for DC testing. In yet another expansion/success, a 2.5 MW rectifier system was designed and implemented by Clemson staff to enhance the Center’s capabilities. The program required over 250,000 man-hours of on-site construction labor reworking the brownfield facility on the former Navy Base, clearly satisfying one of the major goals of the Reinvestment Act. This was done while winning numerous awards for design and construction of the facility, including the Top US Project for 2014 from the Trade Journal Engineering News Record. The project was a major collaborative developmental activity managed by Clemson University staff that involved the DOE and many partners and organizations.

17 WIND ENERGY↗
DOE OSTI2015

Public perception of hazardousness caused by current trends of municipal solid waste management

Highlights: • Contribution to the scientific literature by examining the relationship between concern for the environment and waste disposal in the frame of household waste treatment mechanism specifically in developing countries. • The awareness of the citizens satisfaction level and the local existing capacities in developing countries significantly contribute to decision making on MSW management sustainability in Palestine and other developing countries when applied. • Identification of the differences and similarities among DC resulting to failures or success in WM field. - Abstract: Municipal solid waste (MSW) piling up is becoming a serious problem in all developing countries (DC) as a result of inequitable waste collection and treatment. Citizens’ collaboration is partly based on understanding their views and their active involvement in MSW planning; on the other hand the assessment of the perception of hazardousness related with MSW is considered rather important as well since the identification of the weak points of the applied MWM strategy is eased and the level of required training is determined. Researchers implemented a case study in the West Bank (WB) and Gaza Strip (GS) regions of Palestine, taking into consideration previous researches in other developing countries. They reached to safe and useful conclusions regarding the parameters which mean the greatest in the waste management field as far as DC are concerned. Lack of skilled manpower, irregular collection services, inadequate equipment used for waste collection, inadequate legal provisions, and resource constraints are additional factors that are confirmed to be challenging the waste management scenarios in all DCs today. The research takes those factors under consideration but focuses on the educational gap and the results revealed interesting trends a significant relationship between respondent’s educational attainment and their awareness of hazardous waste (hazard perception); the results will indicate the measure taking required to avoid accidents occurred in those regions (burns from toxics, cuts from sharps, etc). National policy and legislation development based on the research outcomes will ensure equitable and accessible services are in place in order to move towards a healthier environment. Specialized health education and training programs on national scale are also needed to enhance awareness on hazardous waste.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2017

Report on in-situ studies of flash sintering of uranium dioxide

Flash sintering is a novel type of field assisted sintering that uses an electric field and current to provide densification of materials on very short time scales. The potential for field assisted sintering techniques to be used in producing nuclear fuel is gaining recognition due to the potential economic benefits and improvements in material properties. The flash sintering behavior has so far been linked to applied and material parameters, but the underlying mechanisms active during flash sintering have yet to be identified. This report summarizes the efforts to investigate flash sintering of uranium dioxide using dilatometer studies at Los Alamos National Laboratory and two separate sets of in-situ studies at Brookhaven National Laboratory’s NSLS-II XPD-1 beamline. The purpose of the dilatometer studies was to understand individual parameter (applied and material) effects on the flash behavior and the purpose of the in-situ studies was to better understand the mechanisms active during flash sintering. As far as applied parameters, it was found that stoichiometry, or oxygen-to-metal ratio, has a significant effect on the flash behavior (time to flash and speed of flash). Composite systems were found to have degraded sintering behavior relative to pure UO 2 . The critical field studies are complete for UO 2.00 and will be analyzed against an existing model for comparison. The in-situ studies showed that the strength of the field and current are directly related to the sample temperature, with temperature-driven phase changes occurring at high values. The existence of an ‘incubation time’ has been questioned, due to a continuous change in lattice parameter values from the moment that the field is applied. Some results from the in-situ experiments, which should provide evidence regarding ion migration, are still being analyzed. Some preliminary conclusions can be made from these results with regard to using field assisted sintering to fabricate nuclear fuel. First, the pure UO 2 -based system shows promising behavior with flash sintering, but composite systems are likely to show better sintering behavior with spark plasma sintering. Efforts to develop these methods should therefore be tailored towards the likelihood of success. Additionally, modeling is a rapidly developing aspect of current flash sintering research and should be used in parallel with experiments. Ultimately, ongoing flash sintering studies on various materials, like those summarized in this report, are rapidly contributing to the feasibility of controlling this method for use in the future.

