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DOE OSTI2021

Open Building Control

Best practice control sequences are often not implemented correctly, or are not implemented at all, in large commercial buildings. This typically leads to 10-30 percent energy waste, along with reduced occupant productivity and unnecessary equipment wear. The current process of designing and implementing such control sequences is a manual process that starts with designers who often don’t have adequate training, then requires controls programmers to interpret and program a verbose written sequence. This process has been shown to fail to deliver high performance control sequences at scale. The Open Building Control project digitizes the current control delivery process. The project is developing tools for system designers to select control sequences, assess their energy performance and load flexibility potential using whole building simulation, specify the sequence for implementation using machine-to-machine translation by a control provider and formally testing the as-installed sequences by a commissioning agent. The project developed tools for each stage of this delivery process. The key innovation of the project is the development of the Control Description Language, a language that allows such a digitized control delivery process with end-to-end verification. Libraries of control sequences have been implemented using the Control Description Language, and their performance has been demonstrated using whole building energy simulation. An automated translation of such sequences to a commercial control product line has been conducted using a prototype translator. Tools for formal verification of as-installed control sequences relative to their specification have been developed and demonstrated. The American Society of Heating, Refrigerating and Air-Conditioning Engineers (ASHRAE) started the process of forming a committee to make this language an ASHRAE/ANSI Standard. This new standard will complement existing and emerging ASHRAE standards for building communication and semantic modeling by providing a standard for expressing the control logic - the actual brain of the building. We expect this language and the process it enables to be an important contribution to the deployment of high performance building control sequences at scale because it allows taming the complexity of the control delivery process, which is continually increasing due to the need for higher performance and increased load flexibility to meet goals for net zero energy and increased renewable integration.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

Design of Nuclear Criticality Safety Framework for Hands-on Construction of Fast Systems Over Ranges of Multiplication

Since 1945, Los Alamos National Laboratory (LANL) has performed critical experiments, primarily at the Los Alamos Critical Experiments Facility (LACEF) at Technical Area 18 (TA-18). Since 2011, these experiments have been conducted by the National Criticality Experiments Research Center (NCERC), operated by LANL, at the Device Assembly Facility (DAF) in the Nevada National Security Site (NNSS). These experiments utilize various types of Special Nuclear Material (SNM). Some of these experiments utilize what is referred to as the Rocky Flat Shells, which are called such as they came from the Rocky Flats Plant. These concentric hemi-shells are made of Highly Enriched Uranium (HEU), which is 93 w/o 235U. Fig. 1. Subset of the Rocky Flat Shells LANL is designing a new subcritical hands-on experiment with the goal of achieving a neutron multiplication in the range of 50 to 200, which correlates to Keff values of 0.98 to 0.995. ANSI/ANS-1 is the standard for Conduct of Critical Experiments which governs critical operations at NCERC. Section 3.9 of ANSI/ANS-1 states that when manipulating a critical assembly by hand, the predicted k eff of a known configuration should not exceed 0.95 (a neutron multiplication of 20). This presents a challenge, as this system would have a higher multiplication than 20 and the assembly would have to remain subcritical in normal and credible accident scenarios. To ensure the safety of such an assembly, the different normal and abnormal conditions that could alter the criticality 1 MCNP® and Monte Carlo N-Particle® are registered trademarks owned by Triad National Security, LLC, manager and operator of Los Alamos National Laboratory. Any third party use of such registered marks should be properly of the system must be considered and analyzed. If such a condition is deemed to be credible, it will be further investigated using the Monte Carlo N-Particle (MCNP) transport code. If the results of these simulations show that a k eff larger than one could be possible, modifications to the assembly will be made until such an event is deemed no longer possible.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2017

Application of Structured Decision Making to Hanford Site Radiological Air Monitoring - 17924

Radiological air monitoring is a component of an Environmental Surveillance (ES) program that has been in operation at the Department of Energy Hanford Site for several decades. The primary objectives of the ES program are protection of human health and the environment (on and off-site) as well as regulatory compliance. The ES program was designed decades ago when the plutonium-production reactors and related facilities at the Hanford Site were operational and air emissions were more widespread and significant than today. We employed a structured decision making (SDM) approach that integrates science with values and preferences to a Hanford Site air monitoring program decision. Specifically, a decision was necessary pertaining to the possible replacement of three air monitoring stations located in the 100 Area of the Hanford Site because the power line that supports these stations was near the end of its lifecycle. Although focused on this specific decision, the SDM model is more broadly applicable to decisions pertaining to adapting the air monitoring network to current Hanford operations. The value focused thinking approach that underlies SDM facilitates transparent and defensible decision making, and aids in communicating monitoring rationale. Some of the fundamental objectives elicited from the decision makers regarding management options for the three air monitoring stations included maximizing the ability to measure releases, minimizing environmental impacts, and maximizing social and economic sustainability. The fundamental objectives were linked to six objectives that could be measured (quantified) to allow a decision-analytic solution to the decision problem. Value functions and preference weights were developed for each of the objectives measures based on information obtained during a project workshop as well as by review and analysis of environmental data. Lastly, a set of five management options was identified that might achieve at least one of the objectives. A Bayes Network was developed as a solution to the decision problem pertaining to the three air stations (the 3 air stations decision). The Bayes Network describes the decision model graphically, and also serves as the computational engine for the decision analysis. The Bayes Network defines the relationship among the five management options and six objectives measures. In addition to the weights and value functions noted above, key inputs to the Bayes Network include a set of probabilities related to the different model states defined by the network. These include the probability of a significant release occurring, the probability that a release would be detected under each of the five management options, and the probability of achieving the other objective measures under each management option. In this manner the Bayesian Network captures the uncertainty in the components of the decision model. Replacing the three air monitoring stations with thermoluminescent dosimeters was identified as the preferred management option. A brief report was developed documenting the SDM model, including the workshop notes and analyses that were used to develop the objectives and model input variable values. This application demonstrates SDM's utility for supporting monitoring program decisions and, critically, providing a transparent and traceable basis for the decision. This relatively simple SDM model also provides a basis for an SDM model for monitoring decisions related to the more complex and holistic goal of achieving ES program objectives. (authors)

