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Tracer-Guided Characterization of Dominant Pore Networks and Implications for Permeability and Wettability in Shale

Pore network characterization is an important aspect in unconventional reservoir evaluation. While application of the technique of scanning electron microscope (SEM) brings substantial advances in pore characterization in shale, understanding the connected pore network that dominates flow in shale samples is limited by using SEM alone because of small fields of view and lack of views of connectivity in 3D. In this research, a technique integrating tracer imbibition, micro-computed tomography (CT) imaging, and SEM imaging was developed to provide a solution for multiscale imaging in shale. Tracer imbibition indicates pore connectivity; micro-CT imaging after tracer imbibition thus provides an overview of the connected pore network at the millimeter scale. With guidance from micro-CT images after tracer imbibition, a more accurate and detailed characterization of pore systems and related mineralogy can be conducted using higher-resolution SEM. The method was applied to five samples from Wolfcamp and Eagle Ford Formations. Results reveal the effectiveness of the integrated method by showing different patterns of distribution of the dominant pore network and different controlling mineralogy. Dominant porosity, estimated from grayscale analyses, displays a good correlation with permeability. This result indicates that dominant porosity is more relevant to permeability than is total porosity. Results from imbibition tests are also compared with that from contact angle measurement, and important implications on wettability can be obtained. The integrated method thus has the capacity to link the dominant pore network and wettability with microscale to submicroscale mineralogy, which can help better understand the pore systems and fluid flow in shale. Plain Language Summary Pore network characterization and wettability are two important aspects in unconventional reservoir evaluation and are crucial to understanding the nature of shale oil or gas storage and production. Here, a new technique integrating tracer imbibition, micro-computed tomography imaging, and scanning electron microscope imaging was developed for a more representative and effective pore characterization in shale. This integrated technique can provide a direct visualization of the dominant pore network in a millimeter-scale sample and, at the same time, can provide a guided pore network characterization under nanoscale resolution. This method thus can generate results that are more representative and more accurate in a more efficient way compared with the traditional scanning electron microscope method. The new technique can also reveal the local wettability in microscale. High-resolution analysis on the tracer imbibition or fluid displacement and mineralogy can shed light on the local wettability and the controlling mineralogy in shale.

58 GEOSCIENCES↗

A Distributed Intelligent Automated Demand Response Building Management System

The goal of the 2.5 year Distributed Intelligent Automated Demand Response (DIADR) project was to reduce peak electricity load of Sutardja Dai Hall at UC Berkeley by 30% while maintaining a healthy, comfortable, and productive environment for the occupants. We sought to bring together both central and distributed control to provide “deep” demand response1 at the appliance level of the building as well as typical lighting and HVAC applications. This project brought together Siemens Corporate Research and Siemens Building Technology (the building has a Siemens Apogee Building Automation System (BAS)), Lawrence Berkeley National Laboratory (leveraging their Open Automated Demand Response (openADR), Auto-­Demand Response, and building modeling expertise), and UC Berkeley (related demand response research including distributed wireless control, and grid-­to-­building gateway development). Sutardja Dai Hall houses the Center for Information Technology Research in the Interest of Society (CITRIS), which fosters collaboration among industry and faculty and students of four UC campuses (Berkeley, Davis, Merced, and Santa Cruz). The 141,000 square foot building, occupied in 2009, includes typical office spaces and a nanofabrication laboratory. Heating is provided by a district heating system (steam from campus as a byproduct of the campus cogeneration plant); cooling is provided by one of two chillers: a more typical electric centrifugal compressor chiller designed for the cool months (Nov-­ March) and a steam absorption chiller for use in the warm months (April-­October). Lighting in the open office areas is provided by direct-­indirect luminaries with Building Management System-­based scheduling for open areas, and occupancy sensors for private office areas. For the purposes of this project, we focused on the office portion of the building. Annual energy consumption is approximately 8053 MWh; the office portion is estimated as 1924 MWh. The maximum peak load during the study period was 1175 kW. Several new tools facilitated this work, such as the Smart Energy Box, the distributed load controller or Energy Information Gateway, the web-­based DR controller (dubbed the Central Load-­Shed Coordinator or CLSC), and the Demand Response Capacity Assessment & Operation Assistance Tool (DRCAOT). In addition, an innovative data aggregator called sMAP (simple Measurement and Actuation Profile) allowed data from different sources collected in a compact form and facilitated detailed analysis of the building systems operation. A smart phone application (RAP or Rapid Audit Protocol) facilitated an inventory of the building’s plug loads. Carbon dioxide sensors located in conference rooms and classrooms allowed demand controlled ventilation. The extensive submetering and nimble access to this data provided great insight into the details of the building operation as well as quick diagnostics and analyses of tests. For example, students discovered a short-­cycling chiller, a stuck damper, and a leaking cooling coil in the first field tests. For our final field tests, we were able to see how each zone was affected by the DR strategies (e.g., the offices on the 7th floor grew very warm quickly) and fine-­tune the strategies accordingly.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Elevated Ozone Concentration Reduces Photosynthetic Carbon Gain but Does Not Alter Leaf Structural Traits, Nutrient Composition or Biomass in Switchgrass