##CAI suggestions##↗
DOE OSTI2021

Development of Energy Storage: Cost models

Energy storage technologies offer a promising solution to electric grid stability issues associated with the integration of variable renewable generators. The capability to match the electrical power output to instantaneous fluctuations in grid demand is crucial to ensure continuity of service. Including energy storage capability in an integrated energy system (IES) can provide the flexibility needed to meet variable electric demand and reduce the load following demands place on the reactor. In this report, economic data collected for energy storage (ES) technologies are described to support the objective of assessing the profitability of ES integration within the IES framework. In particular, there is a growing interest in thermal energy storage (TES) given its unique capability for long-duration storage for improving electricity reliability at a low levelized cost. It is common practice to evaluate the total lifetime cost and profitability before commercializing new technologies. In this report we identify and examine the models needed to better understand the economics of thermal energy storage. We extend the TES cost model in RAVEN in the context of a balance of plant (BOP) that incorporates thermal storage. To focus the discussion, following a general overview of the most promising TES technologies, we consider a use case that involves a sensible heat, two-tank, molten-salt system. Structural and operational details are reported to identify the source of construction capital expenditure and operation and maintenance cost. A detailed description of the different cost items is provided as well as the cost scaling with different storage capacity and power ratings for capacity optimization purpose. In addition, the capital expenditure and the recurring cost of representative two-tank, molten salt coupled with concentrated solar plants are provided for readers’ reference. The ES use case is noteworthy as it is in the pilot stage of commercialization. We identify those areas that would benefit from an increased economic focus to obtain a more complete compilation of cost data. We also describe the thermal coupling issues that arise from integration of the two-tank molten salt thermal energy storage system with a BOP, which is the subject of our current research. Some components of costs will need to be evaluated through dedicated technoeconomic analysis in future modeling activities using modeling procedures proposed in this report. With the data presented and the procedures described in this report, sufficiently accurate models can be implemented for the solution of both the power dispatch and the capacity expansion problems within the RAVEN-based HYBRID framework.

25 ENERGY STORAGE↗
DOE OSTI2021

Tailoring Cementitious Materials Towards Value-Added Use of Large CO 2 Volumes

Hydraulic cements with alternative chemistries were developed for large-volume and value-added use of carbon dioxide. The hydraulic cements were processed using the energy-efficient mechanochemical technique at room temperature and atmospheric pressure. Carbon dioxide was captured directly from combustion emissions during processing. For this purpose, mechanochemical processing of hydraulic cements was accomplished under a flow of combustion emissions prior to the release of emissions to the atmosphere. The process removed a significant fraction of carbon dioxide from combustion emissions. The hydraulic cements captured carbon dioxide at about 10% of their weight. Two hydraulic cement chemistries were developed, and their mechanochemical processing was successfully scaled-up. The characteristic feature of one chemistry was its relatively low (near-neutral) pH where the integration of carbon dioxide yielded clear value. The second cement chemistry was based on alkali activation of industrial wastes. This chemistry could make value-added use of carbon dioxide, but it had to be refined to control the pH drop caused by CO 2 integration. These two cements render binding effects upon hydration by forming a combination of stable carbonates and aluminosilicates or phosphates. Efforts to develop cement chemistries based solely on carbonates were not successful. The mechanochemical process was found to integrate carbon dioxide into the alternative cement chemistries in the form of disordered and metastable carbonates. During hydration reactions, the disordered/metastable carbonates are either transformed into stable carbonate phases with desired binding efforts, or carbonates get integrated into the primary inorganic binders (hydrates). When compared with mechanochemical processing in pure carbon dioxide, mechanochemical processing in combustion emissions produced hydraulic cements with improved engineering properties. The mechanochemical process was scaled-up, and its variables as well as the raw materials formulations were optimized for implementation at pilot scale. Scale-up was found to enhance the carbon capture potential and the engineering qualities of the resulting hydraulic cements. This was because scale-up raises the intensity of mechanical energy input to raw materials. Certain mechanochemical phenomena cannot be induced, irrespective of the cumulative mechanical energy input, unless the intensity of impact is raised above a minimum level that cannot be achieved in laboratory-scale implementation of the process. Due to this effect, the duration of the mechanochemical process as well as its energy demand could be reduced significantly (by an order of magnitude) upon transition from laboratory to pilot scale, with the hydraulic cements produced at pilot scale offering engineering properties that were superior to those realized in laboratory-scale mechanochemical processing. The hydraulic cements produced at pilot scale via mechanochemical processing under a flow of combustion emissions were thoroughly characterized. They were found to meet standard requirements for ‘General Use’ hydraulic cements. They were compatible with the industrial-scale concrete production and construction practices that are used with the currently prevalent hydraulic cements. The new hydraulic cements with integrated carbon dioxide were found to offer distinct advantages over the currently prevalent Portland cement in terms of net carbon footprint and energy content. The combined raw materials and energy costs of the new hydraulic cements are competitive, and major cost savings can be realized because of the simplified production process that significantly lowers the capital investment in cement production plants. Mechanochemical processing of the new hydraulic cements under a flow of combustion emissions can be implemented using some existing components of cement manufacturing plants; this facilitates adoption of the technology by the cement industry.

36 MATERIALS SCIENCE↗