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

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At least 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Experimental Investigation of Polymer Induced Fouling of Heater Tubes in the First-Ever Polymer Flood Pilot on Alaska North Slope

Mineral fouling in heat exchangers has been extensively investigated by researchers in recent times. The oil and gas industry has a long history of fouling issues in production systems as a result of produced fluids treatment. Due to decline in production rates in oilfields new technologies are being developed and field tested in pilots. Polymer flooding is one such technology that involves addition of polymers to injection fluids to enhance oil production. A polymer flood pilot has been set up in the Schrader Bluff viscous oil reservoir at Milne Point field on the Alaska North Slope (ANS). The results from the pilot are encouraging, however a major concern of the operator is the influence of polymer on the production system after breakthrough, especially the fouling in heat exchangers. This study investigates the propensity of polymer fouling on the heater tubes as a function of different variables, with the ultimate goal of determining safe and efficient operating conditions. This work applies a multi-experimental approach to study the severity of polymer-induced fouling in both dynamic and static states of produced fluids as well as studying the stability of polymer solutions at different temperatures. A unique experimental setup was designed and developed in-house to simulate the fouling process on the heating tube. The influence of heating tube skin temperature, tube material, and polymer concentration on fouling tendency was investigated. Each test was run five times with the same tube, and in each run, the freshly prepared synthetic brine and polymer solution was heated from 77°F to 122°F to mimic field-operating conditions. The heating time and fouling amount were recorded for each run. Dynamic Scale Loop (DSL) tests were conducted to study fouling due to polymer at different temperatures (165°F to 350°F) in a dynamic state of fluid flow where the fluids mimic the residence time of fluids in the heat exchanger on the field pilot. Cloud point measurement has also been conducted to find the critical temperature at which the polymer in solution becomes unstable and precipitates out. The morphology and composition of the deposit samples were analyzed by environmental scanning electron microscopy (ESEM) and X-ray diffraction (XRD), respectively. It was found that the presence of polymer in produced fluids would aggravate the fouling issues on both carbon steel and stainless-steel surfaces at all tested skin temperatures. Only higher skin temperatures of 250°F and 350°F could cause polymer-induced fouling issues on the copper tube surface, and the fouling tendency increased with polymer concentration. At the lower skin temperatures of 165°F, no polymer-induced fouling was identified on the copper tube. A critical temperature that is related to the cloud point of the polymer solution was believed to exist, below which polymer-induced fouling would not occur, and only mineral scale was deposited but above which the polymer would aggravate the fouling issue. The cloud point of the tested polymer solution was determined to be between 220°F and 230°F. In the DSL tests it was found that at higher skin temperatures of 250°F and 350°F tube blocking was observed in the DSL tests whereas the tests at 165°F and 200°F did not show any tube blocking in the same time period. These experiments also manifested the influence of cloud point of the solution as deposit rate increased significantly in both carbon steel and stainless-steel tubes when the skin temperature was higher than the solution cloud point. The results of this study have provided guidance to the operator for the field-operations.