Elevated tropospheric ozone concentration (O3) increases oxidative stress in vegetation and threatens the stability of crop production. Current O3 pollution in the United States is estimated to decrease the yields of maize (Zea mays) up to 10%, however, many bioenergy feedstocks including switchgrass (Panicum virgatum) have not been studied for response to O3 stress. Using Free Air Concentration Enrichment (FACE) technology, we investigated the impacts of elevated O3 (~100 nmol mol−1) on leaf photosynthetic traits and capacity, chlorophyll fluorescence, the Ball–Woodrow–Berry (BWB) relationship, respiration, leaf structure, biomass and nutrient composition of switchgrass. Elevated O3 concentration reduced net CO2 assimilation rate (A), stomatal conductance (gs), and maximum CO2 saturated photosynthetic capacity (Vmax), but did not affect other functional and structural traits in switchgrass or the macro- (except potassium) and micronutrient content of leaves. These results suggest that switchgrass exhibits a greater O3 tolerance than maize, and provide important fundamental data for evaluating the yield stability of a bioenergy feedstock crop and for exploring O3 sensitivity among bioenergy feedstocks.

59 BASIC BIOLOGICAL SCIENCES↗

Assessment of radar resolution requirements for soil moisture estimation from simulated satellite imagery

Radar simulations were performed at five-day intervals over a twenty-day period and used to estimate soil moisture from a generalized algorithm requiring only received power and the mean elevation of a test site near Lawrence, Kansas. The results demonstrate that the soil moisture of about 90% of the 20-m by 20-m pixel elements can be predicted with an accuracy of + or - 20% of field capacity within relatively flat agricultural portions of the test site. Radar resolutions of 93 m by 100 m with 23 looks or coarser gave the best results, largely because of the effects of signal fading. For the distribution of land cover categories, soils, and elevation in the test site, very coarse radar resolutions of 1 km by 1 km and 2.6 km by 3.1 km gave the best results for wet moisture conditions while a finer resolution of 93 m by 100 m was found to yield superior results for dry to moist soil conditions.

