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DOE OSTI2024

Energy Systems Integration Facility (ESIF): World-Class Systems Integration Capabilities and Research

The Energy Systems Integration Facility (ESIF), located at the National Renewable Energy Laboratory (NREL) South Table Mountain campus, is a world-renowned user facility for research and development of modern, advanced, and clean energy technologies. ESIF is distinguished by its continuously evolving, highly integrated systems that span throughout the building, connecting research capabilities across multiple laboratories and test areas. The primary ESIF research systems include: [1] data, cyber, and control networks, [2] research electrical distribution buses (REDB), [3] thermal integration infrastructure, and [4] hydrogen systems. The data, cyber, and control networks provide monitoring, control, communication, automation, visualization, and time series data storage and tagging capabilities for research projects and ESIF systems, including facility safety functions. The REDB system consists of four dedicated AC and DC electrical power networks that can connect devices located across the facility through versatile, automatic circuit configuration to support complex power electronics experiments up to the megawatt-scale. The thermal integration infrastructure consists of three temperature-conditioned water loops that provide heating and cooling interfaces and capabilities for thermal energy research. The hydrogen systems provide megawatt-scale hydrogen production, drying, compression, high-pressure storage, and delivery to laboratory end uses, including hydrogen fuel cell vehicle fueling. The ESIF research systems interconnect and extend throughout the various lab areas of the facility to create elaborate networks composed of diverse technologies for cutting-edge research. The ESIF capabilities are operated and stewarded by the ESIF Research Operations group, who also actively upgrade and advance the systems to ensure they remain ahead of anticipated research - enabling the success of many pioneering energy integration projects. The poster, created by members of the ESIF Research Operations team, highlights and summarizes the four core integrated systems at ESIF. The poster was first presented at the internal NREL Energize Forum on May 13th, 2024, and received the "Best Poster" award.

capabilities↗

DOE OSTI2024

Acoustic Monitoring of Pyroprocessing for Safeguards

As pyroprocessing continues to be an attractive option for the reprocessing of spent nuclear fuel worldwide, safeguards technologies are needed to address the monitoring capabilities that can help state level authorities, or the International Atomic Energy Agency (IAEA) maintain continuity of knowledge of the plant operations. Idaho National Laboratory (INL) is studying the possibility of using acoustic monitoring as a means to monitor a pyroprocessing facility for safeguards purposes. This paper discusses the experimental design and some preliminary results of tests conducted at the Fuel Conditioning Facility, a pyrochemical capable facility, at INL.

98 - NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL↗

DOE OSTI2025

High Energy Physics Network Requirements Review: Final Report, July 2024–December 2024

The world-class research infrastructure at the US Department of Energy (DOE) Office of Science (SC) provides the research community with premier observational, experimental, computational, and network capabilities. Each user facility is designed to provide unique capabilities to advance the core DOE mission in science and technology for its SC program to stimulate rich scientific discoveries and enhance its innovation ecosystem. Research communities gather and flourish around each user facility, bringing together new and enhanced perspectives. The continual reinvention of the practice of science — as users and staff forge novel approaches expressed in research workflows — unlocks new discoveries and propels scientific progress. Within this research ecosystem, the high-performance computing (HPC) and networking user facilities stewarded by the SC’s Advanced Scientific Computing Research (ASCR) program play a dynamic cross-cutting role, enabling complex workflows demanding high-performance data, networking, and computing solutions. The ASCR facilities enterprise seeks to understand and meet the needs and requirements across SC and DOE domain science programs and priority efforts, highlighted by the formal requirements review methodology. Between July and December 2024, the Energy Sciences Network (ESnet) and the Office of High Energy Physics (HEP) of the DOE-SC organized an ESnet requirements review of HEP-supported program activities. Preparation for these events included identification of key stakeholders: program and facility management, research groups, and technology providers. Each stakeholder group was asked to prepare formal case study documents about its relationship to the HEP program to build a complete understanding of the current, near-term, and long-term status, expectations, and processes that will support the science going forward.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2026

