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At least 109 records · Page 6

Towards the Flexibility of HVDC-Interconnected Systems: A Novel Emergency Freqeuncy Response Model

In this paper, we propose a novel multi-time scale emergency frequency response model by unlocking the flexibility of High Voltage Direct Current (HVDC) systems. Unlike assigning power ramping rates for FACTS to regulate frequency in traditional methods, this paper designs a step-change electromagnetic power frequency response (EPFR) scheme, by leveraging the temporal over/under DC voltage capability of HVDC. Wherein the Kullback-Leibler Divergence is adopted to convexify the modified swing equation after integrating the step-change power. Further, to avoid the complicated differential equations, we equivalently reformulate the duration limits of DC voltage deviation into the HVDC decreasing power ramping rates, which participate in the system primary frequency response. Finally, the new steady-state operation level of HVDC is involved with the secondary frequency response. As a result, an improved three-level algorithm is developed to solve the model, wherein the instant step-change, primary, and secondary frequency response are coordinated together. After applying the proposed frequency response scheme on the test system, the EPFR is validated to effectively provide the most instantaneous supports when faced with bulk power loss due to extreme contingencies, and the resilience is ensured within acceptable expenditures.

Jiang, Sufan↗

STOCHASTIC OPTIMIZATION FOR LONG TERM CAPITAL STRUCTURES, SYSTEMS, AND COMPONENTS REFURBISHMENT AND REPLACEMENT

As commercial nuclear power plants (NPPs) pursue extended plant operations in the form of Second License Renewals (SLRs), opportunities exist for these plants to provide capital investments to ensure long-term, safe, and economic performance. Several utilities have already announced their intention to pursue extended operations for one or more of their NPPs via SLR2. The goal of this research is to develop a riskinformed approach to evaluate and prioritize plant capital investments made in preparation for, and during the period of, extended plant operations to support decisions in NPP operations. In order to prioritize project selection via a riskinformed approach we developed a single decision-making tool that integrates safety/reliability, cost, and stochastic optimization models to provide users with data analysis capabilities to more cost effectively manage plant assets. Both stochastic analysis methods—such as Monte Carlo-based sampling strategies—and multi-stage stochastic optimization strategies are employed to provide priority lists to decisionmakers in support of risk-informed decisions. We applied the proposed method to a trial application of projected replacement/refurbishment expenditures for plant capital assets (i.e., Structures, Systems, and Components [SSCs]). The objective is to optimize the SSC replacement/refurbishment schedule in terms of economic constraints, data uncertainties, and SSC reliability data, as well to generate a priority list for maximizing returns on investment.

42 ENGINEERING↗

SSRS (Stochastic Soaring Raptor Simulator)

SSRS (Stochastic Soaring Raptor Simulator) is a generalizable, probabilistic, and predictive tool for wind energy developers, ecologists, wildlife managers and industry consultants to estimate the potential for soaring raptors to interact with operating wind turbines, without the need for site-specific data collection. Rapid expansion of wind energy development across the world has exposed the risk of turbine collisions for birds and bats. The risk to obligate soaring raptors such as golden eagles is of particular concern due to their small population and influence on ecological balance. Golden eagles rely heavily on updrafts to subsidize their flight, putting them in direct conflict with operational wind turbines that utilize the same wind resource. Understanding the behavior of soaring raptors with varying atmospheric conditions is crucial for predicting and mitigating the risk of turbine collision. This software contains a predictive movement model that simulates individual flight paths of golden eagles during updraft-subsidized long-distance flight, including migration. For a given set of atmospheric conditions, the model simulates thousands of eagles at turbine-scale spatial resolution (50m) to produce a relative presence density map. The simulated eagles rely on updrafts to pursue uninterrupted directional flight with minimal energy expenditure, following fluid-flow principles. The simulator includes a stochastic model of eagle behavior and a systematic method of accounting for spatiotemporal variations in atmospheric conditions. This framework only requires publicly available atmospheric data to estimate orographic and thermal updrafts, ensuring general usability.

