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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 217 records · Page 12

Towards functionalized lignin and its derivatives for high-value material applications

In pursuit of low-carbon development, the production of diverse functional materials from renewable resources, especially lignocellulosic biomass, is of vital importance. Lignin is a major component of lignocellulose, and it is nature's only true high-volume aromatic polymer, which has the advantages of biodegradability, biocompatibility, and low acquisition cost. After modification by a variety of physicochemical strategies, it can be applied as an alternative to basic industrial materials, including polyurethanes, phenolic, and epoxy resins, which stands comparably to conventional synthetic polymers in terms of both performance and reduced cost. To further unlock the potential of lignin, an alluring opportunity is the exploitation of lignin for high-value materials, especially nanomaterials, that find extensive applications in energy and environment areas. This review provides a systematic summary and perspective of research that has been devoted to lignin transformation to high-value materials, ranging from industrially well-established engineering materials to the recently emerged nanomaterials that were used for energy and environment applications. Latest cutting-edge innovations on lignin modification, controlled depolymerization, and assembly during the last five years are summarized. Structure-function relationships of lignin materials in terms of their specific applications are analyzed. Furthermore, challenges and future opportunities for lignin conversion to high-value materials are also provided. We wish this review will stimulate further advances in lignin based high-value materials, and promote “waste” into “wealth”.

36 MATERIALS SCIENCE↗

Cooperative Research and Development Agreement among National Energy Technology Laboratory, Advanced Manufacturing LLC, and Connecticut Center for Advanced Technology [Abstract]

The National Energy Technology Laboratory (NETL), Advanced Manufacturing LLC (AMLLC) and Connecticut Center for Advanced Technology (CCAT) will collaborate to develop and manufacture cost-effective, oxide dispersion-strengthened, NiCrFeCo-rich high entropy alloys that are superior to Nickel-based superalloys (e.g. IN740) for repair or replacement service in extreme environments. The new alloys can result in higher efficiency and reduced cost of advanced power systems such as advanced ultra-supercritical (AUSC) boilers and gas turbines. High throughput, multiscale computational modeling will be performed to accelerate alloy discovery by interrogating the intrinsic properties of the alloys including thermodynamic, kinetic, and mechanical properties. Validation and evaluation will be performed, including additive manufacturing, microstructure characterization, and mechanical properties tests.

36 MATERIALS SCIENCE↗

Unalakleet Microgrid Optimization for Tribal Community Resilience

The Unalakleet Microgrid Optimization Project aimed to strengthen the reliability and efficiency of the isolated electric power system that serves the Tribal community of Unalakleet, Alaska. The community relies entirely on a local wind-diesel microgrid, consisting of four 475 kW diesel generators and six 100 kW wind turbines, to provide electricity to approximately 745 residents and Tribal facilities. Because Unalakleet is not on a road system and is located nearly 400 miles from the nearest major power grid, maintaining a resilient and efficient local energy system is critical. The scope of this project included upgrading a portion of the transmission line between the wind farm and the power plant to increase voltage and reduce line losses, along with modernizing the Supervisory Control and Data Acquisition (SCADA) system to improve monitoring, control, and data management of the power system. These upgrades were designed to increase wind energy utilization, reduce diesel fuel consumption by tens of thousands of gallons annually, and improve overall grid stability. By allowing more of the community’s electricity to be supplied by local renewable wind resources, the project was designed to lower operating costs, reduce dependence on imported fuel, and strengthen the long-term resilience of the power system. These improvements represent an important step toward the community’s long-term energy vision of expanding renewable generation, incorporating energy storage, and eventually achieving “diesels-off” operation, where essential Tribal loads are powered primarily by local renewable resources.

