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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Solid oxide electrolysis cell and stack testing best practices

Solid oxide electrolyzer (SOE) technology is an emerging method for hydrogen production, noted for its superior electrical efficiency. Despite the significant progress made in recent years, the broad development of SOE technology is often constrained by the necessary and extensive "skill of the craft" required to successfully test simple single cell test articles. This may be linked to the dearth of practical and pragmatic guidance within the literature for safe, reliable, and performant test equipment and test procedures. Researchers at the Idaho National Laboratory (INL) have been actively testing SOEs ranging from button cells to stacks up to 500 kW, in collaboration with industry and other national laboratories. Based on operational experience, INL has developed system design procedures that ensure safe and reliable operation of SOE systems with the level of support required for each test. This paper presents key aspects of SOE stack and system testing, including safe design procedures, balance of plant components design, and specific implementations at INL. Practical design details of reactants, heat, and power management are presented along with lessons learned from the SOE test facility operations at INL.

08 HYDROGEN↗
DOE OSTI2024

Stack Test Summary for TA-59-0001

The Radioactive Air Emissions Management (RAEM) team performed stack flow characterization tests at Technical Area (TA) 59 Building 0001 Exhaust Stack (ES) 8. These tests were completed in accordance with Title 40 of the Code of Federal Regulations (CFR), Part 61, Subpart H and the American National Standards Institute (ANSI) N13.1-1999 required by the Clean Air Act. Subpart H of the regulation is the National Emission Standards for Hazardous Air Pollutants (NESHAP) for radionuclides, which compliance with is maintained by the REAM team.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

Summary of Stack Tests at TA-16-Bldg 205: Horizontal Duct on WETF Roof

In late 2023 and early 2024, testing was done at the Weapons Engineering Tritium Facility (WETF) rooftop exhaust duct to verify that the stack sample location was in compliance with the ANSI standard for stack sampling, ANSI N13.1-1999. This ANSI standard is called out by the Clean Air Act rules for airborne radionuclide emissions from DOE facilities, 40 CFR 61 Subpart H. This sample location is designated 16020504, indicating Technical Area 16, Building 0205. The rooftop duct formerly discharged to Exhaust Stack 04, but in 2007 it was re-routed to exhaust out Building 0450, Exhaust Stack 05. For continuity, we have kept the 16020504 designation to represent this duct sample location.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Hanford Waste Treatment Plant LAB Facility Stack Effluent Monitoring: Sampling Probe Location Qualification Evaluation

The Waste Treatment Plant laboratory (LAB) facility stack monitor locations were qualified using scale model stacks to mitigate the risk of identifying that sampling locations do not meet the qualification criteria on the full-scale stack. As required by the American National Standards Institute/Health Physics Society (ANSI/HPS) N13.1-1999 standard, the scale model and its sampling location were geometrically similar to the actual stack and the Reynolds numbers for both the actual and model stacks were >10,000. An additional criterion is that the product of the hydraulic diameter and mean velocity (DV) of the full-scale stack must be between 1/6 DV and 6 DV of the scale model stack tests. Verification tests of the LAB stacks were performed at normal operating conditions. The minimum 1/6 DV value, along with the maximum 6 DV value from the scale model testing determines the range of conditions for which the full-scale stack may be operated and remain in compliance with the stack verification criterion. Based on these DV values, the corresponding stack flow rates for each of the LAB stacks are 625 to 47,237 scfm for LB-C2, 1,704 to 103,131 scfm for LB-S1, and 467 to 18,088 scfm for LB-S2. The remaining criteria for the stack verification to be considered valid involve the flow angle and velocity uniformity results. First, the flow angle at the full-scale stack must be =20°. Second, the velocity uniformity at the full-scale stack must be =20% coefficient of variance (COV). Finally, the velocity uniformity results for the actual and scale model stack tests must agree within 5% COV. These criteria were met through the full-scale stack tests at the LAB facility. Flow angle results were primarily less than 10 degrees, except for the LB-C2 Fan A results, which were an average of 17.6 degrees; all flow angle results were within the =20° criterion. The velocity uniformity results for each test condition averaged between 1.5 and 3.5% COV, which were all within the range of the target %COV values from the scale model tests. Based on these stack verification test results, the three LAB filtered exhaust stack sampling locations meet the qualification criteria provided in the ANSI/HPS N13.1-1999 standard for all fan operating configurations. This includes single-fan as well as dual-fan operations for LB-C2, each of the dual-fan operating conditions for LB-S1, and each single-fan operating condition for LB-S2. Further changes to the system configuration or operating conditions that are outside the bounds described in this report may require additional tests or analyses to determine compliance with the standard.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2022

