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DOE OSTI2023

Low Weight, High Strength Coal-Based Building Materials for Infrastructure Products (Rev.A)

Semplastics has developed, tested, and proven the viability of a new class of composite infrastructure components that use coal as the primary component. Phase I resulted in the production of brick and block components, called X-BRIX and X-BLOX, with dimensions comparable to commercially available bricks and concrete blocks, but with superior mechanical strength, lower weight, greater hardness, improved toughness, greater abrasion resistance, and greater chemical resistance than concrete. Multiple samples of full-size (16” × 8” × 8”) X-BLOX and full-size (8” × 4” × 2.5”) X-BRIX were made to demonstrate the technology, and to support the development of mortar or joining techniques. Phase I moved the coal-based composite materials technology from a current Technology Readiness Level (TRL) of 3 to TRL 5. Semplastics’ coal-based composite materials exhibit a number of high-performance characteristics, including high strength (five times the flexure strength of the best commercial brick, and more than twice the compressive strength of construction-grade concrete block), lower density (by 37 to 41%), improved mechanical durability and abrasion resistance, and resistance to chemicals, acids, salts, and chemical wastewater. These properties offer significant improvements over conventional bricks, concrete blocks, and pavers. The coal particles are completely encapsulated and bonded using a specially formulated polymer-derived ceramic (PDC) that is cured to form an “aggregate” of coal and PDC resin. This aggregate can be further processed and lightly pressed (at 10 to 50 psi) to produce a brick. After pyrolyzing (similar to the processing used to make standard clay bricks), the finished coal-based brick is significantly harder and more abrasion-resistant than regular bricks. We have produced prototype X-BRIX and X-BLOX that contain at least 55% coal by weight (71% carbon by weight, due to the controlled carbon content of the PDC) and showed their superior mechanical properties through in-house and contracted testing.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2022

ReNew100: Reliable Power System Operation with 100% Renewable Generation

The ReNew100 project has developed and demonstrated an operator support system (OSS) to operate power systems with 100% renewable power generation from inverter-based resources (IBRs) like wind and solar that significantly reduces the risk of widespread power outages in a simulated operational environment at Technology Readiness Level (TRL) 6. The OSS achieves resilient operation for power systems under changing operation modes including varying combinations of conventional and renewable generation, including cases with 100% renewable generation from wind and solar IBRs. The OSS continuously monitors the N-1 security of the power system, which refers to the ability of the power systems to survive single outages of power system elements, like the loss of a generator or a power line, without causing widespread power outages beyond those expected and planned for. If the OSS identifies that the system is not N-1 secure, an automatic Controller Parameter Optimization (CoPO) developed within Renew100 is activated to optimize the N-1 security of the system by tuning controller parameters within different assets like batteries, wind, and solar plants. The core innovation of ReNew100 is the development of this CoPO as well as the demonstration of the OSS for a real-time simulation of the Hawai'i Island power system. Moreover, Renew100 has developed new model calibration techniques for dynamic power system models and demonstrated them for Hawai'i Island.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2023

Long-Duration Energy Storage: Resiliency for Military Installations

This report provides a quantitative techno-economic analysis of a long-duration energy storage (LDES) technology, when coupled to on-base solar photovoltaics (PV), to meet the U.S. Department of Defense's (DoD's) 14-day requirement to sustain critical electric loads during a power outage and significantly reduce an installation's carbon footprint. The LDES modeled is Antora Energy's battery energy storage system (BESS). It is currently at a technology readiness level (TRL) of 7 and not ready for full-scale deployment. To support decisions on the value of near-term demonstrations, this analysis looked at the potential value of Antora Energy's BESS if deployed in the future.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2023

High Strength, Encapsulated, Commercially Useful Components and Particles Made from Coal Combustion Residuals

