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DOE OSTI2022

Foam Fracturing Study for Stimulation Development of Enhanced Geothermal Systems

This is a final technical report for the project: Foam Fracturing Study for Stimulation Development of Enhanced Geothermal Systems (EGS). The goal is to demonstrate the feasibility of foam fracturing in EGS applications. The project, led by Oak Ridge National Laboratory (ORNL), was conducted in collaboration with Temple University. The report describes the research activities with Task 1 at ORNL: foam fracturing testing system development and experimental study on foam fracturing, and Task 2 at Temple University: foam testing and foam characterization. Main findings are: 1. A foam fracturing test system has been developed at ORNL, which can be used to perform foam fracturing under pressure up to 6,000 psi. The system monitors foam density during fracturing online and is capable of testing materials in both monotonic and cyclic (up to 50 Hz) injections. 2. Foam fracturing tests were carried out on Charcoal black granite specimens with a blind borehole to the middle length. Two diameters of blind borehole were tested; G2 series: 9.53 mm and G3 series: 4.76 mm. N2-in-water foam was used with AOS as a surfactant. 3. There was a hole-size effect on fracture initiation pressure. The effect is smaller in the case of foam, which was influenced by the high penetrability of gas in foam. Breakdown pressure showed a behavior just as that of fracture pressure; namely an increased value for small hole samples, while the effect in water fracture was more impressive than in foam fracture. 4. Water mass was reduced in foam fracturing within similar range of breakdown pressures. In G2 series, it was decreased from 10.44 g for water fracturing to 5.17 g, representing more than 50% water reduction. Therefore, there is the potential to reduce water use in EGS stimulation through foam fracturing. 5. Use of cyclic injection has the potential to reduce the breakdown pressure and seismicity in EGS application. Experiments using 4-s cycle period found that specimens can be fractured with a low number of cycles. The fatigue pressure was approximately 64 - 77% of monotonic breakdown pressure for water fracturing and 58 - 94% of the breakdown pressure for foam fracturing. 6. A foam stability testing system has been developed that can test foam at 220 Deg C to 2,000 psi. Tested components of candidate foams included two gases: N2 and CO2; 4 surfactants: AOS, SDS, NP-40 and CTAC; 5 stabilizing agents: guar, bentonite clay, borate salt, silica NPs, and GO. 7. N2 and AOS provided the most stable performance over the tested ranges. Furthermore, the AOS foam with stabilizing agents of guar and borate salt (crosslinker) offered the highest half-life of 20 minutes at 200 Deg C and 1,000 psi. 8. Arrhenius equation and modified power law have been demonstrated to fit well the half-time vs. temperature and pressure data, respectively. These relations can be useful to provide the suggestion for future foam stability study. This submission contains the supporting data developed during the project: 1) A final technical report 2) Granite fracturing data in monotonic and cyclic injections with water and N2 foam Foam performance data in various temperatures and pressures, including half-time, is submitted separately.

15 GEOTHERMAL ENERGY↗
DOE OSTI2025

Kölliker's Organ Functions as a Developmental Hub in Mouse Cochlea Regulating Spiral Limbus and Tectorial Membrane Development

Kölliker's organ is a transient developmental structure in the mouse cochlea that undergoes significant remodeling postnatally. Utilizing an epithelial-specific conditional deletion mouse model of Prdm16 (marker and regulator of Kölliker's organ), we show that Prdm16 is required for interdental cell development, and thereby the development of the limbal domain of the tectorial membrane and its medial anchorage to the spiral limbus. Additionally, we show that Kölliker's organ is involved in normal tectorial membrane collagen fibril development and maturation. Interestingly, mesenchymal cells of the spiral limbus underneath Prdm16 -deficient Kölliker's organ failed to produce interstitial matrix proteins, resulting in a hypoplastic and truncated spiral limbus, indicating a non-cell autonomous role of Prdm16 in regulating spiral mesenchymal matrix development. Single-cell RNA sequencing identified differentially expressed genes in Prdm16 -deficient Kölliker's organ suggesting a role for connective tissue growth factor (CTGF) downstream Prdm16 in epithelial-mesenchymal signaling involved in spiral limbus matrix deposition. Prdm16 -deficient mice showed a hearing deficit, as indicated by elevated auditory brainstem response thresholds at most frequencies, consistent with the cochlear structural defects. Both sexes were studied. This work establishes Prdm16 as a deafness gene in mice through its role in regulating Kölliker's organ development. Such understanding recognizes Kölliker's organ as a developmental hub regulating multiple surrounding cochlear structures.

