Large Format CMOS Imager Integration Utilizing an Indium Bonding Process and Buried ARC Reveal.
Abstract not provided.
Jordan, Matthew↗
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Designing the PR100 Study: Puerto Rico Grid Resilience and Transition to 100% Renewable Energy
Puerto Rico has committed to meeting its electricity needs with 100% renewable energy by 2050, along with realizing interim goals of 40% by 2025, 60% by 2040, the phaseout of coal-fired generation by 2028, and a 30% improvement in energy efficiency by 2040 as established in Act 17. [1] To meet these goals and support widespread end-use electrification, the territory must explore how renewable energy and other generation technologies can be developed with energy storage, distributed generation, distribution control, electric vehicles, and energy efficient and responsive loads in each of Puerto Rico's cities and communities. To support Puerto Rico in reaching its renewable energy goals; help ensure energy system resilience against future extreme weather events; improve energy justice; and provide inputs to LUMA Energy's walk, jog, and run approach in its coordinated planning roadmap, the U.S. Department of Energy, National Renewable Energy Laboratory, Argonne National Laboratory, Lawrence Berkeley National Laboratory, Oak Ridge National Laboratory, Pacific Northwest National Laboratory and Sandia National Laboratories propose to evaluate 100% renewable energy pathways through an integrated analysis process. This talk will present steps in designing a two-year study entitled Puerto Rico Grid Resilience and Transitions to 100% Renewable Energy (PR100). [1] U.S. Energy Information Administration (EIA). 2020. Puerto Rico Territory Energy Profile.
100% renewable energy↗
High Volume Production of Nanoscale Elements
The utility of nanoscale elements spans numerous potential markets including healthcare, communications, energy, optics, and structures. The energy market in particular will require large volumes and is price sensitive. In this talk we will discuss strategies to scale nanoscale elements, including nanoparticle inks and nanoscale thin films, for the large area deposition (hundreds of square meters) using high through put processes. Historically, roll-to-roll production of thin films has been carried out at very high speeds over large areas using solution phase inks. Nanoparticles are produced in a bottom-up approach in solution phase that simplifies the processing and is amenable to ink formulations. Sintering and annealing of the thin films can be increased by using radiation thermal processing that integrates easily into roll-to-roll manufacturing. Results of printed films on the order of tens of nanometers to hundreds of nanometers are presented including studies of morphologies and uniformity over large areas. Solar cells devices using the roll-to-roll setup are demonstrated and a techno-economic analysis of the manufacturing is proposed. These results are presented with a comparison to the current photovoltaic technologies in production.
Druffel, Thad↗
Biomethanation to Upgrade Biogas to Pipeline Grade Methane
NREL is working closely with DOE, Electrochaea GmbH, and Southern California Gas Company (SoCalGas) to reduce costs of a biomethanation process capable of megawatt-scale deployment that upgrades organic biogas waste streams to produce pipeline quality renewable natural gas (RNG). Biomethanation is a two-step process using a single-celled methanogenic archaea that converts low-carbon low-cost hydrogen (H2) and waste carbon dioxide (CO2) to produce renewable methane (CH4). The process upgrades the biogenic CO2 - while allowing the CH4 to pass through - from biogas sources like dairies, wastewater treatment plants, and landfills. The CH4 produced is a drop-in direct replacement fuel and producers can participate in the growing number of carbon markets; like California's Low Carbon Fuel Standard and the Federal Renewable Fuel Standard. NREL and Argonne National Laboratory have completed a life cycle analysis using the GREET model to show that the biomethanation process produces RNG that is carbon negative even when H2 production via low-temperature water electrolysis is driven by the existing carbon intensity of California's electricity grid. And of course, even further carbon negative (-233 kg CO2e/kWh) when the electricity is produced from low-carbon sources like wind and solar. Leveraging lessons learned from operating SoCalGas' 700L 18-bar bioreactor system, NREL is designing and building a flexible RD&D platform that will enable field trials at biogas and other CO2 sources. A custom 16' long trailer will house a 20L 18-bar bioreactor, 3 - 25 kW proton exchange membrane electrolyzer, and dosing, thermal, and controls systems to support operations with only power, biogas, and water feedstocks required by the field locations. The end-of-project goal is to demonstrate pipeline quality RNG production (> 95% CH4, < 4% H2, <1% CO2, < 0.2% O2 and < 4 parts per million H2 sulfide) using real biogas feedstocks - thereby recycling both greenhouse gases for injection into the natural gas network or to be used onsite.
