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At least 343 records · Page 19
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Manufacturing Supply Chain Development for Modular Solar-Thermochemical Conversion Platform - CRADA 387 (Final Report)

Modular chemical process intensification (MCPI) is an emerging field where chemical processing is performed using small-scale modular equipment instead of conventional large centralized chemical plants. Conventional chemical plants benefit from economies of scale that encourage scale-up to ever larger plants. A goal of MCPI is to develop technology that intensifies processing so that equipment can be dramatically smaller and integrated into modular systems. Scale-up occurs by adding more modules in parallel rather than making the equipment larger. A key concept is that equipment and modules can ultimately be cheaper by leveraging economies of mass production, analogous to the automotive industry, in manufacturing the equipment. This project made significant progress toward this outcome by meeting the RAPID institute metric to reduce equipment cost by 20% for each doubling in manufacturing volume. The MCPI application was thermochemical technology that is being commercialized by STARS Technology Corporation, one of the CRADA partners. The technology converts solar and renewable power to chemical energy to produce renewable hydrogen, fuels, and chemicals. The benefit to the public is reduction in greenhouse gases that are contributing to climate change. The project transitioned the steam methane reforming (SMR) reactor from conventional fabrication methods to additive manufacturing (AM) direct metal laser sintering (DMLS) process. This is projected to reduce the cost of making a reactor by 58% when producing 100 reactors per year. Innovations in the DMLS process produced a patented design that reduces reactor weight by 60%. Reductions in material costs and processing time extend the DMLS advantage to higher production volumes. The new design promises to be 38% cheaper than the conventional processes at 1000 units per year. The resulting 87% reduction in the steam methane reforming (SMR) module cost in scaling from current costs meets the RAPID metric. The project was successful in producing and testing the first ever additively manufactured SMR reactors. A reactor achieved over 82% efficiency in converting electric power to chemical energy, which is a world record for an inductively heated SMR. The project has contributed to the design and assembly of a first demonstration plant that is headed to a hydrogen bus filling station in Thousand Palms, CA.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Evaluation of Low-Pressure-Sintered Multi-Layer Substrates for Medium-Voltage SiC Power Modules: Preprint

Direct-bonded aluminum (DBA) multi-layer substrates have been fabricated using low-pressure silver sintering. These multi-layer substrates can be used to reduce the peak electric field strength inside power modules. This benefit is particularly important for medium-voltage silicon carbide (SiC) MOSFETs due to their higher operating voltages. The voiding content and defect density of the bond used to create the multi-layer substrate stackup is critical to the thermal performance and reliability of the power module. This work two low-pressure-assisted sintering techniques; one using nano-silver preform and the other using nano-silver paste to bond 23 mm by 49 mm DBA substrates. Scanning acoustic microscopy (C-SAM) is used to evaluate the bond quality after sintering. To evaluate the reliability of the sintered multi-layer substrates, passive thermal cycling from –40 °C to 200 °C was performed. Cross-sections were cut at pre-determined intervals and imaged with Scanning Electron Microscopy (SEM). After 1,000 thermal cycles, minor cracking was observed, but no failures have occurred.

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

In vitro enhancement of Zika virus infection by preexisting West Nile virus antibodies in human plasma-derived immunoglobulins revealed after P2 binding site-specific enrichment