61 RADIATION PROTECTION AND DOSIMETRY↗
DOE OSTI2021

Risk-based area of review estimation in overpressured reservoirs to support injection well storage facility permit requirements for CO 2 storage projects

This paper by the Energy & Environmental Research Center presents a workflow and modeling approach for delineating a risk-based area of review (AOR) to support a U.S. Environmental Protection Agency (EPA) Class VI permit for a carbon dioxide (CO 2 ) storage project. The approach combines semianalytical solutions for estimating formation fluid leakage through a hypothetical leaky wellbore with the results of numerical reservoir simulations to define the AOR. The modeling utilizes 1) semianalytical solutions from the peer-reviewed literature for formation fluid leakage through abandoned wellbores by Raven (1990) and Avci (1994), 2) a FORTRAN model compiled and described in Cihan et al. (2011, 2012) called ASLMA (Analytical Solution for Leakage in Multilayered Aquifers), and 3) a computational framework for estimating a risk-based AOR first proposed by Oldenburg et al. (2014, 2016). Therefore, the approach builds upon well-established research and underlying hydrogeological principles that have been upheld for nearly three decades. Moreover, the ASLMA model has been broadly applied to an array of storage projects. The work presented herein extends these earlier works using a custom wrapper written in the software environment, R (R Core Team, 2020), which was developed to perform multiple runs of the ASLMA model using given ranges for one or more input parameters. In addition, the current work simulates the pressure buildup within the storage reservoir in response to CO 2 injection using a compositional simulator to better accommodate the temporospatial evolution of pressure buildup within the storage reservoir that is more accurately modeled using a heterogeneous geologic model and a compositional simulator that accounts for the multiphase interactions. The workflow is demonstrated using a case study for a 180,000-metric-ton-per-year storage project located in the PCOR (Plains CO 2 Reduction) Partnership region. For the storage project evaluated here, under the scenario where the leaky wellbore is open to a saline aquifer (thief zone) between the overlying seal (cap rock) and the underground sources of drinking water (USDW), the risk-based AOR essentially collapses to the areal extent of the CO 2 plume in the storage reservoir because the pressure buildup in the storage reservoir beyond the CO 2 plume is insufficient to drive formation fluids up a hypothetical leaky wellbore into the USDW. However, even under the conservative assumption that the leaky wellbore is not open to a thief zone, beyond the areal extent of the CO 2 plume, the incremental leakage is less than 400 m 3 over 20 years, which represents ~0.0001% or less of the total volume of water contained within the USDW rock volume. As discussed in the text, the threshold criterion for defining the risk-based AOR is site-specific and should be informed by the results of the sensitivity analysis and available site characterization data. The approach outlined in this paper is designed to be protective of USDWs and, therefore, comply with the Safe Drinking Water Act requirements and provisions for the U.S. EPA Class VI Underground Injection Control (UIC) Program (Class VI Rule) and North Dakota Administrative Code Chapter 43-05-01.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2017

Evaluation of U.S. Building Energy Benchmarking and Transparency Programs: Attributes, Impacts, and Best Practices

In the last decade, a new policy area has emerged to boost energy efficiency in buildings that focuses on the simple action of measuring energy use as compared to buildings of similar type and size, and making that data publicly available. These efforts, referred to as benchmarking and transparency (B&T) policies, seek to unlock new energy efficiency opportunities in the country’s existing buildings by promoting data-driven decision-making and creating stronger market signals. This report focuses on the 24 state and local jurisdictions that (as of December 31, 2016) require owners of privately owned commercial buildings, multifamily buildings, or both to comply with a B&T policy. The report provides a summary of U.S. B&T policy design and implementation characteristics, reports results and impacts for jurisdictions with B&T policies, and discusses opportunities for increasing the efficacy of B&T policies, as well as suggested areas for further research. Among the findings, all but one of the B&T policy evaluation studies reviewed indicate some reduction (from 1.6% to 14%) in energy use, energy costs, or energy intensity over the two- to four-year period of the analyses. More specifically, most of the studies reviewed indicate 3% to 8% reductions in gross energy consumption or energy use intensity over a two- to four-year period of B&T policy implementation. Two additional evaluation studies indicate that there is a causal relationship between B&T policies and energy savings or energy cost savings. These documented impacts should be reviewed with some caution. While consistently showing energy savings benefits associated with B&T policies, these savings estimates should be considered preliminary because of the limited period of analyses and inconsistencies in analysis methods for the various studies. A nationally standardized method for data collection, reporting, and evaluation of B&T policies—developed with an advisory group of state and local jurisdictions, energy efficiency and evaluation experts, building owner and real estate associations, and other stakeholders—could improve the consistency and quality of B&T impact studies, providing policymakers and others with a more complete understanding of the present and future impacts of these policies.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Concrete Thermal Energy Storage Enabling Flexible Operation without Coal Plant Cycling

