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DOE OSTI2023

Analysis of Tasks in Autonomous Systems Using the EMRALD Dynamic Risk Assessment Tool

An autonomous system refers to the system that has the power and ability for self-governance in the performance of system functions. Autonomous systems have been actively pursued in a variety of domains such as automotive, aviation, maritime, medicine, and nuclear fields. As an unmanned concept employing the highest automation level, the autonomous system basically performs most of the work in normal operations or emergency situations. However, despite advances in technology, many researchers have noted these systems still require human actions. The nature of human actions on autonomous systems is different than the human actions that are considered in existing systems. Nevertheless, only a few studies have been conducted on 1) characterizing the different types of errors and risks associated with human actions interacting with autonomous systems and 2) how to evaluate human actions in the autonomous operations. As a starting point, this study aims to investigate differences of tasks in autonomous operation compared to those in existing nuclear power plant operation using the Event Modeling Risk Assessment Using Linked Diagram (EMRALD) software. In this paper, insights aspect of human error and time are derived out and discussed based on the output of the EMRALD models.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2025

Impacts of PV Module Connector Failures on Cost and Performance of Utility Scale Photovoltaic Systems

The reliability, cost and performance of electrical connectors are a concern in all types of electrical systems, and demands on connectors used on photovoltaic (PV) systems include that connectors maintain electrical conductivity and physical strength, endure ultraviolet sunlight and high ambient temperature, and resist moisture and chemical intrusion over a very long (>25 year) performance period. Connector failures increase operation and maintenance (O&M) costs and reduce plant production, but connector failure can also cause safety and liability problems, which are of greater concern. This work results from a three-year collaboration between Sandia National Laboratories (SNL), the Electric Power Research Institute (EPRI), and the National Renewable Energy Laboratory (NREL) and funded by the U.S. Department of Energy (DOE) Solar Energy Technology Office (SETO) under Agreements #39035 and #38531 "Connector Reliability Across the US Solar Sector." a multi-pronged investigation of PV connector health across the US (see https://energy.sandia.gov/pvconnectors/). This report presents derivation of a Techno-Economic Analysis (TEA) that models failure modes and frequencies (how often failure occurs), estimates O&M costs and lost production associated with connector failures, and then calculates the effect that PV module connectors can have on Levelized Cost of Energy (LCOE). The model is informed with initial data from quantitative assessment of failure rates, root causes and mechanisms, in-situ diagnostics and data collection, lab-based forensics, and interviews with PV connector manufacturers and plant operators. SNL conducted site inspections at multiple utility-scale sites in different climates and subjected field samples of new, used, and degraded connectors to visual and electrical characterization. EPRI conducted metallurgical analysis of the pin and sleeve conductors to study failure-induced morphological and compositional changes. There is in general a shortage of statistically valid data, but data from PVROM database maintained by SNL was sufficient to ascertain failure rates and lost production as well as provide qualitative insight in its curated maintenance records. This report details the structure of the mathematical model but the sources of data to inform the model will continue to evolve. Analysis of a 100 MW PV plant is provided as an example of the use of the model, with results indicating that connectors are responsible for Annualized O&M Costs of $\$$71,933/year; Annualized Unit O&M Costs of $\$$0.72/kW/year; that a Reserve Account of $\$$187,220 should be available to fund repairs related to connectors; that connectors add $\$$1,494,004 to the Net Present Value of the O&M Costs (project life); and that O&M related to connectors adds about $\$$0.00088/kWh to the Levelized Cost of Energy. The impact of this model is to provide a tool to make the US solar sector more robust by quantifying and monetizing the reliability risks to utility-scale PV systems posed by poorly installed, mismatched and/or poorly designed and manufactured connectors. The TEA provides a model incorporating failure statistics, O&M cost data, and lost production into a single figure of merit, informing decisions and enabling practitioners to optimize cost and performance trade-offs. Stakeholders include connector manufacturers, system designers and equipment specifiers, standards bodies, installers and O&M providers, investors and insurance underwriters. This report supports continued growth of PV predicated on assurances that properly installed and maintained PV system connectors are safe and reliable. The project team is proposing future work including accelerated testing of connectors and expanding the approach taken here to other PV system components, such as TEA for rapid shut-down devices.

