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DOE OSTI2025

Deep Learning–Assisted Multiobjective Optimization of Geological CO 2 Storage Performance under Geomechanical Risks

In geological CO 2 storage, designing the optimal well control strategy for CO 2 injection to maximize CO 2 storage while minimizing the associated geomechanical risks is not trivial. This challenge arises due to pressure buildup, CO 2 plume migration, the highly nonlinear nature of geomechanical responses to rock-fluid interaction, and the high computational cost associated with coupled flow and geomechanics simulations. In this paper, we introduce a novel optimization framework to address these challenges. The optimization problem is formulated as follows: maximize total CO 2 storage while minimizing geomechanical risks by adjusting the injection schedules within bounded constraints. The geomechanical risks are primarily driven by injection-induced pressure build-up, which is characterized by ground displacement and the induced microseismicity. We used the Fourier neural operator (FNO)-based deep learning model to construct surrogate models, replacing the time-consuming coupled flow and geomechanics simulations for evaluating the aforementioned objective functions. The developed surrogate models have been incorporated into a multiobjective optimization framework through a genetic algorithm to reduce the computational burden. The proposed optimization framework reduces the computational cost from approximately 2,400 hours, when using objective function evaluations based on physics-based simulations, to around 20 minutes. A set of Pareto-optimal solutions of the proposed workflow yields nontrivial optimal decisions, reducing the microseismicity potential and the vertical displacement. This Pareto front highlights the optimal trade-offs between CO 2 storage amount, safety, and ground displacement, emphasizing the need for careful optimization and management of injection strategies to achieve a balanced outcome. The novelty of this work is twofold. First, we demonstrate the importance of incorporating the minimization of the geomechanical risks as objective functions into the CO 2 storage optimization workflow to mitigate the potential risk of induced microseismicity and ground displacement. Second, we leverage the FNO-based surrogate models to optimize a real-field CO 2 storage operation.

42 ENGINEERING↗
DOE OSTI2021

Melt extruded versus extrusion compression molded glass-polypropylene long fiber thermoplastic composites

Long fiber thermoplastic (LFT) composites are processed either with extrusion compression or fiber injection processes. The properties of LFT materials are highly influenced by processing techniques, which lead to different porosity contents, fiber length distributions, and fiber orientation distributions. It is important to understand the various LFT processing techniques and their effects on mechanical, thermal, and microscopic properties. This work considered LFT sheets processed via extrusion, which offers highly aligned fibers (referred to as “Tecnogor composites”), and LFT composites produced via extrusion compression molding (ECM), which offers a random distribution of fibers. Tecnogor composites exhibited higher flexural strength (35–65%), flexural modulus (132–172%), tensile strength (39–52%), tensile modulus (67–75%), and Izod impact resistance (195–220%) than the random LFT composites. This response was attributed to the aligned fibers in Tecnogor composites. Mathematical models including Halpin-Tsai and Lavengood-Goettler were used to predict and compare the Young’s modulus of Tecnogor and ECM composites, respectively.

mechanical testing↗
DOE OSTI2016

Investigation of the therapeutic potential of N-acetyl cysteine and the tools used to define nigrostriatal degeneration in vivo

The glutathione precursor N-acetyl-L-cysteine (NAC) is currently being tested on Parkinson's patients for its neuroprotective properties. Our studies have shown that NAC can elicit protection in glutathione-independent manners in vitro. Thus, the goal of the present study was to establish an animal model of NAC-mediated protection in which to dissect the underlying mechanism. Mice were infused intrastriatally with the oxidative neurotoxicant 6-hydroxydopamine (6-OHDA; 4 μg) and administered NAC intraperitoneally (100 mg/kg). NAC-treated animals exhibited higher levels of the dopaminergic terminal marker tyrosine hydroxylase (TH) in the striatum 10d after 6-OHDA. As TH expression is subject to stress-induced modulation, we infused the tracer FluoroGold into the striatum to retrogradely label nigrostriatal projection neurons. As expected, nigral FluoroGold staining and cell counts of FluoroGold{sup +} profiles were both more sensitive measures of nigrostriatal degeneration than measurements relying on TH alone. However, NAC failed to protect dopaminergic neurons 3 weeks following 6-OHDA, an effect verified by four measures: striatal TH levels, nigral TH levels, nigral TH{sup +} cell counts, and nigral FluoroGold levels. Some degree of mild toxicity of FluoroGold and NAC was evident, suggesting that caution must be exercised when relying on FluoroGold as a neuron-counting tool and when designing experiments with long-term delivery of NAC—such as clinical trials on patients with chronic disorders. Finally, the strengths and limitations of the tools used to define nigrostriatal degeneration are discussed. - Highlights: • N-acetyl cysteine (NAC) was injected into animals infused with the toxicant 6-OHDA. • Retrograde tracing with FluoroGold was used to define nigrostriatal cell loss. • Infrared Odyssey imaging and cell counts were used to screen for nigral cell loss. • NAC protected transiently against 6-OHDA but this effect waned over time. • Mildly toxic effects of chronic NAC delivery may influence future clinical trials.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2020

Fast and Accurate Core Analysis by the Full-Immersion Pressure-Pulse Decay: Part 1—Theory

