Removal of the Need for Boreholes for Micropile Design and Installation
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16 TIDAL AND WAVE POWER↗
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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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How To Work With the Tribe's Electric Utility To Install Electric Vehicle Charging Infrastructure
The electric utility is a crucial partner for electric vehicle (EV) charging infrastructure projects. Tribes should engage with the utility early and often for successful charging projects. This fact sheet outlines key information a Tribe needs for engagement.
33 ADVANCED PROPULSION SYSTEMS↗
Robotics for Energy Infrastructure Construction on Earth and Beyond: Pilot Study Exploring Level 3-4 Semi-Autonomous Installation of a Reduced-Scale Photovoltaic Power Plant Prototype: Preprint
There is a growing need to build energy infrastructure at massive scale on both Earth and in space. On Earth, increasing electricity demand from applications such as AI data centers is driving rapid expansion of power systems, while in space, long-duration missions such as lunar operations require reliable and resilient energy infrastructure that can be deployed quickly. These needs outpace the capabilities of conventional construction methods. Robotic construction offers a path to faster, lower-cost, and more consistent deployment, yet most existing approaches focus on automating individual tasks rather than end-to-end assembly. The Industrialized Construction Innovation (ICI) team at the National Laboratory of the Rockies (NLR), in collaboration with the Colorado School of Mines, has been investigating robotics and automation strategies for rapid end-to-end energy infrastructure construction. This paper presents a pilot study demonstrating level 3-4 semi-autonomous, end-to-end robotic assembly of a reduced-scale photovoltaic power plant prototype under terrestrial conditions. The approach combines hardware redesign of photovoltaic components for robotic compatibility, discrete-event and physics-based robotic simulations in synthetic environments, and sim-to-real deployment to execute end-to-end robotic assembly of[NM1.1][NM1.2] tracking components, structural members, photovoltaic modules, and embedded electrical connections. The pilot identifies key limitations like tolerance management, perception and localization, end effector capability, fastening methods, and multi-physics simulation fidelity, that must be addressed to enable end-to-end robotic assembly of full-scale energy infrastructure. The study highlights how these insights inform scaling strategies for terrestrial energy infrastructure and adaptation to unstructured and extreme environments, including off-world scenarios such as robotic assembly of vertical tall lunar towers.
14 SOLAR ENERGY↗
Field Validation of Thermoelectric Generation System at Holcim Cement Plant in Alpena, Michigan
Executive Summary Project Background The Industrial Technology Validation (ITV) program aims to identify and demonstrate the performance of new, emerging, and underutilized energy-saving technologies in the industrial sector to help inform decisions to help accelerate their commercialization and deployment, as well as to help make industries more competitive. This ITV demonstration evaluated a thermoelectric generation (TEG) technology at a cement plant, aiming to reduce energy demand in the cement industry. A median cement plant consumes 5.73 million British thermal units per ton of clinker production (resulting in 0.838 metric tons of carbon dioxide [CO₂] emissions per ton of clinker) (Boyd and Zhang 2011, EPA 2021), equivalent to approximately 6.9 trillion British thermal units (TBtu) per year in energy consumption at a cement plant producing 3,300 tons of clinker per day.¹ Collaborating with Holcim, Advanced Thermovoltaic Systems (ATS) developed and deployed a pilot-scale thermoelectric power system to efficiently capture and convert waste heat to electricity. The system leverages the Seebeck effect to convert temperature differences on two sides of semiconductor cartridges into electrical power (ScienceDirect, n.d.). This generation is realized with minimal moving parts compared to existing waste-heat-to-generation solutions and allows capture from heat sources with temperatures as low as 150°C. This project aimed to validate a scalable solution applicable for capturing medium-temperature waste heat, including ambient losses from other high-temperature processes, and high-temperature sources less suitable for other waste-heat-to-power solutions. By recovering this otherwise wasted heat, this project intends to validate improvements to overall process efficiency through reduction in purchased electricity, thereby reducing operational costs while enhancing resiliency and competitiveness. Description and Scope This study evaluated the performance of a TEG system from ATS as a solution to convert waste heat into useful power at a Holcim cement plant in Alpena, Michigan. This plant is a fully integrated cement plant that has been operating since 1907. The facility operates continuously (24/7/365) with approximately 250 employees and five long dry kilns, yielding a total production capacity of 7,852 tons of cement per day (EPA 2023). Currently, the Alpena plant uses waste heat boilers to convert waste heat from the exhaust of each kiln into steam, which drives steam turbine generators. The ATS TEG is being evaluated for its potential to supplement the steam turbines by capturing the remaining lower grade heat. This technology is also being considered for other Holcim plants where steam turbines are not a viable option. ATS installed a pilot-scale TEG unit with an array of 582 individual thermoelectric semiconductor cartridges, of which 573 were operational. The cartridges are sandwiched between 48 hot plates and 49 cold plates. Each cartridge is designed to generate 20 watts (W) of gross power at a hot-side temperature of 240°C and cold-side temperature of 20°C. As such, the total gross generation capacity of the installed system is 11.5 kilowatts (kW) at design conditions. The system configuration