14 SOLAR ENERGY↗

DOE OSTI2022

Automatic Generation of Event Trees and Fault Trees: A Model-Based Approach

In the past few decades, the increasing complexity of modern engineering systems has been driven by the integration of a large number of components whose operations may involve many disciplines (e.g., thermal hydraulics, plant operations, cybersecurity). Most computational tools used by industry and regulators for system safety and reliability assessments are still based on the traditional fault tree (FT) and event tree (ET) approach, which may not be able to capture complex interactions among system constituents. The use of simulation tools has widely increased in the past few decades to improve the fidelity of the reliability and safety analyses. However, the direct use of simulation tools as part of dynamic probabilistic risk assessment (DPRA) methods is not getting traction since (1) modeling the whole system under consideration with DPRA methods may be computationally expensive and unnecessary, and (2) the manual integration of DPRA models into existing state-of-practice probabilistic risk assessment models (i.e., based on FTs and ETs) can be time consuming and prone to errors. Here, in this paper we propose a procedure to overcome this limitation by presenting several algorithms designed to automatically construct subsystem ETs and FTs from DPRA methods for integration into an existing ET/FT system model.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2022

Development and Commercialization of an IDAES-Based Power Plant Performance Monitoring and Optimization System

DOE and NETL have created an advanced, open-source computational platform through the Institute for the Design of Advanced Energy Systems (IDAES). The IDAES platform is a very extensive modeling environment that can be used for a broad range of power plant and process applications. MapEx Software is developing and commercializing a software application that makes it easier to set-up and run IDAES-based analyses. The MapEx-developed software application will replace the need for custom Python language coding with a user-friendly graphical user interface where the user can construct a flowsheet diagram of the IDAES model by inserting icons representing the plant equipment onto the screen. This application will make the implementation of modeling and optimization of existing fossil-fired power plants more straight-forward and less time-consuming. The effort focuses on performance monitoring and optimization of plant operations for the existing coal-fired power plant fleet but is built on a structure that allows expansion into the broad range of applications where IDAES methods may be applied.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2023

Cost of Capturing CO 2 from Industrial Sources

The objective of this study is to provide an estimate of the cost to capture carbon dioxide (CO 2 ) from select industrial processes (ammonia, ethylene oxide, ethanol, natural gas processing, coal-to-liquids, gas-to-liquids, refinery hydrogen, cement, iron/steel, and pulp/paper). Each of the ten processes were chosen for analysis due to either the high purity of the CO 2 emission source (99–100 mole percent CO 2 ) or the large quantity of CO 2 potentially available. For each industrial process considered, available plant information, such as existing average plant size, projected new development plant size, or existing plant operations data was used to develop a reference plant for this study.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2024

Exploring Multidimensional Spatial-Temporal Hydropower Operational Flexibilities by Modeling and Optimizing Water-Constrained Cascading Hydroelectric Systems

Because of unique characteristics such as clean and cost-competitive electricity as well as fast-ramping and storage abilities, the power industry continues to evolve its operation strategies for cascading hydroelectric (CHE) systems for providing enhanced values to the grid, especially under the deeper renewable resource integration. However, existing operation practices of CHEs predate the integration of renewables, which could prohibit the effective utilization of their inherent flexibilities in delivering maximum financial benefits and providing valuable grid services to the power system and electricity market operations. Indeed, modeling and optimizing these resource-limited while flexible CHE assets with uncertainties and imperfect information across multiple spatial-temporal dimensions present significant challenges. To facilitate CHE facility operators in effectively coordinating water usage and hydropower plant operations across multiple timescales, this project aims to fill the existing gaps by developing a suite of accurate water inflow (WI) forecast models as well as enhanced CHE modeling and optimization approaches with proper consideration of their unique characteristics, which would help explore their multidimensional spatial-temporal operational flexibility potentials. The developed approaches could better align reservoir operation strategies with variability and uncertainty of future water availability. They can also promote more effective utilization of multidimensional spatial-temporal hydropower operational flexibility potentials by designing long-term evacuation plans of reservoirs and short-term operation of CHEs, along with their coordination with other types of renewables. The project leverages various resources to facilitate the research and development activities, including actual characteristics data of CHE systems and a library of current and future cases of Portland General Electric (PGE). These realistic data enable the project team to study how to maximize the value of CHEs under current and future portfolios and evaluate opportunities to improve operation practices.