Ulaby, F. T.↗

Final Report UCLA-Thermochemical Storage with Anhydrous Ammonia

In ammonia-based thermochemical energy storage (TCES), ammonia is dissociated endothermically as it absorbs solar energy during the daytime. When energy is required, the reverse reaction releases energy to heat a working fluid such as steam, to produce electricity. Ammonia-based TCES has great advantages of simplicity, low cost reactants, and a strong industrial base in the conventional ammonia industry. The concept has been demonstrated over three decades of research at Australian National University, achieving a 24-hour demonstration of a complete system. At the start of this project, three challenges were identified that would have to be addressed to show that the system is technically and economically viable for incorporation into a CSP plant with an advanced, high temperature power block. All three of these challenges have now been addressed: 1. The ammonia synthesis reaction had not, to our knowledge, been carried out at temperatures consistent with modern power blocks (i.e., ~650°C). The technical feasibility of operating a reactor under high-temperature, near-equilibrium conditions was an unknown, and was therefore a technical risk. The project has successfully demonstrated steam heating to 650°C and energy recovery to steam at the 5 kWt level. 2. The ammonia system has a relatively low enthalpy of reaction combined with gas phase reactants. This is not a direct disadvantage since the reactants themselves are low cost. The challenge lies in storing the required volume of reactants cost effectively. Therefore, a second key goal was to show, through techno-economic analysis, that underground storage technologies can be used to store the energy-rich gas at a cost that is consistent with the SunShot cost goal. We have identified two promising technologies for gas storage: storage in salt caverns has an estimated cost of 1(USD)/kWht and storage in drilled shafts could be on the order of 7(USD)/kWht. Together these two options answer the technical challenge associated with storage of gas phase components. 3. While this project is primarily concerned with high-temperature heat recovery and methods to store the gaseous components, it is also important to consider the feasibility of the entire system. Consequently, an additional goal was to perform analysis to show the feasibility of integrating endothermic reactors within a tower receiver. A conceptual design of an ammonia dissociation receiver/reactor has been developed that fits into the same size cylindrical envelope as the molten salt receiver in SAM, and has the same design thermal capacity. The calculated thermal efficiency of this receiver is 94.6%. Thus, this investigation has established the technical feasibility of a surround field tower system using ammonia dissociation. With these challenges addressed, we proceeded to design a full-scale synthesis and heat recovery system. A model was developed and validated by comparison with our experimental data. A parametric study showed, among other things, the importance of using small tube diameters and spacing to enhance heat transfer. Multi-parameter optimization was used to find a design that minimizes the wall material volume. Finally, cost estimation shows that the ammonia system has good prospects of meeting the Sunshot 15(USD)/kWht target: estimated costs of the entire synthesis system for the 220 MWt plant with 6 hours of storage are 13(USD)/kWht using salt cavern storage and 18(USD)/kWht using shaft drilling. Costs per kWht are even lower with more hours of storage. With the established technology of ammonia synthesis as a starting point, the successes of the project have mitigated technical risks associated with high-temperature synthesis reaction, underground storage, and tower receiver design. Estimated costs are less than 15(USD)/kWht with salt cavern storage. It is now possible to map a time line to commercial deployment that is likely to be shorter and less risky than other thermochemical cycles under active investigation. UCLA has filed a patent that protects the new ideas developed during this project. Discussions are ongoing with potential investors with the aim of partnering for further work. As well as immediate improvements and extra work with the existing experimental system, a key goal is to extend it to a small solar-driven project at an early opportunity.

14 SOLAR ENERGY↗

The terrestrial biosphere as a net source of greenhouse gases to the atmosphere

The terrestrial biosphere can release or absorb the greenhouse gases, carbon dioxide (CO2), methane (CH 4 ) and nitrous oxide (N 2 O), and therefore has an important role in regulating atmospheric composition and climate 1 . Anthropogenic activities such as land-use change, agriculture and waste management have altered terrestrial biogenic greenhouse gas fluxes, and the resulting increases in methane and nitrous oxide emissions in particular can contribute to climate change 2, 3 . The terrestrial biogenic fluxes of individual greenhouse gases have been studied extensively 4, 5, 6 , but the net biogenic greenhouse gas balance resulting from anthropogenic activities and its effect on the climate system remains uncertain. Here we use bottom-up (inventory, statistical extrapolation of local flux measurements, and process-based modelling) and top-down (atmospheric inversions) approaches to quantify the global net biogenic greenhouse gas balance between 1981 and 2010 resulting from anthropogenic activities and its effect on the climate system. We find that the cumulative warming capacity of concurrent biogenic methane and nitrous oxide emissions is a factor of about two larger than the cooling effect resulting from the global land carbon dioxide uptake from 2001 to 2010. This results in a net positive cumulative impact of the three greenhouse gases on the planetary energy budget, with a best estimate (in petagrams of CO 2 equivalent per year) of 3.9 ± 3.8 (top down) and 5.4 ± 4.8 (bottom up) based on the GWP100 metric (global warming potential on a 100-year time horizon). Lastly, our findings suggest that a reduction in agricultural methane and nitrous oxide emissions, particularly in Southern Asia, may help mitigate climate change.

