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Brentwood Lessons Learned Project Report

The purpose of this report is to document lessons learned in the installation of the hydrogen fueling station at the National Park Service Brentwood site in Washington, D.C., to help further the deployment of hydrogen infrastructure required to support hydrogen and other fuel cell technologies. Hydrogen fueling is the most difficult infrastructure component to build and permit. Hydrogen fueling can include augmenting hydrogen fueling capability to existing conventional fuel fueling stations as well as building brand new hydrogen fueling stations. This report was produced as part of the Brentwood Lessons Learned project. The project consisted of transplanting an existing modular hydrogen fueling station from Connecticut to the National Park Service Brentwood site. This relocation required design and construction at the Brentwood site to accommodate the existing station design as well as installation and validation of the updated station. One of the most important lessons learned was that simply moving an existing modular station to an operating site was not necessarily straight-forward - performing the relocation required significant effort and cost. The station has to function at the selected operating site and this functionality requires a power supply, building supports connecting to an existing alarm system, electrical grounding and lighting, providing nitrogen for purging, and providing deionized water if an electrolyzer is part of the station package. Most importantly, the station has to fit into the existing site both spatially and operationally and not disrupt existing operations at the site. All of this coordination and integration requires logistical planning and project management. The idea that a hydrogen fueling station can be simply dropped onto a site and made immediately operational is generally not realistic. Other important lessons learned include that delineating the boundaries of the multiple jurisdictions that have authority over a project for all parties involved in the project are key to an efficient approval process; and site investigation is necessary when integrating a new station design onto an existing site, particularly an older existing site that may have limited documentation on the site history and operations. The lessons learned for permitting and subcontracting construction work can be applied to other similar sites and to commercial sites.

30 DIRECT ENERGY CONVERSION↗

Solvent hold tank sample results for MCU-17-150-152 (July 2017) and MCU-17-153-155 (August 2017): Quarterly report

A trend summary that includes the last two Solvent Hold Tank (SHT) monthly samples is shown; MCU- 17-150-152 (July SHT) and MCU-17-153-155 (August SHT). Since the last SHT sample sent for analysis was the August sample the chemical state of the solvent is best approximated by the chemical analysis of the August SHT sample (MCU-17-153-155). This report mainly focused on the chemical analysis of the August SHT sample. The analysis data from the July SHT sample are presented in the “trend” plots of this report. Analysis of the August SHT sample (MCU-17-153-155) indicated that the modifier (CS-7SB) was 2% below but the extractant (MaxCalix) concentration was at its nominal recommended level (169,000 mg/L and 46,400 mg/L respectively). The suppressor (TiDG) level has decreased since the last measurement taken while the Modular Caustic-Side Solvent Extraction unit (MCU) was operating in January 2017, but has remained steady in the range of 666 (observed in April) to 715 mg/L (observed in the August 2017 sample) since February 2017, well above the minimum recommended level (479 mg/L), but below the nominal level. The “flat” trends observed in the TiDG, MaxCalix, modifier, and Gamma measurement are consistent with the solvent being idle since January 10, 2017. A strong correlation between density and modifier concentration in the solvent continues to be observed in the SHT samples. This analysis confirms the Isopar™L addition to the solvent in January 2017. This analysis also indicates the solvent did not require further additions. Based on the current monthly sample, the levels of TiDG, Isopar™L, MaxCalix, and modifier are sufficient for continuing operation but are expected to decrease with time if the Modular Caustic-Side Solvent Extraction Unit (MCU) returns to processing radioactive liquid waste. Otherwise, the levels of these components will remain steady. A future Isopar™L trimming addition to the solvent is recommended when MCU resumes processing waste. Two unknown impurities related to the modifier (but not sec-butyl phenol: a modifier degradation product observed before) at the 290 and 110 mg/L levels were observed in the August SHT sample by the Gas - Chromatography-Mass Spectrometry (GC-MS) method. They were observed in a second GC-MS re-run with a new column. Their identification can’t be ascertained at this time. No impurities were observed in the Hydrogen Nuclear Magnetic Resonance (HNMR). Another impurity observed in the samples was mercury. Based on the August SHT sample, up to 23 ± 5 micrograms of mercury per mL of solvent was detected (the average of the Cold Vapor-Atomic Adsorption [CV-AA] and X-Ray Fluorescence [XRF] methods). The higher mercury concentration in the solvent (as determined in the last three-monthly samples) is possibly due to either a higher mercury concentration in Salt Batches 8 and 9 (Tank 49H) . The gamma level (~ 2.0E4 dpm/mL) measured in the August SHT samples was one order of magnitude lower than the gamma levels observed in the December 2016 and January 2017 SHT samples. A similar level was observed in the July SHT sample (MCU-SHT-150-152). The gamma level has remained consistently steady since January 10, 2017 when MCU stopped processing radioactive liquid waste. The laboratory will continue to monitor the quality of the solvent in particularly for any new impurities or degradation of the solvent components.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Multi-Speed Transmission For Commercial Delivery Medium Duty PEDVs

