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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 325 records · Page 18

EV Charging Infrastructure Energization: An Overview of Approaches for Simplifying Processes and Accelerating Timelines to Processing EV Charging Load Service Requests

The United States has seen significant growth in electric vehicle (EV) adoption, leading to increased demand for EV charging infrastructure and electricity. Growth in electricity demand from EV charging, coupled with growth in other sectors like data centers and electrification of other sectors, is impacting electricity infrastructure and load service request processes after two decades of relatively flat electricity demand. While most electric vehicle charging occurs at home, enroute and depot charging for medium and heavy-duty vehicles, both using high-powered EV charging, are critical to meet electric vehicle operational needs. Over the past decade, EV charging infrastructure site developers, site hosts, and electric distribution utilities have navigated the process to integrate chargers onto the electric grid. Site developers and site hosts have expressed distress that the integration process for high-powered EV charging projects does not meet the needs of the EV market for timeliness or cost. High-powered charging stations typically require a load service request or an agreement with the local utility to connect to the grid. The process of energizing a new high-powered charging site can be complex and time consuming, often taking up to 2 years. This timeline is the result of current utility energization processes having been designed for construction projects that take longer to build (i.e., buildings). The specific challenges stem from various factors, including compartmentalization in application processes, the integration of EV charging process approvals with other distributed energy resources (DERs), and the need to ensure grid reliability. The energization process needs to evolve to meet the growing demand for high-powered EV charging. This white paper compiles information gathered through various conversations with key stakeholders, including utilities, utility regulators, EV charging operators, site developers, and authorities having jurisdiction (AHJ) as well as through an extensive literature review. This document identifies the challenges and provides potential solutions to streamline the process of connecting EV charging infrastructure to the power grid in the United States, serving as a starting point for future conversations around these solutions.

33 ADVANCED PROPULSION SYSTEMS↗

Durable High Power Density Fuel Cell Cathodes for Heavy-Duty Vehicles

The aim of this project was to advance the performance and durability of proton exchange membrane fuel cells (PEMFCs) for their use in the electrification of heavy-duty vehicles (HDVs). With an emphasis on total cost of ownership for HDVs, the development of the fuel cells focuses more heavily on the efficiency and lifetime (i.e., durability) than past focus on platinum group metal (PGM) costs and power density. This project takes a unique approach to achieving these goals – using next-generation polymer electrolytes in the electrodes that yield significant improvements in performance and dramatic reductions in degradation rates. A key outcome of the project was an ionomer/catalyst combination of a Pt catalyst on a low surface area carbon support (Pt/LSC) with a high oxygen permeability ionomer (HOPI) that met both the project’s performance target (current at 0.8 V, >0.3 A/cm 2 ) and durability target (voltage loss at 0.8 A/cm 2 , <30 mV) with the goal of projected a >4X increase in life-time.

08 HYDROGEN↗

C2C Expert Match Technical Assistance: City of Reading, Pennsylvania [Slides]

The City of Reading, located in southeastern Pennsylvania, is the main city in the Greater Reading Area and the county seat of Berks County, with a population of approximately 95,112 as of 2020. Historically a disinvested manufacturing community, it has a poverty rate of around 40%, a housing stock averaging 90 years old, and an owner-occupied housing rate below 40%. In 2019, Reading adopted a resolution to achieve 100% renewable energy by 2050. The city aims to transition residential, small commercial, and small manufacturing sectors to renewable energy for electricity and heating, bypassing natural gas. This C2C Expert Match aimed to improve the energy efficiency and comfort of older rowhomes in Reading, which often rely on home heating oil and lack cooling systems. A representative energy model of a typical rowhome was developed to evaluate retrofit strategies focused on reducing overheating risk, as well as the potential impacts of heat pump installation. Additionally, resources such as case studies and best practices on energy efficiency, thermal resilience, and electrification retrofits were gathered to support the implementation of effective measures in the community.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