Zhang, Hongji↗
DOE OSTI2019

Easing the Control System Application Development for CMS Detector Control System with Automatic Production Environment Reproduction

The Detector Control System (DCS) is one of the main pieces involved in the operation of the Compact Muon Solenoid (CMS) experiment at the LHC. The system is built using WinCC Open Architecture (WinCC OA) and the Joint Controls Project (JCOP) framework which was developed on top of WinCC at CERN. Following the JCOP paradigm, CMS has developed its own framework which is structured as a collection of more than 200 individual installable components each providing a different feature. Everyone of the systems that the CMS DCS consists of is created by installing a different set of these components. By automating this process, we are able to quickly and efficiently create new systems in production or recreate problematic ones, but also, to create development environments that are identical to the production ones. This latter one results in smoother development and integration processes, as the new/reworked components are developed and tested in production-like environments. Moreover, it allows the central DCS support team to easily reproduce systems that the users/developers report as being problematic, reducing the response time for bug fixing and improving the support quality.

43 PARTICLE ACCELERATORS↗
DOE OSTI2020

What's in a Name? Developing a Standardized Taxonomy for HVAC System Faults

Faults occurring in heating, ventilation and air-conditioning (HVAC) systems have significantly negative impacts on building energy consumption, occupant comfort, and indoor air quality. In the past thirty years, extensive research has been conducted on fault detection and diagnostics (FDD) methods, and there are now dozens of commercially available FDD software tools. Growing adoption of FDD tools has the potential to generate a massive and useful data set on fault characteristics. However, the lack of a unifying taxonomy is a significant barrier to efficient analysis and evaluation of FDD outputs. Therefore, there is a strong need to develop a robust taxonomy which can better represent and interpret FDD output data. This paper documents the development of a unifying taxonomy for HVAC system faults in commercial buildings, with initial focus on air handling units, variable air volume terminal units, and roof top unit systems. The developed fault taxonomy employs both a physical hierarchy of HVAC equipment and a cause-effect relationship model as tools to better understand and support root cause analysis for HVAC faults. A variable air volume terminal unit is used as an example to demonstrate the application of the developed fault taxonomy. The taxonomy has short-term application in a major U.S. study on fault prevalence, and promises longer term benefits to FDD software developers and building operators by creating a foundation for improved approaches to identifying and resolving HVAC faults.

Chen, Yimin↗
DOE OSTI2017

Development of ITM Oxygen Technology for Low-cost and Low-emission Gasification and Other Industrial Applications

Air Products carried out a scope of work under DOE Award No. DE-FE0012065 “Development of ITM Oxygen Technology for Low-cost and Low-emission Gasification and Other Industrial Applications” with subcontractors Ceramatec, Penn State, and WorleyParsons. The scope of work under this award was aimed at furthering the development of the Ion Transport Membrane (ITM) Oxygen production process toward a demonstration-scale facility known as the Oxygen Development Facility (ODF). Specific activities will help to enable design and construction of the ODF through advancement of a number of challenging technical elements that are required to manage risk in the initial deployment of ITM technology. Major objectives of the work included developing ITM Oxygen ceramic membrane materials with improved performance and reliability, optimizing ceramic module geometry and fabrication methods, testing module performance, trialing the improved fabrication process at commercial scale in the Ceramic Membrane Module Fabrication Facility (CerFab), and advancing engineering development of the ITM oxygen production process, including vessel design and contaminant control measures to prepare for deployment of the ODF. The comprehensive report that follows details the team’s work, which includes several notable accomplishments: 1) compressive creep, a likely limiter of ceramic module lifetime in service, was demonstrated to be retarded by an order of magnitude by changes in material formulation, module joining dimensions, and internal wafer geometry; 2) two promising new materials were shown to be superior to the incumbent ITM material in a key material parameter related to oxygen flux; 3) module degradation mechanisms were identified following operation in large pilot-scale equipment; 4) options for utilizing ITM in a coal-to-liquids (CTL) facility to enable liquids production with carbon capture were identified and studied; and 5) the benefits of potential improvements to the technology were assessed for their cost impact on ITM Oxygen applications to clean power, fuels, and other applications.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2017

