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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 343 records · Page 19
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Improved Solid-State Reaction Method for Scaled-Up Synthesis of Ceramic Proton-Conducting Electrolyte Materials

Protonic ceramic electrochemical cells (PCECs) represent promising technologies in the production of clean electricity, decarbonized hydrogen, chemicals, and fuels at intermediate temperatures. One of the challenges in commercializing PCECs is to produce the electrolyte materials on a large scale. The conventional solid-state reaction (SSR) method suffers from tedious synthesis procedures and low phase purity of the products due to the formation of unwanted secondary phases. Herein, we report an improved SSR (i-SSR) method for kilogram-scale production of high phase-purity electrolyte material BaZr 0.4 Ce 0.4 Y 0.1 Yb 0.1 O 3–δ (BZCYYb4411). In this method, the ball-milled precursor powders are pelletized prior to calcination, which effectively reduces the length of the diffusion paths between the components during perovskite phase formation. In this study, the synthesis procedure and calcination temperature are carefully optimized for efficient and repeatable production based on the powder crystallization behavior. A combined technoeconomic analysis and life cycle assessment modeling suggest that the i-SSR method could reduce the total production cost and greenhouse gas emissions by up to 19% and 39%, respectively, compared to the conventional SSR method. The high quality of the synthesized electrolyte material is corroborated by the excellent electrical conductivity and electrochemical performance of the fabricated PCEC cells.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Synthesis of 2D layered transition metal (Ni, Co) hydroxides via edge-on condensation

Abstract Layered transition metal hydroxides (LTMHs) with transition metal centers sandwiched between layers of coordinating hydroxide anions have attracted considerable interest for their potential in developing clean energy sources and storage technologies. However, two-dimensional (2D) LTMHs remain largely understudied in terms of physical properties and applications in electronic devices. Here, for the first time we report > 20 μm α-Ni(OH) 2 2D crystals, synthesized from hydrothermal reaction. And an edge-on condensation mechanism assisted with the crystal field geometry is proposed to understand the 2D intra-planar growth of the crystals, which is also testified through series of systematic comparative studies. We also report the successful synthesis of 2D Co(OH) 2 crystals (> 40 μm) with more irregular shape due to the slightly distorted octahedral geometry of the crystal field. Moreover, the detailed structural characterization of synthesized α-Ni(OH) 2 are performed. The optical band gap energy is extrapolated as 2.54 eV from optical absorption measurements and the electronic bandgap is measured as 2.52 eV from reflected electrons energy loss spectroscopy (REELS). We further demonstrate its potential as a wide bandgap (WBG) semiconductor for high voltage operation in 2D electronics with a high breakdown strength, 4.77 MV/cm with 4.9 nm thickness. The successful realization of the 2D LTMHs opens the door for future exploration of more fundamental physical properties and device applications.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

Picolinate-based acyclic ligand for rare earth element extraction and separation

The rare earth elements (REEs) play an important role in many modern technologies, particularly those relevant to clean energy. Despite their increasing importance, obtaining them in elementally pure forms suitable for downstream applications is challenging due to their similar chemical properties. This problem has impeded efforts to efficiently and selectively extract them from end-of-life materials and electronic waste. Here, we report a cost-efficient acyclic picolinate-based chelator H 4 aapa. The REE stability constants (log K ML ) of this chelator were measured via pH potentiometric and UV-Visible spectrophotometric titrations, revealing it to preferably bind light over heavy REEs like many recently reported 18-membered macrocycles. Its REE complexes were characterized by X-ray crystallography and NMR spectroscopy, demonstrating that this chelator can attain different conformations. The unique properties of aapa were subsequently used to separate REEs via the dissolution of insoluble REE oxalate mixtures. This dissolution-based separation led to large separation factors, the most significant being that for the Ce 3+ /Lu 3+ pair (38.6) at pH 4. Leveraging the strong REE binding affinity of aapa, we further demonstrated this chelator can leach REEs from authentic end-of-life materials in the form of magnet waste and autocatalyst smelting (autocat) slag. With this approach, exposure of these materials to a 20 mM solution of aapa at neutral pH generates a metal-containing solution enriched in Nd 3+ and Dy 3+ by 56.9 wt% and 3.0 wt%, marking a 4-fold improvement over the use of 4 M HNO 3 .

