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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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DOE OSTI2024

Wholesale Electricity Analysis via Simulation & Learning Experiments (WEASLE): Platform Development and Pilot Competition

This document reports the development of the Wholesale Electricity Analysis via Simulation and Learning Experiments (WEASLE) platform and the pilot competition that was conducted to test the platform. Due to the increasing reliance on variable renewable energy resources for bulk power, the pilot competition, called the Energy Storage Participation Algorithm Competition (ESPA-Comp), was used to test the effect of various market designs on storage utilization and market efficiency. Basic details of the platform are provided, including an overview of the market clearing engine, the battery dispatch and degradation models, electric grid topology and resource mix, and software architecture. Two market designs were tested: a two-settlement market analogous to typical ISO design today, and a multi-settlement market that allows additional forward-trading periods during the real-time market. Results from the pilot competition show that the storage bidding problem is nontrivial and is well suited for future challenges. We find that: 1) all four teams utilized different approaches to the bidding problem, 2) different methodological approaches led to substantially different offer behaviors, 3) resource profits are clustered by team and methodological approach, 4) simulated offers reduced market surplus by about 0.5%, 5) substantially different prices between two-settlement and multi-settlement markets albeit minimal difference in overall market surplus.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2023

Lighting for Health and Wellness Recommendations in Offices: A Circadian Lighting Pilot Project in Chicago, IL

In 2019 Cook County initiated a request for proposals for a pilot project aimed at designing and specifying an advanced tunable lighting system for government offices in Chicago, Illinois. The primary goal of the project was to replace the existing tubular LED (TLED) lighting system with a lighting system that supported the circadian rhythms and wellbeing their office employees. A secondary goal was to evaluate the potential impacts of the new lighting system, informing Cook County’s internal workplace design standards. Schuler Shook, a Chicago-based lighting design firm, was awarded the Circadian Lighting Pilot Project in October 2019 and invited Pacific Northwest National Laboratory (PNNL) to contribute as a research partner. Based on the initial project goals, Schuler Shook and PNNL established design objectives that would enable a human factors study in the office spaces, investigating the benefits and drawbacks of using a tunable LED lighting system to meet existing recommendations for lighting and health. The following report details the lighting design process through design development, with summaries of the relevant circadian lighting metrics, simulation tools, energy considerations, and research plan for the Circadian Lighting Pilot Project.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

Cross-flow separation characteristics and piloting of graphene oxide nanofiltration membrane sheets and tubes for kraft black liquor concentration

Dewatering of weak black liquor (WBL) in the kraft cycle by evaporation is highly energy intensive. Membranes are an attractive alternative for energy-efficient dewatering, but existing commercial polymeric or ceramic membranes are either degraded in BL or have high capital costs. Our recent works have demonstrated the engineering of graphene oxide (GO) nanofiltration membranes, their stability and promising performance in BL conditions, and preliminary scale-up into sheets and tubes. Here, we describe in detail the separation characteristics of GO membrane sheets and tubes under real BL conditions and crossflow operation. Recycle-mode piloting of a GO tubular membrane showed average “production flux” of 16 L/m2/h (LMH) and high rejections of lignin (98.3%), total solids (66%), and total organic carbon (83%), with no signs of irreversible fouling identified. A corresponding GO sheet membrane produced an average flux of ~25 LMH and maintained high lignin rejection of ~97% during a slipstream pilot at a kraft mill site using WBL with ~16 wt% total solids (TS). Finally, we piloted a Dow/DuPont XUS1808 polyamide composite reverse osmosis (RO) membrane for last-mile processing of the GO nanofiltration membrane permeate. The RO membrane showed a steady state flux of 19 LMH at 65 bar and produced ~0.02 wt% TS water product, which is highly suitable for reuse in pulp washing operations in the kraft process. The results have strong positive implications for the industrial application of GO membranes in BL concentration and other related applications.