The work described in this report is responsive to the Office of Fossil Energy program “Energy Storage for Fossil Power Generation.” The pilot plant built as a result of this project demonstrated the feasibility and performance of a concrete thermal energy storage (CTES) system integrated with a supercritical coal power plant. The 10 MWh electrical (>25 MWh thermal) CTES unit, developed by Storworks Power, was designed to enable flexible operation of coal plants without cycling damage. The project's key technical achievements showcase a significant advancement in energy storage technology. A modular CTES system using 42 “Bolderblocs” units was successfully designed and constructed at Alabama Power’s Plant Gaston Unit 5, with each block containing embedded stainless-steel coils in specialized, cost-effective high-temperature concrete. The system interfaced seamlessly with the plant's 3500 psig (241 barg), 1000°F (538°C) supercritical steam, demonstrating operational flexibility. Over 86 full cycles, the CTES exhibited rapid charging and discharging capabilities, effectively mimicking steam turbine feed conditions and handling varying load profiles and storage durations. Performance validation confirmed the system's ability to consistently meet design target steam conditions of 75 bar-a and ~400°C for nominal baseline discharge. The concrete material withstood repeated thermal cycling without degradation, validating earlier lab-scale tests. Integration of balance of plant components, including a condensate management system with storage tank and air-cooled condenser, minimized plant interfaces and water consumption. A robust control scheme ensured safe, automated operation across various scenarios. Key learnings from the project were invaluable: 1. Initial concrete drying and commissioning procedures were refined for future deployments, enhancing efficiency in subsequent installations. 2. System flexibility exceeded expectations, with rapid response to changing conditions. 3. Design improvements were identified including optimized insulation and piping that will enhance overall system efficiency in future deployments 4. Full cycle thermal roundtrip efficiencies exceeded 88%. While the roundtrip electrical efficiency was somewhat limited by known challenges using input steam, such constraints may be mitigated by swapping steam for hot air as thermal input. 5. A summary of key performance parameters for the pilot test and predicted performance of a full scale commercial system with specified improvements determined from the pilot are shown in Section 8. The project faced challenges, including COVID-19 delays and host plant availability constraints. However, these were overcome through adaptive planning and execution. The successful management of these obstacles demonstrated the resilience and adaptability of the project team and the robustness of the CTES technology. This successful pilot demonstrates the potential for CTES to enhance coal plant flexibility, supporting grid stability as renewable penetration increases. The validated design and operational data provide a solid foundation for scaling up to utility-scale implementations, potentially transforming how thermal plants operate in evolving energy landscapes. The system's ability to rapidly respond to changing grid conditions while maintaining high efficiency makes it a promising solution for balancing intermittent renewable energy sources. Furthermore, the project highlighted the potential for even greater efficiencies in future iterations. The use of air as an input medium could potentially eliminate the limitations observed with steam input, opening new possibilities for energy storage applications beyond coal plant integration. In conclusion, this pilot project not only achieved its primary goals but also uncovered additional benefits and potential applications of the CTES technology. It represents a significant step forward in addressing the challenges of grid stability and flexibility in an increasingly renewable-driven energy landscape.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2013

Low-Cost Illumination-Grade LEDs

Solid State Lighting is a cost-effective, energy-conserving technology serving a rapidly expand- ing multi-billion dollar market. This program was designed to accelerate this lighting revolution by reducing the manufacturing cost of Illumination-Grade LEDs. The technical strategy was to investigate growth substrate alternatives to standard planar sapphire, select the most effective and compatible option, and demonstrate a significant increase in Lumen/$ with a marketable LED. The most obvious alternate substrate, silicon, was extensively studied in the first two years of the program. The superior thermal and mechanical properties of Si were expected to improve wavelength uniformity and hence color yield in the manufacture of high-power illumination- grade LEDs. However, improvements in efficiency and epitaxy uniformity on standard c-plane sapphire diminished the advantages of switching to Si. Furthermore, the cost of sapphire decreased significantly and the cost of processing Si devices using our thin film process was higher than expected. We concluded that GaN on Si was a viable technology but not a practical option for Philips Lumileds. Therefore in 2012 and 2013, we sought and received amendments which broadened the scope to include other substrates and extended the time of execution. Proprietary engineered substrates, off-axis (non-c-plane) sapphire, and c-plane patterned sapphire substrates (PSS) were all investigated in the final 18 months of this program. Excellent epitaxy quality was achieved on all three candidates; however we eliminated engineered substrates and non-c-plane sapphire because of their higher combined cost of substrate, device fabrication and packaging. Ultimately, by fabricating a flip-chip (FC) LED based upon c-plane PSS we attained a 42% reduction in LED manufacturing cost relative to our LUXEON Rebel product (Q1-2012). Combined with a flux gain from 85 to 102 Lm, the LUXEON Q delivered a 210% increase in Lm/$ over this time period. The technology was commercialized in our LUXEON Q product in Sept., 2013. Also, the retention of the sapphire increased the robustness of the device, enabling sales of low-cost submount-free chips to lighting manufacturers. Thus, blue LED die sales were initiated in the form of a PSS-FC in February, 2013.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2015

Photovoltaic at Hollywood and Desert Breeze Recreational Centers

In accordance with the goals of the Department of Energy (DOE) Office of Energy Efficiency and Renewable Energy for promoting solar energy as clean, carbon-free and cost-effective, the County believed that a recreational center was an ideal place to promote solar energy technologies to the public. This project included the construction of solar electricity generation facilities (40kW) at two Clark County facility sites, Desert Breeze Recreational Center and Hollywood Recreational Center, with educational kiosks and Green Boxes for classroom instruction. The major objectives and goals of this Solar Project include demonstration of state of the art technologies for the generation of electricity from solar technology and the creation of an informative and educational tool in regards to the benefits and process of generating alternative energy. Clark County partnered with Anne Johnson (design architect/consultant), Affiliated Engineers Inc. (AEI), Desert Research Institute (DRI), and Morse Electric. The latest photovoltaic technologies were used in the project to help create the greatest expected energy savings for60443 each recreational center. This coupled with the data created from the monitoring system will help Clark County and NREL further understand the real time outputs from the system. The educational portion created with AEI and DRI incorporates material for all ages with a focus on K - 12. The AEI component is an animated story telling the fundamentals of how sunlight is turned into electricity and DRI‘s creation of Solar Green Boxes brings environmental education into the classroom. In addition to the educational component for the public, the energy that is created through the photovoltaic system also translates into saved money and health benefits for the general public. This project has helped Clark County to further add to its own energy reduction goals created by the energy management agenda (Resolution to Encourage Sustainability) and the County’s Eco-initiative. Each site has installed photovoltaic panels on the existing roof structures that exhibit suitable solar exposure. The generation systems utilize solar energy creating electricity used for the facility’s lighting system and other electrical requirements. Unused electricity is sent to the electric utility grid, often at peak demand times. Educational signage, kiosks and information have been included to inform and expand the public’s understanding of solar energy technology. The Solar Green Boxes were created for further hands on classroom education of solar power. In addition, data is sent by a Long Term PV performance monitoring system, complete with data transmission to NREL (National Renewable Energy Laboratory), located in Golden, CO. This system correlates local solar irradiance and weather with power production. The expected outcomes of this Solar Project are as follows: (1) Successful photovoltaic electricity generation technologies to capture solar energy in a useful form of electrical energy. (2) Reduction of greenhouse gas emissions and environmental degradation resulting from reduced energy demand from traditional electricity sources such as fossil fuel fired and nuclear power plants. (3) Advance the research and development of solar electricity generation. (4) The education of the general public in regards to the benefits of environmentally friendly electricity generation and Clark County’s efforts to encourage sustainable living practices. (5) To provide momentum for the nexus for future solar generation facilities in Clark County facilities and buildings and further the County’s energy reduction goals. (6) To ultimately contribute to the reduction of dependence on foreign oil and other unsustainable sources of energy. This Solar Project addresses several objectives and goals of the U.S. Department of Energy’s Solar Energy Technology Program. The project improves the integration and performance of solar electricity directly through implementation of cutting edge technology. The project further addresses this goal by laying important ground work and infrastructure for integration into the utility grid in future related projects. There will also be added security, reliability, and diversity to the energy system by providing and using reliable, secure, distributed electricity in Clark County facilities as well as sending such electricity back into the utility electric grid. A final major objective met by the Solar Project will be the displacement of energy derived by fossil fuels with clean renewable energy created by photovoltaic panels.