Hanford Waste Treatment Plant Low Activity Waste Facility Stack Effluent Monitoring - Sampling Probe Location Qualification Evaluation

The Hanford Tank Waste Treatment and Immobilization Plant low activity waste (LAW) facility stack monitor locations were qualified using scale model stacks to mitigate the risk of identifying that sampling locations do not meet the qualification criteria on the full-scale stack. As required by the American National Standards Institute/Health Physics Society (ANSI/HPS) N13.1-1999 standard, the scale model and its sampling location were geometrically similar to the actual stack and the Reynolds numbers for both the actual and model stacks were >10,000. An additional criterion is that the product of the hydraulic diameter and mean velocity (DV) of the full-scale stack must be between 1/6 DV and 6 DV of the scale model stack tests. Verification tests of the LAW stacks were performed at normal operating conditions. The minimum 1/6 DV value, along with the maximum 6 DV value from the scale model testing determines the range of conditions for which the full-scale stack may be operated and remain in compliance with the stack verification criterion. Based on these DV values, the corresponding stack flow rates for each of the LAW stacks are 815–55,758 scfm for LV-S1, 980–112,078 scfm for LV-S2, 264–22,901 scfm for LV-S3, and 981–79,832 scfm for LV-C2. The remaining criteria for the stack verification to be considered valid involve the flow angle and velocity uniformity results. First, the flow angle at the full-scale stack must be =20°. Second, the velocity uniformity at the full-scale stack must be =20% coefficient of variance (COV). Finally, the velocity uniformity results for the actual and scale model stack tests must agree within 5% COV. These criteria were met through the full-scale stack tests at the LAW facility. Flow angle results were primarily less than 10°, except for one LV-S2 Fan A result, which was 13.2°; all flow angle results were within the =20° criterion. The velocity uniformity results for each test condition ranged between 1.5 COV and 9.2% COV, which were all within the range of the target % COV values from the scale model tests. Based on these stack verification test results, the four LAW filtered exhaust stack sampling locations meet the qualification criteria provided in the ANSI/HPS N13.1-1999 standard for all fan operating configurations. This includes single-fan operating conditions for LV-S1 and LV-S2, dual-fan operations for LV-S3 at both the continuous air monitor and record sampler locations, and both the single-fan as well as the dual-fan operations for LV-C2. Further changes to the system configuration or operating conditions that are outside the bounds described in this report may require additional tests or analyses to determine compliance with the standard.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2021

Hanford Waste Treatment Plant LAB Facility Stack Effluent Monitoring: Sampling Probe Location Qualification Evaluation

