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DOE OSTI2022

Modular, Crushed-Rock Thermal Energy Storage Pilot Design (Final Report)

The goal of this project was to design a next-step pilot to advance near-term energy storage integrated with a fossil plant to provide a facility capable of being viable and effective in a market with growing penetration of variable renewable energy (VRE). Thermal energy storage (TES) represents an ideal technology for this purpose. The completed effort included a feasibility study to prepare for the Phase II pre-front end engineering design (pre-FEED) for implementing a crushed-rock TES system integrated with a natural gas combined cycle (NGCC) plant. The crushed rock storage technology, which is being developed by Brenmiller Energy, is a modular TES system termed bGen™, which can accommodate both thermal and electrical inputs and output steam, hot water, or hot air. For this application, the estimated efficiency is 80% thermal to thermal. For the feasibility study, the Brenmiller technology was designed to operate on a slipstream from NYPA’s Eugene W. Zeltmann Power Project (Zeltmann) NGCC plant in Astoria, New York. The projected size of the system will be up to 4 MWe with at least 4 hours of storage duration, or 16 MWh-e total. The study also included a techno-economic evaluation of a 200 MWh commercial-scale demonstration. Prior to this project, EPRI had reviewed Brenmiller’s technology, which is being built to demonstrate bGen™ at 1.7 MWe on a solar plant (Rotem) and has been designed for an NGCC facility in Italy, assessing it at technology readiness level (TRL) 5. Brenmiller is also conducting a separate 1-MWth pilot with NYPA that pairs a bGen™ module with a microturbine for a combined-heat-and-power (CHP) application to improve efficiency and provide flexibility. The next-step pilot being designed as part of this project would represent a 5-fold increase in scale, versus Rotem, and would show the technology’s ability to provide effective and economical energy storage, bringing the technology to TRL 6. This pilot would represent the next-to-last demonstration scale before the technology could be commercial ready at GWh-e scales in the 2030 timeframe. The main objective of the work completed by the Electric Power Research Institute, Inc. (EPRI), Brenmiller Energy (Brenmiller), New York Power Authority (NYPA), and United E&C (formerly AECOM) was to perform a Phase I feasibility study on the integration of a crushed-rock thermal energy storage (TES) with a fossil plant. Under this project, the EPRI-led team successfully completed a feasibility study to prepare for the potential future Phase II pre-front end engineering design (pre-FEED) to implement a crushed-rock TES system integrated with a natural gas combined cycle (NGCC) plant. Specific deliverables under this project included the Technology Maturation Plan, Conceptual Study, Techno-Economic Assessment, Technology Gap Assessment, Project Plan for Phase II (submitted as Phase II Renewal Application), Commercialization Plan, and the Final Report (this document). This Final Report includes a compilation of the various summary reports that were prepared during the 12-month schedule of the Phase I project execution under award DE-FE0032017.

03 NATURAL GAS↗

DOE OSTI2022

Materials for Advanced Ultra-Supercritical (A-USC) Steam Turbines --- A-USC Component Demonstration

