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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Carbon Ore-Derived Critical Materials for Clean Energy Technologies

Conference presentation at American Institute of Chemical Engineers (AIChE) Annual Meeting, San Diego, California, October 27–31, 2024. Trends in the manufacture of electric vehicles that use graphite-based LIBs are rising steeply in the United States and globally, but the U.S. domestic supply chains for graphite, the largest component in an LIB by mass, is severely limited and faces complicated geopolitical dynamics with foreign sources. Consequently, the United States has designated graphite as a critical mineral to focus attention and resources to develop technologies to meet the challenge of limited domestic graphite supply chains. Results obtained so far based on the UCOP process have successfully validated the technology at the laboratory scale, with the produced graphite material showing up to 95% degree of graphitization, high carbon purity of ~99.98%, residual ash content of ≤0.02%, negligible moisture, low trace elements, and high electrochemical stability. These results suggest that the emerging UCOP technology is a promising approach to effectively synthesize high-quality graphite from abundant coal and coal waste resources in the United States to create a sustainable domestic critical graphite supply chain. A brief description of the status of UCOP process development and representative results will be presented.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2025

A Novel Optical Instrument for On-Line Measurement of Particle Size Distribution—Application to Clean Coal Technologies

A flow cell is a critical measurement interface for many optical instruments. However, the flows are often sampled under harsh conditions, such as under high pressure and/or high temperature, in the presence of particles, moisture, vapors with high dew points or corrosive gases. Therefore, obtaining a high-optical-quality flow cell that does not perturb the measurement is a significant challenge. To address this challenge, we proposed a new flow cell that employs a unique laminar coaxial flow field (for the purge and sample flows). A test system was built to conduct particle size distribution (PSD) measurements with no sampling bias using a state-of-the-art analyzer (Malvern Panalytical Insitec). The results revealed that the measurement zone is well defined solely by the sample flow, and the optical windows are well protected by the purge flow, with minimal risk of any depositions from the sample flow. Using this flow cell, the Insitec can successfully measure PSD under high pressure and temperature under moist, corrosive conditions without generating any sampling bias. Importantly, we successfully applied this flow cell for on-line PSD measurement for the flue gas of a 100 kWth pressurized oxy-coal combustor operating at 15 bara.

Cheng, Mao (ORCID:0000000213273900)↗
DOE OSTI2023

Clean Cities Coalitions: Advancing Affordable, Efficient, and Clean Transportation Fuels and Technologies

This fact sheet provides an overview of the U.S. Department of Energy's (DOE's) Vehicle Technologies Office Clean Cities Coalition Network, which boosts the country's economic vitality, energy security, and quality of life by advancing the deployment of affordable, efficient, and clean transportation fuels and technologies. Coalitions provide the technical expertise local decision makers and fleets need to understand and implement alternative and renewable fuels, electric vehicles, idle-reduction measures, fuel economy improvements, new mobility choices, and emerging transportation technologies.

accomplishments↗
DOE OSTI2025

Leveraging a Southern California Energy Innovation Cluster to Pilot and Validate Emerging Energy Technologies

The EPIC Pilot Program, led by the Los Angeles Cleantech Incubator (LACI), was designed to help early-stage clean technology startups accelerate technical validation, investment readiness, and market entry. The project focused on supporting startups in designing and deploying small-scale pilots with the guidance of EPIC Partners, a network of regional stakeholders in the Southern California energy ecosystem, including but not limited to: the Los Angeles Department of Water and Power (LADWP), the California Energy Commission (CEC), Los Angeles County Metropolitan Transportation Authority (LA Metro), and Edison International, among others. Through mentorship, funding, and site access for technology deployments, the program provided a structured pathway for startups to test and refine their technologies in real-world settings.

14 SOLAR ENERGY↗
DOE OSTI2025

Automation of debris removal and resurfacing of insulators in terawatt pulsed power systems using state of the art laser technology

The increasing complexity and scale of pulsed power systems necessitate effective maintenance strategies to ensure optimal performance and safety. This report investigates the automation of debris removal and resurfacing of insulators in terawatt pulsed power systems using advanced laser cleaning technologies. The motivation for this research stems from the limitations of current manual cleaning methods, which are labor-intensive and pose health risks due to hazardous materials. The study addresses the problem of surface flashover, a significant issue affecting insulator performance, by evaluating two innovative cleaning techniques: Pulsed Laser Cleaning (PLC) and Flash Lamp Annealing (FLA). Experimental results demonstrate that PLC effectively restores the dielectric strength of Rexolite insulators, while FLA shows limited success. The findings highlight the potential for automated cleaning solutions to enhance safety and efficiency in insulator maintenance, paving the way for future advancements in pulsed power technology.