14 SOLAR ENERGY↗
DOE OSTI2015

Advanced Burner Reactor with Breed-and-Burn Thorium Blankets for Improved Economics and Resource Utilization

This study assesses the feasibility of designing Seed and Blanket (S&B) Sodium-cooled Fast Reactor (SFR) to generate a significant fraction of the core power from radial thorium fueled blankets that operate on the Breed-and-Burn (B&B) mode without exceeding the radiation damage constraint of presently verified cladding materials. The S&B core is designed to maximize the fraction of neutrons that radially leak from the seed (or “driver”) into the subcritical blanket and reduce neutron loss via axial leakage. The blanket in the S&B core makes beneficial use of the leaking neutrons for improved economics and resource utilization. A specific objective of this study is to maximize the fraction of core power that can be generated by the blanket without violating the thermal hydraulic and material constraints. Since the blanket fuel requires no reprocessing along with remote fuel fabrication, a larger fraction of power from the blanket will result in a smaller fuel recycling capacity and lower fuel cycle cost per unit of electricity generated. A unique synergism is found between a low conversion ratio (CR) seed and a B&B blanket fueled by thorium. Among several benefits, this synergism enables the very low leakage S&B cores to have small positive coolant voiding reactivity coefficient and large enough negative Doppler coefficient even when using inert matrix fuel for the seed. The benefits of this synergism are maximized when using an annular seed surrounded by an inner and outer thorium blankets. Among the high-performance S&B cores designed to benefit from this unique synergism are: (1) the ultra-long cycle core that features a cycle length of ~7 years; (2) the high-transmutation rate core where the seed fuel features a TRU CR of 0.0. Its TRU transmutation rate is comparable to that of the reference Advanced Burner Reactor (ABR) with CR of 0.5 and the thorium blanket can generate close to 60% of the core power; but requires only one sixth of the reprocessing and fabrication capacity per unit of core power. Nevertheless, these high-performance cores were designed to set upper bounds on the S&B core performance by using larger height and pressure drop than those of typical SFR design. A study was subsequently undertaken to quantify the tradeoff between S&B core design variables and the core performance. This study concludes that a viable S&B core can be designed without significant deviation from SFR core design practices. For example, the S&B core with 120cm active height will be comparable in volume, HM mass and specific power with the S-PRISM core and could fit within the S-PRISM reactor vessel. 43% of this core power will be generated by the once-through thorium blanket; the required capacity for reprocessing and remote fuel fabrication per unit of electricity generated will be approximately one fifth of that for a comparable ABR. The sodium void worth of this 120cm tall S&B core is significantly less positive than that of the reference ABR and the Doppler coefficient is only slightly smaller even though the seed uses a fertile-free fuel. The seed in the high transmutation core requires inert matrix fuel (TRU-40Zr) that has been successfully irradiated by the Fuel Cycle Research & Development program. An additional sensitivity analysis was later conducted to remove the bias introduced by the discrepancy between radiation damage constraints -- 200 DPA applied for S&B cores and fast fluence of 4x1023 n(>0.1MeV)/cm2 applied for ABR core design. Although the performance characteristics of the S&B cores are sensitive to the radiation damage constraint applied, the S&B cores offer very significant performance improvements relative to the conventional ABR core design when using identical constraint.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2023

Coupling SCALE with DAKOTA for Axial Burnup Profiles Assessment in Burnup Credit

This paper presents a computational study that demonstrates the application of the SCALE code system in conjunction with the Design Analysis Kit for Optimization and Terascale Applications (DAKOTA) for the analysis of key factors influencing the evaluation of burnup credit (BUC) in pressurized water reactors (PWRs). The primary objective of this analysis is to characterize the model by utilizing parameterization, uncertainty quantification, and optimization studies. Using this approach, we can comprehensively assess the system and conduct informed predictive studies. This study highlights the effectiveness of the SCALE code system integrated within the DAKOTA framework in terms of efficiency and capability. With the coupling of the burnup code ORIGAMI with the CSAS or TSUNAMI-3D sequence embedded in a DAKOTA analysis, we can characterize the factors that influence the k eff of PWR 17x17 spent nuclear fuel (SNF) in the GBC-32 computational benchmark cask for the assessment of BUC in criticality safety analysis. The coupling methodology used in this study is not exclusive to BUC analysis. However, the choice to apply this methodology to the BUC problem is particularly significant because of the diverse range of aspects it encompasses in nuclear criticality safety analyses. This problem presents a unique opportunity to explore and address multiple facets of such analyses related to BUC and illustrates the capability of the SCALE code system with DAKOTA. This analysis makes use of historical reference data for the axial burnup profile, where the entire space within the bounds is considered. Both SCALE and DAKOTA are currently integrated in the Nuclear Energy Advanced Modeling Simulation (NEAMS) Workbench code system, which has a user-friendly graphical interface that simplifies the setup of simulations and configuration of input parameters as well as the visualization of simulation results.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2016

Adoption of High Performance Computational (HPC) Modeling Software for Widespread Use in the Manufacture of Welded Structures