Advanced Ultrasupercritical (AUSC) Tube Membrane Panel Development

Alstom Power Inc., a wholly owned subsidiary of the General Electric Company (GE), has completed the project “Advanced Ultrasupercritical (AUSC) Tube Membrane Panel Development” under U.S. Department of Energy (DOE) Award Number DE-FE0024076. This project was part of DOE’s Novel Crosscutting Research and Development to Support Advanced Energy Systems program. AUSC Tube Membrane Panel Development was a two and one half year project to develop and verify the manufacturability and serviceability of welded tube membrane panels made from high performance materials suitable for the AUSC steam cycles, defined as high pressure steam turbine inlet conditions of 700-760°C (1292-1400°F) and 24.5-35MPa (3500-5000psi). The difficulty of this challenge lies in the fact that the membrane-welded construction imposes demands on the materials that are unlike any that exist in other parts of the boiler. Tube membrane panels have been designed, fabricated, and installed in boilers for over 50 years with relatively favorable experience when fabricated from carbon and Cr-Mo low alloy steels. The AUSC steam cycle requires membrane tube panels fabricated from materials that have not been used in a weldment with metal temperatures in the range of 582-610°C (1080-1130°F). Fabrication materials chosen for the tubing were Grade 92 and HR6W. Grade 92 is a creep strength enhanced ferritic Cr-Mo alloy and HR6W is a high nickel alloy. Once the materials were chosen, GE performed the engineering design of the panels, prepared shop manufacturing drawings, and developed manufacturing and inspection plans. After the materials were purchased, GE manufactured and inspected the tube membrane panels, determined if post fabrication heat treatment of the tube membrane panels was needed, performed pre- and post-weld heat treatment on the Grade 92 panels, conducted final nondestructive inspection of any heat treated tube membrane panels, conducted destructive inspection of the completed tube membrane panels,and performed simulated shop repairs on the panel fabricated using Grade 92. GE executed the program as the prime contractor under the direction of Principal Investigator Mr. James Pschirer. Other participants in this project included GE Boiler Engineering, GE Chattanooga Manufacturing, GE Materials Technology Center, GE Rocky Mountain Service Center, and a Technical Consultant from Electric Power Research Institute (EPRI).

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2017

User input verification and test driven development in the NJOY21 nuclear data processing code

Before physically-meaningful data can be used in nuclear simulation codes, the data must be interpreted and manipulated by a nuclear data processing code so as to extract the relevant quantities (e.g. cross sections and angular distributions). Perhaps the most popular and widely-trusted of these processing codes is NJOY, which has been developed and improved over the course of 10 major releases since its creation at Los Alamos National Laboratory in the mid-1970’s. The current phase of NJOY development is the creation of NJOY21, which will be a vast improvement from its predecessor, NJOY2016. Designed to be fast, intuitive, accessible, and capable of handling both established and modern formats of nuclear data, NJOY21 will address many issues that many NJOY users face, while remaining functional for those who prefer the existing format. Although early in its development, NJOY21 is quickly providing input validation to check user input. By providing rapid and helpful responses to users while writing input files, NJOY21 will prove to be more intuitive and easy to use than any of its predecessors. Furthermore, during its development, NJOY21 is subject to regular testing, such that its test coverage must strictly increase with the addition of any production code. This thorough testing will allow developers and NJOY users to establish confidence in NJOY21 as it gains functionality. This document serves as a discussion regarding the current state input checking and testing practices of NJOY21.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2017

Scoping study to expedite development of a field deployable and portable instrument for UF6 enrichment assay

The primary objective of the present study is to identity the most promising, viable technologies that are likely to culminate in an expedited development of the next-generation, field-deployable instrument for providing rapid, accurate, and precise enrichment assay of uranium hexafluoride (UF6). UF6 is typically involved, and is arguably the most important uranium compound, in uranium enrichment processes. As the first line of defense against proliferation, accurate analytical techniques to determine the uranium isotopic distribution in UF6 are critical for materials verification, accounting, and safeguards at enrichment plants. As nuclear fuel cycle technology becomes more prevalent around the world, international nuclear safeguards and interest in UF6 enrichment assay has been growing. At present, laboratory-based mass spectrometry (MS), which offers the highest attainable analytical accuracy and precision, is the technique of choice for the analysis of stable and long-lived isotopes. Currently, the International Atomic Energy Agency (IAEA) monitors the production of enriched UF6 at declared facilities by collecting a small amount (between 1 to 10 g) of gaseous UF6 into a sample bottle, which is then shipped under chain of custody to a central laboratory (IAEA’s Nuclear Materials Analysis Laboratory) for high-precision isotopic assay by MS. The logistics are cumbersome and new shipping regulations are making it more difficult to transport UF6. Furthermore, the analysis is costly, and results are not available for some time after sample collection. Hence, the IAEA is challenged to develop effective safeguards approaches at enrichment plants. In-field isotopic analysis of UF6 has the potential to substantially reduce the time, logistics and expense of sample handling. However, current laboratory-based MS techniques require too much infrastructure and operator expertise for field deployment and operation. As outlined in the IAEA Department of Safeguards Long-Term R&D Plan, 2012–2023, one of the IAEA long-term R&D needs is to “develop tools and techniques to enable timely, potentially real-time, detection of HEU (Highly Enriched Uranium) production in LEU (Lowly Enriched Uranium) enrichment facilities” (Milestone 5.2). Because it is common that the next generation of analytical instruments is driven by technologies that are either currently available or just now emerging, one reasonable and practical approach to project the next generation of chemical instrumentation is to track the recent trends and to extrapolate them. This study adopted a similar approach, and an extensive literature review on existing and emerging technologies for UF6 enrichment assay was performed. The competitive advantages and current limitations of different analytical techniques for in-field UF6 enrichment assay were then compared, and the main gaps between needs and capabilities for their field use were examined. Subsequently, based on these results, technologies for the next-generation field-deployable instrument for UF6 enrichment assay were recommended. The study was organized in a way that a suite of assessment metric was first identified. Criteria used in this evaluation are presented in Section 1 of this report, and the most important ones are described briefly in the next few paragraphs. Because one driving force for in-field UF6 enrichment assay is related to the demanding transportation regulation for gaseous UF6, Section 2 contains a review of solid sorbents that convert and immobilized gaseous UF6 to a solid state, which is regarded as more transportation friendly and is less regulated. Furthermore, candidate solid sorbents, which show promise in mating with existing and emerging assay technologies, also factor into technology recommendations. Extensive literature reviews on existing and emerging technologies for UF6 enrichment assay, covering their scientific principles, instrument options, and current limitations are detailed in Sections 3 and 4, respectively. In Section 5, the technological gaps as well as start-of-the-art and commercial off-the-shelf components that can be adopted to expedite the development of a fieldable or portable UF6 enrichment-assay instrument are identified and discussed. Finally, based on the results of the review, requirements and recommendations for developing the next-generation field-deployable instrument for UF6 enrichment assay are presented in Section 6.

