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DOE OSTI2025

JUSTIFI: Software for Improving Performance Objectives via Energy Efficiency

With growing energy supply concerns and rising costs, energy efficiency is a critical component of industrial energy resilience and competitiveness by directly reducing energy operating costs. Energy efficiency projects in manufacturing also yield valuable benefits to other key metrics, such as improved quality, reduced maintenance costs, improved safety, decreased pollution, and enhanced productivity. However, it is difficult to receive approval for energy efficiency projects, so implementation rates are low, even when meeting capital project payback period criteria. The inclusion and quantification of non-energy benefits (NEBs) in the decision-making process for energy efficiency projects can improve the overall financial payback period while demonstrating a positive impact on the firm's key performance metrics and business strategy. Despite their significant financial and strategic value, NEBs are rarely factored into decision-making due to lack of tools to effectively identify and quantify them. Therefore, a comprehensive and integrative approach is needed for the rapidly evolving energy landscape. To address these challenges, through funding from U.S. Department of Energy, our new assessment methodology integrates common continuous improvement six sigma concepts, such as the DMAIC process, and a protocol of guiding questions, into energy efficiency assessments to identify NEBs. We have also developed open-source software, JUSTIFI, to guide users through this process, data collection, and quantification. It is designed to be used concurrently with DOE energy system analysis software suite, MEASUR. Our methodology and tools inform energy assessors, firm engineering, decision makers, and workforce seeking to increase energy resilience and to maximize benefits aligned with performance metrics.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2026

Organic Rankine Cycle Integration and Optimization for High Efficiency CHP Genset Systems (Final Technical Report)

This project successfully advanced the integration of Organic Rankine Cycle (ORC) technology with reciprocating engine–based combined heat and power (CHP) systems to improve electrical efficiency, total CHP efficiency, and grid-responsive operation. Over three budget periods, the work progressed from high-temperature ORC component development and thermodynamic model validation to next-generation system design, working fluid transition, and techno-economic analysis. Key technical accomplishments include development and validation of a thermodynamic model capable of accurately predicting ORC performance across an expanded temperature and pressure envelope; successful identification and validation of low-global-warming-potential (GWP) working fluids—most notably R1233zd(E)—as viable replacements for R245fa; and demonstration of scalable ORC architectures suitable for integration with 1–20 MW class reciprocating engines. These advances enable flexible CHP configurations that can increase electrical output while maintaining high overall utilization of available thermal energy. The project also produced a clean-sheet design for a next-generation ORC system targeting substantially higher power output per unit, supported by detailed component selection, heat exchanger evaluation, and system-level modeling. Techno-economic analyses indicate that ORC-enabled flexible CHP systems can meet or exceed Department of Energy (DOE) efficiency targets while providing value to both facility operators and the electric grid.. Late-stage testing of the largest next-generation ORC prototype identified limitations related to pump net positive suction head (NPSH) requirements and condenser flooding under certain operating conditions. Although these issues constrained full validation of that configuration within the project timeframe, they provided clear and actionable design guidance for future system refinements. Importantly, validated modeling, smaller-scale testing, and working fluid evaluations confirmed the technical viability of the overall approach. In aggregate, this project met its core objectives by establishing validated design tools, de-risking key ORC technologies for CHP applications, and defining a credible pathway toward commercialization of flexible, high-efficiency CHP systems. The results form a strong foundation for continued development and deployment beyond the conclusion of the DOE-funded effort.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2026

Machine Tool Data Analytics for Digital Twin and Machine Predictive Maintenance

The primary objective of this project is to improve machining process performance using in-process machining data from the machine tool controller and external sensors. Advances in the Industrial Internet of Things (IIoT) enable monitoring of machines using controller data. Examples of the data provided by a controller include execution status of the controller, part count, block of code being executed, door status, tool position, the spindle and axis load, etc. MTConnect and OPC-UA are the two common protocols for capturing machine information. In this collaboration, methods for retrieving the machine controller data from selected machine tool controls and making these data accessible in different subsystems (such as digital twins and machine maintenance portals, etc.) will be developed and tested. In addition, analytics to improve machining process performance (by increasing productivity and reducing downtime) will be developed.

42 ENGINEERING↗

DOE OSTI2025

Novel technology of non-contact real-time radiation damage sensors for high power targets.