Successful completion of the proposed project will set a course for improving quality of life by overcoming key challenges in the gearbox for commercial-delivery, medium-duty, plug-in electric drive vehicles: It will reduce US dependency on foreign oil through the use of electric driven propulsion instead of fuel driven. It will reduce health risks by replacing tailpipe emissions in densely populated city centers. Finally, it will improve the performance-cost basis to meet or exceed the expectations of the targeted medium duty vehicle fleet owners and the independent customers. The proposed multi-speed transmission will narrow motor operation to the peak efficiency region, thereby increasing the electric powertrain efficiency to help close the range gap. Further, it will enhance customer satisfaction by improving vehicle acceleration, top speed and gradeability over the baseline. The project was conducted in three budget periods: In BP1: Technology Development, High-level vehicle powertrain models were used to optimize candidate transmission architectures and ratios along with a variety of traction motor characteristics for concept selection. The detailed driveline designs and component dynamics were investigated to meet medium-duty EV requirements; In BP2: Technology Development and Prototype Demonstration, The modeling and simulations with multi-speed transmissions were extended to other MD and HD EV platforms. Clean sheet design of a compact, lightweight, flexible, and modular, four-speed transmission was completed. Development of novel shifting and controls strategies were started and procurement of the prototype transmission and the controller hardware was begun; In BP3: Technology Integration, Testing, and Demonstration, Prototyping the four-speed automated mechanical transmission was completed. The transmission controls system and software development and preliminary gearbox dyno tests were done at Eaton. ORNL conducted integrated powertrain HIL tests. One of the prototype units was fully integrated into a Proterra BE35 demonstration electric bus. The shift control strategy was fine-tuned on the integrated vehicle at Eaton Marshall Proving Grounds. NREL tested the vehicle and validated the performance gains. Simulations predicted up to 20% increase in system energy efficiency depending on drive cycles, a top speed of greater than70 mph on flat road, 40% faster acceleration and a doubled gradeability with four-speed transmission as compared to the baseline EVs. Chassis Dyno Tests at NREL verified the simulation results of Eaton team and the HIL test results of ORNL team. The new four-speed EV transmission is efficient, reliable, modular, scalable, light weight, small size, and will be affordable. Furthermore, four-speed transmission enables downsizing of motor, battery and final drive, thereby reducing the total system cost.