17 WIND ENERGY↗

Applying corrective machine learning in the E3SM atmosphere model in C++ (EAMxx)

The Simple Cloud-Resolving E3SM Atmosphere Model (SCREAM) is the newest addition to the family of earth system models capable of explicitly resolving convective systems. SCREAM is a kilometer-scale configuration of the advanced E3SM Atmosphere Model (EAMxx), designed for heterogeneous computing architectures. While the enhanced accuracy of kilometer-scale modeling offers significant benefits, it comes with a substantial computational cost, limiting feasible simulation durations to only a few years to a few decades, even on the fastest supercomputers. Machine learning presents an opportunity for scientists to achieve the high accuracy of storm-resolving models at a significantly reduced cost. Building on the previous success of applying corrective machine learning (ML) to the FV3GFS earth system model, this study explores the effects of implementing corrective-ML in EAMxx-SCREAM. We also address the computational challenges of integrating our implementation of corrective-ML, which is written in Python, with the C++/Kokkos EAMxx driver, as well as potential reasons why this approach has not proved as effective for EAMxx-SCREAM as for FV3GFS.

Environmental sciences↗

Towards a Techno-Economic Analysis of PCM Integrated Hybrid HVAC Systems

Thermal end uses dominate building energy consumption and are a major driver of peak demand. As heating is electrified, peak electrical power required will surge, prompting a need for innovative HVAC system designs and controls.These designs must incorporate novel technologies at the component level and new integration techniques at the system level. One such possibility involves the addition of thermal energy storage (TES) in heating and cooling equipment using a phase change material (PCM) heat exchanger. Here, thermal energy storage via phase change can be used to shift the HVAC system loads to times of lower electricity cost, reduced carbon intensity, and greater energy efficiency. Most of the current utilization of PCM in buildings involves passive components. By actively controlling when heat is stored and released from PCM, we can optimize the building HVAC system to cost-effectively meet consumer needs with the flexibility to draw on renewable energy resources when they are abundant and available. While this combination of technologies is promising in theory, simulation-based evaluation of a prototype can be difficult due to the modeling requirements at the component level and the large number of possible configurations and operating modes at the system level. To conduct this evaluation, we use the Modelica language for modeling and simulation because it enables users to represent the important physics of the problem, interchange and rearrange components in an efficient manner, and implement a range of control configurations. In this work, we considered three case studies: a portable building, a large commercial retail store, and a multifamily residential apartment unit. Each of these employs a different system design, ranging from a single package vertical unit incorporating PCM to a central plant with independent heat pump, evaporative cooling, and thermal energy storage components. This paper describes the technologies in question, presents modeling at the component and system levels, and demonstrates building energy and demand charge cost savings with local time-of-use tariffs in a hot-dry climate.

Helmns, Dre↗

Recent Advances toward Efficient Calculation of Higher Nuclear Derivatives in Quantum Chemistry

In this article, we provide an overview of state-of-the-art techniques that are being developed for efficient calculation of second and higher nuclear derivatives of quantum mechanical (QM) energy. Calculations of nuclear Hessians and anharmonic terms incur high costs and memory and scale poorly with system size. Three emerging classes of methods—machine learning (ML), automatic differentiation (AD), and matrix completion (MC)—have demonstrated promise in overcoming these challenges. We illustrate studies that employ unsupervised ML methods to reduce the need for multiple Hessian calculations in dynamics simulations and those that utilize supervised ML to construct approximate potential energy surfaces and estimate Hessians and anharmonic terms at reduced cost. By extension, if electronic structure operations could be written in a manner similar to functions underlying ML methods, rapid differentiation or AD routines can be employed to inexpensively calculate higher arbitrary-order derivatives. While ML approaches are typically black-box, we describe methods such as compressed sensing (CS) and MC, which explicitly leverage problem-specific mathematical properties of higher derivatives such as sparsity and low-rank, to complete higher derivative information using only a small, incomplete sample. The three classes of methods facilitate reliable predictions of observables ranging from infrared spectra to thermal conductivity and constitute a promising way forward in accurately capturing otherwise intractable higher-order responses of QM energy to nuclear perturbations.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗

Uncertainty Quantification and Sensitivity Analysis of Nuclear Construction Cost Reduction Pathways

High construction costs have plagued recent nuclear projects and they hamper the widespread deployment of nuclear technology. The Nuclear Cost Reduction Tool is a plant economic framework that quantifies the impact that various plant design and construction attributes have on construction costs and cost overruns and shows the positive effects of learning over a series of deployments. However, a downside of the current model is that all model outputs and capabilities are deterministic. To provide a more comprehensive view, this study evaluated the impact of model parameter uncertainty through a sensitivity analysis applied to 18 model parameters. This approach quantified the impact of model uncertainty on the output variables of Net Overnight Capital Cost (Net OCC), Construction Duration (CD), and Levelized Cost of Electricity (LCOE). Monte Carlo analysis revealed uncertainty distributions for these variables, showing that absolute uncertainty decreases over a series of deployments. A local sensitivity analysis showed that even small parameter perturbations (5%) can have a significant impact on project execution, highlighting areas that could reduce costs by billions across an order book of plants. The results of this study have improved the understanding of the model and identified the most impactful model parameters and construction attributes.