for the evaluation was designed to prioritize convenience of installation and minimize disruption to production at the site, while ensuring that the heat required can be obtained for evaluating the TEG system at various operational conditions. To accomplish this, a portion of the steam supplied to Alpena’s steam turbine generation system was diverted to be used as the heat source for the TEG system, while water was supplied to the cold side of the system from nearby Lake Huron. This configuration was designed for the evaluation of the pilot-scale system to assess the performance at different conditions. A commercial-scale system will likely vary from the pilot system depending on typical configurations, including both scale and application. Future commercial applications of the ATS system would involve integrating the system into the exhaust from kiln preheaters, clinker coolers, or radiant heat capture from kiln shells for the heat source. For the cold source, a range of cooling solutions can be considered, including a mechanical cooling system, depending on the location and the application. To increase the generation capacity for commercial applications, the technology provider is working toward developing a commercial-scale TEG system, which would combine multiple TEG units (each similar in design to the pilot system) together. The scope of this evaluation includes the pilot-scale TEG system and all impacted equipment including pumps, controllers, and power handling equipment. Study Objectives The evaluation's goal was to assess the potential of the ATS TEG system to generate useful electrical power by capturing waste heat from cement production kilns. The objectives of this study are to evaluate and verify the following claims made by ATS regarding the pilot-scale system installed at the Holcim Alpena plant. The following design parameters and claims are also outlined in Table ES- 1 and Table ES- 2: • Gross Power: The thermoelectric system converts heat into power to create gross power, the total measured power generated by the system. The 573 active cartridge pilot-scale system is expected to generate 11.5 kW of gross power at the designed hot-side temperature of 240°C and cold-side temperature of 20°C. Power production is dependent on the temperature difference between the heat source (ultimately from the waste heat) and cold temperature supply source. • Net Power: The net power is the total usable power provided to the site by the TEG system after deducting parasitic power loads from the gross generated power. Supplementary equipment is required to operate the TEG system including pumps, controllers, and, in certain anticipated applications, mechanical cooling, which introduce parasitic loads to system operation. After deducting the parasitic loads from the gross power generation, ATS anticipates achieving a net power generation of 7.5 kW from the pilot-scale system. • Thermal Efficiency: The thermal efficiency is the percent of the total heat transferred to the TEG system that is converted to gross power. Historically, TEGs have a thermal efficiency of 2%–5% (DOE 2008). Prior industrial-scale TEG systems, such as the E1 TEG offered by Alphabet Energy, operated at an efficiency of 2.5% (Lamonica, 2014). ATS anticipates achieving an average efficiency of 4.8% or higher in converting heat energy to usable electricity. • Cartridge Performance: The TEG system comprises 573 active individual semiconductor cartridges, each of which generates a portion of the total power. Cartridge optimization and selection is an important design consideration for potential future TEG system design performance. Therefore, understanding the distribution of gross power and efficiency within the pilot system is vital to understanding what is achievable. At a design hot-side temperature of 240°C and cold-side temperature of 20°C, ATS anticipates a cartridge performance of 20 W of gross power per cartridge at an efficiency of 4.8% per cartridge. In addition to evaluating the claimed performance of the TEG pilot-scale unit, the study estimated the potential annual impacts of a scaled-up commercial system used to capture kiln waste heat over annual operations. The evaluation estimated the gross and net annual electric generation achievable by capturing heat from the two proposed tap-in points: the kiln exhaust and the clinker cooler exhaust; see Section 2.1 for details. Two use cases were examined: • Holcim Alpena: The Holcim Alpena site consists of long dry kilns with superheater boilers, which differs from the rest of Holcim’s cement plant portfolio and results in lower waste heat temperatures. The study estimates gross and net annual generation using the superheater boiler exhaust and clinker cooler exhaust, based on 2023 operational data. • Typical Installation: Common cement plants have preheater kilns with higher exhaust temperatures than Holcim Alpena across a range of production rates. The study estimates gross and net annual generation using the preheater exhaust and clinker cooler exhaust, with a sensitivity analysis to account for the typical range of preheater exhaust temperatures, clinker cooler exhaust temperatures, and clinker production rates. Methodology The evaluation methodology followed a measurement and verification (M&V) strategy based on the International Performance Measurement and Verification Protocol Option B through comprehensive measurements and analyses of the affected systems. Evaluation data was collected from March 9 to March 11, 2024, the test period of the pilot TEG system. During the test period, in coordination with the ITV team, the ATS team adjusted system operations to capture the range of variability expected for each of the variables pertinent to performance of the system. The methodology consisted of two parts: evaluating the performance of the pilot unit's TEG system and estimating the annual TEG impact in terms of gross and net power based on a given waste heat profile. First, the evaluation of the thermoelectric generation performance of the pilot unit relative to the claims was performed by analyzing the collected test data. Gross power of the pilot TEG system was directly measured. Net