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Industrial Wireless Sensor Standards; A User Perspective

Future industrial use of wireless instrumentation will undoubtedly increase dramatically in the coming years. Deployment of such instrumentation in an industrial setting with its security and robustness criteria that are much more stringent than residential performance criteria hinges on user acceptance of verified performance as well as meeting cost requirements. Today, circa 2011, these industrial users are faced with many choices when specifying a wireless sensor network, including radio performance, battery life, interoperability concerns, and standards compliance. With industrial users standing on the precipice to order and deploy (literally) millions of wireless instruments, it is imperative that accurate information for applying the technology to real-world applications be available to the end-user.

47 OTHER INSTRUMENTATION↗

Industrial Wireless Sensors: A User's Perspective on the Impact of Standards on Wide-spread Deployment

The role of wireless sensing technologies in industrial instrumentation will undoubtedly become more important in the years ahead. . Deployment of such instrumentation in an industrial setting with its heightened security and robustness criteria hinges on user acceptance of verified performance as well as meeting cost requirements. Today, industrial users face many choices when specifying a wireless sensor network, including radio performance, battery life, interoperability, security, and standards compliance. The potential market for industrial wireless sensors is literally millions of wireless instruments and it is imperative that accurate information for applying the technology to real-world applications be available to the end-user so that they can make informed deployment decisions. The majority of industrial wireless automation designs now being deployed or being considered for deployment are based on three different standards . The HART Communications Foundation s WirelessHART (IEC 62591), the International Society of Automation s ISA100.11a, and the offering from the Industrial Wireless Alliance of China known as WIA-PA (IEC 62601). Aside from these industrial automation standards, users must also be cognizant of the underlying wireless network standards IEEE 802.11, IEEE 802.15.4, and IEEE 802.15.3a and their interactions with the three principal industrial automation protocols mentioned previously. The crucial questions being asked by end users revolve around sensor network performance, interoperability, reliability, and security. This paper will discuss potential wireless sensor applications in power plants, barriers to the acceptance of wireless technology, concerns related to standards, and provide an end user prospective on the issues affecting wide-spread deployment of wireless sensors. Finally, the authors conclude with a discussion of a recommended path forward including how standards organizations can better facilitate end user decision making and how end users can locate and use objective information for decision making.

99 GENERAL AND MISCELLANEOUS↗

ARPA-E Program: Advanced Management Protection of Energy Storage Devices (AMPED) - Fifth Quarterly Project Report - FY14 Q1

Technology has been developed that enables monitoring of individual cells in high - capacity lithium-ion battery packs, with a distributed array of wireless Bluetooth 4.0 tags and sensors, and without proliferation of extensive wiring harnesses. Given the safety challenges facing lithium-ion batteries in electric vehicle, civilian aviation and defense applications, these wireless sensors may be particularly important to these emerging markets. These wireless sensors will enhance the performance, reliability and safety of such energy storage systems. Specific accomplishments to date include, but are not limited to: (1) the development of wireless tags using Bluetooth 4.0 standard to monitor a large array of sensors in battery pack; (2) sensor suites enabling the simultaneous monitoring of cell voltage, cell current, cell temperature, and package strain, indicative of swelling and increased internal pressure, (3) small receivers compatible with USB ports on portable computers; (4) software drivers and logging software; (5) a 7S2P battery simulator, enabling the safe development of wireless BMS hardware in the laboratory; (6) demonstrated data transmission out of metal enclosures, including battery box, with small variable aperture opening; (7) test data demonstrating the accurate and reliable operation of sensors, with transmission of terminal voltage, cell temperature and package strain at distances up to 110 feet; (8) quantification of the data transmission error as a function of distance, in both indoor and outdoor operation; (9) electromagnetic interference testing during operation with live, high -capacity battery management system at Yardney Technical Products; (10) demonstrat ed operation with live high-capacity lithium-ion battery pack during charge-discharge cycling; (11) development of special polymer-gel lithium-ion batteries with embedded temperature sensors, capable of measuring the core temperature of individual of the cells during charge-discharge cycling at various temperatures, thereby enabling earlier warning of thermal runaway than possible with external sensors. Ultimately, the team plans to extend this work to include: (12) flexible wireless controllers, also using Bluetooth 4.0 standard, essential for balancing large-scale battery packs. LLNL received $925K for this project, and has $191K remaining after accomplishing these objectives.

