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DOE OSTI2025

Industrial Electrification Assessment Framework

Electrification refers to the process of transitioning from fuel-powered systems to electric-powered systems, or electrotechnologies. This document first provides an overview of industrial electrification, including possible advantages and common applications. Next, it provides a comprehensive, step-by-step framework for assessing the potential for electrification at an individual industrial facility. The steps in this framework include inventorying current fuel-powered systems, evaluating a manufacturing facility’s electrification readiness, and identifying, evaluating, and prioritizing strategies and technologies. This document also contains information about project implementation, and the appendices provide tools and resources to support organizations pursuing electrification.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2021

cerf: A Python package to evaluate the feasibility and costs of power plant siting for alternative futures

Long-term electric power sector planning and capacity expansion is a key area of interest to stakeholders across a wide range of organizations because it helps in making informed decisions about investments in infrastructure within the context of potential future vulnerabilities under various natural and human stressors. Future power plant siting costs will depend on a number of factors including the characteristics of the electricity capacity expansion and electricity demand (e.g., fuel mix of future electric power capacity, and the magnitude and geographic distribution of electricity demand growth) as well as the geographic location of power plants. Electricity technology capacity expansion plans modeled to represent alternate future conditions meeting a set of scenario assumptions are traditionally compared against historical trends which may not be consistent with current and future conditions. We present the `cerf` Python package (a.k.a., the Capacity Expansion Regional Feasibility model) which helps evaluate the feasibility and structure of future, scenario-driven electricity capacity expansion plans by siting power plants in areas that have been deemed the least cost option while considering dynamic future conditions. We can use `cerf` to gain insight to research topics such as: 1) under what conditions future projected electricity expansion plans from models such as GCAM-USA are possible to achieve, 2) where and which on-the-ground barriers to siting (e.g., protected areas, cooling water availability) may influence our ability to achieve certain expansions, and 3) how electricity infrastructure build-outs and value may evolve into the future when considering locational marginal pricing (LMP) based on the supply and demand of electricity from a grid operations model.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2022

A High-Voltage High-Reliability Scalable Architecture for Electric Vehicle Power Electronics (Final Report)

This project developed and demonstrated new composite converter technologies that lead to high power density (> 20 kW/L) at power levels of 10s of kW, 100s of kW, or possibly higher, with fundamental advances in converter efficiency and Q that lead to substantial increases in mean time to failure (MTTF). These advantages were realized through development of new composite converter topologies that perform buck, boost, or other conversion functions and that are scalable to higher voltage and power levels through sharing of voltage and current stresses among multiple dissimilar partial-power converter modules. The project led to experimental demonstration of a125 kW multifunction electric vehicle power conversion system having in-creased dc bus voltage (950 V nominal, 1200 V peak) that interfaces a 200 V to 400 V battery pack, and that includes integrated level 2 wired charging and wireless charging functions. The project incorporated SiC MOSFET modules having switching frequencies in excess of 100 kHz, planar magnetics, a hierarchical control architecture that enables scaling to higher voltages and powers with additional converter modules, and a high-power density in excess of 20 kW/L. The research demonstrated how a more complex converter approach can increase mean-time-to-failure, even though the number of elements is increased. This is achieved through significant reduction of temperature rise through fundamentally superior converter circuit topologies. The research also demonstrated new high power planar magnetics that increase power density. The technology is appropriate to a variety of applications including EV power trains, EV charging, PV inverters, battery storage, and similar areas. These systems potentially can be manufactured in the U.S.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2021

Safe Reinforcement Learning for Emergency Load Shedding of Power Systems

The paradigm shift in the electric power grid necessitates a revisit of existing control methods to ensure the grid’s security and resilience. In particular, the increased uncertainties and rapidly changing operational conditions in power systems have revealed outstanding issues in terms of either speed, adaptiveness, or scalability of the existing control methods for power systems. On the other hand, the availability of massive real-time data can provide a clearer picture of what is happening in the grid. Recently, deep reinforcement learning (RL) has been regarded and adopted as a promising approach leveraging massive data for fast and adaptive grid control. However, like most existing machine learning (ML)- based control techniques, RL control usually cannot guarantee the safety of the power systems. In this paper, we introduce a novel method for safe RL-based load shedding of power systems that can enhance the safe voltage recovery of the electric power grid after experiencing faults. Numerical simulation on the IEEE 39-bus testcase is performed to demonstrate the effectiveness of the proposed safe RL emergency control, as well as its adaptive capability to faults not seen in the training.