Materials Science↗
DOE OSTI2022

Plasma Imaging, LOcal Measurement, and Tomographic Experiment (PILOT): A Mission Concept for Transformational Multi-Scale Observations of Mass and Energy Flow Dynamics in Earth’s Magnetosphere

We currently do not understand the fundamental physical processes that govern mass and energy flow through the Earth’s magnetosphere. Knowledge of these processes is critical to understanding the mass loss rate of Earth’s atmosphere, as well as for determining the role that a planetary magnetic field plays in atmospheric retention, and therefore habitability, for Earth-like planets beyond the solar system. Mass and energy flow processes are challenging to determine at Earth in part because Earth’s planetary magnetic field creates a complex “system of systems” composed of interdependent plasma populations and overlapping spatial regions that perpetually exchange mass and energy across a broad range of temporal and spatial scales. Further, the primary mass carrier in the magnetosphere is cold plasma (as cold as ~0.1 eV), which is invisible to many space-borne instruments that operate in the inner magnetosphere. The Plasma Imaging LOcal and Tomographic experiment (PILOT) mission concept, described here, provides the transformational multi-scale observations required to answer fundamental open questions about mass and energy flow dynamics in the Earth’s magnetosphere. PILOT uses a constellation of spacecraft to make radio tomographic, remote sensing, and in-situ measurements simultaneously, fully capturing cold plasma mass dynamics and its impact on magnetospheric systems over an unprecedented range of spatial and temporal scales. This article details the scientific motivation for the PILOT mission concept as well as a potential mission implementation.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2020

NREL's Biochemical Conversion Pilot Plant Capabilities

NREL's biochemical conversion plant is a flexible pilot plant for testing a wide range of bio-based technologies for producing renewable fuels and byproducts. The biochemical conversion pilot plant is housed in the Integrated Biorefinery Research Facility located on the National Renewable Energy Laboratory's (NREL's) main campus. The facility provides industry partners the opportunity to test and develop their own biorefining technology using NREL equipment or rental equipment that can be brought into the plant. The pilot plant can process materials up to one dry ton per day in an integrated fashion using a variety of operating modes including batch, fed-batch, and continuous processing.

biochemical↗
DOE OSTI2021

Delivering Effective Virtual Energy-Focused Trainings: Successful Strategies and Lessons Learned from the Virtual Cohort In-Plant Training Pilot

While there are always barriers to energy efficiency efforts, few challenges have been as severe as the global COVID-19 pandemic. Many manufacturers throughout the United States and the world have been trying to determine how to safely open and operate their plants. To minimize the number of people working within facilities and maximize the physical distance between workers, only essential facility engineers are allowed into plants to ensure proper operations. The Department of Energy’s Better Plants Program created In-Plant Trainings (INPLTs) to help partners develop in-house expertise in energy efficiency. Delivering INPLTs in the traditional in-person fashion is infeasible under these circumstances. To continue providing INPLTs during this difficult time, the Better Plants Program piloted Virtual Cohort In-Plant Trainings (VINPLTs) on wastewater treatment and ammonia industrial refrigeration systems from October 27 to November 19, 2020. This paper provides an overview of the pilot, then discusses successful strategies and lessons learned from this pilot for delivering effective virtual energy-focused trainings.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

History Matching and Prediction of a Polymer Flood Pilot in Heavy Oil Reservoir on Alaska North Slope