25 ENERGY STORAGE↗

ARPA-E Program: Advanced Management Protection of Energy Storage Devices (AMPED) - Monthly Report - November 2013

Technology has been developed that enables monitoring of individual cells in high - capacity lithium-ion battery packs, with a distributed array of wireless Bluetooth 4.0 tags and sensors, and without proliferation of extensive wiring harnesses. Given the safety challenges facing lithium-ion batteries in electric vehicle, civilian aviation and defense applications, these wireless sensors may be particularly important to these emerging markets. These wireless sensors will enhance the performance, reliability and safety of such energy storage systems. Specific accomplishments to date include, but are not limited to: (1) the development of wireless tags using Bluetooth 4.0 standard to monitor a large array of sensors in battery pack; (2) sensor suites enabling the simultaneous monitoring of cell voltage, cell current, cell temperature, and package strain, indicative of swelling and increased internal pressure, (3) small receivers compatible with USB ports on portable computers; (4) software drivers and logging software; (5) a 7S2P battery simulator, enabling the safe development of wireless BMS hardware in the laboratory; (6) demonstrated data transmission out of metal enclosures, including battery box, with small variable aperture opening; (7) test data demonstrating the accurate and reliable operation of sensors, with transmission of terminal voltage, cell temperature and package strain at distances up to 110 feet; (8) quantification of the data transmission error as a function of distance, in both indoor and outdoor operation; (9) electromagnetic interference testing during operation with live, high -capacity battery management system at Yardney Technical Products; (10) demonstrat ed operation with live high-capacity lithium-ion battery pack during charge-discharge cycling; (11) development of special polymer-gel lithium-ion batteries with embedded temperature sensors, capable of measuring the core temperature of individual of the cells during charge-discharge cycling at various temperatures, thereby enabling earlier warning of thermal runaway than possible with external sensors. Ultimately, the team plans to extend this work to include: (12) flexible wireless controllers, also using Bluetooth 4.0 standard, essential for balancing large-scale battery packs. LLNL received $925K for this project, and has $191K remaining after accomplishing these objectives.

25 ENERGY STORAGE↗

Novel Battery Management System with Distributed Wireless and Fiber Optic Sensors for Early Detection and Suppression of Thermal Runaway in Large Battery Packs, FY13 Q4 Report, ARPA-E Program: Advanced Management Protection of Energy Storage Devices (AMPE

Technology has been developed that enables monitoring of individual cells in highcapacity lithium-ion battery packs, with a distributed array of wireless Bluetooth 4.0 tags and sensors, and without proliferation of extensive wiring harnesses. Given the safety challenges facing lithium-ion batteries in electric vehicle, civilian aviation and defense applications, these wireless sensors may be particularly important to these emerging markets. These wireless sensors will enhance the performance, reliability and safety of such energy storage systems. Specific accomplishments to date include, but are not limited to: (1) the development of wireless tags using Bluetooth 4.0 standard to monitor a large array of sensors in battery pack; (2) sensor suites enabling the simultaneous monitoring of cell voltage, cell current, cell temperature, and package strain, indicative of swelling and increased internal pressure, (3) small receivers compatible with USB ports on portable computers; (4) software drivers and logging software; (5) a 7S2P battery simulator, enabling the safe development of wireless BMS hardware in the laboratory; (6) demonstrated data transmission out of metal enclosures, including battery box, with small variable aperture opening; (7) test data demonstrating the accurate and reliable operation of sensors, with transmission of terminal voltage, cell temperature and package strain at distances up to 110 feet; (8) quantification of the data transmission error as a function of distance, in both indoor and outdoor operation; (9) electromagnetic interference testing during operation with live, high-capacity battery management system at Yardney Technical Products; (10) demonstrated operation with live high-capacity lithium-ion battery pack during charge-discharge cycling; (11) development of special polymer-gel lithium-ion batteries with embedded temperature sensors, capable of measuring the core temperature of individual of the cells during charge-discharge cycling at various temperatures, thereby enabling earlier warning of thermal runaway than possible with external sensors. Ultimately, the team plans to extend this work to include: (12) flexible wireless controllers, also using Bluetooth 4.0 standard, essential for balancing large-scale battery packs. LLNL received $925K for this project, and has $191K remaining after accomplishing these objectives.