This report summarizes the contributions of an intern participating in the Community College Internship (CCI) program at Fermilab, focusing on the development of a novel, non-contact, real-time radiation damage sensor technology. The core objective is to create a reliable sensor capable of measuring radiation-induced degradation on high-power targets without physical contact. The experiment involves using a Class 3B supercontinuum laser directed toward a single material sample placed within a vacuum test chamber. The laser beam reflects off the sample's surface, with changes in reflectivity, indicative of radiation damage, measured by a spectrometer positioned at the chamber’s output port. The intern’s primary responsibilities included designing an interlock system to ensure laser operational safety, developing a camera-based monitoring system using Raspberry Pi devices, and creating structural supports using 3D modeling and printing techniques. Components for the interlock and camera systems were successfully designed and ordered, with preliminary 3D models printed and refined through iterative testing. Challenges encountered in the 3D printing process, such as fragile initial prototypes and difficult support removal, were overcome by adjusting printer settings and incorporating design enhancements like chamfered edges. Future activities, pending component delivery, involve installing and configuring the interlock and camera systems, as well as further improving the structural supports. Overall, the internship significantly enhanced the intern’s technical proficiency in hardware design, software integration, and advanced 3D printing, contributing directly to Fermilab’s operational safety standards and experimental effectiveness in high-energy physics research.

Pumarino Meza, Rafael [Unlisted; Fermilab]↗

DOE OSTI2024

Relationship Between Radiation Dose and Markers of Insulin Resistance and Inflammation in Atomic Bomb Survivors

Abstract Context In recent studies of childhood cancer survivors, diabetes has been considered a late effect associated with high therapeutic doses of radiation therapy. Our recent study of atomic bomb (A-bomb) survivors also suggested an association between radiation dose and diabetes incidence, with exposure city and age at exposure as radiation dose effect modifiers. Insulin resistance mediated by systemic inflammation and abnormal body composition has been suggested as a possible primary mechanism for the incidence of diabetes after total body irradiation; however, no studies have examined low to moderate radiation exposure (<4 Gy) and insulin resistance in A-bomb survivors. Objective To examine the association between radiation dose and markers of inflammation and insulin resistance. Methods This study investigated 3152 survivors who underwent a health examination between 2008 and 2012 and who were younger than 15 years at exposure. Multivariate linear regression analyses were used to evaluate the radiation effects on levels of markers of inflammation and insulin resistance. Results Radiation dose was significantly and positively associated with levels of C-reactive protein, triglycerides, homeostasis model assessment of β-cell function (HOMA-β), and HOMA of insulin resistance (HOMA-IR) after adjustment for relevant covariates including sex, city, and age at exposure. Adiponectin and high-density lipoprotein cholesterol levels were also associated significantly and negatively with radiation dose. However, city was not a dose modifier of the radiation response on these markers of inflammation and insulin resistance. Conclusion Insulin resistance might be a possible factor in radiation-related diabetes incidence in A-bomb survivors.

Endocrinology & Metabolism↗

DOE OSTI2025

A free association semantic task for fNIRS-based perinatal depression assessment

Perinatal depression (PD) is a highly prevalent psychological disorder that has a detrimental effect on infant and maternal physical and mental health, but effective and objective assessment of PD is still insufficient. In recent years, the functional near-infrared spectroscopy (fNIRS) has been acknowledged as an effective non-invasive tool for clinical assessment of depression. This study proposed a free association semantic task (FAST) paradigm for fNIRS-based assessment of PD. To better address the emotion characteristics of PD, the participants are required to generate a dynamic concept chain based on positive, negative or neutral seed words, while 48-channel fNIRS recordings over frontal and bilateral temporal regions. Results from twenty-two late-pregnant women revealed that, the oxyhemoglobin (oxy-Hb) changes during the FAST with the positive and negative seed words over the frontal region were correlated with PD severity, which was different from the correlation patterns in the FAST with neutral seed word and the classical verbal fluency test (VFT). Furthermore, distinct correlation patterns were also observed in the FAST with the positive and negative seed words, manifested in fNIRS channels corresponding to the right dorsolateral prefrontal cortex (DLPFC) and right inferior frontal gyrus (IFG), respectively. Moreover, regression analyses showed that the FAST with positive and negative seed words can well explain the severity of PD. Our findings suggest the proposed FAST paradigm as a promising approach for PD assessment.