This report summarizes the final product developed for the US DOE Small Business Innovation Research (SBIR) Phase II grant made to Engineering Mechanics Corporation of Columbus (Emc 2 ) between April 16, 2014 and August 31, 2016 titled ‘Adoption of High Performance Computational (HPC) Modeling Software for Widespread Use in the Manufacture of Welded Structures’. Many US companies have moved fabrication and production facilities off shore because of cheaper labor costs. A key aspect in bringing these jobs back to the US is the use of technology to render US-made fabrications more cost-efficient overall with higher quality. One significant advantage that has emerged in the US over the last two decades is the use of virtual design for fabrication of small and large structures in weld fabrication industries. Industries that use virtual design and analysis tools have reduced material part size, developed environmentally-friendly fabrication processes, improved product quality and performance, and reduced manufacturing costs. Indeed, Caterpillar Inc. (CAT), one of the partners in this effort, continues to have a large fabrication presence in the US because of the use of weld fabrication modeling to optimize fabrications by controlling weld residual stresses and distortions and improving fatigue, corrosion, and fracture performance. This report describes Emc 2 ’s DOE SBIR Phase II final results to extend an existing, state-of-the-art software code, Virtual Fabrication Technology (VFT®), currently used to design and model large welded structures prior to fabrication - to a broader range of products with widespread applications for small and medium-sized enterprises (SMEs). VFT® helps control distortion, can minimize and/or control residual stresses, control welding microstructure, and pre-determine welding parameters such as weld-sequencing, pre-bending, thermal-tensioning, etc. VFT® uses material properties, consumable properties, etc. as inputs. Through VFT®, manufacturing companies can avoid costly design changes after fabrication. This leads to the concept of joint design/fabrication where these important disciplines are intimately linked to minimize fabrication costs. Finally service performance (such as fatigue, corrosion, and fracture/damage) can be improved using this product. Emc 2 ’s DOE SBIR Phase II effort successfully adapted VFT® to perform efficiently in an HPC environment independent of commercial software on a platform to permit easy and cost effective access to the code. This provides the key for SMEs to access this sophisticated and proven methodology that is quick, accurate, cost effective and available “on-demand” to address weld-simulation and fabrication problems prior to manufacture. In addition, other organizations, such as Government agencies and large companies, may have a need for spot use of such a tool. The open source code, WARP3D, a high performance finite element code used in fracture and damage assessment of structures, was significantly modified so computational weld problems can be solved efficiently on multiple processors and threads with VFT®. The thermal solver for VFT®, based on a series of closed form solution approximations, was extensively enhanced for solution on multiple processors greatly increasing overall speed. In addition, the graphical user interface (GUI) was re-written to permit SMEs access to an HPC environment at the Ohio Super Computer Center (OSC) to integrate these solutions with WARP3D. The GUI is used to define all weld pass descriptions, number of passes, material properties, consumable properties, weld speed, etc. for the structure to be modeled. The GUI was enhanced to make it more user-friendly so that non-experts can perform weld modeling. Finally, an extensive outreach program to market this capability to fabrication companies was performed. This access will permit SMEs to perform weld modeling to improve their competitiveness at a reasonable cost.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

Using Natural Gas Liquids to Recover Unconventional Oil and Gas Resources (Final Report)

This document presents final technical findings for the project Using Natural Gas Liquids to Recover Unconventional Oil and Gas Resources (FE0031782). The project is part of the U.S. Department of Energy Oil and Gas Program to develop and advance technologies that can significantly improve the recovery efficiencies of unconventional oil and gas resources. The overall objective of this project is to improve the ultimate recovery from unconventional oil and gas (UOG) resources in the United States by developing a method for using unrefined natural gas liquids (NGLs) as treatment fluids to improve hydrocarbon production. Horizontal extended-lateral drilling coupled with high volume hydraulic fracturing has significantly increased production from UOG resources in the U.S. However, the recovery efficiency is low compared to the estimated oil and gas in place. Recent data indicate that less than 10% of the oil in the liquid-rich UOG reservoirs is produced. Alternative completion methods using NGLs could increase production (Battelle, 2016; Wan et al., 2013; Wan, 2013; Downey et al, 2021); however, field validation tests are needed to develop an approach that is economical, efficient, and compatible in the UOG setting to advance towards commercial deployment. This project aims to develop and field test a method to improve recovery of oil resources in UOG shale plays by using Y-Grade NGLs, or a similar combination of NGLs, as treatment fluids. Refined NGLs have been used as a hydraulic treatment fluid in UOG plays for decades and are shown to be particularly effective because their miscibility with oil allows oil to flow more freely; however, the use of Y-Grade (unrefined) NGLs has not been studied. The use of Y-Grade NGLs would be advantageous over refined NGLs because Y-Grade NGLs do not require infrastructure or investment in refining and are already being produced from many UOG reservoirs. The concept was tested and monitored in the field at a commercial well site owned by project partner Hopco, Ltd. The project team, which consists of multiple oil and gas operators, Linde Gas North America LLC (Linde) and the Ohio Division of Geological Survey (ODGS), has extensive experience with oil and gas production in the Appalachian basin and the ability to work together quickly to solve technical issues and research needs. A key part of the proposed work was the use of existing wells for field testing and monitoring. A total of four wells (three vertical and one horizontal) were available for this project. One of the vertical wells was utilized as the test well for the NGL treatment test. A nearby vertical well was used for microseismic monitoring. The remaining vertical well and the horizontal well provided a baseline for typical UOG production in the oil window of the Utica/Point Pleasant (UPP). Major technical tasks of the project include characterization of the geotechnical properties of the UPP with an emphasis on the field site; design and planning for the NGLs testing; field testing and monitoring; analysis and integration of field data; and economic and resource/reserve assessment. The Shoman monitoring well and Doughty NGL treatment well were successfully plugged back during September-October 2020 in preparation for treatment and monitoring. A nitrogen diagnostic fracture injection test (DFIT) was completed on the Doughty well on July 22, 2021, consisting of 133,000 scf (91 Bbl.) of nitrogen. A nitrogen foam frac was completed in the Utica-Point Pleasant interval on August 17, 2021 with funding from outside sources. A microseismic monitoring array was installed in the Shoman well and monitored microseismic activity during the Doughty well frac job. Y-Grade NGL injection commenced on August 26, 2021. A total of 215 Bbl. was injected but the job was shut down due to a small leak on the suction hose on the pump truck. The Y-Grade treatment resumed on August 27, 2021 and an additional 726 Bbl. of Y-Grade NGL was injected at a well head pressure of 3850 psi. Total volume of injected Y-Grade over the two days of injection was 941 Bbl. The well was shut-in for 17 days following injection to allow the Y-Grade NGLs to soak on the formation. Y-Grade treatment flow back commenced on 9/13/2021 on a weekly basis. Production data, including surface pressures, oil, nitrogen, natural gas, and flow times was measured and recorded. Periodic gas samples were collected and analyzed to determine composition of flowback gas. As of July 2022, the treatment well had produced 726 Bbl of oil and 2,888 mcf gas. In August 2022, tubing and packer in the well were removed and a pump was installed to enhance oil recovery. Currently, the operator is producing the well about 2 days a week for a few hours. The performance of the NGL treatment test was evaluated based on reservoir simulations of the treatment process, processing of well testing data, analysis of micro seismic monitoring data, and production data analysis. This analysis suggested that oil production in the small test would continue through 2025. Upscaling the treatment to a horizontal Utica Point-Pleasant well would allow more oil recovery, but the process would involve more investment, services, and operational support. An economic analysis was conducted for scenarios aimed at upscaling the NGL treatment process for more typical horizontal UPP wells in the Appalachian Basin.