33 ADVANCED PROPULSION SYSTEMS↗

Achieving Tier 4 Emissions in Biomass Cookstoves

Previous literature on top-lit updraft (TLUD) gasifier cookstoves suggested that these stoves have the potential to be the lowest emitting biomass cookstove. However, the previous literature also demonstrated a high degree of variability in TLUD emissions and performance, and a lack of general understanding of the TLUD combustion process. The objective of this study was to improve understanding of the combustion process in TLUD cookstoves. In a TLUD, biomass is gasified and the resulting producer gas is burned in a secondary flame located just above the fuel bed. The goal of this project is to enable the design of a more robust TLUD that consistently meets Tier 4 performance targets through a better understanding of the underlying combustion physics. The project featured a combined modeling, experimental and product design/development effort comprised of four different activities: Development of a model of the gasification process in the biomass fuel bed; Development of a CFD model of the secondary combustion zone; Experiments with a modular TLUD test bed to provide information on how stove design, fuel properties, and operating mode influence performance and provide data needed to validate the fuel bed model; Planar laser-induced fluorescence (PLIF) experiments with a two-dimensional optical test bed to provide insight into the flame dynamics in the secondary combustion zone and data to validate the CFD model; Design, development and field testing of a market ready TLUD prototype. Over 180 tests of 40 different configurations of the modular TLUD test bed were performed to demonstrate how stove design, fuel properties and operating mode influences performance, and the conditions under which Tier 4 emissions are obtainable. Images of OH and acetone PLIF were collected at 10 kHz with the optical test bed. The modeling and experimental results informed the design of a TLUD prototype that met Tier 3 to Tier 4 specifications in emissions and Tier 2 in efficiency. The final prototype was field tested in India.

09 BIOMASS FUELS↗

Reliable SOFC Systems

The goal of this U.S. Department of Energy (DOE) sponsored project was to advance the reliability, robustness and endurance of low-cost SOFC technology suitable for ultimate deployment in ≥100 MWe Integrated Gasification Fuel Cell (IGFC) or Natural Gas Fuel Cell (NGFC) systems capable of ≥97% CO2 capture. The ultimate SOFC program goals are ≤ 0.2% per 1000 hours power degradation over a 5-plus year stack life, high-volume (≥ 250 MW/year) stack production cost of ≤$225/kWsystem net AC, and “power block” (exclusive of fuel supply, contaminant removal, and CO2 capture subsystems) capital cost of ≤ 900/kWsystem net AC (in year 2011). To progress towards the ultimate program goals, the specific objectives of this project were to achieve an SOFC stack power degradation rate of ≤1.5% per 1000 hours in a 100 kW (125 kW Peak) Modular Power Block (MPB) stand-alone power system under thermally self-sustained normal operating conditions and to verify the prospects for high volume SOFC stack production cost below the DOE target of ≤ 225/kW. This final technical report summarizes the progress made during the project period of 36 months. Significant progress was made in the areas of cell and stack technology development, Modular Power Block (MPB) development, sub-MW MPB system development, and MW-class SOFC System Development and Costing. The work focused on areas necessary for comprehensive development of an SOFC fuel cell system, including, active cell improvement, contaminant resistance, process engineering, and development of non-repeat module components. Additionally, several custom built balance-of-plant components were designed and fabricated to support the fuel cell system. SOFC cell and stack development focused on improving cell performance and durability. Enhancements were achieved in areas of electrode stability and impurity tolerance. Additionally, several quality control techniques and tools were developed to ensure predictable and repeatable fabrication of SOFC stacks. Module development continued previous development efforts to achieve footprint reduction and higher efficiency by incorporating balance-of-plant functional equipment into the fuel cell containment module. Several improvements were made to prior design. Control and instrumentation hardware was integrated within the module for serviceability and size reduction. The design efforts culminated in a complete SOFC power plant system. The designed plant was constructed and tested at FCE. Stack and system costs were updated, reflecting advances made in this program.

20 FOSSIL-FUELED POWER PLANTS↗

Solar Thermochemical Fuel Production via a Novel Low Pressure, Magnetically Stabilized, Non-volatile Iron Oxide Looping Process (University of Florida)

The UF Solar Fuels team has developed a modular reactor at the 10kW scale for the thermochemical conversion of H 2 O and CO 2 to H 2 and CO, respectively, using concentrated solar energy to drive high-temperature redox reactions. Various materials, including ferrites, doped and mixed metal ferrites, and ceria, were investigated and reported on. Ceria was chosen as the reactive material, with thermogravimetric and bench-scale analysis concurring with literature review and pointing towards reasonable kinetics and stability at temperatures on the order of 1500°C. A combined radiation, conduction, and species reaction/mass transport model was developed, utilizing Monte Carlo ray tracing, Lattice Boltzmann, and random walk particle tracking for the respective components to direct development and optimization of the reactor. With experimental data used for reaction rates, the model showed a path to efficiencies >20%, which could be market competitive with current PV-hydrolysis hydrogen generation systems. Economic analysis of a larger-scale plant (100kW modular system with cost performed at 500 modules) has been performed, assuming 0.5% and 10% internal rate of return. Without compression costs, H 2 production cost using this is technology at 12 USD/kg H 2 and 17 USD/kg H 2 for realized efficiencies of 20% and 15%, respectively.

