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DOE OSTI2024

Techno-economic feasibility of geothermal energy production using inactive oil and gas wells for district heating and cooling systems in Tuttle, Oklahoma

Oil and gas wells have been drilled in the United States and often encounter hot co-produced water possibly suitable for geothermal direct-use applications. Here this study evaluated geothermal resources, heating and cooling demand, and techno-economic potential of four oil and gas wells repurposed for geothermal energy production to serve two public schools and 250 nearby houses in Tuttle, Oklahoma, USA. Subsurface geology in the study area primarily consists of Permian to Mississippian sandstone and limestone formations approximately from 2 km to 3.5 km depth. With a geothermal gradient of 25.3 °C/km, the temperature of geothermal energy production was estimated as 68.2 °C at 2.1 km. The potential of calcite scaling within boreholes and pipes was minimal. Using the characterized reservoir properties, techno-economic analyses were conducted for evaluating levelized costs of geothermal energy production for direct-use heating and cooling and district heating systems with five different production scenarios. Heating and cooling demand in two schools and 250 houses and additional 0.3 MW and 0.6 MW base heating loads for potential geothermal direct-use applications in the study area were also incorporated in the modeling. Results indicated that the levelized cost of heating of geothermal district heating systems utilizing existing wells were significantly lower than those of conventional geothermal energy systems that include well drillings. The geothermal energy production with doublet and quartet configurations was generally sufficient to supply total annual heating demand in the district, while a peaking boiler was used to supply peak loads. Doublet configurations showed higher production temperature with a lower thermal drawdown than the quartet configurations. The doublet system at 2.1 km production depth with 9.3 kg/s flow rate represented the optimal levelized cost of $71/MWh and 91.2% utilization factor. These results imply that the Tuttle geothermal district heating system is techno-economically feasible and comparable to geothermal district heating systems in the United States and the regional natural gas rate for residentials by recycling inactive oil and gas wells with no drillings.

15 GEOTHERMAL ENERGY↗

DOE OSTI2021

Cooling methods for medium voltage drive systems

In one aspect, a medium voltage power converter includes a cabinet having: a power cube bay to house a plurality of power cubes, each of the plurality of power cubes adapted within a corresponding enclosure and comprising a low frequency front end stage, a DC link and a high frequency back end stage, the plurality of power cubes to couple to a high speed machine; and a plurality of first barriers adapted to isolate and direct a first flow of cooling air through one of the plurality of power cubes; and a transformer bay having at least one transformer to couple between a utility connection and the plurality of power cubes, the transformer bay including a plurality of cooling fans to cool the at least one transformer.

Ledezma, Enrique↗

DOE OSTI2021

Unraveling compacted graphite evolution during solidification of cast iron using in-situ synchrotron X-ray tomography

In spite of many years of research, the physical phenomena leading to the evolution of compacted graphite (CG) during solidification is still not fully understood. In particular, it is unknown how highly branched CG aggregates form and evolve in the semi-solid, and how local microstructural variations at micrometer length scale affect this growth process. We present here the first time-resolved synchrotron tomography combined with a bespoke high-temperature environmental cell that allows direct observation of the evolution of CG and relates this dynamic process to the local surrounding microstructures in a cast iron sample during repeated melting and solidification. Distinct processes are identified for the formation of CG involving the nucleation, growth, development of branches and interconnection of graphite particles, ultimately evolving into highly branched graphite aggregates with large sizes and low sphericities. CG is found to nucleate with a spheroidal or a plate-like shape, developing branches induced by high carbon concentration, e.g. thin melt channels. Additionally, CG grows much faster than spheroidal graphite during subsequent cooling in solid state. The direct visualization of the dynamic solidification process provides unprecedented new insights into formation mechanisms of CG and correlating factors such as local microstructural variations, and guides the development of CG iron solidification models.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Impact to Cooling Airflow from Truck Platooning