This project has developed and demonstrated two high-volume applications for Coal Combustion Residuals (CCR) with annual usage on the order of billions of pounds. The CCR is encapsulated in a recently developed water-impervious inorganic resin coating to reduce leaching of toxic elements from CCR by more than 80% as a first step. Target commercial applications demonstrated for the encapsulated CCR were as reinforcement for high-strength structural columns composed of CCR embedded in a ceramic matrix and as filler in high-volume plastics such as polypropylene. The encapsulated particles produced columns with properties superior to concrete, and a 30% to 50% improvement in stiffness over current fillers in plastics. CCR from bituminous and lignite coal was evaluated and shown to provide high performance, with the bituminous CCR producing the strongest columns and the lignite-based CCR provided the best performance as coated filler in polypropylene. The two-year project advanced both material systems from a Technology Readiness Level (TRL) of 2 to TRL 4.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2023

Development and Testing of an Integrated Acid Mine Drainage (AMD) Treatment and Rare Earth/Critical Mineral Plant

The overall objective of this project was to design, construct, and test a pilot-scale continuous process for efficiently treating acid mine drainage (AMD) while producing rare earth element/critical mineral (REE/CM) concentrates. The process technology evaluated in this project included two distinct operations: 1. an upstream pre-concentration unit that treats raw AMD to environmentally compliant discharge standards while capturing an REE/CM preconcentrate, and 2. a downstream REE purification process that further enriches the pre-concentrate while producing mixed or partially separated rare earth oxides (REOs). The project team members successfully completed all of the proposed goals of the project and advanced the technology readiness levels (TRL) of the constituent operations to TRL 7 for the upstream concentration unit (full-scale system demonstration) and TRL 6 for the downstream purification process (pilot-scale demonstration).

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2024

Strategy to Develop a Control Scheme for Core Thermal Performance Optimization

This report outlines a three-year research plan for optimizing reactor core thermal performance through use of a Digital Twin (DT) model and a set of neutron detectors to correspondingly adapt the reactor control strategy. It identifies reactor features and achievable neutron measurements that factor into this optimization task. It considers spatial effects that are important and how they can be managed by a real-time algorithm that controls reactivity actuators. The report presents a set of tasks, along with corresponding methods, for accomplishing this objective. The final task in this set is to validate the combined optimization procedure in the Purdue University’s PUR-1 reactor, for which we have an agreement of understanding. Additionally, we describe an alternative approach for overcoming some of the limitations inherent in the above approach, which includes the computational costs of high-fidelity simulations and achievable integration of neutron measurements into the DT. The proposed algorithms lower the technology readiness level (TRL) of the overall approach as some additional analysis and the development of a new neutron detector concept are necessary. In particular, a sensor measuring the gradient of the neutron flux is required, and the prototype is expected to be validated in the PUR-1 reactor. The potential benefits and the opportunity to significantly push forward the state-of-the-art make this approach worthy of further exploration in the upcoming years.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2023

High-Speed and Dynamic Diaphragm Compressor for High-Capacity Fueling (Final Technical Report)

Goal of the project is to scale the NEL hydrogen compressor technology from 1.1 kg/minute to 5.5 kg/minute capacity (scale 1:5). This will enable achievement of 330 kg/hour capacity, sufficient to achieve fast high-capacity heavy-duty vehicle (HDV) fueling. The technology readiness level (TRL) maturity objective is to develop and test a scaled-up compressor that is to advance from TRL3 to TRL7.

08 HYDROGEN↗

DOE OSTI2025

Enhancement of Carbon Capture Reactor Performance (Final Technical Report)

Significant challenges are still present in post-combustion CO 2 capture and new technologies and advanced components are needed to significantly advance the deployment of CO 2 capture for natural gas combined cycle (NGCC) plants. Critical elements of CO 2 capture that still need to be addressed include how to increase CO 2 mass transfer in the absorber column with liquid to gas ratios of <1.2, while reducing the size of the absorber column to reduce capital costs. Research involving chemical mechanism with design, synthesis, and assembly of materials with targeted functionally were combined with advanced additive manufacturing techniques towards development of enhanced CO 2 capture reactors that can lead to safe, reliable, and low-cost carbon capture technologies. The objective of the project was to develop and test novel carbon capture materials and reactor components that contribute to increased CO 2 mass transfer through increased turbulent gas-liquid interface and improved solvent wetting within the absorber. A technoeconomic analysis (TEA) was completed showing how the proposed technology decreases capital costs by reducing the size of the absorber column and the amount of packing required for high CO 2 capture rates. A technology maturation plan (TMP) was also developed to describe the current technology readiness levels (TRL) and outline additional research and development (R&D) needed to further develop these advanced components for NGCC CO 2 capture plants. The successful completion of this project has shown a pathway to reduce the absorber size and associated construction costs of post-combustion NGCC CO 2 capture systems at 97% capture and promote the utilization of abundant natural gas for production of reliable electricity.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2025