Gao, Yangyang [University of California, Santa Bar↗
DOE OSTI2020

Cost Efficient and Highly Weather-Resistant Solar Panel Backsheet Produced through Continuous Co-Extrusion Processing

The efficient generation and delivery of ‘clean energy” through photovoltaic (PV) technology relies heavily on the cost, performance and reliability of solar panels, along with the individual components used in assembly of those panels. In order to continue towards the Department of Energy’s (DOE) goals of driving costs down, the lifetime of high-output power generation equipment (i.e. solar modules) must be extended to reduce costs associated with power output degradation and replacement of failed or degraded panels. One of the major sources of module failures in the past 30 years has been the failure of the solar panel backsheet. Failure of this component causes severe output losses due to oxidation and yellowing of the module while creating safety concerns as the major electrical insulation of the module is compromised. Tomark-Worthen LLC was formed in 2012 with the goal of designing and manufacturing novel PV backsheets and encapsulants that would be produced in the United States of America and exceed expectations of domestic and international module producers. These backsheets would improve upon known backsheet design failures (i.e. Isovoltaic’s AAA backsheet) and create domestic manufacturing jobs in the PV sector. This goal became a reality with a first-generation product in 2018 and now, with the support of the DOE, Tomark-Worthen has launched a second-generation product known as PhotoMark® Reflections™ 205-3 and 360-3. This 2+ year effort began in late 2017 with a screening of potential polymeric materials and backsheet structural designs. Performance evaluations of each material provided the necessary data needed to select the proper material combinations and move forward into the design of the manufacturing process. These decisions were made by teaming with a local university, well-respected government laboratories, and private research organizations who provided the tools necessary to predict long-term performance of these materials in much shorter periods of time. Once the go/no-go criteria were met at the mid-point of the project, the effort transitioned to predicting 30+ year performance, achieving certifications, and improving manufacturing efficiencies designed to lower costs in order to be competitive in a cost-driven market. Major project accomplishments include recognition of the new backsheet by Underwriters Laboratories (UL) and international certification for 1000V and 1500V modules by TUV Sud. Both 1000V and 1500V products have been proven on several module manufacturing lines and initial customer orders have been received by both domestic and international module producers. Accelerated exposure testing has shown that the performance of this backsheet exceeds the prior polyamide-based backsheet known to fail in the field. Cost-models and initial customer orders have shown the ability to produce this backsheet at a cost acceptable to many domestic manufacturers, while International costs for standard backsheet remains extremely low. Tomark-Worthen remains one of the only U.S. companies manufacturing backsheet domestically and this has drawn interest from many domestic module manufacturers looking to improve their material supply logistics by avoiding long lead times and custom’s headaches while avoiding current tariffs on Chinese-made components. Along with the launch of a new PV backsheet, this project has provided a critical deliverable to the PV R&D community. This deliverable is the knowledge that not all polyamide-containing backsheets are doomed to failure as the earlier versions did. There has been a fear amongst the PV community to consider these materials due to the failure of one design. This effort has brought a new level of interest to the scientific community as it has been shown that polyamides can be used successfully in a well-designed backsheet. As we move forward from this project, we are excited to see how backsheet technology and manufacturing in the U.S. will continue to progress and grow.

14 SOLAR ENERGY↗
DOE OSTI2022

Reliability and Resiliency in South Asia's Power Sector - Pathways for Research, Modeling, and Implementation

Reliability and resilience are the core principles of power system planning and operations around the world. Power systems in South Asia are transforming with increasing penetration of clean energy generation resources, emerging technologies, increasing electricity demand and electrification. At the same time, these power systems are facing challenges posed by extreme weather events and climate change. All these factors would add furthermore importance to the reliability and resilience of future power systems in South Asia. This has motivated us to better understand the country specific challenges and chalk out the pathways for research, modelling and implementation in South Asia. Our research, experience in the region and feedback from key stakeholders indicate following as the key areas where more work is needed to improve reliability and resilience of power systems in the region: Renewable energy Data for power system studies, New Tools and Studies, Resilience Planning, Resource Adequacy, Advanced RE Forecasting, Cybersecurity, Load Forecasting, and Coordinated Planning and Operations.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2022