Levelized Cost of Electricity↗

Solar Photovoltaic and Storage Supply Chains and Technology and Market Opportunities

This talk will highlight the most recent efforts from the National Renewable Energy Laboratory (NREL) to track solar photovoltaic (PV) and storage supply and demand in the United States and globally, as well as bottom-up calculations of manufacturing costs for facilities across the globe. We will begin with an overview of the global solar PV supply chain and 2022 benchmark input data used for NREL's bottom-up crystalline silicon (c-Si) and thin film PV module manufacturing cost models. For the polysilicon, wafer, cell conversion, and module assembly steps of the c-Si supply chain, and for thin film modules, we will review the industry-collected input data and methods used for calculating the costs of goods sold (COGS); research and development (R&D) expenses; and sales, general, and business administration (S, G, and A) expenses. This 2022 benchmark analysis is compiled for state-of-the-art c-Si and thin film PV module manufacturing in several countries and regions; and will also include a quantified summary of the impacts of the manufacturing incentives and tax credits that are available for solar manufacturing and installations within the United States. Next generation technologies that lower PV manufacturing and installation costs, reduce operations and maintenance (O&M) expenses, and improve system energy yield will also be highlighted. We will conclude with projections of solar market penetration to 2050 from NREL's Solar Futures Study and Annual Technology Baseline (ATB) model, which includes solar coupled with lower-cost storage scenarios as well as the range of future cost scenarios for other power generation sources. We look forward to sharing NREL's extensive work in these areas and discussing ideas for future directions.

economics↗

Non-planar platinum group metal-free fuel cell cathodes for enhanced oxygen transport and water rejection

Proton exchange membrane fuel cells (PEMFC) with cathodes using platinum group metal-free (PGM-free) catalysts could significantly reduce costs, but the lower volumetric oxygen reduction reaction (ORR) activity requires thick electrodes that suffer from liquid water flooding and increased oxygen transport resistance. To address these challenges, we developed a 3D gas diffusion electrode (GDE) architecture to enhance liquid water removal through the diffusion media and reduce cathode saturation. The cathode features a uniform catalyst layer adjacent to the membrane for high ORR activity and then pillars of the hydrophilic catalyst layer that pass through the microporous layer (MPL), providing a low capillary pressure barrier pathway to the carbon fiber paper layer and channel. The non-planar cathode also increases the interfacial area between the catalyst layer and hydrophobic MPL for a greater fraction of the cathode with high O 2 concentration. Our studies included parametric experimental study of the pillar density to identify the optimum pitch between pillars. Our measurements show significant improvements in the mass transport region of the polarization curve with 3D structured electrodes leading to an 8% increase in maximum current density, 19% increase in maximum power density, and 16% increase in current density at 0.67 V with air.

25 ENERGY STORAGE↗

Build-To-Replace Strategy to Reduce O&M Costs of Advanced Reactors

This paper targets the goal of reducing fixed operations and maintenance (O&M) costs to $2/MWh for advanced reactor (AR) designs, an order of magnitude reduction from current nuclear fleets. Such goal will be severely constrained if the underlying assumptions of O&M approaches and practices are not questioned and reexamined, especially today when changes can be implemented effectively and efficiently. Achieving a 90% reduction in AR O&M costs requires a completely new way of thinking – a paradigm shift – not through incremental, technology-focused approaches alone. Here, we address this challenge by evaluating the impact of moving to shorter design life for major structures, systems and components (SSCs) and shorter, more predictable refurbishment cycles as modeled by the commercial airline industry. This paper provides a brief overview of this different mindset to O&M applied to ARs: the build-to-replace approach. We provide a direct example of analysis of a build-to-replace scenario by identifying and evaluating scenarios for reduced system and component lifetimes and associated replacement and refurbishment schedules to evaluate impacts on O&M costs and other lifecycle elements such as SSC reliability.