The WTP LAB stack monitor locations were qualified using scale model stacks to mitigate the risk of identifying that sampling locations do not meet the qualification criteria on the full-scale stack. As required by the ANSI/HPS N13.1-1999 standard, the scale model and its sampling location were geometrically similar to the actual stack and the Reynolds numbers for both the actual and model stacks were >10,000. An additional criterion is that the DV of the full-scale stack must be between 1/6 DV and 6 DV of the scale model stack tests. Verification tests of the LAB stacks were performed at normal operating conditions. The maximum 6 DV value from the scale model testing determines the maximum conditions for which the full-scale stack may be operated and remain in compliance with the stack verification criterion. The remaining criteria for the stack verification to be considered valid involve the flow angle and velocity uniformity results. First, the flow angle at the full-scale stack must be = 20°. Second, the velocity uniformity at the full-scale stack must be = 20% COV. Finally, the velocity uniformity results for the actual and scale model stacks must agree within 5% COV. In general, these criteria were met through the full-scale stack tests at the LAB facility. Some specific items for each scale model and full-scale stack comparison should be noted in assessing the validity of the verification tests. The LB-C2 scale model stacks were performed with single fan operations at then-minimum flow conditions. These conditions resulted in DV values that were too low to meet the DV range criterion, and therefore are unable to be used in qualifying single fan operations on the full-scale stack. However, the single fan operations demonstrated COV values for velocity uniformity as well as flow angles that were comparable to the dual-fan operations at high flows. Overall, the test conditions and test results were within the range of acceptable values based on current design flow rates. Single fan operations are expected to only occur infrequently for maintenance needs and is therefore not a planned operating condition at this time. The LB-S1 scale model stacks were performed at three fan combinations, and in each combination, at least one test was performed at the then-minimum flow conditions as well as at then-maximum flow conditions. While the then-minimum flow conditions result in a DV range that is lower than the verification test DV value, and therefore does not meet the criterion, these tests are un-necessary for the verification test acceptance. The normal and maximum flow conditions from the scale model stack tests meet the DV range criterion, and the velocity uniformity test results compare favorably with the full-scale stack results. The LB-S2 scale model stacks were performed at nominally the same maximum flow condition; however, the 6 DV value for Fan A operation was slightly lower than the full-scale stack test DV. The COV values from the scale model stacks were comparable between the Fan A and Fan B results, and the overall test conditions are within the range of acceptable values. The stack verification is therefore considered acceptable for both Fan A and Fan B operations. The verification tests were performed at flows that were appreciably higher than the design conditions, and further elevated flow rates would be beyond the range of acceptable DV. Based on these stack verification test results, the three LAB filtered exhaust stacks meet the qualification criteria provided in the ANSI/HPS N13.1-1999 standard. Further changes to the system configuration or operating conditions that are outside the bounds described in this and the scale model test reports (Glissmeyer, Flaherty, and Piepel (2001), Glissmeyer and Geeting (2013)) may require additional tests and additional analyses to determine compliance with the standard.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2022

Hanford Waste Treatment Plant Effluent Management Facility Stack Effluent Monitoring: Sampling Probe Location Qualification Evaluation

The Hanford Tank Waste Treatment and Immobilization Plant Effluent Management facility (EMF) stack monitor location was qualified using the LV-S1 scale model stack as a baseline, augmented by the LB-S1 and LV-S2 scale model stacks to address the Direct Feed Low Activity Waste Effluent Management Facility Vessel Vent Process (DVP) injection into the main Active Confinement Ventilation (ACV) system duct. As required by the American National Standards Institute/Health Physics Society (ANSI/HPS) N13.1-1999 standard, the scale models and its sampling locations were geometrically similar to the actual stack and the Reynolds numbers for both the actual and model stacks were >10,000. An additional criterion is that the product of the hydraulic diameter and mean velocity (DV) of the full-scale stack must be between 1/6 DV and 6 DV of the scale model stack tests. Verification tests of the EMF stack was performed at normal operating conditions. The minimum 1/6 DV value, along with the maximum 6 DV value from the scale model testing determines the range of stack flow rates for which the full-scale stack may be operated and remain in compliance with the stack verification criterion. Based on the LV-S1 scale model test DV values, the corresponding stack flow rates for the EMF stack are as listed in Table S1. Table S1. Effluent Management Facility Stack Qualified Flow Range. Stack Parameter EM-1 Minimum Qualified Stack Flow (scfm) 781 Maximum Qualified Stack Flow (scfm) 53,432 The remaining criteria for the stack verification to be considered valid involve the flow angle and velocity uniformity results. First, the flow angle at the full-scale stack must be =20°. Second, the velocity uniformity at the full-scale stack must be =20% coefficient of variance (COV). Finally, the velocity uniformity results for the actual and scale model stack tests must agree within 5% COV. These criteria were met through the full-scale stack test at the EMF. Flow angle results were less than 5°; all flow angle results were within the =20° criterion. The velocity uniformity results for each test condition ranged between 2.2% COV and 4.3% COV, which were all within the range of the target % COV values from the scale model tests on the LV-S1, LB-S1, and LV S2 scale models. Based on these stack verification test results, the EMF filtered exhaust stack sampling location meets the qualification criteria provided in the ANSI/HPS N13.1-1999 standard for all fan operating configurations. This includes each combination of ACV fan with the DVP exhausters. Further changes to the system configuration or operating conditions that are outside the qualified flow rates described in this report may require additional tests or analyses to determine compliance with the standard.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2023