power was determined by deducting the measured parasitic power from the gross power. The gross power generation was compared to heat transferred to the system by the working fluid (which was heated by steam generated from the kiln waste heat) to calculate the thermal efficiency achieved by the system. Performance of individual semiconductor cartridges within the pilot array was also assessed in terms of measured gross cartridge power and calculated cartridge thermal efficiency. The second part of the evaluation estimated the annual TEG impacts in terms of gross power and net power (calculated from the difference between gross power and parasitic power). This analysis comprised development of mathematical regression models for gross power and parasitic power, with assessment of each model’s goodness-of-fit characteristics to ensure satisfaction of statistical requirements. The models predicted the gross power generation, the parasitic load based on the temperature difference between the hot working fluid and the cold-side fluid (cold water from Lake Huron) entering the system, the volumetric flow rate of the cold-side fluid at the inlet, and the volumetric flow rate of the hot working fluid at the inlet. The annual impact analysis considered a theoretical commercial-scale system sized to capture the available waste heat at a cement plant, consisting of linked pilot-scale units that receive heat from a theoretical gas-to-working-fluid heat exchanger. To estimate annual impacts at the Alpena plant, the gross power and parasitic power regression models were applied to the arrays in the theoretical commercial-scale system. The heat supplied to the unit was calculated based on the kiln run time, annual production, kiln exhaust waste heat, and clinker cooler waste heat derived from 2023 Holcim Alpena kiln operational data. Net power impacts were calculated by deducting the resulting parasitic power from the estimated gross power. Inputs for the model were generated from a combination of hourly data, assumed design considerations for TEG system scale-up from the pilot-scale unit, and assumptions regarding TEG system operations. This analysis was then used as the basis for estimating annual impacts of typical TEG installation at cement plants, by applying sensitivity analyses to key kiln operational characteristics including kiln preheater exhaust temperatures, cooler clinker exhaust temperatures, and plant daily production rates across a range of expected values. Project Results/Findings Table ES- 2 and Table ES- 2 provide a summary of the operating conditions and evaluation results compared to the stated claims from the technology provider. Key takeaways include: • Gross Power: The peak gross power achieved during the testing period was 10.0 kW, compared to the 11.5 kW expected for 573 active cartridges. The claimed gross power was associated with a target hot side of 240°C; however, the system only received a maximum hot-side mean plate temperature of 212°C during the testing period. • Net Power: The pilot-scale unit exceeded the claims for net power, achieving a peak of 7.7 kW net compared to a claim of 7.5 kW. One factor contributing to the higher achieved net power is the relatively high water pressure available through Lake Huron. The pilot TEG system did not require cold-side pumps during the test, whereas most installations would. This reduced the parasitic loads on the system, ultimately contributing to higher net power relative to the gross power. • Thermal Efficiency: The pilot-scale unit outperformed the claimed efficiency, achieving a peak system efficiency of 5.0% thermal efficiency compared to the stated 4.8%. • Cartridge Performance: To compare cartridge performance against claims, the study focused on the third day of testing, which aimed for conditions closest to the design specifications, with a hot side of 240°C and cold-side exit temperature of 6.4°–30°C. On this day, the mean gross power observed in the cartridges within the TEG array was 18.1 W/cartridge, and the peak performance was 34.7 W/cartridge. The estimated mean cartridge efficiency was 5.2%, and the estimated efficiency at peak gross cartridge power was 10%. The regression models developed for gross power generation and parasitic loads were used to estimate the generation impact for given heat input to the TEG from the working fluid (captured from the waste heat) and from the cold loop (Lake Huron) on an hourly basis for a year of operation. Based on this analysis, installation of a commercial-scale TEG system at the Holcim cement plant in Alpena, Michigan, with a waste heat exchanger of 0.85 effectiveness, would generate up to 391 kW of net power, translating to between 920,000 and 1,800,000 kilowatt-hours (kWh) in net electricity per year. Based on typical grid emissions for Alpena, this would avoid estimated net emissions by 752 metric tons of CO₂ annually.² The sensitivity analysis estimated that typical TEG system installations at cement plants could generate an average of 56–1,040 kW of net power, or between 488,000 and 9,110,000 kWh of net energy. This generation potential is most significantly affected by plant production rates and also influenced by preheater and clinker cooler exhaust temperatures. Applying the national average emission rate, typical commercial-scale installations at Holcim plants are projected to avoid between 182 and 3,401 metric tons of CO₂ annually per site. Table ES- 3 shows a summary of the estimated annual impacts.³ While parasitic loads are significant and vary by application, this analysis assumed the use of heating loop pumps and access to Lake Huron as a cold sink. This setup assumed no need for cooling loop pumps due to the available water pressure at the test site. Applications that require cooling towers or additional equipment are likely to experience higher parasitic loads. Therefore, the study’s estimates are most applicable to scenarios with similar parasitic load configurations—namely, access to a high-pressure cold sink. Applicability to other locations may be limited, as differing conditions could necessitate additional pumps and cooling systems, potentially impacting performance significantly.