97 - MATHEMATICS AND COMPUTING↗

Review of Layered Transition Metal Oxide Materials for Cathodes in Sodium-Ion Batteries

The growing interest in sodium-ion batteries (SIBs) is driven by scarcity and the rising costs of lithium, coupled with the urgent need for scalable and sustainable energy storage solutions. Among various cathode materials, layered transition metal oxides have emerged as promising candidates due to their structural similarity to lithium-ion battery (LIB) counterparts and their potential to deliver high energy density at reduced costs. However, significant challenges remain, including limited capacity at high charge/discharge rates and structural instability during extended cycling. Addressing these issues is critical for advancing SIB technology toward industrial applications, particularly for large-scale energy storage systems. This review provides a comprehensive analysis of layered sodium transition metal oxides, focusing on their structural properties, electrochemical performance, and degradation mechanisms. Special attention is given to the intrinsic and extrinsic factors contributing to their instability, such as structural phase transitions, and cationic/anionic redox behavior. Additionally, recent advancements in material design strategies, including doping, surface modifications, and composite formation, are discussed to highlight the progress toward enhancing the stability and performance of these materials. This work aims to bridge the knowledge gaps and inspire further innovations in the development of high-performance cathodes for sodium-ion batteries.

Ahangari, Mehdi (ORCID:0000000345803969)↗

A Scalable Approach to Minimize Charging Costs for Electric Bus Fleets

Incorporating battery electric buses into bus fleets faces three primary challenges: a BEB’s extended refuel time, the cost of charging, both by the consumer and the power provider, and large compute demands for planning methods. When BEBs charge, the additional demands on the grid may exceed hardware limitations, so power providers divide a consumer’s energy needs into separate meters even though doing so is expensive for both power providers and consumers. Prior work has developed a number of strategies for computing charge schedules for bus fleets; however, prior work has not worked to reduce costs by aggregating meters. Additionally, because many works use mixed integer linear programs, their compute needs make planning for commercial-sized bus fleets intractable. This work presents a multi-program approach to computing charge plans for electric bus fleets. The proposed method solves a series of subproblems where the solution to the charge problem becomes more refined with each problem, moving closer to the optimal schedule. The results demonstrate how runtimes are reduced by using intermediate subproblems to refine the bus charge solution so that the proposed method can be applied to large bus fleets of 100+ buses. Not only will we demonstrate that runtimes scale linearly with the number of buses but we will also show how the proposed method scales to large bus fleets of over 100 buses while managing the monthly cost of energy.

Mortensen, Daniel (ORCID:0000000276494452)↗

Waste Glass Property Database and Data Qualification Plan

The U.S. Department of Energy vitrification facilities currently employ glass property-composition models to ensure processability of waste streams and acceptability of the final glass products. The efficiency (e.g., process flexibility, reduced down time, and reduced cost) of waste vitrification is directly tied to the size of the waste processing envelope. To increase the size of the processing envelope, a larger database was developed. The database will improve the prediction accuracy of glass properties, leading to higher waste loadings, higher waste throughput, broader process flexibility, and reduced mission life. Some of the data in this expanded database has insufficient quality assurance (QA) rigor for use in nuclear facility operation and glass qualification. A plan was developed to qualify high-value data under the appropriate QA rigor for use at the Hanford Waste Treatment and Immobilization Plant’s High-Level Waste (HLW) Facility. This qualification plan first compares the data coverage over the composition region of interest to Hanford HLW by property. Those studies that significantly improve the data coverage in the Hanford HLW glass composition region were prioritized for qualification activities. Qualification methods including QA equivalence, peer review, data corroboration, and confirmatory testing have been assigned to each high-priority study.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

High Temperature Anode Recycle Blower for Solid Oxide Fuel Cell, Phase II (Final Report)