25 ENERGY STORAGE↗

SBIR Phase II Final Report - A Robust Wireless Communication System for Harsh Environments Including Nuclear Facilities

This is the Final Report for the DOE Phase II SBIR project “A Robust Wireless Communication System for Harsh Environments Including Nuclear Facilities.” The topics covered herein include technical progress made, progress against the planned milestones and deliverables, project outcomes, and a discussion on future expectations of deployment and impacts of the results of this work. In brief, all planned work for the project was successfully completed, on or ahead of schedule and on budget. The major accomplishment was the successful development of new sensor/communications systems with wideband (WB)/ultra-wideband (UWB) communications based on the software-defined-radio (SDR) technology to improve sensing and control in nuclear power plants and then a broad range of similar sensing applications. The impacts of these disciplines/focuses of this SBIR include: A new multi-frequency SDR-based architecture with WB/UWB communications integrated with sensors was developed, utilizing 310 MHz, 450 MHz, 915 MHz, and 5 GHz frequencies; Secure communications using Advanced Encryption Standard (AES) algorithm; Sensing possibilities not effectively addressed by previous technologies was addressed; and, The newly developed wireless sensor communications system can adapt its communications parameters to its operational environment for optimal performance. The performance of this system has been evaluated by systematic laboratory and field testing. The field testing was conducted at Massachusetts Institute of Technology (MIT)’s Nuclear Test Reactor, and the McClellan Nuclear center at the University of California Davis (UC Davis), as well as at Oak Ridge National Laboratory (ORNL). The success in this project resulted in DSI being awarded “The DOE’s 2018 SBIR/STTR Small Business of the Year”. This technology has attracted interest from The Rolls Royce company with ongoing discussions under NDA for potential strategic partnership between DSI and Rolls Royce in providing wireless sensor communications in nuclear facilities. Furthermore, the success of this project has attracted significant interest from the United Nations International Atomic Agency (IAEA) in Vienna, Austria, as well as other DOE and DOD offices. Currently, per request from IAEA, DOE’s office of International Safeguards has funded DSI to develop a WB/UWB wireless communication system for real-time transmission of images from IAEA’s safeguards cameras in various nuclear facilities. DSI also has received a Phase II and Phase II.5 SBIR awards from ARMY and NAVY for wireless communications capability for various DOD aircraft.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Prognostics and Health Management in Nuclear Power Plants: A Review of Technologies and Applications

This report reviews the current state of the art of prognostics and health management (PHM) for nuclear power systems and related technology currently applied in field or under development in other technological application areas, as well as key research needs and technical gaps for increased use of PHM in nuclear power systems. The historical approach to monitoring and maintenance in nuclear power plants (NPPs), including the Maintenance Rule for active components and Aging Management Plans for passive components, are reviewed. An outline is given for the technical and economic challenges that make PHM attractive for both legacy plants through Light Water Reactor Sustainability (LWRS) and new plant designs. There is a general introduction to PHM systems for monitoring, fault detection and diagnostics, and prognostics in other, non-nuclear fields. The state of the art for health monitoring in nuclear power systems is reviewed. A discussion of related technologies that support the application of PHM systems in NPPs, including digital instrumentation and control systems, wired and wireless sensor technology, and PHM software architectures is provided. Appropriate codes and standards for PHM are discussed, along with a description of the ongoing work in developing additional necessary standards. Finally, an outline of key research needs and opportunities that must be addressed in order to support the application of PHM in legacy and new NPPs is presented.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Improved Biomass Cooking Stoves and Improved Stove Emission Equipment