Design of a SMART Valve Testbed for Nuclear Thermal Dispatch

By the year 2050, the United States aims to achieve net-zero carbon emissions. To achieve this target, the licensing of the Light Water Reactor (LWR) fleet has been extended for 20 more years. To stay economically competitive with other power sources such as renewable and fossil-fuel power plants, the U.S. Department of Energy has introduced a plan to modernize the existing LWR fleet and diversify the revenue stream. One of the plans is to dispatch thermal energy to endothermic industrial processes. SMART valves will play an important role in this initiative by efficiently balancing the load by regulating valves in a coordinated manner while monitoring the thermal-hydraulic systems to enhance safety and maintain the integrity of the power plant. This research aims to develop a facility to test the coordinated control algorithm and produce various test results for training the monitoring system. The constructed facility is capable of simulating various operational and accidental scenarios by coordinating all the valves (positions) and pump (flowrate). The facility is developed with an Internet of Things (IoT)-based custom system and a python-based valve position control and coordination mechanism. It has achieved stable sensor outputs, pump control, and coordinated valve regulation in all three valves with minimum obstruction in the system.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2025

Current Progress on the High-Field Cable Testing Facility at Fermilab

Fermi National Accelerator Laboratory (Fermilab) is constructing a new High Field Vertical Magnet Test Facility (HFVMTF) with capabilities comparable to the European facilities EDIPO and FRESCA2. The facility, located at Fermilab, will feature a background magnetic field of 15 T, generated by a magnet provided by Lawrence Berkeley National Laboratory (LBNL). The HFVMTF will support two U.S. national programs under the DOE Office of Science: the U.S. Fusion Energy Science (FES) program and the Magnet Development Program (MDP). It will enable the testing of HTS samples in high magnetic fields across a wide range of temperatures and facilitate the development of hybrid magnets combining LTS and HTS superconductors. This paper presents an overview of the current progress in constructing the facility, including updates on the test cryostat, power supplies, and systems for quench protection and monitoring.

Velev, G. [Fermilab]↗

DOE OSTI2024

Sustainable Aviation Fuel State-of-Industry Report: Hydroprocessed Esters and Fatty Acids Pathway

Climate change is a pressing issue that requires immediate and decisive action to ensure a sustainable future. To reduce CO 2 emissions and speed up the transition to net-zero aviation, the Biden administration has launched the "Sustainable Aviation Fuels (SAF) Grand Challenge" to scale up production of SAF. The challenge aims to achieve 20% reduction in aviation emissions by producing 3 billion gallons per year (BGPY) of SAF by 2030 and to meet 100% of aviation fuel demand by producing 35 BGPY of SAF by 2050. In this report, we provide an overview of the current state of the hydroprocessed esters and fatty acids (HEFA) SAF industry, guided by the perspectives of the interviewed experts. Currently, the HEFA pathway is the only commercially deployed method to produce significant amounts of SAF. As a result, SAF produced via the HEFA pathway is expected to make the largest contribution to achieving the 2030 production target and play a key role in boosting and establishing the SAF market. Announced SAF's total capacity, including alcohol-to-jet, FT, and power-to-liquid facilities, is expected to reach 2 BGPY by 2030 (1), with the expected from HEFA. Total HEFA capacity, including construction and planned projects, is expected to reach about 9 BGPY by 2030; if completely executed, this would contribute to renewable diesel (RD) and SAF. The production ratio of SAF and RD will depend on market conditions, incentives, and the capabilities of facilities. While some stakeholders believe that the 2030 goal may be achieved solely via HEFA, others believe that overly relying on HEFA may be detrimental to the development of other necessary pathways to meet 2050 goals. Our conclusion is that the HEFA pathway alone will not be sufficient to reach the 2030 target. It is crucial to implement additional pathways to reach the goal. This report conducts a comprehensive analysis and evaluation of the HEFA SAF value chain. Our aim is to provide current status of the industry and to identify potential challenges that could hinder the commercial production and use of SAF produced through the HEFA pathway. We have had extensive discussions, consultations, and collaborative sessions with stakeholders in the HEFA SAF value chain, including HEFA feedstocks, potential volume of HEFA SAF, economic and sustainability metrics when compared to petroleum, and assessment of the HEFA SAF industry's ability to grow and contribute to achieving the "SAF Grand Challenge." Since the HEFA pathway produces both SAF and RD, this report compares both pathways: HEFA to SAF and HEFA to RD.