Summary Core-scale measurements are considered the ground truth that oil and gas or electric utility companies use to predict the migration of fluids such as oil, natural gas, carbon dioxide, or brine deep underground during their extraction or injection operations. To provide a greater understanding of petrophysical properties of low-permeability geologic formations such as shales and tight gas sandstones, this study introduces a novel core-analysis procedure. The technique follows conventional pressure-pulse-decay permeametry, where the pressure in an inlet chamber adjacent to a cylindrical core plug undergoes a rapid pressurization, the system is shut in, and the pressure reaches a new equilibrium. However, unlike a standard unidirectional pressure-pulse decay, the full-immersion pressure-pulse decay (Hannon 2019) applies a pressure disturbance to the entire outer surface area of the sample. This article covers the numerical simulator designed to model flow through an anisotropic porous sample in this scenario. The model assumes distinct but uniform permeabilities along the radial and axial directions of the cylindrical plug sample. When extracting a plug vertically (or perpendicular to bedding), the permeability along the radial direction associates with the horizontal permeability (i.e., parallel to bedding), whereas in the axial direction, flow occurs perpendicular to bedding (a vertical permeability). Investigations of these model outputs demonstrate an approximately 20-fold decrease in time to complete a full-immersion experiment compared with conventional pressure-pulse decay. Furthermore, the pressure-decay curves resulting from the full-immersion method have slightly different shapes than those resulting from other unidimensional transient methods. These differences begin to demonstrate that, under achievable experimental conditions, the analysis of pressure data from one full-immersion test could enable the simultaneous estimation of the apparent permeabilities parallel and perpendicular to bedding of a cylindrical sample in addition to its porosity. A follow-up article finalizes the proof of this capability with a parameter-estimation procedure and presents experimental verification through a proof-of-concept study. Described in greater detail in that article, the parameter estimator requires multiple forward simulations to analyze the data, which behooves minimizing the compute time for each simulation. By using an alternating direction implicit time-marching scheme and a structured but variably spaced grid, the numerical simulator built for this purpose provides a forward model output with suitable accuracy in approximately 0.5 seconds.

Energy & Fuels↗
DOE OSTI2021

Robust Distributed State Estimator for Interconnected Transmission and Distribution Networks (Final Report RPPR-1)

This project’s objective is to develop a combined transmission and distribution state estimator which accounts for very large system size and model complexity (by way of distributing the computations) and large number of solar PV units connected to the distribution system on multiple feeders. The project not only provides a robust formulation and solution to this problem but also tests the solution by implementing it on a well-established large utility system. It introduces several improvements with respect to the state of the art in existing state estimation software: (a) The developed state estimator (SE) allows robust and accurate monitoring of bidirectional flows in distribution systems which result due to the distributed energy sources which are not observable and thus not incorporated in generation dispatch; (b) Large utility systems with tens of thousands of transmission buses and hundreds of thousands of distribution nodes are difficult to model as a single integrated system. This shortcoming is addressed by developing a “scalable distributed computational framework” which allows splitting the ultra large system models into several small subsystems and coordinating their solution by a robust and practical state estimation formulation; (c) Measurement errors irrespective of their locations are detected and removed by the developed state estimator. Historically, transmission and distribution systems were analyzed and operated as two independent systems. Given the non-transposed short feeder sections, unevenly loaded phases, strictly radial configuration and unidirectional power flows in the absence of remote generation, distribution system analysis was customized to account for these characteristics. However, some of these assumptions are no longer valid (non-radial configuration, bidirectional power flows) and thus distribution system analysis should be revisited. Furthermore, in the past, the interaction between the transmission and distribution systems was quite passive, where distribution substations were modeled as lumped loads in the transmission system model. With substantial generation injected by renewable generation located in the distribution systems, such modeling will no longer be accurate. The developed state estimator facilitates proper monitoring of the interactions between the transmission and distribution systems and enables smart dispatch of these units which are made observable by the state estimator.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2017

Steady-State Pool Boiling in Sea Water

Boiling heat transfer has attracted broad attention because of its high efficiency of heat removal and many possible applications, such as nuclear safety issues. From the lessons learned from the Fukushima Daiichi accident in Japan in 2011, Taiwan Power Company proposed an 'Ultimate Response Guideline' to ensure that there is sufficient water which can be injected into the core and prevent the core from being uncovered. However, if the core uncovered accident really happens, one still needs to continuously inject water into the core to keep the situation from getting worse. This is so called the 'quenching process'. Usually, a nuclear power plant is located near the bank of river or coast, so it is easy to get river or sea water as water resources during an emergency condition. Sea and deionized water (DI water) show significantly different performance during the quenching process. Hsu et al. conducted quenching experiments using different metal spheres (stainless steel 304 and zircaloy 702) initially at 1000 deg. C in deionized water and sea water to compare their difference. Their results indicated that sea water demonstrates a more rapid quenching process due to the suppression of film boiling, the zeta-potential between the hot surface and sea water and other effects prevent the formation of the vapor blanket. Lee et al. also studied quenching process by a reflooding method. They reported the rapid quenching time in sea water is due to higher boiling point and easily top quenching by sea salt solution. Despite the fact that better quenching performance has been observed in sea water, more fundamental experiments must be carried out to investigate basic boiling phenomena in sea water. For the past few years, many researchers studied steady boiling behavior based on pool boiling experiments. The parameters that may affect heat transfer coefficient include nucleation site density, wettability, surface tension, etc. Jamialahmadi et al. selected sodium sulfate (high solubility in water) and calcium sulfate (low solubility in water) solution as testing liquids with rod heaters used. They discovered sparingly soluble salts with inversed solubility may deposit on the heating surface and block heat transfer to bulk liquid. However, the addition of highly soluble salts may reduce heat transfer coefficient at modest heat flux but increase slightly at high heat flux. A few years later, Jamialahmadi et al. suggested the decrease in heat transfer coefficient of electrolyte solution has to do with the mass transfer in the liquid phase and developed a model with high accuracy. For nuclear safety, the use of sea water as an alternative emergency coolant, more basic physical phenomena of boiling in sea water must be investigated. The present work conducts pool boiling of sea water by using a platinum wire and compares with that in deionized water.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2016