The U.S. Advanced Ultra-Supercritical (A-USC) Consortium was formed in 2001 as a government/industry program, sponsored by the U.S. Department of Energy (DOE) and the Ohio Coal Development Office (OCDO) and cost shared by industrial and not-for-profit partners. The purpose of the consortium was to advance the state of the art for power generation by evaluating and developing materials that allow the use of advanced steam cycles in coal-based power plants. These advanced cycles, with steam temperatures up to 1400°F (760°C), can increase the efficiency of coal-fired boilers from an average of 35% (current U.S. fleet) to more than 45% higher heating value (HHV) (>49% lower heating value [LHV]). The increase in a plant’s efficiency is limited unless new materials able to withstand these higher operating temperatures and pressures are identified and approved for use. The A-USC Consortium identified these needed materials during earlier phases of the program. It developed the welding and joining techniques along with manufacturing processes for casting and wrought products made from these new high-nickel alloys. It subjected these materials to extensive laboratory and steam loop testing. It then obtained ASME code approval for their use in U.S. boiler systems. The program’s successes leave this last remaining activity (ComTest Phase 2) that the U.S. utility industry has recommended to be accomplished prior to commercialization. The focus of the activity is the evaluation and demonstration of commercial readiness for “full scale” components to be made from these nickel-based alloy materials and provided by a U.S. domestic supply chain that is new to working with these alloys. According to studies completed by the Electric Power Research Institute (EPRI), the cost of an A-USC plant is approximately 20% higher than a non-A-USC plant because of its use of nickel-based alloys needed for the high temperature operating conditions. However, CO 2 reductions of approximately 30% from the current fleet average provide a strong incentive for its consideration. The actual costs and perceived value for CO 2 abatement will determine whether new or retrofitted plants are undertaken, although decisions to build A-USC plants in India would indicate its economic feasibility while also being part of a global carbon emissions strategy. The work by the A-USC Consortium, prior to the start of the ComTest project, has included lab scale and pilot scale materials testing, both in air and oxy-combustion. This testing has included air-cooled and steam-cooled “loops” that were installed into existing operating utility boilers to gain exposure of these materials to realistic conditions of high temperature and corrosion caused by the constituents in the coal ash. The A-USC Consortium also gained ASME Code approval of the Inconel 740 material, has cast and extruded the largest high nickel precipitation hardened alloys, and developed unique welding techniques to avoid problems identified by the competing European program. However, as valuable as these material test loops and accomplishments have been for obtaining information, their scale is below that required to minimize the risk associated for a U.S. utility to build a multibillion-dollar A-USC power plant. To reduce the final identified risk barrier to full-scale commercialization of these advanced materials and systems, the A-USC Consortium (guided by a utility industry advisory committee) has identified the key areas of the technology they desire to see as being capable of full-scale manufacturing and/or fabrication from an identified, capable U.S. domestic supplier base. A significant amount of work was accomplished during Phase 1 to identity the components, as well as the component size, that would be manufactured from advanced alloys such as Inconel 740H or Haynes 282 alloys. Pathways to supply these components for ComTest have been identified, as well as any further development that would be required. The Phase 2 effort used Phase 1 findings for designing these key full-scale components for A-USC boilers and turbines to include large castings; extrusions, forgings, fabrication of water walls and steam loops with headers from advanced materials, raw material (such as pipe extrusion billets) are at the commercial readiness level to permit advancement to a demonstration project. The Phase 2 work scope was addressed by a diverse team, including government, industry, and not-for-profit partners. The work scope under Phase 2 addressed fabrication of components identified as being outside of the proven capabilities of the existing supply chain, including the following: Steam turbine rotor forging and Haynes 282 nozzle carrier casting Superheater and reheater header and tube assemblies Large-diameter pipe extrusions and forgings Test valve articles to support ASME Code approval. In addition, key fabrication steps were completed, including boiler weld overlays and simulated field repairs. Throughout, extensive inspection and quality assurance testing of the components were performed. The team worked to advance ASME Code approval for key components and processes. Although much of the focus of ComTest Phase 2 was the high-temperature nickel-based alloy materials, a broader range of materials were incorporated, which would be representative of the materials used in full-scale A-USC power plant applications and have cross-cutting applicability on other high-temperature power generation options, such as advanced nuclear, supercritical CO 2 cycles, and central solar receivers. This report that has been submitted is organized in the following manner: Section 1 contains an Executive Summary. Section 2 discusses the ComTest project background and organization. Section 3 discusses project management and reporting. Section 4 discusses the procurement of nickel-based alloy and other A-USC materials and components. Section 5 discusses the fabrication of procurement of nickel-based alloy and other A-USC materials and components. Section 6 discusses the fabrication of cast nickel-based A-USC steam turbine components. Section 7 discusses the fabrication of forged nickel-based A-USC steam turbine piping and steam pipe components. Section 8 discusses the qualification of pressure relieve valves (PRVs) for A-USC power plants. Section 9 discusses proposed plans for future evaluation of A-USC components. Section 10 contains the summary and conclusion.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2022

Nuclear Energy in Long-Term System Models: A Multi-Model Perspective

Long-term energy system models–including electric sector capacity expansion models–are widely used tools for informing planning, technology assessment, and policy analysis. Recent decarbonization goals and rapid technological change have increased the need to appropriately represent economic characteristics and technical details of energy system resources, including variable renewable energy, energy storage technologies, carbon-capture-equipped capacity, and nuclear energy. Nuclear power represents about 20% of electricity generation and 50% of carbon-free electricity in the United States as of 2021. However, there are many perspectives on the role of existing and new nuclear in the future U.S. energy system, which is reflected in the broad range of potential contributions reported in the literature. This project aims to understand how issues central to nuclear energy are represented in long-term energy models. Building on earlier collaborations that focused on variable renewable energy and energy storage, this project convenes four modeling teams that use national-scale long-term energy system models from the Electric Power Research Institute, the National Renewable Energy Laboratory, the U.S. Energy Information Administration, and the U.S. Environmental Protection Agency to share methods and data, update models, run coordinated scenarios, and identify research needs. Improving tools can provide more insightful analyses and ensure that methods are more transparent.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2022