09 BIOMASS FUELS↗

DOE OSTI2024

Fusion Energy Sciences Network Requirements Review: Mild-cycle Update

The US Department of Energy (DOE) Office of Science (SC) world-class research infrastructure provides the research community with premier observational, experimental, computational, and network capabilities. Each user facility is designed to provide unique capabilities to advance core DOE mission science for its sponsor SC program and to stimulate a rich discovery and innovation ecosystem. Research communities gather and flourish around each user facility, bringing together diverse perspectives. The continual reinvention of the practice of science — as users and staff forge novel approaches expressed in research workflows — unlocks new discoveries and propels scientific progress.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2026

Data Fusion for the Development of a Multimodal Freight Transload Facilities Dataset in the U.S.

To withstand the growing demand of commodity volume and its strain on the transportation infrastructure, it is necessary to identify the flow of commodities by route and mode. However, a national multimodal freight routing model does not exist for the U.S. The development of such model requires multiple building blocks, such as virtual representations of roadway, railway, and waterway networks, transload facilities (TFs), and access/egress links. Most of these blocks have a robust database in the U.S., except for the TFs. Here, this paper presents the fusion of dispersed and heterogeneous representations of multimodal TFs into a single, comprehensive, geospatial freight TF dataset. The TF dataset is derived from several sources, including the U.S. Army Corps of Engineers Master Docks Plus, the National Transportation Atlas Database, the Intermodal Association of North America, industry publications, and other public information. First, individual datasets were queried and reconciled. A geocoding/reverse geocoding process was applied to get the best street address and latitude/longitude location for each terminal. Then, duplicate terminals were identified by a fuzzy match algorithm based on terminal name and location, and removed. Validation was performed by visual inspection of random facilities. The main contributions of this work are: a publicly available version of the TF dataset, including facility location and multimodal transfer capability of 9,003 facilities, and an enterprise-version with the same facilities but including commodity handling capabilities. The main purpose of developing the TF dataset is to inform multimodal routing algorithms. The proposed TF dataset allows for credibly modeling the multimodal transfer of commodities within shipment routes.

Commodity Routing↗

DOE OSTI2025

Photochemical Ligand-Based CO 2 Reduction Mediated by Ruthenium Formyl Species

Here, a new, ligand-based strategy for CO 2 reduction to formate has been demonstrated. This approach relies on the photochemical generation of a coordinatively saturated transient ruthenium metalloformyl species, Ru-CHO, capable of reducing CO 2 to free formate directly. Under this paradigm, a highly reactive radical cation which is capable of facile formal hydrogen atom transfer (HAT) is generated via reductive quenching of an excited-state photosensitizer. Sequential electron transfer (ET) and HAT steps to a ruthenium carbonyl complex subsequently yield the Ru-CHO species, which upon further reduction undergoes fast hydride transfer to CO 2 , producing free formate. High formate selectivity (up to 98%) and impressive catalytic performance (TON ~5300; TOF ~0.1 s -1 ) was observed. Detailed mechanistic studies revealed that the overall process is highly sensitive to the identity of the radical cation, with divergent reactivity observed when HAT thermodynamics are altered. These findings provide new insights into ligand-based hydride transfer mechanisms and establish a foundation for the rational design of selective CO 2 reduction catalysts.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Opportunities for gas-phase science at short-wavelength free-electron lasers with undulator-based polarization control