In developing countries, there is an urgent need for access to safe, efficient, and more affordable cooking technologies. Nearly 2.5 billion people currently use an open fire or traditional cookstove to prepare their meals, and recent models predict that use of biomass for cooking will continue to be the dominant energy use in rural, resource-poor households through 2030. For these families, cooking poses serious risks to health, safety, and income. An alarming 4 million people, primarily women and children, die prematurely each year from indoor and outdoor exposure to the harmful emissions released by solid fuel combustion. Use of traditional stoves can also have a significant impact on deforestation and climate change. This dire situation creates a critical need for cookstoves that significantly and verifiably reduce fuel use and emissions in order to reach protective levels for human health and the environment. Additionally, advances in the scientific equipment needed to measure and monitor stove fuel use and emissions have not kept pace with the significant need within the industry. While several testing centers in the developed world may have hundred thousand-dollar emissions testing systems, organizations in the field have had little more than a thermometer, a scale, and subjective observations to quantify the performance of stove designs. There is an urgent need for easy-to-use, inexpensive, accurate, and robust stove testing equipment for use by laboratory and field researchers around the world. ASAT and their research partner, Aprovecho Research Center (ARC), have over thirty years of experience addressing these two needs, improved cookstoves and emissions monitoring equipment, with expertise spanning the full spectrum of development from conceptual design to product manufacturing and dissemination. This includes: 1) research, design, and verification of clean biomass cookstove technology and emissions monitoring equipment; 2) mass production of quality-controlled stove and emissions equipment at levels scalable to meet global demand; and 3) global distribution through a variety of channels and partners. ARC has been instrumental in designing and improving more than 100 stove designs over the past thirty years. In the last four years, ASAT and ARC have played a key role in the production and sales of over 200,000 improved stoves in the developed and developing world. The ARC-designed emissions equipment is currently used by researchers in laboratories and field studies on five continents. During Phase I of the DOE STTR grant, ASAT and ARC worked together to apply their wealth of product development experience towards creating the next generation of improved cookstoves and emissions monitoring equipment. Highlights of Phase I for the biomass cookstove project include 1) the development of several new stove technologies that reached the DOE 50/90 benchmark; 2) fabrication of new stove prototypes by ASAT’s manufacturing partner, Shengzhou Stove Manufacturing (SSM); 3) field testing of prototype stoves with consumers in Puerto Rico and the US; and 4) the selection of three stove prototypes for further development and commercialization during Phase II. Highlights of Phase I for the emissions monitoring equipment project include: 1) creation of a new emissions monitoring equipment product, the Laboratory Emissions Monitoring System (LEMS 2) the addition of gravimetric PM measurements to the stove testing systems to meet International Standards Organization criteria; 3) the addition of a CO{sub 2} sensor and wireless 3G capability to the IAP Meter; and 4) and the improvement of sensors and signal quality on all systems. Twelve Regional Testing and Knowledge Centers purchased this equipment during the Phase I project period.

09 BIOMASS FUELS↗

Thread/OpenThread: A Compromise in Low-Power Wireless Multihop Network Architecture for the Internet of Things

Extending an Internet subnet by connecting resource-constrained nodes (e.g., embedded sensors and actuators) over multiple wireless hops is necessary to support the future Internet of Things (IoT). RPL, the IPv6 routing standard for low-power and lossy networks, tried to achieve this goal but has not seen wide adoption in practice. As an alternative, Thread is a recently standardized low-power network protocol for IoT, driven by the Thread group, an industry consortium led by Google/Nest. Here, we provide a comparative analysis of the technical aspects of RPL and Thread based on their specifications, explaining why using Thread, as opposed to RPL, may make sense for the future Internet. Specifically, the fundamental differences between RPL and Thread are their respective scopes and multihop network architectures, which result in Thread's unique design and advantages over RPL. Lastly, we evaluate Thread in an indoor multihop wireless testbed using OpenThread, an official open source implementation of Thread. This work serves as the first analysis of the Thread protocol in academia.