ABSTRACT Human immunoglobulin preparations contain a diverse range of polyclonal antibodies that reflect past immune responses against pathogens encountered by the blood donor population. In this study, we examined a panel of intravenous immunoglobulins (IGIVs) manufactured over the past two decades (1998–2020) for their capacity to neutralize or enhance Zika virus (ZIKV) infectionin vitro. These IGIVs were selected specifically based on their production dates in relation to the occurrences of two flavivirus outbreaks in the U.S.: the West Nile virus (WNV) outbreak in 1999 and the ZIKV outbreak in 2015. As demonstrated by enzyme-linked immunosorbent assay (ELISA) experiments, IGIVs made before the ZIKV outbreak already harbored antibodies that bind to various peptides across the envelope protein of ZIKV because of the WNV outbreak. Using phage display, the most dominant binding site was mapped precisely to the P2 peptide between residues 211 and 230 within domain II, where BF1176-56, an anti-ZIKV monoclonal antibody, also binds. When tested in permissive Vero E6 cells for ZIKV neutralization, the IGIVs, even after undergoing rigorous enrichment for P2 binding specificity, failed, as did BF1176-56. Meanwhile, BF1176-56 enhanced ZIKV infection in both FcγRII-expressing K562 cells and human peripheral blood mononuclear cells. However, for enhancement by the IGIVs to be detected in these cells, a substantial increase in their P2 binding specificity was required, thus linking the P2 site with ZIKV enhancementin vitro. Our findings warrant further study of the significance of elevated levels of anti-WNV antibodies in IGIVs, considering that various mechanisms operatingin vivomay modulate ZIKV infection outcomes. IMPORTANCE We investigated the capacity of intravenous immunoglobulins manufactured previously over two decades (1998–2020) to neutralize or enhance Zika virus infectionin vitro. West Nile virus antibodies in IGIVs could not neutralize Zika virus initially; however, once the IGIVs were concentrated further, they enhanced its infection. These findings lay the groundwork for exploring how preexisting WNV antibodies in IGIVs could impact Zika infection, bothin vitroandin vivo. Our observations are historically significant, since we tested a panel of IGIV lots that were carefully selected based on their production dates which covered two major flavivirus outbreaks in the U.S.: the WNV outbreak in 1999 and the ZIKV outbreak in 2015. These findings will facilitate our understanding of the interplay among closely related viral pathogens, particularly from a historical perspective regarding large blood donor populations. They should remain relevant for future outbreaks of emerging flaviviruses that may potentially affect vulnerable populations.

Microbiology↗
DOE OSTI2020

One piece ceramic heat exchanger for concentrating solar power electric plants

Using additive manufacturing techniques, a ceramic heat exchanger was optimized for a concentrating solar power (CSP) electric power plant with a corrosive molten salt at atmospheric pressure as the solar field heat transfer fluid and supercritical carbon dioxide at 200 bar as the power block fluid. Temperatures ranged from 750 °C to 540 °C. The plant heat exchanger was optimized for heat transfer and stress using 1 m³ modules arranged in parallel. Heat transfer was optimized using COMSOL Multiphysics software resulting in a unique semi-elliptical cross section for the fluid flow channels in a counter-flow configuration. Counter-flow was made possible through additive manufacturing of the fluid headers as part of each modular heat exchanger thus producing the entire module as a single piece and minimizing cost. Using reasonable parametric values, a heat exchanger module was optimized to 0.5 MW/m³, and a section of it was manufactured including the fluid headers. Here, parametric studies showed the potential for a module to reach 3.5 MW/m³.

14 SOLAR ENERGY↗
DOE OSTI2015

SU-E-I-24: Method for CT Automatic Exposure Control Verification

Purpose: Design of a phantom and a simple method for the automatic exposure control (AEC) verification in CT. This verification is included in the computed tomography (CT) Spanish Quality Assurance Protocol. Methods: The phantom design is made from the head and the body phantom used for the CTDI measurement and PMMA plates (35×35 cm2) of 10 cm thickness. Thereby, three different thicknesses along the longitudinal axis are obtained which permit to evaluate the longitudinal AEC performance. Otherwise, the existent asymmetry in the PMMA layers helps to assess angular and 3D AEC operation.Recent acquisition in our hospital (August 2014) of Nomex electrometer (PTW), together with the 10 cm pencil ionization chamber, led to register dose rate as a function of time. Measurements with this chamber fixed at 0° and 90° on the gantry where made on five multidetector-CTs from principal manufacturers. Results: Individual analysis of measurements shows dose rate variation as a function of phantom thickness. The comparative analysis shows that dose rate is kept constant in the head and neck phantom while the PMMA phantom exhibits an abrupt variation between both results, being greater results at 90° as the thickness of the phantom is 3.5 times larger than in the perpendicular direction. Conclusion: Proposed method is simple, quick and reproducible. Results obtained let a qualitative evaluation of the AEC and they are consistent with the expected behavior. A line of future development is to quantitatively study the intensity modulation and parameters of image quality, and a possible comparative study between different manufacturers.