The first-ever polymer flood pilot to enhance heavy oil recovery on Alaska North Slope is ongoing. After more than 3 years of polymer injection, significant benefit has been observed from the decrease in water cut from 65% to less than 15% in the project producers. The primary objective of this study is to develop a robust history-matched reservoir simulation model capable of predicting future polymer flood performance. In this work, the reservoir simulation model has been developed based on the geological model and available reservoir and fluid data. In particular, four high transmissibility strips were introduced to connect the injector-producer well pairs, simulating short-circuiting flow behavior that can be explained by viscous fingering and reproducing the water cut history. The strip transmissibilities were manually tuned to improve the history matching results during the waterflooding and polymer flooding periods, respectively. It has been found that higher strip transmissibilities match the sharp water cut increase very well in the waterflooding period. Then the strip transmissibilities need to be reduced with time to match the significant water cut reduction. The viscous fingering effect in the reservoir during waterflooding and the restoration of injection conformance during polymer flooding have been effectively represented. Based on the validated simulation model, numerical simulation tests have been conducted to investigate the oil recovery performance under different development strategies, with consideration for sensitivity to polymer parameter uncertainties. The oil recovery factor with polymer flooding can reach about 39% in 30 years, twice as much as forecasted with continued waterflooding. Besides, the updated reservoir model has been successfully employed to forecast polymer utilization, a valuable parameter to evaluate the pilot test’s economic efficiency. All the investigated development strategies indicate polymer utilization lower than 3.5 lbs/bbl in 30 years, which is less than that of the same polymer used in a polymer pilot in Argentina.

Wang, Xindan↗
DOE OSTI2022

sCO2 Primary Power Large-Scale Pilot Plant FEED Summary

Echogen Power Systems and its project partners the Electric Power Research Institute, CDM Smith, Riley Power Inc. (a Babcock Power Inc. company), and the University of Missouri completed the Front-End Engineering Design (FEED) study of a nominal 10 MWe supercritical carbon dioxide (sCO2) large-scale pilot plant based on Recompression Brayton Cycle (RCBC) architecture. The FEED study was completed under Phase II of the U.S. Department of Energy Fossil Fuel Large-Scale Pilots program. The FEED study scope included the preliminary design of the combustion and environmental control systems, the primary heater, the sCO2 power cycle and its associated turbomachinery, and the balance of plant equipment to determine accurate cost and schedule requirements for fabrication and installation of the system at the University of Missouri’s Combined Cooling, Heat, and Power Plant, located in Columbia, Missouri. The RCBC sCO2 cycle presents superior thermodynamic efficiency compared to steam-Rankine cycles and is adaptable to a broad range of heat sources. The risk aversion of the power generation industry requires a successful large-scale pilot plant demonstration to enable financing and deployment of commercial-scale plants. Therefore, successful construction and demonstration of a 10 MWe RCBC sCO2 power plant would empower a transformational step forward for the efficiency of the next generation of utility power plants. This paper provides details on the primary heater, environmental control systems, and sCO2 power cycle design and performance.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2020

PILOT PLANT EVALUATIONS OF RARE EARTH ELEMENT RECOVERY AND CONCENTRATION FROM PRE-COMBUSTION BITUMINOUS COAL SOURCES

Rare earths and other critical elements are commonly associated with coal-based sources and sometimes at concentrations that may be attractive for recovery as a byproduct of coal production. The results obtained from laboratory research performed during the past five years have led to the design, construction and testing of a pilot plant that recovered rare earth elements from several bituminous coal-based materials including coarse refuse as well as solutions from a small heap leach and acid mine drainage. From this initial design, rare earth oxide (REO) concentrates having a purity greater than 90% have been produced using solvent extraction as the primary means of concentration. Following cost reduction and process intensification efforts, the circuit was revised to include feed calcination and several selective precipitation stages as a substitute for the original direct leach-solvent extraction circuit. Pilot test results revealed that the modified circuit was ideal for treating the relatively low-grade feedstocks and provided similar final REO purities at a significantly lower cost. This communication will present the flowsheets evaluated in the pilot plant along with technical and economic analyses for each circuit.

Coal↗
DOE OSTI2025

Leveraging a Southern California Energy Innovation Cluster to Pilot and Validate Emerging Energy Technologies

The EPIC Pilot Program, led by the Los Angeles Cleantech Incubator (LACI), was designed to help early-stage clean technology startups accelerate technical validation, investment readiness, and market entry. The project focused on supporting startups in designing and deploying small-scale pilots with the guidance of EPIC Partners, a network of regional stakeholders in the Southern California energy ecosystem, including but not limited to: the Los Angeles Department of Water and Power (LADWP), the California Energy Commission (CEC), Los Angeles County Metropolitan Transportation Authority (LA Metro), and Edison International, among others. Through mentorship, funding, and site access for technology deployments, the program provided a structured pathway for startups to test and refine their technologies in real-world settings.