30 DIRECT ENERGY CONVERSION↗

ULTRA SECURE HIGH RELIABILITY WIRELESS RADIATION MONITOR

Radiation monitoring in nuclear facilities is essential to safe operation of the equipment as well as protecting personnel. In specific, typical air monitoring of radioactive gases or particulate involves complex systems of valves, pumps, piping and electronics. The challenge is to measure a representative sample in areas that are radioactively contaminated. Running cables and piping to these locations is very expensive due to the containment requirements. Penetration into and out of an airborne or containment area is complex and costly. The process rooms are built with thick rebar-enforced concrete walls with glove box containment chambers inside. Figure 1 shows high temperature radiation resistance cabling entering the top of a typical glove box. In some case, the entire processing area must be contained in a 'hot cell' where the only access into the chamber is via manipulators. An example is shown in Figure 2. A short range wireless network provides an ideal communication link for transmitting the data from the radiation sensor to a 'clean area', or area absent of any radiation fields or radioactive contamination. Radiation monitoring systems that protect personnel and equipment must meet stringent codes and standards due to the consequences of failure. At first glance a wired system would seem more desirable. Concerns with wireless communication include latency, jamming, spoofing, man in the middle attacks, and hacking. The Department of Energy's Savannah River National Laboratory (SRNL) has developed a prototype wireless radiation air monitoring system that address many of the concerns with wireless and allows quick deployment in radiation and contamination areas. It is stand alone and only requires a standard 120 VAC, 60 Hz power source. It is designed to be mounted or portable. The wireless link uses a National Security Agency (NSA) Suite B compliant wireless network from Fortress Technologies that is considered robust enough to be used for classified data transmission in place of NSA Type 1 devices.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Developing Flexible, Networked Lighting Control Systems That Reliably Save Energy in California Buildings

An important strategy to meet California's ambitious energy efficiency goals is to use innovative wireless communications, embedded sensors, data analytics and controls to significantly reduce lighting energy use in commercial buildings. This project developed a suite of networked lighting solutions to further this goal. The technologies include a platform for low-cost sensing, distributed intelligence and communications, the “PermaMote,” which is a self-powered sensor and controller for lighting applications. The project team also developed a task ambient daylighting system that integrates sensors with data-driven daylighting control using an open communication interface, called the “Readings-At-Desk” (RAD) system. To address the problem of building occupants being confused about how to operate traditional lighting control systems, the research team created content that could be the basis for a user interface standard for lighting controls. Finally, to address the difficulty of ensuring that advanced lighting control systems actually deliver their promised energy savings, the project team developed a new method for evaluating and specifying lighting systems’ performance. The research team validated these technologies in the laboratory, showing significant lighting energy savings, up to 73% for the PermaMote sensor system from occupancy control and daylight dimming features, compared to the same light source (LED replacement lamps) operated via simple on/off scheduling. The project team also developed a proposed standard lighting data model and user interface elements, which were contributed to the ANSI Lighting Systems Committee (C137) for standardization. Existing data models are incomplete and inconsistent, whereas the lighting-specific data model developed here is clear and comprehensive, to serve as a starting point for creating common, universally agreed upon semantic definitions of key lighting parameters, to promote interoperability. For the task on verifiable performance of lighting systems, the project team developed a more effective metric for capturing the actual energy impact of a lighting system over time — the energy usage intensity (kWh/ft2/year). Three commercial lighting systems were tested in FLEXLAB® using this new metric, and the tests show a wide range in the accuracy of the self-reported energy-use metric, from 0.5% to 28% error compared to direct measurement of lighting energy using dedicated submeters. Overall, the project team estimates that these advanced technologies can reduce California office lighting energy use by 20% (above and beyond normal advanced lighting controls mandated by Title 24), resulting in about 1,600 GWh/year in savings.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Correlation of Surface Acoustic Wave (SAW) force myography sensor output with elbow joint torque