07 ISOTOPE AND RADIATION SOURCES↗
DOE OSTI2022

Reliability Evaluation of Bifacial and Monofacial Glass/Glass Modules with EVA and non-EVA Encapsulants

The market share for bifacial modules is projected to be doubled from 30% to 60% in the next ten years. For the monofacial crystalline silicon glass/backsheet (G/B) modules, extensive reliability data has been available for over 40 years. However, practically little/no long-term field or accelerated reliability test data is available for the new generation glass/glass (G/G) bifacial modules and glass/transparent (G/T) bifacial modules. Therefore, the primary motivation of this project was to identify the reliability strengths and weaknesses of new generation G/G modules compared to G/B modules. In this 3-year project, the goal was to objectively recommend the best construction materials for the new generation G/G (bifacial) modules through a systematic experimental approach with appropriate tasks including: Evaluation of field retrieved old-generation G/G modules; Inspection of new-generation G/G modules installed in the plants; Evaluation of new-generation G/G, G/B and G/T modules using EAST (Extended Accelerated Stress Testing), CAST (Combined Accelerated Stress Testing) and FAST (Field Accelerated Stress Testing); and, dynamic literature search and review. Major accomplishments and outcomes of this project are: Accomplishments: Evaluated more than 60 field retrieved modules and constructed and characterized more than 135 mini-modules with three substrate types (G, B, and T), two encapsulant types (EVA and POE), and two cell types (monofacial and bifacial) as well as evaluated more than 30 commercial G/G and G/B modules; Subjected all the modules to multitude characterization tests and various indoor and outdoor accelerated stress tests including FAST (Field Accelerated Stress Testing), EAST (Extended Accelerated Stress Testing), and CAST (Combined Accelerated Stress Testing) to identify and correlate the failure modes in both field and lab tests. Outcomes: Based on the accelerated test results and handling/mounting experience obtained in this project, the recommended best construction for the glass/glass modules is: “Framed GG modules with cut-cells and POE encapsulant (UVpass front; UVpass back).” However, from a statistical and manufacturing point of view (along with stakeholders surveys), the following cautionary notes are added to the above-mentioned recommendation: (i) Cut cells could introduce a higher level of manufacturing issues, including a higher number of cell interconnects; (ii) POE encapsulant is more expensive than EVA and could present a delamination risk and lower throughput during manufacturing due to lower adhesion strength. Other encapsulants, such as coextruded EPE (EVA/POE/EVA), are also recommended to be investigated. The potential public benefit of the proposed project is to present the strengths and weaknesses of glass/glass modules, so an informed procurement decision can be made.

14 SOLAR ENERGY↗
DOE OSTI2026

Tandem Photovoltaics Core Program Final Technical Report

The Tandem Photovoltaics Core Program was a multi-year initiative aimed at advancing hybrid tandem solar cell technologies to enhance solar module efficiency beyond the limits of single junction devices. This project focused on the development, testing, and scaling of prototype photovoltaic devices, with the goal of achieving commercial relevance and driving industry adoption. The work was divided into three tasks: 1) Comparative Analysis of Tandem Technologies: This task focused on quantifying energy yield under real-world conditions and assessing economic viability of tandems relative to silicon-based modules. The project's modeling framework incorporated performance data, cost of materials, and manufacturing process impacts to optimize tandem designs 2) Tandem Integration and Prototyping: In this task, we developed innovative tandem designs by combining metal halide perovskite (MHP) top cells and silicon (Si) bottom cells. The project focuses on both mechanical integration and direct deposition techniques to enable compatibility with commercially relevant Si technologies, such as passivated contact or PERC cells. 3) Scale-up and Reliability: This task addressed the challenges of large-area fabrication by developing scalable deposition methods and robust interconnection schemes for tandems. The project looked at different accelerated testing such as thermal cycling, damp heat exposure, and potential induced degradation, to ensure long-term stability of devices in field conditions. Tandem solar cells can greatly increase module efficiency beyond conventional single junction (SJ) devices, which are approaching their theoretical limit. There are many ways to fabricate a tandem cell or module in terms of materials used, configuration, and terminal connection. This SETO core project focused critical factors in enabling tandems to enter the market, including hardware integration, technoeconomic analysis (TEA), and energy yield analysis. We focused on MHP/Si hybrid tandem solar cells and modules as a model system for their versatility in module design comparisons, providing valuable insights for other tandem options. While champion cells with areas <1cm2 are regularly demonstrated by groups around the world, it is significantly more challenging to translate these advances into modules, and fewer institutions and companies are working at the module level. This project addressed questions about module fabrication, testing, and reliability that are hard to answer without actually fabricating prototypes. We also performed analysis and road-mapping activities to understand the potential for a wider variety of tandems, including all-perovskite tandems fabricated in collaboration with the Perovskite PV core program. Detailed technical results from this project are described for each task in Section 7.

