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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 433 records · Page 24

Computational Modeling of Atmospheric Processes at Texas Southern University

Texas Southern University (TSU) is strengthening its research program in atmospheric chemistry and physics with a climate science emphasis by leveraging partnerships with the U.S. Department of Energy’s Atmospheric Radiation Measurement (ARM) Facility, Brookhaven National Laboratory (BNL), and the Tracking Aerosol Convection Interactions ExpeRiment (TRACER). This RDPP-supported program focuses on secondary organic aerosols (SOAs) and reactive atmospheric species that influence cloud formation, precipitation processes, and radiative forcing. SOAs play a critical role in cloud microphysics and Earth’s energy balance, yet the chemical and physical mechanisms governing SOA–cloud interactions remain a significant source of uncertainty in predictive climate models. Through computational modeling, observational data analysis, and national laboratory collaboration, this program develops a skilled cohort of students trained in atmospheric science, environmental data analysis, and climate-relevant modeling. These research experiences build technical competencies that are transferable to careers in government laboratories, academia, and industry. By engaging students from historically underrepresented communities in high-impact climate research, TSU expands participation in the atmospheric sciences workforce while contributing meaningful scientific insights to DOE-supported ARM research activities. This partnership strengthens national capacity in climate science and supports the development of the next generation of atmospheric researchers.

54 ENVIRONMENTAL SCIENCES↗

A hub and spoke approach to optimizing energy wheeling of renewable resources

The deployment of zero carbon renewable energy sources needs to increase significantly to support the goal of net zero greenhouse gas emissions by 2050. At the same time energy end use needs to decarbonize. This will change both energy supply and energy demand patterns, requiring the energy delivery infrastructure (grid-based transmission circuits) to become increasingly flexible to maintain security of supply everywhere and always. The integration of zero carbon renewable energy requires cross-border and cross energy system coupling and a fit-for-purpose design. Nowadays, energy systems are planned, designed and operated in silos with a strong national focus. However, large-scale offshore wind production needs to be transported to deep inland locations, across country borders. The increased peak generation capacity of renewable energy sources will, at times, significantly exceed demand (Matthew Langholtz, 2020). The traditional solution of continuously reinforcing and extending the electricity grid is not sustainable from a cost and societal perspective. This paper will, however, propose a deterministic approach on how networked (interconnected grid) Points of receipt (POR) to Points of Delivery (POD) can be optimized for wheeling renewable energy resources while minimizing energy cost with a hub and spoke approach. The statistical approach will be done via using existing daily energy market clearing prices, available transmission capacity and firm daily transmission prices in open access energy markets. Renewable energy targets, including specific offshore wind targets, need to be in line with the ramp-up as implied by the Paris Agreement. These targets are required to provide industry with a secure market outlook that allows them to build up supply chains accordingly. Optimizing wheeled energy paths from carbon neutral resources such as renewables make them not only cost competitive on the unit commitment stack, but also more accessible on the dispatch stack to other carbon heavy forms of generation such as coal and natural gas turbines (Matthew Langholtz, 2020). This correlates to maximizing renewable resource inertia (wind, solar, biomass) within an interconnected grid without having to consider additional expansion of resources via land purchases and de-forestation.

Mukherjee, Srijib↗

Hydrogel-assisted self-healing of biomineralized living building materials

Living building materials (LBMs) are an emergent class of structural materials that leverage the biomineralization capability of microorganisms within sand-hydrogel scaffolds to produce living, load-bearing structures. Here we produced LBMs using a physically crosslinkable sand-hydrogel scaffold and two microorganisms with different biomineralization pathways - Synechococcus sp. PCC 7002 (photosynthetic) and S. pasteurii (ureolytic) - and investigated their self-healing capacity. Our results reveal that both Synechococcus sp. PCC 7002 and S. pasteurii demonstrated exceptional viability within all LBMs for more than 20 days. Damaged LBMs containing Synechococcus sp. PCC 7002 exhibited 103% and 112% of their original compressive and flexural strengths, respectively, after three days of healing at 50% relative humidity (RH) (i.e., ambient conditions). In contrast, LBMs containing S. pasteurii exhibited 71% and 66% of their original compressive and flexural strengths, respectively, after three days of healing at 50% RH. The compressive and flexural strengths of all LBMs rebounded to 93-100% after seven days of healing at 50% RH. Data substantiate that the self-healing ability of the hydrogel plays a critical role in facilitating healing of LBMs, as evidenced by the 82-118% rebounds in compressive and flexural strengths by the sand-hydrogel scaffold alone after three or seven days of healing at 50% RH. Healing was less effective at 100% RH for all LBMs investigated herein.