Gasification of Coal and Biomass: The Route to Net-Negative-Carbon Power and Hydrogen

One promising process that is a candidate for meeting the goals of the US Department of Energy’s 21st Century Power Plant initiative is to gasify a mixture of coal and biomass to yield a syngas, which can have CO2 removed and then be used to produce hydrogen as well as an off-gas that can be used to flexibly produce power. This concept would overall be carbon net-negative and readily meet the 21st Century Power Plant initiative targets of smaller scale MW generation, high ramp rates and turndown, feedstock flexibility, and high efficiency—at a reasonable cost. Moreover, adding the large-scale production of “ultra-green” hydrogen yields a system tailored for the coming hydrogen economy, providing long-term energy storage and an attractive co-product for sale. The objective of the work being led by the Electric Power Research Institute, Inc. (EPRI), with support by Bechtel Corporation (Bechtel), Gas Technology Institute (GTI), Hamilton Mauer International, Inc. (HMI), Nebraska Public Power District (NPPD), NexantECA, Inc. (Nexant), and Wärtsilä, is to perform a front-end design and engineering (FEED) study on an oxygen-blown gasification system coupled with water-gas shift, pre-combustion CO2 capture, and pressure-swing adsorption working off a coal/biomass mix to yield high-purity hydrogen and a fuel off-gas that can generate power. Several designs are being considered that will be capable of producing 50 MW net from a flexible generator, over 8500 kg/hr of hydrogen, and net-negative CO2 emissions, at an efficiency of 50% net HHV. The plant would be hosted at an NPPD site, where opportunities for enhanced oil recovery and sequestration have been investigated and the need for low-carbon power and hydrogen is imminent. The principal biomass to be used is corn stover—prevalent in Nebraska where the plant will be located—mixed with Powder River Basin (PRB) coal, necessitating a gasifier that can use this feedstock and be flexible to allow other types. Waste plastics will also be reviewed for use. Two oxygen-blown gasifiers have been identified as candidates that have done testing with biomass including corn stover: the GTI gasifier—a high-pressure, fluidized-bed type—and HMI’s, a lower pressure moving-bed type. Both have relative advantages that are being investigated in the Phase I design study, with a resultant down select of one system for which the FEED will be performed in Phase II. The technical tasks for the proposed project are: • Design Development: Completion of design activities necessary to provide inputs for the FEED study. Multiple design cases will be assessed with the selection of the optimal one for the FEED. • Investment Case Preparation: Development of the draft investment case for the proposed process with business cases performed for the proposed host site and two other locations. • Host Site Selection: Evaluation of the two potential host sites within NPPD’s portfolio to select the preferred candidate based on technical, economic, and environmental considerations. • Environmental Information Volume (EIV) Development: Completion of the EIV for the host site. • FEED Study: Completion of a FEED study based on the design selected in Phase I. A Greenhouse Gas Life Cycle Analysis will also be performed for the process. • Update Investment Case: Finalization of the investment case based on findings from the FEED. The advantages of the proposed project are significant. Having an engaged U.S. power utility willing to provide a host site that will produce energy from coal plus a deep and experienced team is critical; the process meets all the goals of DOE’s 21st Century Power Plant initiative at an estimated total plant cost of ~$880M and a production cost of hydrogen of ~$2/kg-H2 while producing net-negative carbon power. If developed, this process has real commercial potential in the United States—supported by EPRI’s initial review of the considerable interest from selected U.S. utilities—and elsewhere around the globe. The process has fewer environmental hurdles compared to other concepts, lowering regulatory and protest risks—providing a pathway to preserving the viability of a critical indigenous energy source by transforming its use to match a changing world. This presentation will outline the motivation for the effort, summarize project plans, work completed to date, results of the Design Development task, and detailed work scope for the remainder of the project.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2022

Performance Testing of a Moving-Bed Gasifier Using Coal, Biomass, and Waste Plastic Blends to Generate White Hydrogen

