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DOE OSTI2021

Best Practices at the End of Photovoltaic System Performance Period

Responsible and cost-effective dissolution of photovoltaic (PV) system hardware at the end of the performance period has emerged as an important business and environmental consideration. Alternatives include extending the performance period and existing contracts for power purchase, lease, and utility interconnect; refurbishing the plant by correcting any deficiencies; repowering the plant with new PV modules and inverters; or decommissioning the plant and removing all the hardware from the site. Often key decisions are made very early in the project development and might require decommissioning by some certain date after the end of a power purchase agreement. To “abandon in place” is not an alternative acceptable to landowners and regulators, so any financial prospectus should include costs associated with decommissioning, even if those costs are deferred by extending operations, refurbishment, or repowering. Decommissioning costs are driven by regulations regarding the handling and disposal of waste, with reuse and recycling of PV modules and other components preferred as a way to reduce both costs and environmental impact. Each alternative is discussed with order-of-magnitude costs, and recommendations are provided considering site-specific details of that situation, such as estimated costs to refurbish or repower, projected revenue from continued operations, and tax considerations.

14 SOLAR ENERGY↗

DOE OSTI2022

Laboratory and pilot-scale studies of membrane distillation for desalination of produced water from Permian Basin

Substantial quantities of produced water generated during the extraction of oil and gas from unconventional reservoirs present significant environmental concern and increase the operating cost for this industry. Membrane Distillation (MD) can serve as a potential solution for beneficial reuse of produced water by generating high-quality permeate and reducing the volume of produced water requiring disposal. This study investigated treatment of produced water from Permian Basin in both laboratory and pilot-scale studies. Laboratory tests revealed the potential to successfully recover 50% of produced water although some increase in permeate conductivity was observed due to the passage of ammonia from the feed side. Initial pilot-scale test with filtration of raw produced water as the only pre-treatment step led to precipitation of SrSO 4 , NaCl, and Fe in the system once the solubility limits for these salts were exceeded. However, chemical pretreatment that included pH adjustment, aeration, and barite precipitation, allowed successful steady-state operation of the AGMD pilot system for 5 days where the produced water was concentrated from 127 g/L to 255 g/L (~50% water recovery) while recovering high quality permeate. Overall, greater than 99.7 % salt rejection was achieved with the average permeate flux of 1.86 LMH. Finally, mass balance analysis suggested potential Ba and Ca precipitation in the system but there was no impact on AGMD performance and permeate quality during 5 days of continuous operation in the field.

42 ENGINEERING↗

DOE OSTI2023

Ultrathin stable Ohmic contacts for high-temperature operation of β -Ga2O3 devices

Beta gallium oxide (β-Ga2O3) shows significant promise in high-temperature, high-power, and sensing electronics applications. However, long-term stable metallization layers for Ohmic contacts at high temperatures present unique thermodynamic challenges. The current most common Ohmic contact design based on 20 nm of Ti has been repeatedly demonstrated to fail at even moderately elevated temperatures (300–400 °C) due to a combination of nonstoichiometric Ti/Ga2O3 interfacial reactions and kinetically favored Ti diffusion processes. Here, we demonstrate stable Ohmic contacts for Ga2O3 devices operating up to 500–600 °C using ultrathin Ti layers with a self-limiting interfacial reaction. The ultrathin Ti layer in the 5 nm Ti/100 nm Au contact stack is designed to fully oxidize while forming an Ohmic contact, thereby limiting both thermodynamic and kinetic instability. This novel contact design strategy results in an epitaxial conductive anatase titanium oxide interface layer that enables low-resistance Ohmic contacts that are stable both under long-term continuous operation (>500 h) at 600 °C in vacuum (≤10−4 Torr), as well as after repeated thermal cycling (15 times) between room temperature and 550 °C in flowing N2. This stable Ohmic contact design will accelerate the development of high-temperature devices by enabling research focus to shift toward rectifying interfaces and other interfacial layers.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2021