Electricity demand in South Asia – data gaps and pathways for research and modeling

South Asia is one of the fastest growing regions - economically and energy-wise in the world. However, there are significant uncertainties in how the energy demand would grow given the rapidly rising incomes, urbanization, industrialization, access to energy, warming climate and technological change. The transition to clean energy in the region is a priority and is critical to limiting emissions in the region and increasing regional energy security. The power sector will play an important role in decarbonization of energy systems, lowering emissions in other sectors through electrification. However, as existing end uses are scaled up more and new end uses are electrified, the temporal and spatial patterns of electricity consumption could change. These changes have implications for the magnitude, shape, and timing of peak demand, which in turn affects the power sector’s investments and operations, and ability to provide reliable power. In this report, we outline key uncertainties in demand growth that South Asian countries would face in the near to medium term, along with summarizing insights from stakeholder consultations we held over the past 6 months.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2025

Next-Generation Energy Technologies for Connected and Automated On-Road Vehicles (NEXTCAR) - Predictive Data-Driven Vehicle Dynamics and Powertrain Control: from ECU to the Cloud (Final Scientific/Technical Report)

This project developed and demonstrated a predictive, data-driven vehicle control system designed to improve energy efficiency and driving performance. The team created intelligent self-driving car technology that optimizes fuel and electricity use by proactively planning vehicle actions. By combining Level 4 autonomous driving capabilities with vehicle-to-everything (V2X) connectivity, the system enables vehicles to adjust speed and change lanes in response to traffic signals, surrounding vehicles, and road conditions, reducing unnecessary stops and delays. In testing, the system improved vehicle fuel economy by more than 30% and reduced travel time by approximately 10%, compared to a conventional adaptive cruise control baseline. These results demonstrate the technical effectiveness of using predictive, V2X-enabled strategies, such as traffic light timing and surrounding traffic awareness, to inform real-time vehicle powertrain control and driving behavior. Additionally, a supporting cloud platform was developed to provide dispatch and route recommendations as well as to log vehicle data, demonstrating the economic feasibility of this approach at the fleet level. By optimizing dispatching and routing operations, this technology enables electric fleet operators to use their vehicles more efficiently and reduce reliance on diesel backups, lowering both operating costs and energy consumption. Overall, this project’s technology advances the future of clean, energy-efficient transportation, enabling vehicles and fleets to reduce energy waste, cut costs, and lower emissions through intelligent automation and connectivity.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

Optimizing the combustion synthesis of FeAlxOy catalysts for microwave-assisted thermocatalytic dehydrogenation of fossil fuels

The growing demand for hydrogen requires the development of clean and energy-efficient technologies for its synthesis. Microwave-assisted thermocatalytic dehydrogenation of fossil fuels has demonstrated the potential to produce H2 with high yield and selectivity, and simultaneously generate valuable nanostructured carbon byproducts. In prior work, iron-based alumina (FeAlxOy) catalysts for this process were made via solution combustion synthesis (SCS). However, the effect of SCS parameters on the dehydrogenation performance is not well understood. The present study investigates this by varying the SCS fuel, Fe:Al molar ratio, and heating mode. The results show subtle changes of these parameters can result in significant differences in the phase composition, specific surface area, and microwave absorbing properties of FeAlxOy, which all affect microwave-assisted dehydrogenation. Notably, H2 selectivity can be increased from 30% to 74%. Statistical testing determined that the SCS fuel used was the most significant SCS parameter affecting dehydrogenation performance.

Chanoi, Zachary A.↗
DOE OSTI2024

Sonic Wafering of III-V substrates for High Efficiency Cells: A path to <$0.50/W

This project developed and demonstrated Sonic Lift-off, a novel technology that enables the reuse of expensive semiconductor substrates used to manufacture high-efficiency solar cells. By using sound waves to precisely separate thin layers of material, the process significantly reduces manufacturing costs while maintaining the performance of advanced III–V solar cells. These solar cells are among the most efficient in the world and are used in space, aerospace, and emerging terrestrial applications. The results of this work show that substrate reuse can be achieved without degrading device performance, offering a pathway to more affordable, high-performance solar technologies. This advancement supports U.S. clean energy goals by enabling broader deployment of renewable energy systems and strengthening domestic manufacturing capabilities in advanced photovoltaics.