Hanford Waste Treatment Plant Effluent Management Facility Stack Effluent Monitoring: Sampling Probe Location Qualification Evaluation

The Hanford Tank Waste Treatment and Immobilization Plant Effluent Management Facility (EMF) stack monitor location was qualified using a combination of scale model stacks to mitigate the risk of identifying that the sampling location does not meet the qualification criteria on the full-scale stack. The LV-S1 scale model stack was used as a baseline, augmented by the LB-S1 and LV-S2 scale model stacks to address the Direct Feed Low Activity Waste Effluent Management Facility Vessel Vent Process (DVP) injection into the main Active Confinement Ventilation (ACV) system duct. As required by the American National Standards Institute/Health Physics Society (ANSI/HPS) N13.1-1999 standard, the scale model and its sampling locations were geometrically similar to the actual stack, and the Reynolds numbers for both the actual and model stacks were >10,000. An additional criterion is that the product of the hydraulic diameter and mean velocity (DV) of the full-scale stack must be between 1/6 DV and 6 DV of the scale model stack tests. The LV-S1, LB-S1, and LV-S2 scale model stack tests have met the criteria of the ANSI/HPS N13.1-1999 standard to demonstrate the stack sampling locations are well mixed. Verification tests of the EMF stack were performed at normal operating conditions. The minimum 1/6 DV value and the maximum 6 DV value from the scale model testing determine the range of stack flow rates for which the full-scale stack may be operated while remaining in compliance with the stack verification criterion. A practical range for the full-scale stack qualification uses the average DV through 6 DV from the scale model tests to compute the corresponding flow rates. Table S1 lists the operating flow rate along with the average and maximum qualified stack flow rate based on the LV-S1 scale model DV values. The operating flow is below the maximum qualified stack flow, which means that the scale model test results are acceptable for stack qualification. The remaining criteria for the stack verification to be considered valid involve the flow angle and velocity uniformity results. First, the flow angle at the full-scale stack must be ≤20°. Second, the velocity uniformity at the full-scale stack must be ≤20% coefficient of variance (COV). Finally, the velocity uniformity results for the actual and scale model stack tests must agree within 5% COV. These criteria were met through the full-scale stack test at the EMF. Flow angle results were <5°; all flow angle results were within the ≤20° criterion. The velocity uniformity results for each test condition ranged between 2.2% COV and 4.3% COV, all of which were within the range of the target % COV values from the scale model tests on the LV-S1, LB-S1, and LV S2 scale models. Based on these stack verification test results, the EMF filtered exhaust stack sampling location meets the qualification criteria provided in the ANSI/HPS N13.1-1999 standard for all planned fan operating configurations. This includes each combination of ACV fans with DVP exhausters. Further changes to the system configuration or operating conditions that are outside the qualified flow rates described in this report may require additional tests or analyses to determine compliance with the standard.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2023

Hanford Waste Treatment Plant LAB Facility Stack Effluent Monitoring: Sampling Probe Location Qualification Evaluation