36 MATERIALS SCIENCE↗

Lithium-Ion Battery Supply Chain for E-Drive Vehicles in the United States: 2010–2020

Understanding the battery supply chain is particularly important for the strategic planning and development of a battery recycling infrastructure to secure critical materials supply and enable a circular economy. Argonne has been tracking plug-in electric vehicle (PEV) sales in the United States (U.S.) by make and model since December 2010, when the Chevrolet Volt and Nissan Leaf were first sold in the U.S. Building on detailed monthly sales data, this report summarizes the manufacturing and production locations of lithium-ion (Li-ion, or LIB) battery cells and packs by make and model for PEVs sold in the U.S. from 2010 to 2020. It also summarizes the annual and cumulative Li-ion battery capacity installed in hybrid electric vehicles (HEVs) sold in the U.S. Overall, there are about 20 different battery cell and pack manufacturers, which are currently supplying about 20 gigawatt-hours (GWh) of batteries annually for the U.S. PEV market. Panasonic and LG Chem are the largest cell suppliers to the U.S. market. Beyond the U.S, South Korea and Japan are major countries supplying PEV batteries to the U.S. market.

25 ENERGY STORAGE↗

Field Study of 120-volt Heat Pump Water Heaters in the Big Easy

To meet long-term goals for reducing carbon emissions and lessen the impacts of climate change, the U.S. plans to decarbonize its building stock, which includes the replacement of fossil fuel-burning end uses with energy efficient electric alternatives. As part of this strategy, the replacement of fossil fuel water heaters with heat pump water heaters (HPWH) has the potential to avoid substantial carbon emissions. An estimated 10-15 million single-family homes with fossil fuel water heaters do not have the electrical panel capacity to install a 240-volt, 30-amp HPWH. For these homes, a technology recently introduced to the market, the 120-volt plug-in HPWH, can provide energy efficient electrification of water heating without an expensive panel and wiring retrofit. This paper presents the results of an ongoing 120-volt HPWH field study conducted in 17 homes in New Orleans, LA. Key installation scenarios are profiled for retrofitting from gas-fired water heaters to 120-volt HPWHs, accounting for space, air volume, air temperature, condensate drainage, and electrical. Each HPWH had its surrounding air temperature, relative humidity, inlet and outlet water temperature, flow, and energy consumption monitored. Using these data, hot water delivery and energy efficiency performance were analyzed based on home characteristics. Hot water run outs were investigated to understand how hot water usage, inlet water temperature, and surrounding air temperature impact the HPWH’s ability to meet load. From these results, best practices for 120-volt HPWH siting, sizing, and installation were developed. In addition, results are explored further to add insight for electrification policies and product development.

heat pump water heater, 120-volt, Residential buil↗

Nuclear Energy in Long-Term System Models: A Multi-Model Perspective

Long-term energy system models–including electric sector capacity expansion models–are widely used tools for informing planning, technology assessment, and policy analysis. Recent decarbonization goals and rapid technological change have increased the need to appropriately represent economic characteristics and technical details of energy system resources, including variable renewable energy, energy storage technologies, carbon-capture-equipped capacity, and nuclear energy. Nuclear power represents about 20% of electricity generation and 50% of carbon-free electricity in the United States as of 2021. However, there are many perspectives on the role of existing and new nuclear in the future U.S. energy system, which is reflected in the broad range of potential contributions reported in the literature. This project aims to understand how issues central to nuclear energy are represented in long-term energy models. Building on earlier collaborations that focused on variable renewable energy and energy storage, this project convenes four modeling teams that use national-scale long-term energy system models from the Electric Power Research Institute, the National Renewable Energy Laboratory, the U.S. Energy Information Administration, and the U.S. Environmental Protection Agency to share methods and data, update models, run coordinated scenarios, and identify research needs. Improving tools can provide more insightful analyses and ensure that methods are more transparent.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DISSPATCH H2: Assessing Subsurface Storage Potential for Hydrogen

This project evaluates the technical feasibility of long-term underground hydrogen storage in the Anadarko Basin, integrating subsurface science, reservoir engineering, and system-level analysis to build a cohesive understanding of how hydrogen may be stored and recovered in porous media. Although salt caverns currently dominate commercial-scale hydrogen storage, their limited geographic availability necessitates alternative options that can support a more resilient energy system. Depleted oil and gas reservoirs offer a widely distributed and potentially high-capacity solution, but their suitability depends on formation-specific geologic, petrophysical, microbial, and operational factors. This study provides the first coordinated assessment of these factors within the Simpson Group of Oklahoma.