14 SOLAR ENERGY↗
DOE OSTI2023

Comparing Numerical Models of the TALOS Wave Energy Converter

In this study, we present the development of a numerical model of the TALOS Wave Energy Converter (WEC) in WEC-Sim and compare it with existing numerical in-house models from Lancaster and results from DNV's Sesam code. The objective of this work is to validate the performance of the TALOS WEC using WEC-Sim and compare the results with those obtained from other numerical models. The TALOS WEC is a promising technology for the generation of clean, renewable energy from ocean waves. The development of a reliable numerical model for the TALOS WEC is crucial for its design and optimization. To achieve this, we have implemented the TALOS WEC in WEC-Sim and compared the results to in-house models from Lancaster and to results from DNV's Sesam code. Our results show good agreement with the results from Lancaster and DNV, demonstrating the accuracy and reliability of the numerical model developed in WEC-Sim. This work advances the field of wave energy conversion by providing a verified numerical model of the TALOS WEC, which can be used for further optimization and design studies.

CFD↗
DOE OSTI2024

Microwave-assisted pyrolysis of hydrocarbons using iron-based alumina catalysts obtained via solution combustion synthesis

The demand for hydrogen is growing which makes the development of clean and efficient H2 synthesis technologies imperative. Microwave-assisted, thermocatalytic, dehydrogenation of hydrocarbons has demonstrated the ability to generate H2 with high yield and selectivity, leaving behind valuable solid carbon byproducts. However, this microwave-assisted process is unoptimized which prevents it from being utilized in industry. A critical component of optimization is the development of a catalyst that is catalytically active, a good microwave absorber, and can be regenerated for repeated dehydrogenation cycles. Previous studies that focused on plastic waste decomposition have used iron-based alumina (FeAlxOy) made via solution combustion synthesis (SCS). Unexplored is the effect of tuning SCS parameters on dehydrogenation performance, the use of these materials in hydrocarbon decomposition to H2, and the regeneration of these catalysts. This dissertation has three objectives: (1) characterize the relationship between SCS parameters and the material properties of FeAlxOy, (2) determine how differences in the material properties of FeAlxOy influence their performance as catalysts during microwave-assisted pyrolysis of fossil fuels, and (3) investigate the Boudouard reaction to regenerate the FeAlxOy post-dehydrogenation.

Chanoi, Zachary Aidan↗
DOE OSTI2024

Baseload Hydrogen Production Using Nuclear and Renewable Energy: A Comparative Analysis

As the global push towards net zero carbon gains momentum, the demand for clean hydrogen is expected to grow rapidly across various sectors, including transportation, industries and electrical grids. To meet this growing hydrogen demand, baseload hydrogen production facilities capable of providing a continuous and reliable supply of hydrogen will be necessary throughout the world. This paper explores the technoeconomic feasibility of establishing baseload electrolytic hydrogen production facilities in the United States, utilizing different clean generation resources. The key criteria include maintaining a consistent supply of clean hydrogen without putting baseload demand stress to already vulnerable power grid. In order to do that, the proposed facilities will host onsite clean power generation and energy storage technologies. The proposed facilities can capitalize on available investment and production incentives and have ability to export excess electricity to the utility at a bulk price. Several scenarios are considered based on the clean energy resources to support the electrolysis process including light water reactors (LWRs) currently evaluating retirement options, wind, solar PVs, and advanced small modular reactors (SMRs). For each scenario, a hypothetical hydrogen production facility is considered in a location in the US where the primary generation resource is at its peak strength. Comparative analysis in this paper reveal that the nuclear power plants are most economically viable for baseload hydrogen production facilities, outperforming renewable-based facilities with significantly lower levelized cost of hydrogen (LCOH). Even under best-case scenarios for resource availability, incentives and export prices, renewable-based facilities face challenges due to daily and seasonal generation variability, resulting in large installation sizes and lower capacity factors. Among renewable-based facilities, complementarity hybrids, providing more stable power supply, demonstrate superior economics compared to facilities based on a single renewable technology. While LWR-powered facility can achieve a negative LCOH with incentives, SMR-powered facilities can provide economic hydrogen supply with LCOH below $1/kg with high temperature electrolysis option. The analysis in this paper underscores the pivotal role of nuclear energy in the future hydrogen economy.