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
Solar Energy Extension Project
The town of Stratford plans to develop and own a 6 kilowatt (kW) solar array on the roof of a municipal-owned public pavilion on the town green. A SolarEdge level 2 EV charging station will be installed at the pavilion to be used by the public. The charging station will have one charging port. The town will install 3 air source heat pumps in the library located adjacent to the pavilion to reduce the use of propane to heat the library. The town will install 4 air source heat pumps in the Town Hall to reduce the use of #2 heating oil to heat the facility. The 6 kW solar array will provide electricity to the library to offset electricity usage, and when an EV plugs into the charging station the solar will provide electricity to the charging station. There is no ground disturbance or ground trenching associated with this project. The 6 kW solar array on the roof of the pavilion will include 20 (390) watt all black panels. A SolarEdge level 2 EV charger will be installed at the pavilion with the 240 V inverter. The solar array will provide electricity to the library and when a vehicle plugs into the EV charger the solar array will switch to power the charger. Any excess electricity that is generated by the array and not used by the library or the EV charger will be fed onto the grid and the town will receive a net metering credit applied towards future consumption. There is no ground disturbance associated with the EV charger or solar array, and the town will install signage to direct the public to the charger. The library will install 2 (18,000) BTU ductless air source heat pumps and 1 (24,000) BTU unit. This will significantly reduce the amount of propane required to heat the library. The Town Hall will install 2 (36,000) BTU ductless air source heat pumps and 2 (9,000) BTU units to reduce the amount of #2 heating oil required to heat the building.
14 SOLAR ENERGY↗
Energy Improvements of Fire Station 71
Since 2018, the City of Shawnee, Kansas has completed two phases of the State of Kansas Facility Conservation Improvement Program (FCIP), an initiative that guarantees operational cost and energy savings through targeted construction improvements on City facilities and infrastructure. The City is currently in the third phase of this FCIP, where one of the projects included an investment in energy improvements for Fire Station 71 (FS 71). The City partnered with Navitas, an Energy Service Company (ESCO), to implement a Photovoltaic Solar Array on FS71. The purpose of this project was to invest in sustainable building improvements with Energy Conservation Measures (ECM) to bring cost savings to the City and to provide sustainable benefits to the residents of Shawnee. In the first task of the project, Navitas collaborated with the City of Shawnee and the Community Development Department to determine the optimal layout and schedule for the installation of the solar array on FS 71. In the second task of the project, Navitas installed the 99.8 kW DC Photovoltaic solar array system. This system installation comprised of racking, inverters, optimizers, load center, and disconnect, which were all installed at a total ECM price of $\$$247,948. The third task focused on start-up and commissioning of the array. Navitas installed a real-time data analytics information management system integrated with utility meters, which evaluates the operations of the utility system and verifies operation of equipment and ensures optimum operation for energy efficiency. In the final task of this project, this analytics system was used for monitoring and verification, which will continue to be used to evaluate the success of the project for the coming years. The primary goal of the project was to install the 99.8 kW DC PV solar array at FS 71 to demonstrate the viability of solar energy systems in essential municipal facilities. Fire stations are energy demanding structures, as they require a constant intake of power and have a high baseline energy usage. The success of solar arrays on a fire station exemplifies their energy efficiency and effectiveness and displays their potential for application on other city facilities. By installing a solar array at such a facility, the City sought not only to offset electricity usage but also to serve as a model for ECMs in other municipal facilities and infrastructure projects. From an economic standpoint, this project demonstrates the feasibility of renewable energy at the municipal level. The total project cost of $\$$247,948 was split evenly between city funds and award funding, minimizing financial risk while ensuring guaranteed long-term savings. Any excess savings that are beyond the guaranteed minimums remain with the city, which enables future investment in sustainable energy initiatives. This project provides many benefits to the public. In addition to reducing the environmental footprint of city operations, it lowers taxpayer-funded utility spending and improves the energy security of a critical facility. The knowledge gained from this implementation motivates the City to focus on similar efforts across other public facilities in future FCIP phases and other City projects.