Sandhu, Rimple↗

Disaggregating Future Retail Electricity Rate Growth [Slides]

Recent Berkeley Lab research found that modest retail rate increases over the past 10 years were mostly driven by large increases in capital expenditures (CapEx) that were offset in part by substantial wholesale price reductions. Decision-makers are increasingly concerned about the potential future rate impacts of a number of policies and industry trends that support rapid decarbonization, electrification, and grid modernization. Using historical FERC Form 1 data and the existing literature on policies and industry trends that are likely to affect utility-incurred costs and retail sales, Berkeley Lab researchers developed ranges of forecasted growth rates for cost-related rate drivers (i.e., fuel and purchased power; transmission, distribution, generation, and other categories of both non-fuel operations & maintenance and CapEx) and non-cost related rate drivers (i.e., retail sales, peak demand, and customers). These were then used as inputs to a pro-forma utility financial model (FINDER) that estimated the growth in retail electric rates between 2020 and 2030 for a prototypical vertically-integrated investor-owned utility in the United States. The analysis produced the following results: 1. Assuming average growth rates in all rate drivers, future retail rate growth is driven by sizable increases in all CapEx costs, where fuel and purchased power costs are replaced by generation CapEx as the largest rate component between 2020 and 2030. 2. Growth in sales/peak demand/customers, generation CapEx costs, and fuel and purchased power (FPP) costs, in isolation, produce the most uncertainty in rate growth. Specifically, a 1% increase in the compound annual growth rate (CAGR) of retail sales, coincident peak demand (CP), and customers (Sales-CP-Cust) results in a 0.88-0.93% decrease in the CAGR of rates, in isolation. However, a 1% increase in the CAGR of generation CapEx budgets results in a 0.07-0.14% increase in the CAGR of rates, while a 1% increase in the CAGR of FPP costs causes a 0.10-0.14% increase in the CAGR of rates, all else being equal. 3. Taking into account the correlation and variability of the growth in all rate drivers jointly, generation CapEx is expected to be both the largest and most uncertain rate component by 2030 (20-25% share of the retail rate). Transmission and distribution CapEx, along with fuel and purchased power costs are each expected to comprise between 12% and 17% of retail rates.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Uplifting winds: The surprisingly positive community-wide impact of wind energy installations on property values

A primary concern of stakeholders when considering a new wind project is the potential negative effects wind turbines may have on home values. Yet, what has been surprisingly overlooked in the literature and general discourse around wind energy is that the well-researched positive economic development and fiscal and amenity benefits of wind energy (e.g., increased tax base, tax revenue, better public services and employment gains) might positively affect jurisdiction-wide housing values. With a focus on school districts in the United States, we compare home values in school districts with wind energy installations, before and after a wind energy installation becomes operational, to home values in other school districts located in the same county but without a wind energy installation to provide some of the first causal evidence on the relationship between wind energy projects and district-wide property values. We find that wind projects lead to economically meaningful increases in district-wide housing values of approximately 3 %, when those values are compared to similar homes located in school districts in same-county without wind energy. The effect is strongly correlated with wind project size. The mechanisms, our research suggests, are likely related to relatively large increases in school district per-pupil revenues and expenditures, which are also correlated with wind project size. We suggest other possible mechanisms for the increased values as well.

Attitudes↗

Feasibility and Prospects of the High Resolution Rapid Refresh Model For Dynamic Line Rating

The ampacity of transmission lines is defined as the maximum amount of current the conductor can safely carry. It is necessary for transmission line operators to apply ampacity limits due to the thermal properties of the conductor. Dynamic Line Rating (DLR) is a technology and technique that uses the environmental conditions or a set of the conditions to calculate the ampacity of the conductor. The way the DLR is calculated has depended upon some amount of physical technology to implement the solution. The High Resolution Rapid Refresh (HRRR) Model is an atmospheric model that may provide enough resolution to perform dynamic line rating without any hardware at all. The objective is to use this model to perform Dynamic Line Rating. This will solve two of the most pervasive problems in Dynamic Line Rating, how to instrument a transmission line hundreds of miles long and then how to predict near future ampacity sufficient for transmission operators to effectively use, This technique will use the Idaho National Laboratory site as the test location for analysis. The High Resolution Rapid Refresh model is a reliable, freely available, and well-maintained weather forecasting model for the entire United States of America. The model provides enough special resolution that additional local weather monitoring devices at location are not necessary to conduct dynamic line rating. The HRRR ratings are lower on average than the locally measured ratings which allows for an additional margin of safety. The adoption of using purely digital methods for dynamic line rating could allow for wide scale adoption of the technology with very little overhead expenditure of implementation.