08 - HYDROGEN↗
DOE OSTI2025

Integrated Systems-to-Atoms (S2A) Framework for Designing Resilient and Efficient Hydrogen Infrastructure Solutions

The success of a future clean hydrogen infrastructure will depend on technology performance, operating conditions, and system configuration, which will be integrated to meet specific end-use requirements. We introduce a Systems-to-Atoms framework to cosimulate material, device, and system design for clean hydrogen storage and transport. Here we present a demonstration scenario in which hydrogen is distributed using a liquid organic hydrogen carrier to 700 bar refueling stations. Cross-scale analysis on hydrogen release at the refueling station reveals that while a high reaction pressure (up to 100 bar) may not enhance the catalyst performance, it can lead to system-level cost savings (up to 5% of total refueling station cost) due to savings in downstream gas compression. Further, a typically low-performing dehydrogenation catalyst material (e.g., copper) may be preferred over a high-performing catalyst (e.g., palladium) at different operating conditions when considering overall system affordability and supply chain resilience.

08 HYDROGEN↗
DOE OSTI2023

Laboratory-Scale Coal-Derived Graphene Process (Final Report)

The Energy & Environmental Research Center (EERC) conducted a laboratory-scale coal-derived graphene (CDG) project focused on developing a technological process for making graphene from four U.S. domestic coal or coal wastes, including lignite from North Dakota, subbituminous coal from Wyoming, bituminous coal from Utah, and anthracite from Pennsylvania. The project was divided into two performance or budget periods (BPs), with BP1 comprising the up-front laboratory experiments to make graphene materials from coal beginning on May 1, 2020, to April 30, 2022. BP2 was conducted from May 1, 2022, to April 30, 2023, and was focused on analyzing the CDG process economic feasibility and the technical gaps for technological scale-up and commercialization. During this project, a few different coal-derived high-value products have been demonstrated, including graphite, graphene oxide (GO), reduced graphene oxide (rGO), and graphene quantum dots (GQDs). A new graphite microstructure was discovered and named “croissant graphite” because of the exterior morphological and textural resemblance to croissant food items sold in commercial groceries stores. The new graphite structure and the associated preparation from coal or coal waste feedstocks has been the subject of a U.S. patent application. The systematic experimental processes involving coal cleaning, upgrading, and conversion to high-value carbon products culminated into a developed upgraded coal-to-products (UCP) technology that is being pursued for potential fast-track commercialization, if funding is available. It is envisioned that commercialization of the UCP technology would increase consumption of U.S. domestic coals or coal wastes to make environmentally sustainable high-value products for the electronics industry, high-energy-storage applications, and clean energy technologies such as electric vehicle (EV) lithium-ion batteries (LIBs), for which graphite has become a critical mineral commodity. Croissant graphite microstructures, when observed by field emission scanning electron microscopy (FESEM), display wavy surface morphology and often grow from a base that is made of graphitized particles with honeycomb-like layers, which are believed to be graphene layers. While more studies are needed to fully ascertain the mechanisms of the croissant graphite microstructure formation, it is postulated that their growth may begin from curling of the graphene sheets into ribbon-like structures, and continuous growth and densification of the ribbon-like structures forms croissant microstructures. Additional studies are ongoing to evaluate the electrochemical performance of croissant graphite for LIB applications and to determine the experimental conditions necessary to tune on/off croissant formation so that it can be either optimized or suppressed depending on performance evaluation results. In addition to the discovery of croissant graphite, the graphitization process from the four coal ranks in general was successful. X-ray diffraction (XRD) analysis showed that the degree of graphitization (DoG) ranged from 12% to 80% in an early sample set, and further optimization on lignite coal produces a DoG of about 92%, which was spectacular to see as lignite is the lowest-rank coal. Thus, it is expected that the graphitization performance for higher-rank coals will be similar or better when optimized as well. The coal-derived graphite was used to make GO and rGO. Analytical characterization, e.g., by methods such as Raman spectroscopy, XRD, Fourier transform infrared (FTIR) spectroscopy and FESEM, showed that the sequence of converting the coal to graphite, exfoliating it to GO, and then chemically reducing the GO to rGO was successful. Although coal naturally contains aromatic compounds and some relatively small-sized condensed aromatic units, it does not contain graphene sheets. In the UCP process, the aromatic domains in the coals, particularly low-rank coals, are concentrated and condensed further into graphene sheets, which are ordered into a 3D stack during graphitization. The synthesized graphite is then unpacked by methods such as exfoliation to various graphene products. GQDs were synthesized from all four coal types, and their optical properties were demonstrated to be tunable by the coal precursor preprocessing treatments. In all four coal types, enhanced optical properties were observed for the produced GDQs with incremental improvements made to the coal precursors. GQDs produced from raw coal samples displayed lower ultraviolet–visible (UV–Vis) spectroscopy absorbance intensity compared to those obtained from cleaned and upgraded coal residues. The