Ultra High Speed High Temperature Motor

The goal of this project was to develop a high-speed, high-temperature motor capable of operating at 650 ºC, 60,000 rpm, and 125 kW with 50 kW/L. Key objectives to achieve this goal were to develop a suitable high-temperature wire, designing and fabricating rotor and stator subassemblies, designing an inverter assembly, and thermomechanical validation of the fully assembled motor. Four candidates for high-temperature wire were evaluated using test solenoid structures and finite element analysis modeling. The best candidate was a silicone-enameled copper wire suitable for continuous operation at 593 ºC. The rotor for the motor was designed to use a composite material comprised of 74% iron and 26% mullite by volume. This material would be suitable for 3D printing of the rotor. At the end of the project a vacuum mixer was under construction to produce the bubble-free material needed to achieve the highest strength composite after 3D printing. Rotor testing at 60,000 rpm would have commenced immediately following the additive manufacturing process. The project abruptly ended when key personnel left the project without notice.

42 ENGINEERING↗

DOE OSTI2020

CO 2 Capture Using Electrochemically Mediated Amine Regeneration

We describe the current status of our research on, and the development of, the Electrochemically Mediated Amine Regeneration (EMAR) process for the capture of CO2 from flue gases. The absorption step in the EMAR process is the same as in the widely used amine process, but the desorption step is accomplished electrochemically as opposed to by a thermal swing used in the amine process. Our laboratory unit has operated continuously for over 200 h, spanning 130 absorption/desorption cycles. We have established an understanding of the thermodynamics of the EMAR process and provided engineering estimates of key features (energetics and sizing) of this technology. The EMAR system does not rely on steam integration, making it a truly plug-and-play unit that can be easily deployed for a range of applications. The EMAR system can also be scaled-down for distributed, modular, and small-scale operations (e.g., stainless steel mini-mills, etc.). Here, results to date indicate that the EMAR process has the potential to be a viable option for post-combustion CO2 capture.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2022

AmeriFlux FLUXNET-1F US-Ne1 Mead - irrigated continuous maize site

This is the AmeriFlux Management Project (AMP) created FLUXNET-1F version of the carbon flux data for the site US-Ne1 Mead - irrigated continuous maize site. This is the FLUXNET version of the carbon flux data for the site US-Ne1 Mead - irrigated continuous maize site produced by applying the standard ONEFlux (1F) software. Site Description - The study site is one of three fields (all located within 1.6 km of each other) at the University of Nebraska Eastern Nebraska Research, Education and Extension Center near Mead, Nebraska. This site is irrigated with a center pivot system. Prior to the initiation of the study, the irrigated site had a 10-yr history of maize-soybean rotation under no-till. A tillage operation (disking) was done just prior to the 2001 planting to homogenize the top 0.1 m of soil, incorporate P and K fertilizers, as well as previously accumulated surface residues. This field was planted with maize every growing season. Since the 2001 tillage operation, the site has been under no-till management until the harvest of 2005. Following harvest, a conservation-plow tillage operation was initiated where a small amount of N fertilizer is sprayed on the residue immediately prior to the plow operation. Approximately 1/3 of the crop residue is left on the surface. The post-harvest conservation-plow operation continued until 2022. Since 2022, the site management has changed such that the field is now a strictly no-till, maize-soybean rotation (maize odd years and soybean even years).

Suyker, Andy↗

DOE OSTI2023

In Situ Wind and Turbulence Measurements in a Field of Full-Size Parabolic Trough Solar Collectors