A Roadmap for a Lightning Modeling Grand Challenge

This document is a roadmap for building an interconnected model of the physical processes that produce a lightning discharge, and its observable optical and radio signals. We call this a Lightning Modeling Grand Challenge, recognizing that significant effort and coordination of human and financial resources is required to realize the capability. The roadmap serves to outline the coordination of resources necessary to enable stitching together existing knowledge and model components to make a lightning prediction, and to test these predictions with observations. Such a capability does not currently exist. The roadmap is motivated not only by a spirit of scientific inquiry, but by practical challenges faced by US Federal and societal stakeholders. Advancements in lightning observations have outpaced our tests of integrated understanding, leaving many stakeholders unsure how to design their missions to properly detect and discriminate lightning, and unsure how to apply the sometimes-disagreeing lightning signals from diverse instruments. The time is right to connect existing theories and models to support stakeholders in understanding the signals they observe, for needs as diverse as climate monitoring, national security, weather forecasting, public safety, and protection of natural and built environments. The roadmap’s two main technical sections describe the components of a linked physical model, followed by a description of models of lightning signals and sensors that are driven by outputs from the physical model. The goal is to predict the time-varying physical properties of lightning that are self-consistent with the thunderstorm’s structure and dynamics. These lightning signals then propagate through the storm, with realistic dispersion and attenuation, to receivers on the ground or in space. At a high level, the model begins with weather (cloud) model output, including explicit prediction of the electrification of cloud particles. The cloud’s electrical structure drives a model of lightning physics, from initiation, through channel development, and discharges along those channels. Key lightning parameters, such as the temperature and currents in the channel, and their space and time distribution, are then used to produce optical and electromagnetic signal sources that propagate to modeled receivers. This architecture therefore generates a dataset suitable for comparison to existing and envisioned observing systems. The need for additional measurements and field campaigns to support model development is described. In each model sub-component, inputs, outputs, uncertainties, evaluation methods, and next steps are summarized, interleaved with references to the scientific literature. Identifying boundaries between the model sub-components aids in segmenting an integrated, complex model into practical work packages and system sub-components, allowing a diverse team to contribute and maintain the system. We estimate that at least five years of effort and a $\$$10M initial investment is necessary to make a significant step forward. Mechanisms to facilitate community coordination, including annual workshops and open-source code repositories, are described.

54 ENVIRONMENTAL SCIENCES↗

Mixing-Controlled Compression Ignition Combustion with Low-Lifecycle-CO 2 Fuels

Reducing lifecycle carbon-dioxide (CO 2 ) and toxic emissions via electrification or switching to carbon-free fuels is not currently feasible for many off-road, rail, and marine applications. This is due to factors including excessive cost, weight, or size of a battery of sufficient capacity to meet the application requirements, lack of infrastructure, insufficient time for recharging, demanding duty cycles, and severe ambient conditions. The guiding vision for the activities described herein is to enable rapid, cost-effective reductions of the environmental impacts of such applications by using improved, high efficiency engine combustion strategies with currently available and emerging low lifecycle-CO 2 fuels (LLCFs). This report summarizes progress toward achieving this vision in two project areas. The first is a Technology Commercialization Fund (TCF) project focused on facilitating the commercialization of ducted fuel injection (DFI) with LLCFs. The second is a more fundamental, Advanced Combustion Engines (ACE) research project focused on elucidating a new strategy called lean mixing-controlled combustion (LMCC) for use with emerging LLCFs.