biogas upgrading↗
Development of utility generic functional requirements for electronic work packages and computer-based procedures - 273
The Nuclear Electronic Work Packages - Enterprise Requirements (NEWPER) initiative is a step toward a vision of implementing an eWP framework that includes many types of eWPs. This will enable immediate paper-related cost savings in work management and provide a path to future labor efficiency gains through enhanced integration and process improvement in support of the Nuclear Promise (Nuclear Energy Institute 2016). The NEWPER initiative was organized by the Nuclear Information Technology Strategic Leadership (NITSL) group, which is an organization that brings together leaders from the nuclear utility industry and regulatory agencies to address issues involved with information technology used in nuclear-power utilities. NITSL strives to maintain awareness of industry information technology-related initiatives and events and communicates those events to its membership. NITSL and Light Water Reactor Sustainability Program researchers have been coordinating activities, including joint organization of NEWPER-related meetings and report development. The main goal of the NEWPER initiative was to develop a set of utility generic functional requirements for eWP systems. This set of requirements will support each utility in their process of identifying plant-specific functional and non-functional requirements. The NEWPER initiative has 140 members where the largest group of members consists of 19 commercial U.S. nuclear utilities and eleven of the most prominent vendors of eWP solutions. Through the NEWPER initiative two sets of functional requirements were developed; functional requirements for electronic work packages and functional requirements for computer-based procedures. This paper will describe the development process as well as a summary of the requirements. (authors)
22 GENERAL STUDIES OF NUCLEAR REACTORS↗
Recent Metallic Fuel Data Recovery in FIPD
The Metallic Fuels Irradiation and Physics Database (FIPD) [1] is an organized collection of metallic fuel test pin data (U-xPu-yZr, = 0 ~ 28; y = 2 ~ 10) and documentation available to industry. FIPD mainly contains three types of data: (1) Fuel pin fabrication data, including fuel slug diameter, fuel slug length, cladding diameter, smear density, etc. (2) Fuel pin operation conditions, including axial distributions for power, temperatures, fluences, burnup, and isotopic densities, etc. and (3) Fuel pin post-irradiation examination (PIE) data, including fission gas release and gas chemistry, profilometry, and neutron radiography, etc. The operating conditions for pins with PIE data available in FIPD span significant ranges across key parameters. The fuel peak burnup extends from less than 5% up to 20 at%. The cladding peak temperature varies from about 490°C to 660°C. Finally, the cladding peak DPA shows a wide range from less than 5 to 120. These broad ranges reflect the diverse testing conditions and operational parameters captured in the available PIE data. More detail about FIPD can be found in ref. [2]. The database development is an ongoing effort covering metallic fuel experiments from the Experimental Breeder Reactor II (EBR-II) and the Fast Flux Test Facility (FFTF). As reported in the ref. [3, 4], most of the PIE data generated during the IFR program [5] has been collected, reviewed, processed, and integrated into FIPD. The most recently added PIE data can be found in ref. [4], which shows the collection of over 95% of the PIE data by the time of this paper. The recent improvements to the database are summarized in this paper.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
Optimizing Energy Use in Pulp & Paper with DOE’s Energy Intensive Industries Resources
The U.S. pulp and paper industry is the third-largest energy consumer in manufacturing, accounting for roughly 10% of sector energy use. Improving energy efficiency reduces operating costs and strengthens competitiveness. To support this effort, the U.S. Department of Energy (DOE), through Oak Ridge National Laboratory (ORNL), launched the Energy Intensive Industries (EII) Initiative. A two-year pilot across 45 industrial sites identified more than 4 trillion Btu/year in potential energy savings. This presentation outlines plans for a follow-up technical assistance program tailored to pulp and paper mills. Available resources include a cost-savings scoping tool, implementation planning guidance, and technical support for applying advanced methods such as Pinch Analysis for integrated process-utilities optimization. The session introduces key Pinch Analysis principles and highlights case studies demonstrating measurable improvements. ORNL also seeks industry feedback on barriers to efficiency improvements, including technology gaps and resource needs. DOE’s broader objective is to accelerate productivity and economic competitiveness across U.S. energy-intensive industries.