36 MATERIALS SCIENCE↗
DOE OSTI2017

PIPER: Performance Insight for Programmers and Exascale Runtimes: Guiding the Development of the Exascale Software Stack

The PIPER project set out to develop methodologies and software for measurement, analysis, attribution, and presentation of performance data for extreme-scale systems. Goals of the project were to support analysis of massive multi-scale parallelism, heterogeneous architectures, multi-faceted performance concerns, and to support both post-mortem performance analysis to identify program features that contribute to problematic performance and on-line performance analysis to drive adaptation. This final report summarizes the research and development activity at Rice University as part of the PIPER project. Producing a complete suite of performance tools for exascale platforms during the course of this project was impossible since both hardware and software for exascale systems is still a moving target. For that reason, the project focused broadly on the development of new techniques for measurement and analysis of performance on modern parallel architectures, enhancements to HPCToolkit’s software infrastructure to support our research goals or use on sophisticated applications, engaging developers of multithreaded runtimes to explore how support for tools should be integrated into their designs, engaging operating system developers with feature requests for enhanced monitoring support, engaging vendors with requests that they add hardware measure- ment capabilities and software interfaces needed by tools as they design new components of HPC platforms including processors, accelerators and networks, and finally collaborations with partners interested in using HPCToolkit to analyze and tune scalable parallel applications.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2018

Biomass Pyrolysis to Hydrocarbon Fuels in the Petroleum Refining Context: Cooperative Research and Development Final Report, CRADA Number CRD-12-500

This work focuses on developing a thermochemical route to produce biofuels from agricultural wastes such as sugar cane bagasse, wood chips or corn stover; more specifically it intends to develop the biomass pyrolysis route, which produces bio-oils. Production of bio-oils by pyrolysis is a commercial technology. However, bio-oils are currently not being used for liquid fuels production. Although bio-oils can be produced by high-pressure liquefaction, pyrolysis is a less expensive technology. Nevertheless, bio-oils cannot be used directly as a transportation fuel without upgrading, since they are generally unstable, viscous, and acidic. Thus NREL and Petrobras intend to use their combined expertise to develop a two-step route to biofuels production: in the first step, a stable bio-oil is produced by NREL biomass pyrolysis technology, while in the second step it is upgraded by using two distinct catalytic processes under development by Petrobras. The first process converts bio-oil into gasoline, LPG, and fuel oil using the catalytic cracking process, while the second one, converts bio-oil into synthesis gas. Syngas gasification catalysts provided by both NREL and Petrobras will be tested. The work includes experiments at both sites to produce bio-oil and then biofuels, life-cycle analysis of each route, personnel training and development of analytical methods with a duration time of two years.

09 BIOMASS FUELS↗
DOE OSTI2017

Development of Integrated Die Casting Process for Large Thin-Wall Magnesium Applications

