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The Role of Hybrid Energy Systems in Decarbonizing Industry: A Carbon Handprint–Based Case Study
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Development of Multiphysics Dynamic Solid Oxide Electrolysis Cell (SOEC) Models for Hybrid Energy Systems
For presentation at the ASME Power Applied R&D 2023 Conference, Long Beach, CA, August 6-8, 2023.
Review of Computer-Aided Manufacturing (CAM) strategies for hybrid directed energy deposition
Hybrid additive manufacturing intertwines both additive and subtractive manufacturing layer by layer to digitally fabricate parts with complex geometries, improved surface finish and tight dimensional accuracies, the sum of which is difficult to obtain with any single process. Computer-Aided Manufacturing (CAM) software is required to orchestrate the machine toolpathing for both the deposition as well as the machining processes and is crucial for the successful fabrication of high quality structures. Additionally, CAM requires substantial operator input to account for challenging aspects of each fabricated structure. For example, deciding at which layer of deposition will the machining process continue to maintain access to complex cavities for finishing - internal features that would otherwise be unfinishable due to reach limitations or obstructions. Moreover, of the many commercially-available hybrid systems, each has a unique kinematic environment which can benefit from specific optimization of toolpath planning and substantial research has directly correlated toolpathing with the microstructure evolution, mechanical properties, porosity and residual stress state of the final fabricated part. This review explores the available strategies for CAM in the context of hybrid direct energy deposition, discusses the advantages and disadvantages of each and considers future CAM trends for this transformational digital manufacturing technology.
Review of in situ process monitoring for metal hybrid directed energy deposition
Hybrid manufacturing, or the combination of additive and subtractive manufacturing within a single build volume is transforming the way products are being fabricated. Additive manufacturing confers unprecedented freedom of design and reduced material usage while enabling serial customization. Subtractive manufacturing provides superior surface finish and improved dimensional accuracies. Interwoven, these two digital manufacturing paradigms are enabling the rapid manufacturing of complex, highly accurate, and customized geometries in a diversity of high-performance alloys. In situ monitoring, heavily relied upon in either additive or subtractive, becomes even more crucial with the interplay of the two processes in a single combined build sequence. Moreover, challenges that do not exist in either process alone can now have a dramatic impact on final part quality: (1) a large amount of heat is generated during additive manufacturing deposition, which is primarily dissipated into the machine tooling and impacts accuracy by deforming the material and causing misaligned machining; (2) microstructure, mechanical properties, and residual stresses are the result of the complex thermal histories generated by additive manufacturing and can impact subsequent cutting performance. This comprehensive review considers previous research in monitoring and providing closed-loop control in both additive and subtractive manufacturing separately and then considers the implications of the effectiveness of these monitoring techniques when additive and subtractive processes are integrated together.
Hybrid piezoelectric energy harvesting transducer system
A hybrid piezoelectric energy harvesting transducer system includes: (a) first and second symmetric, pre-curved piezoelectric elements mounted separately on a frame so that their concave major surfaces are positioned opposite to each other; and (b) a linear piezoelectric element mounted separately on the frame and positioned between the pre-curved piezoelectric elements. The pre-curved piezoelectric elements and the linear piezoelectric element are spaced from one another and communicate with energy harvesting circuitry having contact points on the frame. The hybrid piezoelectric energy harvesting transducer system has a higher electromechanical energy conversion efficiency than any known piezoelectric transducer.