13 HYDRO ENERGY↗

DOE OSTI2025

Laboratory Testing and Performance Characterization of the High Efficiency Dehumidification System (HEDS) Technology

The high efficiency dehumidification system (HEDS) is a unique air handling unit (AHU) design with two water coils. Connected in series, these water coils can sensibly reheat the airstream after it is cooled and dehumidified, thereby mitigating (or sometimes eliminating) the need for conventional sensible reheat with additional energy from hot water, electric resistance or steam coils. Another unique design feature is the size of the HEDS primary cooling coil. While typical AHU cooling coils have a 6-row geometry, the HED's cooling coil has a deeper 10-row geometry enabling discharge air dew point temperatures at or below 55 degrees F despite warmer chilled water supply temperatures approaching (sometimes exceeding) 50 degrees F. The ability to meet acceptable discharge air dew points with warmer chilled water supply temperatures improves both operational efficiency and system resilience against chilled water plant operational or control issues. This report summarizes the 59 steady-state test results that form a comprehensive performance map of the HEDS technology including its reheat capability. The breadth of outdoor air conditions and flow rates over which the HEDS technology was tested and characterized encompasses the unit 1) operating as a dedicated outdoor air system or mixed air system and 2) controlled with constant air volume or variable air volume fan control.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2025

AUTOMATIC GENERATION OF EVENT TREES AND FAULT TREES: A MODEL-BASED APPROACH

In the past few decades, increasing complexity in modern engineering systems has been driven by the integration of a large number of components and by the fact that the system operations involve many disciplines (e.g., thermal-hydraulics, plant operations, cyber-security). Current safety/reliability modeling approaches to such systems are labor intensive, difficult to learn, and rely heavily on simplistic Boolean logic to depict failure propagation and accident progression. While these methods serve well for simple systems (i.e., linear causal systems with limited small inter- and intra-system interactions), their results are difficult to verify when modeling complex systems (typically performed through the extensive use of modeling assumptions). The development of new methods is addressed to meet these challenges through a model-based system engineering (MBSE) lens. Under MBSE philosophy, every aspect of the system (form or function) is represented by a model that completely characterizes its architecture or behavior. MBSE approach greatly improves the management of design, analysis and verification of complex systems. An integration of Dynamic Probabilistic Risk Assessment (DPRA) methods with MBSE models is proposed to perform safety/reliability analyses of engineering systems. In particular, MBSE representation of the system (performed using Systems Modeling Language [SysML]) is coupled with DPRA methods to automatically generate event trees and fault trees.

97 - MATHEMATICS AND COMPUTING↗

DOE OSTI2023

Quantifying Uncertainty of Deep Reinforcement Learning Based Decision Making for Operations and Maintenance of Nuclear Power Plant

This paper summarizes research that integrates condition monitoring and prognostics with decision making for nuclear power plant operations and maintenance. As part of this research, we have developed an online asset management tool to help reduce life-cycle maintenance and repair costs. Using the latest advancements in condition monitoring, supply chain analytics, and deep reinforcement learning, we have created a predictive maintenance tool that can optimize the maintenance and spare-part management of a repairable nuclear system. To demonstrate these methods, preliminary studies were conducted on a simple, representative maintenance system undergoing a stochastic degradation process that requires repairs or replacement to continue operation. Through Monte Carlo simulations, we were able to reduce maintenance spending by approximately 50% compared to optimized, time-based maintenance strategies. Not only does the decision maker reduce the average life-cycle costs, it also minimizes the chance of high cost scenarios, lowering the variance of the expected cost distributions, and reducing overall financial risk. Furthermore, this work also studies the ability of the decision maker to handle various levels of noise from observation uncertainty. By introducing uncertainty into the decision-making process, we have quantified the robustness and resiliency of the decision maker, as well as identified necessary levels of observability to demonstrate cost effectiveness.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2023

Transient Efficiency, Flexibility, and Reliability Optimization of Coal-Fired Power Plants - Final Report

