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DOE OSTI2016

Power generation from nanostructured PbTe-based thermoelectrics: comprehensive development from materials to modules

In this work, we demonstrate the use of high performance nanostructured PbTe-based materials in high conversion efficiency thermoelectric modules. We fabricated the samples of PbTe-2% MgTe doped with 4% Na and PbTe doped with 0.2% PbI2 with high thermoelectric figure of merit (ZT) and sintered them with Co-Fe diffusion barriers for use as p- and n-type thermoelectric legs, respectively. Transmission electron microscopy of the PbTe legs reveals two shapes of nanostructures, disk-like and spherical. The reduction in lattice thermal conductivity through nanostructuring gives a ZT of similar to 1.8 at 810 K for p-type PbTe and similar to 1.4 at 750 K for n-type PbTe. Nanostructured PbTe-based module and segmented-leg module using Bi2Te3 and nanostructured PbTe were fabricated and tested with hot-side temperatures up to 873 K in a vacuum. The maximum conversion efficiency of similar to 8.8% for a temperature difference (Delta T) of 570 K and B11% for a Delta T of 590 K have been demonstrated in the nanostructured PbTe-based module and segmented Bi2Te3/nanostructured PbTe module, respectively. Three-dimensional finite-element simulations predict that the maximum conversion efficiency of the nanostructured PbTe-based module and segmented Bi2Te3/nanostructured PbTe module reaches 12.2% for a Delta T of 570 K and 15.6% for a Delta T of 590 K respectively, which could be achieved if the electrical and thermal contact between the nanostructured PbTe legs and Cu interconnecting electrodes is further improved.

Hu, Xiaokai↗

DOE OSTI2011

Efficient direct magneto-optical phase modulation of light waves in spun microstructured fibres

We have proposed a phase modulator of optical radiation for an interferometric electric-current sensor. The modulator takes advantage of the Faraday effect in spun microstructured optical fibres. Such fibres enable small-diameter multiturn fibre coils to be produced, which is necessary for achieving a preset phase modulation amplitude at a moderate drive current. The principal characteristics of the modulator have been studied experimentally: frequency response, magneto-optical sensitivity and output signal contrast. The results demonstrate that the modulator ensures high efficiency, approaching the theoretical one, provided the modulation period exceeds the time it takes light to pass through the fibre. We have examined the influence of spun fibre parameters on the performance of the modulator.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2020

The ABC130 barrel module prototyping programme for the ATLAS strip tracker

For the Phase-II Upgrade of the ATLAS Detector [1], its Inner Detector, consisting of silicon pixel, silicon strip and transition radiation sub-detectors, will be replaced with an all new 100% silicon tracker, composed of a pixel tracker at inner radii and a strip tracker at outer radii. The future ATLAS strip tracker will include 11,000 silicon sensor modules in the central region (barrel) and 7,000 modules in the forward region (end-caps), which are foreseen to be constructed over a period of 3.5 years. The construction of each module consists of a series of assembly and quality control steps, which were engineered to be identical for all production sites. In order to develop the tooling and procedures for assembly and testing of these modules, two series of major prototyping programs were conducted: an early program using readout chips designed using a 250 nm fabrication process (ABCN-250) [2,2] and a subsequent program using a follow-up chip set made using 130 nm processing (ABC130 and HCC130 chips). This second generation of readout chips was used for an extensive prototyping program that produced around 100 barrel-type modules and contributed significantly to the development of the final module layout. This paper gives an overview of the components used in ABC130 barrel modules, their assembly procedure and findings resulting from their tests.