Final report of “A Detailed Study of the Physical Mechanisms Controlling CO2-Brine Capillary Trapping in the Subsurface” (University of Arizona, DE-SC0006696)

Carbon capture and storage (CCS) of carbon dioxide emissions generated by production or combustion of fossil fuels is a technologically viable means to reduce the build-up of CO2 in the atmosphere and oceans. Using advantages of scale and location, CCS is particularly suitable for large point sources near ubiquitous deep saline aquifers, depleted gas reservoirs, or at production reservoirs for enhanced oil recovery (EOR). In the BES-funded research project, Oregon State University (OSU) carried out capillary trapping experiments with proxy fluids that mimic the properties of the scCO2/brine system under ambient temperatures and pressures, and successfully developed a unique and novel x-ray compatible, high-pressure, elevated temperature setup to study the scCO2/brine system under challenging reservoir conditions. Both methodologies were applied to a variety of porous media, including synthetic (glass bead) and geologic (Bentheimer sandstone) materials. The University of Arizona (UA) developed pore-scale lattice Boltzmann (LB) models which are able to handle the experimental conditions for proxy fluids, as well as the scCO2/brine system, that are capable of simulating permeability in volumes of tens of millions of fluid elements. We reached the following summary findings (main institute indicated): 1. (OSU/UA) To understand capillary trapping in a multiphase fluid-porous medium system, the system must be analyzed from a pore-scale force balance perspective; trapping can be enhanced by manipulating wetting and nonwetting phase fluid properties. 2. (OSU) Pore-scale fluid connectivity and topology has a clear and direct effect on nonwetting phase capillary trapping efficiency. 3. (OSU) Rock type and flow regime also have a pronounced effects on capillary trapping. 4. (OSU/UA) There is a predictable relationship between NWP connectivity and NWP saturation, which allows for development of injection strategies that optimize trapping. The commonly used Land model (Land, 1968) does not predict amount of trapped NWP accurately. 5. (UA) There are ambiguities regarding the segmentation of large-volume gray-scale CT data into pore-volumes suitable for pore-scale modeling. Simulated permeabilities vary by three orders of magnitude and do not resemble observed values very well. Small-volume synchrotron-based CT data (such as produced by OSU) does not suffer significantly from segmentation ambiguities. 6. (UA) A standard properly parameterized Shan-Chen model LB model is useful for simulating porous media with proxy fluids as well as the scCO2/brine system and produces results that are consistent with tomographic observations. 7. (UA) A LB model with fluid-interactions defined by a (modified) Peng-Robinson Equation of State is able to handle the scCO2/brine system with variable solid phase wettability. This model is numerically stable at temperatures between 0 and 250 °C and pressures between 3 and 50 MPa, and produces appropriate densities above the critical point of CO2 and exhibits three-phase separation below. Based on above findings OSU and UA have proposed continued experimentation and pore-scale modeling of the scCO2/brine system. The reported research has extensively covered capillary trapping using proxy fluids, but due to limited beam-time availability we were unable to apply our high-pressure CO2 setup to sufficient variation in fluid properties, and initial scCO2 connectivity. New data will also allow us to test, calibrate and apply our LB models to reservoir conditions beyond those that are currently feasible experimentally. Such experiments and simulations will also allow us to provide information how suitable proxy fluids are for the scCO2/brine system. We believe it would be worthwhile to pursue the following new research questions: 1. What are the fundamental differences in the physics underlying capillary trapping at ambient vs. supercritical conditions? 2. Do newly developed pore-scale trapping interactions and relationships translate to continuum scales? A motivation for these questions was elaborated in “Capillary Trapping of Super-Critical CO2: Linking Pore and Continuum Scales to Verify new Relationships” that was submitted to DOE-BES in 2015.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2024

Linear gyrokinetic simulations of toroidal Alfvén eigenmodes in the Mega-Amp Spherical Tokamak

Linear gyrokinetic (GK) simulations using the Gyrokinetic Toroidal Code (GTC) have been performed to investigate Toroidicity-driven Alfvén Eigenmodes (TAEs) driven by the neutral beam injection (NBI) induced fast ions in the Mega-Amp Spherical Tokamak (MAST) to identify the non-perturbative and kinetic effects of thermal plasma. A specific TAE in MAST discharge 26887, with an on-axis NBI power of approximately 1.5 MW and plasma current around 800 kA, exhibited frequency chirping, and the tangential soft x-ray camera array resolved the radial mode structure peaked near |q|=1.5. Various excitation methods were used in the GTC linear simulations, illustrating this code's capability to realistically represent the mechanisms and behaviors of fast ion-driven TAEs in spherical tokamaks. The radial structures from these GK simulations closely match measurements and calculations performed using the NOVA ideal MHD code, though with the frequencies approximately 10 kHz lower, likely due to various kinetic and non-perturbative effects. The simulations measured the damping rates due to continuum damping, radiative damping, and ion Landau damping, revealing that ion Landau damping has the most significant contribution to the total damping rate of the TAE. A comparison of growth rates of TAEs excited by fast ion Maxwellian and slowing-down distributions shows that the TAEs excited by a fast ion anisotropic pitch distribution (as part of the slowing-down distributions) are more unstable compared to those excited by a Maxwellian distribution with an equivalent fast ion beta. This shows that the use of fast ion anisotropy alters the number of fast ions to be in shear Alfvén resonance, and hence, it can greatly affect the stability of TAEs. These tests can be performed with the GTC but impossible with ideal MHD simulations, highlighting the necessity of kinetic simulations such as the GTC for a precise prediction of the TAE stability.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