We investigate tradeoffs between the airflow strategies related to engine cooling and the aerodynamic-enabled fuel savings created by platooning. By analyzing air temperatures, engine temperatures and cooling air flow at different platoon distances, we show the thermal impact to the engine from truck platooning. Previously, we collected wind and thermal data for numerous heavy-duty truck platoon configurations (gaps ranging from 4 to 87 meters) and reported the significant fuel savings enabled by these configurations. The fuel consumption for all trucks in the platoon were measured using the SAE J1321 gravimetric procedure as well as calibrated J1939 instantaneous fuel rate while travelling at 65 mph and loaded to a gross weight of 65,000 lb. Using thermocouples mounted 1 m ahead of each truck, anemometers at the grill and a grid of under-hood thermocouples as well as J1939 reported engine temperatures, we analyze the impact to critical operating temperatures from different platoon configurations. Results show significant changes in the engine and under-hood air temperatures that correlate with vehicle gap distance and platoon position.

adaptive cruise control (ACC)↗

DOE OSTI2021

Improving chiller performance and energy efficiency in hydrogen station operation by tuning the auxiliary cooling

In a hydrogen station that operates with direct fueling through the use of a 700 bar boost compressor, the outlet hydrogen temperature can significantly increase, stressing the chiller system. Here, this paper evaluates improvements that can be made to the auxiliary cooling system integrated with the compressor. Both theoretical modeling and experiments were performed at Cal State LA Hydrogen Research and Fueling Facility. The findings suggest that adjusting the auxiliary closed-loop cooling system from 15 °C to 10 °C reduced the station energy consumption and decreased the demand on the station chiller that needed to provide –20 °C hydrogen at the hose. The overall energy consumption for a single fueling reduced by between 2.86 and 9.43% for the set of experiments conducted. After the temperature of the closed-loop cooling system was reduced by 5 °C, the boost compressor outlet temperature dropped from 46-50 °C–40 °C and consequently at the hose the hydrogen temperature declined by 3 °C. Results were scaled up with a forecast on the number of daily refueling events. With a low number of daily fuelings, the proposed set-up showed a minor influence on the overall station energy consumption. However, the benefits were more pronounced for a connector station with sales at 180 kg/day, where the energy efficiency improved by between 1.4 and 5.5%, and even more so for a higher capacity station at 360 kg/day, where the improvement was between 2.9 and 8%.

08 HYDROGEN↗

DOE OSTI2026

SAM Finite Volume Method Development Status Update: GCR Application, Restart, and MultiApp

The System Analysis Module (SAM) is being developed as a modern system analysis code for advanced non-light-water-reactor safety analysis under the U.S. DOE NEAMS program. Previous feasibility studies have demonstrated that a staggered-grid finite volume method (SG-FVM), implemented under the MOOSE framework, can deliver more than an order of magnitude speedup over the existing continuous Galerkin finite element method (CG-FEM) solver for liquid-cooled, incompressible but thermally expandable flow systems. This work extends the previous effort to compressible, gas-cooled reactor applications, where pressure couples directly into the mass equation adding additional nonlinearity into the equation system. New code capabilities are implemented for pebble bed high-temperature gas-cooled reactor (PB-HTGR) analysis, including a pebble bed CoreChannel component, built-in pebble bed effective thermal conductivity model and channel-to-channel crossflow model. The capabilities are tested, benchmarked, and demonstrated for problems with increased level of model and physical complexities, including the HTTU effective thermal conductivity test, the SANA passive cooling test, and a demonstration case using the GPBR200 reactor design covering steady-state operation, DLOFC and PLOFC transients. Across all cases, the SG-FVM solver demonstrated strong robustness and efficiency, and the solutions agree well with reference results and data. The finding of this work proves that SG-FVM is a viable and efficient solver pathway for compressible, gas-cooled reactor system analysis in SAM. In addition, work has been done to successfully support SAM-FVM recover/restart code feature that is essential to reactor safety analysis applications, and MultiApp code feature that is essential to multi-scale and multi-physics simulations. In summary, this work continued from previous feasibility studies, and further demonstrated that the SG-FVM will serve as a strong foundation for SAM’s advanced solver algorithm for future deployment.