The purpose of this project was to develop a process and product which would utilize magnesium die casting and result in energy savings when compared to the baseline steel product. The specific product chosen was a side door inner panel for a mid-size car. The scope of the project included: re-design of major structural parts of the door, design and build of the tooling required to make the parts, making of parts, assembly of doors, and testing (both physical and simulation) of doors. Additional work was done on alloy development, vacuum die casting, and overcasting, all in order to improve the performance of the doors and reduce cost. The project achieved the following objectives: 1. Demonstrated ability to design a large thin-wall magnesium die casting. 2. Demonstrated ability to manufacture a large thin-wall magnesium die casting in AM60 alloy. 3. Tested via simulations and/or physical tests the mechanical behavior and corrosion behavior of magnesium die castings and/or lightweight experimental automotive side doors which incorporate a large, thin-wall, powder coated, magnesium die casting. Under some load cases, the results revealed cracking of the casting, which can be addressed with re-design and better material models for CAE analysis. No corrosion of the magnesium panel was observed. 4. Using life cycle analysis models, compared the energy consumption and global warming potential of the lightweight door with those of a conventional steel door, both during manufacture and in service. Compared to a steel door, the lightweight door requires more energy to manufacture but less energy during operation (i.e., fuel consumption when driving vehicle). Similarly, compared to a steel door, the lightweight door has higher global warming potential (GWP) during manufacture, but lower GWP during operation. 5. Compared the conventional magnesium die casting process with the “super-vacuum” die casting process. Results achieved with cast tensile bars suggest some improvement in tensile properties with vacuum casting. Plant trials with large castings revealed cavity fill issues attributed to cooling and partial solidification of metal in the shot sleeve while waiting for vacuum to be established in the die cavity. 6. Developed age-hardenable Mg-based alloys as potential alternatives to the AM60 and AZ91 alloys typically used in automotive applications. Mg-7%Al-based alloys having Sn or Sn+Si additions exhibited significant age hardening, but more work is needed to demonstrate significant improvement in tensile properties. Corrosion behavior of these alloys is between those of AM60 and AZ91 alloys. 7. Evaluated the die casting of magnesium directly onto either steel or aluminum tubes as a potential process to make large lightweight subassemblies. Samples were free of gross defects, but additional work is needed to increase the interfacial shear strength. Overall, the project demonstrated that an automotive door-in-white design incorporating a die cast magnesium inner panel and a stamped aluminum outer panel can achieve approximately 50% mass reduction compared to the stamped steel baseline door-in-white. This leads to reduced energy consumption when driving the vehicle, which should more than offset the increased embedded energy of manufacture associated with the lighter metals. However, additional design work would be needed in order to meet the mechanical performance required of a door. Development of high-strength, high-ductility magnesium alloy castings would help make this technology more attractive for potential use in the side doors on automobiles. Also, increased use of recycled magnesium and aluminum would reduce the embedded energy and greenhouse gas emissions associated with the manufacture of this type of lightweight door. Commercialization planning of the type of lightweight door technology addressed in this project would be contingent upon the doors meeting all technical performance requirements of the car maker. The specific lightweight door developed in this project didn’t meet some of those requirements, but a preliminary business case study was conducted anyhow. This study considered the ratio of cost increase to mass decrease when the lightweight door is compared to a baseline steel door. The ratio was found to be in an acceptable range for some vehicle programs, especially if the number of such vehicles to be produced is equal to or slightly less than the estimated 250,000-shot life of the die set. This would allow for the investment in the dies to be spread across many parts and thereby help minimize the cost increase.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2018

Advanced Ultrasupercritical (AUSC) Materials Thick-Walled Cycling Header Development for ComTest-AUSC (Final Report)

Alstom Power Inc., a wholly owned subsidiary of the General Electric Company (GE) recently completed “Advanced Ultrasupercritical (AUSC) Materials Thick-Walled Cycling Header Development for ComTest-AUSC” under Award No. DE-FE0026183 for the U.S. Department of Energy National Energy Technology Laboratory (DOE NETL). This project developed a design for testing of a high temperature nickel-based superalloy thick-walled header to simulate cycling and flexible plant operation in new and existing plants. The objective was to simulate the expected thermal stresses of a new AUSC plant or a retrofit header in an existing plant to improve flexible dynamic operation while maintaining component integrity and overall power plant reliability. The high performance superalloy materials that enable higher operating temperatures and pressures can support future transformational power technologies including new AUSC plants at 4250-5000 psi, 730°C/760°C or will serve as a replacement component in a repowered or retrofit USC coal powered cycling plant at 3600 psi, 600°C. These alloys can also enable supercritical CO2 cycles, nuclear power, solar power and more efficient natural gas combined cycle units as targeted by the U.S. DOE/NETL Cross-Cutting Research Technology Program Plan. Recently developed advanced nickel alloys such as Inconel 740H (740H) and Haynes 282 (H282) have been successfully tested on a pilot scale for fireside corrosion using steam loop tubing at AUSC temperatures of 760°C in actual operating coal fired boiler. These high strength materials have been demonstrated their adequacy for use in other high temperature boiler components such as superheater tubes. Thick-walled superheater outlet headers which operate at high temperatures and pressure under severe cycling condition are considered as one of the most critical component in the AUSC coal fired boiler. Over the design life of a plant, these headers are exposed to the most severe fatigue and creep damage accumulation and need to be properly designed for the expected cycling in an AUSC plant with flexible operation. These materials need to demonstrate adequate design life of 20 to 30 years for creep and fatigue conditions. The following tasks were performed: 1. A conceptual design was developed of a thick-walled component representative of typical headers with several tube connections and proper flow rates (~100,000 lbs/hr) suitable for Phase II test at 760°C operation. This was based on a process analysis of expected full scale new and component retrofit designs for AUSC; 2. A multi-physics flow and heat transfer computational fluid dynamics (CFD) analysis of the component for proper layout of the header configuration, number and geometry (size) of tubes required for bypass flow, flow rates through the tubing, and sectional pressure drops was performed. Steam to header metal heat transfer film coefficients in the header section and the tubes during the two stages (half load and full load) of the cycling operation were evaluated and used in the stress analysis; 3. Detailed analytical evaluation of the thick-walled pipe and tube connections for mechanical integrity under cycling conditions was performed. This included transient thermal stress analysis and fatigue usage estimation including the tube-to-pipe weld geometries and weld materials; 4. A layout and design of the thick-walled test component was developed and instrumentation required for a test was identified; 5. Continuum Damage Mechanics (CDM) creep prediction models were extended to 740H and H282 and validated with public data on 740H and H282 for use in creep analysis. In addition, detailed creep analyses were performed separately for the design life of the conceptual AUSC superheater outlet header using these General Electric (GE) creep constitutive models. GE was the prime contractor for the project, which was directed by Principal Investigator Robert Schrecengost and Lead Scientist Dr. B. Reddy Ganta. Other collaborative participants in this project included GE Global Research, GE Boiler Engineering, and a Technical Consultant from EPRI.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2017