03 NATURAL GAS↗

Scalable Predictive Control and Optimization for Grid Integration of Large-Scale Distributed Energy Resources: Preprint

Integration of a large number of distributed energy resources (DERs) into the power grid needs a scalable power balancing method. We formulate the power balancing problem as a look-ahead optimization problem to be solved sequentially by a power distribution system aggregator based on a model predictive control (MPC) framework. Solving large-scale look-ahead control problem requires proper configuration of the control steps. In this paper, to solve large-scale control problems, we propose a variable time granularity where control time steps nearby the current control step have finer resolutions. The aggregator objective includes maximization of power production revenue and minimization of power purchasing expense, renewable power curtailment, and mileage costs for energy storage and electric vehicle (EV) charging stations while satisfying system capacity and operational constraints. The control problem is formulated as a mixed-integer linear program (MILP) and solved using the XpressMP solver. We perform simulations considering a copper plate representation of a large distribution network consisting of 2507 devices (controllable DERs) including curtailable photovoltaics (PVs), energy storage batteries, EV charging stations, and buildings with heating, ventilation, and air conditioning units (HVACs). We show the effectiveness of the proposed approach in managing DERs interactively for maximum energy trading profit and local supply-demand power balancing. Finally, we demonstrate that the proposed method outperformed other benchmark controllers regarding computation time without compromising operational performance.

DER↗

Scalable Predictive Control and Optimization for Grid Integration of Large-Scale Distributed Energy Resources

Integrating a large number of distributed energy resources (DERs) into the power grid needs a scalable power balancing method. We formulate the power balancing problem as a look-ahead optimization problem to be solved sequentially by a power distribution system aggregator based on a model predictive control (MPC) framework. Solving large-scale look-ahead control problems requires proper configuration of the control steps. In this paper, to solve large-scale control problems, we propose a variable time granularity where control time steps nearby the current control step have finer resolutions. The aggregator objective includes maximization of power production revenue and minimization of power purchasing expense, renewable power curtailment, and mileage costs for energy storage and electric vehicle (EV) charging stations while satisfying system capacity and operational constraints. The control problem is formulated as a mixed-integer linear program (MILP) and solved using the XpressMP solver. We perform simulations considering a copper plate representation of a large distribution network consisting of 2507 devices (controllable DERs), including curtailable photovoltaics (PVs), energy storage batteries, EV charging stations, and buildings with heating, ventilation, and air conditioning units (HVACs). We show the effectiveness of the proposed approach in managing DERs interactively for maximum energy trading profit and local supply-demand power balancing. Finally, we demonstrate that the proposed method outperforms other benchmark controllers regarding computation time without compromising operational performance.

DER↗

Factors Impacting Nuclear Energy Share in U.S. Energy Markets

The purpose of this report is to collate information and findings from recent studies conducted by national and international bodies/institutes to identify approaches for maintaining/enhancing the role of nuclear energy in the current and future energy mix of the United States. This report shows how nuclear generation grew quickly to provide 20% of U.S. electricity, sustaining that level for three decades without the benefit of new construction, but is now projected to decline going forward. Nuclear construction costs in the U.S. spiraled out of control, ending construction for two decades and the recent resumption of construction has continued the pattern of schedule delays and cost overruns. However, nuclear operations exhibited strong learning, achieving and sustaining the highest capacity factor of any electricity generation technology and license extensions and uprates have sustained nuclear market share. The share of nuclear energy in the U.S. electricity market is projected to decline by ~1/3rd over the next 30 years The report provides an overview of how the markets work in theory and in practice. It indicates how market deregulation and clean energy policies have created conditions where nuclear plants are being retired for economic rather than technical reasons. The report also shows how many of the markets do not in practice have free competition but instead have outcomes that are being determined more and more by policy instead of market forces. While electricity costs from existing nuclear plants are low, electricity from new builds is projected to be too expensive to be competitive head-to-head with natural gas, even for nth-of-a-kind costs. Wind and solar energy have enjoyed an extended period of sustained subsidy. This protected environment has resulted in a sustained reduction in plant level costs to the point that some of these Variable Renewable Energy (VRE) technologies are becoming competitive even if their direct subsidies are removed. But plant level costs underestimate total VRE costs which include a number of system-level externalities. The incremental system value of additional VRE capacity was shown to decline as market share increases, with solar value declining more quickly than wind. The report closes with examination of a possible future for nuclear generation as part of deep decarbonization of the electricity sector. This approach avoids direct competition with natural gas. The two options for achieving 100% decarbonization are to use only renewables or to use all zero emissions technologies, and the report shows the second approach is much less expensive than the first.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Evaluation of the Energy, Hygrothermal, and Thermal Capacity Performance of Cross-Laminated Timber