Zou, Ling↗

DOE OSTI2023

Low-Temperature Geothermal Geospatial Datasets: An Example from Alaska: Preprint

This project is part of a broader effort focused on geothermal heating and cooling with the purpose of demonstrating the multi-faceted value of integrating GHC/GHX into national decarbonization plans and community energy plans. Currently, there is a need to better define and evaluate low-temperature geothermal resource potential to provide the basis for supporting private sector investment. For shallow GHC/GHX fields, there is no formal compilation of subsurface characteristics shared among industry practitioners that can improve system design and operations. Alaska is specifically noted in this work, because heretofore, it has not received a similar focus in geothermal potential evaluations as the contiguous United States. The methodology consists of leveraging relevant data generate a baseline low-temperature resources (< 150 degrees C) geospatial dataset to compare and analyze information accessible to anyone trying to understand the potential of GHC/GHX and small-scale low-temperature geothermal power in Alaska (e.g., energy modelers, communities, planners, and policymakers). Importantly, this project is identifying data related to (1) the evaluation of GHC/GHX in the shallow subsurface, and (2) the evaluation of low-temperature geothermal resource availability. Additionally, data is being compiled to assess repurposing of oil and gas wells to contribute co-produced fluids toward the geothermal direct use and heating and cooling resource potential. The goal of this project is facilitating future deployment of GHC/GHX analysis and community-led programs and update the low-temperature geothermal resources assessment of Alaska. A better understanding of shallow potential for geothermal heat exchange (GHX) will improve design and operations of highly efficient GHC systems. The deployment and impact that can be achieved for low temperature geothermal resources will contribute to decarbonization goals and facilitate widespread electrification by shaving and shifting grid loads.

bottom-hole temperature↗

DOE OSTI2023

Low-Temperature Geothermal Geospatial Datasets: An Example from Alaska

This project is a component of a broader effort focused on geothermal heating and cooling (GHC) with the aim of illustrating the numerous benefits of incorporating GHC and geothermal heat exchange (GHX) into community energy planning and national decarbonization strategies. To better assist private sector investment, it is currently necessary to define and assess the potential of low-temperature geothermal resources. For shallow GHC/GHX fields, there is no formal compilation of subsurface characteristics shared among industry practitioners that can improve system design and operations. Alaska is specifically noted in this work, because heretofore, it has not received a similar focus in geothermal potential evaluations as the contiguous United States. The methodology consists of leveraging relevant data to generate a baseline geospatial dataset of low-temperature resources (less than 150 degrees C) to compare and analyze information accessible to anyone trying to understand the potential of GHC/GHX and small-scale low-temperature geothermal power in Alaska (e.g., energy modelers, communities, planners, and policymakers). Importantly, this project identifies data related to (1) the evaluation of GHC/GHX in the shallow subsurface, and (2) the evaluation of low-temperature geothermal resource availability. Additionally, data is being compiled to assess repurposing of oil and gas wells to contribute co-produced fluids toward the geothermal direct use and heating and cooling resource potential. In this work we identified new data from three different datasets of isolated geothermal systems in Alaska and bottom-hole temperature data from oil and gas wells that can be leveraged for evaluation of low-temperature geothermal resource potential. The goal of this project is to facilitate future deployment of GHC/GHX analysis and community-led programs and update the low-temperature geothermal resources assessment of Alaska. A better understanding of shallow potential for GHX will improve design and operations of highly efficient GHC systems. The deployment and impact that can be achieved for low-temperature geothermal resources will contribute to decarbonization goals and facilitate widespread electrification by shaving and shifting grid loads.

15 GEOTHERMAL ENERGY↗

DOE OSTI2022

Formation and detection of metastable formic acid in a supersonic expansion: High resolution infrared spectroscopy of the jet-cooled cis -HCOOH conformer