Chen, Danni↗

DOE OSTI2025

Experimental analysis of gas dynamics in the reactor cavity section of a High-Temperature Gas-Cooled Reactor during an accident scenario

Here, this study investigates the behavior of a High-Temperature Gas-Cooled Reactor (HTGR) during a break of the helium pressure boundary event. Understanding the gas dynamics that occur during a break could help develop safety systems that reduce the probability of air entering the reactor core. To achieve this objective, experimental studies were conducted in a scaled-down HTGR experimental facility to provide information on the air-helium gas mixture within the confinement building and the impact of the ventilation system on the helium/air gas concentration following the depressurization event. The study evaluated different configurations, including active ventilation time scales, break sizes, and locations. The analysis of the active ventilation time revealed that a ventilation time of 22 seconds produced positive results, and smaller break sizes resulted in longer depressurization times, which improved the ventilation process. The orientation and elevation of the breaks had little effect on the oxygen concentration in the cavity but did impact the gas velocities.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

Dust and Ions: Self Organization and Stability (Final Report)

This project explores the stability and structure of systems with non-reciprocal interactions, challenging the traditional understanding based on Newton's third law, which states that every action has an equal and opposite reaction. Reciprocal forces are fundamental to the stability of systems ranging in size from atomic nuclei to galactic clusters. Our research investigates what happens when the forces between two objects are not equal and opposite. We used dusty plasmas as a model system to study non-reciprocal interactions. In a plasma chamber, micron-sized dust particles acquire a negative charge and form 2D planar "dust crystals" when levitated by the electric field present in the plasma sheath at the interface between the plasma and the lower surface of the chamber. This electric field also drives a vertical ion flow, creating a positively charged "plasma wake" downstream of the dust grains. While horizontally aligned dust grains interact reciprocally, a slight vertical displacement causes non-reciprocal interactions due to the attraction of the lower dust grain to the upper dust grain’s ion wake. Our experiments investigated the range of plasma conditions (gas pressure and system power) where stable dusty plasma structures are able to self-organize, aided by the ion wake. We studied systems ranging from pairs of dust particles to large 2D crystals, providing insights into the conditions that lead to stable or unstable structures. We used numerical simulations to investigate how ion wakes changed in response to changes in the operating conditions as well as how the wakes of separate grains interact when dust grains are in close proximity.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2026

JUSTIFI: Software for Improving Performance Objectives via Energy Efficiency

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2025

Large-scale deep learning for metastasis detection in pathology reports

Objectives No existing algorithm can reliably identify metastasis from pathology reports across multiple cancer types and the entire US population. In this study, we develop a deep learning model that automatically detects patients with metastatic cancer by using pathology reports from many laboratories and of multiple cancer types. Materials and Methods We use 60 471 unstructured pathology reports from 4 Surveillance, Epidemiology, and End Results (SEER) registries. The reports were coded into 1 of 3 labels: metastasis negative, metastases positive, or metastasis undetermined. We utilize a task-specific deep neural network trained from scratch and compare its performance with a widely used large language model (LLM). Results Our deep learning architecture trained on task-specific data outperforms a general-purpose LLM, with a recall of 0.894 compared to 0.824. We quantified model uncertainty and used it to defer reports for human review. We found that retaining 72.9% of reports increased recall from 0.894 to 0.969. Discussion A smaller deep learning architecture trained on task-specific data outperforms a general LLM. Equally critical to model performance is the incorporation of uncertainty quantification, achieved here through an abstention mechanism. Conclusions This study’s finding demonstrate the feasibility of developing algorithms to automatically identify metastatic cancer cases from unstructured pathology reports.

machine learning↗

DOE OSTI2024

An Approach to Realize Generalized Optimal Motion Primitives Using Physics Informed Neural Networks

Autonomous manipulation is a challenging problem in field robotics due to uncertainty in object properties, constraints, and coupling phenomenon with robot control systems. Humans learn motion primitives over time to effectively interact with the environment. We postulate that autonomous manipulation can be enabled by basic sets of motion primitives as well, but do not necessitate mimicking human motion primitives. Here, this work presents an approach to generalized optimal motion primitives using physics-informed neural networks. Our simulated and experimental results demonstrate that optimality is notionally maintained where the mean maximum observed final position percent error was 0.564% and the average mean error for all the trajectories was 1.53%. These results indicate that notional generalization is attained using a physics-informed neural network approach that enables near optimal real-time adaptation of primitive motion profiles.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2024

Bubbler Design Updates for Nuclear Safeguards Applications

The accurate monitoring of molten salt is crucial for nuclear safeguards, particularly in the context of mixtures used in molten salt reactors and pyropocessing. To attain material accountancy in actinide bearing molten salts, fluid volume and density are needed. Previous work utilized a triple bubbler sensor to measure the fluid level and density in processing tanks. This triple bubbler system utilized three gas dip-tubes strategically positioned at different heights within the molten salt such that the molten salt level, density, and surface tension were determined simultaneously. This investigation explores the effectiveness of an updated bubbler design with larger internal diameters for the dip-tubes to reduce plugging. The findings of this study will provide valuable insights into a bubbler design and configuration for applications in nuclear safeguards. This will contribute to enhanced accountability and transparency in the monitoring of actinide bearing molten salts, promoting objectives in nuclear safeguards.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

