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DOE OSTI2014

Cyberspace modernization. An interest protocol planning advisory

A common challenge across the communications and information technology (IT) sectors is Internet + modernization + complexity + risk + cost. Cyberspace modernization and cyber security risks, issues, and concerns impact service providers, their customers, and the industry at large. Public and private sectors are struggling to solve the problem. New service opportunities lie in mobile voice, video, and data, and machine-to-machine (M2M) information and communication technologies that are migrating not only to predominant Internet Protocol (IP) communications, but also concurrently integrating IP, version 4 (IPv4) and IP, version 6 (IPv6). With reference to the Second Internet and the Internet of Things, next generation information services portend business survivability in the changing global market. The planning, architecture, and design information herein is intended to increase infrastructure preparedness, security, interoperability, resilience, and trust in the midst of such unprecedented change and opportunity. This document is a product of Sandia National Laboratories Tribal Cyber and IPv6 project work. It is a Cyberspace Modernization objective advisory in support of bridging the digital divide through strategic partnership and an informed path forward.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2014

Evaluation of the U.S. Department of Energy Challenge Home Program Certification of Production Builders

The purpose of this project was to evaluate integrated packages of advanced measures in individual test homes to assess their performance with respect to Building America program goals, specifically compliance with the DOE Challenge Home Program. BSC consulted on the construction of five test houses by three cold climate production builders in three U.S. cities and worked with the builders to develop a design package tailored to the cost-related impacts for each builder. Also, BSC provided support through performance testing of the five test homes. Overall, the builders have concluded that the energy related upgrades (either through the prescriptive or performance path) represent reasonable upgrades. The builders commented that while not every improvement in specification was cost effective (as in a reasonable payback period), many were improvements that could improve the marketability of the homes and serve to attract more energy efficiency discerning prospective homeowners. However, the builders did express reservations on the associated checklists and added certifications. An increase in administrative time was observed with all builders. The checklists and certifications also inherently increase cost due to: adding services to the scope of work for various trades, such as HERS Rater, HVAC contractor; and increased material costs related to the checklists, especially the EPA Indoor airPLUS and EPA WaterSense® Efficient Hot Water Distribution requirement.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2018

Final Scientific / Technical Report: Enabling Technologies for Heavy-Duty Vehicles – Cummins 55BTE

The Cummins 55% BTE (55BTE) program has completed the planned technical work on the project. This work includes the planned engine system demonstration in pursuit of the goal of demonstrating a peak system brake thermal efficiency (BTE) of 55%. The engine system included a high efficiency diesel engine integrated with a state-of-the-art waste heat recovery (WHR) system and an advanced aftertreatment system capable of meeting the current emissions standards. While the ultimate program goal of 55% BTE was not fully achieved due to hardware issues during the final testing phase, the program demonstrated a significant increase in reported engine system BTE for a heavy duty sized engine. The previous demonstrations in the Department of Energy funded SuperTruck 1 programs ranged between 50% - 51% BTE. The Cummins 55% BTE program demonstrated 54% BTE. Additionally, the program established a revised path-to-target showing how the system could be improved to reach the ultimate program goal of 55% BTE with some minor modification to the engine system. The changes in the revised path-to-target were unable to be completed during the course of this program due to time and money constraints placed on the program. The program’s goals were challenging in both scope and timing. Although the program’s goal can be simply stated in terms of demonstrating a system efficiency of 55%, the achievement of a heavy-duty diesel engine capable of full torque curve operation, adequate transient performance, low emissions and high brake thermal efficiency (>51% BTE) had not been previously demonstrated in a heavy-duty engine. The closest efforts to date included the SuperTruck 1 programs referenced earlier. The program made several advancements in all system areas. The combustion system was re-designed for a shorter combustion duration and lower in-cylinder heat loss. This was achieved through optimization of the fuel injection rate shape, number of spray holes, piston bowl shape, compression ratio, piston oil cooling, heat flow through the piston and in-cylinder charge motion. The air handling system was re-designed to provide cooled EGR at virtually no pumping penalty. This was achieved through implementation of a dual loop EGR system, reduction of EGR system pressure drop, and implementation of advanced turbocharger efficiency technologies. The engine friction and parasitic signature was dramatically reduced by the program through adoption of variable flow pumps, advanced rings and coatings, rollerized valvetrain, adoption of low viscosity lubricants and reduction in cylinder line bore distortion. The aftertreatment system was optimized through use of low dP substrates and an ammonia gas injection system. The WHR system development included the use of a dual-entry turbine and a mixed charger cooler. Finding and implementing these solutions in a short two-year program at the budgeted funding provided the greatest challenge for the program.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2023