14 SOLAR ENERGY↗
DOE OSTI2024

Design of Modular Test Facility for Particle/sCO2 Heat Exchanger Evaluation

Heliogen has designed a 1.3 MW particle and supercritical carbon dioxide (sCO2) test loop to retire technical and manufacturing risks. The data from this facility will be used to validate near commercial-scale particle heat exchanger modules. The heat exchanger is scaled to capture all features of the full-scale modules. Testing will be conducted with CARBOBEAD HSP 16/30, a larger particle size than other recent testing. The system was designed to ASME codes with the constraint that sCO2 piping and other major components are stainless steels.

14 SOLAR ENERGY↗
DOE OSTI2016

Expanding the modular ester fermentative pathways for combinatorial biosynthesis of esters from volatile organic acids

ABSTRACT Volatile organic acids are byproducts of fermentative metabolism, for example, anaerobic digestion of lignocellulosic biomass or organic wastes, and are often times undesired inhibiting cell growth and reducing directed formation of the desired products. Here, we devised a general framework for upgrading these volatile organic acids to high‐value esters that can be used as flavors, fragrances, solvents, and biofuels. This framework employs the acid‐to‐ester modules, consisting of an AAT (alcohol acyltransferase) plus ACT (acyl CoA transferase) submodule and an alcohol submodule, for co‐fermentation of sugars and organic acids to acyl CoAs and alcohols to form a combinatorial library of esters. By assembling these modules with the engineered Escherichia coli modular chassis cell, we developed microbial manufacturing platforms to perform the following functions: (i) rapid in vivo screening of novel AATs for their catalytic activities; (ii) expanding combinatorial biosynthesis of unique fermentative esters; and (iii) upgrading volatile organic acids to esters using single or mixed cell cultures. To demonstrate this framework, we screened for a set of five unique and divergent AATs from multiple species, and were able to determine their novel activities as well as produce a library of 12 out of the 13 expected esters from co‐fermentation of sugars and (C2‐C6) volatile organic acids. We envision the developed framework to be valuable for in vivo characterization of a repertoire of not‐well‐characterized natural AATs, expanding the combinatorial biosynthesis of fermentative esters, and upgrading volatile organic acids to high‐value esters. Biotechnol. Bioeng. 2016;113: 1764–1776. © 2016 Wiley Periodicals, Inc.

Layton, Donovan S.↗
DOE OSTI2018

Scalable fabrication of perovskite solar cells

Perovskite materials use earth-abundant elements, have low formation energies for deposition and are compatible with roll-to-roll and other high-volume manufacturing techniques. These features make perovskite solar cells (PSCs) suitable for terawatt-scale energy production with low production costs and low capital expenditure. Demonstrations of performance comparable to that of other thin-film photovoltaics (PVs) and improvements in laboratory-scale cell stability have recently made scale up of this PV technology an intense area of research focus. Here, we review recent progress and challenges in scaling up PSCs and related efforts to enable the terawatt-scale manufacturing and deployment of this PV technology. We discuss common device and module architectures, scalable deposition methods and progress in the scalable deposition of perovskite and charge-transport layers. We also provide an overview of device and module stability, module-level characterization techniques and techno-economic analyses of perovskite PV modules.