Cross-laminated timber (CLT) construction is gaining momentum in the US because it offers multiple advantages over traditional construction methods. Benefits that have received the most attention focus on constructability, the environment, and protection (e.g., blast resistance), although CLT construction is likely to offer other benefits, as well. Still, these have not been studied at length because such evaluations are costly, requiring long-term assessments in an actual building and specialized technical knowledge. Among the possible benefits, CLT construction likely provides a higher-performing building envelope. Using CLT panels to enclose a building means fewer joints in the opaque envelope than what is required in traditional stick-framed construction. Fewer joints mean fewer locations where the air- and water-resistive barrier (WRB) could be compromised; thus, a CLT building enclosure may require less maintenance and have a longer lifespan than a traditionally built structure because of fewer air and water leaks. In addition, CLT’s thermal mass moderates indoor temperatures, allowing the heating, ventilation, and air conditioning (HVAC) system to operate more efficiently during peak hours, reducing operational energy consumption throughout the lifetime of the CLT building (Salonvaara et al., 2022). Furthermore, more stable indoor temperatures can increase occupant comfort. The CLT’s thermal mass can also reduce energy costs by adjusting to utility time-of-use pricing without affecting occupant comfort. The ability of CLT buildings to bridge periods without HVAC operation prepares them for future grid interaction and provides a certain level of resilience against power outages. Researchers have attempted to quantify these benefits; however, their work is based on simplified simulations with numerous assumptions. To correctly understand the benefits, an actual building must be monitored. Therefore, information needs to be gathered on indoor and outdoor temperatures, HVAC energy consumption, thermostat setpoints, temperatures, and thermal transport in CLT components to comprehend how these parameters are affected by the CLT’s thermal mass. These data are needed to reduce the number of assumptions and calibrate simulation models to optimize HVAC controls to minimize overall energy consumption, reduce energy use and higher fees during peak demand, and maintain occupant comfort. Additionally, the calibrated simulation model allows the optimization exercise to be repeated in various US climates. Potential benefits can be tailored to buildings in various locations, and decisions can be made on where CLT construction could be most advantageous. Furthermore, monitoring and simulation results are needed to evaluate the durability of the CLT structures in different climates. This project’s researchers gathered information to help understand and quantify the benefits of CLT buildings concerning operational energy, moderated indoor temperatures, and comfort; the dynamic operation to provide grid services; and resilience in times of power outage. Through the corroboration of simulation models with real-world measurements, this study paves the way for extrapolating findings to other climatic zones and building typologies, thereby broadening the understanding of CLT’s multifaceted benefits and reinforcing its position as a material of choice in sustainable construction.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Lithium-Sulfur Batteries with a Block Copolymer Electrolyte Analyzed by X-ray Microtomography

Most of the work on Lithium-sulfur (LiS) batteries use liquid electrolytes that have limited stability when coupled with Li metal anodes. We have studied LiS batteries with a solid block copolymer electrolyte which exhibits improved stability against Li anodes. Additionally, the electrolyte comprises a polystyrene-b-poly(ethylene oxide) (SEO) copolymer doped with a Li salt. Hollow carbon nanospheres impregnated with sulfur were used to build a composite cathode. Two types of sulfur-impregnated functionalized carbon nanospheres were used: One with carboxylic acid groups and the other with short lithium poly(4-styrenesulfonyl(trifluoromethylsulfonyl)imide) (PSTFSI-Li) chains. Cells with Li S dissolved in the SEO based electrolyte served as the baseline. After cycling, the reason for capacity fade was determined by imaging the batteries using synchrotron hard X-ray microtomography. It is generally assumed that LiS cells fail due to dissolution of polysulfide into the liquid electrolyte, i.e., the main problems related to the cathode. In our all-solid cells, failure was primarily due to delamination of the Li foil from the polymer electrolyte layer. Delamination is also observed at the sulfur cathode. It is likely that the large changes in volume of the active materials during cycling induce delamination in all-solid LiS cells. 2 8