The Waste Treatment Plant laboratory (LAB) facility stack monitor locations were qualified using scale model stacks to mitigate the risk of identifying that sampling locations do not meet the qualification criteria on the full-scale stack. As required by the American National Standards Institute/Health Physics Society (ANSI/HPS) N13.1-1999 standard, the scale model and its sampling location were geometrically similar to the actual stack, and the Reynolds numbers for both the actual and model stacks were >10,000. An additional criterion is that the product of the hydraulic diameter and mean velocity (DV) of the full-scale stack must be between 1/6 DV and 6 DV of the scale model stack tests. Verification tests of the LAB stacks were performed at normal operating conditions. The minimum 1/6 DV value, along with the maximum 6 DV value from the scale model testing, determines the range of conditions for which the full-scale stack may be operated and remain in compliance with the stack verification criterion. A practical range for the full-scale stack qualification uses the average DV through 6 DV from the scale model tests to compute the corresponding flow rates. Table S1 lists the operating flow rates along with the average and maximum qualified stack flow rates for each of the LAB facility stacks. For each stack, the operating flow is below the maximum qualified stack flow, which means that the scale model test results are acceptable for stack qualification. The remaining criteria for the stack verification to be considered valid involve the flow angle and velocity uniformity results. First, the flow angle at the full-scale stack must be ≤20°. Second, the velocity uniformity at the full-scale stack must be ≤20% coefficient of variance (COV). Finally, the velocity uniformity results for the actual and scale model stack tests must agree within 5% COV. These criteria were met through the full-scale stack tests at the LAB facility. Flow angle results were primarily less than 10°, except for the LB-C2 Fan A results, which were an average of 13.7°; all flow angle results were within the ≤20° criterion. The velocity uniformity results for each test condition averaged between 1.5 and 4.1% COV, which were all within the range of the target percent coefficient of variation values from the scale model tests. Based on these stack verification test results, the three LAB filtered exhaust stack sampling locations meet the qualification criteria provided in the ANSI/HPS N13.1-1999 standard for all fan operating configurations. This includes single-fan as well as dual-fan operations for LB-C2, each of the dual-fan operating conditions for LB-S1, and each single-fan operating condition for LB-S2. Further changes to the system configuration or operating conditions that are outside the bounds described in this report may require additional tests or analyses to determine compliance with the standard.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2025

Pulse: An Outlier Sensitive Downsampling Algorithm For Timeseries Data

Pulse is a downsampling algorithm for timeseries data. Frequently datasets become so large that visualization tools and web browsers cannot effectively render graphics due to memory constraints. Downsampling algorithms are commonly applied to minimize the quantity of data required to visualize important features or trends in the data, but some datasets are composed by distinct enough features and trends that most existing downsampling algorithms fail to preserve them. Pule was developed to downsample timeseries data for galvanostatic stack test data at the Idaho National Laboratory. These datasets were composed by approximately 4 million records, most of them being extremely uniform. However, during relatively brief time periods when the stack test changes state, for example when the test article is powered on, or a load is added, the data produce sparse asymptotes. No existing downsampling algorithm was capable of preserving the sparse asymptotes in electrolysis stack test data. Instead, we develop a downsampling algorithm that preserves important outliers in data, and otherwise aggressively downsamples uniform data. The algorithm has applications in other domains like seismology, in the measurement of earthquakes, or astronomy, in the measurement of quasars or transit photometry.