Plasma–surface interaction in the stellarator W7-X: conclusions drawn from operation with graphite plasma-facing components

W7-X completed its plasma operation in hydrogen with island divertor and inertially cooled test divertor unit (TDU) made of graphite. A substantial set of plasma-facing components (PFCs), including in particular marker target elements, were extracted from the W7-X vessel and analysed post-mortem. The analysis provided key information about underlying plasma–surface interactions (PSI) processes, namely erosion, transport, and deposition as well as fuel retention in the graphite components. The net carbon (C) erosion and deposition distribution on the horizontal target (HT) and vertical target (VT) plates were quantified and related to the plasma time in standard divertor configuration with edge transform ι = 5/5, the dominant magnetic configuration of the two operational phases (OP) with TDU. The operation resulted in integrated high net C erosion rate of 2.8 mg s -1 in OP1.2B over 4809 plasma seconds. Boronisations reduced the net erosion on the HT by about a factor 5.4 with respect to OP1.2A owing to the suppression of oxygen (O). In the case of the VT, high peak net C erosion of 11μm at the strike line was measured during OP1.2B which converts to 2.5 nm s -1 or 1.4 mg s -1 when related to the exposed area of the target plate and the operational time in standard divertor configuration. PSI modelling with ERO2.0 and WallDYN-3D is applied in an interpretative manner and reproduces the net C erosion and deposition pattern at the target plates determined by different post-mortem analysis techniques. This includes also the 13 C tracer deposition from the last experiment of OP1.2B with local 13 CH 4 injection through a magnetic island in one half module. The experimental findings are used to predict the C erosion, transport, and deposition in the next campaigns aiming in long-pulse operation up to 1800 s and utilising the actively cooled carbon-fibre composite (CFC) divertor currently being installed. The CFC divertor has the same geometrical design as the TDU and extrapolation depends mainly on the applied plasma boundary. Extrapolation from campaign averaged information obtained in OP1.2B reveals a net erosion of 7.6 g per 1800 s for a typical W7-X attached divertor plasma in hydrogen.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2016

Gas Gun Model and Comparison to Experimental Performance of Pipe Guns Operating with Light Propellant Gases and Large Cryogenic Pellets

Injection of multiple large (~10 to 30 mm diameter) shattered pellets into ITER plasmas is presently part of the scheme planned to mitigate the deleterious effects of disruptions on the vessel components. To help in the design and optimize performance of the pellet injectors for this application, a model referred to as “the gas gun simulator” has been developed and benchmarked against experimental data. The computer code simulator is a Java program that models the gas-dynamics characteristics of a single-stage gas gun. Following a stepwise approach, the code utilizes a variety of input parameters to incrementally simulate and analyze the dynamics of the gun as the projectile is launched down the barrel. Using input data, the model can calculate gun performance based on physical characteristics, such as propellant-gas and fast-valve properties, barrel geometry, and pellet mass. Although the model is fundamentally generic, the present version is configured to accommodate cryogenic pellets composed of H2, D2, Ne, Ar, and mixtures of them and light propellant gases (H2, D2, and He). The pellets are solidified in situ in pipe guns that consist of stainless steel tubes and fast-acting valves that provide the propellant gas for pellet acceleration (to speeds ~200 to 700 m/s). The pellet speed is the key parameter in determining the response time of a shattered pellet system to a plasma disruption event. The calculated speeds from the code simulations of experiments were typically in excellent agreement with the measured values. With the gas gun simulator validated for many test shots and over a wide range of physical and operating parameters, it is a valuable tool for optimization of the injector design, including the fast valve design (orifice size and volume) for any operating pressure (~40 bar expected for the ITER application) and barrel length for any pellet size (mass, diameter, and length). Key design parameters and proposed values for the pellet injectors for the ITER disruption mitigation systems are discussed.

Combs, S. K.↗
DOE OSTI2023

Final Technical Report: Innovative Magnetron Power Sources for Superconducting RF (SRF) Accelerators

In this project, MUONS is designing and building custom magnetrons at Richardson Electronics (RELL) to test the predictions of the models and make improvements to the designs to match the needs of NP SRF accelerators and their life-cycle costs. To increase lifetime, the filament temperature is controlled by a feedback circuit that includes a model of back streaming of electrons. The gain of the magnetron is optimized by the design of an input port. A permanent magnet design with trim coil for amplitude adjustment reduces energy consumption. Moving the construction of the magnetron from prototype to manufacturing includes the utilization of RELL processes and designs. To the extent that outgassing of materials influences the lifetime of the magnetron, methods for minimizing outgassing was explored. Further experimentation of the potential of sub-critical voltage operation continues to be explored. The commercialization goal of the project will be naturally achieved as RELL already has world-wide marketing, sales, and support to exploit the assembly-line capabilities generated by this project to enable magnetron technologies for NP accelerators.