25 ENERGY STORAGE↗

Midwest Nuclear-based Net-Zero Carbon Steelmaking Demonstration

Globally, the iron and steel industry accounts for around a quarter of GHG emissions from the manufacturing sector , which is about 7% of the 33 gigatonnes (Gt) of global CO 2 emissions . Thus, globally, the steel industry is a 2-3 Gt CO 2 per year emissions challenge. The steel industry is important to the U.S. economy with output equal to $0.5 trillion and domestic production capacity is critical to national defense, infrastructure, energy production, and transportation. President Biden’s executive order on climate identifies actions and policies to put the Nation on a path to achieve net-zero carbon emissions, economy-wide, by no later than 2050. To achieve this, deep carbon reductions in the power, transportation, buildings and capital-intensive industrial manufacturing segments such as steel, cement and chemicals need to be addressed. In its recent “Accelerating Decarbonization of the U.S. Energy System” report , the National Academy of Sciences (NAS) stated that, “while technology exists to decarbonize all parts of the energy system, some sectors remain at precommercial or first-of-a-kind demonstration stages and require significant improvement in cost and performance to become commercially viable.” The NAS goes on to state that these hard to decarbonize sectors include “aviation, shipping, and industrial subsectors such as steel, cement, and chemicals manufacturing .” The Administration has proposed a timeline to decarbonize energy, transportation and then industry and manufacturing. From a life-cycle approach, decarbonizing steel and other large industrial inputs are necessary to decarbonize transformations in energy and transportation. DOE’s TRI-Lab Consortium’s Integrated Energy Systems (IES) program is a collaboration amongst DOE’s three applied energy laboratories: the National Energy Technology Laboratory; National Renewable Energy Laboratory and Idaho National Laboratory. The IES approach looks at more tightly integrating low-carbon nuclear energy, renewable electricity, energy storage, load/demand balancing, and biomass (including plastics and other wastes) with one or more industrial processes that utilize heat and/or power from these clean and waste energy sources to produce a low-carbon commodity-scale product.

08 HYDROGEN↗

Scalable Predictive Control and Optimization for Grid Integration of Large-Scale Distributed Energy Resources

Integrating a large number of distributed energy resources (DERs) into the power grid needs a scalable power balancing method. We formulate the power balancing problem as a look-ahead optimization problem to be solved sequentially by a power distribution system aggregator based on a model predictive control (MPC) framework. Solving large-scale look-ahead control problems requires proper configuration of the control steps. In this paper, to solve large-scale control problems, we propose a variable time granularity where control time steps nearby the current control step have finer resolutions. The aggregator objective includes maximization of power production revenue and minimization of power purchasing expense, renewable power curtailment, and mileage costs for energy storage and electric vehicle (EV) charging stations while satisfying system capacity and operational constraints. The control problem is formulated as a mixed-integer linear program (MILP) and solved using the XpressMP solver. We perform simulations considering a copper plate representation of a large distribution network consisting of 2507 devices (control-lable DERs), including curtailable photovoltaics (PVs), energy storage batteries, EV charging stations, and buildings with heating, ventilation, and air conditioning units (HVACs). We show the effectiveness of the proposed approach in managing DERs interactively for maximum energy trading profit and local supply-demand power balancing. Finally, we demonstrate that the proposed method outperforms other benchmark controllers regarding computation time without compromising operational performance.

DER↗

Sustainable aviation fuels from biomass and biowaste via bio- and chemo-catalytic conversion: Catalysis, process challenges, and opportunities

Sustainable aviation fuel (SAF) production from biomass and biowaste streams is an attractive option for decarbonizing the aviation sector, one of the most-difficult-to-electrify transportation sectors. Despite ongoing commercialization efforts using ASTM-certified pathways (e.g., lipid conversion, Fischer-Tropsch synthesis), production capacities are still inadequate due to limited feedstock supply and high production costs. New conversion technologies that utilize lignocellulosic feedstocks are needed to meet these challenges and satisfy the rapidly growing market. Combining bio- and chemo-catalytic approaches can leverage advantages from both methods, i.e., high product selectivity via biological conversion, and the capability to build C-C chains more efficiently via chemical catalysis. Herein, conversion routes, catalysis, and processes for such pathways are discussed, while key challenges and meaningful R&D opportunities are identified to guide future research activities in the space. Bio and chemo-catalytic conversion primarily utilize the carbohydrate fraction of lignocellulose, leaving lignin as a waste product. This makes lignin conversion to SAF critical in order to utilize whole biomass, thereby lowering overall production costs while maximizing carbon efficiencies. Thus, lignin valorization strategies are also reviewed herein with vital research areas identified, such as facile lignin depolymerization approaches, highly integrated conversion systems, novel process configurations, and catalysts for the selective cleavage of aryl C–O bonds. The potential efficiency improvements available via integrated conversion steps, such as combined biological and chemo-catalytic routes, along with the use of different parallel pathways, are identified as key to producing all components of a cost-effective, 100% SAF.