14 SOLAR ENERGY↗

High-resolution time-resolved experiments on mixing and entrainment of buoyant jets in stratified environments

Fluid jets interacting with a stratified layer play an important role in the safety of several reactor designs. In the containment of nuclear power plants, fluid jets dominate the transport and mixing of gaseous species and consequent hydrogen distribution in case of a severe accident. The mixing phenomena in the containment are driven by buoyant high-momentum injections (jets) and low momentum injection plumes. Mixing near the postulated break is initially dominated by high flow velocities. Plumes with moderate flow velocities are instead relevant in the break compartment during the long-term pressurization phase, or in any of the apertures between two connected compartments if the mass flows are sufficiently high and the density differences between efflux and ambient are sufficiently low. Phenomena of interest include free plumes (as produced by the efflux from the break compartment in a larger room or directly from a break flow), wall plumes (such those produced by low mass flows through inter-compartment apertures), and propagating stratification fronts in the ambient (for any stably stratified conditions). These phenomena have been highly ranked about nuclear reactor design, especially regarding of safety protocols. During a Pressurized Thermal Shock (PTS) scenario, the interaction between the cold ECCS injection plume and the stratified fluid present in the cold (or hot) leg is important in order to determine the temperature at the time-dependent temperature at the inlet of the reactor pressure vessel (RPV) and the potential to cause a thermal shock on the RPV wall. In sodium-cooled fast reactors (SFRs), core channels are typically hydro-dynamically isolated so that there exists a considerable temperature variation at the exit of adjacent fuel assemblies. All the above phenomena are characterized by the interaction of buoyant jets with the stratified flow. In stratified layers baroclinic forces create significant redistribution of turbulent kinetic energy and scales, which leads to anisotropy. This important physical phenomenon is highly three dimensional and is challenging to capture even with high-fidelity CFD simulations, due in part to lack of sufficiently resolved validation data. Furthermore, the experimental data available in the open literature do not feature the level of fidelity needed for an extensive validation of turbulence models in lower order CFD. To shed new lights into the crucial phenomena object of the present research project, it was proposed to conduct coordinated experiments and simulations at the University of Michigan and the George Washington University. The project has resulted in an experimental database of high-resolution time-resolved measurements of jets in uniform and stratified environments. The novel experimental data will be used to validate computational fluid dynamic (CFD) codes, including both Large Eddy Simulations (LES) and unsteady Reynolds-averaged Navier-Stokes equations (URANS) methodologies. In the Experimental and Multiphase flow (ECMF) laboratory at Univerisity of Michigan, we built two experimental facilities to investigate also the effect of scaling. The first facility, DESTROJER (DEnsity Stratified Turbulent ROund free Jet ExpeRiment), featuring a contoured jet nozzle with a diameter of D=12.7mm and a 1m×1m×1m cubic tank, which is made of acrylic glass for optical access. The ratio between the tank width and the nozzle diameter is equal to 78, which ensures that there is no direct interaction between the jet and the side walls. A second, modular experimental facility, features three different tank sizes of size 10×10×30, 20×20×30, 30×30×30 cm3 respectively (all tanks have the same height of 30 cm), and a jet diameter of 2mm. For the modular facility, tank-to-nozzle ratio of 50, 100, and 150 are obtained respectively. Experiments with different-density jet impactions and sharp interface with a density difference of 3.16% In the Laboratory at George Washington University, complementary experiments have been carried out at a facility featuring the same dimensions as DESTROYER. Experiments with different jet diameters have been carried out as well. High-resolution time-resolved measurements have been performed at all facilities using high-speed particle image velocimetry (PIV) and planar laser-induced fluorescence (PLIF). In this way, simultaneous measurements of velocity and density fields have been carried out. At the University of Michigan, wire-mesh sensors have been designed and built to gather high-resolution, time-dependent data of the stratified front in the tank. These measurements are important to provide accurate initial conditions for the CFD simulations. An important outcome of the project has been the development of novel techniques to achieve refractive index matching (RIM) of acqueous solutions with high density differences. RIM is crucial if optical techniques such as PIV are used to measure velocity fields. Previous to this project, experiments up to 3% density difference had been reported in the literature. With the methodology developed in this project, we have been able to push the envelop to density differences up to 9%. The experiments have been used to validate Reynolds Averaged Navier-Stokes (RANS) turbulence models and Large Eddy Simulations (LES) models. Both NEK5000 and the commercial CFD code STAR-CCM+ have been used. The experimental data will be made available to the community through the NE-KAMS databasehave been successfully conducted in the scaled facility.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Conceptual Silicon Beta Cell Design

