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At least 73 records · Page 4

Williston Basin Resource Study for Commercial-Scale Subsurface Hydrogen Storage

The Energy & Environmental Research Center (EERC), in partnership with the U.S. Department of Energy (DOE) National Energy Technology Laboratory (NETL), the EERC’s State Energy Research Center (SERC), MPLX Operations LLC, and TC Energy Development Holdings Inc. (a subsidiary of TC Energy Corporation), studied the potential for subsurface hydrogen storage and recovery in the Williston Basin of western North Dakota. The project’s goal was to evaluate the feasibility of large-scale, secure geologic H 2 storage to support future hydrogen generation, storage, and use. This work included laboratory testing, H 2 –rock–fluid exposure experiments, literature reviews on H 2 embrittlement, and reservoir modeling and simulations. The study included an assessment of storage potential across three types of storage reservoirs using both reservoir simulation and DOE’s web-based tool SHASTA-HELP (Subsurface Hydrogen Assessment, Storage, and Technology Acceleration – Hydrogen Estimator for Logistical Planning), as well as investigation of potential H 2 production and markets for commercial-scale deployment. Building on prior EERC gas storage research, three storage options were selected for detailed evaluation: the Broom Creek Formation (a clastic saline reservoir), the Dickinson Lodgepole Mounds (DLM) complex (carbonate mud mound structures) of the Lodgepole Formation (an active oil and gas producing reservoir), and the Dunham Salt Interval of the Piper Formation (to be used for engineered salt cavern development). These targets were prioritized based on prior EERC research using datasets related to seal capacity, reservoir quality, mechanical integrity, and injectivity. Exposure tests on Broom Creek and DLM samples showed mineral dissolution and precipitation that increased brine salinity and altered reservoir rock surfaces. Although these results provide useful insight, they are limited by small sample sizes and short-term (30-day) exposure, requiring further study to assess long-term storage integrity. Salt formations were not tested because of their known nonreactivity and established mechanical stability. Results of reservoir simulations performed for a single site demonstrated that the Broom Creek Formation may be capable of receiving up to 42,000 tonnes of injected H 2 over 7 months via one well. H 2 recovery took place over 5 months, resulting in approximately 26,000 tonnes (~62% without cushion gas [CG]). This work suggests water production may be important and subsequent cycles of injection and production may perform more efficiently; however, significant site-specific work in the future is needed to assess actual reservoir performance of injection and withdrawal of H 2 storage. For oil reservoir potential, a multiple-well model was used to simulate injection of approximately 32,000 tonnes of H 2 into a single wellbore while simultaneously producing in place reservoir fluids from four offset wells to maintain reservoir pressure. The simulation results suggested a high recovery (~98%); in addition, cost advantages through existing infrastructure could be realized. Challenges in this reservoir include vi managing gas purity and leakage risks. In both scenarios, production of H 2 takes place in a single-well scenario with 10 cycles (7 months of injection and 5 months of production) over 10 years. Finally, the use of engineered caverns in the Dunhan Salt was evaluated, and the results suggest that while they have a smaller capacity (<1000 tonnes per cavern), they exhibit nearly complete gas recovery (>99%), fast response times, and low purity risk. While caverns in North Dakota may be smaller in capacity, fields can be developed in galleries to accommodate the volumetric needs and rapid turnaround times necessary to meet market demands. Geographic limitations and thin salt intervals in North Dakota may represent less total storage potential than salt domes elsewhere, but significant opportunities exist to expand this market for gas storage in North Dakota. A basinwide assessment was performed to estimate a first-of-its-kind value for H 2 storage on a large scale. DOE’s SHASTA-HELP, combined with EERC simulation work, was used to perform the assessment. Estimated H 2 storage potential varied widely for each formation type. The Broom Creek saline formation was estimated to have a storage potential of approximately 1.7–90.5 million tonnes (MMt). The DLM oil reservoirs were estimated to have 0.07–0.19 MMt of capacity. Notably, each of these estimates relies on significant assumptions regarding reservoir thickness, porosity, permeability, and CG needed for operation. Much research is needed to understand the true site-specific storage resource potential of each formation. Using the Dunham Salt Interval for cavern development may result in as much as 4.79 MMt (up to 2.87 MMt working gas) of H 2 storage potential. An important note for consideration is that the values presented here need significantly more geological characterization and engineering assessments prior to gaining confidence in performance. This will be a focal point for future research and development needs. The basinwide evaluation also indicated that North Dakota has significant H 2 generation potential, with estimates up to a possible 13 MMt annually, suggesting a substantial opportunity for H 2 market development and thus the need for commercial-scale H 2 storage to facilitate growth and resilience. Key Recommendations 1. Conduct detailed site characterization (3D seismic, well logs, core sampling) to reduce geologic uncertainty. 2. Perform techno-economic analyses incorporating market, regulatory, and incentive frameworks. 3. Investigate long-term interactions among H 2 , CGs, well materials, and formations to assess risks. 4. Develop pilot- and field-scale demonstrations to validate models and establish best practices.