43 PARTICLE ACCELERATORS↗
DOE OSTI2021

Pore accessibility and trapping of methane in Marcellus shale

Accessibility of pore space in unconventional reservoirs is an important factor influencing both methane storage capacity and the kinetics of methane desorption. The determination of open (accessible) versus closed (inaccessible) porosity is therefore vital for the prediction of gas production potential. This study investigates accessibility of pores to methane in overmature middle Devonian Marcellus shale samples (cut parallel and perpendicular to bedding) using small and ultra-small neutron scattering (SANS and USANS) with contrast matching (CM), supplemented by other complementary techniques, such as mercury injection capillary pressure (MICP) and low pressure gas (N2 and CO2) adsorption. Our results demonstrate that for the samples studied, only about 6 % of pores with diameter 25-500 nm are accessible to methane. The accessibility fraction for pores larger than 500 nm is 35%. For nanopores smaller than 25 nm, pore accessibility could not be quantitatively determined due to increased methane density and condensation effects in confinement. Our observations indicate that methane penetrates the accessible small mesopores and micropores down to at least 1 nm in diameter, and the density of confined deuterated methane (CD4) is 0.68 g/cm3 for pores of diameter 25 nm and gradually increases with the decreased pore size. Moreover, elevated gas pressure causes formation of additional high-density methane nano-clusters. These clusters have a form of slightly anisotropic polydisperse discs oriented along bedding plane, about 1-12 nm in diameter and with average thickness of 3.6 nm. Utilizing samples cut parallel and perpendicular to the bedding, this study also briefly addresses anisotropy of pores. Based on the iso-size intensity ratio R, our SANS and USANS results demonstrate anisotropy in the out-of-bedding direction and suggest that the degree of anisotropy depends on the pore size. Specifically, for pore diameters ~2.5 to 250 nm, the extent of anisotropy is smaller than for pores ~500 nm to 6 µm in diameter. Finally, comparison of pore size distribution results calculated from SANS/USANS to those obtained using MICP shows good agreement at low pressures, but large difference at pressures above 1000 bar. Here, this discrepancy requires further testing; it is possible that the high mercury pressure used in MICP alters the mesopore and micropore structure of shales.

03 NATURAL GAS↗
DOE OSTI2019

Lean Miller Cycle System Development for Light-Duty Vehicles (Final Report)

This report summarizes activities conducted in support of the project “Lean Miller Cycle System Development for Light-Duty Vehicles” under Cooperative Agreement Number DE-EE0006853. In order to accomplish the government objective of achieving breakthrough thermal efficiencies while meeting U.S. EPA emission standards, this project focused on combining two enabling technologies in a gasoline engine: lean combustion and “Miller Cycle.” Lean combustion is thermodynamically more efficient than stoichiometric combustion but requires a more complex exhaust aftertreatment system compared to a traditional three-way catalyst system. The “Miller Cycle” concept increases expansion of combustion gases to extract additional work, reduces pumping losses, and increases efficiency. The objective of the project was to research, develop, and demonstrate the new Lean Miller Cycle (LMC) combustion concept to achieve a 35% improvement in fuel economy over a 2010 production baseline vehicle. The baseline vehicle chosen was a Chevrolet Impala equipped with a 3.5L V6 port-fuel injected naturally-aspirated engine, a four-speed automatic transmission with a peak-power and -torque of 157 kW and 290 N-m respectively. The enabling technologies were developed and demonstrated on a single cylinder engine and then integrated into a multicylinder engine and aftertreatment system. Along with achieving the efficiency targets, the downsized boosted LMC engine system was projected to achieve a peak-power and –torque of 172 kW at 354 Nm respectively exceeding the baseline engine performance. The multicylinder engine was optimized and calibrated over a set of steady-state operating points on an engine dynamometer. The target of the project was a 35% improvement in combined city/highway fuel economy at SULEV30 tailpipe emissions over the baseline vehicle. The project achieved a projected 42.4% from the vehicle drive cycle analysis assuming no penalty for management of the lean-aftertreatment system. This penalty was projected to fall within the fuel economy margin achieved and include control and calibration compromises for catalyst heating, NH3 formation for lean-NOx SCR and drive quality. A final vehicle demonstration was planned where emissions, drivability and performance were to be confirmed. Four decision gates were set up annually with deliverables to assess progress and determine whether status to deliverables warranted project continuation through the final vehicle demonstration. The project was closed in June 2019 at the end of budget period three after not passing the third decision gate due to projected system costs prohibiting economic feasibility in the light-duty vehicle industry landscape. However, the project’s efficiency targets were achieved by validation through steady-state dynamometer testing of the multicylinder engine.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2022