Silicon detectors have the potential to significantly improve the sensitivity limits for radioxenon detection. While silicon has beneficial attributes like improved energy resolution and memory effect, the sensitivity improvements will not occur without a properly designed beta cell that utilizes silicon detectors. This report details the key parameters that have been incorporated into the design of a silicon beta cell. Parameters that have the potential to change as a prototype silicon beta cell is developed and during the future commercialization process are also discussed. The design of the silicon beta cell has focused primarily on simulations and analytical models to optimize the mechanical properties. Additionally, a team of experts provided guidance and potential alternatives for the silicon detectors and electronics fabrication. A conceptual design for a silicon beta cell was completed, with an emphasis on the modularity of the system. The modularity allows for any potential changes that may be of interest during the prototyping phase or future spiral development to be implemented with minimal impact on the complete system. The impact of the silicon based beta cell is discussed in the conclusions, along with potential next steps. Mechanical design drawings for the beta cell could be used to manufacture a prototype beta cell and are available in an appendix document.

36 MATERIALS SCIENCE↗

NEAMS-IPL MOOSE Midyear Framework Activities

Multiphysics Object Oriented Simulation Environement (MOOSE) is a modular, pluggable framework for building complex simulations. The ability to add new objects with custom syntax is a core capability that makes MOOSE a powerful platform for coupling multiple applications together within a single environment. Documentation is not only a required component for a complete software quality assurance plan, but is critical to the overall success and wide-spread adoption of the platform by other researchers and institutions. Therefore, the notion of a modular, pluggable framework has been extended to the creation of documentation content. This report details the methodology for defining the NQA-1 compliant requirements in a manner that allows for the automatic generation of the Software Requirement Specification (SRS), Software Design Description (SDD), and Requirement Traceabiltity Matrix (RTM) from any repository revision.

97 MATHEMATICS AND COMPUTING↗

Advanced Compact X-ray Spectrometer with High Resolution and Efficiency

Under this Phase I SBIR Project, the Square One engineering team (in collaboration with a team of scientists from Brookhaven National Laboratory) designed, built, and tested a prototype Modular X-Ray Detection System. This Detection System was comprised of two primary subsystems, the Aiming Mechanism and the Optics Train. The Optics Train can be further subdivided into the following three components: the Collection Optic, the Discrimination Optic, and the Detection Unit. It is these three components that determine the modularity of the System. For example, the Collection Optic could accommodate either a polycapillary half lens or a Soller Slit. Similarly, the Detection Unit could accommodate either a Silicon Drift Diode (SDD) or some other diode. The Discrimination Optic can be included in the Optics Train, but is not necessary to the operation of the System.