The objective of this DOE-funded project by the Electric Power Research Institute, Inc. (EPRI), Hamilton Maurer International (HMI) and Sotacarbo S.p.A. (Sotacarbo), is to qualify coal, biomass, and plastic waste blends based on performance testing of selected pellet recipes in a pilot-scale updraft moving-bed gasifier. The testing will provide relevant data to advance the commercial-scale design of the moving-bed gasifier to be able to successfully use these feedstocks to produce hydrogen. In particular, the effects of the waste plastics on feedstock development (i.e., blending and pelletizing) and the resulting products (i.e., syngas compositions, organic condensate production, and ash characteristics) are a focus. The gasifier is Hamilton Mauer International, Inc. (HMI)’s moving-bed gasifier, which has been proven capable of gasifying nearly all coal ranks. It has also shown the ability in prior testing work to gasify wood chips. However, mixtures of these fuels with plastic wastes have not been prepared and gasified together. The feedstocks will be prepared by California Pellet Mill (CPM) under contract to HMI. The technical tasks and current status for this two-year research project are: Feed Procurement and Preparation: Nine different feedstocks were prepared from varying compositions of PRB coal, corn stover biomass, and car fluff waste plastics. Fuel pellets were produced by California Pellet Mill and shipped to Sotacarbo’s test facility in Italy. Test Plan Development: A test plan was created to define the test runs to be performed. The test plan detailed the different tests that were run, instrumentation used, extractive samples taken, and relevant figures of merit. Gasifier Testing: Tests are currently being performed in the pilot-scale gasifier at Sotacarbo using nine different fuel feedstocks generated from varying mixtures of coal, biomass, and plastic wastes. The testing will provide information on gasification reaction efficiency/performance, yielding relevant data for models used to scale up the gasifier design. This task will also include work to reassemble the gasifier at Sotacarbo and perform a baseline 100% coal run. Data Analysis and Reporting: Review of the data, determination of figures of merit, and interpretation of the results to be reported. The results will be used to specify the range of feedstock blends that can be successfully gasified as well as quantify gasifier outputs based on specific blends. This paper will be summarize the pelletizing procedure that insures the viability of the tri-fuel pellets for the gasification runs that are being performed at Sotacarbo’s 30mm up draft moving bed gasifier. Initial gasification tests have been conducted, and all the lab scale tri-fuel pellet gasification runs will be completed by the fall of 2022. Performance data will enable modeling of a full-scale HMI industrial scale gasifier supporting both CHP and Hydrogen production.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2022

Commercial-Scale Front-End Engineering Design (Feed) Study for MTR’s Membrane CO 2 Capture Process

This is the final report for a DOE sponsored project (DE-FE00031846) where MTR, Sargent & Lundy (S&L), Trimeric Corporation (Trimeric), in cooperation with Basin Electric Power Cooperative (BEPC), and Electric Power Research Institute (EPRI), completed a full-scale Front End Engineering and Design (FEED) study to evaluate the retrofit of MTR’s membrane-based post-combustion carbon dioxide (CO2) capture technology to the BEPC Dry Fork Station (DFS) Unit 1. The capture plant is designed to treat the entire flue gas flow from DFS; it is estimated that this system will capture 6,560 tonnes per day (TPD) of carbon dioxide. The overall goal of the project was to develop an AACE Level 2 Capital Cost Estimate with an accuracy of ±15% to demonstrate the economic feasibility of constructing and operating the MTR CO2 capture plant.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2023

Gasification of Coal and Biomass: The Route to Net-Negative-Carbon Power and Hydrogen