Bubbler Design Updates for Nuclear Safeguards Application

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

Acetate as a Platform for Carbon-Negative Production of Renewable Fuels and Chemicals (Final Technical Report)

This project was an industrial-academic collaboration between experts at the University of Wisconsin-Madison, the University of Kentucky, and LanzaTech, a world leader in the use of gas fermentation to sustainably produce fuels and chemicals. The project developed technologies to create an integrated process for converting carbon dioxide and renewable hydrogen into molecules that can be blended with liquid transportation fuels or used in an array of chemical applications. The project was motivated by the Program Objectives of eliminating carbon dioxide release in the production of chemicals by integrating the unique and efficient capabilities of two microorganisms into a single process. The first microbe, an acetogen, produces acetate from carbon dioxide and hydrogen while the second microbe upgrades acetate from acetogen fermentation permeates to higher-value chemical products. The carbon dioxide released in the upgrading process is recycled internally to produce more acetate. As such, the process can be designed to operate with zero carbon dioxide release and net positive carbon dioxide capture. The process has the potential to provide an alternative paradigm to the current bioeconomy – one in which acetate is the primary energy carrier instead of sugars. Our process by-passes photosynthesis and the barriers created by biomass as primary chemical feedstock. As such, the process can be scaled to meet existing sources of carbon dioxide emissions and located anywhere renewable hydrogen can be provided. Our work developed microorganisms with optimized metabolism for producing acetate and other microorganisms with improved conversion of acetate to dodecanol and dodecyl-acetate. We developed synthetic biology tools for a promising non-model bacterium that could enhance metabolic engineering efforts to convert acetate to chemical products. We conducted protein engineering studies to improve the activity of key enzymes involved in our metabolic pathways. We conducted a full technoeconomic analysis that set technical targets for each strain to meet economic goals. We identified key technical barriers in our process and proposed strategies to overcome them.

09 BIOMASS FUELS↗

DOE OSTI2026

Assessment of BPM options for the EIC Beam Accumulator Ring

The electron injection system for the Electron-Ion Collider (EIC) at BNL is designed to provide a beam of polarized electrons, which is crucial for studying the structure of protons and atomic nuclei. The Beam Accumulator Ring (BAR) is a part of the injection chain between the 750 MeV linear accelerator and the Rapid Cycling Synchrotron (RCS), which accelerates the beam up to full energy (5–18 GeV). The functional role of the BAR is to accumulate the charge injected from the linear accelerator in order to achieve the high intensity of the polarized electron beam required by the specifications for injection into the RCS. This objective will be realized through the sequential injection of bunches with a charge of 1.1 nC at a repetition rate of 30 Hz. Once the charge of a single bunch reaches 28 nC, the beam will be extracted from the BAR and injected into the RCS. The beam instrumentation needs to provide reliable measurements with the required accuracy over the dynamic range from 0.1 nC (one tenth of a typical injected bunch charge) to 32 nC – the maximum expected accumulated current. There are 10 Beam Position Monitors (BPMs) in the ring, 1 extra button-electrode assembly for the RF system, and 8 BPMs in the beam transport lines. The BPM locations are shown in Fig. 1, marked by blue rectangles. The ring BPMs will be capable of both average orbit and turn-by-turn measurement modes. Accurate measurement of the beam position with a large horizontal offset requires polynomial correction of the BPM nonlinearity.

43 PARTICLE ACCELERATORS↗

DOE OSTI2024

Collapse of neutrino wave functions under Penrose gravitational reduction

Models of spontaneous wave function collapse have been postulated to address the measurement problem in quantum mechanics. Their primary function is to convert coherent quantum superpositions into incoherent ones, with the result that macroscopic objects cannot be placed into widely separated superpositions for observably prolonged times. Many of these processes will also lead to loss of coherence in neutrino oscillations, producing observable signatures in the flavor profile of neutrinos at long travel distances. The majority of studies of neutrino oscillation coherence to date have focused on variants of the continuous state localization model, whereby an effective decoherence strength parameter is used to model the rate of coherence loss with an assumed energy dependence. Another class of collapse models that have been proposed posit connections to the configuration of gravitational field accompanying the mass distribution associated with each wave function that is in the superposition. A particularly interesting and prescriptive model is Penrose’s description of gravitational collapse which proposes a decoherence time τ determined through E g τ ∼ ℏ , where E g is a calculable function of the Newtonian gravitational potential. Here we explore application of the Penrose collapse model to neutrino oscillations, reinterpreting previous experimental limits on neutrino decoherence in terms of this model. We identify effects associated with both spatial collapse and momentum diffusion, finding that the latter is ruled out in data from the IceCube South Pole Neutrino Observatory so long as the neutrino wave packet width at production is σ ν , x ≤ 2 × 10 − 12 m . Published by the American Physical Society 2024