This program developed an advanced model-based monitoring and model-predictive control algorithms for a coal fired power plant (CFPP), and deployed these algorithms in a real-time platform to demonstrate performance benefits for transient flexibility and plant operation efficiency. More specifically, the objectives were successfully achieved through a combination of (i) developing a high-fidelity transient plant model in Apros, which was used as a high-fidelity plant simulation between $100-50\% TMCR$ where TMCR denotes the turbine maximum continuous rating, i.e., baseload, (ii) developing a very fast physics-based reduced-order model (ROM) of the plant, which ran more than $100\times$ faster than real-time, enabling its use as real-time embedded model for model-based estimation (MBE) and model predictive control (MPC) (iii) implementing a real-time MBE based on ROM using a robust unscented Kalman filter (UKF) to continuously tune the ROM to match the measurements from high-fidelity Apros plant model despite significant plant-model mismatch, and thus, obtain a Digital Twin of the plant (iv) designing and implementing a real-time MPC with dual objectives of transient plant load tracking with high ramp rates and minimizing coal consumption, i.e., improving plant efficiency in the baseload-partload operation range of $100-50\% TMCR$. Each key element above was developed and tested individually, and has been reported in corresponding Topical Reports. Finally, all the individual elements were integrated in an overall closed-loop system, that was successfully tested in desktop Simulink test harness simulations with ROM or high-fidelity model as the plant. Thereafter, the Simulink implementation was used to auto-generate C-code and deploy as real-time Docker microservice containers in Linux, and validate that they can run in real-time in the hardware-in-the loop (HIL) setup and produce the same results as in Simulink. The results of the integrated simulation tests in Simulink as well as the real-time HIL deployment are documented in this final report, showing good load tracking for load ramps at $3-4\%/min$ ramp rates, and achieving up to $5.5\%$ reduction in coal relative to baseline operation at $50\% TMCR$ load. The desktop and HIL simulations show successful performance of the overall model based estimation and control solution and achieve the key objectives of the program for flexible, efficient and reliable operation of subcritical coal fired power plants.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2023

Projecting Future Colorado River Basin Water and Hydropower Operations

Drought, variable renewable energy (VRE) resources (primarily wind and photovoltaic technologies), and power markets can all impact hydropower plant operations. We analyze how these three factors collectively may potentially change the future operation and economics of federal dams and hydropower plants located in the Colorado River Basin (CRB). Federal CRB energy and capacity resources, including 4,200 MW of hydropower capacity, are marketed by Western Area Power Administration (WAPA) and sold through long-term Firm Electric Service (FES) contracts to entities located in 15 western and central States that serve millions of electricity consumers. The parameters of FES contracts allow a wide range of scheduling flexibility for FES customers. The FES customers will adjust the timing of energy delivery according to the changing water, power market, and VRE contribution level to the power grid. We simulate and project water and hydropower operations with two models: 1) reservoir operation and 2) power system operation (production cost) with various temporal granularity. We consider two sets of grid scenarios (one representing today's infrastructure, and one representing higher VRE contributions in 2036) and two sets of water scenarios (drought and normal hydrology). We modeled scenarios to understand the power market-energy price levels and patterns, FES customer scheduling, hydropower economics, WAPA finances and hydropower operation for various hydrologic conditions, and VRE contribution level to the power grid. The detailed modeling framework includes: (1) creating ensembles of CRB hydrologic and hydropower futures, (2) selecting representative futures, (3) simulation of FES customer contracts, (4) simulating western U.S. power grid economic scheduling and dispatch under two VRE contribution levels, utilizing information from modeling steps (1)-(4), (5) assessment of reservoir water and hydropower operation, and (6) comparing scenario operations and economics. Our study team comprising WAPA, and an interdisciplinary team of national labs will gain insight into how WAPA can prepare for and adapt its practices in response to an evolving U.S. power grid.

Colorado River↗

DOE OSTI2024

Life Cycle Greenhouse Gas Emissions of Coal-Biomass Co-Firing Power Plants with Carbon Capture and Storage

The United States has set a target to achieve the net-zero economy by 2050. Bioenergy with Carbon Capture and Sequestration (BECCS) is one of the promising negative-emission routes in the mitigation portfolio to help meet this goal. Coal-biomass co-firing with carbon capture and storage (CCS) is a key BECCS technology to realize the carbon mitigation at fossil-fuel power plants. The mitigation potential of co-firing option is affected by numerous critical factors, such as biomass properties, co-firing level, and carbon capture rate. The objectives of the study are to characterize and estimate the life cycle greenhouse gas (GHG) emissions and performance of coal-biomass co-firing power plants with CCS, determine the breakeven co-firing level at power plants necessary to achieve net-zero life cycle emissions, and quantify the variabilities and uncertainties in life cycle emissions. The scope of the life cycle assessment includes the fuel supply, combustion-based power generation, and CO2 transport and storage. A fuel-based life cycle module is developed and embedded in the Integrated Environmental Control Model (IECM), a fossil-fuel power plant modeling tool. This study then applies the enhanced IECM to conduct the process-based life cycle assessment for an array of biomass co-firing scenarios. Deterministic analysis indicates that reaching net-zero life cycle emissions in a biomass co-firing plant without CCS deployment is challenging. Combining biomass co-firing and CCS deployment can significantly lower the overall life cycle emissions of power plants. Net-zero life cycle emissions can be achieved with a 20 wt.% co-firing level and 90% CCS when the Powder River Basin coal is co-fired with energy crops or forestry residues. However, the breakeven co-firing level for net-zero emissions depend on the selected fuel properties. Fuel supply and plant operation are the critical stages influencing the life cycle emissions of power plants with 90% CCS. Deployment of deep CCS beyond 90% CO2 capture can remarkably reduce operational emissions and the breakeven co-firing level. With 99% CCS, the breakeven co-firing rate can be reduced to 12% on average. These findings highlight the trade-offs between technical performance and environmental impact of biomass co-firing at coal-fired power plants and emphasize the role of deep CCS in achieving a net-zero emissions future.