33 ADVANCED PROPULSION SYSTEMS↗

MLSPICE: Machine Learning based SPICE Modeling Platform for Power Magnetics

Electrical power converters are critical to a wide range of applications ranging from renewable integration to transportation electrification, and can be a key factor determining the size, weight, and efficiency of energy conversion systems. Magnetic components are typically the largest and least efficient components in power electronics. While there have been major strides in the modeling and analysis of power semiconductor devices and circuit simulations, the necessary advances in the design of power magnetics have lagged. In this project, we have transformed the modeling and design of power magnetics with machine learning enabled methods and catalyze simultaneous disruptive improvements for ML-based power electronics design tools. A fully automated open-source machine learning based magnetics modeling platform – the MagNet project - with innovations in full stack have been developed to greatly accelerate the design process and provide new insights to magnetic material and geometry design. The ARPA-E funded MagNet platform contains three major building blocks: 1) a ML-Integrated Data Acquisition System (MIDAS): a highly automated data acquisition testbed which is capable of measuring a large number of magnetic cores with a wide range of electrical circuit excitations; 2) a ML-integrated Core Loss Model (MICLM): a machine-learning trained modeling method for modeling the core loss and saturation effects of magnetic materials for arbitrary excitation waveforms; 3) ML-guided Magnetics SPICE Simulation Tool (PMSPICE): a fully integrated CAD tool which can simulate the magnetics in SPICE. It can help the designers to quickly model the linear and non-linear characteristics of magnetic components and evaluate their behavior in SPICE simulations. The developed MagNet system has fully demonstrated the proposed performance target and has been open sourced to the entire power electronics community to advance the modeling and design of power magnetics from many different angles.

36 MATERIALS SCIENCE↗

Validation of a Co-Optimized, Smart Hybrid Heat Pump Control

This study examines a residential dual fuel (DF) heating system that integrates heat pump and gas furnace technology with a home’s forced-air distribution ducts. Specifically, it explores a retrofit where an “add-on” heat pump replaces the air conditioning (A/C) system and is combined with the home’s existing furnace and air handler. The research team developed and validated an innovative control scheme for this integrated DF system that selected the more economical heating source (furnace or heat pump) while maintaining comfort in the home. The project’s field study and subsequent modeling analysis show that this control scheme can decrease energy use, cost, and emissions compared to a furnace-only system. As homes in mixed and cold climates transition to more electric space heating, furnace-to-dual fuel system retrofits offer a solution that can alleviate the retrofit costs, energy cost concerns, and peak load impacts of full electrification.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

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↗

Highly Resolved Reference Projections of Building Energy Use for the Contiguous United States: Building Sector Energy Baselines, Projection Methods, and Results

This report describes one methodology of projecting energy consumption of the US residential and commercial building sectors using NREL's ResStock™ and ComStock™ as well as growth rates derived from EIA's Annual Energy Outlook (AEO). The impetus for this work is to provide an intermediate method for compiling demand-side sectoral energy projections that is suitable for grid-scale analysis, such as NREL's Standard Scenarios. ResStock and ComStock are physics-based and statistically representative building stock models of the US residential and commercial sector, respectively. Using the 2012 actual meteorological year (AMY) weather data, the sectoral energy baselines are simulated and then segmented along key dimensions (e.g., geography, dwelling/building type). The segmented results are then scaled using the corresponding annual growth rates derived from the 2021 AEO reference case to produce energy projections out to 2050. The compiled result is a demand-side grid model (dsgrid) data set suitable for use in NREL's large-scale grid models, such as the Regional Energy Deployment System (ReEDS). This simple projection method does not endogenously represent how the building stock could evolve through time. Most notably, it does not reflect large-scale electrification, for example, the conversion of space heating, water heating, clothes drying, and cooking from primary fossil fuels to electricity, as this is not part of AEO's reference case assumptions. Nonetheless this approach is more resolved and potentially extensible compared to the current method used by Standard Scenarios's reference case, which augments a sector's total load based on a single growth rate from AEO.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Exploring Catalyst Compositions for Microwave-Assisted Methane Dehydroaromatization

The flaring of natural gas in U.S. shale regions remains a challenge for producers. One alternative to flaring is converting the wasted gas into valuable chemicals. Microwave-based processes offer a promising solution, potentially enabling the development of compact, modular systems for on-site production of chemicals, such as aromatics, from natural gas. This is due to the advantages of microwave heating, including efficient heating of compact volumes, accelerated reaction rates, and electrification of heating. However, developing effective catalysts for microwave-based processes is challenging, as conventional materials often require modification to be effectively heated by microwaves. This study provides an overview of a catalyst development project focused on a molybdenum-supported zeolite catalyst, optimized for the direct conversion of methane into aromatics under microwave irradiation. It details the synthesis, characterization, and the effects of promoters, as well as computational efforts undertaken to understand and enhance the catalyst's performance.

flare gas↗

Managing Increased Electric Vehicle Shares on Bulk Power Systems

The convergence of transportation electrification, other load growth, and the integration of many power sector technologies presents a complex planning problem requiring realistic, region-specific modeling and analysis to ensure the power system can support new loads quickly and affordably.