Astronomy & Astrophysics↗

DOE OSTI2026

Final DOE-ASR Report for the Project “Using LASSO to bridge the gap between model and observations and to learn about atmospheric convection”

Atmospheric convection spans a wide range of spatial and temporal scales and involves complex interactions with the surrounding dynamic and thermodynamic environment, particularly over tropical continental regions. These processes remain a major source of uncertainty in weather and climate models, including persistent biases in the diurnal cycle of convective precipitation that directly affect estimates of climate sensitivity. Addressing these challenges requires the combined use of high-resolution observations and cloud-resolving modeling frameworks. In this context, the DOE Atmospheric Radiation Measurement (ARM) program’s Large-Eddy Simulation ARM Symbiotic Simulation and Observation (LASSO) activity provides a powerful platform that pairs comprehensive observations with numerical simulations to enable process-level understanding of atmospheric convection. Within this context, this Research and Development Partnership Pilot (RDPP) project was designed to initiate and expand DOE ARM/ASR research capacity at minority-serving institutions, while advancing scientific understanding of convective processes over the Amazon rainforest. Consistent with the RDPP mission, the project emphasized partnership development, training, and workforce capacity building alongside exploratory research activities. On the scientific side, the project produced two peer-reviewed journal articles, and one manuscript currently under review (see list in section 3.1). Together, these studies combine long-term ARM observations and cloud-resolving and convection-permitting modeling to investigate the environmental controls on the shallow-to-deep convective transition during the Amazon wet season. The results demonstrate the central role of early-day moisture preconditioning and large-scale dynamical forcing in regulating isolated deep convection, provide mechanistic insight into convective evolution, and establish physically informed modeling frameworks for future sensitivity experiments. These scientific outcomes are described in sections 2.1 to 2.3 and were disseminated in 8 conference presentations (see section 3.2) and 5 invited talks (see section 3.3), reflecting broad engagement with our community. Equally important, the project achieved its RDPP capacity-building objectives (see section 2.4). A sustained research partnership was established among the University of Maryland, Baltimore County (UMBC), Morgan State University (MSU), and Howard University (HU), and extended to include collaboration with Pacific Northwest National Laboratory (PNNL). The project organized multiple multi-day training events focused on ARM data, LASSO simulations, and quantitative analysis methods, directly engaging students, postdoctoral researchers, and faculty across institutions. These activities broadened participation in ASR research and led to independent adoption of LASSO workflows by students beyond the immediate project team. Finally, the project successfully positioned the participating institutions to pursue future DOE research. Preliminary scientific results, coupled with strengthened partnerships and technical capacity, enabled the submission of follow-on proposals to DOE ASR funding opportunities. In this way, the project fulfilled the RDPP goal of seeding durable research capacity and laying the foundation for larger-scale, sustained engagement with DOE ARM and ASR programs.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2024

Correlation of the L-mode density limit with edge collisionality

The "density limit'' is one of the fundamental bounds on tokamak operating space, and is commonly estimated via the empirical Greenwald scaling. This limit has garnered renewed interest in recent years as it has become clear that ITER and many tokamak pilot plant concepts must operate near or above the widely-used Greenwald limit to achieve their objectives. Evidence has also grown that the Greenwald scaling - in its remarkable simplicity - may not capture the full complexity of the disruptive density limit. In this study, we assemble a multi-machine database to quantify the effectiveness of the Greenwald limit as a predictor of the L-mode density limit and identify alternative stability metrics. We find that a two-parameter dimensionless boundary in the plasma edge, $\nu_{*\rm, edge}^{\rm limit} = 3.0 \beta_{T,{\rm edge}}^{-0.4}$, achieves significantly higher accuracy (true negative rate of 97.7\% at a true positive rate of 95\%) than the Greenwald limit (true negative rate 86.1\% at a true positive rate of 95\%) across a multi-machine dataset including metal- and carbon-wall tokamaks (AUG, C-Mod, DIII-D, and TCV). The collisionality boundary presented here can be applied for density limit avoidance in current devices and in ITER, where it can be measured and responded to in real time.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