Implementation and test of an automated control hunting fault correction algorithm in a fault detection and diagnostics tool

Control hunting due to improper proportional–integral–derivative (PID) parameters in the building automation system (BAS) is one of the most common faults identified in commercial buildings. It can cause suboptimal performance and early failure of heating, ventilation, and air conditioning (HVAC) equipment. Commercial fault detection and diagnostics (FDD) software represents one of the fastest growing market segments in smart building technologies in the United States. Implementation of PID retuning procedures as an auto-correction algorithm and integration into FDD software has the potential to mitigate control hunting across a heterogeneous portfolio of buildings with different BAS in a scalable way. This paper presents the development, implementation, and field testing of an automated control hunting fault correction algorithm based on lambda tuning open-loop rules. The algorithm was developed in a commercial FDD software and successfully tested among nine variable air volume boxes in an office building in the United States. The paper shows the feasibility of using FDD tools to automatically correct control hunting faults, discusses scalability considerations, and proposes a path forward for the HVAC industry and academia to further improve this technology.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2021

High-energy micrometre-scale pixel direct conversion X-ray detector

The objective of this work was to fabricate and characterize a new X-ray imaging detector with micrometre-scale pixel dimensions (7.8 µm) and high detection efficiency for hard X-ray energies above 20 keV. A key technology component consists of a monolithic hybrid detector built by direct deposition of an amorphous selenium film on a custom designed CMOS readout integrated circuit. Characterization was carried out at the synchrotron beamline 1-BM-B at the Advanced Photon Source of Argonne National Laboratory. The direct conversion detector demonstrated micrometre-scale spatial resolution with a 63 keV modulation transfer function of 10% at Nyquist frequency. In addition, spatial resolving power down to 8 µm was determined by imaging a transmission bar target at 21 keV. X-ray signal linearity, responsivity and lag were also characterized in the same energy range. Finally, phase contrast edge enhancement was observed in a phase object placed in the beam path. This amorphous selenium/CMOS detector technology can address gaps in commercially available X-ray detectors which limit their usefulness for existing synchrotron applications at energies greater than 50 keV; for example, phase contrast tomography and high-resolution imaging of nanoscale lattice distortions in bulk crystalline materials using Bragg coherent diffraction imaging. Here, the technology will also facilitate the creation of novel synchrotron imaging applications for X-ray energies at or above 20 keV.

36 MATERIALS SCIENCE↗

DOE OSTI2014

Computer-based procedure for field activities: Results from three evaluations at nuclear power plants

Nearly all activities that involve human interaction with the systems of a nuclear power plant are guided by procedures. The paper-based procedures (PBPs) currently used by industry have a demonstrated history of ensuring safety; however, improving procedure use could yield tremendous savings in increased efficiency and safety. One potential way to improve procedure-based activities is through the use of computer-based procedures (CBPs). Computer-based procedures provide the opportunity to incorporate context driven job aids, such as drawings, photos, just-in-time training, etc into CBP system. One obvious advantage of this capability is reducing the time spent tracking down the applicable documentation. Additionally, human performance tools can be integrated in the CBP system in such way that helps the worker focus on the task rather than the tools. Some tools can be completely incorporated into the CBP system, such as pre-job briefs, placekeeping, correct component verification, and peer checks. Other tools can be partly integrated in a fashion that reduces the time and labor required, such as concurrent and independent verification. Another benefit of CBPs compared to PBPs is dynamic procedure presentation. PBPs are static documents which limits the degree to which the information presented can be tailored to the task and conditions when the procedure is executed. The CBP system could be configured to display only the relevant steps based on operating mode, plant status, and the task at hand. A dynamic presentation of the procedure (also known as context-sensitive procedures) will guide the user down the path of relevant steps based on the current conditions. This feature will reduce the user’s workload and inherently reduce the risk of incorrectly marking a step as not applicable and the risk of incorrectly performing a step that should be marked as not applicable. As part of the Department of Energy’s (DOE) Light Water Reactors Sustainability Program, researchers at Idaho National Laboratory (INL) along with partners from the nuclear industry have been investigating the design requirements for computer-based work instructions (including operations procedures, work orders, maintenance procedures, etc.) to increase efficiency, safety, and cost competitiveness of existing light water reactors.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2025