17 WIND ENERGY↗

Techno-Economic Analysis and Optimization of a Compressed-Air Energy Storage System Integrated with a Natural Gas Combined-Cycle Plant

To address the rising electricity demand and greenhouse gas concentration in the environment, considerable effort is being carried out across the globe on installing and operating renewable energy sources. However, the renewable energy production is affected by diurnal and seasonal variability. To ensure that the electric grid remains reliable and resilient even for the high penetration of renewables into the grid, various types of energy storage systems are being investigated. In this paper, a compressed-air energy storage (CAES) system integrated with a natural gas combined-cycle (NGCC) power plant is investigated where air is extracted from the gas turbine compressor or injected back into the gas turbine combustor when it is optimal to do so. First-principles dynamic models of the NGCC plant and CAES are developed along with the development of an economic model. The dynamic optimization of the integrated system is undertaken in the Python/Pyomo platform for maximizing the net present value (NPV). NPV optimization is undertaken for 14 regions/cases considering year-long locational marginal price (LMP) data with a 1 h interval. Design variables such as the storage capacity and storage pressure, as well as the operating variables such as the power plant load, air injection rate, and air extraction rate, are optimized. Results show that the integrated CAES system has a higher NPV than the NGCC-only system for all 14 regions, thus indicating the potential deployment of the integrated system under the assumption of the availability of caverns in close proximity to the NGCC plant. The levelized cost of storage is found to be in the range of 136–145 $/MWh. Roundtrip efficiency is found to be between 74.6–82.5%. A sensitivity study with respect to LMP shows that the LMP profile has a significant impact on the extent of air injection/extraction while capital expenditure reduction has a negligible effect.

25 ENERGY STORAGE↗

Integration of renewable energy generation and storage systems for emissions reduction in an islanded campus microgrid

Microgrid connected building communities are projected to play an integral part in the clean energy transition. These types of systems, when integrated with distributed energy resources (DERs) such as combined heat and power (CHP), district heating and cooling, renewable generation, and energy storage, can provide clean, reliable power to critical facilities and vulnerable communities. The intermittent nature of renewable generation is a challenge when integrating renewables into any grid system, but particularly in islanded microgrids. The University of Texas at Austin (UT) operates an islanded microgrid powered by a CHP plant, while also utilizing district heating and cooling systems and thermal energy storage (TES). High fidelity operating data was used to develop a validated reduced order model of UT’s integrated campus energy systems to serve as a testbed for use in a case study. Hypothetical renewable energy installations on land owned by UT in west Texas were modeled and integrated into the validated campus models along with battery energy storage (BES). Simulations showed that a combination of renewable energy from wind, and optimally controlled 24-hour thermal and battery storage systems could reduce carbon dioxide emissions on campus by 45.4%. The additional retrofit of burner systems to utilize hydrogen natural gas blends resulted in an overall annual emissions reduction of 54.7%. Carbon capture and storage eliminated the majority of the remaining emissions with increased plant energy expenditure. The presented simulations display the practical limitations of a CHP system complemented by renewable generation and short-term storage in eliminating emissions. Furthermore, results highlight the need for further research and development in long duration storage technologies and hydrogen fueled turbines to increase penetration of renewable energy and reduce emissions.

CHP↗

Slot-die-coating operability windows for polymer electrolyte membrane fuel cell cathode catalyst layers