03 NATURAL GAS↗

Challenges of designing, operating, and managing brine extraction at a carbon dioxide storage site

Developing and deploying commercial-scale carbon dioxide (CO 2 ) storage at a site requires operational strategies to manage pressure and CO 2 plume distribution. In the natural gas storage and oil and gas industries, fluid extraction has been successfully implemented as a strategy to manage pressure and control fluid distribution (i.e., hydrocarbon recovery and natural gas storage efficiency, respectively). The technical challenges of integrating brine extraction at CO 2 storage sites are expected to be similar, if not identical, to those in the natural gas storage and petroleum industries. Major technical challenges of using brine extraction to manage storage in a storage unit include (1) designing and completing the brine extraction wells, (2) locating the brine extraction well, (3) assessing the efficacy of brine extraction, and (4) handling the extracted brine. The design and completion of the brine extraction well include the well type (i.e., vertical or horizontal) and perforated interval. The location of the well is influenced by the timing of extraction operations (i.e., prior or after CO 2 injection starts) and project objectives (i.e., desired directional movement of the CO 2 plume and avoid or minimize CO 2 extraction). The efficacy of brine extraction requires a baseline projection of the pressure and CO 2 plume distribution. Options for handling extracted brine include subsurface disposal, surface disposal, and industrial use. Here this paper addresses means of overcoming technical challenges that may likely be encountered before or after CO 2 injection starts.

25 ENERGY STORAGE↗

Controllable Solar Flux Heating for Freeze Recovery in Molten Salt Parabolic Trough Collectors

In molten-salt parabolic trough plants, the melting process is particularly important for freeze recovery of salt that is solidified in a collector loop, should such an event occur. Currently impedance heating is expected for freeze recovery of the collector loops, but this method can be expensive. Here, a lower-cost alternative is proposed to use controllable concentrated solar flux directly from the parabolic mirrors to thaw salt that is frozen in the collector. A computational fluid dynamics model was developed to explore the solidification and melting processes of molten salt in a parabolic trough receiver and to assess the viability of this concept. Results indicate that concentrated solar heating has the potential to melt frozen salt in 5.6 h, compared to that in 8.8 h for a 300 W m –1 impedance heating system. At the same time, controllable solar flux heating introduces nonuniform solar fluxes on the receiver surface, which can induce significant thermal stress on the receiver tube. A preliminary stress analysis indicates that the temperature difference across the receiver tube should be maintained below about 70 °C for heating up to 300 °C at internal pressures ≤10 bar. At these conditions, freeze recovery using solar flux heating will not significantly affect receiver lifetime. These results suggest that controllable solar flux heating could effectively supplement or replace impedance heating in the freeze recovery system. Incorporating this methodology in future parabolic trough concentrating solar power plants is an opportunity for capital and operational cost-savings.