photoluminescence (PL) intensities also varied with pretreatment conditions and with the concentration of GQDs in aqueous solutions. GQDs obtained from anthracite show longer emission wavelengths and can be excited by visible light as opposed to GQDs derived from the other coal ranks. UV fluorescence 3D maps and spectra revealed that the emission wavelength at which the GQDs solutions display the highest intensity was slightly redshifted based on the coal precursor pretreatments. In low-rank coal (lignite and subbituminous) samples, two clusters were observed in the maps for GQDs, which may suggest that there are potentially two types of fluorophores in solution or two main size populations. The ability to tune the properties of GQDs based on processing methods can be exploited to make GQDs for various optical display or optoelectronics applications. The results also highlight the importance of removing coal-borne impurities to improve the quality of the coal precursor for preparation of graphene products. Coal and/or coal wastes preprocessing methods were developed and applied to clean and upgrade the coal precursors prior to graphitization and subsequent conversion to graphene products. The preprocessing methods involve high specific-gravity separations, mineral acid cleaning (no hydrofluoric acid), and subsequent upgrading by reducing the coal-borne heteroatom (nitrogen, sulfur, and oxygen) content using proprietary chemical agents. Analytical characterization revealed that the preprocessing steps were successful, with ash reductions that range from 38% to 80% and residual ash content that was below the 5 wt% initial target. Based on proximate and ultimate analysis, the heteroatom reduction reactions produced upgraded coal residues with the oxygen content reduced by 8% to 24%, with additional reductions in the nitrogen and sulfur contents. An initial assessment of the waste streams from the UCP process shows very small to negligible environmental impact due to CO 2 , NO x , and SO x because most process steps are performed under inert atmosphere with argon. Consequently, reactive oxygen environments that tend to create these species are avoided. The inorganic and potentially hazardous species are released into aqueous waste streams that are easy to handle for proper disposal. The liquid waste streams were found to contain low-level concentrations of rare-earth elements (REEs), which could be concentrated and recovered as value-added by-products. Additionally, the volatile and gaseous fractions from carbonization and heat treatment contain useful organic compounds that can also be recovered as potential valuable by-products. Thus, the UCP technology is considered an environmentally sustainable and promising emerging technology for making high-value products from coal and coal wastes, with potential additional value-added by-products. Analysis of potential markets for the coal-derived carbon products shows a strong demand in both niche market sectors and across a wide variety of other industrial sectors. Graphite is currently considered a critical mineral commodity that has a large and growing demand in the LIB industry for EV applications. Based on data from Fortune Business Insights (2022) and Marketwatch (2023) reports, the average global graphite market is projected to reach about 33 billion by 2028, growing at a compound annual growth rate (CAGR) of about 7%, with much of this growth expected to be in the LIB industry. GO and rGO have strong market potentials in various application areas, such as coatings for anticorrosion, anti-icing, and antimicrobial protection, thermal barriers, wear resistance, sensors, additive manufacturing such as 3D inks, and others. GQDs are the emerging key player in the bioimaging, photovoltaics, and light-emitting diodes (LEDs) applications, with the potential to replace traditional semiconductor quantum dots (SQDs), which are based on metallic systems that are more toxic and more expensive. Biomedical applications of GQDs are becoming more attractive because of low to no toxicity and extremely low cost compared to SQDs. The major challenges for scale-up and commercialization of coal-derived carbon products such as graphene vary from the inherent attributes of graphene itself to reluctance to accept graphene in new manufacturing processes because of the uncertainty of the unknown. The 2D nature of graphene materials with a thickness of one atom presents significant challenges to proper handling/processing, and process scale-up becomes difficult because it requires high-end, expensive equipment, even for routine handling and analysis for quality assurance and control. Pristine graphene can also be extremely difficult to work into other matrices, thus hindering downstream processibility, especially at large scale. Currently, the cost of graphene and graphene products is still high and presents an economic risk that tends to slow down investment in scaling up emerging technologies. The lack of a standard for graphene materials for quality assurance and quality control poses a great challenge not only for the markets but also for commercialization efforts. A first-look economic feasibility analysis of the UCP technology provided valuable information that suggests the UCP process would be feasible, especially when it is scaled to a pilot scale and could be more competitive at the full scale. Graphitization was found to be the most energy-consuming and most capital-intensive step in the overall process. In small laboratory- and bench-scale experiments, labor is a significant contributor to the total process costs. Although these energy, capital, and labor constraints contribute to a higher selling price for the product, a preliminary economic model suggests that the process would be feasible at large scale when the process is fully integrated, optimized, and automated.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2023