02 PETROLEUM↗
DOE OSTI2021

Atomic-scale Imaging of PGM-free Catalyst Active Sites by 30 keV 4D-STEM

Platinum group metal (PGM)-free catalysts have attracted a large amount of attention due to their potential for enabling low-cost, commercially viable hydrogen fuel cells and electrolyzers [1]. Degradation of cell performance remains a significant challenge, however, currently limiting implementation of devices that utilize PGM-free materials [2]. Controlling degradation in these materials requires a better understanding of the atomic structure of active sites, thought to be FeN4 structures within a graphitic carbon lattice, which would enable more accurate prediction of the associated degradation pathways. The exact structural arrangement of active sites in these materials is still debated since a range of structures have been computationally predicted and methods to directly validate these models are still needed [1,3-5].While scanning transmission electron microscopy (STEM) has provided initial glimpses into the nature of the proposed active sites, detailed evaluation of the structure of these sites is challenging since they involve defects, edges, and nitrogen dopants in the graphitic lattice, which are susceptible to beam damage [6,7]. Conventional STEM imaging and spectroscopy methods exacerbate this problem with dose-inefficiency or nonideal contrast characteristics for imaging light and heavy elements simultaneously. A method that minimizes damage while generating dose-efficient, easily-interpretable contrast for both light and heavy elements is therefore needed to facilitate imaging of sensitive active site atomic structure.Here, we demonstrate direct atomic-scale imaging of PGM-free catalyst active sites by low-voltage four-dimensional (4D)-STEM. To accomplish this, we pair a 30 keV aberration-corrected probe, which minimizes knock-on damage, with a fast pixelated detector that has optimal performance at low beam energies [8]. We show how this setup enables relatively simple center-of-mass (CoM) techniques [9,10] to produce images with an increased signal-to-noise ratio (SNR) and light-element contrast over conventional imaging modes, allowing the entire active site structure to be imaged at the atomic scale. Moreover, we show how electron ptychography [11,12] enables images with further improved characteristics to be obtained, for example by minimizing residual aberrations, which provides a more accurate structural representation. The increased understanding that these low-voltage 4D-STEM techniques will provide about the atomic structure of PGM-free active sites and their associated degradation pathways will facilitate rational design of next-generation materials, promoting development of low-cost hydrogen fuel cells, electrolyzers, and other energy conversion devices [13]. References:[1] U Martinez et al., Adv. Mater. 31 (2019), p. 1806545.[2] Y Shao et al., Adv. Mater. 31 (2019), p. 1807615.[3] J Kneebone et al., J. Phys. Chem. C 121, (2017), p.16283.[4] T Mineva et al., ACS Catal. 9 (2019), p. 9359.[5] J Li et al., Nat. Catal. 4 (2021), p. 10.[6] T Susi et al., ACS Nano 6 (2012), p. 8837.[7] P Zelenay and DJ Myers, US Department of Energy Hydrogen and Fuel Cells Program 2017 Annual Merit Review and Peer Evaluation Meeting, Washington, DC (2017).[8] H Ryll et al., J. Inst. 11 (2016), p. P04006.[9] K Müller et al., Nat. Commun. 5 (2014), p. 5653.[10] I Lazic et al., Ultramicroscopy 160 (2016), p. 265.[11] H Yang et al., Nat. Commun. 7 (2016), p. 12532.[12] Y Jiang et al., Nature 559 (2018), p. 343. [13] Research sponsored by the Hydrogen and Fuel Cell Technologies Office, Office of Energy Efficiency and Renewable Energy, US Department of Energy (DOE). Research was conducted at the Center for Nanophase Materials Sciences, which is a DOE Office of Science User Facility.

Zachman, Michael↗
DOE OSTI2014

SERIIUS-MAGEEP Visiting Scholars Program

Recent studies have assessed closed-loop supercritical carbon dioxide (s-CO 2 ) Brayton cycles to be a higher energy-density system in comparison to equivalent superheated steam Rankine systems. At turbine inlet conditions of 700°C and 20 MPa, a cycle thermal efficiency of ~50% can be achieved. Achieving these high efficiencies will help concentrating solar power (CSP) technologies to become a competitive alternative to current power generation methods. To incorporate an s-CO 2 Brayton power cycle in a solar power tower system, the development of a solar receiver capable of providing an outlet temperature of 700°C (at 20 MPa) is necessary. To satisfy the temperature requirements of an s-CO 2 Brayton cycle with recuperation and recompression, the s-CO 2 must undergo a temperature rise of ~200°C as it flows through the solar receiver. The main objective is to develop an optical-thermal-fluid and structural model to validate a tubular receiver that will receive a heat input ~0.33 MWth from the heliostat field at the National Solar Thermal Test Facility (NSTTF), Albuquerque, NM, USA. We also commenced the development of computational models and testing of air receivers being developed by the Indian Institute of Science (IISc) and the Indian Institute of Technology in Bombay (IIT-B). The helical tubular receiver is expected to counteract the effect of thermal expansion while using a cavity to reduce the radiative and convective losses. Initially, this receiver will be tested for a temperature range of 100-300°C under 1 MPa of pressurized air. The helical air receiver will be exposed to 10kWth to achieve a temperature rise of ~200°C. Preliminary tests to validate the modeling will be performed before the design and construction of a larger scale receiver. Lastly, I focused on the development of a new computational tool that would allow us to perform a nodal creep-fatigue analysis on the receivers and heat exchangers being developed. This tool was developed using MATLAB and is capable of processing the results obtained from ANSYS Fluent and Structural combined, which was limited when using commercial software. The main advantage of this code is that it can be modified to run in parallel making it more affordable and faster compared to commercial codes available. The code is in the process of validation and is currently being compared to nCode Design Life.