14 SOLAR ENERGY↗
DOE OSTI2023

Pilot Scale Testing of Lignite Adsorption Capability and the Benefits for the Recovery of Rare Earth Elements from Dilute Leach Solutions

Naturally occurring organic materials containing humic acids show a strong affinity towards rare earth elements (REE) and other critical elements. Leaching experiments on lignite coal waste produced from construction sand production revealed that the contained REEs were associated with the organic matter. Furthermore, adsorption studies revealed that the lignite waste was capable of extracting REEs from a model solution and increased the REE content of the lignite waste by more than 100%. As such, this study aimed to utilize the lignite waste to adsorb REEs from pregnant leach solutions and acid mine drainage sources having low REE concentrations and subsequently leach the lignite material to produce pregnant leach solutions containing relatively high amounts of REEs, which benefits the performance and economic viability of downstream separation and purification processes. An integrated flowsheet was developed based on this concept and tested at a pilot scale. The pregnant leachate solution (PLS) was generated from a heap leach pad containing 2000 tons of Baker seam coarse refuse. The pilot scale circuit was comprised of aluminum precipitation, adsorption using the waste lignite, and rare earth-critical metal (RE-CM) precipitation stages in succession. The results indicated that the aluminum precipitation stage removed over 88% and 99% of the Al and Fe, respectively. The adsorption stage increased the REE content associated with the waste lignite from 457 ppm to 1065 ppm on a whole mass basis. Furthermore, the heavy REE (HREE) content in the feedstock increased by approximately 250%, which raised the percentage of HREE in the REE distribution by 19 absolute percentage points. In addition to the REEs, concentrations of other critical elements such as Mn, Ni, and Zn also improved by 75%, 37%, and 250%, respectively. Bench-scale tests revealed that increasing the solids concentration in the waste lignite and PLS mix from 1% to 20% by weight enhanced the adsorption efficiency from 32.0% to 99.5%, respectively. As such, a new flowsheet was proposed which provides significantly higher REE concentrations in the PLS that can be fed directly to solvent extraction and/or oxalic acid precipitation and, thereby, enhancing process efficiency and economics.

58 GEOSCIENCES↗
DOE OSTI2023

High-moisture pelleting of corn stover using pilot- and commercial-scale systems: Impact of moisture content, L / D ratio and hammer mill screen size on pellet quality and energy consumption

Here, high-moisture pelleting of corn stover was tested in pilot- and commercial-scale systems. For the pilot-scale study, a 6.35 mm screen size hammer mill ground corn stover was reconditioned to moisture between 14 and 29.6% (w.b.), and 5, 7 and 9 L/D ratio pellet die were used. At 29% corn stover moisture content and L/D ratios of 5 and 9, the bulk density and durability of the pellets were ≤450 kg/m 3 and <90% and >540 kg/m 3 and >90%, respectively. Increasing the feedstock moisture and L/D ratio increased the pelleting energy. Increasing the hammer mill screen size to 11.11 mm reduced the bulk density but not the durability. The response surface models adequately described the pelleting process (R 2 ≥ 0.88), and analysis of variance showed a strong interaction between the process variables and pellet properties. Commercial-scale testing of high-moisture pelleting using 6.35 mm ground corn stover bales in the moisture range 24–26% (w.b.) produced pellets with a density of >675 kg/m 3 and durability of >98%, whereas increasing the hammer mill screen size to 11.11 mm reduced the bulk density by about 100 kg/m 3 but not the durability. The energy consumption of the commercial-scale unit operations for the high-moisture pelleting process was in the range 98–124 kW h/ton, which is 64–72% less energy than conventional pelleting that requires energy about 350 kW h/ton for biomass drying from 30% (w.b.) to 10% (w.b.) moisture content before pelleting. Pellets produced using high-moisture pelleting met International Organization for Standardization and Pellets Fuel Institute international standards. Published 2023. This article is a U.S. Government work and is in the public domain in the USA.