Technology Case Study: Economic, Sustainability, and Deployment Considerations for Sustainable Aviation Fuels Produced via Lignocellulosic Sugar Catalysis

This report presents a technology case study reflecting one exemplary representative pathway for the conversion of lignocellulosic sugars to sustainable aviation fuels (SAF) via aqueous phase reforming (APR) catalysis, considered within a broader integrated biorefinery framework based on biochemical processing operations. While far from the only option for converting sugars to SAF, this pathway was selected as a case study here based on its relatively high technology maturity and simplistic processing approach (avoiding complex separations or other equipment scalability challenges), coupled with the potential for high fuel yields and favorable costs/carbon intensities with opportunities for further near-term optimization. The report considers key process integration and engineering design considerations for a modeled hypothetical, nth-plant commercial biorefinery, reflecting a number of processing options and parameters envisioned to be achievable as future goals. Resultant outputs from Aspen Plus process simulations are evaluated through techno-economic and life cycle analyses (TEA and LCA), including implications for marginal cost of CO2 abatement and inclusion of currently-applicable policy incentives. Moving beyond base case configurations, a number of alternative scenarios are also evaluated for their ability to further improve economics, greenhouse gas (GHG) emissions, and marginal cost of abatement, highlighting a path to achieve deep decarbonization goals of more than 70% GHG reduction for SAF (with the potential to reach net-negative carbon intensities in some cases) under reasonable fuel production costs. The report also highlights future opportunities and gaps for further research on this technology pathway.

09 BIOMASS FUELS↗

DOE OSTI2025

Integral Experiment Request 523 CED-2 Report

This report documents the final design phase of the Critical Experiment Design (CED-2) conducted as part of integral experiment request (IER) 523. The purpose of IER 523 is to determine critical configurations of 35 weight percent (wt%) enriched uranium dioxide beryllium oxide (UO 2 -BeO) material driven by an annular ring of Seven Percent Critical Experiment (7uPCX) fuel rods at Sandia National Laboratories (Sandia). The experiments will provide benchmark data on water moderated, intermediately enriched UO2 systems as well as Be nuclear data. The experiment will also provide partial validation for the beryllium oxide (BeO) thermal neutron scattering law (TSL) in the thermal energy range. Experiment design concepts, neutronic analysis results, and proposed paths for continuing the CED process are presented. This report builds on the feasibility and justification of experimental need report (CED-0) and preliminary experiment design report (CED-1) completed in December 2021 and September 2023, respectively [1, 2].

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2025

V-INT: Automated Vulnerability Intelligence and Risk Assessment

The project team, including the University of Arkansas (UA) as the lead, the University of Arkansas at Little Rock (UALR), Network Perception (NP), and Bastazo, has successfully researched, developed, and demonstrated the V-INT toolset, and also integrated it into the commercial products of NP (i.e., NP-View) and Bastazo (i.e., Spartan). The end product is a cybersecurity software tool for energy utilities that can automatically assess the risks of software vulnerabilities in an organization’s assets considering the organization’s firewall policies. It allows security operators to identify the small portion of vulnerabilities that poses true threats to their system (i.e., those that are not protected by firewall policies) and prioritize the mitigation of these vulnerabilities to minimize risks. It also allows security operators to identify the vulnerability-induced attack paths under their organization’s firewall policy, providing effective decision supports for mitigating potential attacks.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2015

Multidimensional Skyrme-density-functional study of the spontaneous fission of 238 U

We determined the spontaneous fission lifetime of 238 U by a minimization of the action integral in a three-dimensional space of collective variables. Apart from the mass-distribution multipole moments Q 20 (elongation) and Q 30 (left–right asymmetry), we also considered the pairing-fluctuation parameter λ 2 as a collective coordinate. The collective potential was obtained self-consistently using the Skyrme energy density functional SkM*. The inertia tensor was obtained within the nonperturbative cranking approximation to the adiabatic time-dependent Hartree–Fock–Bogoliubov approach. As a result, the pairing-fluctuation parameter λ 2 allowed us to control the pairing gap along the fission path, which significantly changed the spontaneous fission lifetime.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2023