Dhaliwal, Anshul↗
DOE OSTI2025

University Data Management Pilot Utilizing the Nuclear Research Data System

Background In 2022, the Office of Science and Technology Policy (OSTP) issued a memo that significantly reshaped the landscape of access to federally funded research. The memo mandated that all taxpayer-funded research be made available to the public without delay upon publication, without an embargo period, superseding the 2013 OSTP public access policy. This public access policy promotes transparency and the democratization of knowledge, ensuring that the fruits of scientific endeavors funded by federal agencies could be immediately accessed and built upon by scientists, educators, students, and the public at large. To implement the requirements of the OSTP guidance and DOE Public Access Plan, the Office of Nuclear Energy (NE) has implemented public access plan guidance and has identified several areas where better data management practices would further expand public access to important nuclear energy related scientific data, reports, and other technical products. Significant NE supported efforts are already underway for data management and public access to important nuclear energy related data.1 2 To address gaps in data management practices, and improve retention and accessibility of data, NE is actively exploring enhanced data management options utilizing its high-performance computing resources administered by its Nuclear Scientific User Facility Program. A newly piloted system, the Nuclear Research Data System (NRDS) acts as a portal for data collection and dissemination. Nuclear Energy University Program Research and Development Portfolio According to Web of Science, NEUP has produced 2,345 journal publication that have been cited more than 61,000 times3 and countless conference proceedings. These publications are publicly available through OSTI.gov and in the open literature. Additional scientific and technical products including project milestones that are not publications and NEUP project final reports are vetted through OSTI.gov and released once reviewed and approved by DOE. Since 2009, NEUP has awarded close to 1,000 different R&D projects in technical areas across the NE research programs. As of June 2023, 512 NEUP reports are publicly available on OSTI. The underlying data for projects is still held at universities, and data transfer, co-location, and dissemination has not occurred in a systematic way. NEUP data is currently accessible through myriad university-based data repositories, or through direct requests to PIs. The program identified this patchwork of repositories, or often lack of publicly available data, as a significant barrier to an organized, accessible, and comprehensive solution to sharing data with the larger nuclear energy community. Approach The goal of this pilot project is to establish a pathway to a consolidated long-term repository for NEUP project data. To accomplish this goal, the pilot strives to accomplish the following objectives: Establish data collection standards, including a standard set of required supplementary information to contextualize and support raw data files. Work with the HPC group collect and upload information and to modify the NRDS system, as needed, to support a standardized approach. Resolve potential barriers to successful roll out of an expanded data collection strategy, including modifying data management plan guidelines and establishing a document and data release process that accounts for potential intellectual property and/or export control concerns. Results Overall, the pilot was successful in collecting 8,982 raw and processes data files, 220 reports, 56 calibration files, and 5,931 other supplementary documents. Supplementary documents included experimental plans, methods, journal publications and conference proceedings, milestone reports, and final reports. Figure 2 shows the number of data sets and supplementary project information provided by each project. Projects has significantly different input, depending on experimental data produced and completeness of the datasets provided.

Data collection↗
DOE OSTI2022

Laboratory and pilot-scale studies of membrane distillation for desalination of produced water from Permian Basin

Substantial quantities of produced water generated during the extraction of oil and gas from unconventional reservoirs present significant environmental concern and increase the operating cost for this industry. Membrane Distillation (MD) can serve as a potential solution for beneficial reuse of produced water by generating high-quality permeate and reducing the volume of produced water requiring disposal. This study investigated treatment of produced water from Permian Basin in both laboratory and pilot-scale studies. Laboratory tests revealed the potential to successfully recover 50% of produced water although some increase in permeate conductivity was observed due to the passage of ammonia from the feed side. Initial pilot-scale test with filtration of raw produced water as the only pre-treatment step led to precipitation of SrSO 4 , NaCl, and Fe in the system once the solubility limits for these salts were exceeded. However, chemical pretreatment that included pH adjustment, aeration, and barite precipitation, allowed successful steady-state operation of the AGMD pilot system for 5 days where the produced water was concentrated from 127 g/L to 255 g/L (~50% water recovery) while recovering high quality permeate. Overall, greater than 99.7 % salt rejection was achieved with the average permeate flux of 1.86 LMH. Finally, mass balance analysis suggested potential Ba and Ca precipitation in the system but there was no impact on AGMD performance and permeate quality during 5 days of continuous operation in the field.

42 ENGINEERING↗
DOE OSTI2023

Performance of hydrophobic physical solvents for pre-combustion CO 2 capture at a pilot scale coal gasification facility

Here, in this paper, we present the first pilot plant data for hydrophobic physical solvents for CO 2 and H 2 S removal from coal-derived H 2 -rich syngas. Four physical solvents were tested under pre-combustion CO 2 capture conditions at bench scale and pilot plant scale: one baseline hydrophilic solvent and three hydrophobic solvents. The solvents were: (1) polyethylene-glycol-dimethyl ether (PEGDME), a hydrophilic solvent analog for the commercial process Selexol, (2) tributyl- phosphate (TBP), a commercially available hydrophobic solvent, (3) polyethylene glycol-poly(dimethylsiloxane) (PEG-PDMS-3), and (4) diethyl sebacate (CASSH-1), a novel, computationally screened hydrophobic solvent developed by the National Energy Technology Laboratory (NETL). All solvents were studied under pure gas (CO 2 /N 2 /H 2 /CH 4 ) equilibrium conditions at NETL followed by pilot plant testing with syngas at the University of North Dakota Energy & Environmental Research Center (UND EERC). Long term performance of CASSH-1 and PEDGME was then assessed with results compared to process simulation predictions. Within experimental uncertainties, all solvents showed comparable CO 2 absorption performance at above room temperature operation while the hydrophobic solvents had limited water uptake and low vapor pressure, which alleviates concerns related to corrosion, water absorption, and solvent loss to evaporation. These results indicate low viscosity, low vapor pressure hydrophobic solvents are a promising option for lower cost CO 2 capture from high pressure syngas applications.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Pilot-Scale Algal Oil Production