54 ENVIRONMENTAL SCIENCES↗

Numerical Modeling & Size Optimization of Thermal Energy Storage for Iron & Steel Production

Iron and steel production are responsible for 90 million MtCO2 per year in the United States. Hydrogen direct reduction of iron (H2DRI) is a promising pathway for a more sustainable iron production than commercially deployed technologies which rely on natural gas. The H2DRI process requires hydrogen at a temperature of up to 950 degrees C fed into a reduction furnace to produce pellets or briquettes that are used in the downstream iron and steelmaking process. In this work, we propose to use an electrical thermal energy storage (ETES) system, that can use renewable electricity to store high-temperature heat and dispatch it upon demand. Such a system can buffer the H2DRI plant from the variability of electricity prices by charging during curtailment and running the plant from storage during times of peak electricity price. We have developed heat transfer models for two different ETES systems that can be used to heat up hydrogen to the required temperatures: a particle-based ETES and a firebrick ETES. These models are used to evaluate the performance of such a system and support the sizing and preliminary cost estimation. The preliminary results using both models show that designing ETES systems for an industrial-scale H2DRI furnace is feasible. The firebrick ETES system has limited operational duration, which might limit the price buffering effect unless significantly oversized. The particle ETES system heat exchanger has industry-feasible dimensions, but its storage capacity would be decided upon the number of particle storage silos.

25 ENERGY STORAGE↗

Model Analysis of the Factors Regulating Trends and Variability of Methane, Carbon Monoxide and OH: 1. Model Validation

Methane (CH4) is the second most important anthropogenic greenhouse gas (GHG). Its 100-year global warming potential (GWP) is 25 times larger than that for carbon dioxide. The 100-yr integrated GWP of CH4 is sensitive to changes in OH levels. Methane's atmospheric growth rate was estimated to be more than 10 ppb yr(exp -1) in 1998 but less than zero in 2001, 2004 and 2005 (Kirschke et al., 2013). Since 2006, the CH4 is increasing again. This phenomena is yet not well understood. Oxidation of CH4 by OH is the main loss process, thus affecting the oxidizing capacity of the atmosphere and contributing to the global ozone background. Current models typically use an annual cycle of offline OH fields to simulate CH4. The implemented OH fields in these models are typically tuned so that simulated CH4 growth rates match that measured. For future and climate simulations, the OH tuning technique may not be suitable. In addition, running full chemistry, multi-decadal CH4 simulations is a serious challenge and currently, due to computational intensity, almost impossible.

OH↗

A PROPOSED METHOD FOR ESTIMATING FAILURE RATES OF DEGRADED PASSIVE COMPONENTS IN THE NRC SIGNIFICANCE DETERMINATION PROCESS

This paper outlines a methodology for estimation of the incremental core damage frequency associated with the degradation of passive components with a view to its application in the US Nuclear Regulatory Commission's significance determination process. The method involves use of simplified physics-based models of materials degradation and the probabilistic comparison of transient loads with deteriorating system capacities.

passives↗

Uranium Adsorbent Fibers Prepared by Atom-Transfer Radical Polymerization (ATRP) from Poly(vinyl chloride)- co -chlorinated Poly(vinyl chloride) (PVC- co -CPVC) Fiber