Free-electron lasers (FELs) are the world's most brilliant light sources with rapidly evolving technological capabilities in terms of ultrabright and ultrashort pulses over a large range of photon energies. Their revolutionary and innovative developments have opened new fields of science regarding nonlinear light-matter interaction, the investigation of ultrafast processes from specific observer sites, and approaches to imaging matter with atomic resolution. A core aspect of FEL science is the study of isolated and prototypical systems in the gas phase with the possibility of addressing well-defined electronic transitions or particular atomic sites in molecules. Notably for polarization-controlled short-wavelength FELs, the gas phase offers new avenues for investigations of nonlinear and ultrafast phenomena in spin-orientated systems, for decoding the function of the chiral building blocks of life as well as steering reactions and particle emission dynamics in otherwise inaccessible ways. This roadmap comprises descriptions of technological capabilities of facilities worldwide, innovative diagnostics and instrumentation, as well as recent scientific highlights, novel methodology, and mathematical modeling. The experimental and theoretical landscape of using polarization controllable FELs for dichroic light-matter interaction in the gas phase will be discussed and comprehensively outlined to stimulate and strengthen global collaborative efforts of all disciplines. Published by the American Physical Society 2025

Ilchen, Markus↗

DOE OSTI2025

SiC Receiver/Reactor by Additive Manufacturing for Concentrated Solar Thermocatalysis with Thermal Energy Storage (Final Technical Report - Public)

The direct use of solar thermal energy provides opportunities for low-cost heating sources for a variety of applications. Ultra-high temperatures around 1000°C are high value and highly useful for energy-demanding industries. Many materials cannot withstand these conditions. In the area of Sustainable Chemicals, further limitations on material stability exist. Combining state-of-the-art materials with new designs provides a promising pathway for harvesting solar thermal energy and performing high temperature chemical processes. However, conventional manufacturing limits the potential for design flexibility. In this project, Additive Manufacturing was combined with advanced materials and new chemical reactor designs. In addition, 24/7 energy is necessary for chemical processing, and designs for ultra-high temperature thermal storage were devised. Specifically, preliminary design of a novel solar thermal receiver was developed in this project and designed to work with thermocatalytic reactors for producing sustainable chemicals and fuels. An ultra-high temperature particle storage system and heat exchangers were proposed to transport ultra-hot air as thermal fluid for the system. On a broader scale, this system could be used to tap solar thermal energy for a centralized facility with capability of transferring that heat to various segments at a full range of temperatures to 1000°C. The project pushed the temperature boundaries past those in current use, and Additive Manufacturing was envisaged for fabricating the receiver to meet requirements of extreme environments. An extensive analysis of silicon carbide additive manufacturing was performed to compare the thermal and mechanical properties of complex geometries compared to conventional material and those manufactured via other methods. The Additive Manufacturing via Binder-Jet printing was optimized and characterized to provide high quality and reproducible components capable of withstanding the proposed extreme environments. The designs for the concentrating solar thermal cavity with ultra-hot air thermal fluid showed high performance in simulations, attributable to the complex optimized geometries of the 3D printed systems. The bright future of Additive Manufacturing with advanced materials developments should provide more options and even higher quality as the technology further develops. Current costs for Additive Manufacturing of advanced ceramics is relatively low, however post-processing of the materials for extreme environments is currently high. There is little industrial-scale infrastructure for these, but it is growing as niche applications become more mainstream. The results of the project can be translated into similar extreme environments for concentrating solar thermal energy as well as its integration with ultra-hot air thermal fluids. A number of industries that require ultra-high temperatures need to electrify or otherwise decarbonize for climate goals, and this project showed that theoretically there is a pathway to do so with direct concentrated solar thermal power.

10 SYNTHETIC FUELS↗

DOE OSTI2025

Updates on Nuclear Imaging Capabilities at the National Ignition Facility

Explore the source record for details and available documents.