14 SOLAR ENERGY↗

Water-gas shift reaction in ceramic-carbonate dual-phase membrane reactor at high temperatures and pressures

Water-gas-shift (WGS) reaction is a critical step in integrated gasification combined cycles (IGCC) power plants with CO 2 capture. Membrane reactors made with a CO 2 -permselective ceramic-carbonate dual-phase (CCDP) membrane offers the potential to enhance hydrogen yield with simultaneous CO 2 capture for WGS reaction. The present work studies operation of WGS reaction in a tubular membrane reactor made of samarium-doped ceria infiltrated with lithium/sodium molten carbonate mixture. The WGS reaction was performed in the membrane reactor with and without a high-temperature WGS catalyst at 800–850 °C, feed pressure of 7 bar, the space velocity of 150–3000 h –1 , and a feed gas mixture of 45.7/13.1/41.3 mol% CO/CO 2 /N 2 with steam to carbon ratio of 4. The results show that the catalyst-free membrane reactor can convert 92% of carbon monoxide into CO 2 and H 2 and recover 29% CO 2 at 850 °C and a space velocity of 150 h –1 . However, in the catalyst-free membrane reactor, a significant amount of unwanted carbon deposition is observed. The side reactions can be minimized by reducing the operating pressure and increasing the operating temperature and space velocity, and completely avoided using a high-temperature catalyst at space velocity>500 h –1 . The membrane reactor with a WGS catalyst achieves CO conversion of about 85%, above the equilibrium conversion, and 40% CO 2 recovery without carbon deposition at high temperature and pressure. Finally, the membrane remains in the same structure and gas-tightness after the WGS reaction tests.

20 FOSSIL-FUELED POWER PLANTS↗

Chelation-Driven Chemistry Controls Dissolution Pathways for Facile Critical Mineral Recovery from Ultramafic Resources

The efficient recovery of critical minerals, such as nickel (Ni) and manganese (Mn) from the subsurface is of vital importance, given their role in modern technologies ranging from batteries to advanced alloys. This study explores an approach that employs chelation to enhance critical mineral recovery from ultramafic rocks using chelating ligands under ambient pressures and systematically evaluates the extraction process for the first time. Experimental results demonstrate the superior performance of EDTA and PrDTA in achieving high extraction efficiencies for both Ni and Mn. To further highlight the ability for optimization, the fluid exchange and variation of fluid-to-rock ratio experiments were conducted, revealing tunable controls for engineering recovery. We show that under optimized conditions, a Ni extraction efficiency of ?82% and a Mn extraction efficiency of ~60% is achieved at ambient pressures, which is equivalent to over 23 times the current global Ni production, and 2 million metric tonnes (MMT) greater than the current global Mn production. From both in-situ and ex-situ mining perspectives, the results highlight the potential of chelation to advance sustainable mineral processing. Overall, this work highlights the environmental benefits of innovative ligand-assisted recovery methods, addressing the critical need for the efficient utilization of olivine resources.

Krishnan, Keerthana↗

Mass flow rate effect on a rotating detonation combustor with an axial air injection

Changing the flow rate of reactants being injected into a rotating detonation combustor (RDC) results in interesting behavior of the system. Prior studies have found that an increase in mass flow rate gradually increases the detonation wave speed before splitting the wave into multiple fronts. Here, the focus of this study is in understanding the physics of such behavior through a combination of experiments and numerical simulations. For this purpose, the axial air inlet-based RDC geometry is used. In the experiments, the wave velocity increased similar to prior studies. Corresponding full-scale simulations show that increase in mass flow rate by increasing pressure of the feed plenums shortens the recovery time of the injectors. This causes a more uniform fuel–air mixture to form prior to the arrival of the detonation wave. As a result, a more ideal detonation is observed, which leads to an increased wave velocity. Details of the detonation structure and variation with mass flow rate are analyzed. The presence and variation of the different deflagration zones in such non-premixed RDCs are also discussed.