reinforcement learning, emergency control, power g↗

DOE OSTI2025

Analysing a multi‐stage cyber threat and its impact on the power system

Abstract Electric power systems are composed of physical and cyber sub‐systems. The sub‐systems depend on each other. If the cyber sub‐system is compromised by a cyber threat, what is the impact on the physical system? This paper presents a case study that shows the steps of a multi‐stage cyber threat involving a database injection attack, and what happens to the power system if this threat is not detected in its early stages. The threat first affects one utility but it can spread to the balancing authority, which is responsible for keeping the voltage and frequency stable in the power grid. During the cyber threat, the authors also show defence tools, such as a cyber‐physical data fusion tool that displays and analyses power and cyber telemetry.

Al Homoud, Leen [Texas A&amp,M University College ↗

DOE OSTI2023

Maximizing Wave Energy Converter Power Extraction by Utilizing a Variable Negative Stiffness Magnetic Spring

Complex conjugate impedance matching is a key concept for wave energy converter design. Matching the impedance of the power take-off (PTO) system to the complex conjugate of the wave energy converter's (WEC) impedance ensures efficient transfer of energy from the WEC body motion to electrical power. In low frequency waves, impedance matching often requires a negative PTO stiffness. In this paper, an adjustable stiffness magnetic torsion spring will be presented and modeled to understand its potential to improve WEC performance. The spring has the ability to provide a negative stiffness, allowing the PTO impedance to more closely match the complex conjugate of the WEC impedance at low frequencies. The spring also supports an adjustable stiffness value, meaning it can be tuned according to the incoming wave conditions. The spring's tunability may put less stress on the rest of the PTO system in wave conditions outside its normal operation zone without sacrificing electrical power output. The adjustable magnetic spring's effects are modeled and explored in this paper by examining the resultant average annual electrical power and capacity factor. The study suggests that the tunable magnetic spring has the potential to significantly improve capacity factor while maintaining a high average electrical power.

16 TIDAL AND WAVE POWER↗

DOE OSTI2024

Rugged WBG Devices and Advanced Electric Machines for High Power Density Automotive Electric Vehicles

This work explored two very important approaches for supporting transportation electrification and reducing dependence on imports of critical materials. In the first task, several novel electric machine architectures with low rare earth metal content were compared analytically, then experimentally to verify their performance. Rare earth metals are imported largely from China and are widely used in many clean energy systems such as wind turbines and EV motors. Reducing our dependence on this critical material is an important objective for ensuring our independence and continued economic prosperity. In the second task, a GaN based inverter for EV inverters was developed to demonstrate the suitability of that wide bandgap semiconductor device in this important application.

42 ENGINEERING↗

DOE OSTI2024

Appliance level battery-based energy storage

A powered building system that includes an electric power distribution system configured to distribute electrical power to a plurality of receptacles; one or more load sources; and one or more battery systems associated with: a respective receptacle of the plurality of receptacles and a respective load source of the one or more load sources.

Griffith, Saul Thomas↗

DOE OSTI2024

Energy storage system

A system, a method, and a computer program product for providing heterogeneous unifying battery storage. A state-of-health value of a battery is determined. The state-of-health value of the battery is less than an original capacity value of the battery. The battery is connected to an electrical power source for re-conditioning. A target state-of-health value for the battery and a number of cycles required to achieve the target state-of-health value of the battery are determined. Each cycle in the number of cycles includes at least one of: a charging the battery and a discharging the battery. The battery is re-conditioned by cycling the battery using the determined number of cycles. Cycling includes drawing electrical power from the electrical power source.