33 ADVANCED PROPULSION SYSTEMS↗

Hourly Load Profile Dataset for Electric Transit Bus Depots in the United States

Transit buses operate primarily in dense urban areas, where nearby populations face increased exposure to fine particulates, nitrogen oxides, and other harmful pollutants. Electrifying transit buses presents a clear opportunity to reduce greenhouse gas emissions and improve urban air quality. However, widespread adoption may pose significant energy and infrastructure challenges, which can be mitigated through proactive planning and investment. This report presents a robust modeling framework and an initial estimation of the hourly electricity demand at transit bus depots across the United States. The resulting depot-level dataset, available at data.nrel.gov/submissions/282, provides valuable insights for infrastructure planning and electricity demand forecasting, supporting the scalable electrification of transit bus fleets nationwide.

33 ADVANCED PROPULSION SYSTEMS↗

Research and Development on Advanced Electrochemical Energy Storage Devices Enabling a Spectrum of Electrified Vehicles

The USABC Advanced Battery development plan had the following three focus areas: 1. Existing technology validation, implementation, and cost reduction 2. Identification of the next viable technology with emphasis on the potential to meet USABC cost and energy density goals. 3. Support high-risk, high-reward battery technology R&D The primary aim of this project was focused on the barriers that most impede wider public adoption of electrification in vehicles-cost, energy density, low-temp performance, calendar life, and improvements in abuse tolerance. The specific objectives are as follows: Cost Reduction: drive to significantly reduce battery cost to be in-line with the $\$$100/kWh or less (by the end of calendar year 2020) DOE cost goals. Additionally, goals of $\$$75/KWh were set for 2023 aligned with fast charge and some offset of energy density. Energy Density Increase: focus on improving the cell-level specific energy and energy densities to >350 watt hours per kilogram (Wh/kg) and >750Wh/L. Low Temperature Performance Increase: strive toward developments that improve the discharge power and eliminate or dramatically reduce the life limiting lithium plating associated with regenerative braking at low temperatures, during the program. Calendar Life Increase: drive to achieve a 15-year calendar life. Abuse Tolerance Improvement: strive to develop improvements in Li-ion abuse tolerance and/or development of electrochemical energy storage technologies with inherently better response to abuse circumstances. Emerging Areas: initiate new programs that address emerging technologies that arise during the contract period.

25 ENERGY STORAGE↗

Multilayer Electrodes with Metalized Polymer Current Collector for High-Energy Lithium-Ion Batteries with Extreme-Fast-Charging Capability

The pursuit of batteries capable of extreme fast charging (XFC), that also satisfy high energy and safety criteria, poses a significant challenge to current lithium-ion battery technologies. Additionally, the increasing demand for aluminum (Al) and copper (Cu) in electrification, and vehicle lightweighting is driving these metals towards near-critical status in the medium term. This study introduced metalized polymer films by depositing an Al or Cu thin layer onto two sides of a polyethylene terephthalate (PET) film – named mPET/Al and mPET/Cu, as lightweight, cost-effective alternatives to traditional metal current collectors in LIBs.

25 ENERGY STORAGE↗

Glass Furnace Decarbonization Technology Stack (Final Technical Report)

This report summarizes the objectives, approach, and outcomes of the Glass Furnace Decarbonization Technology Stack project undertaken by Owens-Brockway Glass Container Incorporated under award number DE-CD0000093. The project aimed to implement a pioneering combination of furnace technologies at the Zanesville, OH manufacturing site to reduce carbon intensity (CI) by 20–40% compared to baseline operations. The proposed Furnace Technology Stack included a Gas/Oxy-fuel system, OPTIMELT™ Heat Recovery System, raw material pre-heating, electric boosting, and forehearth electrification—designed to demonstrate commercial feasibility and drive industry-wide decarbonization.