Kamath, Dipti [ORNL] (ORCID:0000000278739994)↗
Development of an advanced spacecraft water and waste materials processing system
An Integrated Waste Management-Water System (WM-WS) which uses radioisotopes for thermal energy is described and results of its trial in a 4-man, 180 day simulated space mission are presented. It collects urine, feces, trash, and wash water in zero gravity, processes the wastes to a common evaporator, distills and catalytically purifies the water, and separates and incinerates the solid residues using little oxygen and no chemical additives or expendable filters. Technical details on all subsystems are given along with performance specifications. Data on recovered water and heat loss obtained in test trials are presented. The closed loop incinerator and other projects underway to increase system efficiency and capacity are discussed.
Murray, R. W.↗
Flexible cryogenic air separation unit—An application for low-carbon fossil-fuel plants
In this study, the rapid integration of intermittent renewable sources into the electricity grid is driving the need for a flexible cryogenic air separation unit (ASU) coupled with a low-carbon fossil-fuel plant. However, the state-of-the-art ASU process is highly integrated and nonlinear, which can significantly restrict its ramping rate. In this work, we study the fundamental dynamics of a state-of-the-art double-column ASU, focusing on the dynamic characteristics of the highly integrated and nonlinear heat and mass transfers, and we propose basic control methods for achieving high process ramping rates. We found that the vapor–liquid countercurrent flows in the low-pressure column are critical to the cryogenic rectification of air, which governs the ramp rate of the ASU. This countercurrent flow structure is created through a complex heat integration process in the ASU. Here, this process is simplified as a countercurrent heat transfer to reduce the complexity of studying the ASU dynamics. To preserve this flow structure, the heat integration is maintained so that its heat duty follows the ASU load, using several basic controllers on the critical stream flowrates. A flow-driven dynamic ASU model is built in Aspen Plus Dynamics to capture the basic ramping dynamics. This model revealed a fundamental mismatch in the dynamics in the ASU column that causes a significant loss of O 2 product purity when ramping down the ASU and slightly increases the purity when ramping up. Based on these findings, we propose a basic control method for rapidly ramping down/up the ASU while maintaining O 2 product purity. Simulation results show the ASU basic dynamic process successfully ramps at a rate up to 10 %/min (40–100 % load) while maintaining the O 2 product purity at 95.2–95.6 mol%.
42 ENGINEERING↗
Environmental impacts and benefits of state-of-the-art technologies for E-waste management
Highlights: • The most promising e-waste management scenario features integrated e-waste processes. • Treatment of mobile phones in an integrated e-waste management provides the best environmental performance. • Incineration of the hazardous portion of PCBs with energy recovery is an option that deserves attention. • Landfills of e-waste should be avoided, especially for washing machines, TVs, and refrigerators. • If landfill to be used, a recycling scheme with precious metals can notably mitigate the impacts of landfills. - Abstract: This study aims to evaluate the environmental impacts and benefits of state-of-the-art technologies for proper e-waste handling using Jordan as a case study. Life Cycle Assessment (LCA) was employed to evaluate five advanced management systems represent state-of-the-art treatment technologies, including sanitary landfilling; proper recycling of metals, materials, and precious metals (PMs); and incineration of plastic and the hazardous portion of printed circuit boards (PCBs). Six e-waste products that contribute the most to the e-waste in Jordan were included in the assessment of each scenario, which resulted in 30 total cases of e-waste management. The findings indicated that landfills for the entire components of the e-waste stream are the worst option and should be avoided. The most promising e-waste management scenario features integrated e-waste processes based on the concept of Integrated Waste Management (IWM), including recycling materials such as non-PMs and PMs, incinerating plastic and the hazardous content of PCBs using the energy recovered from incineration, and using sanitary landfills of residues. For this scenario, the best environmental performance was obtained for the treatment of mobile phones. Incineration of the portion of hazardous waste using energy recovery is an option that deserves attention. Because scenario implementation depends on more than just the environmental benefits (e.g., economic cost and technical aspects), the study proposes a systematic approach founded on the IWM concept for e-waste management scenario selection.