42 ENGINEERING↗

A Hybrid Heavy-Duty Diesel Power System for Off-Road Applications - Concept Definition

A multi-year Power System R&D project was initiated with the objective of developing an off-road hybrid heavy-duty concept diesel engine with front end accessory drive-integrated energy storage. This off-road hybrid engine system is expected to deliver 15-20% reduction in fuel consumption over current Tier 4 Final-based diesel engines and consists of a downsized heavy-duty diesel engine containing advanced combustion technologies, capable of elevated peak cylinder pressures and thermal efficiencies, exhaust waste heat recovery via SuperTurbo™ turbocompounding, and hybrid energy recovery through both mechanical (high speed flywheel) and electrical systems. The first year of this project focused on the definition of the hybrid elements using extensive dynamic system simulation over transient work cycles, with hybrid supervisory controls development focusing on energy recovery and transient load assist, in Caterpillar’s DYNASTY™ software environment. Three key off-road applications were the focus of the hybrid concept definition with an aim of understanding the system’s modular capability for the diverse off-road heavy-duty market. Core engine performance 1D and 3D simulations isolated the efficiency contributions from the downsized engine, turbocompounding, and in-cylinder thermal barrier coatings. A fuel consumption improvement range of 14 to 24% was predicted, resulting in successful project progression to the design and experimental validation phase. Furthermore, an overview of the experimental engine and hybrid system status concludes the discussion along with the multi-year project’s next steps.

33 ADVANCED PROPULSION SYSTEMS↗

Extreme Metastability of Diamond and its Transformation to the BC8 Post-Diamond Phase of Carbon

Diamond possesses exceptional physical properties due to its remarkably strong carbon–carbon bonding, leading to significant resilience to structural transformations at very high pressures and temperatures. Despite several experimental attempts, synthesis and recovery of the theoretically predicted post-diamond BC8 phase remains elusive. Through quantum-accurate multimillion atom molecular dynamics (MD) simulations, we have uncovered the extreme metastability of diamond at very high pressures, significantly exceeding its range of thermodynamic stability. We predict the post-diamond BC8 phase to be experimentally accessible only within a narrow high pressure–temperature region of the carbon phase diagram. The diamond to BC8 transformation proceeds through premelting followed by BC8 nucleation and growth in the metastable carbon liquid. Here we propose a double-shock compression pathway for BC8 synthesis, which is currently being explored in experiments at the National Ignition Facility.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Supplementary Data for "Evaluation of the Economic Implications of Varied Pressure Drawdown Strategies Generated Using a Real-time, Rapid Predictive, Multi-fidelity Model for Unconventional Oil and Gas Wells" by Bello, K., Vikara, D., Sheriff, A., Viswanathan, H., Carr, T., Sweeney, M., O'Malley, D., Marquis, M., Vactor, R.T., and Cunha, L.

The Bello et al. study evaluates the impact of contrasting pressure drawdown on gas productivity and the resulting economics of a well in the Marcellus Shale of the Appalachian Basin. This research applies a techno-economic analysis approach to help identify potential ways pressure management strategies can be used to improve cumulative recovery of hydraulically fractured horizontal wells while maintaining project profitability. Gas production forecast outlook scenarios of the Marcellus Shale Energy and Environment Laboratory Laboratory's MIP-3H well were generated under varying pressure drawdowns using two approaches: 1) a novel physics-informed machine learning (PIML) workflow and 2) via traditional reservoir simulation in Computer Modeling Group’s (CMG) GEM Compositional & Unconventional Simulator. Cash flow and other economic metrics of interest were compiled on the production outlook using the U.S. Department of Energy's (DOE) National Energy Technology Laboratory (NETL) Unconventional Shale Well Economic Model (UShWEM).The sheets within this Microsoft ExcelTM workbook provide the economic metric outputs for the baseline condition and the one-at-a-time (OAT) sensitivity analysis of UShWEM's input parameters for each of the production scenarios evaluated.

Fracture Network Model↗

Protein Extraction, Precipitation, and Recovery from Chlorella sorokiniana Using Mechanochemical Methods

Protein extraction, precipitation, and recovery methods were evaluated by this study using a green alga—Chlorella sorokiniana. A mechanochemical cell disruption process was applied to facilitate protein extraction from microalgal biomass. Optimization of the mechanochemical process resulted in milling conditions that achieved a protein extraction of 52.7 ± 6.45%. The consequent acid precipitation method was optimized to recover 98.7% of proteins from the microalgal slurry. The measured protein content of the protein isolate was 41.4% w/w. These results indicate that the precipitation method is successful at recovering the extracted proteins in the algal slurry; however, the removal of non-protein solids during centrifugation and pH adjustment is not complete. The energy balance analysis elucidated that the energy demand of the protein extraction and recovery operation, at 0.83 MJ/kg dry algal biomass, is much lower than previous studies using high-pressure homogenization and membrane filtration. This study concludes that mechanochemical protein extraction and recovery is an effective, low-energy processing method, which could be used by algal biorefineries to prepare algal proteins for value-added chemical production as well as to make algal carbohydrates and lipids in the residual biomass more accessible for biofuel production.