Wu, Wanying↗

DOE OSTI2023

Transient Efficiency, Flexibility, and Reliability Optimization of Coal-Fired Power Plants - Final Program Review

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2021

Influence of Business Models on PV-Battery Dispatch Decisions and Market Value

PV-battery hybrid projects dominate interconnection queues in some regions in the United States, but few projects have been operational long enough to assess how the hybrid capabilities may be used in practice. We interview plant operators and analyze empirical dispatch data for eleven large-scale PV-battery hybrids in three organized wholesale markets in the United States. We use the dispatch data and wholesale market prices to estimate the market value of our sample hybrids in 2020. The empirical increase in market value of a PV-battery hybrid relative to a standalone PV plant varies by project and ranges from $\$$1 to $\$$48/MWhsolar. The premium is driven by market, location, technical characteristics of the PV and battery asset, and battery dispatch strategies. In contrast to the widespread assumptions in the PV-battery hybrid modeling literature, only three of the eleven project operators optimize battery usage for wholesale market revenue as merchant plants. Instead, the majority of operators in the sample have alternate objectives. For example, load-serving entities target peak load reductions, incentive program participants focus on compliance with program requirements, and large energy consumers prioritize resiliency and utility bill minimization. Understanding prevalent dispatch signals and the degree of alignment with system-wide grid needs can increase the market value of PV-battery hybrids.

14 SOLAR ENERGY↗

DOE OSTI2023

Report on the Creation and Progress of the Hydrogen Regulatory Research Review Group

The current U.S. nuclear generation fleet is increasingly recognized by governmental, scientific, public policy, and industrial communities as having a strategic role in support of the ongoing national transition to a clean energy future. Federal incentives and actions are aligning to expand the role of nuclear power as a viable and more flexible contributor to the evolving national clean energy mix through programs and initiatives such as nuclear power loan guarantees; the Inflation Reduction Act’s (IRA) clean nuclear electrical, steam, and hydrogen incentives; the Infrastructure Investment and Jobs Act (IIJA, also referred to as the Bipartisan Infrastructure Act or BIL); and near term Department of Energy (DOE) funding opportunities related to nuclear based hydrogen hubs and nuclear integrated hydrogen demonstration projects. . Additionally, leveraging clean nuclear electricity and steam is being explored by industries desiring to transition away from carbon-intensive energy sources. Even with all these emerging enablers, notable barriers remain for the widespread adoption of these opportunities within the U.S. nuclear fleet, including the following: • Assurance of the markets for alternate products needed to support decision-making for large capital modification investments • Electric utility mindset and business history centered solely on producing electricity • Design change complexity and regulatory uncertainty associated with plant modifications needed to support alternate product streams The DOE Light Water Reactor Sustainability (LWRS) Flexible Plant Operations and Generation (FPOG) Pathway is developing options to help U.S. nuclear power plants (NPP) in all these areas to enable NPPs designed for steady baseload operation to integrate with intermittent wind and solar capacity to assure reliable clean energy for the nation. Current and near-term laboratory research is focusing on the technical, regulatory, safety, demonstration, and economic elements in support of improving nuclear plant flexibility through hybrid production of electricity and other non-electric products such as hydrogen and energy arbitrage.