09 BIOMASS FUELS↗

Impact of installation faults in air conditioners and heat pumps in single-family homes on U.S. energy usage

To ensure that new residential air conditioners and heat pumps operate optimally, care must be taken during the initial system design and installation to avoid missteps that immediately degrade a system’s performance. Laboratory and simulation studies have quantified the impact that faults can have on capacity and efficiency. Field studies have demonstrated that installation-related faults are commonplace. However, the national impact of installation-related faults cannot be accurately estimated by only simulating a limited number of homes at several fault levels because of the variety of home characteristics and climates involved. In our analysis, we use an improved residential building stock simulation tool to predict the annual energy increase and additional utility costs resulting from two common installation faults: indoor airflow rate and refrigerant charge level. Our method considers the wide range of building characteristics and climate zones of the U.S. housing stock. We use existing field data to develop fault intensity probability distributions to inform our analysis. The study shows that these two faults result in approximately 20.7 TWh/y of additional energy use for central air conditioners and air-source heat pumps in U.S. single-family detached homes, which is a 9% increase over baseline (no-fault) usage, costing homeowners approximately $2.5 billion annually on utility bills. Air-source heat pumps are responsible for a disproportionate fraction of this energy use increase because of the larger number of operating hours compared to central air conditioners and the sensitivity of heating mode performance to the faults analyzed compared to cooling mode.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Biaxial steel plated concrete constitutive models for composite structures: Implementation and validation

The Steel-plated Concrete (SC) technique is an alternative construction technique with faster onsite construction speed, reduced construction time, and increased structural performance. Aiming to predict the force transfer mechanism of SC elements, an innovative constitutive model package is proposed by implementing experimental-based biaxial steel plate concrete models into the nonlinear finite element (FE) model “Membrane Model of SC (MM-CS).” First, the formulation and implementation of the MM-SC is illustrated in detail, including the equilibrium and compatibility equations and the implementation of constitutive models. Next, various experimental data of SC members are selected and simulated using the proposed MM-SC model. In this research, two types of structures, SC panels and framed SC shear walls, and three types of loading conditions, including uniaxial compression, pure shear, and combined axial-flexural-shear tests, are analyzed respectively. Good agreements were obtained between the reported results and the FE simulation results in terms of yield capacity and ultimate capacity, proving the reliability of the implemented analytical constitutive material models and the biaxial membrane model formulations.

42 ENGINEERING↗

Next Generation Integrated PV Products Cost and Workflow Analysis (Final Report)

Residential photovoltaic (PV) costs have fallen consistently for over a decade (Ardani et al. 2018). DOE has subsequently developed a new residential PV cost target for 2030 of $0.05/kilowatt hour (SETO 2023). Ardani et al. (2018) conclude that integrated roofing and PV (RIPV) products may be key to achieving the residential target for both new construction and retrofit residential PV. In RIPV, the PV product is incorporated into or replaces the roofing material. RIPV systems can use conventional crystalline or thin-film technologies, may be aesthetically attractive alternatives to traditional racked and mounted PV systems, and may increase building property values (Cook et al. 2023). These products also have the potential to provide customer acquisition, labor, and equipment cost savings over traditional, racked and mounted residential rooftop PV and several companies have recently introduced integrated roofing and PV (RIPV) products (Cook et al. 2023). In 2022, Tesla was the market leader, representing 94% of RIPV capacity installed in 2022 through its Solar Roof offering, while GAF Energy and its Timberline Solar product was second capturing 3% (Feldman et al. 2023). In this project, NREL analyzed three research questions: (1) How do current RIPV products compare to racked and mounted PV in terms of costs, install times and processes? (2) How are RIPV products installed and are there opportunities for cost savings? (3) What are the key barriers to expanding market opportunities for integrating solar and roofing products? In this project, we explored residential RIPV cost reduction opportunities by analyzing installation processes. Our study documented residential RIPV installations at two reroofing sites (20.52 kilowatts) and the equivalent of nine new construction sites (71.75 kW) in California through a methodology known as time and motion study. We also conducted 15 interviews with subject-matter experts to identify barriers and solutions to maximize these products' market penetration.

14 SOLAR ENERGY↗