Concentrated Solar Power (CSP) is a promising method for using Solar power for electricity generation with thermal energy storage. One of the primary drivers of structural design costs of CSP collector structures is wind loading. To date, the design of these structures has relied on data from wind tunnels that do not adequately capture the dynamic effects observed at scale. NREL initiated a field measurement campaign at the operational Nevada Solar One (NSO) powerplant that uses parabolic troughs as solar collectors. The aim of the project is a detailed characterization of prevailing wind and turbulence conditions and resulting operational loads on parabolic troughs, providing insights on structural dynamic response, and generating a first-of-a-kind, comprehensive, high-resolution wind-loading dataset available for validating simulations of wind loading on collector structures. The measurements at NSO consist of Sonic anemometers on masts at different heights to characterize the incoming flow and conditions within and above the trough field, in combination with a Doppler Lidar scanning the horizontal plane above the troughs. The wind measurements at NSO have been continuously operating since October 2021 and provide a year-long dataset characterizing wind and turbulence conditions. The structural load measurements start in November 2022 and will complement the wind measurements. In this poster, we present first results of the wind measurement campaign by highlighting days with different atmospheric flow conditions. We identified three main factors altering the flow over the parabolic troughs: Wind speed, wind direction, and the angle of the parabolic troughs. The highest loads are expected when the wind blows perpendicular to the trough rows. In this case, the first rows experience the highest loads and block the subsequent rows, creating conditions with decreased wind speed and enhanced turbulence within the trough field. Also, turbulent length scales change. These affected conditions produce unique load cases on the structures that will be captured by the load measurements. If the wind blows along the trough rows, wind and turbulence conditions are less influenced by the troughs.

atmospheric turbulence↗

DOE OSTI2023

In Situ Wind and Turbulence Measurements in a Field of Full-Size Parabolic Trough Collectors

concentrated solar power↗

DOE OSTI2024

Sentinel Devices LLC (CRADA Final Report)

Industrial equipment is a critical component of virtually all at-scale manufacturing and infrastructure. Broadly speaking, modern equipment is predominantly controlled using hardened digital controllers – computers designed to be able to operate continuously for sometimes extremely long periods of time, with little to no maintenance. Due to the nature of how these digital controllers have evolved, they are solely optimized to execute a single task, and do not have the capabilities or resources to monitor or analyze their internal state beyond simple execution of their program. As a result, for many “common sense” situations where individual data points can be easily determined to be out-of-normal, the controllers are unable to identify these incorrect operational modes unless a human has explicitly programmed in detection of this degradation. This project seeks to develop an AI/ML system which can identify incorrect or anomalous trends in industrial data streams, of exactly the kind that would be produced and seen by these digital controllers, with a minimal amount of computing resources. The benefits produced by developing this system would ultimately be self-monitoring and self-reporting infrastructure, capable of identifying and alerting humans to issues as soon as they happen, potentially long before they have the chance to impact the industrial process.

42 ENGINEERING↗

DOE OSTI2021

Effect of Temperature on the Pilot-Scale Catalytic Pyrolysis of Loblolly Pine

A pilot-scale biomass catalytic pyrolysis unit with a nominal throughput of one tonne of biomass per day (1TPD) has been in operation since 2013 to investigate the process parameters that have the largest influence on biocrude yield, oxygen content, and chemical composition. A parametric study was conducted to investigate the effect of pyrolysis temperature, ranging from 433 to 581 °C, on biocrude yield and quality. A locally sourced loblolly pine feedstock and a commercially available, spray dried, nonzeolitic γ-Al 2 O 3 catalyst were used in individual experiments conducted at each pyrolysis temperature to achieve a minimum of 4 h of steady-state continuous operation. Typically, 600–800 kg of biomass was fed over a 12-h period, with one experiment extended to almost 29 h (1144-kg biomass fed) and one experiment interrupted by a process upset after just 7 h (411-kg biomass fed). Comprehensive analysis of collected gas, liquid, and solid products were used to calculate carbon balances (77% to 107%) for each experiment. The biocrude yield ranged from 12 to 18 wt % C and, in general, decreased with increasing pyrolysis temperature. The average steady-state biocrude yield as a function of temperature translated to a biocrude production rate between 40 and 50 gallons per dry ton. The biocrude oxygen content varied between 21 and 31 wt %, on a dry basis, and as expected, decreased with increasing pyrolysis temperature. The identified components in the semivolatile biocrude products are mostly methoxyphenols and other multiphenolic compounds. The multiphenolic compounds are demethoxylated at pyrolysis temperatures above 500 °C, producing biocrudes with higher concentrations of monophenols and polycyclic aromatic hydrocarbons. The concentration of anhydrosugars, like levoglucosan in the biocrudes, decreased with increasing pyrolysis temperature from ∼15 to ∼1 vol %.

biofuels↗

DOE OSTI2021

Geometric Optimization of an Electrochemical Purification Cell to Prevent Corrosion in CSP Plants During Operation