Woodruff, Nathan [Idaho National Laboratory (INL),↗
DOE OSTI2024

Evaluation of Significance Tests on Stack Sample Data

In October 2023, external assessors visiting LANL’s Rad-NESHAP team reviewed the annual source term documentation package for stack emissions. This document discusses how the team uses significance tests to determine whether or not a measurement represents an actual detection of emitted radioactive material. The significance tests used in the evaluation compare the measured sample result to the Minimum Detectable Activity (MDA) for the sample; to the uncertainty of that measurement; and to the mean blank sample for the same time period. The blank test uses the average blank plus 2-standard deviations (2σ) of the blank results as a comparison threshold for this final evaluation.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

Hanford Waste Treatment Plant Low Activity Waste Facility Stack Effluent Monitoring: Sampling Probe Location Qualification Evaluation (Rev.1)

The Hanford Tank Waste Treatment and Immobilization Plant Low Activity Waste (LAW) facility stack monitor locations were qualified using scale model stacks to mitigate the risk of discovering that sampling locations do not meet the qualification criteria on the full-scale stacks. As required by the American National Standards Institute/Health Physics Society (ANSI/HPS) N13.1-1999 standard, the scale model and its sampling location were geometrically similar to the actual stack and the Reynolds numbers for both the actual and model stacks were >10,000. An additional criterion is that the product of the hydraulic diameter and mean velocity (DV) of the full-scale stack must be between 1/6 DV and 6 DV of the scale model stack tests. Verification tests of the LAW stacks were performed at normal operating conditions. The minimum 1/6 DV value, along with the maximum 6 DV value from the scale model testing, determines the range of stack flow rates for which the full-scale stack may be operated and remain in compliance with the stack verification criterion. For this analysis, the range of qualified flow rates listed is conservatively based on the average DV through 6 DV for LV-S1, LV-S2, and LV-C2, and 1/3 DV to 3 DV for LV-S3. Table S1 lists the operating flow rates along with the conservative lower and upper qualified stack flow rates for each of the LAW facility stacks. For each stack, the operating flow is below the upper qualified stack.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2020

Assessment of the 3420 Building Filtered Exhaust Stack Sampling Probe Location: Stack Verification Following Fan and Air Blender Additions

The Pacific Northwest National Laboratory (PNNL) 3420 Building, which is part of the Physical Sciences Facility (PSF), houses radiological capabilities that results in the requirement that emissions monitoring must be conducted for potential radionuclides in the exhaust air discharge of this building. The air monitoring system is required to conform to Title 40 of the Code of Federal Regulations part 61 (40 CFR 61) Subpart H, which in turns requires a sampling probe in the exhaust stream to conform to the criteria of American National Standards Institute / Health Physics Society (ANSI/HPS) N13.1-2011, Sampling and Monitoring Releases of Airborne Radioactive Substances from the Stack and Ducts of Nuclear Facilities. To support the air emissions permit for the 3420 Building on the PNNL campus, stack testing that used computational fluid dynamics (CFD) modeling as a surrogate stack and verification tests of velocity uniformity and flow angle on the retrofitted facility stack was performed. The ANSI/HPS N13.1-2011 criteria for the air monitoring probe location are that velocity uniformity, gaseous tracer uniformity, and particulate tracer uniformity must be less than or equal to 20%COV. Furthermore, no point in the sampling location may have a gaseous tracer concentration that varies from the mean concentration by more than 30%. Additionally, the flow angle at the sampling location must not be more than 20°. The CFD modeling of the stack, as reported by Recknagle et al. (2018) demonstrated that the stack meets the criteria at the probe location. The velocity uniformity and flow angle results from the 3420 stack verification tests, performed in October 2020, demonstrated that the CFD model results may be used to support the qualification of the stack sampling location. The measured velocity uniformity verification test result was 1.4%COV. This value is well within the uniformity criterion, which is that the velocity uniformity be =20%COV. Additionally, this value is well within the criterion that the actual stack measurement must be within 5% of the surrogate stack result of 2.1%COV when all four fans were operating. Additionally, the measured average flow angle at the 3420 stack monitor location was 15.5 degrees. Although this is higher than expected based on the CFD model, the result is =20 degrees, so the criterion is met. Based on these stack verification test results, the reconfigured 3420 Building filtered exhaust stack meets the qualification criteria given in the ANSI/HPS N13.1-2011 standard. Further changes to the system configuration or operating conditions that are outside the bounds described in this and the CFD report (Recknagle et al., 2018) may require additional tests and additional analysis to determine compliance with the standard.