Tong, Shijie↗

DOE OSTI2023

Energy Resilience for Mission Assurance: Case Study Scoping Document

The Energy Resilience for Mission Assurance (ERMA) project—a Department of Energy Grid Modernization Lab Consortium effort carried out via a partnership among five national laboratories— seeks to develop metrics to quantify how improvements to energy system resilience translate to improved Department of Defense (DoD) mission assurance (MA) during wide-scale, long-duration outages of the bulk power system. DoD missions are integral to national security and highly dependent on electric power. However, energy system planners—both civilian and military—lack a clear and quantifiable mapping between electric power system resilience and MA, leaving a gap in their ability to understand and consider national security outcomes within their planning efforts. The ERMA project seeks to fill this gap, providing stakeholders with new capabilities to understand the impact of electric power system resilience on MA during hazard scenarios.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2023

Frequency Recovery in Power Grids Using High-Performance Computing

Maintaining electric power system stability is paramount, especially in extreme contingencies involving unexpected outages of multiple generators or transmission lines that are typical during severe weather events. Such outages often lead to large supply-demand mismatches followed by subsequent system frequency deviations from their nominal value. The extent of frequency deviations is an important metric of system resilience, and its timely mitigation is a central goal of power system operation and control. This paper develops a novel nonlinear model predictive control (NMPC) method to minimize frequency deviations when the grid is affected by an unforeseen loss of multiple components. Our method is based on a novel multi-period alternating current optimal power flow (ACOPF) formulation that accurately models both nonlinear electric power flow physics and the primary and secondary frequency response of generator control mechanisms. We develop a distributed parallel Julia package for solving the large-scale nonlinear optimization problems that result from our NMPC method and thereby address realistic test instances on existing high-performance computing architectures. Our method demonstrates superior performance in terms of frequency recovery over existing industry practices, where generator levels are set based on the solution of single-period classical ACOPF models.

nonlinear model predictive control↗

DOE OSTI2022

Securing against malicious control of circuit breakers in electrical substations

An example method for detecting and mitigating attacks on electric power substations comprises detecting a command to open or close a circuit breaker in the electric power substation. A modified extended substation model for the electric power substation is generated, based on the detected command and based on measurements in substation, where the modified extended substation model is a power flow model for the substation and for one or more directly connected neighboring substations. A power flow analysis is performed, using the modified extended substation model, to generate a predicted voltage for each of a plurality of nodes in the substation and in the one or more directly connected neighboring substations. Each predicted voltage is compared to a corresponding allowable voltage range, and execution of the command is blocked in response to determining that one or more of the voltages is outside the corresponding allowable voltage range.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2023

Housing Energy Connection Project (Final Technical Report)

This project expanded existing medium-voltage distribution to 33 households, a daycare, a mechanical shop, irrigation pumps, and a sewer lift station, all of which previously received electric service from the local electric utility. As part of the project, automatic meter reading (AMR) and advanced metering infrastructure (AMI) was installed to allow the Tribe to set up its own electric metering like a utility. The primary objective of this project was to expand the Tribe-owned electrical distribution to provide highly reliable electrical service to these existing loads. The objective was successfully met after project completion. The project reduced high costs for electric energy previously supplied by the utility, by supplanting utility-supplied electric power with Tribe-generated electric power. The project gave the Tribe greater independence from traditional power sources and provided jobs for the community.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2022

Thermoelectric power generation in the core of a nuclear reactor

Thermoelectric energy converters offer a promising solution to generate electrical power using heat in the nuclear reactor core. Despite significant improvements in thermoelectric efficiency of nanostructured materials, the performance of these advanced materials has yet to be demonstrated in the harsh radiation environment of a reactor core. Herein, we demonstrate a thermoelectric generator (TEG) made from nanostructured bulk half-Heusler (HH) materials generating stable electrical power density > 1140 W/m 2 after 30 days in the MIT Nuclear Research Reactor under an unprecedented fast-neutron (>1 MeV) fluence of 1.5 × 10 20 n/cm 2 . Despite an initial degradation due to irradiation damage when operating under relatively low temperatures, our TEG showed a 20-fold increase in power output when operating under high temperature due to in-situ annealing and resulting thermoelectric property recovery. First-principles modeling indicates that a chemically disordered metallic phase was formed under irradiation at lower temperatures, resulting in a drastic degradation in thermoelectric properties, while at sufficiently high temperatures the system returned to the initial chemically ordered HH phase and the thermoelectric properties recovered. Transmission electron microscopy and electron diffraction demonstrated that the chemically disordered phase was formed upon ion irradiation, confirming the prediction from first-principles simulations. Furthermore, the results suggest that with proper control over the TEG operating temperatures, the nanostructured bulk TEGs could produce stable electrical power and operate indefinitely in the core of a nuclear reactor.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2020

SAM™ (System Advisor Model™) [SWR-16-02, SWR-10-13]