Research and Development Toward Massive Liquid Argon Time Projection Chambers for Neutrino Detection

Liquid argon (LAr) time projection chambers (TPC) have rapidly increased in importance as particle detectors throughout the past four decades. While much research has been completed, there are still many areas which require further development to build and operate the next generation LAr TPC experiment, such as the Deep Underground Neutrino Experiment (DUNE). These include high voltage breakdown, argon purification and purity monitoring, and vacuum ultraviolet (VUV) scintillation light measurement. Visual monitoring of high voltage breakdown is helpful in allowing assessment of the performance of high voltage component design. Thus, a system of cryogenic cameras, the first of its kind, was developed for use in a large LAr cryostat, without the need for additional electronics heating. The system functioned without problem for 50 days at cryogenic temperature, with some degradation of image quality, and provided a useful monitor for the DUNE 35-ton cryogenics systems. The system did not observe any high voltage breakdowns during the run. Further development of the concept is ongoing for future installation in other experiments. The monitoring of LAr purity using TPC data is a fundamental study for LAr TPC experiments. However, the study has not been performed for a large LAr TPC in the presence of high electronic noise. Custom software was developed and validated for the accurate reconstruction of signals in noisy TPC data. The results of the reconstruction were used to successfully measure the LAr electron lifetime with an uncertainty comparable to alternate methods of measurement. The electron lifetime of the 35-ton Phase II run is determined to be 4.12 ± 0.17 (stat.) ±0.40 (syst.) ms. For general purpose research and development of high purity LAr as a particle detection medium, a dedicated test stand was designed, constructed, and commissioned. The system is used to test the gaseous photomultiplier (GPM) performance at cryogenic temperatures. The GPM functions with photoelectron multiplication at 77 K, at a reduced gain. Further study is required to show the detector’s direct sensitivity to LAr VUV scintillation light.

Thiesse, Matthew↗
DOE OSTI2018

Development of Mixed-Salt Technology for CO 2 Capture from Coal Power Plants (Final Report)

SRI International (SRI), in collaboration with Stanford University, OLI Systems (OLI), Politecnico de Milano (PoliMi), and Aqueous Systems Aps (ASApS) performed a 45-month effort to develop a promising Mixed-Salt Process (MSP) for carbon dioxide capture. The MSP combines existing ammonia and potassium-carbonate technologies with improved absorption steps for rate enhancement and ammonia emission reduction and a novel selective regeneration process with a high-pressure CO 2 product to introduce a new and advanced transformational solvent-based technology. The striking advantages of the SRI MSP include: low heat of reaction, high loading of CO 2 , high-pressure regeneration of > 99% pure dry CO 2 , low sensitivity to impurities, low process cost, use of a non-degradable low-cost solvent with a very low carbon footprint for its production, low emissions, and reduced water use compared to the state-of-the-art ammonia-based and amine technologies. The overall objective of the project was to develop and test a solvent-based CO 2 capture technology that can capture CO 2 from existing or new pulverized coal (PC) power plants at low cost. Our specific goal was to test SRI’s newly developed MSP at the large bench-scale level to demonstrate that the process could capture CO 2 at high efficiency (> 90%) with very high CO 2 loading (> 10 wt.%), require less than 2 GJ/tonne for solvent regeneration, and produce a CO2 stream at high pressure with a purity > 95 vol.%. This 45-month MSP development program was designed to conduct (1) extensive test campaigns with different process flowsheet variants, and (2) detailed thermodynamic, kinetic, and process modeling. These tests and models were very important to identify any issues associated with the process in the early stages and then resolve them before moving into the next scale-up (> 1 MWe scale) testing. Such an approach reduces the risks associated with the process operability at large scales and provides capital and operating expenditure (CAPEX/OPEX) predictions with improved accuracies. Under the MSP development program at SRI, we performed an aggressive testing campaign with individual subsystems as well as integrated CO 2 capture and regeneration system to identify the best operating conditions. The project was carried out in two budget periods (BP1 & BP2).