High-resolution direct absorption infrared spectra of metastable cis-formic acid (HCOOH) trapped in a cis-well resonance behind a 15 kcal/mol barrier are reported for the first time, with the energetically unstable conformer produced in a supersonic slit plasma expansion of trans-formic acid/H 2 mixtures. We present a detailed high-resolution rovibrational analysis for cis-formic acid species in the OH stretch (ν 1 ) fundamental, providing first precision vibrational band origin, rotational constants, and term values, which in conjunction with ab initio calculations at the couple-cluster with single, double, and perturbative triple [CCSD(T)]/ANOn (n = 0, 1, 2) level support the experimental assignments and establish critical points on the potential energy surface for internal rotor trans-to-cis isomerization. Relative intensities for a- and b-type transitions observed in the spectra permit the transition dipole moment components to be determined in the body fixed frame and prove to be in good agreement with ab initio CCSD(T) theoretical estimates but in poor agreement with simple bond-dipole predictions. As a result, the observed signal dependence on H 2 in the discharge suggests the presence of a novel H atom radical chemical mechanism for strongly endothermic “up-hill” internal rotor isomerization between trans- and cis-formic acid conformers.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2026

Tracking Thermal Transport in Colloidal Quantum Dot Films Using in Situ Time-Resolved X-ray Diffraction

Colloidal quantum dots (QDs) and their thin films are increasingly used in electronic and photonic devices replacing traditional bulk semiconductors. However, thermal properties of QDs remain underexplored relative to device development efforts. This study shows the use of time-resolved X-ray diffraction as a contact-free method to probe the thermal response of QDs in environments representative of the active layer in QD optoelectronic devices, providing in situ insights for future thermal management strategies. Through the extraction of Debye–Waller factors on a subnanosecond time scale, we directly capture the heating and cooling of core/shell CdSe/CdS QDs following pulsed optical excitation. In a QD thin film that actively provides optical gain, the thermal conductivity is found to be as low as 0.13 W m –1 K –1 , because of the poor heat flow between close-packed QD solids. For QDs dispersed in liquids, interfacial thermal conductance dominates thermal relaxation, with a conductance of 15 MW m –2 K –1 .

36 MATERIALS SCIENCE↗

DOE OSTI2024

DIRECT RF SAMPLING BASED LLRF CONTROL SYSTEM FOR C-BAND LINEAR ACCELERATOR

Low Level RF (LLRF) control systems of linear accel- erators (LINACs) are typically implemented with hetero- dyne based architectures, which have complex analog RF mixers for up and down conversion. The Gen 3 Radio Fre- quency System-on-Chip (RFSoC) device from AMD Xilinx integrates data converters with maximum RF frequency of 6 GHz. This enables direct RF sampling of C-band LLRF signal typically operated at 5.712 GHz without any analogue mixers, which can significantly simplify the system architec- ture. The data converters sample RF signals in higher order Nyquist zones and then up or down convert digitally by the integrated data path in RFSoC. The closed-loop feedback control firmware implemented in FPGA integrated in RF- SoC can process the base-band signal from the ADC data path and calculate the updated phase and amplitude to be up- mixed by the DAC data path. We have developed a C-band LLRF control RFSoC platform with direct RF sampling, which targets Cool Copper Collider (𝐶3) and other C or S band LINAC research and development projects. In this paper, the architecture of the platform will be described. We have optimized the configuration of the data converter and characterized performance of them with RF pulses. The test results for some of the key performance parameters for the LLRF platform with our custom solid-state amplifier, such as phase and amplitude stability, will be discussed in this paper.