99 GENERAL AND MISCELLANEOUS↗

Electrogenerative Reactors for Process Intensified Cogeneration of Power and Liquid Fuel from Shale Gas

With the abundance of natural gas and its primary components of methane, ethane and propane, there is the opportunity to convert these light alkanes to higher-value products. The growth in natural gas supply in the U.S. has increased substantially since the mid-2000s due to advances in horizontal drilling and hydraulic fracturing. As petroleum prices are volatile, natural gas resources are progressively attractive as alternative fuel sources. However, many of these shale gas wells are in regions of the U.S. that are remote and costly to transport to petrochemical and refining centers. In addition, much of this shale gas is “wet gas” that contains condensable amounts of ethane. While dedicated ethane gas pipelines have been built to get a small fraction of this gas to market, they are very capital intensive and compete for existing land use. As a result of this Phase I project, we developed a process to convert ethane to a transportable liquid fuel. This was achieved by implementing process intensification for this gas-to-liquids approach; we use novel eletrogenerative reactors in a two-step process rather than multi-step well-known technologies such as Fisher-Tropsch synthesis. These reactors borrow on well proven solid oxide fuel cell technology. Therefore, when produced in mass will be a very low-cost modular chemical reactor. This project demonstrated that EcoCatlaytic’s catalysts are highly selective towards ethylene and are compatible with anode materials. These integrated catalysts with the anode were able to maintain stable activity under ethane. Process simulations demonstrate an energy savings while producing gasoline and electricity for a modular system that produces 1,000 bbl/day gasoline. The system, not only produces gasoline, but also generates electricity which is a very valuable commodity in the remote shale gas facilities. This process could potentially allow remote natural gas producers to upgrade their feedstock to valuable gasoline on-site rather than flaring.

03 NATURAL GAS↗

DE-FE0031180 Final Report - LGFCS Prototype System Testing - R0

In the project, LGFCS assembled and tested its modular SOFC Power System that incorporates all critical technology improvements identified for its “product-like” demonstration. This product demonstrator is expected to meet customer and LGFCS performance expectations for operation, availability, durability and serviceability. The principal technology improvements are aimed at increasing the fuel cell power output and reducing the stack degradation rate. Improvements were also made for added system robustness and increased reliability. The objective of this program is to test a 250kWe thermally self-sustaining modular solid oxide fuel cell (SOFC) Power System for a minimum of 5,000 hours while advancing this commercial prototype product demonstrator to a Technical Readiness Level (TRL) 7. The SOFC system was tested on a site provided by Stark State College in North Canton, Ohio. System performance and degradation as well as cost estimates were compared to established SOFC Program performance metrics to assess progress. The major achievements were to assemble, and QA qualify 70 fuel cell strips for 12 integrated blocks into a fuel cell vessel and install it into a generator module with the fuel and power electronics modules on the test site. Performance to date included over 1800 hours on load at 250 KW-AC to the grid with a DC efficiency of 61% and AC efficiency of 55%. Power degradation was less than 0.4% per 1000 hours and NOx emissions met standards. The LGFCS SOFC Prototype System (GEN0) was demonstrated in an operational environment and therefore achieving Technical Readiness Level 7. The work presented here represents the efforts of all the employees of LG Fuel Cell Systems. Their dedication and hard work made GEN0 possible and successful.

03 NATURAL GAS↗

Conversion of Coal Wastes and Coal Plus Other Opportunity Fuel Mixtures, Such as Coal Plus Municipal Solids, to Produce Electricity and/or Liquid Fuels