When exposed to moisture or oxygen, molten chloride salts produce corrosive impurities which degrade containment alloys. As a result, this can significantly decrease the lifetime and increase costs of molten-salt-based systems. To overcome this barrier, we designed and modeled an electrochemical purification cell to remove the corrosive impurity MgOH+. Various reactor architectures, including constant stirred tank reactors (CSTRs) and plug flow reactors (PFRs) were investigated. Steady-state thermoelectric properties were evaluated, allowing assessment of the effects of structure and design parameters such as flow rate, cell length, and cross-sectional area of molten salt. The results suggest that our design could most effectively increase reliability and decrease costs of molten-chloride-salt-based systems by protecting them during continuous operation using an annular plug flow reactor.

chloride salts↗

DOE OSTI2023

Optically heralded microwave photon addition

Photons with optical frequencies of a few hundred terahertz are perhaps the only way to distribute quantum information over long distances. Superconducting qubits, which are one of the most promising approaches for realizing large-scale quantum machines, operate on microwave photons at frequencies that are ~40,000 times lower. To network these quantum machines across appreciable distances, we must bridge this frequency gap. Here we implement and demonstrate a transducer that can generate correlated optical and microwave photons. In this study, we use it to show that by detecting an optical photon we generate an added microwave photon with an efficiency of ~35%. Our device uses a gigahertz nanomechanical resonance as an intermediary, which efficiently couples to optical and microwave channels through strong optomechanical and piezoelectric interactions. We show continuous operation of the transducer with 5% frequency conversion efficiency, input-referred added noise of ~100, and pulsed microwave photon generation at a heralding rate of 15 Hz. Optical absorption in the device generates thermal noise of less than two microwave photons. Improvements of the system efficiencies and device performance are necessary to realize a high rate of entanglement generation between distant microwave-frequency quantum nodes, but these enhancements are within reach.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2022

A cryogenic torsion balance using a liquid-cryogen free, ultra-low vibration cryostat

We describe a liquid-cryogen free cryostat with ultra-low vibration levels, which allows for continuous operation of a torsion balance at cryogenic temperatures. The apparatus uses a commercially available two-stage pulse-tube cooler and passive vibration isolation. Here, the torsion balance exhibits torque noise levels lower than room temperature thermal noise by a factor of about four in the frequency range of 3–10 mHz, limited by residual seismic motion and by radiative heating of the pendulum body. In addition to lowering thermal noise below room-temperature limits, the low-temperature environment enables novel torsion balance experiments. Currently, the maximum duration of a continuous measurement run is limited by accumulation of cryogenic surface contamination on the optical elements inside the cryostat.

47 OTHER INSTRUMENTATION↗

DOE OSTI2025

Silver(I) Supported Liquid Membranes for Selective Ethylene Recovery from Mixed-Gas Streams of Tandem CO 2 Electrolysis

Large-scale olefin separations from unreacted paraffins and other byproduct gases are primarily done by energy-intensive cryogenic distillation processes at refineries. Silver(I) supported liquid membranes (Ag SLMs) can be implemented at smaller production scales of ethylene (C 2 H 4 ), a critical industrial chemical, such as its electrocatalytic (EC) production from CO 2 . Challenges of EC C 2 H 4 production mainly stem from reducing gases like hydrogen (H 2 ), where the redox reactions pertinent to Ag(I) facilitators diminish olefin transport. Herein we report that aqueous Ag(I) solution in a composite Ag SLM can operate in mixed-gas conditions containing H 2 gas utilizing reduced titania compounds, such as titanium(III) oxide (Ti 2 O 3 ). Embedding Ti 2 O 3 in the polydimethylsiloxane layer of Ag SLM assisted in selectively separating C 2 H 4 from mixed-gas feed streams related to CO 2 electrolysis containing H 2 . The direct exposure of a mixed-gas stream containing C 2 H 4 , CO 2 , CO, N 2 , and CH 4 with as high as 50 vol % H 2 maintained excellent C 2 H 4 separations for 7 days of continuous operation. The Ag SLM provided effective separations of C 2 H 4 from CO (at detection limits), CH 4 (selectivity ratio (α) = 20–30), and H 2 (α = ∼20), but C 2 H 4 from CO 2 (α = 2–4) revealed a slightly lower separation. These data show that aqueous Ag(I) solution(s) used in the SLMs can separate C 2 H 4 for extended periods, even under highly reducing gas conditions. Also, we report C 2 H 4 recovery from the gas mixture produced in the EC CO 2 reduction process. In conclusion, the Ag SLM gave C 2 H 4 selective separation from a five-component complex mixed-gas stream, relevant to tandem CO 2 electrolysis.