14 SOLAR ENERGY↗
Integration of a real-time orientation measurement system for a real-time evaluator (RTE) to measure the position and orientation of crane-lifted components
Prefabrication of building components holds the potential to revolutionize the construction industry. Prefabrication consists of manufacturing building components, modules, and other elements in a factory to be shipped and installed on a construction site. Prefabricated components have been produced for various applications including precast concrete panels for new construction and exterior wall retrofits. The manufacturing process has seen much innovation in recent years; however, the installation process has seen minimal advancements. A real-time evaluator (RTE) was developed to reduce the installation cost of prefabricated components by reducing installation time, decreasing rework, and improving accuracy. The RTE uses off-the-shelf hardware and novel algorithms to assist erectors with component installation by measuring the real-time positions of connections and prefabricated components, providing installation guidance through a graphical user interface, and monitoring the accumulated installation errors. An overview of the RTE and the proposed workflow is presented. Previous on-site demonstrations provided valuable feedback from users on the potential areas for improvement of the system. One common request was real-time measurement of component orientation during lifting, a process that previously required that the component remain stationary while the laser tracker cycled through target prisms. This paper will present the incorporation and testing of a real-time orientation measurement system as it was implemented into the RTE, allowing for measurement of component orientation during movement.
Selvakumar, Balaji [ORNL]↗
Parabolic Trough Collector Cost Update for Industrial Process Heat In The United States
Despite great potential, the worldwide adoption of concentrating solar thermal (CST) collectors for solar industrial process heat (SIPH) is modest. Industrial process heat (IPH) demands for heat and steam are typically below 300 degrees C, where CST collectors can provide the needed heat. Parabolic trough collectors (PTCs) are the most deployed CST technology for SIPH applications. This paper is focused on the United States, and a summary of known operating parabolic trough plants is shown. A previous analysis of a modern PTC in 2016 found that for SIPH applications, the installed solar field cost could be $200/m2 (2016$). Recent advances in PTC design and manufacturing have led to reduced cost per square meter of aperture area, and for a field of 510 solar collector assemblies (SCAs), the installed cost was $120/m2 (2020$). On one hand, the results from this study showed that the solar field cost for large solar fields (510 SCAs or ~804,000 m2) would increase to $184/m2 (2023$) due to post pandemic inflation and increase in metal prices. On the other hand, medium SIPH sized fields (90 SCAs or ~142,000 m2) cost analysis indicated an installed cost could be $197/m2 (2023$). When small SIPH fields (12 SCAs or ~19,000 m2) are considered, this jumps to $297/m2 (2023$). These are cost estimates for the Installed Cost of the solar fields using the United States 2023$ steel prices. When Chinese steel is used for comparison, the installed cost could be between $162 - $210/m2 for the range of SIPH sizes.
concentrating solar thermal↗
Tracking the Sun: Pricing and Design Trends for Distributed Photovoltaic Systems in the United States, 2024 Edition [Slides]
Berkeley Lab’s annual Tracking the Sun report describes trends among grid-connected, distributed solar photovoltaic (PV) and paired PV+storage systems in the United States. For the purpose of this report, distributed solar includes residential systems, roof-mounted non-residential systems, and ground-mounted systems up to 5 MW-AC. Ground-mounted systems larger than 5 MW-AC are covered in Berkeley Lab’s companion annual report, Utility-Scale Solar. The latest edition of the report is based on 3.7 million systems installed through year-end 2023, representing close to 80% of systems installed to date. The report describes and discusses key trends related to: -Project characteristics, including system size, module efficiencies, roof-coverage ratios, prevalence of paired PV with storage, use of module-level power electronics, third-party ownership, mounting configurations, panel orientation, and customer segmentation -Median installed-price trends, both nationally and by state -Variability in pricing according to system size, state, installer, equipment type, and other factors, relying on both descriptive analysis and a multi-variate regression to estimate the effects of key pricing drivers for residential systems installed in 2023.