59 BASIC BIOLOGICAL SCIENCES↗

Compressor system with heat recovery

A system includes a first working fluid compressor configured to pressurize a working fluid, and a prime mover coupled to the first working fluid compressor and configured to provide a mechanical input into the first working fluid compressor. An exhaust assembly is coupled to the prime mover and is configured to receive exhaust heat from the prime mover, the exhaust assembly including a generator configured to generate electric current based on the exhaust heat received by the exhaust assembly. A second working fluid compressor includes an electric motor electrically and synchronously coupled to the generator and configured to pressurize the working fluid.

Torrey, David Allan↗

Biomass pretreatment with distillable ionic liquids for an effective recycling and recovery approach

Ionic liquid (IL) pretreatment methods show incredible promise for the efficient conversion of lignocellulosic feedstocks to fuels and chemicals. Given their low vapor pressures, distillation-based methods of extracting ionic liquids out of biomass post-pretreatment have historically been ignored in favor of alternative methods. We demonstrate a process to distill four acetate-based ionic liquids ([EthA][OAc], [PropA][OAc], [MAEthA][OAc], and [DMAEthA][OAc]) at low pressure and high purity that overcome some disadvantages of “water washing” and “one pot” recovery methods. Out of four tested ILs, ethanolamine acetate ([EthA][OAc]) is shown to have the most agreeable conversion metrics for commercial bioconversion processes achieving 73.6% and 51.4% of theoretical glucose and xylose yields respectively and >85 % recovery rates. Our process metrics are factored into a techno-economic analysis where [EthA][OAc] distillation is compared to other recovery methods as well as ethanolamine pretreatment at both milliliter and liter scales. In conclusion, although our TEA shows [EthA][OAc] distillation underperforming against other processes, we show a step-by-step avenue to reduce sugar production cost below the wholesale dextrose price at scale.

09 BIOMASS FUELS↗

Comparative techno-economic assessment of osmotically-assisted reverse osmosis and batch-operated vacuum-air-gap membrane distillation for high-salinity water desalination

New developments in pressure- and thermally driven membrane desalination technologies offer the potential to cost-effectively treat high-salinity waters, especially when powered by low-cost solar electricity and thermal energy. This paper presents a comparative techno-economic assessment of the state-of-the-art most promising pressure- and thermally driven membrane technologies for high recovery desalination, namely, osmotically-assisted reverse osmosis (OARO) and batch-operated vacuum-air-gap membrane distillation (batch V-AGMD), to produce potable water while concentrating brine within the range of 140–290 g/L TDS for minimum-liquid-discharge (MLD) and zero-liquid-discharge (ZLD) applications. It is shown that both OARO and batch V-AGMD can treat feedwater and brines with TDS in the range of 30–125 g/L with corresponding fresh water recovery rates of 85–25%. When low cost solar electricity and thermal energy are used, the resulting levelized cost of water (LCOW) from OARO is in the range of 0.70–6.28 $/m 3 , and that from batch-V-AGMD is in the range of 1.74–2.77 $/m 3 . OARO is more cost-effective than batch V-AGMD when feedwater salinity is below 70 g/L and recovery below 75%, whereas batch V-AGMD is more cost-effective at higher recovery rates and salinity levels. Finally, the sensitivity of this comparison on energy prices and module costs is discussed.