47 OTHER INSTRUMENTATION↗

DOE OSTI2021

Magnetic triggering — time-resolved characterisation of silicon strip modules in the presence of switching DC-DC converters

Modules for the ATLAS Inner Tracker (ITk) strip tracker include a DC-DC converter circuit glued directly to the silicon sensor which converts the 11 V supplied to the module to the 1.5 V required for the operation of the readout chips. The DC-DC converter unit, consisting of a copper solenoid and custom ASIC, is located directly above the silicon strip sensor and therefore needs to be shielded to protect the sensor from EMI noise created during the operation of the circuit. Despite dedicated shielding, consisting of an aluminium shield box with continuous solder seams encompassing the surface components and a copper layer in the PCB beneath it, module channels connected to sensor strips located beneath the converter circuit were found to show a noise increase. While the DC-DC converter unit causing the underlying EMI noise operates at a frequency of 2 MHz, module characterisation measurements for ITk strip tracker modules are typically performed asynchronously to the DC-DC switching and are therefore averaged over the full range of time bins with respect to the converter frequency. In order to investigate the time dependence of the noise injection relative to the DC-DC switching frequency, a dedicated setup to understand the time-resolved performance change in modules was developed. By using a magnetic field probe to measure the field leaking through the shield box and triggering on its rising edge, data taking could be synchronised with the DC-DC switching. This paper illustrates the concept and setup of such time-resolved performance measurements using magnetic triggering and presents results for the observed effects on signal and noise for ATLAS ITk strip modules from both laboratory and beam tests.

47 OTHER INSTRUMENTATION↗

DOE OSTI2022

Motivation, benefits, and challenges for new photovoltaic material & module developments

Abstract In the last decade and longer, photovoltaic module manufacturers have experienced a rapidly growing market along with a dramatic decrease in module prices. Such cost pressures have resulted in a drive to develop and implement new module designs, which either increase performance and/or lifetime of the modules or decrease the cost to produce them. In this paper, the main motivations and benefits but also challenges for material innovations will be discussed. Many of these innovations include the use of new and novel materials in place of more conventional materials or designs. As a result, modules are being produced and sold without a long-term understanding about the performance and reliability of these new materials. This has led to unexpected new failure mechanisms occurring few years after deployment, such as potential induced degradation or backsheet cracking. None of these failure modes have been detected after the back then common single stress tests. New accelerated test approaches are based on a combination or sequence of multiple stressors that better reflect outdoor conditions. That allows for identification of new degradation modes linked to new module materials or module designs.

Oreski, G. (ORCID:0000000342239047)↗

DOE OSTI2022

Design and Implementation of Automated Characterization of T-type based Power Module for PV Inverter Reliability Assessment

Reliability of power electronics holds the key for future power and energy systems since it is essential for system integration with renewables and energy storage systems. Variation of power module characteristics over the converter’s operational lifetime is a critical indicator to assess its reliability. Device characterization consists of different steps to collect, process, and visualize results, which is usually time-consuming, especially for power modules based on a non-phase-leg configuration, such as T-type circuits, widely applied for PV inverters. To reduce the time, ensure repeatability, and guarantee consistency, an automated test bench can be helpful. This paper focuses on a T-type-based power module and proposes a unique characterization platform and corresponding automation procedure and implementation. Considering the major characterization difference between T-type power modules over the conventional phase-leg power module, first, the special consideration for static characterization is highlighted. Second, the unique dynamic characterization design associated with the T-type power module is described. Finally, the automation of the power module characterization and the test platform is presented along with results and special considerations.

Siraj, Ahmed↗

DOE OSTI2020

Detection and Localization of Damaged Photovoltaic Cells and Modules Using Spread Spectrum Time Domain Reflectometry

The operating efficiency of photovoltaic (PV) plants can be improved if damaged or degraded modules can be detected and identified. Currently, string-level power electronics can detect problems with modules or cabling but not locate them, which would facilitate addressing these issues. Here, we investigate the ability of spread spectrum time domain reflectometry (SSTDR) to both detect and locate/identify damaged cells and modules within a series-connected PV string. We tested the ability of SSTDR to detect and locate single-cell mini-modules and full-sized PV modules, which were intentionally damaged by impacts with a hammer (breaking the glass and damaging the silicon below) or by cutting through some or all busbars. Damage to the glass and silicon of cells was detected and located within a small string of minimodules. Busbar damage was detectable only if an open was created by cutting through all intercell busbars. Furthermore, physical impact damage to the glass and silicon of a full-sized PV module could be detected, but further development of signal processing is needed to achieve localization of such damaged modules within a string.