14 SOLAR ENERGY↗
Microscopic Measurement: Need for Nuclear Material Sample Specimen Characterization Capability
The Surveillance, Fabrication, and Off-Site Operations team at Lawrence Livermore National Laboratory is beginning an update to the nuclear material machining lab in Superblock. Plutonium and other nuclear materials tend to accelerate the aging process for equipment and machines that would otherwise be maintainable for long lives. They have their lifespans shortened from deteriorated seals, embrittled polymer components, accelerated corrosion, and damage to electronics from exposure to radioactive materials. The cost of installation of equipment into a glove box (GB) tends to outstrip the cost of the equipment itself. Due to the magnification of cost, the historical approach to equipment installs has been to purchase and install the highest-quality and most robust equipment available to maximize time between failures and updates. To make room for the installation of a new lathe, the inspection GB is being moved to a different location within the machining lab. As part of the overall effort, the equipment within the inspection GB is being revisited. Current measurement capabilities are antiquated and starting to become problematic due to age. Advances in metrology are sought for more comprehensive characterization of scientific samples. This document aims to identify several options for the replacement of current measurement equipment and identify a system for purchase and eventual installation. The intention is not to select the cheapest system, but rather to identify a system that best meets the needs of both the operators and principal investigators (PI). Following the convention of the SYSM-5620 Design Thinking and System Engineering, it was determined that a laser confocal measurement system from Keyence is the most suitable option for our programmatic need. Form factor, capability, and maintainability were considered. Along with stakeholder input, to ensure the best decision for the Nuclear Material Technology Program.
36 MATERIALS SCIENCE↗
Lessons Learned: Summary of Insights From the HERO WEC and Waves to Water Deployments Between 2022 and 2024
In 2020, a team from the National Renewable Energy Laboratory (NREL) partnered with the East Carolina University Coastal Studies Institute to develop a small, modular, wave-powered point absorber desalination prototype. That prototype, known as the hydraulic and electric reverse osmosis wave energy converter (HERO WEC), was intended to de-risk the installation activities planned for the Waves to Water Prize sponsored by the Water Power Technologies Office. The NREL team was given approximately 18 months to design, build, bench test, and deploy the HERO WEC prototype. Since the initial HERO WEC development, it has been used for two in-lab test programs and three ocean deployments. The first in-lab test program focused on ensuring that the overall operation of the device occurred as expected and on validating the operation of safety systems such as pressure relief valves or electrical breakers for load mitigation. The second in-lab test program was the first time the NREL team leveraged NREL’s large-amplitude motion platform to characterize the performance of the HERO WEC. Of the three in-water deployments, the first deployment was effectively an installation and recovery practice with no meaningful wave activity during the time that it was installed. The second deployment was a 2-week effort that enabled both the electric and hydraulic configurations of the device to be in the water for approximately 5 days each. This deployment was also the first time that the team had the opportunity to perform a drivetrain swap on the Coastal Studies Institute research vessel. The third deployment had to be split into two separate installations due to minor damage incurred from the WEC spinning during the initial installation. This report summarizes the deployments, the challenges encountered with each deployment, and the lessons learned for future work.
16 TIDAL AND WAVE POWER↗
Component pose reconstruction using a single robotic total station for panelized building envelopes
The construction industry can benefit greatly from increased automation in construction processes in terms of precision, time, and labor costs. This is especially true for prefabricated construction for either new buildings or envelope retrofits. Here, prefabricated components are manufactured offsite according to design specifications and installed onsite. Accurate information on the components position and orientation (pose) is needed to achieve this. A tool named Real-Time Evaluator (RTE), designed to autonomously track prefabricated components as they are being installed and provide real-time installation instructions, is currently under development using a single robotic total station. This is challenging since at least three points are needed to determine the pose of an object in space. To achieve this goal with a single robotic total station, two key algorithms were developed: the resection algorithm aligns the digital twin with the physical twin regardless of the location of the total station, and the transformation algorithm gives instructions of translations and rotations to installers to achieve the desired installation pose. The algorithms were evaluated experimentally on a lab-scale demonstration. Results show that the resection algorithm achieved an average error of < 3.1 mm, while the transformation algorithm predicted the rotation angle along a single axis with an error of < 0.5◦.
Tang, Mengjia↗
Force-Triggered, Biobased Sealants for Prefabricated Building Components: Toward Improved Efficiency and Performance
The prefabricated building construction industry has made extensive progress in expediting the manufacture of prefabricated components at off-site plants. However, the sealing of joints between these components, which is crucial to ensuring the weatherproofing of the assembly, still represents a labor-intensive, on-site effort that relies on the manual installation of tapes and caulks. Here, to reduce work at the jobsite and improve the airtightness and waterproofness of building envelopes, we developed a sealant that can be installed at the plant on prefab components and have the curing reaction triggered at the jobsite by using microencapsulation technology to separate the reactive agents. A series of force-triggered, high-strength, and fast-curing sealants derived from biobased feedstocks were developed, which consist of a biobased epoxy agent encapsulated in a polymer shell, embedded in a biobased amine curing agent. The shell of the microcapsules allows an effective separation of the reactive species in the one-part sealant, allowing shelf stability to an otherwise fast-curing system as well as improving the hydrophobicity of the whole system. When force activates and breaks the microcapsules, the highly reactive epoxy and amine mix and cure, exhibiting peel strength values of up to 143 ppi (pounds per inch). The hydrophobicity of the sealants allows them to retain up to 94% of the original peel strength after complete submersion in water for 24 h, showcasing the water resistivity of the sealant system. The open-air shelf stability of the sealant complex is demonstrated by the obtention of peel strength values of ∼16 ppi when triggering the curing reaction even after being exposed 8 months to open air and humidity. The successful on-demand triggering of curing reactions and the shelf stability provide efficacy of these force-triggered sealants for installation on prefabricated components, storage for months prior to delivery, and assembly at a jobsite. These force-triggered biobased sealants for prefabricated buildings can result in lower installation time and cost and better performance than tapes and caulks at the jobsite.