12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
A Numerical Tool for the Design of Enhanced Geothermal Reservoirs based on Modeling of Thermo-Hydro-Mechanical Processes and Explicit Representation of 3D Discrete Fracture Networks
This project has developed a coupled thermo-hydro-mechanical numerical modeling tool for prediction of energy production from Enhanced Geothermal Reservoirs (EGS). The tool is unique because it can explicitly represent thousands of pre-existing natural fractures. The capabilities developed in this project were built on the already existing expertise of Itasca arising from thirty years of research and development in discrete element modeling of fractured rocks. A thermal module suitable for analysis of different heat transfer mechanisms in fractured rocks percolated by fluids was developed and coupled with the already existing hydro-mechanical calculation in 3DEC, a commercial software for analysis of jointed rock based on the discrete element method (DEM). The heat transfer module simulates heat conduction, heat advection by moving fluid in rock fractures, and convective heat exchange at the fracture walls between the rock and the moving fluid. Techniques for spatial discretization of heat transfer in EGS-type problems were evaluated, and a boundary layer meshing approach was developed. Also, given the significant differences in time scale of physical processes involved, temporal integration schemes for coupled advection-diffusion processes and coupled thermal-hydro-mechanical processes were developed by taking advantage of both implicit and explicit time integration and also optimizing the coupling intervals. These improvements were necessary for modeling EGS reservoirs. Also, the DFN capacities in 3DEC were extended to include a larger number of fractures. Research was carried out on approaches to simplify the DFN so that the model can meet computational demands, while preserving thermo-hydro-mechanical characteristics of the DFN. The developed modules were coupled with the already existing capabilities of 3DEC. The results were presented as a submitted conference paper (Riahi et al., 2018a). A series of benchmark and test examples showed the developed capabilities. Finally, the developed tool was tested for a large-scale reservoir model for longer periods of injection and production. The thermal draw-down curves were generated and presented. The project successfully met all the milestones laid out in the proposal. Results demonstrated the feasibility of developing a fast and reliable software for the EGS community to use for assessment and prediction of reservoir performance. Some of its applications include assessment of stimulated volume and produced temperature and power. It can also be used for improved engineering, design and optimization of EGS reservoirs as well as other unconventional resources such as shale gas. Finally, the 3D analysis presented in this study showed that simulating EGS reservoirs with tens of thousands of fractures is feasible, and confirmed that the developed tool can serve toward meeting the goals and objectives of Geothermal Technologies Office in overcoming technical barriers associated with commercial EGS development.
15 GEOTHERMAL ENERGY↗
Electricity production and sludge reduction by integrating microbial fuel cells in anoxic-oxic process
Highlights: • Four identical microbial fuel cells were constructed in an anoxic–oxic process. • The electricity produced by each MFC was within 0.371–0.477 V and 138–227 mW/m{sup 3}. • The coulombic efficiencies of the system were 0.31–1.68% (mean = 0.72%). • The integration of MFCs enhance COD and TN removal of anoxic–oxic process. • The integration of MFCs reduce sludge production and sludge yield by 24.0% and 24.2%. - Abstract: To produce energy and reduce sludge production from the treatment of municipal wastewater, four identical microbial fuel cells (MFCs) were constructed in an anoxic–oxic (A/O) process (MFCs-A/O system). Experimental results indicated that this system enhance the removals of chemical oxygen demand (COD) and total nitrogen (TN). The electricity produced by each MFC were ranged from 0.371 to 0.477 V (voltage) and from 138 to 227 mW/m{sup 3} (power density) at the stable stage, when the external resistance was fixed at 1000 Ω. The coulombic efficiency of the MFCs-A/O system ranged from 0.31% to 1.68% (mean = 0.72%) at the stable stage, respectively. The removals of COD and TN in the MFCs-A/O system were slightly higher than those in the control system. Compared with the control system, the MFCs-A/O system can reduce waste activated sludge production and sludge yield by 24.0% and 24.2%, respectively. The experimental results indicated that the MFC constructed in A/O system improves wastewater treatment and the MFCs-A/O system can produce electricity while reducing sludge production and increasing wastewater treatment efficiency.