14 SOLAR ENERGY↗

DOE OSTI2021

Multiscale Characterization of Photovoltaic Modules—Case Studies of Contact and Interconnect Degradation

The current popularity of photovoltaic (PV) systems is due in large part to their exceptional reliability and significantly lower cost than other energy sources. Studying cell and module degradation is key to promote further development in the state of the art. Fielded or accelerated aged modules exhibit different failure modes, of which metallization degradation (contacts and interconnections) is prevalent. In this work, we discuss how multiscale characterization methods can be applied to a variety of module technologies that have been field exposed and have undergone accelerated age testing. These methods include performing characterization on the module level, cell level, and finally the materials level. The observed performance losses from the module- and cell-level characterization can be correlated with materials properties to find out the root cause of degradation. We recommend an initial nondestructive characterization suite, including module- and cell-level current-voltage ( I--V ), Suns-V OC , photoluminescence and electroluminescence imaging, quantum efficiency, ultraviolet fluorescence imaging, and thermal infrared imaging. Samples are then extracted from particularly degraded regions of the module and prepared for materials characterization techniques, such as top-down and cross-sectional scanning electron microscopy, energy-dispersive X-ray spectroscopy, X-ray photoelectron spectroscopy, secondary ion mass spectrometry, Raman spectroscopy, and transmission electron microscopy, allowing a deeper look into the mechanism behind the metallization degradation. This article serves as an instructional review to introduce the different multiscale characterization methods and how they can be effectively applied to perform PV degradation studies. Furthermore, we also share some of our examples and discuss the strengths, limitations, and best practices for each of the characterization techniques.

14 SOLAR ENERGY↗

DOE OSTI2014

Evaluation of Maxim Module-Integrated Electronics at the DOE Regional Test Centers: Preprint

Module-embedded power electronics developed by Maxim Integrated are under evaluation through a partnership with the Department of Energy's Regional Test Center (RTC) program. Field deployments of both conventional modules and electronics-enhanced modules are designed to quantify the performance advantage of Maxim's products under different amounts of inter-row shading, and their ability to be deployed at a greater ground-coverage-ratio than conventional modules. Simulations in PVSYST have quantified the predicted performance difference between conventional modules and Maxim's modules from inter-row shading. Initial performance results have identified diffuse irradiance losses at tighter row spacing for both the Maxim and conventional modules. Comparisons with published models show good agreement with models predicting the greatest diffuse irradiance losses. At tighter row spacing, all of the strings equipped with embedded power electronics outperformed their conventional peers. An even greater performance advantage is predicted to occur in the winter months when the amount of inter-row shading mismatch is at a maximum.

14 SOLAR ENERGY↗

DOE OSTI2018

PV Lifetime Project: Measuring PV Module Performance Degradation: 2018 Indoor Flash Testing Results

Photovoltaic (PV) module and system performance degradation is being measured by periodic flash testing of fielded PV modules at three sites. As of early 2018, results from modules fielded in New Mexico and Colorado are now available. These data indicate that module degradation varies significantly between module types and can also vary between modules of the same model. In addition, degradation rates for some module types appear to vary over time. Great care is made to control for stability and repeatability in the measurements over time, but there is still a +/-0.5% uncertainty in flash test stability. Therefore, it will take several more years for degradation rate results to be known with higher confidence.

14 SOLAR ENERGY↗

DOE OSTI2024

Field Study of Nighttime Leakage Currents in Bifacial PV Modules: Correlation with Atmospheric Electric Field Data