Synergistic Heat Pumped Thermal Storage and Flexibly Carbon Capture System

As the U.S. grid evolves toward a lower-carbon system, fossil generation assets need to operate in energy markets with high variable renewable energy (VRE) penetration while also decreasing carbon emissions. Current carbon capture and storage (CCS) technologies suffer from high capital cost and an inability to operate flexibly during periods of oscillating demand. The ARPA-E FLECCS Program Phase 1 was created to fund designing and optimizing innovative CCS processes that enable flexibility on a high-VRE grid. To address this need, the Colorado State University (CSU) Team won funding to design a synergized system of thermal energy storage, power generation, and flexible carbon capture to enable breakthrough system performance that achieves an LCOE <$75/MWh with >99% capture rate. This approach will target new or existing natural gas combined cycle power plants. The proposed design utilizes novel hot and cold thermal energy storage (TES) technologies that store low-cost, off-peak electricity as thermal energy to power CCS solvent regeneration and boost plant output during periods of peak demand. The design provides an overall optimized net present value (NPV) by maximizing low carbon power to grid while prices are highest using Storworks Power’s concrete TES technology. The team also capitalizes on decades of ION Clean Energy’s (ION) development in low cost and flexible pioneering solvent technology, which has proven reductions in energy consumption and overall cost of 28% and 38%, respectively, compared with state-of-the-art CCS.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2024

Zero Emission Cargo Transport (ZECT) II Demonstration: South Coast Air Quality Management District (Final Report)

The South Coast Air Quality Management District (South Coast AQMD), California Air Resources Board (CARB) and Southern California Association of Governments (SCAG) — the agencies responsible for preparing the State Implementation Plan required under the federal Clean Air Act — have agreed that attainment of federal air quality standards for the region will require a transition to the broad use of zero and near-zero emission energy sources in cars, trucks and other equipment. Accordingly, the 2012 South Coast AQMD Air Quality Management Plan, the SCAG 2012 Regional Transportation Plan, and the “Vision for Clean Air: A Framework for Air Quality and Climate Control Planning” all identify the need to immediately enact a phasing in of zero and near-zero emission technologies to meet air quality goals. In 2014, South Coast AQMD was awarded grant funding under the US Department of Energy Zero Emission Cargo Transport (ZECT) II Demonstration program to develop and demonstrate zero-emission drayage trucks for goods movement operations between the Port of Los Angeles (POLA) and Port of Long Beach (POLB) near dock rail yards and warehouses: 1) development and demonstration of zero-emission fuel cell range extended electric drayage trucks and 2) development and demonstration of hybrid electric drayage trucks. The purpose of this project was to accelerate deployment of zero emission cargo transport technologies to reduce harmful diesel emissions, petroleum consumption and greenhouse gases in the surrounding communities along the goods movement corridors that are impacted by heavy diesel traffic and the associated air pollution. Between 2014 – 2024, six ZECT II zero-emission fuel cell drayage truck platforms, including fuel cell range extended and CNG hybrid trucks, were successfully designed, developed, integrated, built, tested, and demonstrated with drayage fleet operators in transportation corridors within areas of the South Coast AQMD jurisdiction in Southern California such as in and around POLA and POLB. Portable hydrogen refueling was deployed to support the fuel cell vehicles. The project had real-time improvement with on-going debugging and optimizations while the vehicles were under demonstration. All platforms demonstrated sufficient or excess power, torque, and energy to support 82,000lbs Gross Vehicle Weight Rating and gradeability to perform their daily duty cycles. Collectively, the trucks drove over 23,000 miles during their respective demonstration phases. The ZECT II project was the first of its kind to demonstrate the commercial viability that supported the additional technology breakthroughs for Class 8 zero emission trucks and validations as well as the regulatory basis for all the zero-emission regulation that we know today, such as the Innovative Clean Transit regulation, Advanced Clean Trucks and Clean Fleet regulations.