The main objective of the project is complete: development of a preliminary planning and design for a pilot-scale algal oil cultivation and processing facility, FEL-3 design with -5% / +15% cost estimate accuracy, and conversion of the algal oil to biofuel in an off-site existing bio-oil refinery. The design basis includes 10 tons per day of dried algae cultivated with CO 2 supplied by direct air capture, electricity supplied solar power, well water supply, zero liquid discharge, off-site extraction, and off-site conversion of oil to biofuel. The design and permitting package is an important milestone in the path to commercialization of algal biofuels and bioproducts as it provides the preliminary design, permitting path, long-term land lease, planning documents, and team needed for success in future engineering, construction, start-up and operations of a pilot-scale farm at a site in Paso Robles, CA. Outcomes of the business assessment include (i) identification of a product spectrum for economical algal biofuels using co-products with markets that are commensurate with production of 6-7 billion gallons per year of sustainable aviation fuel (SAF), renewable diesel, and renewable gasoline, (ii) a path toward near-term contribution of algae oil to SAF, and (iii) an approach for long-term operation of a pilot-scale farm.

09 BIOMASS FUELS↗
DOE OSTI2025

Rare Earth Extraction and Concentration at Pilot-Scale from North Dakota Coal-Related Feedstocks (Final Technical Report)

The objectives of this project were to design, construct, commission, and operate a pilot-scale system utilizing UND's REE extraction technology from lignite, and complete saleability and economic evaluations of products. The process includes a dilute-acid extraction process from low-rank-coals, followed by selective precipitations and further processing to produce mixed rare earth oxide materials. The pilot was successfully constructed to a 1,000 lb/hr nameplate capacity and tested with over 100 tons of >300-ppm lignite-based feedstocks and produced saleable-quality products during operation. The team successfully attained a TRL status of 6 with the completion and testing of the pilot system, and the technology is poised for demonstration at a commercial scale.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2026

Carbon Capture Pilot at Vicksburg Containerboard Mill (Final Technical Report)

This is the final technical report for the DOE-OCED project DE-CD0000051. The report provides the progress at the close of the project. The objective of the project is to design and build a large pilot plant for carbon dioxide (CO 2 ) capture from a pulp and paper (P&P) mill using RTI’s non-aqueous solvent (NAS) technology at a capacity of 120,000 t-CO 2 /year, with >90% CO 2 captured. The pilot plant will be used for testing and evaluating the NAS capture process using real flue gas from the P&P mill’s power boiler for a minimum of 1 year of parametric testing and a minimum of 2,000 hours of continuous long-term testing. The testing will provide data for process optimization and scale-up for the P&P industry, provide information on interaction of flue gas contaminants on solvent performance and degradation, and inform strategies for emission control. At the end of the project, the pilot plant will be managed by International Paper (IP), the host site owner, which will continue to capture CO 2 , sequester the captured CO 2 , and be eligible for the 45Q credit.

42 ENGINEERING↗
DOE OSTI2025

A scoping study of far-SOL main-wall protection limiters for steady-state operation of compact pilot plant tokamaks

We present a novel method for handling steady-state heat fluxes incident on the main wall of pilot plant-scale magnetic fusion devices, based on the utilization of protection limiters in the far scrape-off layer (SOL). This method helps avoid large plasma-wall gaps, without excessively compromising blanket performance. We present an optimization algorithm for determining the appropriate size and scale of these protection limiters given (1) probability distributions of SOL plasma parameters and (2) assumed risk tolerance. As part of this optimization, we have developed an analytic description of parallel heat fluxes across limiter shadows, and an objective cost function (the ‘Far-SOL Marginal Cost’) to quantify the impact that different main-wall thermal management design choices have on reactor capital cost. Applying the model to a midscale fusion pilot plant concept shows that making use of far-SOL protection limiters can reduce capital costs on the order of $500 M, relative to naively increasing the plasma-wall gap. Our analysis demonstrates that the far-SOL power decay length is the highest-leverage plasma assumption for thermal loading of the first wall, and the primary cost driver for main wall thermal management. The relative cost efficiency of protection limiters increases as assumptions on the far-SOL heat flux become more pessimistic. The concepts described in this paper motivate the further development of far-SOL protection limiters as part of larger efforts to design economical core-edge-wall compatible solutions for a fusion pilot plant.