Roll-to-roll (R2R) slot-die coating of polymer electrolyte membrane fuel cell (PEMFC) catalyst layers represents a scalable deposition method for producing 10–20 m 2 ·min -1 of catalyst-coated gas diffusion layers (GDLs). This high-throughput production technique will help lower the cost of PEMFC catalyst layers. The uniformity of the wet layer applied by slot die deposition is affected by process parameters such as substrate speed, vacuum pressure applied at the upstream meniscus, gap between the slot die lips and substrate, ink rheology, and other ink and substrate properties. The set of conditions for producing a defect-free coating with a dilute ink typically requires little to no upstream vacuum pressure, so suitable operating conditions can be found easily through trial and error and operator intuition. However, the higher viscosity of more concentrated inks dramatically shifts the range of settings that result in a homogeneous coating to higher vacuum levels, which are harder to find through hit or miss. A predictive model showing the range of operable conditions decreases material wastage inherent in experimentally searching for suitable parameters. In this study, the defect-free coating parameter window is explored experimentally and theoretically for two concentrations of PEFC cathode inks. Both a full capillary hydrodynamic model and a computationally cheaper viscocapillary model successfully predict the experimentally determined coating window within the experimental and model uncertainty limits for inks with 5.3 wt% and 12.0 wt% solids ink while maintaining the 0.1 mg Pt ·cm -2 Pt areal loading target. Here, this paper demonstrates a viable pathway for meeting the $30/kW net ultimate cost target of the United States Department of Energy (U.S. DOE) Hydrogen Fuel Cells Technologies Office (HFTO). The concentrated ink lowers the thermal energy and capital expenditure (CapEx) budget of the coating process by decreasing the amount of time, energy, and floorspace required for drying the coating.

25 ENERGY STORAGE↗

Achieving high ethylene yield in non-oxidative ethane dehydrogenation

Steam cracking of ethane, a non-catalytic thermochemical process, remains the dominant means of ethylene production. The severe reaction conditions and energy expenditure involved in this process incentivize the search for alternative reaction pathways and reactor designs which maximize ethylene yield while minimizing cost and energy input. Herein, we report a comparison of catalytic and non-catalytic non-oxidative dehydrogenation of ethane. We achieve ethylene yields as high as 67 % with an open tube quartz reactor without the use of a catalyst at residence times ~4 s. The open tube reactor design promotes simplicity, low cost, and negligible coke formation. Pristine quartz tubes were most effective, since coke formation was detected when defects were introduced by scratching the surface of the quartz. Surprisingly, the addition of solids to the quartz tube, such as quartz sand, alumina powder, or even Pt-based intermetallic catalysts, led to lower ethylene yield. Pt alloy catalysts are effective at lower temperatures, such as at 575 °C, but conversion is limited due to thermodynamic constraints. When operated at industrially relevant temperatures, such as 700 °C and above, these catalysts were not stable in our tests, causing ethylene yield to drop below that of the open tube. Furthermore, these results suggest that future research on non-oxidative dehydrogenation should be directed at optimizing reactor designs to improve the conversion of ethane to ethylene, since this approach shows promise for decentralized production of ethylene from natural gas deposits.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