A Novel Sediment Passage Module Design in Support of Standard Modular Hydropower

This document is the Final Technical Report (FTR) for University of Minnesota (UMN) project on the development of a novel sediment (e.g., sand) bypass technology for new stream reach development (NSD). The project duration was slightly over four years and organized over two budget periods (BPs), i.e., BP1 and BP2, with a Go/No-Go review at the end of BP1. The initial technology had a Technology Readiness Level (TRL) of two (2) and, over the life of the project, advanced substantially to TRL 3 or 4.

13 HYDRO ENERGY↗

DOE OSTI2025

Acoustophoretic Additive Manufacturing for Scalable 3D Battery Electrodes

This project focused on investigating two acoustic-based processing methods: a nozzle-based printhead and a chamber that map to two different battery electrode architectures: (1) a line-pattern electrode and (2) a grid-pattern electrode. These two parallel manufacturing and electrode geometry explorations were proposed for the project to understand the process space of acoustic-based manufacturing methods to fabricate patterned battery electrodes. This two-path exploration also allowed us to de-risk the overall project and not rely on a single process for creating patterned electrodes. This project consisted of six high-level tasks aimed at transitioning the concept of acoustic focusing for battery electrodes from a technology readiness level (TRL) of 1 to 3 by project conclusion. Overall, we believe we have developed a practical and high-impact processing method that is chemistry agnostic and suitable for large-area fabrication of both 3D LIBs and other functional material systems where structuring on the scale of tens of microns has the potential to break conventional bulk material trade-offs in performance. In the case of batteries for electric vehicles, structuring 3D LIBs with our acoustic process breaks traditional energy and power trade-offs observed with conventional flat battery packs.

25 ENERGY STORAGE↗

DOE OSTI2025

Laser Powder Bed Fusion Additive Manufacture Nb1Zr Development

Next generation fission and fusion nuclear reactors require materials that can withstand operating temperatures greater than 500 °C, neutron irradiation doses of up to 200 displacements per atom (dpa), and potentially corrosive coolants such as the alkali liquid metals sodium, lithium, and NaK (Na33K eutectic alloy). Refractory alloys, such as Nb1Zr (Nb-1wt%Zr) and Molybdenum alloy TZM (Mo-0.5wt%Ti-0.08wt%Zr) have been traditionally considered viable candidates for advanced fission and fusion reactor concepts. However, it is relatively difficult to generate complex geometries of interest from these alloys using traditional manufacturing methods. In addition, there needs to be a concentrated effort to address refractory metal challenges at elevated temperature operation. In order to generate complex geometries of interest, modern manufacturing techniques are considered to increase the technological readiness level (TRL), cost-effectiveness, and schedule savings. This work focused on the continued development of laser powder bed fusion (L-PBF) additive manufacturing (AM) to improve both design flexibility, evaluate microstructure and properties, and ultimately accelerate the TRL and qualification of these processes and alloys for components to potentially be put into service. Niobium alloy Nb1Zr was identified through a down-selection process outlined in previous reports as a candidate to develop in L-PBF AM. Historically, Nb1Zr had been explored for high temperature fast spectrum fission reactors for both terrestrial and space applications. Molybdenum alloy TZM has also been considered for these reactor concepts due to exceptional high-temperature strength, creep resistance, and stability under irradiation. L-PBF AM of TZM has previously been investigated at LANL under the Microreactor program, NASA, ORNL, and in academia. However, due to the crack prone nature of TZM, L-PBF AM of TZM resulted in significant microcracking and additional development is required to pursue viable maturation. Other AM methods have been found to be more successful in printing TZM, and those alternatives approaches are discussed in this effort. The efforts detailed in this report focused on continued development of Nb1Zr through L-PBF and development of TZM via L-PBF and electron powder bed fusion (E-PBF). The objective of this work was to further the development of these AM techniques for the chosen refractory alloys, elucidating and addressing associated challenges through characterization of several demonstration builds. At LANL, Nb1Zr builds were completed using an EOS M290 and M400 machines, and a refractory alloy-dedicated L-PBF system, the Xact Metal XM200G, was installed. The XM200G primary purpose was to do the Nb1Zr parameter development process; however, due to difficulties associated with the machine installation and qualification process, it was decided to pivot development to the larger M400 and M290 machines. Although the supply of Nb1Zr powder was limited, it was sufficient to generate sub-scale metallographic specimens for the purpose of parameter development. This was first accomplished on the EOS M400 then the M290 due to machine schedule availability. Further development of TZM has been initiated at the University of Texas El Paso (UTEP) under contract with LANL to use both a heated build envelope L-PBF machine and E-PBF machine that have been found in the literature to mitigate microcracking. UTEP was provided with TZM powder and build plates to support parallel TZM parameter development across both machines. As part of the contract, UTEP will also be conducting microstructural characterization once optimized process parameters have been identified. The optimized process parameters for each machine will be used to generate a series of metallographic, mechanical, and surface finish specimens for subsequent characterization and testing. In the next section, we provide a detailed discussion of the methodology used for investigating the feasibility of leveraging these alloys for use in advanced reactor applications.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Stereo-vision thermal imaging system for tracking flying animals in wind farm areas (CRADA #763) Abstract