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2018

Development and Rigorous Validation of Modules for Predicting Organic Aerosol CCN Activity from Molecular Properties

The indirect interaction of anthropogenic aerosols with clouds (aerosol indirect forcing) represents one of the main uncertainties in climate projections, and reducing this uncertainty requires improved understanding of the aerosol life cycle, including atmospheric aging and the ability to nucleate cloud droplets or crystals. A key parameter that links the chemical properties of aerosol to its nucleating properties, and ultimately to aerosol indirect forcing, is its hygroscopicity (ability to uptake water). One way to compare and systematize the ability of various chemical compounds or particle types to nucleate cloud drops is via the hygroscopicity parameter κ, which can be used directly in global models to simulate aerosol indirect forcing. In this project we further investigated the relationships between the chemical composition of organic aerosol particles, which are known to be important components of atmospheric particulate matter, and their ability to serve as cloud condensation nuclei (CCN). In particular, we isolated the role of viscosity on κ by applying methods similar to those we used previously in our DOE/ASR research. Our motivation for the focus on viscosity was through its link to particle phase state. Particle phase affects water uptake on timescales relevant to the laboratory and also likely relevant to atmospheric processes, with reduced apparent hygroscopicities for semisolid and solid particles, compared with liquid particles. Water uptake itself affects viscosity, an important feedback that we explored in this project. The objectives of the project were as follows: (1) measure the effects of molecular structure, temperature, and relative humidity on the viscosity of organic aerosol formed via controlled laboratory experiments, (2) measure the effects of organic aerosol viscosity on water uptake and CCN activity above and below water saturation, (3) further develop the κ parameterization of organic aerosol hygroscopicity to include viscosity/phase, and (4) experimentally validate the κ parameterization for organic aerosol with chemical composition ranging from relatively simple to complex. It was proposed that particle viscosity exerts a kinetic control on equilibrium water uptake. High viscosity was expected to delay water uptake based on diffusional limitations. This would manifest itself in reduced observed CCN activity or κ. Understanding the interplay between water content and viscosity (composition control on particle viscosity) and between viscosity and equilibrium water content (diffusional control on water uptake) were the overall science objectives of this grant. Targeted experiments were carried out to test the kinetic control hypothesis. These experiments included studies that explicitly measured the equilibration time scale of water uptake, and experiments that tested the role of viscous particle coatings on the observed CCN activity. From the combined work, it is concluded that mass transfer limitations by glassy organic particles are unlikely to affect cloud droplet activation near laboratory temperatures. This implies that viscosity does not need to be included in parameterizations that link particle chemical composition and κ. A parameterization to predict κ through the UNIFAC group contribution method was developed with previous ASR funding. As planned, this computational module was further developed and validated here through targeted laboratory studies. The computational module has been made available as free software under the GNU public license. A database of κ-values to aid model development has been compiled and is available online via an open access model. In conducting this work, significant effort was made to understand how aerosol composition, including the associated aerosol water content, affects viscosity. This included a study detailing the influence of functional group composition on organic aerosol viscosity. We identified a strong link between volatility and viscosity. Functional groups responsible for low vapor pressure also promote high viscosity. Specifically, carboxylic acid and hydroxyl groups were identified as major contributors to high viscosity. Several studies were carried out to characterize the link between composition and the glass-to-liquid phase transition. Compositions tested include models of organic/inorganic particles and models of complex organic aerosol formed through secondary processes. A simple computational model to predict the amorphous phase diagram was developed and tested. Excellent agreement between model and measurements was obtained for organic/inorganic mixtures. The computational model is simple enough to be included in global model simulations. However, constraints of input parameters such as the Gordon-Taylor constant for binary mixtures for a wide range of complex mixtures have not yet been fully evaluated. Combined, the performed work provides new constraints on the amorphous phase state of organic aerosols.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2018