Initial Engineering and Design for CO 2 Capture from Ethanol Facilities

The Energy & Environmental Research Center, in partnership with the U.S. Department of Energy (DOE) and North Dakota ethanol producer Red Trail Energy, LLC (RTE) and with technical support from Trimeric Corporation and the KLJ engineering firm, completed an initial engineering design (IED) for a hybrid capture system to estimate associated costs for retrofitting the operational RTE ethanol plant. The project goal supports the DOE objective to achieve negative emissions using commercially available technologies to attain Technology Readiness Level 6+ from a facility emitting >100,000 tonnes of carbon dioxide (CO 2 ) annually. The RTE CCS (carbon capture and storage) Project is currently operating a CO 2 capture facility, adjacent to the RTE ethanol facility in western North Dakota, and injecting the CO 2 more than a mile below RTE property for permanent storage. This novel hybrid capture system would process about 310,000 tonnes of CO 2 annually for the RTE host site and includes CO 2 capture and compression from bioprocessing as well as capturing CO 2 produced from natural gas boilers. The bioprocessing capture process, based on past RTE studies investigating ammonia liquefaction technology with CO 2 produced from natural gas boilers captured utilizing chemical absorption with amine, was shown to be technically feasible for the RTE site. Activities conducted to support the project goal included 1) designing a hybrid capture system using CO 2 emissions from both bioprocessing and heat production at the host site facility; 2) conducting a pre-front-end engineering and design analysis of the hybrid capture system to include environmental health and safety, a constructability report, identification of permits, and corporate approvals; and 3) performing a techno-economic assessment in accordance with DOE’s methodology, as demonstrated by the bituminous baseline study. In addition, a life cycle assessment (LCA) was completed for the RTE site to estimate the carbon life cycle for ethanol-CCS implementation using the designed hybrid capture system to determine potential for net-negative carbon emissions. Results of the IED showed the hybrid system to be technically viable, with a moderate estimated cost of $55/tonne CO 2 captured for the hybrid system. The cradle-to-gate LCA showed preliminary net-negative carbon emissions potential anticipated from implementing a hybrid CCS system at a commercial scale. Recommended next steps toward potential implementation include hybrid capture system demonstration testing for detailed engineering and LCA model comparisons with low-carbon fuel incentive programs for financial support.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2018

Assessment of CO 2 Storage Resources in Depleted Oil and Gas Fields in the Ship Shoal Area, Gulf of Mexico

The Gulf of Mexico is one of the most important regions in the United States for energy resources and infrastructure. Gulf of Mexico federal offshore oil and gas production accounts for 17% of total U.S. crude oil production and 5% of total U.S. gas production (EIA Gulf of Mexico Fact Sheet). This region presents an excellent combination of high need and significant opportunity for large scale geologic storage of CO 2 . The Ship Shoal Area is located about 20 miles offshore Louisiana within the Gulf Coast federal waters. Miocene and Pliocene sediments in the Ship Shoal Area are proven to provide excellent and secure traps for oil and gas. The Ship Shoal Area contains a large number of depleted oil and gas fields either currently abandoned, or planned for abandonment by 2025, which may provide very significant potential CO 2 storage capacity. GeoMechanics Technologies conducted a comprehensive research project to better characterize Neogene sediments in the Ship Shoal Area for high volume CO 2 storage. The data generated from literature, well data, well log, and formation evaluation were input into Rockwork 16 geologic software to create a detailed geologic model for the Ship Shoal study area. The geologic grids were then fed into TOUGH2, the gas migration model software and FLAC 3D, the geomechanical model software. The fluid flow modeling for both the Miocene and Pliocene simulation from both Block 107 and Block 84 indicated that Pliocene and Miocene are a good reservoir for the CO 2 sequestration. Thirty years of CO 2 injection (at a rate of 1 million metric tons CO 2 per year) and 30 years of observation simulations were run with the fluid flow modeling. The 3D geomechanical modeling for Ship Shoal Block 107 and Block 84 were developed to evaluate induced surface deformation and potential fault reactivation after 30 years CO 2 injection at base of Pliocene and at upper Miocene injection locations. Evaluation results indicate low to no risks for fault slips or fault reactivation. Twelve well bores and 76 well bores for Ship Shoal Blocks 84 and 107 respectively were reviewed for their cement history. Most wells (57 out of 76 and 7 out of 12 wells in Ship Shoal Block 107 and 84 respectively) have good integrity. Nineteen and 5 wells (in Ship Shoal Block 107 and 84 respectively) with no top plug, incomplete cement or Plug and Abandonment information are given yellow cautionary indicators. These cautionary wells may provide leakage paths of CO 2 through the well bores to the USDWs. Using our Quantitative Risk & Decision Analysis Tool (QRDAT) for caprock integrity evaluation, we compared Ship Shoal’s risk to that of In Salah, Sleipner, Kevin Dome, Loudon, Illinois Industrial CCS and Wilmington Graben. We found the risk at the Ship Shoal Blocks 84 and 107 fields are similar to the known CO 2 active sequestration sites, but lower than the Wilmington Graben turbidities offshore California studied site. The risk of natural seismicity in the Gulf of Mexico is relatively low. Geomechanics Technologies has documented the top 25 CO 2 emission sources within the close proximity of the Ship Shoal Block 84 and 107 fields. All the offshore and onshore pipelines have been digitized and can be viewed in an interactive website (http://www.geomechanicstech.com/shipshoal.html). We also performed a feasibility study on the potential for converting existing oil or gas pipelines for CO 2 transport. There are abandoned, idled and retired onshore and offshore pipelines. However, there is no standard specification for maximum pipeline pressures needed for CO 2 transport. It is a function of design, materials, and testing provided; thus it will be the responsibility of the pipeline operator to correctly determine, maintain and operate within the limits of the pipelines. There are a few transit corridors extending from onshore Louisiana (Cailou Bay) to offshore trunk-lines. The cost for constructing a pipeline has increased about 46% from 2015 to an average cost of $5,064,046 per mile in 2016. We use the NETL CO 2 storage resource mass estimate to calculate the potential resources for Ship Shoal Block 84 and 107 fields using the depleted oil and gas reservoir volume and sand volume generated from our geologic modeling. The estimated storage resource results are greater when using the sand volumes derived through geologic modeling than the oil and gas reservoir data. The difference is due to the depleted oil and gas reservoir information not accounting for the water-flooded sand located below the oil/gas-water contact or unproductive sand units. Resource calculation using the sand volume obtained through geologic modeling overestimate the storage capacity as the model accounts for all sand within the formation, not just the interconnected sand.