One promising process that is a candidate for meeting the goals of the US Department of Energy’s 21st Century Power Plant initiative is to gasify a mixture of coal and biomass to yield a syngas, which can have CO2 removed and then be used to produce hydrogen as well as an off-gas that can be used to flexibly produce power. This concept would overall be carbon net-negative and readily meet the 21st Century Power Plant initiative targets of smaller scale MW generation, high ramp rates and turndown, feedstock flexibility, and high efficiency—at a reasonable cost. Moreover, adding the large-scale production of “ultra-green” hydrogen yields a system tailored for the coming hydrogen economy, providing long-term energy storage and an attractive co-product for sale. The objective of the work being led by the Electric Power Research Institute, Inc. (EPRI), with support by Bechtel Corporation (Bechtel), Gas Technology Institute (GTI), Hamilton Mauer International, Inc. (HMI), Nebraska Public Power District (NPPD), NexantECA, Inc. (Nexant), and Wärtsilä, is to perform a front-end design and engineering (FEED) study on an oxygen-blown gasification system coupled with water-gas shift, pre-combustion CO2 capture, and pressure-swing adsorption working off a coal/biomass mix to yield high-purity hydrogen and a fuel off-gas that can generate power. Several designs are being considered that will be capable of producing 50 MW net from a flexible generator, over 8500 kg/hr of hydrogen, and net-negative CO2 emissions, at an efficiency of 50% net HHV. The plant would be hosted at an NPPD site, where opportunities for enhanced oil recovery and sequestration have been investigated and the need for low-carbon power and hydrogen is imminent. The principal biomass to be used is corn stover—prevalent in Nebraska where the plant will be located—mixed with Powder River Basin (PRB) coal, necessitating a gasifier that can use this feedstock and be flexible to allow other types. Waste plastics will also be reviewed for use. Two oxygen-blown gasifiers have been identified as candidates that have done testing with biomass including corn stover: the GTI gasifier—a high-pressure, fluidized-bed type—and HMI’s, a lower pressure moving-bed type. Both have relative advantages that were investigated in the Phase I design study, with a resultant down select of one system for which the FEED will be performed in Phase II. The technical tasks for the project are: • Design Development: Completion of design activities necessary to provide inputs for the FEED study. Multiple design cases will be assessed with the selection of the optimal one for the FEED. • Investment Case Preparation: Development of the draft investment case for the proposed process with business cases performed for the proposed host site and two other locations. • Host Site Selection: Evaluation of the two potential host sites within NPPD’s portfolio to select the preferred candidate based on technical, economic, and environmental considerations. • Environmental Information Volume (EIV) Development: Completion of the EIV for the host site. • FEED Study: Completion of a FEED study based on the design selected in Phase I. A Greenhouse Gas Life Cycle Analysis will also be performed for the process. • Update Investment Case: Finalization of the investment case based on findings from the FEED. The advantages of the proposed project are significant. Having an engaged U.S. power utility willing to provide a host site that will produce energy from coal plus a deep and experienced team is critical; the process meets all the goals of DOE’s 21st Century Power Plant initiative at an estimated total plant cost of ~$880M and a production cost of hydrogen of ~$2/kg-H2 while producing net-negative carbon power. If developed, this process has real commercial potential in the United States—supported by EPRI’s initial review of the considerable interest from selected U.S. utilities—and elsewhere around the globe. The process has fewer environmental hurdles compared to other concepts, lowering regulatory and protest risks—providing a pathway to preserving the viability of a critical indigenous energy source by transforming its use to match a changing world. This presentation outlines the motivation for the effort, summarizes project plans, work completed to date, results of the Phase I effort and, and detailed work scope for the remainder of the project in the Phase II FEED effort.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2023

Refining Principal Stress Measurements in Reservoir Underburden in Regions of Induced Seismicity through Seismological Tools, Laboratory Experiments - Final Technical Report

This project developed methodologies to measure the in-situ principal stress in the deep subsurface through use of multiple independent, but complementary, seismic methods, laboratory verification, and development of theoretical frameworks. By leveraging existing regional and local datasets we developed, tested, and refined a set of diagnostic tools for determining the in-situ stress state with reduced uncertainty at and below reservoir depths (1.5-6 km). A set of novel tools was produced that are scale independent, such that their utility is equivalent on regional, field scale, and near borehole monitoring of principal stresses in reservoir underburden for carbon storage projects. During a 4-year Department of Energy (DOE) and Southern Company funded project, carried out by the Electric Power Research Institute (EPRI), Lawrence Livermore National Laboratory (LLNL), the University of Oklahoma (OU), and the U.S. Geological Survey (USGS), the project team developed methodologies to measure the far-field in-situ principal stress in the deep subsurface, leveraging induced seismicity data from waste-water disposal projects. These methodologies consisted in the use of well-established and technically advanced seismic processing methods, such as virtual seismometer method-moment tensor (VSM-MT) and shear wave splitting (SWS), that are adept at recovering the stress orientation and certain components of the stress tensor. These methods were applied to robust seismicity catalogs created with matched filter techniques near sites of active fluid disposal—a proxy for carbon storage sites where such datasets are more limited. Estimates of the stress orientation made with seismic processing tools were considered along with laboratory acoustic emission experiments conducted on rock samples from the region of interest. Stress orientations in the studied region do not vary significantly across distances of ~100 km, nor are they found to rotate through time as a consequence of local wastewater disposal, as previously speculated. Finally, the project team investigated the trade-offs among the different seismic methods and evaluated the range of uncertainty that is generated with these methodologies, which led to a practical use and refinement of the VSM-MT technique when it is applied to field datasets. Understanding the trade-offs between these different methods highlighted the potential benefits of improved quantification of uncertainties on stress field estimations.

58 GEOSCIENCES↗

DOE OSTI2023

Inventory for Crystalline Silicon Module Recycling: Cooperative Research and Development (Final Report)