25 ENERGY STORAGE↗
DOE OSTI2014

Experimental design applications for modeling and assessing carbon dioxide sequestration in saline aquifers

This project was a computer modeling effort to couple reservoir simulation and ED/RSM using Sensitivity Analysis, Uncertainty Analysis, and Optimization Methods, to assess geologic, geochemical, geomechanical, and rock-fluid effects and factors on CO 2 injectivity, capacity, and plume migration. The project objective was to develop proxy models to simplify the highly complex coupled geochemical and geomechanical models in the utilization and storage of CO 2 in the subsurface. The goals were to investigate and prove the feasibility of the ED/RSM processes and engineering development, and bridge the gaps regarding the uncertainty and unknowns of the many geochemical and geomechanical interacting parameters in the development and operation of anthropogenic CO 2 sequestration and storage sites. The bottleneck in this workflow is the high computational effort of reactive transport simulation models and large number of input variables to optimize with ED/RSM techniques. The project was not to develop the reactive transport, geomechanical, or ED/RSM software, but was to use what was commercially and/or publically available as a proof of concept to generate proxy or surrogate models. A detailed geologic and petrographic mineral assemblage and geologic structure of the doubly plunging anticline was defined using the USDOE RMOTC formations of interest data (e.g., Lower Sundance, Crow Mountain, Alcova Limestone, and Red Peak). The assemblage of 23 minerals was primarily developed from literature data and petrophysical (well log) analysis. The assemblage and structure was input into a commercial reactive transport simulator to predict the effects of CO 2 injection and complex reactions with the reservoir rock. Significant impediments were encountered during the execution phase of the project. The only known commercial reactive transport simulator was incapable of simulating complex geochemistry modeled in this project. Significant effort and project funding was expended to determine the limitations of both the commercial simulator and the Lawrence Berkeley National Laboratory (LBNL) R&D simulator, TOUGHREACT available to the project. A simplified layer cake model approximating the volume of the RMOTC targeted reservoirs was defined with 1-3 minerals eventually modeled with limited success. Modeling reactive transport in porous media requires significant computational power. In this project, up to 24 processors were used to model a limited mineral set of 1-3 minerals. In addition, geomechanical aspects of injecting CO 2 into closed, semi-open, and open systems in various well completion methods was simulated. Enhanced Oil Recovery (EOR) as a storage method was not modeled. A robust and stable simulation dataset or base case was developed and used to create a master dataset with embedded instructions for input to the ED/RSM software. Little success was achieved toward the objective of the project using the commercial simulator or the LBNL simulator versions available during the time of this project. Several hundred realizations were run with the commercial simulator and ED/RSM software, most having convergence problems and terminating prematurely. A proxy model for full field CO 2 injection sequestration utilization and storage was not capable of being developed with software available for this project. Though the chemistry is reasonably known and understood, based on the amount of effort and huge computational time required, predicting CO 2 sequestration storage capacity in geologic formations to within the program goals of ±30% proved unsuccessful.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2020

Development of an In-Situ Method for Cable Condition Monitoring in Nuclear Power Plants (SBIR Phase IIB Final Report)

This is the final report of a Small Business Innovation Research (SBIR) project that Analysis and Measurement Services Corporation (AMS) has conducted for the U.S. Department of Energy (DOE) over a seven-and-a-half year period (February 2013 through April 2020 with the awards of Phase I, Phase II and Phase IIB projects). The goal of the project was to design, develop, validate, and demonstrate a technique for in-situ testing of cable insulation polymers that will identify, locate, and provide the degree of aging for cables commonly used in nuclear power plants. During the Phase I project, AMS established that the frequency domain reflectometry (FDR) technique can successfully identify and measure cable insulation degradation that can be trended with aging. In Phase II, AMS performed extensive cable aging studies to correlate FDR measurements with other laboratory condition monitoring techniques and developed aging condition categories to quantify the severity of insulation degradation. In Phase IIB, the project expanded the research to include a wider variety of cable polymers that are used in the commercial nuclear power industry. This work also involved developing acceptance criteria to objectively assess age-related cable degradation while sharing the results of this research with industry, academia, and national laboratories to advance the state of the art in cable aging management technologies. The products developed under this research project provide the nuclear industry with an effective condition monitoring tool to support safe and long-term plant operation. Throughout the project, collaborations and support were received from a variety of industry organizations and individuals including DOE National Laboratories as well as nuclear plant utilities and several other industry experts and cable manufacturers. Contributions from these organizations included the donation of new cables, naturally aged cables, and research collaboration. The validation and commercialization of the products of this project were achieved through opportunities to test and demonstrate the technologies’ capabilities on-site at nuclear power generation and research facilities as well as in the laboratory alongside industry peers and cable testing service companies. The research resulted in a technology that can be used to identify, locate, and quantify age-related degradation in several types of cable polymers. This included developing software and hardware as well as the methodology for using the FDR technique to assess age-related degradation of installed cables. The technology developed under this project can provide nuclear plant management, engineers, and technicians with an in-situ electrical test method to determine if in-service cables need to be replaced, monitored on a periodic basis, or show no evidence of significant age-related degradation that may require action. Near the end of this Phase IIB project, the FDR product was sold to a nuclear power utility in South Korea. This sale of a dedicated aging assessment tool is the beginning of a comprehensive contract with the expectation of twelve (12) units sold to that country. Additionally, the FDR technology has been sold to several industry organizations including a nuclear research institute and the Diablo Canyon nuclear power plant. This technology is also being leased by other nuclear industry service companies for incorporation into aging management programs. The cable testing technology that was developed under this project was also integrated into a comprehensive cable aging assessment service that is being offered to the nuclear industry at the request of U.S. nuclear utilities and is currently part of onsite testing services provided by AMS.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2015