14 SOLAR ENERGY↗
DOE OSTI2020

Analysis and Evaluation of Thermally Annealed Pyrolytic Graphite Heat Spreader for Power Modules

Next generation power modules demand increased heat extraction capability along with reduced weight and volume. In this paper, thermally annealed pyrolytic graphite (TPG) is analyzed and compared with conventional materials used in power modules for thermal management. Fundamental properties of TPG are explained and compared with commonly used materials in power module heat spreaders and substrates. The encapsulated TPG based heat spreader is manufactured and compared with bulk copper in simulation and experimental based analysis. The results show that encapsulated TPG based heat spreader achieves more than 50% reduction in thermal resistance along with 48% reduction in weight in the heat spreader layer.

Gurpinar, Emre↗
DOE OSTI2018

Advanced QPSK Optical Modulators Using Lithium Niobate Thin Films (Final Scientific Report)

Lithium niobate thin film based optical modulator devices have been produced using this SBIR award. A bonding apparatus was developed that was used to bond lithium niobate to silicon at room temperature. The bonding apparatus was designed, assembled and qualified for production of thin film substrates. The optical properties of ion sliced thin films produced using this bonding apparatus was optimized to achieve low loss optical waveguides. Optical grating coupler and other component of the proposed optical modulator were designed. Preliminary results show the proposed method for making optical modulator meets the required customer specifications. All the required process steps for manufacturing of the devices were developed and optimized. Further funding is required to make a final prototype device that can be provided to customers.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Water Footprint of European Rooftop Photovoltaic Electricity based on Regionalised Life Cycle Inventories

The water use of photovoltaic (PV) electricity has been investigated in very few studies so far, which may be due to the low water demand of PV systems during operation. In this study, the water consumption and water withdrawal of electricity generated by PV systems were assessed by considering all life cycle stages and by taking account of country-level regional differences in water availability. The life cycle inventories of the manufacture of monocrystalline silicon (mono-Si) and cadmium telluride (CdTe) PV modules are based on data collected between 2010 and 2013 and take account of the shares of different countries in total global production. The water use in the life cycle inventories of European rooftop PV systems and conventional electricity generation technologies was regionalised to the country or region (such as continents, political or geographic entities of several countries) level and complemented by the share of water lost by evaporation. The AWARE (Available WAter REmaining) method was used to assess the water stress impact caused by water consumption and water withdrawal of electricity generation by European rooftop PV systems as well as by reservoir hydroelectric power plants and large-scale hard coal and nuclear power plants in Europe. The functional unit of this analysis is 1 kWh of alternating current (AC) electricity (at busbar). The life cycle inventories were linked to KBOB (Coordination Group for Construction and Property Services) life cycle inventory data DQRv2:2016, which are based on ecoinvent data v2.2 and contain updated life cycle inventory data in relevant economic sectors. This study was financed by the Swiss Federal Office of Energy (SFOE) and carried out in the framework of the Task 12 of the Photovoltaic Power Systems Programme (PVPS) of the International Energy Agency (IEA).

14 SOLAR ENERGY↗
DOE OSTI2026

Upstream Extraction of Tellurium from Copper Concentrates

A major barrier to increasing CdTe PV module production is the availability of tellurium (Te), an element necessary to manufacture CdTe PV cells that currently has a very limited supply. Most Te is obtained from ore extracted for copper mining, but the current processing methods only extract 3-4% of the available Te in this ore, with the rest being discarded during other processing steps. This project aims to increase Te supply by developing an innovative extraction method that will recover more Te from the copper ore earlier in the process. This method will also extract toxic elements like antimony and arsenic, making the copper mining process more environmentally friendly.