09 BIOMASS FUELS↗
DOE OSTI2021

Experimental study and demonstration of pilot-scale, dry feed, oxy-coal combustion under pressure

In this paper, we discuss how pressurized oxy-combustion is a promising technology for low-carbon, fossil fuel utilization. It has the potential of improved efficiency and economics compared with conventional atmospheric pressure oxy-combustion. Washington University in St. Louis has proposed a new pressurized oxy-combustion process, namely Staged Pressurized Oxy-Combustion, which has the potential to improve further the plant efficiency, operational flexibility, and economics. This process burns pulverized coal in a pressurized, oxy-combustion environment, which has not been demonstrated in a pilot-scale system before. To address this gap, a 100 kWth pressurized oxy-combustion facility was designed and constructed. This facility has a unique burner and furnace design featuring a co-axial, low-mixing flow field, which is drastically different from conventional coal-fired boiler designs where strong mixing is sought by introducing swirl or recirculating flows. This work aims to present the first pilot-scale experimental results of a dry-feed, pressurized oxy-combustion system. The tests focused on exploring flame stability and shape, char burnout, and fine particulate matter formation. Testing results suggest that the burner has excellent flame stability. The flame shape is consistent with the design philosophy and agrees with large eddy simulations. Importantly, complete char combustion can be achieved with an oxygen mole fraction in the flue gas of only 0.8%, as opposed to a required value of ~3% for conventional atmospheric pressure air-fired or oxyfuel combustion, which reduces the costs of both oxygen generation upstream and oxygen removal downstream. The testing results show promise for dry-feed, pressurized oxy-combustion, and the new burner and furnace design.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2025

Predicting the evolution of biomass bulk density through feedstock preprocessing: Discrete element modeling, regression analysis, and pilot-scale validation

Bulk density is an important material property of biomass feedstocks, influencing handling, storage, transport costs, and conversion efficiency. In this study, predictive regression models for loose and tapped bulk densities of Alamo and Cave-in-Rock switchgrass are developed using a comprehensive dataset generated via calibrated bonded-sphere discrete element method (DEM) simulations. Here, a key contribution of this study is the use of a DEM-based approach, which correlates density with moisture content and particle size distribution parameters and enables analysis across a continuous particle size range, overcoming limitations of purely experimental data. For comparison, regression models are also developed using only experimental data from pilot-scale runs at the Biomass Feedstock National User Facility at Idaho National Laboratory. Validation against pilot-scale data showed reasonable prediction accuracy for both model types, particularly for smaller particle sizes (post-secondary grinding). While the experimental model showed slightly better performance matching the validation data in some cases, the DEM-based model benefits from a much larger dataset, reduced predictor multicollinearity, and continuous parameter coverage, highlighting the utility of validated simulation models for developing robust predictive tools for biomass preprocessing applications.

09 - BIOMASS FUELS↗
DOE OSTI2022

Fusion Pilot Plant performance and the role of a Sustained High Power Density tokamak

Recent U.S. fusion development strategy reports all recommend that the U.S. should pursue innovative science and technology to enable construction of a Fusion Pilot Plant (FPP) that produces net electricity from fusion at low capital cost. Compact tokamaks have been proposed as a means of potentially reducing the capital cost of a fusion pilot plant. However, compact steady-state tokamak FPPs face the challenge of integrating a high fraction of self-driven current with high core confinement, plasma pressure, and high divertor parallel heat flux. This integration is sufficiently challenging that a dedicated sustained-high-power-density (SHPD) tokamak facility is proposed by the U.S. community as the optimal way to close this integration gap. Performance projections for the steady-state tokamak FPP regime are presented and a preliminary SHPD device with substantial flexibility in lower aspect ratio (A=2-2.5), shaping, and divertor configuration to narrow gaps to a FPP is described.