Leakage currents measured on PV modules in the field originate from a potential difference between the modules' frame and the cells. They can be a relative indicator of Potential-Induced Degradation (PID) severity, especially when comparing the same module design in a different environment. As modules are not operating at night, no leakage current should be observed but our team has reported several events of nighttime leakage currents on bifacial PV modules. These events have been firstly observed during a thunderstorm that are characterized by strong atmospheric electrical field values. This lead us to believe that nighttime leakage currents could originate from the atmospheric electric charges. In this paper, we correlate nighttime leakage currents measured on bifacial PV modules with field mill data to identify the origin of nighttime leakage currents. Our results show that so far, no leakage currents at night occur when the atmospheric electric field is between 0 and 150–200 V/m (standard value for fair weather). As soon as the atmospheric electric field is out of this range, leakage currents are observed with or without rain involved. This suggests a transport of charged particles from the atmosphere to the modules' frame. A combination of heavy rain with strong atmospheric electric field results into high nighttime leakage currents with a magnitude up to 8 times higher than what observed during the day with -1500V applied. This is explained by an easier transport of the charged particles through the water droplets. Based on these results, leakage currents observed during the day might not be only due to the inherent potential difference between the frame and the cells depending on the atmospheric electric field activity. We believe that it should be taken into account in PID studies.

14 SOLAR ENERGY↗

DOE OSTI2019

A Hybrid Modulation Method for Single-Stage Soft-Switching Inverter Based on Series Resonant Converter

Pseudo-dc-link inverters are promising due to the single-stage configuration. The inverters can be isolated by high-frequency transformers, which also provide the freedom of step-up/down through winding turns ratio. Conventionally, a pseudo-dc-link inverter is based upon a pulsewidth modulation converter like flyback converter, but the accompanying switching losses can degrade efficiency and overall system performance. Alternatively, resonant converters (e.g., series resonant converter) seem to fit the need as they typically display soft-switching characteristics. However, the relevant research results are scarce because of two main reasons: high resonant current and limited soft-switching range. To overcome the difficulties, a hybrid modulation method is proposed in this article for a pseudo-dc-link inverter based on series resonant converter. In high-line region, the inverter operates with variable-frequency modulation, which leads to zero-voltage switching and relatively low-resonant current. In low-line region, the inverter operates with a short-pulse density modulation so that switching losses are greatly curtailed without excessive resonant current. The merits in both regions together contribute toward the high efficiency of the inverter. This article presents the operational principle of the proposed modulation as well as a comparison with other modulation methods. In addition, a 400 V-230 Vac, 2-kW prototype was built to verify the proposed modulation and the peak efficiency reaches 98.0%.

42 ENGINEERING↗

DOE OSTI2014

SU-E-T-309: Tangential Modulated Arc Therapy: A Novel Technique for the Treatment of Superficial Disease

Purpose: We propose a new type of treatment that employs a modulated and sliding tangential photon field to provide superior coverage of superficial targets when compared to other commonly employed methods while drastically reducing dose to the underlying sensitive structures often present in these cases. Methods: Modulated treatment plans were formulated for a set of three representative cases. The first was a revised treatment of a scalp sarcoma, while the second was a treatment of a right posterior chest wall sarcoma. For these cases, asymmetric jaw placement, angular limitations, and central isocenter placements were used to force the optimization algorithm into finding solutions with beamlines that were not perpendicular to the body surface. The final case targeted the chest wall of a breast cancer patient, in which standard treatments were compared to the use of modulated fields with multiple isocenters along the chest wall. Results: When compared with unrestricted modulated arcs, the tangential arc scalp treatment reduced the max and mean doses delivered to the brain by 33Gy (from 55 to 22Gy) and 6Gy (from 14Gy to 8Gy), respectively. In the right posterior chest wall case, the V10 in the ipsilateral lung was kept below 5% while retaining a Rx dose (45Gy) target coverage of over 97%. For the breast case, the modulated plan achieved reductions in high dose to the ipsilateral lung and heart by a factor of 2–3 when compared to classic laterally opposed tangents and reduced the V5 by 40% when compared to standard modulated arcs. Conclusion: Tangential modulated arc therapy has outperformed the conventional modalities of treatment for superficial lesions used in our clinic. We hope that with the advent of digitally controlled linear accelerators, we can uncover further benefits of this new technique and extend its applicability to a wider section of the patient population.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2014

Characterization of Chemically Induced Liver Injuries Using Gene Co-Expression Modules