3420 Building↗
DOE OSTI2022

Transformational Solid Oxide Fuel Cell (SOFC) Technology

This project was conducted under the Co-operative Agreement No. DE-FE0027584 with the US Department Energy to developed advanced Solid Oxide Fuel Cell (SOFC) Technologies. The overall objective of this project was to advance SOFC technology at the cell and stack level to enhance cell robustness and durability, increase performance, and reduce balance-of-plant (BOP) requirements. By reducing system complexity combined with the increases in power density and efficiency, the ultimate goal of the project was to increased reliability and to reduce capital and operating costs of installed systems. The project was focused on pathways that will reduce the cost of the SOFC cell and stack, including the following areas: Robust, redox tolerant cell technology Lower cost cell manufacturing through advances in cell design, which will reduce the amount of material, energy and time used in the fabrication of SOFCs High performance, low temperature electrolyte based on improvement of established materials Innovative SOFC stack architecture which truly integrates Balance of Plant functionality into the stack level design Thermal management of the fuel cell stack for increased durability and expanded window of operation Novel stack design amenable for use in sub-MW to multi-MW-scale power plants and having low replacement cost The incorporation of balance-of-plant (BOP) equipment into the stack platform increased the economic viability of smaller scale systems. The project objectives were met by a multi-prong approach, including new cell design complemented with modifications to existing cell technology, as well as a new stack design incorporating components typically included in the BOP, such as heat exchangers, oxidizer, fuel reformers, and recycle systems. The project culminated with demonstration of a stack test validating the viability of the cell and stack improvements. A cost model was also developed to estimate costs for the advanced stack technology at high volume manufacturing levels. The net outcome of the project is SOFC cell and stack technology with costs significantly below current DOE targets without compromising and, in some cases, improving on the performance and degradation rate demonstrated with the current state-of-the-art stack design. The results of this project advanced the reliability, robustness, and endurance of low-cost SOFC technology that ultimately are ready to be deployed in coal power systems with greater than 60 percent efficiency (based on higher heating value of fuel) and the capability for ≥97% CO 2 capture at a cost-of-electricity that is approximately 40 percent below presently available Integrated Gasification Combined Cycle systems.

03 NATURAL GAS↗
DOE OSTI2024

Titanium-Cerium Electrode-Decoupled Redox Flow Batteries Integrated With Fossil Fuel Assets For Load-Following, Long-Duration Energy Storage

Operation of fossil plants at partial capacity with frequent cycling results in decreased efficiency, increased emissions and increased wear and maintenance. The objective of this project is to advance the integration of a titanium-cerium electrode-decoupled redox flow battery (RFB) system with conventional fossil-fueled power plants through technical and economic system-level studies and component scale-up and R&D. The Ti-Ce chemistry has a pathway to meet the DOE cost targets of $\$$100/kWh and $\$$0.05/kWh-cycle owing to the use of low-cost, earth abundant elemental actives and incorporation of inexpensive carbon felt electrodes and non-fluorinated anion exchange membrane (AEM) separators. The initial unit cell design was scaled up, with some modifications made to improve ease of manufacturing, from 25 cm 2 cell area to 400 cm 2 . Electrochemical tests demonstrated operation at a current density up to 50 mA/cm 2 , which is on par with other commercial RFB offerings. Furthermore, the Ti-Ce technology developed by WashU was evaluated and tested by industrial team partner, Giner, Inc., in their modular 3-cell stack. Several cell design modifications and alternate component material selections were successfully implemented to accommodate this chemistry while reducing polarization and leakage. Results from stack testing show high columbic efficiency and indicate that further optimization of cell compression and components will lead to successful operation of the Ti-Ce ED-RFB over longer duration at the multi-cell stack level. Engineering and cost analysis showed that an RFB system with power output on the order of 100 MW and with a charge/discharge duration of approx. 12 hours is the most cost effective for integration with fossil plants. At this scale, projected cycling of fossil fuel power plants can be significantly reduced. The use of a storage system is shown to reduce the fossil plant standalone cost of electricity by $\$$7/MWh, through increased capacity factor and improved average efficiency, in the scenario of high penetration of renewable power.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2026