For the foreseeable future, the Nation’s energy demand will continue to come largely from indigenous fossil energy resources and hydrocarbon fuels. Specifically waste coal plus other opportunity fuels need to be utilized as a feedstock to eliminate a waste stream and optimized to maximize energy yield and cleanly minimize pollutant emissions. Modular equipment is needed for installation in coal preparation locations, military installations, and research park facilities. Thermal decomposition of coal, biomass, and mixed solid waste (MSW) have been shown to reduce a waste stream while providing liquid and gaseous fuel products with low pollutant emissions. However, thermal decomposition processes have several challenges associated with preprocessing biomass and MSW, feeding and conveying material into the reactor, and post processing of syngas to remove undesirable products while upgrading to increase yield of high value products. Increasing total energy output from power plants by utilizing biomass and mixed wastes ultimately lowers energy costs, harmful environmental impacts of emissions, and has significant impacts on the energy security and sustainability of the U.S. economy. Entrained flow gasifiers (EFGs) produce very little CH4 and a wide range of H2/CO ratios (0.5–2.0) but are limited in their ability to effectively feed large biomass or MSW particles into the reactor. A solution to the feeding problems is to use pyrolysis torrefaction (PT) for conversion of waste materials to create a feedstock similar to coal and capable of grinding down and mixing with the coal feed. Mainstream experimentally explored reaction pathways for the conversion of coal waste plus municipal solids (CWPMS) and demonstrated a bench-scale reactor used for torrefaction of the municipal solid waste (MSW) to create a coal-like feed for blending with the coal waste. The material was processed in a pilot-scale EFG to determine product yield and emissions with CWPMS fuels, as well as the ash content and slagging properties of these feedstocks. The PT-EFG system was experimentally validated, where emissions and yield data were used to develop a high-fidelity process model and economic analysis. The following was accomplished in the Phase I: Determined optimal torrefaction process conditions for MSW and biomass through TGA; maximized heating value of fuel while maximizing final mass of torrefied product Demonstrated torrefaction of MSW and biomass feedstocks at 334°C, pulverized to uniform 74 µm particle size, and processed into coal-like feedstocks Demonstrated 8 lb/h pilot-scale EFG using MSW and biomass blends with waste coal; demonstrated 100% biomass in EFG Determined major effects of MSW torrefaction and co-gasifying high-ash coal waste-MSW blends have on pilot-scale EFG Demonstrated blending low-ash, low-sulfur torrefied biomass with high-ash waste bituminous and anthracite refuse coals generates a higher quality syngas compared to syngas from high-ash waste coals Demonstrated a high carbon conversion (> 99.5%) and syngas with 29.47% H2 content, and 0% CH4 content; greater water–gas shift occurs in EFG than predicted by equilibrium ASPEN Plus model Blended lower-ash, high-alkali biomass MSW to lower slag viscosities of the high-ash coal refuse sufficiently for better slag flow compared to feeding the high-ash coal Used low-sulfur biomass to greatly reduce the EFG syngas H2S concentrations and produce non-leachable slag and quench water with very little organic and trace metal contamination Developed a process model and TEA showing the modular PT EFG is cost competitive to existing power plants with the advantage of using low- or negative-value feedstocks such as waste coal stockpiles and non-landfilled MSW; providing a large incentive to implement an economical PT-EFG process

30 DIRECT ENERGY CONVERSION↗

LGFCS Prototype System Testing (Final Report)

In the project, LGFCS assembled and tested its modular SOFC Power System that incorporates all critical technology improvements identified for its “product-like” demonstration. This product demonstrator is expected to meet customer and LGFCS performance expectations for operation, availability, durability and serviceability. The principal technology improvements are aimed at increasing the fuel cell power output and reducing the stack degradation rate. Improvements were also made for added system robustness and increased reliability. The objective of this program is to test a 250kWe thermally self-sustaining modular solid oxide fuel cell (SOFC) Power System for a minimum of 5,000 hours while advancing this commercial prototype product demonstrator to a Technical Readiness Level (TRL) 7. The SOFC system was tested on a site provided by Stark State College in North Canton, Ohio. System performance and degradation as well as cost estimates were compared to established SOFC Program performance metrics to assess progress. The major achievements were to assemble, and QA qualify 70 fuel cell strips for 12 integrated blocks into a fuel cell vessel and install it into a generator module with the fuel and power electronics modules on the test site. Performance to date included over 1800 hours on load at 250 KWAC to the grid with a DC efficiency of 61% and AC efficiency of 55%. Power degradation was less than 0.4% per 1000 hours and NOx emissions met standards. The LGFCS SOFC Prototype System (GEN0) was demonstrated in an operational environment and therefore achieving Technical Readiness Level 7. The work presented here represents the efforts of all the employees of LG Fuel Cell Systems. Their dedication and hard work made GEN0 possible and successful.