02 PETROLEUM↗
DOE OSTI2022

Multiple Stream Low-Cost Recycling Method

The global composite industry generates large quantities of waste and which mostly end as landfill due to lack of meaningful end-use applications for the multiple waste streams. In a recent report by the Electric Power Research Institute (EPRI), waste generated by the wind industry could reach 370,000 tons a year of composite wind energy blades being decommissioned and scrapped. Wind energy is just one major industry utilizing composite materials. The waste generated by industry includes End-of-Life (EoL) materials and manufacturing process scrap. GreenTex Solutions has developed a unique and innovative technology to recycle the composite waste streams in a range of forms made from production waste and EoL materials. This includes manufacturing waste materials such as dry chopped fiber tow, loose fibers, shredded fibers from reinforcement fabrics, cured/semi-cured prepregs, and it also includes fully-cured composite structure waste (such as edge trims from cured parts) from manufacturing aircraft, automobiles, wind blades, boats, and composite cylinders (tanks). Current recycling methods involve recovering the structural fiber by removing the matrix resin through methods such as pyrolysis. The resulting fibers are used in injection molding or wet laid nonwoven mats and other usable forms. The GreenTex technology bypasses these intermediate steps to create the lowest possible recycling processing costs and the lowest embodied energy/CO2 emissions. The end-product from the GreenTex technology is a finished industrial composite part/application versus intermediate fibers or fabrics. The GreenTex manufacturing process enables cross-industry reuse of recycled feedstock by taking waste from multiple industries (wind energy, aerospace, marine, etc.) and recycles the waste into a product used in other industries. The initial target market application is structural flooring for intermodal shipping containers and truck bodies. One of the team’s key partners is Wabash National which produced 29,000 truck bodies in 2019. The current flooring system is comprised of solid oak “butcher board” laminated panels. Additionally, Mediterranean Shipping Containers (MSC) transports over 1.8 million twenty-foot equivalent units per year in intermodal shipping containers. The current container floor is laminated hardwood that is harvested from the rain forests of Central and South America. The project is to develop a flooring system made from recycled composites that can be qualified for both companies (Wabash and MSC). Initial prototypes validated that the recycled composites panels are lighter and thinner with much higher mechanical strength. These results suggest a typical truck trailer would have 20% lower tare weight. The GreenTex technology is not limited to flooring and is widely applicable to other transportation elements such as walls, roof elements, cab areas and related structural components. Under this project different composite waste streams were evaluated and then combined to develop a formulation that would meet the targeted performance criteria for a flooring system. Wet compression molding was used to fabricate plaques at different tonnage using various composite waste streams. The plaques were tested for flexure and impact.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Bioremediation of a Large Chlorinated Solvent Plume, Dover AFB, DE

Bioremediation of a Large Chlorinated Solvent Plume, Dover AFB, DE Aleisa Bloom, (Oak Ridge National Laboratory, Oak Ridge, Tennessee, USA) Robert Lyon (bob.lyon@aecom.com), Laurie Stenberg, and Holly Brown (AECOM, Germantown, Maryland, USA) ABSTRACT: Past disposal practices at Dover Air Force Base (AFB), Delaware, created a large solvent plume called Area 6 (about 1 mile long, 2,000 feet wide, and 345 acres). The main contaminants are PCE, TCE, and their degradation products. The remedy is in-situ accelerated anaerobic bioremediation (AAB). AAB started in 2006 and is focusing on source areas and downgradient plume cores. Direct-push injections occurred in source areas where contamination is typically between 5 and 20 feet below ground surface. Lower concentration dissolved-phased contamination is present downgradient at 35 and 50 feet below ground surface. Here, permanent injection/extraction wells installed in transects perpendicular to the flow of groundwater are used to apply AAB. The AAB substrate is a mix of sodium lactate, emulsified vegetable oil, and nutrients. After eight years, dissolved contaminant mass within the main 80-acre treatment area has been reduced by over 98 percent. This successful application of AAB has stopped the flux of contaminants to the more distal portions of the plume. While more time is needed for effects to be seen in the distal plume, AAB injections will soon cease, and the remedy will transition to natural attenuation. INTRODUCTION Oak Ridge National Laboratory Environmental Science Division (ORNL) and AECOM (formerly URS Corporation) have successfully implemented in situ accelerated anaerobic bioremediation (AAB) to remediate chlorinated solvent contamination in a large, multi-sourced groundwater plume at Dover Air Force Base (AFB). AAB has resulted in significant reductions of dissolved phase chlorinated solvent concentrations. This plume, called Area 6, was originally over 1 mile in length and over 2,000 feet wide (Figure 1). It originated from at least four separate source areas that comingled in the subsurface to form the large plume. The major contaminants of concern (COCs) are tetrachloroethene (PCE), trichloroethene (TCE), and 1,1,1-trichloroethane (1,1,1-TCA), which were historically used for degreasing operations in the maintenance of aircraft and support vehicles. Relatively small areas of elevated PCE, TCE, and 1,1,1-TCA were delineated in the shallow portion of the water table aquifer by direct-push groundwater sampling. Focused direct-push AAB treatment occurred in March 2006 at these source areas (Figure 1). Downgradient of the these areas and deeper in the aquifer, AAB treatment was implemented using rows of extraction/injection wells oriented perpendicular to groundwater flow to create multiple reductive zones across the plume cores, defined as areas where more than 1,000 micrograms per liter (ug/L) total solvent concentrations were present. Initial indications of successful degradation were observed within 6 months of starting injections. FIGURE 1. Dover AFB Area 6 plume. This paper describes the AAB implementation and progress of remediation after 8 years of treatment and periodic groundwater monitoring. SITE LITHOLOGY Contamination at the site is limited to the surficial aquifer, which consists of 35 to 50 feet (ft) (11 to 15 meters [m]) of unconsolidated Pleistocene deposits of the Columbia Formation. The Columbia Formation consists of fine to coarse sand with silt and clay lenses and less common gravel lenses. Silts and silty sands are generally encountered to a depth of 10 to 12 ft (3.05 to 3.65 m) below ground surface (bgs) and grade to medium- and coarse-grained sands to a depth of 35 to 50 ft (11 to 15 m) bgs. There is a clay and silt unit (part of the Calvert Formation) below the surficial aquifer that acts as an aquitard to the downward migration of contaminants. The depth to the water table varies across the site but usually ranges from 8 to 15 ft (2.4 to 4.5 m) bgs in the treatment area. REMEDIAL APPROACH AND OPERATIONS Because the Columbia Aquifer is used as a source of potable water off base, the remedial goal is to restore the aquifer to usable condition, i.e., reduce all chemicals of concern to below drinking water maximum contaminant levels (MCLs). To achieve this goal, AAB was selected as the best remedial alternative to reduce the solvent contamination. Source areas with high solvent concentrations were present in the shallow portion of the aquifer. From the source areas, dissolved solvents migrated downgradient and deeper in the aquifer with the flow of groundwater. In the deeper portion of the aquifer, the individual plumes comingle to form the larger Area 6 Plume, which covers approximately 345 acres. Types of Substrate. Previous AAB pilot tests at Dover AFB used either sodium lactate or emulsified vegetable oil (EVO) as substrates to stimulate microbial growth. The best results were obtained with...