SiC as a core-edge integrated wall solution in DIII-D

Silicon carbide (SiC) is a promising material for use in a fusion reactor due to its low hydrogenic diffusivity, high temperature strength and resilience under neutron irradiation. To assess SiC as a main wall material in DIII-D, simulations with TRIM.SP and DIVIMP are performed on a well-diagnosed L-mode discharge. The effective charge, Z eff , across the separatrix is used as a figure of merit in comparing SiC to the current graphite walls. It is found that SiC is expected to reduce Z eff , potentially by as much as ~50%. It is discussed how SiC may be expected to "self-condition" and create wall conditions similar to siliconization, further lowering Z eff due to efficient oxygen gettering. Furthermore, the potential benefits are reviewed and a path towards SiC walls in DIII-D is presented.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2016

Micro-channel heat exchanger integrated into stator core of electrical machine

An electric machine has a stator that comprises a plurality of laminations with an outer periphery, and each of the laminations has teeth about a central opening such that when the laminations are stacked side-by side to form the stator core, the plurality of teeth of adjacent laminations cooperate to form slots disposed circumferentially about the central opening that are configured to receive a plurality of stator windings. Each of the laminations has a plurality of cooling apertures angularly spaced about the central opening. The cooling apertures of adjacent laminations cooperate to form cooling manifolds that extend along a length of the stator core. A portion of the laminations has their cooling apertures offset from other laminations in the stack in a manner to create a plurality of flow path transverse to the manifolds and angularly between laminations and adjacent manifolds.

42 ENGINEERING↗

DOE OSTI2023

Ultra-thin on-chip ALD LiPON capacitors for high frequency application

Multi-layer ceramic capacitors have been used for high frequency decoupling application due to a lower overall impedance leading to fast current response. However, high parasitic inductance limits the application of these capacitors in ultra-high frequency domain. Thus, Multlayer Ceramic Capacitors (MLCCs) are placed close to the IC to improve circuit efficiency and reduce inductance. With next generation applications, the demand for frequency range has further increased which not only requires enhanced capacitor material but improved manufacturing techniques to limit the inductive path. Here, we demonstrate ALD of two different polymorphs of ultra-thin film lithium phosphorus oxynitride (LiPON) as an inorganic solid state electrolyte (SSE) for on chip capacitors for decoupling application. Both the LiPON capacitors shows an electric double layer behavior with a capacitance of 15 μF/cm 2 and a low leakage current (<20 nA/cm 2 ) at 2V. The LiPON shows EDLC behavior up to 10 kHz and beyond, both the polymorphs show an electrostatic behavior with a high dielectric constant (14). Furthermore, this dual frequency behavior along with low parasitic inductance and on chip integration allows for operation in extended frequency ranges.

25 ENERGY STORAGE↗

DOE OSTI2022

FY2022 Filter Test for TRU Waste Drum Prototype Unit

Continuing last year’s (fiscal year 2021) work, a prototype instrument and an NPI-6 Integrated Work Document (IWD) were developed to assess the functionality of filters on transuranic waste containers (commonly called 55 Gallon ring-top drums) without requiring the removal of the drum lid. The purpose of this work is to determine the air flow and pressure characteristics associated with filter clogging, filter pressure drop at a fixed flow rate, and leakage around the lid seal. The FY22 objectives included: (A) Development of prototype device, (B) Drafting an IWD document, (C) Defining a filter clogging parameter, (D) Assessing filter damage due to over-pressure events, and (E) A path forward to obtain approval of the system safety filters in compliance with P101-16 Industrial Ventilation – non HVACR (LANL 2022).