biobased↗
Implementation of a 1550-nm laser system for beam characterization at the Argonne Wakefield Accelerator
Accurately recording an electron bunch’s longitudinal profile is an important diagnostic for wakefield accelerators employing shaped bunches to increase transformer ratios. Electro-optic sampling of terahertz radiation from the bunch is an attractive approach due to its non-destructive nature. In preparation for future characterization experiments, the Argonne Wakefield Accelerator test facility has recently installed a 1550 nm laser system, including the necessary support systems to synchronize with the photoinjector laser system at 81.25 MHz. We report here on the initial installation and synchronization demonstrations.
Ody, Alexander [Argonne, PHY]↗
Lessons from commissioning of the cryogenic system for the Short-Baseline Neutrino Detector at Fermilab
Results from commissioning and first year of operations of the cryogenic system of the Short-Baseline Neutrino Detector (SBND) and its membrane cryostat installed at the Fermi National Accelerator Laboratory are described. The SBND detector is installed in a 200 m$^3$ membrane cryostat filled with liquid argon, which serves both as target and as active media. For the correct operation of the detector, the liquid argon must be kept in very stable thermal conditions while the contamination of electronegative impurities must be consistently kept at the level of small fractions of parts per billion. The detector is operated in Booster Neutrino Beams (BNB) at Fermilab for the search of sterile neutrinos and measurements of neutrino-argon cross sections. The cryostat and the cryogenic systems also serve as prototypes for the much larger equipment to be used for the LBNF/DUNE experiment. Since its installation in 2018-2023 and cooldown in spring of 2024, the cryostat and the cryogenic system have been commissioned to support the detector operations. The lessons learned through installation, testing, commissioning, cooldown, and initial operations are described.
43 PARTICLE ACCELERATORS↗
An Operations and Maintenance Roadmap for U.S. Offshore Wind: Enabling a Cost-Effective and Sustainable U.S. Offshore Wind Energy Industry Through Innovative Operations and Maintenance
The United States is currently targeting 30GW of offshore wind to be installed by 2030, and 150GW by 2050. Even considering future turbine sizes, this represents thousands of new turbines installed in a diverse set of environments, each with their unique design, installation, and maintenance challenges. While much can be learned from European and Asian experience with offshore wind over the past two decades, it is important to understand the unique circumstances of the U.S. This document explores operations and maintenance of offshore wind energy, specific to the U.S. and attempts to lay out a roadmap for needed activities to ensure reliability of future installations. The roadmap was informed through dozens of interviews with a wide cross-section of the industry, including representatives from OEMs, owner/operators, service companies, certification agencies, service providers, and researchers. The roadmap first describes the problem by component - blades, drivetrain and nacelle, structures and foundations, and electrical systems - through a look at current practices and opportunities for improvement in the areas of Failure Mode Analysis and Mitigation; Monitoring, Sensing, and Inspection; and Maintenance Execution. Crosscutting areas of Digitalization, Robotics and Automation, Prognostics and Health Management and O&M Optimization, Experimentation and Demonstration, Standardization, and Design Optimization Considering Reliability and O&M are then discussed. Finally, the roadmap summarizes all of these topics with recommendations for short (1-3 years), medium (4-7 years), and long term (8-12 years) activities, with a description of needed public and private sector contributions.