The need to secure future supplies of energy attracts researchers in several countries to a vast resource of nuclear energy fuel: uranium in seawater (estimated at 4.5 billion tons in seawater). In this study, we developed effective adsorbent fibers for the recovery of uranium from seawater via atom-transfer radical polymerization (ATRP) from a poly- (vinyl chloride)-co-chlorinated poly(vinyl chloride) (PVC-co-CPVC) fiber. ATRP was employed in the surface graft polymerization of acrylonitrile (AN) and tert-butyl acrylate (tBA), precursors for uranium-interacting functional groups, from PVC-co-CPVC fiber. The [tBA]/[AN] was systematically varied to identify the optimal ratio between hydrophilic groups (from tBA) and uranyl-binding ligands (from AN). The best performing adsorbent fiber, the one with the optimal [tBA]/[AN] ratio and a high degree of grafting (1390%), demonstrated uranium adsorption capacities that are significantly greater than those of the Japan Atomic Energy Agency (JAEA) reference fiber in natural seawater tests (2.42-3.24 g/kg in 42 days of seawater exposure and 5.22 g/kg in 49 days of seawater exposure, versus 1.66 g/kg in 42 days of seawater exposure and 1.71 g/kg in 49 days of seawater exposure for JAEA). Adsorption of other metal ions from seawater and their corresponding kinetics were also studied. The grafting of alternative monomers for the recovery of uranium from seawater is now under development by this versatile technique of ATRP.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Melting of Magnesium Borohydride under High Hydrogen Pressure: Thermodynamic Stability and Effects of Nanoconfinement

The thermodynamic stability and melting point of magnesium borohydride were probed under hydrogen pressures up to 1000 bar (100 MPa) and temperatures up to 400 °C. At 400 °C, Mg(BH4)2 was found to be chemically stable between 700 and 1000 bar H2, whereas under 350 bar H2 or lower pressures, the bulk material partially decomposed into MgH2 and MgB12H12. The melting point of solvent-free Mg(BH4)2 was estimated to be 367-375 °C, which was above previously reported values by 40-90 °C. Our results indicated that a high hydrogen backpressure is needed to prevent the decomposition of Mg(BH4)2 before measuring the melting point and that molten Mg(BH4)2 can exist as a stable liquid phase between 367 and 400 °C under hydrogen overpressures of 700 bar or above. The occurrence of a pure molten Mg(BH4)2 phase enabled efficient melt-infiltration of Mg(BH4)2 into the pores of porous templated carbons (CMK-3 and CMK-8) and graphene aerogels. Both transmission electron microscopy and small-angle X-ray scattering confirmed efficient incorporation of the borohydride into the carbon pores. The Mg(BH4)2@carbon samples exhibited comparable hydrogen capacities to bulk Mg(BH4)2 upon desorption up to 390 °C based on the mass of the active component; the onset of hydrogen release was reduced by 15-25 °C compared to the bulk. Importantly, melt-infiltration under hydrogen pressure was shown to be an efficient way to introduce metal borohydrides into the pores of carbon-based materials, helping to prevent particle agglomeration and formation of stable closo-polyborate byproducts.

White, James L.↗

Synthetic Methanol/Fischer–Tropsch Fuel Production Capacity, Cost, and Carbon Intensity Utilizing CO 2 from Industrial and Power Plants in the United States

Captured CO 2 is a potential feedstock to produce fuel/chemicals using renewable electricity as the energy source. In this study, we explored resource availability and synergies by region in the United States and conducted cost and environmental analysis to identify unique opportunities in each region to inform possible regional and national actions for carbon capture and utilization development. This study estimated production cost of synthetic methanol and Fischer–Tropsch (FT) fuels by using CO 2 captured from the waste streams emitted from six industrial [ethanol, ammonia, natural gas (NG) processing, hydrogen, cement, and iron/steel production plants] and two power generation (coal and NG) processes across the United States. The results showed that a total of 1594 million metric ton per year of waste CO 2 can be captured and converted into 85 and 319 billion gallons of FT fuels and methanol, respectively. FT fuels can potentially substitute for 36% of the total petroleum fuels used in the transportation sector in 2018. Technoeconomic analysis shows that the minimum selling prices for synthetic FT fuels and methanol are 1.8–2.8 times the price of petroleum fuel/chemicals, but the total CO 2 reduction potential is 935–1777 MMT/year.