42 ENGINEERING↗

Integrated Distribution Planning

The contemporary distribution planning landscape is comprised of an increasing number of factors that require integration into the engineering of the modern electric grid. Expectations for electric utilities to accommodate heightened awareness of stakeholders' interest in things like decarbonization, resilience and equity are growing. As these interests are formed into objectives, many jurisdictions will experience increasing levels of load modifying technologies like DER, building and industrial electrification and electric vehicles which prove not only to challenge the capabilities of the grid; but the processes by which planning for it is traditionally done. Other related factors that strain the conventional distribution planning mold are the swelling amount and sources of data associated with these technologies and the need it creates for improved capabilities in the processes and tools that manage it. As the complexity of the distribution system expands, so will the distribution system's effects on the transmission and generation systems that it is a part of. Forecasting distribution system load and DER are examples of areas where this complexity will manifest, and harmonizing distribution forecasting with transmission and generation forecasting requires higher amounts of intentionality as these typically separate processes become a solitary one. Of course, core activities do not cease as a utility begins to integrate these other factors, and in this webinar we explore specifics of how distribution planning can be expected to evolve as progress towards Integrated Distribution System Planning is made.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Abstract for CRADA among NETL, Ohio University, and MetalKraft Technologies, LLC

The electrical grid faces challenges for meeting accelerated electricity demand arising from the electrification of building and transportation sectors. According to the DOE Grid Development Office, 70% of transmission lines are approaching the end of their lifecycle. The aging grid and insufficient transmission capacity necessitate the development of new technologies to improve overall grid performance. The conventional conductors used for electrical transmission lines suffer from substantial energy losses, high costs and low durability. These inefficiencies result in higher operational costs, increased energy waste, and difficulties in managing power flow. Improving the grid will require metals and composites with higher electrical conductivity and strength than the materials currently used. This CRADA will develop technologies to improve the grid by fabricating carbon metal composites with improved electrical, structural, and mechanical properties in comparison to metals that do not contain carbon additives. The composites will be made by incorporating carbon materials (graphite, graphene) into aluminum, copper, and other metals. The work will focus primarily on improving material properties that enhance the performance of these materials in electrical conductor applications.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Summary of Pilot Project State Technical Assistance on Multi-Sector Analysis for Electric and Petroleum Fuels

The Oregon Energy Security Plan, (ODOE 2024) published in September 2024, builds a strong case for the state to give acute attention to the fuel supply chain. In December 2024, Pacific Northwest National Laboratory (PNNL) in partnership with Oregon Department of Energy (ODOE), announced a pilot project to conduct an analysis that synthesizes current and projected transportation fuel dynamics, supply chain risks, and risk comparators with relevant sectors, such as transportation electrification, sponsored by the Department of Energy’s (DOE) Office of Cybersecurity, Energy Security, and Emergency Response (CESER). The study, is intended to leverage existing modeling and frameworks from a recent 2024 sector coupling analysis supported by the DOEs Office of Electricity (OE) (B. Mitra, S. Pal, et al., Coupling of the Electricity and Transportation Sectors - Part I: Sector Overviews 2024) (B. Mitra, S. Pal and J. Reeve, et al. 2024). While the PNNL team set out to conduct a quantitative risk analysis driven by detailed data that synthesizes current and projected transportation fuel dynamics, supply chain risks, and risk comparators with relevant sectors. The intention was to provide an approach that could be extendable to other parts of the country. They encountered data limitations and adjusted their approach accordingly. This report summarizes PNNL's original plan for executing the study, including limitations for obtaining data requirements for fuel flows and interim products, as well as a risk matrix that can be used to identify supply chain risks.

02 PETROLEUM↗