42 ENGINEERING↗

DOE OSTI2019

Support for Reactor Operators in Case of Cyber-Security Threats (NEUP Final Report)

Increasing use of digital technology in nuclear power plants (NPPs) poses cyber-security as a crucial threat to public safety and to continuous energy production. Cyber-security risks are comprised of complex known and unknown interactions between various entities, system vulnerabilities, network protocols, human users and malicious attacks. There is little understanding or research geared towards plant operators’ response under cyber-security threats and operational procedures to cope with such threats. This is particularly critical when a cyber-security event masquerades as a safety incident or an evolving accident. Instead of leading operators to the remediation of the accident, the masked cyber event may lead them to circumvent the safety mechanisms of the plant. Given these challenges, the objective of this project is to develop a tool to characterize abnormal NPP events as “cyber” or “safety” incidents, and to further develop this tool as a real-time operator aid to assist in response to the incident. This NEUP Final Report summarizes the research efforts towards the above goals and the results in the following three aspects. First, a methodology for classifying abnormal NPP events as cyber-attacks or safety incidents was developed. This provides the basis for responding to potential cyber-attacks. In this methodology, the causal relationships between various variables (i.e., physical variables, network variables, and control variables) for a nuclear system under consideration are modeled using dynamic Bayesian networks. Based on observations of certain variables (i.e., the evidence), inference is performed to identify the state of hidden variables, which helps indicate the occurrence of cyber-attacks or safety incidents. The proposed methodology was applied to the full scope NPP simulator system at The Ohio State University as a case study. The result shows that the proposed methodology is capable of distinguishing between cyber-attacks and safety incidents. Second, a game-theoretic approach for responding to cyber-attacks on nuclear power plants was developed. This is the second major goal of the project, and the method is used to recommend optimal responses to reactor operators in the case of cyber-attacks. We consider two cases in this research. In the first case, the interaction between the defender (i.e., the reactor operator) and the attacker is modeled as a two-player, nonzero-sum, Markov game with an infinite time horizon. In the second case, we consider a semi-Markov game between the defender and the attacker within a finite time horizon. The model in the second case enables us to consider the time sensitive response of the defender. In each case, the method for deriving the Nash equilibrium is developed. The Nash Equilibrium of the game provides the valid prediction of both players’ actions because no single player can benefit from unilaterally deviating from the equilibrium policy if the other player adheres to his/hers, hence it provides the best response of the defender to cyber-attacks. The proposed method in each case is demonstrated through a simplified benchmark digital feedwater control system. Third, a prototype display is developed to integrate the above information. The prototype display depicts the communication information to the operator and incorporates the cyber-security tool developed by the team into the interface. It consists of the regular display in current control rooms, as well as a panel used to indicate the occurrence of cyber-attacks or safety events and a panel used to guide the operator’s response to detected cyber-attacks.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2026

Valuing Maintenance Strategies for Fusion Plants as Part of a Future Electricity Grid

Scheduled maintenance is likely to be lengthy and therefore consequential for the economics of fusion power plants. The maintenance strategy that maximizes the economic value of a plant depends on internal factors such as the cost and durability of the replaceable components, the frequency and duration of the maintenance blocks, and the external factors of the electricity system in which the plant operates. Here, this paper examines the value of fusion power plants with various maintenance properties in a decarbonized United States Eastern Interconnection circa 2050. Seasonal variations in electricity supply and demand mean that certain times of year, particularly spring to early summer, are best for scheduled maintenance. Seasonality has two important consequences. First, the value of a plant can be 15% higher than what one would naively expect if value were directly proportional to its availability. Second, in some cases, replacing fractions of a component in shorter maintenance blocks spread over multiple years is better than replacing it all at once during a longer outage, even through the overall availability of the plant is lower in the former scenario.

power plant, maintenance, seasonality, electricity↗

DOE OSTI2021

High-Accuracy Simulations to Model Pyrometallurgical Processes in a Secondary Lead Reverberatory Furnace

The US manufacturing industry produces about 1.3 million tons of refined lead each year using secondary sources consisting mainly of lead batteries. ORNL is partnering with Gopher resource, the second largest lead recycling company in the United States, and GTI, to develop a high-fidelity CFD model of a directly fired, reverberatory-style, secondary lead furnace. These High Performance Computing (HPC) simulations are aimed to use first principles modeling for combustion and melting processes of the secondary lead feed while accounting for complex interphase interactions between the gas, solid charge (lead) material, slag, and metal phases. Through validation against operating plant data, this effort will enable significant improvements in design, operational parameters, and energy efficiency, thus improving productivity and refractory lifetime of secondary lead melting furnaces. Estimated savings/reduction of, at least, 1 trillion BTU, 1 million ton/year of greenhouse gas emissions, and $\$50$ million/year to the US lead industry can be expected. ORNL resources and expertise in high-performance computing and multicomponent, multiphase flows were utilized to realize this goal while advancing the understanding of the smelting and melting processes occurring within the furnace.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