A critical challenge for the continued expansion of photovoltaics (PV) is to develop technically feasible, inexpensive and environmentally friendly practices for handling and recycling modules at the end of their usable life. The National Renewable Energy Laboratory (NREL) is requested by the Electric Power Research Institute (EPRI) to collect primary data regarding the environmental performance of currently operational PV module recycling facilities in Europe. Very little has been published regarding crystalline silicon (C-Si) module recycling. Thus, much effort will be needed in direct industry outreach, collection of information and other business intelligence strategies similar to NREL's approaches for developing cost models for PV manufacturing. The goal of this work effort is to produce a detailed inventory that accounts for physical (e.g., energy, water, materials) flows through each step of a C-Si recycling process. The inventory (a life cycle inventory, or LCI) shall be designed so that it can be extended to include an accounting of costs for each process step, inputs, etc. This work effort shall leverage prior LCI data collection NREL performed for the United States Department of Energy, Solar Energy Technologies Office, under the auspices of the U.S. contribution to International Energy Agency's Photovoltaics Power Systems (PVPS) Task 12 (Environmental Health and Safety), which SETO nominated NREL to chair. The primary purpose of this work effort is to augment the prior data collection to increase the sample size of manufacturers' primary data in the LCI.

14 SOLAR ENERGY↗

DOE OSTI2022

Light Water Reactor Sustainability Program: Complete the weld campaign on Ni-base irradiated materials using stress improved laser welding including the preliminary weld quality inspections

This report summarizes the most recent welding campaign on irradiated Ni-base alloy 182 and the preliminary weld quality inspections at the Radiochemical Engineering Development Center (REDC). Equipment and capabilities were developed jointly by the U.S. Department of Energy, Office of Nuclear Energy, Light Water Reactor Sustainability Program, the Electric Power Research Institute, Long Term Operations Program (and the Welding and Repair Technology Center), and Oak Ridge National Laboratory. Irradiated nickel alloy 182, with target helium contents of 5 atom parts-per million (appm), 10 appm, and 20 appm, were laser welded in the hot cell successfully. The significant, on-going effort to weld irradiated alloys with high helium concentrations and comprehensively analyze the results will eventually yield validated repair techniques and guidelines for use by the nuclear industry in extending the operational lifetimes of nuclear power plants. This report fulfills the FY 2023 milestone M3LW-22OR0406013, “Complete the weld campaign on Ni base irradiated materials using stress improved laser welding including the preliminary weld quality inspections”.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2023

Coronado Generating Station Repowering Evaluation - Siting Evaluation

The purpose of this initial siting evaluation is to consider the suitability of the Salt River Project (SRP) owned land at/near Coronado Generating Station (CGS) for a nuclear generating station (including advanced light water reactors, light water small modular reactors, and non-light-water designs1) and to assess if there are any exclusionary or avoidance factors associated with coal to nuclear repowering at CGS. This initial siting evaluation considers several characteristics (e.g., environmental conditions, seismic concerns, site footprint, water use, etc.) and highlights favorable/preferred characteristics as well as potential risks to feasibility. The results are intended to inform SRP on the strengths and weaknesses associated with the CGS site and inform the selection of candidate nuclear technologies for the CGS site that align with SRP’s mission and business objectives. This report relies on industry-recognized siting guidance, including Electric Power Research Institute’s (EPRI’s) Siting Guide (Reference 1) 2 and Nuclear Regulatory Commission’s (NRC’s) Regulatory Guide (RG) 4.7 (Reference 3), as well as nuclear domain expertise within the Gateway for Accelerated Innovation in Nuclear (GAIN), MPR Associates, Inc. (MPR), and the Idaho National Laboratory (INL).

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2024

Ensemble Manufacturing Techniques for Steam Turbine Components Across Length Scales

Faster design to manufacturing requirements were sought for steam turbine components to meet the changing demands of today’s power grid of improved efficiency through operating temperature increases and enhanced operational flexibility from baseload to cyclic operations. Advances in multiple advanced manufacturing (AM) process enabled redesign of turbine components for extreme environments with the potential to reduce cost. AM is of particular interest to improve component functionality, higher temperature capability, and superior durability in large scale steam turbine applications. AM methods have an immense potential to open-up the design space by working directly with the 3D model to produce near-net shapes, enable fast design-manufacturing iterations, thereby significantly reducing product cost and lead-time up to 25 % from current baseline. However, these benefits cannot be fully realized due to the potential for unknown AM processing defects and their resultant effect upon component performance in service. Siemens is partnering with Oak Ridge National Laboratory (ORNL), Electric Power Research Institute (EPRI), and Connecticut Center for Advanced Technology (CCAT) to advance the knowledge of complex process-material interactions for desired microstructures and properties that are closely interlinked to component geometries across different length scales. The proposed program utilized an ensemble of multidisciplinary technologies to accelerate the development of materials, high-throughput experiments for their qualification, and design flexibility/topology optimization for repair/redesign of components to address critical failure mechanisms for improved performance and increased reliability of existing power plant components. The proposed activities, if successfully demonstrated for identified components, will enable paradigm shift in customized manufacturing and accelerated qualification/certification towards increased steam turbine component durability, increased turbine efficiency, and reduced CO 2 emissions in load-following environments compared to today’s technology. Technology maturation is built into the project as successful research will include customized process-component down-selection enabling AM methodologies to be incorporated directly into the existing supply chain. The specific activities of the proposed effort are: 1. Topology optimization of down-selected steam turbine parts that are amenable to additive and hybrid manufacturing for cost/performance improvement. 2. Process-structure-property relationships for five AM processes for steam turbine materials of interest to compare with conventional materials. 3. Perform part/assembly build process using advanced additive/hybrid machine tools followed by quality inspection of the built components for insight into qualification for production scale-up. Steam turbine rig testing of printed components under targeted, well monitored and characterized environmental conditions of for performance comparison of baseline and redesigned components.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Ghent Generating Station Nuclear Study: Siting Evaluation