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↗

University Coalition for Fossil Fuel Energy Research

Following a nationwide open competition, the University Coalition for Fossil Energy Research (UCFER) was established in October 2015 through a cooperative agreement between Penn State and the Department of Energy (DOE) National Energy Technology Laboratory (NETL). Penn State lead UCFER with the objective of advancing basic and applied research for clean and low-carbon energy based on fossil fuels in support of the DOE’s mission. UCFER focused on research that improves the efficiency of production and use of fossil energy resources, while minimizing the environmental impacts and reducing greenhouse gas emissions. Penn State lead a team of nine universities (Massachusetts Institute of Technology, The Pennsylvania State University, Princeton University, Texas A&M University, University of Kentucky, University of Southern California, The University of Tulsa, University of Wyoming, and Virginia Polytechnic and State University) during the competition stage, adding seven more universities in 2017 (Carnegie Mellon University, Louisiana State University, The Ohio State University, University of North Dakota, University of Pittsburgh, University of Utah, and West Virginia University). This Coalition exhibited a wide geographical distribution across the U.S. bringing a wide variety of fossil energy expertise. This national university alliance was a major collaborative effort with NETL to address specific topics of R&D in NETL’s mission area, which involved one or more of NETL’s five core competencies (Geologic and Environmental Systems, Materials Engineering and Manufacturing, Energy Conversion Engineering, Systems Engineering and Analysis, and Computational Science and Engineering). The first five to six months of the project was the definitization stage. During this period, Penn State worked closely with NETL to finalize the Coalition organizational structure and By- Laws, prepare a statement of substantial involvement and a statement of project objectives, and develop operations and membership plans. A major component of this stage included preparing an execution plan to solicit research, evaluate proposals, recommend selected projects to NETL, and award projects. In addition, a plan was prepared to monitor projects, review projects, disseminate knowledge from research projects and develop an online system for Coalition research portfolio management. This included developing a website and several databases. The first of six rounds of solicitations started in mid-2016. Projects from the sixth solicitation started February 1, 2021, and ended January 31, 2023. Projects that were selected represented twelve technology lines. Approximately $16.6 million in funding was available for the six solicitations. Most of the funding was provided by DOE, Office of Fossil Energy (DOEFE) with the DOE Fuel Cells Technologies Office (DOE-FCTO) providing funding for a few projects. Coalition universities submitted 259 proposals in response to the solicitations, requesting approximately $67.0 million in funding, and forty-three projects were selected. However, one project withdrew after the principal investigator left the university. The management of the Coalition projects was a major activity by Penn State. Managing the Coalition projects consisted of monitoring the projects, reviewing the projects through annual technical review meetings, disseminating knowledge from the research projects, and developing an online system for Coalition research portfolio management. Penn State’s OMT monitored projects to ensure that all milestones (technical, schedule, budget) were met, expenditures were allowable, cost share (when applicable) were reported, and all technical reports were submitted. The OMT also posted the technical reports electronically on a secure members-only website for access and review by the Coalition members. Disseminating knowledge from the research projects was done through a website, newsletters, various meetings, conferences, journal articles, publicity/press releases, and project summaries that were prepared after each project was completed. Penn State kept NETL apprised of UCFER progress through quarterly reports (thirtyone were submitted by Penn State), verbal and written communications, yearly updates at the annual technical review meetings, and cost accrual reports. The UCFER project had a significant impacty. The UCFER program established the first national university alliance in fossil energy research with a major collaboration effort with DOE NETL that addressed specific topics in NETL’s research and development mission areas. It generated inter-university collaborations, which was another program interest. Twenty-two out of 259 proposals contained collaborations (≈8.5%) and three of forty-two funded projects involved inter-university collaborations (≈7.0%). The forty-two funded projects provided support at fourteen universities involving 269 personnel. Research was conducted by 106 faculty, 115 graduate and undergraduate students, forty-six research staff and post-doctoral scholars, and two visiting scholars. Students and post-doctoral scholars were also on-site at NETL through CRADAs. In addition, non-Coalition participants included six universities and sixteen companies and national laboratories. The non-Coalition participants were involved as subcontractors, providers of cost share, performed unpaid consultation and sample analysis, served as advisory board members, or were providers of samples and materials for testing. UCFER also produced visibility in that fifty-six refereed journal articles were published, fifty-seven conference papers and twenty-three posters were prepared, 190 presentations were given, eight patent applications were filed, two books/book chapters were written, and ten software codes were developed. Collaboration between NETL and the individual projects was a major requirement for all funded projects. This included NETL staff time to support collaboration, consultation, technical guidance, sample preparation and analysis, internships at NETL, on-site testing and equipment usage by Coalition participants at NETL, co-mentoring students, and coauthoring journal articles and conference papers. Collaboration was impacted by COVID-19 in that not all on-site activities could be performed. NETL personnel were coauthors on eight of the conference papers (fourteen percent of the conference papers that were prepared) and seventeen of the journal articles (thirty percent of the journal articles that were prepared). A website was developed for an online proposal solicitation and review process and to provide exposure to UCFER. A website analysis highlighted the large amount of member and general public interest in UCFER by interpreting access statistics from March 2016 through June 2023. Visitors to the site originated from many different organizations, businesses, and countries. The website provided a means to disseminate information to both the general public and the UCFER members and was successfully used for outreach activities. In addition, NETL required that RFP release, proposal submission, and proposal reviews all be performed online. Penn State successfully developed these capabilities in a secure section of the website, which were used throughout the UCFER project. It is recognized that each project had its technical successes. In addition, highlighted successes were compiled and summarized from the research projects. Information was requested from the PIs of completed projects. In addition, Penn State’s Operations Management Team reviewed subcontract reports to identify project successes. Examples of information requested from PIs included (not all-inclusive): new projects that have been funded as a result of UCFER funding; new commercial products; establishment of a new center; new patent; new software; best paper awards; highly-cited work; and graduate student successes. A total of forty-eight highlighted successes were reported.