See the SAM™ website to build a desktop version of the National Laboratory of the Rockies' (NLR's) System Advisor Model™ (SAM). https://sam.nlr.gov/ The System Advisor Model™ (SAM™) is a free techno-economic software model that facilitates decision-making for people in the renewable energy industry: -Project managers and engineers -Policy analysts -Technology developers -Researchers SAM can model many types of renewable energy systems: -Photovoltaic systems, from small residential rooftop to large utility-scale systems -Battery storage with Lithium ion, lead acid, or flow batteries for front-of-meter or behind-the-meter applications -Concentrating Solar Power systems for electric power generation, including parabolic trough, power tower, and linear Fresnel -Industrial process heat from parabolic trough and linear Fresnel systems -Wind power, from individual turbines to large wind farms -Marine energy wave and tidal systems -Solar water heating -Fuel cells -Geothermal power generation -Biomass combustion for power generation -High concentration photovoltaic systems SAM's financial models are for the following types of projects: -Residential and commercial projects where the renewable energy system is on the customer side of the electric utility meter (behind the meter), and power from the system is used to reduce the customer's electricity bill. -Power purchase agreement (PPA) projects where the system is connected to the grid at an interconnection point, and the project earns revenue through power sales. The project may be owned and operated by a single owner or by a partnership involving a flip or leaseback arrangement. -Third party ownership where the system is installed on the customer's (host) property and owned by a separate entity (developer), and the host is compensated for power generated by the system through either a PPA or lease agreement. For a more detailed description of SAM, see Blair et al. (2018), System Advisor Model (SAM) General Description (Version 2017.9.5), NREL/TP-6A20-70414. https://www.nrel.gov/docs/fy18osti/70414.pdf

Ryberg, David↗

DOE OSTI2025

Industrial Electrification Technologies Booklet

Electrification refers to transitioning from fuel-powered systems to electrically-powered alternatives. In an industrial context, this primarily refers to the electrification of process heat, but there are also widespread opportunities to electrify space heating and cooling as well as onsite transportation (e.g., forklifts). Electrification does not refer to one particular technology, but a wide range of technologies that use different methods to transfer electrical energy into a usable form – usually heat.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2023

Reliability and Decarbonization Resource Adequacy and Resilience

The Electric Power Transformation: 2023 MEGA Symposium has a focus on the transition of the energy generation industry to cleaner and climate resilient electric power that can remain cost-effective and reliable. Electric power energy issues abound as the world and the industry address environmental policy challenges—climate change, air quality, waste and water policy, environmental justice, and Environmental Social Governance —and various technology issues related to energy production and delivery, including the latest cutting-edge options. This presentation discusses reliability and decarbonization of the power sector with a focus on resource adequacy and resilience.

Balash, Peter↗

DOE OSTI2023

A Comparison of Power Take-Off Architectures for Wave-Powered Reverse Osmosis Desalination of Seawater with Co-Production of Electricity

Several power take-off (PTO) architectures for wave-powered reverse osmosis (RO) desalination of seawater are introduced and compared based on the annual average freshwater production and the size of the components, which strongly relate to the costs of the system. The set of architectures compared includes a novel series-type PTO architecture not previously considered. These seawater hydraulic PTO architectures are composed of a WEC-driven pump, an RO module, an intake charge pump driven by an electric motor, and a hydraulic motor driving an electric generator for electric power production. This study is performed using an efficient two-way coupled steady-state model for the average performance of the system in a given sea state, including freshwater permeate production, electric power production, and electric power consumption. A multi-objective design problem is formulated for the purposes of this comparative study, with the objectives of maximizing annual freshwater production, minimizing the displacement of the WEC-driven pump, and minimizing the installed RO membrane area. This establishes a framework for comparison in the absence of a mature techno-economic model. The requirement that the system produces enough electric power to meet its consumption is applied as a constraint on the operation of the system. The oscillating wave surge converter Oyster 1 is assumed as the WEC. Weights on performance of the system in a given sea state are based on historical data from Humboldt Bay, CA. This study finds that (1) architectures in a series configuration allow for a reduction in the WEC-driven pump size of 59–92% compared to prior work, (2) varying the displacement of the WEC-driven pump between sea conditions does not provide any significant advantage in performance, and (3) varying the active RO membrane area between sea condition offers improvements between 7% and 41% in each design objective.

Energy & Fuels↗