42 ENGINEERING↗
DOE OSTI2020

Clean Energy Manufacturing: Renewable Energy Technology Benchmarks

The manufacturing of clean energy technologies has become a global enterprise. An analysis of four clean energy technology manufacturing processes—wind turbine components, crystalline silicon solar photovoltaic modules, light-duty vehicle lithium-ion battery cells, and light-emitting diodes—was conducted to provide a reference point for comparison over time as this sector evolves. The manufacturing supply chain analysis included processing of raw materials, making required subcomponents, and assembling final products, using benchmarks that crossed 12 economies: Brazil, Canada, China, Germany, India, Japan, Malaysia, Mexico, South Korea, Republic of China (Taiwan), the United Kingdom, and the United States. Larger economies, with extensive manufacturing supply chains and high prevailing wages, tend to retain more value added from clean energy manufacturing than small economies. Manufacturing of clean energy technologies drives extensive trade among economies to support the widely distributed supply chain links. Production of wind turbine components and photovoltaic modules is more centralized than production of light-emitting diodes and lithium-ion battery cells. Across the four clean energy technologies evaluated, there was generally an excess of manufacturing capacity relative to global supply.

benchmarks↗
DOE OSTI2020

Renewable Energy Technology and Systems Integration for the Oil and Gas Industry

Introduction to the mission and research of the National Renewable Energy Laboratory (NREL) and the Joint Institute for Strategic Energy Analysis (JISEA). JISEA is co-sponsored by industries, governments, and partnered with several academic institutions (see https://www.jisea.org). Presentation will review statistics about the growth of renewable energy and also discuss potential future trends. It will review several specific case studies relevant to the oil and gas industry, including renewable energy for industrial operations and clean technologies and fuels that would be most relevant to oil and gas technologies and capabilities.

ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2020

Removal of Metal Oxides from Reactor Metals/Alloys by Laser Ablation

Storage of low and intermediate level radioactive waste in a deep geological repository (L and ILW DGR): - Large volumes of metallic waste = increased production of hydrogen gas. - Large fraction of the metallic wastes are out-of-core reactor components. - Carbon steel feeder pipes. - Radioactive contamination is concentrated within the surface oxides. - Removal of surface contaminants would lead to volume reduction of metallic waste that is stored in L and ILW DGR. - Current decontamination techniques generate large volumes of secondary waste. Objectives: Oxide removal from carbon steel using a ytterbium fiber laser (1064 nm) with a particular focus on identifying the key laser parameters that affect the removal efficiency. Advantages of laser ablation: Generate low volumes of waste, Flexibility of deployment, Remote operation. Grow an oxide film on carbon steel with the incorporation of cobalt. Optimize laser cleaning technology for the removal of surface oxides. Incorporate an oxide collection system for the ablated particles. Conclusions: Objective 1 - Simulated inactive oxides on carbon steel, using Co{sup 2+} as a surrogate for Co radionuclide. Objective 2 - Optimized laser parameters (200 MW/cm{sup 2}, 3 scans, 15 μm overlap); Complete removal of cobalt from surface and bulk metal with optimized cleaning settings. Objective 3 - Glass fiber media H14 HEPA filters had highest collection yield; High oxide collection yields (∼100%). Future Work: Further testing of the liquid trap will verify the efficacy of the HEPA filter and determine the amount of ablated oxides that pass through. Testing of the laser ablation system needs to be done on other reactor materials along with the incorporation of different transition metal cations. Improvements to the oxide collection system are required to improve collection yields.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Ash Fouling Free Regenerative Air Preheater for Deep Cyclic Operation

The University of Kentucky (UKy) project titled “Ash Fouling Free Regenerative Air Preheater for Deep Cyclic Operation”, DE-FE0031757, was conducted from 8/15/2019 to 8/14/2024 in two Budget Periods. Other participants included PPL Corporation and Black Dragon Double Boiler. The overall goal was to investigate the proposed self-cleaning technology to achieve ash fouling free air preheater operation in a coal-fired power plant, especially during deep cycling. All project deliverables, milestones, and success criteria were met. UKy obtained the following scientific findings. • Temporary and periodic high temperature of heating elements (450 ~ 500 °F) can prevent ash accumulation and maintain air preheater free of clogging. • The ash samples analysis and unit operation provide solid evidence of ABS formed during low load with SCR ammonia slip being the major cause of ash accumulation, and air preheater clogging can be prevented by raising the heating element temperature up to 450 °F~ 500 °F at which ABS is decomposed. • In-situ self-cleaning can be controlled by monitoring temperature and/or presetting fixed number of cleanings per day. Both approaches in pilot testing show positive results for maintaining an ash free state for the air preheater. • Temperature criteria (cold end or gas outlet temperature) for entering self-cleaning service is critical to balance the number of cleaning cycles with maintaining the ash level. • Temperature criteria (cold end or gas outlet temperature) for exiting self-cleaning service is critical to balance the duration of the cleaning cycles with maintaining the ash level.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2021