The purpose of this initial siting evaluation is to assess the suitability of the PPL Corporation (PPL) owned land at/near the Kentucky Utilities Ghent Generating Station (GGS) for the deployment of advanced nuclear reactors and to determine if there are any exclusionary or avoidance factors associated with siting nuclear power at GGS. The formal siting process for a nuclear reactor requires a great level of time (i.e., multiple years), effort, and detail. The Electric Power Research Institute (EPRI) estimates the formal siting process could take a dedicated team between one and three years to complete. This initial siting evaluation considers several characteristics (e.g., environmental conditions, seismic concerns, footprint, water use, etc.) and highlights favorable/preferred characteristics as well as potential risks to feasibility. Potential risks were explored in greater detail to provide PPL with additional insights to support decision planning. The results indicate the strengths and weaknesses associated with the GGS site as a location for a nuclear generating station and are intended to inform PPL’s next steps. The results of this initial siting evaluation will also inform the selection of candidate nuclear technologies for the GGS site that align with PPL’s mission and business objectives.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2024

Performance Testing of a Moving-Bed Gasifier Using Coal, Biomass, and Waste Plastic Blends to Generate White Hydrogen

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2024

Modeling and Optimization of Zeolites for Contaminant Removal from Coal Combustion Impoundment Leachates

Coal Combustion Residual (CCR) landfills in the U.S. can lead to elevated contaminant concentrations in groundwater and runoff, particularly of arsenic, boron, and selenium. Zeolites can be readily synthesized from materials contained within the coal combustion ash impoundments and can be cation-exchanged to enhance adsorption capacity, selectivity, and reactivity. However, the optimization of zeolites becomes a daunting task when accounting for the variety of Si:Al ratios, the species of extra-framework cations present, and the zeolite pore structure. Molecular simulations provide methods to study and guide the design of zeolites for the sorption of contaminants from aqueous solution. In this work, models that predict the sorption of arsenic, boron, and selenium from water using cation-exchanged zeolites. Because of the lack of experimental adsorption data for these species of contaminants, models were parametrized to reproduce the results of first-principles calculations and then used to predict sorption for zeolites for a dataset containing 6000 combinations of zeolites and sorption conditions. Machine learning was used to train a model to predict sorption for materials in this database based on the results of the molecular simulations. Next, a genetic algorithm was used to optimize zeolites for the removal of each contaminant from aqueous solution for individual impoundment sites based on contaminant concentrations reported by the Electric Power Research Institute.

Findley, John↗

DOE OSTI2024

Virtual Synchronous Machine Grid-Forming Inverter Model Specification (REGFM_B1)

This report describes a generic virtual synchronous machine (VSM) grid-forming inverter (GFM) model - REGFM_B1. The initial model specification was proposed by Pacific Northwest National Laboratory (PNNL), General Electric (GE), and Electric Power Research Institute (EPRI). Siemens Gamesa Renewable Energy (SGRE) also provided inputs to the specification. The model specification has been revised multiple times based on the discussions between all the contributors listed in this report. This work was funded by the Universal Interoperability for Grid-Forming Inverters (UNIFI) Consortium. This generic model is developed to help the utility industry understand the concept of VSM GFMs. The model could be used to represent equipment for long-term planning studies where vendor-specific models are not available. As equipment mature and improve, generic models will be updated to capture the new functionalities of GFMs. It is not intended that these models will always remain representative of all future GFM technologies.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2024

Evaluation of the Turbine Integrated Mortality Reduction (TIMR SM ) Technology as a Smart Curtailment Approach (Final Summary Report)