37 - INORGANIC, ORGANIC, PHYSICAL AND ANALYTICAL C↗

DOE OSTI2020

Risk Model for EM Decision Support Toolsets

The Government Office of Accountability (GAO) has published several reports identifying the need for the Department of Energy (DOE) Office of Environmental Management (EM) to address mounting costs for DoE's cleanup program. DOEEM could greatly benefit from independent decision tool-sets/models that would allow them to evaluate options and inform business decision at the enterprise level considering site-specific life cycle costs and system plans. Program goals: Develop a tool-set that enables EM to independently evaluate alternatives, assess outcomes from different contracting strategies, and inform critical decisions for the enterprise. Project goals: Adaption of a Risk Model for integration with complimentary tool-sets for project level decision making. Operational Events: Discrete event model that evaluates operational variables (e.g. capacity, throughput, maintenance constraints) and identify bottlenecks. Identifying and Bounding Project Risk: Identify risks that impact confidence in meeting goals (e.g. production). Life cycle Cost: Evaluate impacts of staffing levels, inventory, and capital investments on life cycle costs. Methods and approach: Monte Carlo Analysis is being executed to generate results: Input derives from Risk Register Data; Tied to Projected and Target Schedules; Incorporates float duration within the model. Assumes associated risk mitigation actions being completed within a timeline of five fiscal years. Metrics include: Confidence in Meeting Production Goal; Confidence in Safety Standards; Confidence in Continuous Operation; Other Metrics can be added as appropriate regarding specific site needs. The adapted risk model can be used as a stand alone decision tool or can be integrated complementary tool-sets (i.e. process and cost models) for project-specific decisions. These support tool-sets can then be integrated with others for site- and complex- level evaluations. Future work includes designing an adaptable and modular framework that would allow integration of multiple tool-sets for holistic and/or targeted evaluation of alternative strategies for decision making that could lead to risk and cost reduction across the enterprise.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2021

Bipolar Membranes for Ion Management in (Photo)Electrochemical Energy Conversion

Conspectus (Photo)electrochemical energy conversion is important in the development of a carbon-neutral energy economy because it can provide a pathway for mitigating the intermittency of renewable energy sources such as wind and solar. In order to operate efficiently, these technologies, which include photoelectrochemical cells, water and CO 2 electrolyzers, fuel cells, and redox flow batteries, require fast charge transfer kinetics at the electrode/electrolyte interface as well as robust ion management in the electrolyte. In conventional electrolyzers and fuel cells, the electrolyte is strongly acidic or basic and ionic current is carried by H + or OH – ions. In contrast, photoelectrodes and electrocatalysts for water splitting are often studied in buffered solutions. The question of ion balance in these systems led us to analyze the polarization losses due to ion concentration gradients in cells that employed various buffer–membrane combinations. Continuously driving the buffer ions across an ionomer membrane not only lowers the buffer capacity of an aqueous electrolyte but also introduces pH gradients that result in significant energy losses. To address the problem, we and other groups have studied the use of reverse-biased bipolar membranes (BPMs) in (photo)electrolytic cells. BPMs consist of an anion exchange layer (AEL) laminated with a cation exchange layer (CEL) and are usually equipped with a catalytic layer in between to accelerate the water dissociation reaction. At the AEL/CEL interface, water dissociates into protons and hydroxide ions, which replenish those consumed at the cathode and anode. Compared to conventional water electrolyzers with proton/anion exchange membranes (PEM/AEM), BPM electrolyzers provide the unique advantage of continuously operating the cathode and anode under different pH conditions, which is desirable when the two electrode reactions have different pH requirements. BPMs also enable the use of buffered electrolytes at pH values that are optimized for electrode stability and product selectivity in applications such as CO 2 electrolysis. Product crossover losses and CO 2 pumping can be dramatically reduced in BPM-based CO 2 electrolyzers, relative to conventional alkaline membranes, by electrostatic repulsion (of anionic products) and electroosmotic drag (for neutral products). BPM-based gas fed CO 2 electrolyzers can achieve high current density, but they suffer from low Faradaic efficiency (FE) due to the acidic local environment of the CEL. This problem can be mitigated by adding an aqueous buffering layer or by creating a weak acid cation exchange film on the CEL face of the membrane. The use of BPMs in fuel cells and redox flow batteries offers some interesting advantages. Configurations with both reverse and forward bias have been studied, but forward bias has been favored due to material compatibility, reaction kinetics, and thermodynamic considerations. The net reaction at the AEL/CEL interface is the acid–base neutralization reaction, which has a high inherent reaction rate constant, but in the BPM is limited to a nanometric space-charge layer and requires efficient catalysis to achieve high current density. Understanding the mechanism of the acid–base neutralization and the opposite process, the water dissociation reaction, will be essential for improving the performance of forward-biased BPMs. In conclusion, this Account reviews our current understanding of the working mechanisms of BPMs and discusses how we can use them to effectively manage ions for various (photo)electrochemical applications.