Liu, C↗

DOE OSTI2022

Core Design of the Holos-Quad Microreactor

The Holos-Quad micro-reactor concept, developed by HolosGen LLC, is equipped with a 22 MWt (Mega-Watt thermal) core and an integral power conversion system converting the core thermal energy into approximately 10 MWe (Mega-Watt electric). This design can be configured to support a wide range of applications. It is a very innovative high-temperature gas-cooled reactor concept using TRI-structural ISOtropic particle fuel (TRISO) distributed in graphite hexagonal blocks, cooled with helium in a direct Brayton cycle independently executed by four Subcritical Power Modules (SPMs) fitted into a hardened 40-foot container whose dimensions are in compliance with ISO shipping containers requirements. In FY2019 HolosGen LLC was awarded by the Department of Energy Advanced Research Project Agency-Energy (DOE ARPA-E) under the MEITNER funding program. As part of the MEITNER award, the Argonne National Laboratory (ANL) contributed expertise through two specialized teams: The “Design Team” and the “Resource Team”. The Design Team was dedicated to validate feasibility of the Holos-Quad core and to optimize its core design through neutronics analyses. The Resource Team was dedicated to feasibility verification via high-fidelity codes of Holos-Quad thermal-hydraulic, heat transfer, shielding, and structural aspects. This report summarizes the activities conducted by ANL Design Team. A rigorous design approach based on multi-criteria optimization and code-to-code comparison involving stochastic and high-fidelity deterministic solutions was developed and employed at several evolutionary stages of the Holos-Quad design. Several generations of the Holos-Quad core were designed within this project before converging to the current full-scale Gen 2+ design that is detailed in this report. Figure EA-1 illustrates a cross-sectional view of Gen 2+ Holos-Quad core configuration, and Figure EA-2 provides a simplified perspective view of 1-of-4 SPMs. The Holos-Quad uses four thermal-hydraulically independent SPMs locked into stationary positions during power operation, surrounded by BeO reflector and structural component fully comprised within the dimensional constraints represented by traditional ISO containers. One of the benefits of this approach is to enable transportation of each SPM promptly after irradiation in shielded containers. The core is designed to operate for approximately 8 full-power years while the reactivity controls and power conversion system enable load-following operations. The reactivity controls are represented by independent, diversified, and redundant reactivity control systems based on control drums and redundant sets of shutdown rods. The high-fidelity simulation tools were used to assess detailed power and flux distributions of the three-dimensional full-core or quarter-core of the Gen 2+ configuration. Single-physics and multi-physics simulations of the neutronics code PROTEUS and the thermal-hydraulic code System Analysis Module (SAM) were performed to analyze the Holos design configurations with detailed high-fidelity solutions. The design work performed confirmed feasibility of the Holos-Quad concept, provided realistic design description for detailed design of the operational system, and identified several core design improvements to be further considered for future reactor development activities.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

Experimental Investigation on Cooling performance of A Thermoelectric Freezer

Thermoelectric heat pumps (TEHPs) have found widespread use in the electronics cooling industry and portable refrigerators. However, there has been a lack of extensive research on the application of TEHPs in low-temperature refrigeration settings. To address this gap, various configurations of TEHPs were fabricated to assess their suitability for freezer applications. Key parameters such as cooling capacity and system performance of the TEHPs were crucial in evaluating these configurations. Three configurations, each with different numbers of cooling units and fan arrangements, were tested using a 300-liter freezer prototype under typical room conditions (21°C). A cooling unit is comprised of two-stage thermoelectric modules, an aluminum plate fin heat exchanger sink with fans positioned either on top or directing airflow through the center, and a cooling block with circulating icy water for heat dissipation. Across all configurations, the minimum temperature inside the freezer cabinet reached -16.0°C. The cooling capacity peaked at 74.7 W, with the thermoelectric coefficient of performance (COP) reaching a maximum of 0.45. System COP ranged from 0.23 to 0.28. Minimum TE power consumption was recorded at 138.8 W, with TE system power consumption at 174.4 W, indicating feasibility for practical residential freezer applications. This investigation lays the foundation for integrating TE freezers with ice thermal storage systems.

Hu, Yifeng↗

DOE OSTI2023

Assessment of Directionally Solidified Eutectic Sm–Fe(Co)–Ti Alloys as Permanent Magnet Materials

Sm–Fe–Ti and Sm–Fe0.8Co0.2–Ti alloys were prepared via arc-melting and directionally solidified on a water-cooled copper hearth. The as-solidified alloys featured cells of the Sm(Fe,Co,Ti)12–Ti(Fe,Co) 2+δ –(α-Fe) lamellar eutectic. The lamellae of Sm(Fe,Co,Ti)12 phase with a crystal structure of the ThMn12 type were less than 0.2 μm thick, and had their [001] easy-magnetization directions oriented along the temperature gradient of the solidification. The eutectic microstructure led to an increased coercivity, especially in the Co-added alloys. Below 250 °C, this coercivity was found not to vary much with temperature with a temperature coefficient of -0.18 %/°C. However, the modest absolute values, reaching only 0.7 kOe, are insufficient for utilization of the directionally solidified alloys as anisotropic permanent magnets.