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Kansas City, Missouri, Streetlight Electric Vehicle Charging: Strategies and challenges for site selection of streetlight electric vehicle infrastructure in Kansas City, Missouri (Final Report)
Public streetlight charging, whether on streets in central business districts or residential areas, provides easy charging access for apartment residents and homeowners alike. While most electric vehicle (EV) drivers charge at home, they do so in garages or on driveways they own. For renters and residents of multifamily housing (MFH), however, this may not be an option. EVs have a lower cost of ownership compared to conventional vehicles, and a used EV may be an affordable option for a lower-income household. But without easy access to charging, even a low-cost used EV may not be an option for a prospective buyer. An affordable curbside charging network has the potential to expand EV adoption into neighborhoods that have to date seen minimal interest and uptake of the technology and associated charging infrastructure. Streetlight charging networks can provide an economical, scalable, and effective approach to providing equitable and convenient charging. Metropolitan Energy Center (MEC) is dedicated to the mission of creating resource efficiency, environmental health, and economic vitality in the Kansas City region and beyond. Since 1983, MEC has provided resources, outreach, and training to make alternative fuels and energy efficiency commonplace. MEC led a streetlight charging pilot project that installed limited EV charging infrastructure on the streetlight system in Kansas City, Missouri, to demonstrate and test the benefits of curbside charging for EVs at existing on-street parking locations. The project aimed to cost-effectively expand the charging network in Kansas City to support residential charging and provide infrastructure in one or more charging deserts throughout the city. This pilot evaluates the impact and overall success of streetlight charging based on community feedback, utilization of charging infrastructure, technical feasibility, and cost. The project has pursued a data- and community-driven site selection process designed to identify sites with high demand and high opportunity for EV charging. This project was funded by the U.S. Department of Energy (DOE) and awarded to MEC through a competitive proposal process. The novelty and complexity of this project required an organization that could facilitate collaboration across levels of government, community members, and industry partners. For the past 25 years, through Kansas City Regional Clean Cities, MEC has worked with numerous public and private fleets on a variety of projects to improve the environmental performance and efficiency of the regional vehicle fleet. To advance affordable, efficient, and clean transportation efforts, DOE Clean Cities and Communities coalitions create local networks of public and private sector stakeholders and engage communities. Rooted within their local communities, the coalitions serve as experts and ambassadors, bringing to bear the collective knowledge, experience, and practical know-how of the entire network from within DOE, its national laboratories, and diverse stakeholders in the field. MEC and its project partners made in-kind contributions to leverage federal dollars for the benefit of the Kansas City community. Findings from this project will help determine the best applications for streetlight charging technologies to maximize funding impact and serve community needs. The team evaluated locations based on expected charging demand, technical feasibility, safety considerations, and enhanced charging network siting needs. Throughout the project, the team gathered feedback and evaluated ways to make public charging for EVs available to all community members. The insights will help Kansas City and other communities streamline future efforts to support EV drivers through public charging in the city right-of-way. Furthermore, this project will inform citywide guidance for future installations. MEC is committed to a transparent and publicly accessible approach that encourages the collaborative evaluation of streetlight charging. The project has engaged the community to proactively identify and evaluate the benefits and impacts of streetlight charging. It was a priority for the project to ensure the benefits of this pilot are distributed equitably to all members of the Kansas City community and that new charging opportunities and associated resources are available in diverse neighborhoods across the city. The charging infrastructure supports an affordable curbside charging network that will enable more drivers to choose EVs and provide easy charging access for all community members interested in driving an EV. The community feedback received through this project informed future resources and opportunities to make EVs more accessible to all members of the Kansas City community. MEC worked with several community partners on this project, including Missouri University of Science and Technology (MST), Pennsylvania State University (Penn State), the National Renewable Energy Laboratory (NREL); the city of Kansas City, Missouri; Evergy; Black and McDonald (B&M); LilyPad EV; EVNoire; and Westside Housing Organization (WHO). Project partners contributed to the cost match required for DOE grants through capital expenditures, personnel, and other in-kind contributions. Detailed descriptions of project team organizations can be found in Appendix A. Project Partners. Analysts at NREL and MST/PennState developed site maps based on demand and equity considerations. MEC conducted outreach to community members to garner input on project design and site selection, and received approval from the Missouri Public Service Commission (PSC) for Evergy’s EV charging station ownership. MEC worked with all partners to gather additional siting criteria and developed a site selection evaluation checklist, and partners conducted site visits to proposed installation sites. Next, B&M, Evergy, and the city executed all site agreements, conducted site-specific engineering design, acquired associated permits, and issued notices to proceed site by site or in small batches. Finally, from January to April 2023, the project team installed 23 EV charging stations built on Kansas City’s streetlight system in six council districts. Evergy will own, operate, and monitor the stations for 10 years, sharing charging data with MEC for at least 1 year.
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
Cost of Wind Energy Review: 2024 Edition [Slides]
The primary elements of this analysis include: Estimated LCOE for (1) a representative land-based wind energy project installed in a moderate wind resource in the United States, (2) a representative fixed-bottom offshore wind energy project installed in the U.S. North Atlantic, and (3) a representative floating offshore wind energy project installed off the U.S. Pacific Coast. It also updates the LCOE estimates for representative residential-, commercial-, and large-scale distributed wind projects installed in a moderate wind resource in the United States. A sensitivity analyses is included that shows the range of effects that basic LCOE variables could have on the cost of wind energy for land-based and offshore wind projects and provides updated Fiscal Year 2024 values for land-based and offshore wind energy used for Government Performance and Results Act (GPRA) reporting and illustrated progress toward established GPRA targets.
17 WIND ENERGY↗