Liver injuries due to ingestion or exposure to chemicals and industrial toxicants pose a serious health risk that may be hard to assess due to a lack of non-invasive diagnostic tests. Mapping chemical injuries to organ-specific damage and clinical outcomes via biomarkers or biomarker panels will provide the foundation for highly specific and robust diagnostic tests. Here, we have used DrugMatrix, a toxicogenomics database containing organ-specific gene expression data matched to dose-dependent chemical exposures and adverse clinical pathology assessments in Sprague Dawley rats, to identify groups of co-expressed genes (modules) specific to injury endpoints in the liver. We identified 78 such gene co-expression modules associated with 25 diverse injury endpoints categorized from clinical pathology, organ weight changes, and histopathology. Using gene expression data associated with an injury condition, we showed that these modules exhibited different patterns of activation characteristic of each injury. We further showed that specific module genes mapped to 1) known biochemical pathways associated with liver injuries and 2) clinically used diagnostic tests for liver fibrosis. As such, the gene modules have characteristics of both generalized and specific toxic response pathways. Using these results, we proposed three gene signature sets characteristic of liver fibrosis, steatosis, and general liver injury based on genes from the co-expression modules. Out of all 92 identified genes, 18 (20%) genes have well-documented relationships with liver disease, whereas the rest are novel and have not previously been associated with liver disease. In conclusion, identifying gene co-expression modules associated with chemically induced liver injuries aids in generating testable hypotheses and has the potential to identify putative biomarkers of adverse health effects.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2014

Preliminary Thermal Modeling of HI-STORM 100 Storage Modules at Diablo Canyon Power Plant ISFSI

Thermal analysis is being undertaken at Pacific Northwest National Laboratory (PNNL) in support of inspections of selected storage modules at various locations around the United States, as part of the Used Fuel Disposition Campaign of the U.S. Department of Energy, Office of Nuclear Energy (DOE-NE) Fuel Cycle Research and Development. This report documents pre-inspection predictions of temperatures for two modules at the Diablo Canyon Power Plant ISFSI identified as candidates for inspection. These are HI-STORM 100 modules of a site-specific design for storing PWR 17x17 fuel in MPC-32 canisters. The temperature predictions reported in this document were obtained with detailed COBRA-SFS models of these storage systems, with the following boundary conditions and assumptions. • storage module overpack configuration based on FSAR documentation of HI-STORM100S-218, Version B; due to unavailability of site-specific design data for Diablo Canyon ISFSI modules • Individual assembly and total decay heat loadings for each canister, based on at-loading values provided by PG&E, “aged” to time of inspection using ORIGEN modeling - Special Note: there is an inherent conservatism of unquantified magnitude – informally estimated as up to approximately 20% -- in the utility-supplied values for at-loading assembly decay heat values • Axial decay heat distributions based on a bounding generic profile for PWR fuel. • Axial location of beginning of fuel assumed same as WE 17x17 OFA fuel, due to unavailability of specific data for WE17x17 STD and WE 17x17 Vantage 5 fuel designs • Ambient conditions of still air at 50°F (10°C) assumed for base-case evaluations - Wind conditions at the Diablo Canyon site are unquantified, due to unavailability of site meteorological data - additional still-air evaluations performed at 70°F (21°C), 60°F (16°C), and 40°F (4°C), to cover a range of possible conditions at the time of the inspection. (Calculations were also performed at 80°F (27°C), for comparison with design basis assumptions.) All calculations are for steady-state conditions, on the assumption that the surfaces of the module that are accessible for temperature measurements during the inspection will tend to follow ambient temperature changes relatively closely. Comparisons to the results of the inspections, and post-inspection evaluations of temperature measurements obtained in the specific modules, will be documented in a separate follow-on report, to be issued in a timely manner after the inspection has been performed.