36 MATERIALS SCIENCE↗

DOE OSTI2020

The Impact of Storms on Legionella pneumophila in Cooling Tower Water, Implications for Human Health

At the U.S. Department of Energy’s Savannah River Site (SRS) in Aiken, SC, cooling tower water is routinely monitored for Legionella pneumophila concentrations using a direct fluorescent antibody (DFA) technique. Historically, 25–30 operating SRS cooling towers have varying concentrations of Legionella in all seasons of the year, with patterns that are unpredictable. Legionellosis, or Legionnaires’ disease (LD), is a pneumonia caused by Legionella bacteria that thrive both in man-made water distribution systems and natural surface waters including lakes, streams, and wet soil. Legionnaires’ disease is typically contracted by inhaling L. pneumophila , most often in aerosolized mists that contain the bacteria. At the SRS, L. pneumophila is typically found in cooling towers ranging from non-detectable up to 10 8 cells/L in cooling tower water systems. Extreme weather conditions contributed to elevations in L. pneumophila to 10 7 –10 8 cells/L in SRS cooling tower water systems in July–August 2017. L. pneumophila concentrations in Cooling Tower 785-A/2A located in SRS A-Area, stayed in the 10 8 cells/L range despite biocide addition. During this time, other SRS cooling towers did not demonstrate this L. pneumophila increase. No significant difference was observed in the mean L. pneumophila mean concentrations for the towers ( p < 0.05). There was a significant variance observed in the 285-2A/A Tower L. pneumophila results ( p < 0.05). Looking to see if we could find “effects” led to model development by analyzing 13 months of water chemistry and microbial data for the main factors influencing the L. pneumophila concentrations in five cooling towers for this year. It indicated chlorine and dissolved oxygen had a significant impact ( p < 0.0002) on cooling tower 785A/2A. Thus, while the variation in the log count data for the A-area tower is statistically greater than that of the other four towers, the average of the log count data for the A-Area tower was in line with that of the other towers. It was also observed that the location of 785A/2A and basin resulted in more debris entering the system during storm events. Our results suggest that future analyses should evaluate the impact of environmental conditions and cooling tower design on L. pneumophila water concentrations and human health.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2022

Pulling thin single crystal silicon wafers from a melt: The new leading-edge solar substrate

The Floating Silicon Method (FSM) has been established as a viable, stable method for growing single crystal ribbons directly from a silicon melt. With intense helium jet cooling to drive the linear progress of a [111] facet, pulled in the <110> direction, ribbons in the 0.6 – 3.0 mm thickness range can be grown at linear growth rates from 0.3 mm/s to >6 mm/s as reported in the literature. We report on recent progress towards growing (100) oriented ribbons with a net thickness of less than 200 microns and a ribbon width up to 18 cm using a stable, continuous process in the Leading Edge prototype furnace. Here, the 3D details of the single crystal growth are explained by extending the mechanics of the Limit Cycle Theory, with novel Internal Side Effect morphology described by a proposed Facet Flow Theory. Grown-in crystalline defect distributions are described as well as values of critical impurities like oxygen, carbon, dopants, and metals that are relevant for use as wafers for solar cells.

14 SOLAR ENERGY↗

DOE OSTI2020

Heat dissipation systems with hygroscopic working fluid

A heat dissipation system apparatus and method of operation using hygroscopic working fluid for use in a wide variety of environments for absorbed water in the hygroscopic working fluid to be released to minimize water consumption in the heat dissipation system apparatus for effective cooling in environments having little available water for use in cooling systems. The system comprises a low-volatility, hygroscopic working fluid to reject thermal energy directly to ambient air. The low-volatility and hygroscopic nature of the working fluid prevents complete evaporation of the fluid and a net consumption of water for cooling, and direct-contact heat exchange allows for the creation of large interfacial surface areas for effective heat transfer. Specific methods of operation prevent the crystallization of the desiccant from the hygrosopic working fluid under various environmental conditions.

42 ENGINEERING↗

DOE OSTI2023

Heat dissipation systems with hygroscopic working fluid

Martin, Christopher L.↗