08 HYDROGEN↗
DOE OSTI2022

Competitiveness and Commercialization of Energy Technologies: Supply Chain Deep Dive Assessment

The report “America’s Strategy to Secure the Supply Chain for a Robust Clean Energy Transition” lays out the challenges and opportunities faced by the United States in the energy supply chain as well as the federal government plans to address these challenges and opportunities. It is accompanied by several issue-specific deep dive assessments, including this one, in response to Executive Order 14017 “America’s Supply Chains,” which directs the Secretary of Energy to submit a report on supply chains for the energy sector industrial base. The Executive Order is helping the federal government to build more secure and diverse U.S. supply chains, including energy supply chains. Competitive U.S.-based clean energy manufacturers and rapid commercialization of U.S.-developed technologies are critical to secure energy supply chains, generate high quality jobs, and meet the United States’ national security, energy and climate objectives. The February 2021 “Executive Order on America’s Supply Chains” (E.O. 14017) directs the U.S. Department of Energy (DOE) to evaluate supply chains that encompass the energy industrial base, focusing on technologies that are critical to meet U.S. decarbonization goals by 2050. Understanding and analyzing the end-to-end supply chain through economic analysis is crucial to mitigating risks and identifying opportunities to enhance U.S. competitiveness in the clean energy industry. This insight will allow the Department of Energy (DOE) to leverage its research, development, demonstration and deployment (RDD&D) capabilities to most fully realize the objectives of E.O. 14017.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2020

Multi-Stage and Multi-Timescale Robust Co-Optimization Planning for Reliable and Sustainable Power Systems. Final Report

In this project, Clarkson University, in collaboration with Southern Methodist University and University of Pittsburgh, conducted the research to model, design, and implement a sophisticated generation and transmission co-optimization planning decision tool, called Multi-stage and Multi-timescale robust Co-Optimization Planning (MMCOP). The MMCOP decision tool intends to facilitate generation and transmission co-optimization planning of emerging power systems, while mitigating risks and uncertainties in both short-term operation dynamics and long-term policy and technology changes. Long-term power system planning aims at optimizing asset utilization by investing in a proper mix of various generation technologies and transmission lines to supply the future load growth. In particular, the Clean Power Plan (CPP), which is designed to combat climate change and reduce carbon emissions by setting a national limit on carbon pollution from power plants, may dramatically change the landscape of the power industry by further promoting clean energy and phasing out emissions-intensive generation technologies. In addition, novel non-wire alternatives (e.g., demand response (DR), distributed generation (DG), energy efficiency (EE), and smart grid technologies) and the computational complexity for large-scale systems significantly complicate the system planning procedure even further. However, existing conventional planning approaches neglect short-term variability and uncertainty of renewable energy, hourly chronological operation details, and physical nonlinear characteristics of the alternating current transmission network. As a result, existing conventional planning approaches may not work properly, and power systems reliability could be in jeopardy. In observing the limitations of existing conventional planning approaches and addressing new challenges of emerging power systems, the main scope of this project to develop co-optimization planning models within a multi-stage and multi-timescale framework. In particular, random contingencies, key uncertainty factors, and AC power flows are included to derive expansion plans while considering both long-term reliability and short-term flexibility.

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