Durocher, Mora [Los Alamos National Laboratory] (O↗

DOE OSTI2025

Techno-Economic Analysis of Compressed Air Energy Storage and Hydrogen Production from Variable Renewable Energy

This study presents the techno-economic analysis (TEA) results of integrating electrolysis hydrogen (H 2 ) production, compressed air energy storage (CAES), and H 2 -fired combustion turbines in a high variable renewable energy (VRE) market environment. The inconsistent nature of VRE creates challenges for power producers in maintaining a stable electrical grid as it is increasingly utilized. The mission of the National Energy Technology Laboratory (NETL) is driving innovation and delivering energy solutions, and a multiangle approach involving H 2 production, energy storage, and next-level H 2 -fired combustion turbine generator (CTG) technologies could provide one solution for the nation’s growing electrical grid issues with increasing VRE sources. The H 2 production and CAES concept were investigated due to its ability to provide utility-scale H 2 -fueled power generation with large-scale energy storage capabilities. Two facilities with CAES and natural gas-fired CTGs (in McIntosh, Alabama, and Huntorf, Germany) have been operating for decades. In contrast, this study investigates the potential to replace the natural gas fuel with H 2 fuel. This concept has been publicly presented by both Siemens Energy and Bechtel Global Engineering, Construction & Project Management (Bechtel) at two different power generating levels. The CAES and air expansion/combustion turbine power generation in this study are primarily based on the Siemens Energy system (Bailie, Aug. 10-11, 2021) (Scheller, Feb. 21, 2023). The inclusion of a H 2 turboexpander generator is from Bechtel (Gülen, Sep. 6, 2022). A block flow diagram of the proposed process is illustrated in Exhibit ES-1.

08 HYDROGEN↗

DOE OSTI2026

PowerAmerica (Final Technical Report)

The U.S. Department of Energy’s Advanced Manufacturing Office (predecessor to AMMTO) established PowerAmerica in December 2014 to develop and accelerate the adoption of wide bandgap (WBG) semiconductor chips and power electronics in manufacturing. The objective was to spark early commercialization of energy efficient products; educate and train the workforce; create high-tech jobs; and nurture the growth of the U.S. WBG semiconductor manufacturing industry. PowerAmerica isled by North Carolina State University by way of a five-year, $140M cooperative agreement with DoE. This private-public partnership with DoE includes member companies ranging from startups and small-medium enterprises to large system integrators, world-class universities, and national labs. The WBG power electronic ecosystem formed by our diverse membership is focused on using advanced manufacturing to 1) lower the cost of silicon carbide and gallium nitride semiconductor devices to be comparable to silicon devices; 2) demonstrate the system benefits and energy efficiency advantages of WBG semiconductor power electronics through system demonstrations that validate their effectiveness; and 3) build an education pipeline for a skilled workforce to meet the future demand for emerging WBG semiconductor markets — and enhance U.S. economic competitiveness globally. PowerAmerica was initially funded in six budget periods, each lasting 12 to 18 months. By the end of Budget Period 6 (August 2023), PowerAmerica had achieved its major objectives in technology development, semiconductor device cost reduction, ecosystem growth and engagement, and education and workforce development. Through strategic foundry investments, we helped to establish the first U.S. SiC foundry (X-FAB) and supported a lab (Microchip) to start SiC volume production. We’ve helped bring together companies from different parts of the supply chain, resulting in several successful new partnerships and business relationships. Through projects with some of the largest manufacturers of energy-intensive equipment in the U.S. — John Deere, GE, United Technologies, Raytheon, Carrier, Toshiba, and others — we have successfully demonstrated the energy and system benefits of WBG technology. We have also harnessed the unique capabilities and facilities of national labs — the Naval Research Laboratory, National Renewable Energy Laboratory, and Argonne National Laboratory — to help solve challenging technical problems for industry. Thanks to our many webinars, tutorials, annual events, and presence at major energy and electronics conferences around the world, the PowerAmerica name has become synonymous with WBG technology advancement. The commercial interest in WBG technology is higher than ever; companies and governments around the world have announced hundreds of millions of dollarsin future investment to build capacity — and compete with silicon in many markets and applications. We have trained hundreds of engineering students, from universities across the U.S., through hands-on projects and WBG coursework. Working professionals have also benefited through the years from our many targeted short courses, tutorials, and technical webinars. In short, PowerAmerica has made great strides in each of our key objectives, and the organization has been operating without government or NC State