14 SOLAR ENERGY↗
DOE OSTI2018

Spectral-Modulation Characteristics of Vertical-Cavity Surface-Emitting Lasers

The requirements imposed on vertical-cavity surface-emitting lasers in a number of metrological problems in which optical pumping of alkali atoms is used are considered. For lasers produced by different manufacturers, these requirements are compared with the experimentally observed spectral characteristics at a constant pump current and in the microwave modulation mode. It is shown that a comparatively small number of lasers in the microwave modulation mode make it possible to obtain the spectrum required for atomic clocks based on the coherent population-trapping effect.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2021

A Circular Economy for Solar Photovoltaic System Materials: Drivers, Barriers, Enablers, and U.S. Policy Considerations

As PV capacity increases, owners are also decommissioning older system assets. Estimates based on a 30-year lifetime assumption found that cumulative U.S. end-of-life (EoL) PV modules could total one million metric tons (Mt) by 2030 and up to 10 million Mt by 2050 (Weckend, Wade, and Heath 2016). Beyond maintenance replacements, early retirements that are due to efficiency upgrades and extreme weather, as well as PV deployment beyond earlier expectations, would increase these projections. PV system owners must evaluate equipment management options for used modules and system components retired during maintenance activities, refurbishment, repowering and system decommissioning. PV manufacturers must also evaluate material management options from customer returns, defects, and scrap. Management options for early retired and EoL PV system material include reuse, repair for reuse, recycling-based resource recovery, storage, and disposal. Disposal of PV system material increases the burden on landfill capacity, while reuse, repair for reuse, and recycling-based resource recovery (reuse/repair/recovery) options salvage valuable materials and provide secondary market opportunities and ancillary benefits (Weckend, Wade, and Heath 2016; EPA 2019c; SWEEP 2019). PV system owners may also decide store used modules and components as spares, or in the interim before a reuse or EoL management decision is made. Despite potential secondary market opportunities and the potential benefits associated with the repair/reuse/recovery of PV system material, anecdotal evidence suggests that in the United States decommissioned PV modules are stored, landfilled or otherwise disposed of (Salim et al. 2019; CPUC 2019b; DTSC 2019b; NREL 2019a). Some modules are being disposed of in municipal nonhazardous landfills and federally regulated hazardous treatment, storage, and disposal facilities, and others are being stored in warehouses until economically viable repair/reuse/recycling becomes available (CPUC 2019b; DTSC 2019b; NREL 2019a; Libby and Shaw 2018). As awareness of current practices grows, and the demand for critical PV module material increases, U.S. industry stakeholders, regulators, and policymakers are starting to (1) consider solutions to drive and enable environmentally sustainable materials management decisions and behaviors and (2) identify barriers to a circular economy for PV system materials. Circular economy principles attempt to transition from a "take-make-consume-dispose" linear economic system to a circular system that allows for the long life, and the reuse/repair/recovery of products and materials (Ellen MacArthur Foundation 2020). We begin this report by summarizing the drivers, barriers, and enablers to a circular economy for PV system materials in the United States. We then report on our analysis of federal and state regulatory considerations that may impact the repair/reuse/recovery of PV materials, and potential civil and criminal liabilities associated with noncompliance. We then discuss state policies and initiatives in the United States that expressly address PV system decommissioning and repair/reuse/recovery of PV materials. We conclude by providing case studies of U.S. business models for the repair/reuse/recovery of PV system materials. Our results are based on legal and literature-based research and interviews with solar industry stakeholders, regulators, and policymakers.

14 SOLAR ENERGY↗
DOE OSTI2024

High-throughput homogenization of a quasi-Gaussian ultrafast laser beam using a combined refractive beam shaper and spatial light modulator

Efficiently shaping femtosecond, transverse Gaussian laser beams to flat-top beams with flat wavefronts is critical for large-scale material processing and manufacturing. Existing beam shaping devices fall short either in final beam homogeneity or efficiency. Here, we present an approach that uses refractive optics to perform the majority of the beam shaping and then uses a fine-tune device (spatial light modulator) to refine the intensity profile. For the beam that we selected, circularly asymmetric with intensity fluctuations, our method achieved a uniformity of 0.055 within 90% of the beam area at 92% efficiency. The optimization involved an iterative beam shaping process that converged to optimum within 10 iterations.

43 PARTICLE ACCELERATORS↗