Benchmarks of Global Clean Energy Manufacturing, 2014-2016

The Clean Energy Manufacturing Analysis Center (CEMAC), sponsored by the U.S. Department of Energy (DOE) Office of Energy Efficiency and Renewable Energy (EERE), provides objective analysis and up-to-date data on global supply chains and manufacturing of clean energy technologies. This updated version of the Benchmarks of Global Clean Energy Manufacturing sheds light on several fundamental questions about the global clean technology manufacturing enterprise: How does clean energy technology manufacturing impact national economies? What are the economic opportunities across the manufacturing supply chain? What are the global dynamics of clean energy technology manufacturing?

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2021

Severity factor kinetic model as a strategic parameter of hydrothermal processing (steam explosion and liquid hot water) for biomass fractionation under biorefinery concept

Hydrothermal processes are an attractive clean technology and cost-effective engineering platform for bio-refineries based in the conversion of biomass to biofuels and high-value bioproducts under the basis of sustainability and circular bioeconomy. The deep and detailed knowledge of the structural changes by the severity of biomasses hydrothermal fractionation is scientifically and technological needed in order to improve processes effectiveness, reactors designs, and industrial application of the multi-scale target compounds obtained by stream explosion and liquid hot water systems. The concept of the severity factor [log 10 (R 0 )] established > 30 years ago, continue to be a useful index that can provide a simple description of the relationship between the operational conditions for biomass fractionation in second generation of biorefineries. Furthermore, this review develops a deep explanation of the hydrothermal severity factor based in lignocellulosic biomass fractionation with emphasis in research advances, pretreatment operations and the applications of severity factor kinetic model.

09 BIOMASS FUELS↗
DOE OSTI2024

A dynamic solvent chamber propagation estimation framework using RNN for warm solvent injection in heterogeneous reservoirs

Warm solvent injection (WSI), injecting low-temperature solvent into formations to reduce the viscosity of heavy oil, is a clean technology for heavy oil production through reducing greenhouse gas emissions and water usage. The success of WSI operation depends on the uniform development and propagation of solvent chambers in reservoirs. However, reservoir heterogeneity stemming from shale barriers plays a detrimental role in the conformance of solvent chamber development and oil production rate. In this work, we developed a novel recurrent neural network (RNN)-based framework with the capability of efficiently tracking and estimating the solvent chamber positions in heterogeneous reservoirs based on only production time-series data. The developed estimation model utilizes the “sequence-to-sequence" mapping methodology to correlate observed production time-series sequence and solvent chamber edge sequence via a long short-term memory (LSTM) algorithm. The trained RNN models exhibit high accuracy, evidenced by the predicted dynamic solvent chamber locations match the corresponding true locations from numerical simulation, with a high coefficient of determination (R 2 ) and a low mean squared error. Specifically, the achieved R 2 values exceed 0.98 on both the training and testing data. The developed RNN-based workflow was tested via several cases from both regularly- and irregularly-shaped shale barriers, and the results were promising. The predicted solvent chambers showed strong agreement with those obtained from numerical simulations. The major benefits of this workflow include reducing computational time and saving overall monitoring and tracking costs for conventional techniques. In conclusion, the present work would provide a good demonstration of the capability of practical integration of machine learning methods in solving engineering problems.

58 GEOSCIENCES↗
DOE OSTI2024

Turning Outsiders into Insiders: A Call for Papers to Expand the Reach of National Laboratories’ Safety Successes, Challenges, Research, and Approaches

The most complex challenges facing the world today comprise the work of [Department of Energy’s] (DOE’s) 17 National Laboratories: [...] From furthering U.S. energy independence and leadership in clean technologies; to promoting innovation that advances U.S. economic competitiveness; to conducting research of the highest caliber in the physical, chemical, biological, materials, computational, and information sciences to advance understanding of the world around us-the Laboratories’ purview is expansive and further their contributions are indispensable.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2024

Electric light-duty vehicles have decarbonization potential but may not reduce other environmental problems