14 SOLAR ENERGY↗

DOE OSTI2024

High Harmonic Generation Seeding Echo-Enabled Harmonic Generation toward a Storage Ring-Based Tender and Hard X-ray-Free Electron Laser

To align with the global trend of integrating synchrotron light source (SLS) and free electron laser (FEL) facilities on one site, in line with examples such as SPring-8 and SACLA in Japan and ELETTRA and FERMI in Italy, we actively explore FEL options leveraging the ultralow-emittance electron beam of the NSLS-II upgrade. These options show promising potential for synergy with storage ring (SR) operations, thereby significantly enhancing our facility’s capabilities. Echo-enabled harmonic generation (EEHG) is well-suited to SR-based FELs, and has already been demonstrated with the capability of generating extremely narrow bandwidth as well as high brightness, realized using diffraction-limited short pulses in transverse planes and Fourier transform-limited bandwidth in the soft X-ray spectrum. However, regarding a conventional EEHG scheme, the combination of the shortest seed laser wavelength (256 nm) and highest harmonic (200) sets the short wavelength limit to λ = 1.28 nm. To further extend the short wavelength limit down to the tender and hard X-ray region, a vital option is to shorten the seed laser wavelength. Thanks to recent advances in high harmonic generation (HHG), packing 10 9 photons at one harmonic within a few-femtosecond pulse could turn such a novel HHG source into an ideal seeding for EEHG. Thus, compared to the cascaded EEHG, the HHG seeding option could not only lower the cost, but also free the SR space for accommodating more user beamlines. Moreover, to mitigate the SASE background noise on the sample and detector, we combine the HHG seeding EEHG with the crab cavity short pulse scheme for maximum benefit.

36 MATERIALS SCIENCE↗

DOE OSTI2024

EVs@Scale High-Power Charging (HPC) Pillar Deep-Dive Technical Meeting

EVs@Scale Lab Consortium is addressing challenges, developing solutions, and enabling technologies for transportation electrification ecosystem. The consortium has five research pillars one of which focuses on high power charging (HPC). HPC pillar brings together hardware and software expertise, capabilities, and facilities related to high power EV charging, charge management, and grid integration. Deep-dive technical meetings are organized twice a year and provides an opportunity for more industry engagement and technical feedback for the national labs throughout the project lifecycle. High-Power Charging pillar has two active projects: (i) Next-Gen Profiles (NGP) and (ii) High-Power Electric Vehicle Charging Hub Integration Platform (eCHIP). This presentation summarizes the progress made in both projects during the past six months focusing on specific topics. There will be two deep-dive technical meetings twice a year. Every deep-dive meeting will focus on different aspects of the project progress.

ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2024

Nov. 2024 EVs@Scale High-Power Charging Deep Dive Technical Meeting

ADVANCED PROPULSION SYSTEMS,DIRECT ENERGY CONVERSI↗

DOE OSTI2024

Advanced Characterization Capabilities for Nuclear Materials via Nuclear Science User Facilities (NSUF)

Advanced post-irradiation examination (PIE) techniques are required to design new or improved nuclear materials, characterize, and understand in-core behavior of fuel and materials, and support the qualification of new reactor materials. The Nuclear Science User Facilities (NSUF) is the U.S. Department of Energy Office of Nuclear Energy's only designated nuclear science user facility. NSUF provides researchers access to PIE capabilities at Idaho National Laboratory and at a diverse mix of university, national laboratory and industrial partner institutions. The PIE capabilities include novel destructive and non-destructive techniques for radiation damage characterization, such as advanced diffraction techniques (X-ray, electron, or neutron) coupled to extreme environments; in-situ observation of microstructural evolution under irradiation; in-situ irradiation to monitor corrosive attack in coolant environments; in-situ irradiation and mechanical testing; and test methods for synergistic effects of superimposed extreme environments (temperature, irradiation, stress, corrosion) on materials behaviors. This talk will provide an overview of NSUF PIE capabilities.

36 MATERIALS SCIENCE↗