12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
Genome expansion by a CRISPR trimmer-integrase
CRISPR–Cas adaptive immune systems capture DNA fragments from invading mobile genetic elements and integrate them into the host genome to provide a template for RNA-guided immunity. CRISPR systems maintain genome integrity and avoid autoimmunity by distinguishing between self and non-self, a process for which the CRISPR/Cas1–Cas2 integrase is necessary but not sufficient. In some microorganisms, the Cas4 endonuclease assists CRISPR adaptation, but many CRISPR–Cas systems lack Cas4. Here we show here that an elegant alternative pathway in a type I-E system uses an internal DnaQ-like exonuclease (DEDDh) to select and process DNA for integration using the protospacer adjacent motif (PAM). The natural Cas1–Cas2/exonuclease fusion (trimmer-integrase) catalyses coordinated DNA capture, trimming and integration. Five cryo-electron microscopy structures of the CRISPR trimmer-integrase, visualized both before and during DNA integration, show how asymmetric processing generates size-defined, PAM-containing substrates. Before genome integration, the PAM sequence is released by Cas1 and cleaved by the exonuclease, marking inserted DNA as self and preventing aberrant CRISPR targeting of the host. Together, these data support a model in which CRISPR systems lacking Cas4 use fused or recruited exonucleases for faithful acquisition of new CRISPR immune sequences.
59 BASIC BIOLOGICAL SCIENCES↗
Integrated Hardfacing of Stellite-6 Using Hybrid Manufacturing Process
Hybrid manufacturing systems provide a platform for integrated additive, subtractive and inspection methods on a single machine setup. The present work explores use of hybrid manufacturing for hardfacing of performance components for improving wear resistance. In this work, Stellite-6 was applied to a 410 stainless steel substrate using a hybrid manufacturing system incorporating multi-axis directed energy deposition and machining. Experimental testing was conducted to determine the effects of hybrid manufacturing parameters on internal porosity, surface porosity and microstructure in the cladded material, as well as on the roughness of the final machined surface. Correlation between porosity measurements made by x-ray tomography and surface dye-penetrant testing is presented and determination of ideal process parameters for hardfacing of components using hybrid manufacturing systems is briefly discussed.
Praniewicz, Maxwell↗
Expanded Accident Scenarios and Frequency Characteristics for a Fast Spectrum Molten Salt Reactor in an Integrated Energy System
Integration of advanced nuclear reactors to industrial processes in an integrated energy system (IES) has many potential advantages. The coupling of nuclear power to varied industrial processes introduces additional accident scenarios unique to the specific systems included in the IES. Similarly, noise in one system of the IES could potentially create negative effects in the other systems. Because of the limited amount of comparable nuclear IES operating experience, there is added value in scoping the inherent behavior of these systems in response to these transients. Here, this paper investigates the safety-related behavior of an open-source IES dynamic model of a fast spectrum molten salt reactor (MSR) powering a regenerative Rankine cycle for electricity production and a hybrid sulfur (HyS) cycle for hydrogen production. The simulations include a loss of cooling water to the Rankine cycle, a loss of sulfur in the HyS cycle, and the frequency characteristics of the entire IES across six orders of magnitude of frequency. The results show safe behavior in response to the two accident scenarios, wherein a disruption in heat transfer leads to increased salt temperatures and a decrease in reactor power. The frequency analysis shows that at higher frequencies, temperature changes propagating through an IES are increasingly damped to the point of negligibility.