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2025

As part of its commitment to advancing safety and reliability assessment methodologies, Argonne National Laboratory pioneered the use of an evaluation method called the Success Path Method (SPM) to improve risk management for offshore oil and gas operations. The development of the SPM at Argonne has been driven by the need to improve existing risk assessment methodologies by focusing on the steps necessary for success rather than failure modes alone. This is particularly important for industrial environments like offshore facilities that perform multiple functions under a continuously evolving set of operational conditions – such as water depth and temperature, currents, and weather conditions. In these dynamic environments, the traditional Probabilistic Risk Assessment (PRA) approach is far too complex as it focuses on what can go wrong – which comprises an infinite failure space that must be fully explored and understood. By shifting the focus to a finite space of success paths, the SPM enables operators and decision makers to prioritize a manageable number of steps that must go right to ensure success. Building on its five decades of experience in safety assessments for the nuclear industry, Argonne made major adaptations to existing risk assessment methods utilizing features similar to fault trees that are traditionally used in PRA to map all pathways in which the system can malfunction. In contrast, SPM identifies the components and processes that must function correctly to achieve specific outcomes – such as preventing the uncontrolled release of hydrocarbons during drilling operations. The SPM framework integrates equipment, procedures, software, processes, and human actions to ensure that physical barriers meet critical safety functions in dynamic operational conditions. This approach helps identify failure modes and improve operational risk management by narrowing the focus to key success elements, which in turn reduces uncertainty and helps users understand, manage, and respond to failures.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2013

Preliminary photovoltaic arc-fault prognostic tests using sacrificial fiber optic cabling.

Through the New Mexico Small Business Assistance Program, Sandia National Laboratories worked with Sentient Business Systems, Inc. to develop and test a novel photovoltaic (PV) arc-fault detection system. The system operates by pairing translucent polymeric fiber optic sensors with electrical circuitry so that any external abrasion to the system or internal heating causes the fiber optic connection to fail or detectably degrade. A periodic pulse of light is sent through the optical path using a transmitter-receiver pair. If the receiver does not detect the pulse, an alarm is sounded and the PV system can be de-energized. This technology has the unique ability to prognostically determine impending failures to the electrical system in two ways: (a) the optical connection is severed prior to physical abrasion or cutting of PV DC electrical conductors, and (b) the polymeric fiber optic cable melts via Joule heating before an arc-fault is established through corrosion. Three arc-faults were created in different configurations found in PV systems with the integrated fiber optic system to determine the feasibility of the technology. In each case, the fiber optic cable was broken and the system annunciated the fault.

Johnson, Jay Dean↗

DOE OSTI2014

Ultra-Large-Scale Power System Control and Coordination Architecture: A Strategic Framework for Integrating Advanced Grid Functionality

Electric power grids are being stressed by integration of intermittent renewable resources and significant adoption of distributed energy resources. The complexity of the grid is growing rapidly as we attempt to support technical, business, and societal goals for which power grids were not originally designed. Today, we largely take stability of the grid for granted. Stability could significantly degrade or collapse because of new dynamics introduced to the grid, and because the emerging extreme complexity makes traditional control analysis intractable, so that grid behavior is more unpredictable than in the past. This paper describes emerging issues in grid control and provides reasons why the present path of grid control evolution is problematic and presents an ultra-large scale framework for grid control that can solve today’s problems and those expected over the next 30 years. Failure to address these issues in the short term will result in rapidly escalating system deployment and maintenance costs, potential stranded assets related to replacement of the “ad hoc” systems, along with substantial operational risks that are unacceptable under current utility and regulatory practices.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2023

Characterization of Quantum Frequency Processors

Frequency-bin qubits possess unique synergies with wavelength-multiplexed lightwave communications, suggesting valuable opportunities for quantum networking with the existing fiber-optic infrastructure. Although the coherent manipulation of frequency-bin states requires highly controllable multi-spectral-mode interference, the quantum frequency processor (QFP) provides a scalable path for gate synthesis leveraging standard telecom components. Here, we summarize the state of the art in experimental QFP characterization. Distinguishing between physically motivated “open box” approaches that treat the QFP as a multiport interferometer, and “black box” approaches that view the QFP as a general quantum operation, we highlight the assumptions and results of multiple techniques, including quantum process tomography of a tunable beamsplitter—to our knowledge the first full process tomography of any frequency-bin operation. Our findings should inform future characterization efforts as the QFP increasingly moves beyond proof-of-principle tabletop demonstrations toward integrated devices and deployed quantum networking experiments.

42 ENGINEERING↗