Design under uncertainty↗
DOE OSTI2020

Influence of pilot-fuel mixing on the spatio-temporal progression of two-stage autoignition of diesel-sprays in low-reactivity ambient fuel-air mixture

The spatial and temporal locations of autoignition for direct-injection compression-ignition engines depend on fuel chemistry, temperature, pressure, and mixing trajectories in the fuel jets. Dual-fuel systems can provide insight into both fuel-chemistry and physical effects by varying fuel reactivities and engine operating conditions. In this context, the spatial and temporal progression of two-stage autoignition of a diesel-fuel surrogate, n-heptane, in a lean-premixed charge of synthetic natural-gas (NG) and air is imaged in an optically accessible heavy-duty diesel engine. The lean-premixed charge of NG is prepared by fumigation upstream of the engine intake manifold. Optical diagnostics include high-speed (15kfps) cool-flame chemiluminescence-imaging as an indicator of low-temperature heat-release (LTHR) and OH* chemiluminescence-imaging as an indicator high-temperature heat-release (HTHR). NG prolongs the ignition delay of the pilot fuel and increases the combustion duration. Zero-dimensional chemical-kinetics simulations provide further understanding by replicating a Lagrangian perspective for mixtures evolving along streamlines originating either at the fuel nozzle or in the ambient gas, for which the pilot-fuel concentration is either decreasing or increasing, respectively. The zero-dimensional simulations predict that LTHR initiates most likely on the air streamlines before transitioning to HTHR, either on fuel-streamlines or on air-streamlines in regions of near-constant φ. Due to the relatively short pilot-fuel injection-durations, the transient increase in entrainment near the end of injection (entrainment wave) is important for quickly creating auto-ignitable mixtures. To achieve desired combustion characteristics, e.g., multiple ignition-kernels and favorable combustion phasing and location (e.g., for reducing wall heat-transfer or optimizing charge stratification), adjusting injection parameters could tailor mixing trajectories to offset changes in fuel ignition chemistry.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Measured air quality impacts after teaching parents about cooking ventilation with a video: a pilot study

BackgroundCooking-related emissions contribute to air pollutants in the home and may influence children’s health outcomes.ObjectiveIn this pilot study, we investigate the effects of a cooking ventilation intervention in homes with gas stoves, including a video-based educational intervention and range hood replacement (when needed) in children’s homes.MethodsThis was a pilot (n = 14), before-after trial (clinicaltrials.gov #NCT04464720) in homes in the San Francisco Bay Area that had a school-aged child, a gas stove, and either a venting range hood or over-the-range microwave/hood. Cooking events, ventilation use, and indoor air pollution were measured in homes for 2–4 weeks, and children completed respiratory assessments. Midway, families received this intervention: (1) education about the hazards of cooking-related pollutants and benefits of both switching to back burners and using the range hood whenever cooking and (2) ensuring the range hood met airflow and sound performance standards. The educational intervention was delivered via a video developed in conjunction with local youth.ResultsWe found substantially increased use of back burners and slight increases in range hood use during cooking after intervening. Even though there was no change in cooking frequency or duration, these behavior changes resulted in decreases in nitrogen dioxide (NO2), including significant decreases in the total integrated concentration of NO2 over all cooking events from 1230 ppb*min (IQR 336, 7861) to 756 (IQR 84.0, 4210; p < 0.05) and NO2 collected on samplers over the entire pre- and post-intervention intervals from 10.4 ppb (IQR 3.5, 47.5) to 9.4 (IQR 3.0, 36.1; p < 0.005). There were smaller changes in PM2.5, and no changes were seen in respiratory outcomes.ImpactThis pilot before-after trial evaluated the use of a four-minute educational video to improve cooking ventilation in homes with gas stoves and one or more school-aged children. Participant behavior changed after watching the video, and there were decreases in indoor air pollutant concentrations in the home, some of which were significant. This brief video is now publicly available in English and Spanish (wspehsu.ucsf.edu/projects/indoor-air-quality), and this provides suggestive evidence of the utility of this simple intervention, which could be particularly beneficial for households that have children with asthma.