Dunkle, Nicholas [Univ. of Tennessee, Knoxville, T↗
Techno-economic Assessment for Integrating Biosorption into Rare Earth Recovery Process
The current uncertainty in the global supply of rare earth elements (REEs) necessitates the development of novel extraction technologies that utilize a variety of REE source materials. Herein, we examined the techno-economic performance of integrating a biosorption approach into a large-scale process for producing salable total rare earth oxides (TREOs) from various feedstocks. An airlift bioractor is proposed to carry out a biosorption process mediated by bioengineered rare earth-adsorbing bacterium. Techno-econmic asssements were compared for three distinctive categories of REE feedstocks that require different pre-processing steps. Key parameters identified that affect profitability include REE concentration, composition of the feedstock, and costs on feedstock pretreatment and waste management. Among the 11 specific feedstocks investigated, coal ash from the Appalachian Basin was projected to be the most profitable, largely due to its high-value REE content. Its cost breakdown includes leaching (80.7%), biosorption (16.0%), and oxalic acid precipitation and TREO roasting (3.3%). Surprisingly, biosorption from the high-grade Bull Hill REE ore is less profitable due to the high material cost and low production revenue. Altogether, our results confirmed that the economic potential of applying biosorption to low-grade feedstocks is viable.
60 APPLIED LIFE SCIENCES↗
Techno-Economic Assessment for Integrating Biosorption into Rare Earth Recovery Process
The current uncertainty in the global supply of rare earth elements (REEs) necessitates the development of novel extraction technologies that utilize a variety of REE source materials. Herein, we examined the techno-economic performance of integrating a biosorption approach into a large-scale process for producing salable total rare earth oxides (TREOs) from various feedstocks. An airlift bioractor is proposed to carry out a biosorption process mediated by bioengineered rare earth-adsorbing bacteria. Techno-econmic asssements were compared for three distinctive categories of REE feedstocks requiring different pre-processing steps. Key parameters identified that affect profitability include REE concentration, composition of the feedstock, and costs of feedstock pretreatment and waste management. Among the 11 specific feedstocks investigated, coal ash from the Appalachian Basin was projected to be the most profitable, largely due to its high-value REE content. Its cost breakdown includes pre-processing (primarily leaching) (8077.71%), biosorption (1619.04%), and oxalic acid precipitation and TREO roasting (3.35%). Surprisingly, biosorption from the high-grade Bull Hill REE ore is less profitable due to high material cost and low production revenue. Overall, our results confirmed that the application of biosorption to low-grade feedstocks for REE recovery is economically viable.
15 GEOTHERMAL ENERGY↗
7 Innovations in high-rate composite manufacturing: integrating additive manufacturing with compression molding process
Advanced composites play a pivotal role in modern engineering, offering exceptional strength-to-weight ratios and tailored properties, essential for various industries. High-rate composite manufacturing techniques have rapid production capabilities, which are essential for meeting the demands of industries requiring cost-saving, efficiency, and quick turnaround times. This chapter explores the Additive Manufacturing- Compression Molding (AM-CM) system developed by Oak Ridge National Laboratory (ORNL) for advanced composites manufacturing. The AM-CM system integrates additive manufacturing with compression molding, facilitating the production of polymer composite parts with superior mechanical properties and meticulously controlled microstructures. This innovative system not only ensures precise material deposition but also operates as a fast composite manufacturing process, enhancing productivity and performance, which are needed attributes across industrial applications. Through comprehensive mechanical testing and microstructural analysis, AM-CM promotes remarkable fiber alignment and reduced porosity in composite parts compared to alternative thermoplastic high-rate composite manufacturing methods. Furthermore, AM-CM enables overmolding reinforcement using continuous carbon fiber and supports selective reinforcement through customizable toolpaths. It also facilitates the production of hybrid materials to achieve tailored mechanical properties. Future advancements in AM-CM technology aim to enhance process efficiency, broaden material versatility, and improve part performance. This involves exploring novel materials, advancing process monitoring, implementing automation technologies, and integrating artificial intelligence (AI) and machine learning (ML) for predictive modeling and real-time optimization in composite manufacturing. These developments will establish the AM-CM system as a transformative technology in composite manufacturing, driving innovation across industries.
Hassen, Ahmed [ORNL] (ORCID:0000000328521222)↗