core-edge integration↗
DOE OSTI2020

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

Polymer flooding has been validated in the lab and by successful applications in other countries, such as Canada and China, to be an effective EOR technique for heavy oil reservoirs. Currently, polymer flooding is being pilot tested for the first time in the Schrader Bluff viscous oil reservoir at Milne Point field on Alaska North Slope (ANS). One of the major concerns of the operator is the impact of polymer on the oil production system after polymer breakthrough, especially the polymer induced fouling issues in the heat exchanger. 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. A unique experimental set-up was indigenously designed and developed 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. Under each test condition, the test was run five times with the same tube, and in each run, the freshly prepared synthetic brine and polymer solution were heated from 77°F to 122°F to mimic field operating conditions. The heating time and fouling amount were recorded for each run. The morphology and composition of the deposit samples were analyzed by environmental scanning electron microscopy (ESEM) and X-ray diffraction (XRD), respectively. It has been found that, in general, 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 (165°F, 250 °F and 350°F), but 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 deposited, but above which the polymer would obviously aggravate the fouling issue. The heating efficiency of the tube would be reduced gradually as more fouling material accumulates on its surface. The ESEM results indicate that if polymer precipitated and deposited on the surface, it would bond to the mineral crystals to form a stronger three- dimensional network structure, and that is why the polymer induced fouling was tougher and more difficult to be removed from the tube surface. The XRD analysis results confirm that the presence of polymer in the fluids can enhance the mineral scale propensity. Overall, the study results have provided practical guidance to the field operator for the ongoing polymer flooding pilot test on ANS. This study may also prove to be valuable for other chemical EOR projects around the world.

Alaska North Slope↗
DOE OSTI2020

High BMEP and High Efficiency Micro-Pilot Ignition Natural Gas Engine (Final Project Report)

The project objectives were to develop demonstrate a high-efficiency high-output natural gas diesel micro-pilot stoichiometric engine operating with diesel pilot contribution of less than 5% on a medium duty engine. The program’s outcomes achieve in a partnership between Michigan Technological University and Westport Power Inc. were very successful. The engine platform was a 6.7L I6 engine with a compression ratio of 15:1 and achieved 24 bar BMEP and 41% brake thermal efficiency at lambda. Simulation and modeling with an improved turbocharger and combustion chamber improvements demonstrated a clear path to 43% BTE. The operational stoichiometric range was from 5 to 24 bar with minimal throttling. Diesel contribution over the cycle was 4.6%. The results achieved in this program are well above the best in-class baseline natural gas spark ignition engines of 19.5 bar BMEP and 40% BTE.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2021

Development of a framework for sequential Bayesian design of experiments: Application to a pilot-scale solvent-based CO 2 capture process

In this paper, a methodology is developed for sequential design of experiments (SDoE) for process systems and applied to a solvent-based CO 2 capture system. In this approach, the prior knowledge of the system is used to prioritize process data collection at specific operating conditions. These data are then incorporated into a Bayesian inference methodology for updating a stochastic model by refining estimations of its underlying parameters, and the updated model is then used to generate the next set of test runs. Thus, the new knowledge obtained from the data is used to guide subsequent iterations of the experimental runs, ensuring that the overall data collection is maximally informative given that most experimental campaigns, especially at pilot or higher-scale plants, are costly, time-consuming, and resource-limited. The test run objective for this work was to minimize the maximum model prediction uncertainty for key output variables, but the methodology is generic and can be readily applied to other test run objectives. This methodology is applied to an aqueous monoethanolamine (MEA) pilot plant campaign at the National Carbon Capture Center (NCCC) in Wilsonville, Alabama, USA. The SDoE framework was utilized for two iterations, while collecting 18 sets of data representing different process conditions, and this resulted in an overall average reduction in uncertainty of approximately 50% in the prediction of CO 2 capture percentage. Moreover, 11 additional data sets were obtained with variation of absorber packing height for further model validation. This work shows the capability of the SDoE framework to maximize learning given limited resources, allowing for the reduction of model uncertainty, which is of great importance for many applications including reduction of technical risk associated with scale-up and economic analysis.

20 FOSSIL-FUELED POWER PLANTS↗