Accurate assessment of skeletal muscle forces and net joint torque is essential for preventing fatigue-related injuries, optimizing physical training, and monitoring disease progression in neuromuscular conditions. However, existing joint torque evaluation techniques are hindered by limited portability and high operational costs, confining their use to controlled laboratory or clinical settings. Despite substantial advances in wearable joint torque estimation systems, ongoing challenges such as power constraints, bulky wired setups, and susceptibility to environmental or motion artifacts underscore the urgent need for truly batteryless, wireless solutions deployable in real-world settings. This paper proposes a novel surface acoustic wave (SAW)-based force myography (FMG) system for noninvasive measurement of joint torque, validated against a gold-standard electromechanical dynamometer. The approach uses a single SAW sensor embedded in an armband to detect volumetric biceps brachii changes, with a second-order polynomial mapping sensor output and elbow angle to torque. Seven participants were tested in both isometric (15°–90°) and isokinetic (10°/s and 20°/s) supinated elbow flexion tasks. Under isometric conditions, subject-specific calibration achieved a normalized root-mean-square error (NRMSE) of 13.6% ± 6.0% and R 2 = 0.834 ± 0.180, while a group-level model yielded 14.4% ± 6.8% and 0.808 ± 0.208, respectively. For isokinetic trials, the group model produced an NRMSE of 24.1% ± 6.6% at 10°/s and 24.9% ± 08.9% at 20°/s, highlighting the feasibility of using a single-sensor SAW-FMG setup across different speeds. Because SAW devices support wireless, battery-free operation, the proposed system offers a pathway to portable, real-time monitoring for sports medicine, rehabilitation, and clinical diagnostics.

36 MATERIALS SCIENCE↗

Islanding Detection in Rural Distribution Systems

This paper summarizes the literature on detection of islanding resulting from distributed generating capabilities in a power distribution system, with emphasis on the rural distribution systems. It is important to understand the legacy technology and equipment in the rural distribution electrical environment due to the growth of power electronics and the potential for adding the new generations of intelligent sensors. The survey identified four areas needing further research: 1. Robustness in the presence of distribution grid disturbances; 2. the future role of artificial intelligence in the islanding application; 3. more realistic standard tests for the emerging electrical environment; 4. smarter sensors. In addition, this paper presents a synchro-phasor-based islanding detection approach based on a wireless sensor network developed by the University of Texas at Austin. Initial test results in a control hardware-in-the-loop (CHIL) simulation environment suggest the effectiveness of the developed method.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Enabling the Next Generation of Smart Sensors in Coal Fired Power Plants using Cellular 5G Technology

An important need for coal fired power plants is the ability to monitor multiple systems with ease and accuracy. Common implementations of these monitoring systems come with drawbacks due to the nature of coal fired power plants. Harsh environments, High Temperatures, and lots of RF (Radio Frequency) noise can create issues for accurately recording and transmitting data across wireless signals. In addition, as renewable energy sources come online, existing fossil fueled plants will need to operate more flexibly with their maintenance schedules outside of standard conditions. Therefore, additional sensing and control mechanisms need placed in existing plants to provide operators with more information such that maintenance decisions can be made well in advance of failures. A solution to this problem is the Next Generation of Smart Sensors, which leverages the power of 5G cellular signals and machine learning to overcome the myriad of problems with current implementations

20 FOSSIL-FUELED POWER PLANTS↗

Wireless Sensor for Measuring Pump Efficiency: Small Business Voucher Project with KCF Technologies