CRADA 376 Final Report Development of Protective Coatings for 1 kW Hot Zone

Pacific Northwest National Laboratory (PNNL) has extensive experience in the development, fabrication, and evaluation of surface treatments and protective coatings for metallic solid oxide fuel cell (SOFC) components. For example, modified (Mn,Co)3O4 spinel coatings and coating/metal interfaces have been shown to substantially improve oxidation resistance, electrical performance, and oxide scale adhesion of ferritic stainless steel interconnects in planar SOFC stacks. At the time of the establishment of this CRADA, Protonex Technology Corporation had been working in the field of SOFC development for over 12 years and had demonstrated more than 250 thermal cycles with a less than 15 minutes start time and more than 2000 hours of continuous operation on a 250W tubular solid oxide hot zone module as part of a program for the Office of the Secretary of Defense (OSD). An industrial version of the military system, denoted P200i, had been developed that was launched at the 2015 Fuel Cell Expo in Tokyo. Feedback during beta testing of this unit was very positive. However, Protonex recognized that to transition from military markets, the commercial system would require longer life time and higher power. Leveraging their novel thermal management strategy from the tubular hot zone that allowed for rapid and repeated thermal cycling, Protonex developed a planar 1kW module aimed at the industrial and commercial market. However, more robust interconnect coatings were needed to bring the system into the 1000+ hour life time requested by customers. Therefore, PNNL’s experience and technology were engaged to enable the 1kw system to transition from military applications to commercial and industrial applications. In this CRADA, PNNL teamed with Protonex to leverage PNNL’s expertise in protective coating techniques for solid oxide fuel cell (SOFC) applications. As the first step in the collaboration, protective spinel coatings were fabricated at PNNL onto ten AISI 440 stainless steel bus bars provided by Protonex. A precursor slurry containing spinel powder was applied to the steel surfaces via an ultrasonic spray process. The coated bars were then subjected to a reducing atmosphere heat treatment (i.e., heated to 850°C at 3°C/min in a hydrogen atmosphere and held at that temperature for five hours). Five of the bars were left in this reduced condition; the other five bars were subjected to an oxidizing heat treatment (i.e., heated to 1000°C at 3°C/min in air and held at that temperature for one hour). The bars were then sent to Protonex for testing. Subsequently, Protonex decided to discontinue their SOFC development activities, so they had no further interest in continuing the collaboration with PNNL, and the CRADA activities were terminated.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2018

Advanced Control Architecture and Sensor Information Development for Process Automation, Optimization, and Imaging of Chemical Looping Systems

The Syngas Chemical Looping (SCL) process developed at The Ohio State University (OSU) uses an iron-based oxygen carrier to convert syngas into high-purity hydrogen while simultaneously capturing carbon dioxide that is readily sequestrable. A 25 kWth sub-pilot unit was successfully demonstrated multiple times on the OSU Clean Coal Research Facility, and a 250 kWth – 3 MWth pilot demonstration unit has been designed and constructed at the National Carbon Capture Center (NCCC) in Wilsonville, Alabama. The focus of this project is to develop multiple technologies to automate the startup and shutdown of chemical looping system. Success of this project will propel the advanced carbon capture method toward commercialization, hence be disruptive to the fossil fuel and power industries. Advanced process automation control architecture and imaging and optimization sensor software were developed for OSU chemical looping process. A high-level controller (HLC) consisting of decision-making and controller-selection logic integrated with sliding mode controllers (SMCs) were developed to perform chemical looping process startup and shutdown. Babcock & Wilcox Power Generation Group’s FocalPoint Optimization System was implemented to optimize the process operating conditions. The process automation controller and optimization information were realized and tested on OSU’s existing sub-pilot chemical looping test unit under atmospheric condition. The implemented control architecture was able to perform the complete process procedure from startup, steady-state reaction operation to shutdown with minimal operator intervention. The controller was also implemented on the pressurized syngas chemical looping (SCL) pilot test unit constructed at the National Carbon Capture Center (NCCC), demonstrating its pressure control capability with a designed transient state trajectory. An electrical capacitance volume tomography (ECVT) sensor device and its software were developed to image the packed moving bed and slugging fluidized bed of oxygen carriers in chemical looping systems at elevated temperatures. The ECVT device constructed was capable of tracking the subtle voidage variance along the moving bed axis as a feature for directly measuring the oxygen carrier particles’ linear velocity. Also, the high temperature ECVT device was used to study the fluidization characteristics of Geldart Group D particles.

08 HYDROGEN↗
DOE OSTI2018

Report on the completion of the development of processing map from as-cast Alloy 709 materials

This report provides details on the completion of the development of the processing map from the as-cast Alloy 709 materials. The report is a Level 4 deliverable in FY18 (M4NT18AN050502012), under the Work Package NT-18AN05050201, “A709 Development” performed by Argonne National Laboratory, as part of Advanced Structural Materials Program for the Advanced Reactor Technologies (ART). The report describes the development of a processing map to guide the development of hot work regimens for A709. The maps combine high-temperature flow stress measurements, described in a companion report by Oak Ridge National Laboratory, and metallographic observations, described here, into a single diagram that can be used to select hot working parameters to avoid regions of plastic instability and to avoid the development of unfavorable microstructures. This report describes the process of creating the map, provides the final map for A709, and uses the processing map to describe two potential hot work regimens that could be used in processing a DOE round ingot into bar stock.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