01 COAL, LIGNITE, AND PEAT↗

Medium- and heavy-duty value of technology improvement

Improvements in vehicle technology impact the purchase price of a vehicle and its operating cost. In this study, the monetary benefit of a technology improvement includes the potential reduction in vehicle price from using cheaper or smaller components, as well as the discounted value of the fuel cost savings. As technology progresses over time, the value and benefit of improving technology varies as well. In this study, the value of improving a few selected technologies (battery energy density, electric drive efficiency, tire rolling resistance, aerodynamics, light weighting) is studied and the value of the associated cost saving is quantified. The change in saving as a function of time, powertrain selection and vehicle type is also quantified. For example, a 10% reduction in aerodynamic losses is worth $24,222 today but only $8,810 in 2030 in an electric long haul truck. The decrease in value is primarily due to expected battery cost reduction over time. The same loss reduction in a 2030 conventional long haul truck is worth $5,117 and is primarily driven by a reduction in diesel expenditure. For conventional vehicles, the value of technology improvement is likely to increase over time as diesel price is expected to increase over the next decades while for electric vehicles, the value of technology improvement is likely to decrease as battery energy density increases and cost decreases. The study focuses on medium- and heavy-duty applications where cost of driving is of paramount importance. The savings realized from each technology improvement serve as an upper limit for how much can be spent to acquire that improvement in technology.

Freyermuth, Vincent↗

Evaluating alternative steam generation pathways in the food industry

Steam generation in the food sector requires substantial energy and cost expenditures, requiring nearly half of its energy intake. Here, we used life cycle assessment and life cycle cost assessment to investigate the cost and energy impacts of steam generating alternatives: NG, biomass and hydrogen boilers and grid-supplied and self-generated electric steam generation systems (electric boilers, renewable thermal energy storage and industrial heat pumps). The analysis starts with a set of average U.S. conditions, where biomass boilers are the most cost-competitive alternative to NG. In a series of scenarios beyond average conditions, the analysis shows energy procurement costs dominate the total life cycle cost for all technologies and, unfortunately, are highly variable geographically and temporally, significantly affecting the viability of the alternatives. Results show that site-energy consumption ranges from 0.3 MMBtu/klb for industrial heat pumps to 1.6 MMBtu/klb for biomass boilers, with heat pumps achieving up to 78% lower energy use compared to natural gas systems. For the steam costs, the results show a range between $\$$8 and $\$$50/klb for NG, with biomass following closely ($\$$11 – $\$$44/klb) and grey hydrogen and IHP next ($\$$13 – $\$$33/klb and $\$$6 - $\$$78/klb), with cost reductions if IHP's cooling is utilized. Factors like operating hours, the need for cooling, and the ability to negotiate utility rates complicate the decision, making site-specific analyses critical. Therefore, we present a decision-making matrix to help manufacturers identify which steam generating technology is the best business decision for their situation. Overall, these results highlight the importance of steam generation for the facility's organizational goals, as well as the criticality of conducting individual site analyses.