42 ENGINEERING↗

Performance evaluation of an industrial ceramic nanofiltration unit for wastewater treatment in oil production

An industrial ceramic nanofiltration membrane (pore size 0.9 nm) was tested in a Canadian oil field for more than 12,500 h to treat wastewater directly from daily operations, without any type of pre-treatment. This wastewater contained a high content of total suspended solids (13 to 510 mg/kg), and total organic carbon (31 to 134 mg/kg). The membrane unit was operated at different transmembrane pressure (TMP) set points (4–16 bar) and recovery set points (40–80%). The data show that ion and compound rejection depend strongly on a combination of both TMP and recovery, with the largest rejection occurring at low recovery values and high TMP values. Two mechanisms were responsible for rejection: sieving, which mostly impacted compound rejection, and electrostatic phenomena that impacted ion rejection. It is shown that ion rejection depends linearly on charge density of the ion. Ion rejection was measured as high as 85% and compounds (such as TSS) were rejected as high as 100%. The specific flux varied between 1–10 L/(m 2 .h.bar). Results from this field testing indicate the possibility of using these types of ceramic membranes for oil field wastewater treatment.

42 ENGINEERING↗

C1Po2D-04: Cryogenic Testing of the First HL-LHC Q1/Q3 Cryo-Assembly at

In early 2023, Fermilab is conducting horizontal cryogenic testing of the first Q1/Q3 Cryo-Assembly for the high-luminosity LHC upgrade (HL-LHC). The Cryo-Assembly was installed on the upgraded Fermilab horizontal test stand previously used for testing the LHC inner triplet quadrupoles. The cryogenic process requirements of this test include controlled cool-down and warm-up with a 100 K maximum temperature differential between the two ends of the cold mass, operation of a 1.3 bar, 1.9 K bath of subcooled superfluid helium during power testing and magnetic measurements, and operation at pressure up to 18 bar with full helium recovery after a quench.

Rabehl, R.↗

CFD and systems engineering to minimize membrane-based carbon capture costs

In this study, we propose a superstructure for membrane-based carbon capture, addressing these challenges through the formulation of an optimization problem. The case study considers a flue gas with a flowrate of 1000 mol/s and a 30 % CO2 (molar basis), which is representative of steel plants. Reduced models, derived from rigorous CFD simulations of membrane modules, are utilized to enhance the efficiency of the optimization process. The reduced model includes specific input variables such as inlet flow rate, retentate and permeate pressures, and inlet CO2 concentration; while the CO2 recovery and purity in the permeate side are considered as output variables. In this way, we exploit the information from the CFD simulations in the superstructure, aiding in the selection of the optimal configuration for the multi-stage membrane process. The results underscore the efficiency of a multi-stage membrane design, showing capture costs around 45 $/t-CO2.

Pedrozo, Hector A.↗

Cryogenic Testing of HL-LHC Q1/Q3 Cryo-Assemblies at Fermilab

Fermilab is conducting horizontal cryogenic testing of Q1/Q3 Cryo-Assemblies for the high-luminosity LHC upgrade (HL-LHC). Cryo-Assemblies are installed on the upgraded Fermilab horizontal test stand previously used for testing the LHC inner triplet quadrupoles. The cryogenic process requirements of these tests include controlled cool-down and warm-up with a 100 K maximum temperature differential between the two ends of the cold mass, operation of a 1.3 bar, 1.9 K bath of subcooled superfluid helium during power testing and magnetic measurements, and operation at pressures up to 18 bar with full helium recovery after a quench. This paper presents the operational experience gained from the first tests as well as improvements for subsequent tests.

Rabehl, R. [Fermilab]↗

An upgraded cryogenic test stand for HL-LHC cryo-assemblies

The Fermilab horizontal test stand previously used for testing the LHC inner triplet quadrupoles has been upgraded to test cryo-assemblies for the high-luminosity LHC upgrade (HL-LHC). The test requirements of these new cryo-assemblies required additional capabilities of the test stand cryogenic system, including controlled cool-down and warm-up, helium recovery after a quench, and operation at higher pressures. Most of these upgrades were completed to support a zero-magnet test in late 2020, with the remainder of the upgrades completed to support the first pre-series cryo-assembly test in early 2022. An overview of the design and initial operating experience of the upgraded test stand cryogenic system and associated process controls system are presented in this paper.

Rabehl, Roger J.↗