Wind energy is a crucial technology for achieving net-zero emissions by 2050. However, the growth and deployment of wind energy in North America have led to the deaths of many bat species due to operating wind turbines. Hundreds of thousands of bats are estimated to die at wind turbines annually in North America. Operational minimization, which includes feathering turbine blades and curtailment, has been documented to reduce bat fatality effectively. Curtailment refers to altering turbine operation based on wind speed, time of year, temperature, sensors, and activity models. However, when turbines are curtailed, they do not generate power, resulting in energy loss and revenue for wind energy facilities. The Electric Power Research Institute (EPRI) funded the development of Turbine Integrated Mortality Reduction (TIM SM ) Technology, which curtails turbine operation when bats are detected. The initial TIMR system research showed promising results, with an 85% reduction in overall bat fatalities and a 91% reduction for the little brown bat. However, these results were based on a single site during one fall season, and it was unclear if similar results could be replicated at other wind energy facilities. This research aimed to validate the TIMR system results from the prior field study at a second site in the U.S., estimate the power production and reduction in bat mortality at turbines with installed TIMR systems relative to blanket curtailment and fully operational turbines, test the TIMR system in two calendar years and during the summer and fall periods, and evaluate the operational and commercial characteristics of the TIMR system for potential wind industry adoption. The study was conducted at a 500.9-MW wind energy facility in southeast Adair County, Iowa. Three experimental treatments were involved in this randomized block design study: TIMR, Curtailment at 5.0 m/s, and Normal Operation. In 2021, three treatments were used at 18 turbines, expanding to four treatments across 36 turbines in 2022. The TIMR system worked as designed throughout the entire study; however, because of unexpected wind turbine operational challenges in 2021, there was not sufficient sample size to evaluate the treatment differences. In 2022, there were significant differences in fatality levels between treatment types and normal operating turbines. Curtailment at 5.0 m/s reduced fatalities by 30.8% compared to normal operations, and TIMR decreased fatalities by 48.6% compared to normal operations. Two different methods were used to evaluate the differences in energy loss for each treatment. The TIMR system resulted in 1.3% to 1.6 % annual energy loss in 2021 and 1.0% to 1.2 % in 2022. The Curtailment at 5.0 m/s resulted in 0.6% to 0.8 % annual energy loss in 2021 and 0.5% to 0.6 % in 2022. The project achieved all the stated objectives and demonstrated that TIMR is an effective technology that balances bat fatality reduction with energy generation. The results will support the deployment of TIMR and other acoustic sensor-based technologies. The research provides valuable insights into the impact of different treatments on fatality rates and energy outputs, contributing to the ongoing efforts to mitigate the environmental impact of wind energy.

17 WIND ENERGY↗

DOE OSTI2024

NEAMS Burnup Extension Accomplishments and Remaining Modeling Gaps

The economic viability of light-water reactors (LWRs) in the United States is declining in heavily subsidized markets, and as a result, the nuclear industry is looking for opportunities to enhance the economic competitiveness of nuclear power. This is not a foreign concept to the nuclear industry: in the mid-2000s, the nuclear industry set out to achieve zero fuel failures by 2010. The goal in this effort was to drive down the cost of reactor shut down by replacing a pin or bundle in response to fuel rod failure. 2010 brought about the initiative to deliver the nuclear promise to reduce operating cost by 30% to improve nuclear energy’s economic competitiveness before 2020. The emergence of accident-tolerant fuel also offers the nuclear industry an opportunity to build on these past successes and deliver affordable, clean energy. Accident-tolerant fuel has been shown to provide superior performance compared to traditional Zircaloy/UO2 fuel concepts, offering the unique ability to remove operational limitations that inhibit the economic viability of nuclear power. This has led the industry to begin building a technical case to extend the peak rod average burnup beyond 62 GWd/tU to extend pressurized water reactor cycle lengths to 24 months and to develop more efficient boiling water reactor core designs. The Nuclear Energy Advanced Modeling and Simulation (NEAMS) program mission is to develop advanced modeling and simulation tools and capabilities to accelerate the deployment of advanced nuclear energy technologies. The primary safety concern inhibiting the nuclear industry from extending burnup is related to high-burnup fuel fragmentation, relocation, and dispersal. Therefore, the NEAMS program developed a targeted 5-year plan to support the industry’s efforts to extend burnup. This milestone report summarizes the 5-year plan that was enacted in FY20, followed by a discussion of the ongoing activates required to fulfill the 5-year plan, as well as the approach to address the current modeling gaps. Additionally, an LWR stakeholder meeting was held to communicate work performed in the NEAMS program over the past three years, to assess the LWR community’s perspective on the impact of the program, and to identify remaining significant gaps in the NEAMS suite of capabilities. This engagement will be documented by the Electric Power Research Institute and used by NEAMS to redirect current LWR scope as needed and to develop the next phase for LWR research and development.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