CRADA 763: abstract ThermalTracker-3D (TT3D) is a stereo vision thermal imaging system that provides 3D flight information on detected birds, bats, and other flying targets. The system was initially developed for use in the siting and monitoring of offshore wind projects to establish pre-construction and operation collision risk data but can be applied to terrestrial wind energy projects as well as national security monitoring. This technology will reduce monitoring cost, decrease processing time, and provide more accurate data for wind energy developers/operators and regulatory agencies. While the current technology is at a high level of readiness, Technology Readiness Level (TRL) 7, there remain several barriers to commercialization, particularly around ease-of-use, that result in a low Adoption Readiness Level (ARL). The proposed work will advance commercialization readiness by streamlining calibration methods for built systems. This work will:1. 1. develop a software package for factory and dynamic calibration processes 2. test that package with existing prototype TT3D systems, and 3. conduct outreach with industry end-users.

ThermalTracker↗

DOE OSTI2022

A Methodology for Evaluating Operator Usage of Machine Learning Recommendations for Power Grid Contingency Analysis

This work presents the application of a methodology to measure domain expert trust and workload, elicit feedback, and understand the technological usability and impact when a machine learning assistant is introduced into contingency analysis for real-time power grid simulation. The goal of this framework is to rapidly collect and analyze a broad variety of human factors data in order to accelerate the development and evaluation loop for deploying machine learning applications. We describe our methodology and analysis, and we discuss insights gained from a pilot participant about the current usability state of an early technology readiness level (TRL) artificial neural network (ANN) recommender.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2020

Project Methods to Enhance Wellbore Cement Integrity with Microbially-Induced Calcite Precipitation (MICP) (Final Scientific/Technical Report)

The goal of this project was to develop improved methods for sealing compromised wellbore cement in leaking oil and gas wells, thereby reducing the risk of unwanted upward fluid migration. Novel methods for improving wellbore integrity, such as microbially induced calcite precipitation (MICP), can reduce leakage potential, improve the safety of fossil fuel extraction, improve the public perception of hydraulic fracturing, and promote environmentally-prudent unconventional oil and gas development. Microbes, with the urease enzyme, can catalyze the chemical reaction of urea hydrolysis to induce the precipitation of calcium carbonate which can be used as a cementitious material to seal leakage pathways. In this project, methods to promote robust bio-composite cementitious materials were designed and tested in the laboratory. Scale-up of those methods were tested in meso-scale reactor systems and in field applications. In this report, in Section One, we describe laboratory efforts to develop injection strategies to promote precipitation in wellbore analogs and determine the strength of the bio-composite cements as compared to fine cement. In Section Two, we describe the efforts to scale up the work and study the use of materials that can be used in field application, for example exploring the use of calcium chloride ice melt or urea fertilizer as source chemicals. In Section Three, the three field trials (methods and results) performed as part of the project are described and summarized. At the end of the report is a comprehensive summary and conclusion section which highlights the key findings of the project. The work performed during this project significantly advanced the technology readiness level (TRL) of the MICP wellbore sealing strategy.