This document is to fulfill the final report requirements for the Small Business Voucher (SBV) CRADA project with ORNL and KCF Technologies (CRADA/NFE-16-06133). Pumping systems account for nearly 20% of the world’s electrical energy demand and range from 25-50% of the energy usage in many industrial and building power plants. The energy cost is the largest element in the total cost of owning a pump (~40%). In response to a recent DOE mandate for improved pump efficiency pump manufacturers are preparing for the changes that the impending regulations will bring, including design improvements. This mandate also establishes a need for new low cost pump efficiency measurement systems. The standard industry definition of pump efficiency is the mechanical water horsepower delivered divided by the electrical horsepower input to the motor. KCF Technologies has developed a new sensor measurement technique to estimate fluid pump efficiency using a thermodynamic approach. KCF Technologies applied for a SBV grant with ORNL as the research partner. KCF needed a research partner with the proper facilities to demonstrate the efficacy of its wireless sensor unit for measuring pump efficiency. The ORNL Building Technologies Research and Integration Center (BTRIC) test resources were used to test and demonstrate the successful measurement of pump efficiency with the KCF sensor technology. KCF is now working on next steps to commercialize this sensing technology.

42 ENGINEERING↗

Identifying High Potential Well Targets with 3D Seismic and Mineralogy

Seismic reflection the primary tool used in petroleum exploration and production, but use in geothermal exploration is less standard, in part due to cost but also due to the challenges in identifying the highly-permeable zones essential for economic hydrothermal systems [e.g. Louie et al., 2011; Majer, 2003]. Newer technology, such as wireless sensors and low-cost high performance computing, has helped reduce the cost and effort needed to conduct 3D surveys. The second difficulty, identifying permeable zones, has been less tractable so far. Here we report on the use of seismic attributes from a 3D seismic survey to identify and map permeable zones in a hydrothermal area.

15 GEOTHERMAL ENERGY↗

Solid-State Mixed-Potential Electrochemical Sensors for Natural Gas Leak Detection and Quality Control (Final Technical Report)

Mitigation of methane emissions are a critical factor to limiting the impact of the natural gas industry on global climate change. Throughout the period of 2020-2024, the University of New Mexico and its commercialization partner and subcontractor, SensorComm Technologies, Inc. (SCT), have worked together to develop a low-cost Artificial Intelligence (AI)-driven Internet of Things (IoT)-based multi-gas sensor platform for methane emissions detection. In the final year of the project, we extended this work to include hydrogen detection in support of a transition to a hydrogen economy where hydrogen could be transported through existing natural gas infrastructure. Mixed potential electrochemical sensors were first prototyped by ceramic additive manufacturing and then transitioned to conventional ceramic manufacturing tape casting and screen-printing technologies in preparation for mass production. Demonstrated limits of detection of 5 ppm of methane in natural gas and 1 ppm of hydrogen were measured. These limits of detection are among the lowest of solid-state electrochemical sensors that have been reported in the literature or available in the industry. Machine learning algorithms were developed to identify natural gas mixtures with > 98% accuracy level and quantify methane concentrations at 97% accuracy. The presence of hydrogen could also be identified, and its concentration quantified at these accuracy levels. These algorithms were optimized for running on portable computing hardware which enabled > 1 Hz processing rates. A portable packaged IoT system was integrated with the electrochemical sensor in collaboration with SCT. The package consists of readout electronics with < 1 mV resolution, sensor temperature control, and data transmission over cellular wireless and/or Wi-Fi networks. Field testing was performed in two rounds at Colorado State University’s Methane Emissions Technology Evaluation Center (CSU METEC). The first round of testing demonstrated successful measurements of methane from an underground natural gas leak of 20 standard liters per minute (SLPM), which agreed with previously published literature using more sophisticated and expensive analytical equipment. The second round of testing showed that an above ground leak of 2 SLPM of hydrogen could be detected at 32 ft. This project has resulted in six published peer reviewed journal articles, over ten presentations at professional conferences, and one full patent application filed in 2023. Future work on this project includes increased sensitivity, higher production yields, and applications in the hydrogen safety and flare emissions monitoring spaces.

03 NATURAL GAS↗