Holm, Stephanie M↗
DOE OSTI2024

Molecular-level design of alternative media for energy-saving pilot-scale fibrillation of nanocellulose

The outstanding mechanical properties, light weight, and biodegradability of cellulose nanofibrils (CNFs) make them promising components of renewable and sustainable next-generation reinforced composite biomaterials and bioplastics. Manufacturing CNFs at a pilot scale requires disc-refining fibrillation of dilute cellulose fibers in aqueous pulp suspensions to shear the fibers apart into their nanodimensional forms, which is, however, an energy-intensive process. Here, in this study, we used atomistic molecular dynamics (MD) simulation to examine media that might facilitate the reduction of interactions between cellulose fibers, thereby reducing energy consumption in fibrillation. The most suitable medium found by the simulations was an aqueous solution with 0.007:0.012 wt.% NaOH:urea, and indeed this was found in pilot-scale experiments to reduce the fibrillation energy by ~21% on average relative to water alone. The NaOH:urea-mediated CNFs have similar crystallinity, morphology, and mechanical strength to those formed in water. The NaOH and urea act synergistically on CNFs to aid fibrillation but at different length scales. NaOH deprotonates hydroxyl groups leading to mesoscale electrostatic repulsion between fibrils, whereas urea forms hydrogen bonds with protonated hydroxyl groups thus disrupting interfibril hydrogen bonds. This suggests a general mechanism in which an aqueous medium that contains a strong base and a small organic molecule acting as a hydrogen-bond acceptor and/or donor may be effectively employed in materials processes where dispersion of deprotonable polymers is required. The study demonstrates how atomic-detail computer simulation can be integrated with pilot-scale experiments in the rational design of materials processes for the circular bioeconomy.

36 MATERIALS SCIENCE↗
DOE OSTI2022

SolarAPP+ Pilot Analysis: Performance and Impact of Instant, Online Solar Permitting

The National Renewable Energy Laboratory (NREL) led a collaborative effort to develop the Solar Automated Permit Processing Plus (SolarAPP+), a no-cost solar permitting software solution to address residential solar photovoltaic (PV) permitting resource constraints and streamline solar adoption processes among authorities having jurisdiction (AHJs). The SolarAPP+ is an online portal that automates permit plan review, enabling an instant permit approval process for code-compliant residential PV systems. Based on national model building, electrical, and fire codes, the SolarAPP+ automatically performs a compliance check of permit inputs against code requirements and produces an inspection checklist that can be used to verify installation practices, workmanship, and adherence to the approved design. NREL conducted a two-phase pilot with five participating AHJs and 16 solar contractors, spanning from November 2020 through December 2021, evaluating the ability of SolarAPP+ to deliver instant permits and its impact on four critical areas within each AHJ: permit review timelines; solar adoption timelines; AHJ time saved; and inspection results. The pilot confirmed that SolarAPP+ reduced permit review times to less than one day, reduced solar adoption timelines by an average of 12 days, saved an estimated 2,067 staff hours, and had comparable inspection results to those found in traditional permitting. The pilot further identified key lessons for improving SolarAPP+, including ways to streamline SolarAPP+ adoption, development of training resources, and expansion of supported products.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2022