54 ENVIRONMENTAL SCIENCES↗

A method for estimating eruption rates of planetary lava flows

The eruption rates of single-lobed planetary lava flows are presently accounted for by a model for radiative losses from a partially crusted hotter core, assuming thermal characteristics similar to terrestrial flows. Eruption rates are within this framework expressible as functions of (1) exposed core area fraction, (2) initial core temperature, (3) core temperature upon cessation of flow, (3) crust thickness, and (4) the lava's density and heat capacity.

Crisp, Joy↗

Using Willingness to Pay to Forecast the Adoption of Solar Photovoltaics: A ''Parameterization + Calibration'' Approach

Distributed energy resources, such as rooftop solar photovoltaics (PV), are likely to comprise a substantial fraction of new generation capacity in the United States. However, forecasting technology adoption based on people's willingness to pay (WTP) faces two major challenges: the stated-intention and omitted-variable biases. Previous solar adoption literature has neglected to address these two biases altogether. Here, we adopt a 'parameterization + calibration' approach to address both biases and estimate customers' WTP for PV. After collecting survey data on respondents' WTP for adopting PV, we characterize its empirical cumulative density function using a gamma distribution. We further calibrate the gamma distribution parameters using a national distributed PV adoption simulation model, finding the parameters that produce the best fit between simulated and historic solar adoption. We then show that the calibrated gamma distribution improves the raw WTP data after correcting for the two biases. Finally, we use our optimally-calibrated WTP to forecast market demand for residential PV at the county-level of the United States in 2020. Improving estimates of customer willingness to pay has significant implications for policy directly, e.g. estimating the effect of a proposed policy on technology adoption, and other regulatory processes that use forecasting, e.g. integrated resource planning.

14 SOLAR ENERGY↗

Forecasting distributed energy resources adoption for power systems

Failing to incorporate accurate distributed energy resource penetration forecasts into long-term resource and transmission planning can lead to cost inefficiencies at best and system failures at worst. We have developed an open-source tool that employs an advanced Bass specification to calibrate and forecast technology adoption. The advanced specification includes geographic clustering, exogenously estimated market size, and dynamic time steps. Training on historical adoption of rooftop photovoltaics at the U.S. county-level and using detailed techno-economic estimates, our model achieves a two-year average mean-absolute-percentage-error of 19% in predicting system counts at the county-level, weighted by population. Model error was negatively correlated with market maturity - the error was 12% for counties in states with at least 28 W-per-capita of installed capacity. The advanced specification significantly reduces unweighted forecasting percent error compared to a conventional Bass specification: from 196% to 25% for capacity and from 226% to 22% for system count.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Using naturally occurring radionuclides to determine drinking water age in a community water system

Drinking water quality in a community water system is closely linked to the age of water from initial treatment to time of delivery. However, water age is difficult to measure with conventional chemical tracers; particularly in stagnant water, where the relationship between disinfectant decay, microbial growth, and water age is poorly understood. Using radionuclides that were naturally present in source water, we found that measured activity ratios of 90 Y/ 90 Sr and 234 Th/ 238 U in discrete drinking water samples of known age accurately estimated water age up to 9 days old (σ est : ± 3.8 h, P < 0.0001, r 2 = 0.998, n = 11) and 25 days old (σ est : ± 13.3 h, P < 0.0001, r 2 = 0.996, n = 12), respectively. Moreover, 90 Y-derived water ages in a community water system (6.8 × 10 4 m 3 d –1 capacity) were generally consistent with water ages derived from an extended period simulation model. Radionuclides differ from conventional chemical tracers in that they are ubiquitous in distribution mains and connected premise plumbing. The ability to measure both water age and an analyte (e.g., chemical or microbe) in any water sample at any time allows for new insight into factors that control drinking water quality.