Electric vehicles are promoted as ‘clean’ technologies and offer promising reductions in transportation emissions. Nevertheless, their environmental benefits critically depend on the local electricity grid mix and the type of emission being considered. Here, we conduct a comparative life cycle assessment of the four dominant light-duty vehicle categories at both the global scale and in three representative countries: Norway, the US, and China. By analyzing different environmental indicators, particularly global warming potential and respiratory effects, and quantifying related parametric uncertainties, we reveal that the advantages of electric vehicles vary across these regions and across environmental impact types. While electric vehicles offer considerable decarbonization potential as the grid mix becomes cleaner, they might not mitigate other environmental impacts, such as increased respiratory effects on rural, low-income communities. Our results support stakeholders in identifying environmentally friendly vehicle and policy options while considering multiple factors, and emphasize the importance of tailored approaches over one-size-fits-all solutions in sustainable transportation.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2022

Rare earth elements from waste

Rare earth elements (REEs) are critical materials in electronics and clean technologies. With the diminishing of easily accessible minerals for mining, the REE recovery from waste is an alternative toward a circular economy. Present methods for REE recovery suffer from lengthy purifications, low extractability, and high wastewater streams. Here, we report an ultrafast electrothermal process (~3000°C, ~1 s) based on flash Joule heating (FJH) for activating wastes to improve REE extractability. FJH thermally degrades or reduces the hard-to-dissolve REE species to components with high thermodynamic solubility, leading to ~2× increase in leachability and high recovery yields using diluted acid (e.g., 0.1 M HCl). The activation strategy is feasible for various wastes including coal fly ash, bauxite residue, and electronic waste. The rapid FJH process is energy-efficient with a low electrical energy consumption of 600 kWh ton –1 . The potential for this route to be rapidly scaled is outlined.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2024

Strategic styles of hardware product development could accelerate commercialization in cleantech startups

Hardware-based startups risk having longer times-to-market, deterring investment in the clean technologies that are critical to a sustainable future. We interviewed 55 leaders at hardware startups, 20 of which are cleantech, mapped their development timelines, and found prototyping to be the longest development step (median of 19 weeks per prototype) regardless of prototype complexity or iteration. Qualitative interview analysis reveals the prototyping team’s choice of development style is a major factor affecting timeline. We define two development styles: natural and structured, typified by free-form exploration and rule-based execution, respectively. On average, natural development takes 35% less time than structured, and is thus preferred for early iterations, but adopting structure at strategic points is needed for timely commercialization. Critical points of transition to a structured style include adding new team members or engaging external partners, which demand clear communication and expectations. When pivoting to a new product or market, returning to a natural style is beneficial.

Looney, Erin (ORCID:0000000168959312)↗
DOE OSTI2021

Why Regional and Long-Haul Trucks are Primed for Electrification Now

Zero emission freight trucks are needed to both improve public health and reduce global greenhouse gas emissions but at the same time are generally believed to be uneconomical. However, recent dramatic declines in battery prices and improvement in their energy density have created opportunities for battery-electric trucking today that were seldom anticipated just a few years ago. At the current global average battery pack price of $135 per kilowatt-hour (kWh) (realizable when procured at scale), a Class 8 electric truck with 375-mile range and operated 300 miles per day when compared to a diesel truck offers about 13% lower total cost of ownership (TCO) per mile, about 3-year payback and net present savings of about US $200,000 over a 15-year lifetime. This is achieved with only a 3% reduction in payload capacity. Even this small penalty can be reversed cost-effectively through light-weighting, in any case, only matters for a small fraction of trucks which regularly utilize their maximum payload. Electric trucks appear poised to also meet the performance demands for a large share of regional and long-haul trucking today. The estimated average distance traveled between 30- minute driver breaks is 150 miles and 190 miles for regional-haul and long-haul trucks respectively in the US. Thirty minutes of charging using 500 kW or mega-Watt scale fastchargers would add sufficient range without impairing operations and economics of freight movement. However, as with almost any clean technology, higher upfront capital costs of both vehicles and charging infrastructure are major barriers when electric trucking is in its infancy. Without strong policy support, coordinated investments in both vehicle manufacturing and fuel infrastructure will not be forthcoming on the scale needed to harness the true potential of battery electric trucks.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2022

Small Reactors in Microgrids: Technoeconomic Analysis

This report presents the results of technoeconomic analysis that advances understanding of the potential of small modular reactors and microreactors, collectively referred to as small reactors (SRs) in this report, in microgrids. This analysis was conducted using a proxy model for SR in microgrids based on the datapoints that were identified and explored in a predecessor report “Small Reactors in Microgrids: Technical Studies Guidance.” The results and the subsequent comparative analysis in this report show that SRs could be a cost-competitive generation option when capital costs are modeled considering potential economies of scale in sizing. If the CO 2 tax is imposed on carbon fuels, SRs would be even more attractive than gas generators. Then, SRs in microgrids would play a pivotal role in reducing the carbon footprint at the local distribution level. However, it is particularly important to identify the most suitable use cases for early adoption and the right balance of generation mix with other clean technologies as SRs achieve a level of technological and financial maturity.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