Broad commercialization of solid oxide fuel cells (SOFCs) requires anode offgas recycle blowers (ARCB) that are specifically designed for handling the challenging operating conditions presented by the SOFC process gases. Otherwise, they can be susceptible to frequent maintenance, low reliability, and short life. This report presents details of a DOE-funded Phase II effort conducted by Mohawk Innovative Technology, Inc. (MiTi®) for the development and testing of an oil-free, low cost, high-temperature centrifugal ARCB based on compliant foil bearing (CFB) technology for support of a 100 kW solid oxide fuel cell power plant. This Phase II builds on the results of a successful Phase I development project that resulted in the demonstration of a low TRL-6 prototype, shown in Figure 1. This Phase II final report presents design improvements over the Phase I prototype, presents the assembled test ARCBs, and discusses the advantages of this novel technology, particularly its long life and maintenance-free operation, which are derived from the use of CFBs. Also included are preliminary techno-economic analysis considerations for cost-effective deployment of the technology. The specific objectives of this project, as stated in the statement of program objectives (SOPO) were 1) to follow the methodology of design for manufacturing (or manufacturability) and assembly for implementing improvements identified as part of the Phase I effort with the purpose of reducing cost, enabling mass production, and facilitating the commercialization of a revised ARCB design, and 2) to fabricate four complete ARCB units based on the revised design and demonstrating their performance in both a laboratory setting and in an actual SOFC power plant. Execution of this SOPO would be supported by a number of technical tasks resulting in the fabrication and testing of the prototypes. To this end, MiTi continued the teaming relationship started during Phase I of the program with subcontracting partner FuelCell Energy, Inc. (FCE), which integrated (under a parallel effort funded by DOE Award DE-FE0026199) a modular 200 kWe SOFC power plant. MiTi and FCE coordinated to ultimately incorporate one of MiTi’s ARCB prototypes into one of the 100 kWe SOFC Modular Power Blocks (MPB) that constitute the core of FCE’s SOFC power plant for in-situ long-duration testing. Additionally, MiTi would explore the scalability and extendibility of the technology to other applications, as well as conduct a basic techno-economic analysis.

03 NATURAL GAS↗

Cost estimates of production scale semitransparent organic photovoltaic modules for building integrated photovoltaics

Building integrated photovoltaics (BIPVs) are attached to commercial and residential structures to enable solar energy harvesting. While conventional Si photovoltaics (PVs) are dominant in the current market, second and third generation thin film solar cells based on amorphous Si, CdTe, CIGS, perovskites or organic photovoltaics (OPVs) are often considered as an alternative for BIPV applications since they may offer reduced costs compared to Si PVs. Indeed, recent advances in performance suggest that lightweight, flexible and visibly transparent OPVs can potentially be integrated into windows or other applications to which Si PVs are less well suited. Here, we estimate the cost of high efficiency, semitransparent OPVs (ST-OPVs) based on solution processing in a roll-to-roll (R2R) manufacturing line. Assuming modules with 10% power conversion efficiency (PCE), a 70% geometric fill factor (GFF), and 95% inverter efficiency, we anticipate a %1.6 per Wp module manufacturing cost that includes the cost of the microinverter to condition the OPV dc output to be compatible with the ac line voltage of the building. The materials and inverter cost comprise ~90% of the total module cost. Hence, with simplified material synthesis and a lower inverter cost, including marginally improved PCE and GFF, we expect the cost can be as low as $0.47 per Wp. Here, while the module costs ~60% of the average (uninstalled) double-pane window, we expect the payback period can be as short as 2 to 6 years, suggesting that OPVs can be an economic and attractive candidate for BIPV applications.

14 SOLAR ENERGY↗

Analysis of pumped thermal energy storage using particle media integrated with concentrating solar power