Yan, Zhifei↗

DOE OSTI2021

End-of-Life Evaluation of Compressed Natural Gas Vehicle Fuel Tanks

This study evaluated the structural integrity of Type III and Type IV CNG fuel tanks from the Los Angeles (LA) County Metropolitan Transportation Authority to characterize the fuel tank conditions after experiencing a full service life of 15 years in transit bus application. The data produced provide insight about the condition of the CNG fuel tanks at the conclusion of their defined EOL and potential risks of continued operation of the CNG vehicle without replacement of the expired fuel tanks. In addition to physical testing performed on the fuel tanks, a nondestructive evaluation of modal acoustic emission (MAE) was utilized to assess the structural integrity of the tanks. The CNG fuel tanks were evaluated in their received condition and after experiencing artificial damage. The MAE results were then compared to visual inspection results of the procedures defined in the Compressed Gas Association’s (CGA’s) C-6.2 and C-6.4 standards (Compressed Gas Association 2013; 2012) to better understand the effectiveness of the visual inspection and potential safety risks of continued use of the tanks.

03 NATURAL GAS↗

DOE OSTI2026

Autonomous monitoring of algal biomass: Success stories and lessons learned from long-term field deployment

Autonomous, high-frequency monitoring of outdoor algal ponds is needed to quantify biomass productivity and detect culture decline in environments prone to contamination, grazers, and variable operating conditions. We report successes and lessons learned in translating a laboratory spectroradiometric monitoring approach to a multi-year autonomous field deployment at the Arizona Center for Algae Technology and Innovation (AzCATI). The system measures spectrally resolved pond reflectance by ratioing upwelling radiance from each raceway to simultaneous downwelling sky irradiance using fiber-coupled spectrometers. A physics-based reflectance model (ASHARP) is fit to each spectrum pair to estimate optical parameters, including a biomass-proxy coefficient (C a ) which enables near-real-time tracking of biomass accumulation and culture state at 2–5 min intervals. From May 2022 through September 2025 the platform operated continuously while scaling from two to six raceway ponds. Several strains of algae were monitored successfully, including the high productivity Tetraselmis striata and Picochlorum celeri. Transitioning data acquisition from a Windows laptop to a Raspberry Pi improved uptime from 57% (2022) to ~89% (2024–2025) and enabled routine real-time analysis. Further, we converted relative biomass estimates to absolute ash-free dry weight (AFDW) using experimentally-derived calibrations, providing field-relevant biomass predictions with conservative confidence bounds. These results demonstrate the feasibility of long-term, autonomous optical monitoring for well-mixed open-raceway algal cultivation and provide practical guidance for reliable field operation and scaling.

Katinas, Christopher Michael [Sandia National Labo↗