54 ENVIRONMENTAL SCIENCES↗

Makah Tribe Strategic Energy Plan

The U.S. Department of Energy’s (DOE) Energy Transitions Initiative Partnership Project (ETIPP) connects remote and island communities, regional partners, and the DOE national laboratories to support communities as they seek to build resilience in their energy systems. The Makah Tribe faces several energy challenges, including frequent power outages and the potential for an extended outage due to an earthquake or tsunami. The Tribe joined ETIPP in 2022 to address those challenges, seeking to build energy resilience and sovereignty in the community. The Makah Tribe, Spark Northwest, the Pacific Northwest National Laboratory (PNNL), and the National Renewable Energy Laboratory (NREL) collaborated to develop a strategic energy plan as part of the second cohort of ETIPP communities. The long-term energy vision of the Makah Tribe includes increasing energy efficiency in the community, improving energy management capacity, and developing the renewable energy generation and storage sufficient to independently power the Reservation for one year. Additionally, the ETIPP team worked with Makah leadership, staff, and community members to identify a set of community priorities, values, and goals to guide energy development as the Tribe takes the incremental steps toward their vision for energy sovereignty. Those energy values include ecosystem-based management, energy sovereignty and project ownership, workforce development and capacity, economic opportunity, community wellbeing and priorities, and emergency disaster resilience. To understand what would be needed for a year for energy independence, the PNNL team conducted an assessment to determine the current energy usage of the Tribe and also modeled several scenarios for future energy use. Using the energy usage values, the team estimated how two types of renewable energy technology, specifically locally deployed solar and small-scale wind, could contribute towards the energy independence goal. The energy baseline and resource assessment produced the following key findings:

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Experimental Comparison of Elastomeric Materials for Hydraulic Seal Durability under Reciprocating Conditions

Wave Energy Converters (WECs) rely on hydraulic Power Take-Off (PTO) systems to transform the kinetic energy of ocean waves into electricity, where hydraulic seals play a critical role in preventing fluid leakage and ensuring watertight operation under harsh marine conditions. However, seal degradation due to wear, fatigue, and corrosion remains a key challenge limiting system reliability and increasing maintenance costs. In this study, the tribological performance of elastomeric materials for hydraulic sealing applications that are based on commercial polyurethane and custom-compounded Ethylene Propylene Diene Monomer (EPDM) is investigated. Using a CSM tribometer, reciprocating wear tests were conducted in accordance with ASTM G133 under dry sliding conditions, with normal loads ranging from 3 to 10 N, and sliding speeds of 10 to 30 mm/s. Coefficient of friction (COF), specific wear rate, and worn surface morphology are evaluated to understand how load, velocity, and material composition affect seal durability. Improved wear stability and high Shore A hardness (93–94) were demonstrated by the commercial thermoplastic polyurethane (Duralast 4203 and 4758). EPDM-based compounds showed different filler-dependent behaviors, formulations filled with carbon black (E3) had the lowest wear rate (1.45 × 10?4 mm³ N?¹ m?¹) and increased load-bearing capacity, while samples modified with silica and plasticizer (E4, E5) had better conformability and damping but less hardness. Compounded EPDMs showed wider deformation zones because of their lower modulus and filler-matrix interfacial fluctuations, while commercial grades exhibited shallower wear scars (= 380 µm), according to optical profilometry. The Archard model-based lifetime estimation showed that, under 10 N and 30 mm/s, operational endurance ranged from 3.1 to 6.2 years. Because of its low wear rate and steady interfacial behavior, E3 had the longest anticipated life. For medium-load hydraulic sealing applications, these results demonstrate the possibility of customized EPDM formulations as affordable substitutes for commercial polyurethanes. They also offer a quantitative foundation for material selection and lifespan prediction.

Durability↗