Scale-Up of Electrode Coating and Flow-Field for Commercial Hydrogen Peroxide Electrolyzer: Cooperative Research and Development Final Report, CRADA Number CRD-17-00687

Hydrogen peroxide is currently produced at central chemical plants via the anthraquinone oxidation process. This process produces environmental pollutants that are costly to remediate, requires hazardous long distance shipping of highly concentrated peroxide (50% or 70%), and necessitates extra handling costs related to storage and dilution. Peroxygen Systems, Inc. (PSi) is developing breakthrough technology for on-site hydrogen peroxide production. PSi’s on-site on-demand electrolyzer can reduce the cost of producing hydrogen peroxide by 50%, while also completely eliminating the cost and safety issues associated with shipping and handling of high concentration hydrogen peroxide. The challenge for PSi is scaling. To support the next step toward commercialization (customer pilot tests), scaling the prototype into larger single cells and 20-40 cell stacks is required. In addition to internal hardware and flow-field design efforts at PSi, NREL will address three critical problems for this scale-up effort: (1) demonstrating a large scale roll-to-roll (R2R) process to coat uniform electrode materials for 100 cm2 and 500 cm2 stack testing, (2) demonstrating an in-line diagnostic to achieve better electrode quality control, and (3) performing in situ cell/stack testing to better understand and optimize the performance of the flow field design.

28 EE - Advanced Manufacturing Office (EE-5A)↗
DOE OSTI2024

Offshore Wind to Hydrogen - Modeling, Analysis, Testing and International Collaboration Work

This project explores electrolytic hydrogen production from an offshore wind turbine by: Modeling: Simulate an offshore wind turbine and generate power output profiles; Analysis: Analyze offshore conditions and determine operational modes of the stack; Testing: Perform hardware testing to evaluate dynamic characteristics; and International Collaboration Work: Share learnings and publish. Potential Outcomes: Accelerate development of an integrated, in-turbine offshore wind hydrogen system; and Support two DOE Energy Earthshots - Hydrogen and Floating Offshore Wind.

electrolyzer↗
DOE OSTI2026

Stacked reverberation mapping of high-redshift quasars in DESI. I. Feasibility analysis

The broad-line region of quasars has long been probed by reverberation mapping techniques that measure time lags between continuum and broad emission-line variations. Stacked reverberation mapping has been proposed as a less observationally expensive alternative to traditional methods. This ensemble approach also reduces biases from small-number statistics. The Dark Energy Spectroscopic Instrument (DESI) is conducting the most extensive spectroscopic survey of quasars to date. We create mock light curves emulating expected DESI quasar observations at redshifts $1.48\lt z\lt 5.2$ and luminosities $44.68 \le \log \lambda L_{1350 \mathring{\rm A}{}} / \mathrm{erg\, s^{-1}} \le 45.99$ to test stacked reverberation mapping feasibility using sparse spectroscopic data paired with well-sampled photometric data. The pipeline, using the lag estimation code JAVELIN (Just Another Vehicle for Estimating Lags In Nuclei), successfully recovers the simulated C IV lags within 1σ of the true values using spectroscopic light curves composed of only a few spectral epochs (2–10) with irregular cadences. We investigate how observational factors, including C IV flux error magnitude, number of stacked quasars, and spectral epoch count, affect performance. This work motivates a pathway for future stacked reverberation mapping projects with large-scale spectroscopic surveys of quasars having $\ge 2$ spectroscopic observations. Our results suggest an economical alternative for constraining and extending the radius–luminosity relation to higher redshifts and luminosities. Subsequently, this relation can be employed more reliably in single-epoch black hole mass measurements and quasar cosmology in these distant regimes.

quasars: general, quasars: supermassive black hole↗