Pumped Thermal Energy Storage (PTES) is an electricity storage system that converts electricity into thermal energy which is stored and later transformed back into electricity. Previous work has illustrated that particles have low capital costs and can be operated over a wide range of temperatures. PTES with particle storage achieves higher round-trip efficiency and specific power output than when molten salt thermal energy storage is used. This article explores hybrid systems that combine PTES with Concentrating Solar Power (CSP). Hybrid systems share the majority of components thereby reducing costs compared to two stand-alone devices. In addition, hybrid systems can provide multiple services (such as renewable power generation and electricity storage services). Using particle thermal storage in these hybrid concepts provides freedom in choosing the design conditions, since a wide range of operating temperatures is allowable, therefore making it possible to identify hybrid system designs that have good performance. In this article, two concepts for hybrid PTES-CSP are introduced. Thermodynamic models are developed and these are used to evaluate the performance of two hybrid systems. These models account for turbomachinery efficiency, and approach temperature and pressure loss in heat exchangers, as well as other sources of inefficiency, such as motor-generator losses, and air fan power. The “Solar Top-Up” Concept uses CSP to increase the temperature delivered by the charging heat pump. The discharging system uses a topping gas cycle and a bottoming steam cycle to fully exploit the available energy. Using solar heat to increase the maximum temperature from 750 K to 1100 K increases the round-trip efficiency from 41 % to 62 % and the specific work output from 88 kJ/kg to 301 kJ/kg. The second concept is a “Dual-Mode” device which provides both electricity storage and solar electricity generation with the same set of components. The PTES-mode and CSP-mode performance are optimized at different design values but careful parameter selection leads to good performance of both modes: one design produces PTES round-trip efficiency > 60 %, CSP heat engine efficiency > 40 %, and specific work outputs > 150 kJ/kg (for both cycles), when the particle receiver temperature is > 1200 K and maximum heat pump temperature is 1100 K.

14 SOLAR ENERGY↗

Understanding Your Utility Bills: Natural Gas

As a fossil fuel NG is a colorless and odorless gas in its natural state and is one of the cleanest burning hydrocarbons. The factors that contribute to the popularity of natural gas in the US manufacturing sector include ease of availability, clean burning properties, market deregulation, and increased domestic production. Analyzing natural gas (NG) bills can sometimes pose unique problems. Learning to read your utility bills and understand why your utility charges different fees is critical in maximizing your cost savings through energy efficiency. A key to creating a baseline is collecting and analyzing natural gas utility data. Historical data from NG bills can identify trends and help to find the baseline usage for a manufacturing operation. This guide intends to help Better Plant Program partners in understanding natural gas bills and analyzing usage to reduce costs. The guide focuses on natural gas production and transportation, understanding key charges on bills, different rate structures, and saving opportunities. A fictitious worked out example in the final section demonstrates how readers could go about analyzing natural gas bills.

03 NATURAL GAS↗

Promoting the regulatory acceptance of combined ion and neutron irradiation for material degradation in nuclear reactors

The Advanced Materials and Manufacturing Technologies (AMMT) program within the Department of Energy (DOE) Office of Nuclear Energy has developed its current recommendation for promoting the use of combined ion irradiation and neutron irradiation for the accelerated qualification of materials to be deployed in nuclear reactors. This plan is intended to provide a collaborative path forward that can be adopted by academia, national laboratories, and industry, and has been developed with input from the regulatory research arm of the U.S. Nuclear Regulatory Commission (NRC). To deploy new materials or materials manufactured with new technologies, such as additive manufacturing, materials must be evaluated for reactor-induced degradation from the combination of harsh temperatures, corrosive environments, and radiation fields. However, rapid deployment of materials necessitates accelerated testing methods rather than relying on years of neutron irradiation in a material test reactor. Ion irradiation has demonstrated success in reproducing material microstructure and select property evolution resulting from neutron irradiation with three to four orders of magnitude reduction in time and cost, making it an ideal candidate for accelerated irradiation testing. This presentation provides context governing both the scientific and regulatory aspects of the proposed goal. The discussion is aimed at a broad audience including researchers from industry, national laboratories, and academia. The recommended path forward is presented as a conceptual framework of specific steps. In brief, the strategy entails developing an integrated ion and neutron irradiation test plan for the material property of interest based on the fundamental tenet of the linkage of microstructure and properties in materials. Physics-based modeling interprets ion irradiation data and predicts neutron irradiation microstructure and properties with uncertainty bounds. The first round of testing is sufficient for an initial licensing application using a risk-informed approach, while a minimum required neutron irradiation test plan reduces cost and time requirements. A surveillance program with witness specimens in-reactor provides additional data over time to improve model predictions to higher damage levels and further reduce uncertainty bounds, which can be used for license extensions or longer lifetimes in new license applications.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