Small field campaign: aerosol – ice formation closure pilot study. Final Report

Prediction of atmospheric ice formation from aerosol particles by heterogeneous nucleation represents one of the grand challenges in atmospheric science. Our insufficient predictive understanding of primary ice formation is the reason that climate models typically do not include heterogeneous ice nucleation with subsequent effects on climate uncertainty. Mixed-phase clouds, where supercooled water droplets and ice crystals coexist play globally an important role regulating climate. This is especially the case for the Arctic region that experiences the greatest warming due to climate change compared to other regions in the world. Immersion freezing initiated by ice-nucleating particles (INPs) in supercooled water droplets is recognized as the dominant primary ice formation pathway in mixed-phase cloud regimes. For this reason, it is crucial to evaluate our capability to predict immersion freezing for a given ambient aerosol population. The goal of this project is conducting a field-based pilot study at the U.S. DOE Atmospheric Radiation Measurement (ARM) user facility at Southern Great Plains (SGP) to evaluate our capability to predict the number concentration of aerosol particles that serve as INPs in the immersion freezing mode. Successful prediction of INP number concentrations is also termed “closure”. This field-observational approach represents a first-of-its kind attempt of an aerosol–ice formation closure study (AEROICESTUDY). Very few closure studies related to INPs have been conducted, and to our knowledge, none using robust size-resolved ambient aerosol composition measurements as a starting point. Achievement of aerosol–ice formation closure relies on our ability to characterize the ambient aerosol population with respect to particles size and composition and to determine INP number concentrations for specified freezing temperatures. This requires numerous online and offline instrumentation resulting in this pilot field campaign being a multi-institutional and community-collaborative effort. We chose the ARM SGP megasite for this first aerosol-ice formation closure pilot study due to its significant measurement capabilities available to obtain detailed physical characterization of the local aerosol population including size distribution, mass loading, and chemical composition of non-refractory aerosol particles. The overall objective of this project is to identify ice nucleation parameterizations that produce the most robust predictions of INP numbers and thus are best suited to be included in cloud and climate models. This objective includes the following goals for this field and laboratory-based project: i) What are the crucial aerosol physicochemical property measurements needed to accurately guide ice nucleation representations in models and long-term INP measurements? ii) What level of parameter details needs to be known to achieve aerosol–ice formation closure? iii) What are the leading causes for climate model bias in INP predictions? We found that the advances in our understanding of immersion freezing garnered over the last 20 years allowed us to yield partial and full closures of atmospheric immersion freezing from ambient aerosol particles. When the aerosol population is physicochemically complex and parameterizations for representative INP types are not yet available, we still struggle to accurately predict INP number concentrations. This project clearly demonstrates that with more laboratory and field measurements that are accompanied by particle composition analysis, the necessary datasets to achieve aerosol–ice formation closure for various locations will emerge, thus providing a robust foundation for guiding the representation of INPs in cloud and climate models.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2023

Safety-Related Instrumentation and Control Pilot Upgrade: Conceptual - Detailed Design Phase Report and Lessons Learned

Historically, regulatory barriers have precluded nuclear plant safety-related (SR) Instrumentation and Control (I&C) system modernizations. These barriers have been largely addressed by industry and United States Nuclear Regulatory Commission (NRC) efforts, including development of the License Amendment Request (LAR) Alternate Review (AR) process for digital I&C upgrades. The U.S. Department of Energy (DOE) and the Idaho National Laboratory (INL) are supporting a SR I&C pilot upgrade at the Limerick Generating Station (LGS) to demonstrate this process and capturing associated lessons learned for the benefit of industry. In 2021, a paper summarizing lessons learned as captured in INL/EXT-20-59809, Safety Related Instrumentation & Control Pilot Upgrade Initial Scoping Phase Implementation Report and Lessons Learned was presented at the 12th NPIC & HMIT conference. It is recommended that readers of this paper review reference 1 or the associated Nuclear Journal paper for context. This paper summarizes activities performed and lessons learned for the conceptual design phase and portions of the detailed design phase as captured in INL/RPT-23-XXXX, “Safety-Related Instrumentation and Control Pilot Upgrade: Conceptual - Detailed Design Phase Report and Lessons Learned.” The portions of the effort covered by reference 2 include conceptual design phase activities from December 2020, through completion in November 2021, and detailed design activities through September 2022. These efforts and associated detailed documentation in reference 3 are intended to support similar industry upgrades as a foundation stone for a Digital Transformation that will improve plant safety, reliability, and operational performance while lowering plant total cost of ownership.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Final Report for Water Electrodialysis Reversal Pilot