02 PETROLEUM↗

DOE OSTI2020

Methods to Enhance Wellbore Cement Integrity with Microbially-Induced Calcite Precipitation (MICP) (Final Scientific/ Technical Report)

03 NATURAL GAS↗

DOE OSTI2021

A Comparative Techno-Economic Analysis of Sustainable Methanol Synthesis Pathways from Biomass and CO2

The call to reduce global CO2 emissions is at the forefront of research and development in the transportation and petrochemical industries. A potential solution which intersects both sectors is the adoption and commercialization of more sustainable technologies for methanol production. Currently, methanol is gaining popularity as a possible fuel additive, and as a polymer precursor via established methanol-to-olefins routes which are increasing in capacity and utilization, putting methanol in the spotlight and global methanol production on the rise. At the same time, experimental and computational studies have surged, illuminating a wide array of novel process designs to introduce sustainable methanol into the market. However, with numerous competing pathways identified across a variety of fossil and non-fossil feedstocks, there is a need to harmonize the analyses of these pathways using a consistent techno-economic approach and compare them to current commercial pathways to better understand the benefits or limitations inherent to each technology. In this work we conduct a consistent comparative analysis of three sustainable methanol synthesis pathways versus a commercial baseline, with biomass, CO2, and natural gas as the carbon sources. The three sustainable pathways of interest are biomass gasification to syngas with subsequent catalytic conversion of syngas to methanol, indirect conversion of CO2 to syngas via electrolysis with subsequent catalytic conversion of syngas to methanol, and direct conversion of CO2 to methanol via electrolysis. To elucidate the challenges and opportunities in the path to commercialization of each sustainable pathway, we investigate five key process metrics: production cost, carbon efficiency, carbon intensity, energy efficiency, and technology readiness level (TRL).

biomass↗

DOE OSTI2023

Environmental and Social Justice Implications of a Circular Plastics Economy

A consideration of environmental justice (EJ) and social justice (SJ) is critical to minimize the impacts of technology deployment on local communities. SJ and EJ impacts occur in specific geographic locations but can cover a wide range of effects (e.g., air pollution, access to clean water, jobs, wages, and education), making it challenging to determine which metrics are appropriate to evaluate and which data are required. Thus, there is currently a gap in the analysis community's ability to provide useful and universal EJ and SJ metrics for emerging technologies. Here, we present a draft framework for evaluating the human health, local environment, and job implications of processes that are at an early or middle technology readiness level (TRL). Using a case study on enzymatic polyethylene terephthalate (PET) recycling (middle TRL), we demonstrate how to qualitatively and quantitatively assess these EJ and SJ metrics for a circular economy context and how to communicate the results in a manner beneficial to both researchers and local communities.

circular economy↗

DOE OSTI2023

Environmental and Social Justice Considerations in a Circular Economy

A consideration of environmental justice (EJ) and social justice (SJ) is critical to minimize the impacts of technology deployment on local communities. SJ and EJ impacts occur in specific geographic locations but can cover a wide range of effects (e.g., air pollution, access to clean water, jobs, wages, and education), making it challenging to determine which metrics are appropriate to evaluate and which data are required for qualitative or quantitative analysis. This issue is only exacerbated when the technology in question is at an early technology readiness level (TRL) without community specific data. Here, we present a framework for evaluating the human health, local environment, and job implications of processes that are at early to middle TRLs. Using a case study on enzymatic polyethylene terephthalate (PET) recycling (middle TRL), we demonstrate how to qualitatively and quantitatively assess these EJ and SJ metrics for a circular economy context and how to communicate the results in a manner beneficial to both researchers and local communities.

circular economy↗