National Cost-effectiveness of ANSI/ASHRAE/IES Standard 90.1-2013

The U.S. Department of Energy (DOE) Building Energy Codes Program supports the upgrade and implementation of building energy codes and standards, which set minimum requirements for energy-efficient design and construction for new and renovated buildings, and impact energy use and greenhouse gas emissions for the life of buildings. Continuous improvement of building energy efficiency is achieved by periodically updating model energy codes for commercial and residential buildings. Through consensus-based code development processes, DOE recommends revisions and amendments, supporting technologically feasible and economically justified energy efficiency measures. Ensuring that model code changes impacting the cost of building construction, maintenance, and energy services are cost-effective also encourages their adoption and implementation at the state and local levels. Pacific Northwest National Laboratory (PNNL) prepared this analysis to support DOE in evaluating the energy and economic impacts associated with updated codes in commercial buildings. The purpose of this analysis is to examine the cost-effectiveness of the 2013 edition of ANSI/ASHRAE/IES Standard 90.1 (ANSI/ASHRAE/IES 2013). Standard 90.1 is developed by the American Society of Heating, Refrigerating and Air-Conditioning Engineers (ASHRAE) Standard Standing Project Committee (SSPC) 90.1. It is the model energy standard for commercial and multifamily residential buildings over three floors (42 USC 6833). PNNL analyzed the cost-effectiveness of changes in Standard 90.1 from 90.1-2010 to 90.1-2013, as applied in commercial buildings across the United States. During the development of new editions of Standard 90.1, the cost-effectiveness of individual changes (addenda) is often calculated to support the deliberations of ASHRAE Standard Standing Project Committee (SSPC) 90.1. The ASHRAE process, however, does not include analysis of the cost-effectiveness of the entire package of addenda from one edition of the standard to the next, which is of particular interest to adopting State and local governments. Providing States with an analysis of costeffectiveness may encourage more rapid adoption of newer editions of energy codes based on Standard 90.1. This information may also inform the development of future editions of Standard 90.1.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2019

Roll-to-Roll Advanced Materials Manufacturing DOE Laboratory Collaboration - FY2018 Final Report

High-value R2R processing is used to support a wide range of products in applications which span many industrial business sectors. The overall R2R process technology can be considered as “mature” as the process methodology and has been in use for decades. This continuous processing technique traditionally involves deposition of material(s) onto moving webs or carriers or other continuous R2R, belt-fed, or conveyor-based processes that enable successive steps to build a final version which serves to support the deposited materials. Current process technologies, which typify “roll to roll”, include tape casting, silk-screen printing, reel-to-reel vacuum deposition/coating and R2R lithography. Products supported by R2R manufacturing include micro-electronics, electro-chromic window films, PVs, fuel cells for energy conversion, battery electrodes for energy storage, and barrier materials. Due to innovation in materials and process equipment, high-quality yet very low-cost multi-layer technologies can be manufactured on a very cost-competitive basis. To move energy-related products from high-cost niche applications to the commercial sector, a means must be available to enable manufacture of these products in a cost-competitive manner that is affordable by the general consumer. Fortunately, products such as fuel cells, thin- and mid-film PVs, batteries, electrochromic and piezoelectric films, water separation membranes, and other energy saving technologies readily lend themselves to manufacture using R2R approaches.Within the DOE EERE AMO, it was recognized that establishment of a program supported at the DOE National Laboratories, along with their immense design of materials and equipment modelling capabilities enabled with use of high-performance computing, could take advantage of available R2R infrastructure to manufacture new technologies. In FY 2016, a R2R Consortium was established and provided with initial “seed” funding to take an approach that was envisioned to be supportable by advanced manufacturing R2R processes. This collaborative approach was designed to foster identification and development of materials and processes related to R2R for clean-energy product development. Using computational and experimental capabilities by acknowledged subject matter experts within the supported National Laboratory system, this collaborative project would leverage the capabilities and expertise at each of four laboratories to further the development of an enabling high-volume cost-competitive platform technology. The collaboration team that is comprised of ORNL, ANL, NREL and LBNL, coordinating with EPB and other selected industry partners, was formed in April 2016 to initially address enhancing battery electrode performance and R2R manufacturing challenges. The research efforts were to predict and measure changes and results in electrode morphology and performance based on process condition changes; to evaluate mixed, active, particle size deposition and drying for novel electrode materials; to model various process condition changes and the resulting morphology and electrode performance; and to develop and validate NDE techniques for in-line measurement of battery electrode material properties. These efforts carried through FY 2017 and completed at the end of FY 2018.The approach was to look at compositions of materials with different particle sizes to make electrode samples using a R2R manufacturing process. The shape, size, and morphology of the materials, the chemistry of the formulation, the nature of slurries, their coating rate, the rate of drying all play a role in determining the final coating architecture, quality, and performance. A commercial cathode material was selected to make a series of cathodes and anodes by single pass, dual pass and slot die methods. Analysis of all the compiled results for this battery electrode development were that the best performing cathodes included: dual-pass electrode with large particles near the foil, mixed small and large particles, and small particles only. Whereas, the best performing anodes were with a mix of small and large graphite particles. An additional core project was added in FY 2017 to conduct studies of fuel cell materials that can be produced using R2R processes. The goal of this project is to explore, understand and optimize material and process parameters to support increased throughput, increased quality, and reduced cost for high volume production of gas-diffusion electrodes (GDEs) for PEMFCs. Project work in FY 2018 were to use a R2R process to fabricate electrodes without ionomer overlayer that can produce the equivalent mass activity as spray-coated electrodes with an ionomer overlayer. Oxygen-limiting current measurements were utilized to optimize oxygen mass transport. Alcohol-rich solvents were investigated, and results were that the alcohol and water ratio can be tuned to control ionomer distribution. Water-rich solvents produce a more dispersed ink which results in better high-current density performance.

36 MATERIALS SCIENCE↗