This final report presents all the work and tests performed during ION Clean Energy’s Water Electrodialysis Reversal Pilot referred to as the “WERP” Project (DE-FE-0032066). ION Clean Energy Engineering (ION) and Nebraska Public Power District (NPPD) executed the Electrodialysis Reversal (EDR) Pilot Study and developed a commercial cost estimate needed to evaluate the retrofit of an EDR system to NPPD’s Gerald Gentleman Station (GGS). The proven project team was comprised of NPPD, Sargent & Lundy (S&L) and ElectroSep, who is a leading developer, fabricator and operator of electrodialysis units. ION, working in conjunction with NPPD and ElectoSep, developed a test program for evaluating the performance of the EDR technology proposed to be employed and evaluated for this pilot. The Department of Energy’s National Energy and Technology Laboratory (DOE/NETL) awarded ION Clean Energy, Inc. a single budget period (BP) of $816,759 with $207,942 of in-kind contribution from NPPD to investigate ElectroSep’s Electrodialysis technology to clean grey water from NPPD’s GGS.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2024

Sand Thermal Energy Storage Pilot Design (Final Report)

This report summarizes work done on developing a 10-MWhe pilot of the sand-based thermal energy storage (SandTES) technology at Alabama Power’s Plant Gaston Unit 5, an operating, supercritical coal power unit. The system will be integrated to the unit, obtaining steam to heat the sand through an air-blown fluidized-bed heat exchanger, then storing the water to be reused during discharging to produce steam that will then be vented. An electrical particle heater will also be included to provide part of the heat to the sand to provide data and learnings for commercial systems that will be fully electrically heated. Hot sand is contained in one bunker, while cold sand is housed in the other bunker, and standard solids handling equipment moves the sand around. This pilot would advance the SandTES technology to Technology Readiness Level 6 and position it for commercial readiness by 2030. This work was done in two phases: Phase I performed a conceptual study that provided Association for the Advancement of Cost Engineering (AACE) Class 5 costs and estimated performance, and then Phase II, which also involved a design update, performed a more detailed pre-front-end engineering and design study that elicited AACE Class 4 costs. Work was also done to provide estimated costs for commercial applications of the technology, assess its gaps, create its technology maturation and commercialization plans, and finally perform an Environmental Information Volume for the pilot site as a first step in the National Environmental Policy Act process.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2024

Compositional Variation Tests on DuraMelter 100 with LAW Sub-Envelope C1 Feed (LAWC22) Glass in Support of the LAW Pilot Melter (Final Report)

The Vitreous State Laboratory at The Catholic University of America (VSL) is developing and testing glass formulations for RPP-WTP waste envelopes to provide data to meet the RPP-WTP contract requirements and to support system design activities. That work is based upon small-scale batch melts (“crucible melts”) using waste envelope simulants. Selected formulations have also been tested in small-scale continuously-fed joule-heated melters (DM10 and DM100 systems) and, ultimately, in the LAW Pilot Melter. Such melter tests provide information on key process factors such as feed processing behavior, dynamic effects during processing, sulfate incorporation, processing rates, off-gas amounts and compositions, foaming control, etc., that cannot be reliably obtained from crucible melts. This sequential scale-up approach in the vitrification testing program ensures that maximum benefit is obtained from the more costly pilot-scale tests and that the most effective use is made of that resource. The principal objective of the work described in this report was to collect the necessary small-scale melter test data with a LAW Sub-Envelope C1 waste simulant in order to support the next series of tests with the same melter feed on the LAW Pilot Melter. This work was conducted under a corresponding Test Specification and Test Plan.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

Compositional Variation Tests on DuraMelter 100 with LAW Sub-Envelope C2 Feed in Support of the LAW Pilot Melter (Final Report)

One of the principal objectives of the DM100 melter tests was to demonstrate that the LAW Sub-Envelope C2 feeds with ± 15% variations in the amounts of waste simulant are suitable for large-scale tests on the LAW Pilot melter. The other principle objective for the DM100 tests was to determine the relative effects of sugar versus waste organics on glass redox state, NOx emissions, sulfur emissions, sulfur retention in the glass, secondary sulfate layer formation, and glass-melt foaming. Additional objectives included measurement of the feed rheological properties and collection of melter emissions data. Screening tests are conducted at the DM100 scale in order to identify and correct potential problems before testing at the larger scale LAW Pilot melter. Testing goals were met in that the results of the DM100 melter test resulted in selection of LAW Sub-Envelope C2 feed suitable for Pilot Melter testing.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