Biomass boilers↗

2023 Annual Report of Available Drawdowns for Each Oil Storage Cavern in the Strategic Petroleum Reserve

DOE maintains an up-to-date documentation of the number of available full drawdowns of each of the caverns at the U.S. Strategic Petroleum Reserve (SPR). This information is important for assessing the SPR’s ability to deliver oil to domestic oil companies expeditiously if national or world events dictate a rapid sale and deployment of the oil reserves. Sandia was directed to develop and implement a process to continuously assess and report the evolution of drawdown capacity, the subject of this report. This report covers impacts on drawdown availability due to SPR operations during Calendar Year 2022. A cavern has an available drawdown if, after that drawdown, the long-term stability of the cavern, the cavern field, or the oil quality are not compromised. Thus, determining the number of available drawdowns requires the consideration of several factors regarding cavern and wellbore integrity and stability, including stress states caused by cavern geometry and operations, salt damage caused by dilatant and tensile stresses, the effect of enhanced creep on wellbore integrity, and the sympathetic stress effect of operations on neighboring caverns. Finite-element geomechanical models have been used to determine the stress states in the pillars following successive drawdowns. By computing the tensile and dilatant stresses in the salt, areas of potential structural instability can be identified that may represent red flags for additional drawdowns. These analyses have found that many caverns will maintain structural integrity even when grown via drawdowns to dimensions resulting in a pillar-to-diameter ratio of less than 1.0. The analyses have also confirmed that certain caverns should only be completely drawn down one time. As the SPR caverns are utilized and partial drawdowns are performed to remove oil from the caverns (e.g., for oil sales, purchases, or exchanges authorized by the Congress or the President), the changes to the cavern caused by these procedures must be tracked and accounted for so that an ongoing assessment of the cavern’s drawdown capacity may be continued. A methodology for assessing and tracking the available drawdowns for each cavern is reiterated. This report is the latest in a series of annual reports, and it includes the baseline available drawdowns for each cavern, and the most recent assessment of the evolution of drawdown expenditures. A total of 222 million barrels of oil were released in calendar-year 2022. A nearly-equal amount of raw water was injected, resulting in an estimated 34 million barrels of cavern leaching. Twenty caverns have now expended a full drawdown. Cavern BC 18 has expended all its baseline available drawdowns, and has no drawdowns remaining. Cavern BM 103 has expended one of its two baseline drawdowns, and is now a single-drawdown cavern. All other caverns with an expenditure went from at-least-5 to at-least-4 remaining drawdowns.

02 PETROLEUM↗

ORBIT: Offshore Renewables Balance-of-System and Installation Tool

This report describes the Offshore Renewables Balance-of-system Installation Tool ("ORBIT"), a new model developed by the National Renewable Energy Laboratory (NREL) to evaluate the balance-of-system (BOS) costs associated with offshore wind projects. In the context of wind energy projects BOS costs encompass all expenses required to construct a project other than the capital expenditures (CapEx) of the turbines and towers, including the procurement costs for all other components (such as substructures, cables, and electrical infrastructure), offshore and land-based construction costs, port costs, site surveying fees, permitting fees, and leasing fees are all categorized as BOS costs. BOS costs significantly contribute to the levelized cost of energy (LCOE) for offshore wind, typically comprising over 50\% of the CapEx for a fixed-bottom offshore wind project and 60\% for a floating project. In addition, technology solutions and installation methods vary drastically between projects as they are impacted by factors such as vessel availability, geographic considerations and site geotechnical conditions. These effects require a model with appropriate fidelity to understand how these costs scale as turbine rating increases and the offshore wind supply chain, particularly offshore construction vessels, is expanded. For offshore wind, cost savings attributed to increased turbine rating are primarily realized through BOS procurement and project installation as fewer substructures and less cable are required. BOS costs represent both a modeling challenge, as well as an opportunity, for project developers to optimize solutions to reduce costs. It is critical to understand how these costs are affected by novel technologies, innovative installation processes, and operational constraints in order identify meaningful cost reductions for offshore wind energy.

17 WIND ENERGY↗

Oak Ridge National Laboratory FY 2023 Site Sustainability Plan With FY 2022 Performance Data