Site Inspection↗

DOE OSTI2017

Life Cycle Inventory of Current Photovoltaic Module Recycling Processes in Europe

Solar photovoltaic (PV) installations must be properly dismantled and any waste treated and disposed at the end of project life. However, because most of the world's nearly 400 GW of PV systems have been built in the past decade - each expected to operate for between 20 and 30 years - current PV module waste volumes do not yet justify widespread operation of PV recycling facilities. The necessary policies and technologies for recycling PV systems are currently under rapid development. With modifications to the European waste electrical and electronic equipment directive (WEEE 2012/19/EU) in 2012, take back and recycling of PV modules is, in fact, already mandatory in Europe. There, take back and recycling is currently performed in small but annually-increasing quantities. Even though waste treatment is considered part of a module's life cycle, only a few life cycle inventories (LCI) of energy and materials flows are available for the industrial recycling processes that are used today to recycle crystalline silicon-based (c-Si) PV modules. LCI are the data inputs that inform lifecycle assessments which quantify the environmental impacts across the full life cycle of PV modules - from manufacturing and use to end of life. To help progress the industry forward, a survey of European recyclers was performed to characterize existing commercial recycling processes and share associated life cycle inventory data. System Boundaries: The reference unit, or "functional unit" in the vocabulary of life cycle assessment, is defined as the processing of one metric ton of crystalline silicon PV modules in recycling lines for laminated glass, metals, and electronic wastes. Today, all modules are processed in discrete batches, yet not metered at that scale. Thus the process energy for a batch is estimated based on scaled annual production data as well as on input and output streams.

14 SOLAR ENERGY↗

DOE OSTI2023

Bifacial PV Module Energy Modeling Validation Study

The cost delta between monofacial and bifacial photovoltaic (PV) modules was decreasing in 2018 when this study was initially proposed, making bifacial modules an attractive offering. However, there were limited field studies available that could be considered utility-scale representative, and PV module manufacturers were stating large ranges for the expected energy yield improvements of bifacial technology. This generated uncertainties regarding bifacial performance gains and the actual LCOE (levelized cost of energy). There was also relatively low confidence in the industry’s energy modeling tools’ ability to accurately predict bifacial energy yield, meaning that early adopters of bifacial modules were not able to fully account for the increased energy yield in their energy and financial models. The intent of this project was to provide the solar industry with greater certainty on the energy yield gains of bifacial modules and provide higher confidence in the ability for different energy modeling software to model bifacial PV site performance. Achieving this would allow for bifacial technology to become bankable (i.e. accepted by Independent Engineers, site financiers and other PV site stakeholders), offering a step change in PV site performance that had not been seen since the widespread adoption of the single-axis tracker. Over the course of this study other economic factors including a significant tariff exemption for bifacial modules resulted in accelerated adoption of bifacial technology throughout the US utility scale solar segment. The number of early adopters increased rapidly, and with many investors accepting this module choice the question of bifacial bankability was seemingly answered faster than expected. However, PVEL’s study has still achieved significant accomplishments in demonstrating the accuracy of bifacial modeling across three different software platforms. The results of this study have shown that the mean biased error (MBE) between the field data and the predicted values from all three software platforms were aligned with a maximum MBE of 1.3% and a minimum MBE of -1.8%.

14 SOLAR ENERGY↗

DOE OSTI2024

Development of POTATO for 2S Module Grading for the CMS Phase-2 Outer Tracker Upgrade

Due to the High Luminosity-Large Hadron Collider (HL-LHC) upgrade, several detectors of the Compact Muon Solenoid (CMS) will need to be upgraded, specifically the new Outer Tracker detector that will be composed of 13,200 silicon modules. The Outer Tracker features two types of modules; the PS (pixel-strip) and the 2S (strip-strip) modules. With a large influx of production of modules, extensive testing is required to ensure they fulfill the performance requirements. This research introduces POTATO (Phase-II Outer Tracker Analyzer of Test Outputs), a specialized software developed in C++ to analyze, grade, and store results in a centralized database since module data will be collected from various international production facilities. The implementation of POTATO will facilitate the selection of the best performing modules for the Outer Tracker upgrade. This paper is focused on the implementation of the analysis of 2S Module results within POTATO.

43 PARTICLE ACCELERATORS↗