03 NATURAL GAS↗

Exhaust runner soot diagnostic conceptual design for in-line time-resolved soot mass measurements

The Exhaust Runner Soot Diagnostic (ERSD) system is an in-line, time-resolved soot mass measurement system designed to allow rapid measurement of soot mass flux to detect and measure cyclic variability. The ERSD system design was generally split into two sections: conceptual mechanical design and measurement design—meaning the relevant calculations to demonstrate the feasibility of our planned measurement approach. For measurement design, the Beer-Lambert Law was the central focus for design justification. With measured values for the Filter Smoke Number (FSN) and a conversion to soot mass concentration, the required effective optical path length can be calculated for a desired light attenuation percentage. For mechanical design, the key constraints were space and modularity. The design must be placed into an existing mechanical setup with relative ease, as well as being modular enough to be implemented on other engines. The crux of the mechanical design was proper sealing and optical access, as both are crucial to the system's effectiveness. For proper sealing, extensive thermal expansion calculations were performed alongside O-ring design guides to produce the desired sealing and custom gland dimensions. For maximizing optical access, many iterations were modeled to provide full optical access while maintaining effective gas sealing.

02 PETROLEUM↗

Design and Development of a Custom Laser Powder Bed Fusion System

Additive manufacturing (AM) has gained great momentum both in industrial and research applications. Due to the ability to create custom and complex parts directly from a computer-aided design (CAD) file, AM is becoming a more reliable and efficient means to fabricate components. While being implemented throughout the aerospace, medical, automotive, and energy industries, the development of metal AM is still ongoing and presents many unique scientific challenges. For example, in laser powder bed fusion (PBF), intense localized heating of metal powder followed by rapid cooling leads to residual stresses and unique microstructures within a build. This may lead to cracking and a decrease in mechanical performance. In-situ diagnostics enable the laser-material interaction to be monitored as it occurs in order to optimize process parameters, and can be leveraged to develop tailored materials with specific microstructures that are more conducive for the complex thermal patterns encountered during laser PBF. Unfortunately, most commercial laser PBF machines are not suitable for research applications due to their large size, lack of diagnostics, and black box operation. A smaller system is better suited for using smaller quantities of powder to develop new tailored materials for AM, and a custom, modular design permits greater flexibility for incorporating in-situ diagnostics. Therefore, this project consisted of the design and construction of a custom, small scale, modular PBF system.

36 MATERIALS SCIENCE↗

Rocket Engine Test System for Development of Novel Propulsion Technologies

A 150 lb f thrust class, modular, bi-propellant, rocket engine/gas-generator and supporting test infrastructure has been developed in a cooperative effort between Sandia National Laboratories and the New Mexico Institute of Mining and Technology’s (NMIMT’s) Energetic Materials Research and Testing Center (EMRTC). This modular test engine design consists of a head end fuel-oxidizer injector, a spark ignition gaseous H 2 /O 2 torch igniter, combustion chamber and nozzle module. This robust design allows for rapid configuration changes as well as economical repair should hardware become damaged in testing. The engine interfaces with a permanently installed pressurizing system capable of delivering liquid nitrous oxide and a variety of liquid fuels for both rocket engine development and propellant performance evaluation. The regulated high pressure systems allow for delivery of liquefied gases above their saturation pressure as well as allowing for high pressure rocket engine/gas-generator operation. The facility test cell houses a 1 ton thrust capacity test stand leaving room for larger scale engine development.

36 MATERIALS SCIENCE↗

The PROPEL Hydro System (Final Report)

This paper summarizes research, development and outcome of a modular system for powering non-powered dams. There are approximately 77,000 non-powered dams in the US, a non-trivial fraction of which could be used to generate power. Development in this area has been slow because building projects costs too much and takes too long. The PROPEL-Hydro system combines modular components for the intake and foundation, an ai driven project design and evaluation tool, and a turbine optimized for performance on small and low head sites. Work included a combination of site evaluation, refinement of power electronics, value analysis supported by computational fluid mechanics and software development to support a project evaluation tool. The result is a reduction in installed cost/kW and resulting LCOE.

13 HYDRO ENERGY↗