At the close of each fiscal year, the US Department of Energy (DOE) Sustainability Performance Division (SPD) issues guidance documents and technical resource aids/tools necessary for DOE sites and national laboratories to complete sustainability reporting requirements. SPD is part of the DOE Office of Asset Management. As required by DOE Order 436.1, Departmental Sustainability, “each site will develop and commit to an annual Site Sustainability Plan (SSP) that identifies its respective contribution toward meeting the DOE’s sustainability goals.” SPD collects and compiles information reported by each site to develop an agency-wide Sustainability Report and Implementation Plan, which is used to report DOE sustainability progress to the federal government as required by all major federal agencies. DOE launched a formal Sustainability Office and annual SSP process in 2011. Each year, Oak Ridge National Laboratory (ORNL), in concert with the Office of Science (SC), provides the resources essential to fulfill its commitment to deliver a complete and accurate SSP report and quality performance data for entry into the DOE Sustainability Dashboard as managed by SPD. The performance data entered by each DOE site are then combined to disclose the progress of each DOE Program Office and are further combined to show comprehensive progress for the agency. The Office of Asset Management provides assistance to program offices in sustaining their missions, freeing up resources by reducing waste, avoiding excess expenditure on utilities, maximizing productivity, and improving the efficiency of facilities and processes. By focusing on mission needs, programs and associated DOE sites can help the agency meet its sustainability goals, as outlined in federal statutory and regulatory requirements. In FY 2022, the SSP guidance was updated to capture requirements from Executive Order (EO) 14008, Tackling the Climate Crisis at Home and Abroad, the Energy Act of 2020 (EAct 20), actions outlined in DOE’s Climate Adaptation & Resilience Plan and Sustainability Plan, and EO 14057, Catalyzing Clean Energy Industries and Jobs Through Federal Sustainability. Updates in SSP guidance help to minimize and streamline reporting while simultaneously addressing updated federal requirements. Per DOE, each SSP report should provide an overview of the site’s planned actions, as well as an overview of efforts and accomplishments during the reporting period. SPD collects and compiles information reported by each site to develop DOE’s Annual Sustainability Report, Climate Adaptation & Resilience Plan, and Annual Energy Management Report to Congress. The agency goal has been to lower the reporting burden for sites and increase and improve the consistency of information available to decision makers, allowing them to better identify projects and potential for increased efficiency, as well as to reduce waste, lower emissions, and enhance operational resilience. Sites may elect to produce a more polished publication for their leadership and stakeholders, but this step is no longer required. The ORNL SSP narrative report (this document) and the reporting of DOE SPD Sustainability Dashboard performance data is a collaborative effort of approximately 30 subject matter experts (SMEs) from ORNL facility management and research divisions. Annually, these associates come together to provide a report that can be used by DOE to demonstrate continued agency progress in energy efficiency and sustainable federal operations.

99 GENERAL AND MISCELLANEOUS↗

Advanced Coating Compositions and Microstructures to Improve Uptime and Operational Flexibility in Cyclic, Low-Load Thermal Utility Plants

GE, the University of Tennessee, and Oak Ridge National Laboratory collaborated from 2020 to 2023 developing two key technologies for improving the viability of fuel switching and load following in thermal utility plants: a) cost-effective weld overlay compositions for boiler tubing b) cathodic arc coatings that deliver improvements in both erosion resistance and oxidation resistance in high temperature steam for HP turbine blades The team worked through a robust, logical project map to de-risk these two technologies and advance them from TRL 3 to TRL 6. For the cost-effective weld overlay, the team developed a ferritic filler material which was fabricated at a vendor for 18% the average market cost of Inconel 625 wire, had a corrosion rate 3x lower in conditions simulating a biomass-fired superheater and 10x lower in conditions simulating a coal-fired superheater, and was fabricated into prototype overlaid tubing that passed ASME requirements including transverse bending, dye penetrant inspection, and ASTM G-76 evaluation. For the cathodic arc coatings applied to steam turbine blades, the team developed a novel composition that was successfully transferred to a qualified vendor. The vendor was able to produce coated prototypes with 4x the as-deposited erosion resistance and 10.4x the post-steam-exposure erosion resistance of the TiN coating the vendor currently applies on GE steam turbine components, without significantly increasing process cost. These coated prototypes also passed a GE inspection and showed favorable performance in high temperature erosion, nanoindentation, sliding wear, scratch adhesion, and high cycle fatigue testing. If successfully deployed by GE, it is anticipated that the technologies will enable the following: • 25%-50% increase in time between outages for both boilers and HP turbines. • 50% decrease in cost for weld overlay on a per foot basis relative to todays NiCr alloys. • Adequate oxidation resistance and erosion for HP turbine inlet steam at >620°C and >220 bar. • No need for changes in component supply chain or any notable Capital Expenditures. 5 Decreasing component cost, increasing performance, and extending time between outages represent direct value propositions to GE and their customers. For the American consumer, these objectives translate into increased grid reliability (fewer unexpected outages), decreased Levelized Cost of Electricity, and improved environmental health (low-loading/load following to accelerate penetration of renewables). The results also have implications for wear resistant tooling, wire arc additive manufacturing, more durable components for syngas cleanup, and deployment of more efficient thermochemical pathways for carbon negative fuel production

09 BIOMASS FUELS↗