Bloom, Aleisa C↗
DOE OSTI2015

Controlling Subsurface Fractures and Fluid Flow: A Basic Research Agenda

From beneath the surface of the earth, we currently obtain about 80-percent of the energy our nation consumes each year. In the future we have the potential to generate billions of watts of electrical power from clean, green, geothermal energy sources. Our planet’s subsurface can also serve as a reservoir for storing energy produced from intermittent sources such as wind and solar, and it could provide safe, long-term storage of excess carbon dioxide, energy waste products and other hazardous materials. However, it is impossible to underestimate the complexities of the subsurface world. These complexities challenge our ability to acquire the scientific knowledge needed for the efficient and safe exploitation of its resources. To more effectively harness subsurface resources while mitigating the impacts of developing and using these resources, the U.S. Department of Energy established SubTER – the Subsurface Technology and Engineering RD&D Crosscut team. This DOE multi-office team engaged scientists and engineers from the national laboratories to assess and make recommendations for improving energy-related subsurface engineering. The SubTER team produced a plan with the overall objective of “adaptive control of subsurface fractures and fluid flow.”This plan revolved around four core technological pillars—Intelligent Wellbore Systems that sustain the integrity of the wellbore environment; Subsurface Stress and Induced Seismicity programs that guide and optimize sustainable energy strategies while reducing the risks associated with subsurface injections; Permeability Manipulation studies that improve methods of enhancing, impeding and eliminating fluid flow; and New Subsurface Signals that transform our ability to see into and characterize subsurface systems. The SubTER team developed an extensive R&D plan for advancing technologies within these four core pillars and also identified several areas where new technologies would require additional basic research. In response, the Office of Science, through its Office of Basic Energy Science (BES), convened a roundtable consisting of 15 national lab, university and industry geoscience experts to brainstorm basic research areas that underpin the SubTER goals but are currently underrepresented in the BES research portfolio. Held in Germantown, Maryland on May 22, 2015, the round-table participants developed a basic research agenda that is detailed in this report. Highlights include the following: -A grand challenge calling for advanced imaging of stress and geological processes to help understand how stresses and chemical substances are distributed in the subsurface—knowledge that is critical to all aspects of subsurface engineering; -A priority research direction aimed at achieving control of fluid flow through fractured media; -A priority research direction aimed at better understanding how mechanical and geochemical perturbations to subsurface rock systems are coupled through fluid and mineral interactions; -A priority research direction aimed at studying the structure, permeability, reactivity and other properties of nanoporous rocks, like shale, which have become critical energy materials and exhibit important hallmarks of mesoscale materials; -A cross-cutting theme that would accelerate development of advanced computational methods to describe heterogeneous time-dependent geologic systems that could, among other potential benefits, provide new and vastly improved models of hydraulic fracturing and its environmental impacts; -A cross-cutting theme that would lead to the creation of “geo-architected materials” with controlled repeatable heterogeneity and structure that can be tested under a variety of thermal, hydraulic, chemical and mechanical conditions relevant to subsurface systems; -A cross-cutting theme calling for new laboratory studies on both natural and geo-architected subsurface materials that deploy advanced high-resolution 3D imaging and chemical analysis methods to determine the ;rates and mechanisms of fluid-rock processes, and to test predictive models of such phenomena. Many of the key energy challenges of the future demand a greater understanding of the subsurface world in all of its complexity. This greater under- standing will improve the ability to control and manipulate the subsurface world in ways that will benefit both the economy and the environment. This report provides specific basic research pathways to address some of the most fundamental issues of energy-related subsurface engineering.

15 GEOTHERMAL ENERGY↗