Hybrid Energy-Powered Electrochemical Direct Ocean Capture Model
Offshore synthetic fuel production and marine carbon dioxide removal can be enabled by direct ocean capture, which extracts carbon dioxide from the ocean that then can be used as a feedstock for fuel production or sequestered underground. To maximize carbon capture, plants require a variety of low-carbon energy sources to operate, such as variable renewable energy. However, the impacts of variable power on direct ocean capture have not yet been thoroughly investigated. To facilitate future deployments, a generalizable model for electrodialysis-based direct ocean capture plants is created to evaluate plant performance and electricity costs under intermittent power availability. This open-source Python-based model captures key aspects of the electrochemistry, ocean chemistry, post-processing, and operation scenarios under various conditions. To incorporate realistic energy supply dynamics and cost estimates, the model is coupled with the National Renewable Energy Laboratory’s H2Integrate tool, which simulates hybrid energy system performance profiles and costs. This integrated framework is designed to provide system-level insights while maintaining computational efficiency and flexibility for scenario exploration. Initial evaluations show similar results to those predicted by the industry, and demonstrate how a given plant could function with variable power in different deployment locations, such as with wind energy off the coast of Texas and with wind and wave energy off the coast of Oregon. The results suggest that electrochemical systems with greater tolerances for power variability and low minimum power requirements may offer operational advantages in variable-energy contexts. However, further research is needed to quantify these benefits and evaluate their implications across different deployment scenarios.
Co-design optimization of combined heat and power-based microgrids
With the emergent need for clean and reliable energy resources, hybrid energy systems, such as the microgrid, are widely adopted in the United States. A microgrid can consist of various distributed energy resources, for instance, combined heat and power (CHP) systems. Here, the CHP module is a distributed cogeneration technology that produces electricity and recaptures heat generated as a by-product. It is an energy-efficient technology converting heat that would otherwise be wasted to valuable thermal energy. For an optimal system configuration, this study develops a novel co-design optimization framework for CHP-based cogeneration microgrids. The framework provides the stakeholder with a method to optimize investments and attain resilient operations. The proposed co-design framework has a mixed integer programming (MIP) model that outputs decisions for both plant designs and operating controls. The microgrid considered in this study contains six components: the CHP, boiler, heat recovery unit, thermal storage system, power storage system, and photovoltaic plant. After solving the MIP model, the optimal design parameters of each component can be found to minimize the total installation cost of all components in the microgrid. Furthermore, the online costs from energy production, operation, maintenance, machine startup, and disruption-induced unsatisfied loads are minimized by solving the optimal control decisions for operations. Case studies based on designing a CHP-based microgrid with empirical data are conducted. Moreover, we consider both nominal and disruptive operational scenarios to validate the performance of the proposed co-design framework in terms of a cost-effective, resilient system.
Complementarity of Renewable Energy-Based Hybrid Systems
Increased attention has focused on scenarios of rapid and deep decarbonization of the U.S. electricity supply, with least-cost solutions typically involving significant expansion of renewable energy, energy storage, and transmission assets. Strategies that enable the integration of renewable energy projects while minimizing transmission expansion could be especially valuable in the future. It is within this context that the concept of hybrid power plants (or hybrid energy systems) has gained prominence. One specific example is the FlexPower concept, which seeks to demonstrate how coupling variable renewable energy (VRE) and energy storage technologies can result in renewable-based hybrid power plants that provide full dispatchability and a full range of reliability and resiliency services, similar to or better than fuel-based power plants.
Hybrid Solar Thermal Energy System for District Heating Application
Solar district heating (SDH) systems can be good alternatives to conventional systems when they are optimized with hybrid configurations and thermal energy storage (TES). In this scope, a hybrid renewable thermal energy system (RTES) model has been built combining flat plate collector (FPC) solar system with parabolic trough collector (PTC) system via a heat exchanger and coupled with TES. To undertake the hybridization of the system, System Advisor Model (SAM) software was modified, which allowed control over configurations and more accurate modelling of heat transfer between the collectors. The model is first compared to an existing hybrid solar district heating systems (DHS) system in Taars, Denmark. The results showed a good correlation with an overestimation of only 6.4% compared to most recent heat output. Then the same system configuration was modeled in different geographic locations to investigate the impact of changes in direct normal irradiance (DNI) to the heat sink thermal output of the hybrid system. The results showed that the annual net thermal power output in California, USA can be three times more than the annual net thermal power output in Taars, Denmark. Finally, multiple hybrid configurations with varying solar field sizes were simulated based on the heat demand of two different university campuses DHS. The results showed that, retrofit applications of this hybrid DHS system coupled with TES could reduce the natural gas consumption of the existing systems between 25% and 41%. The use of hybrid RTES highlighted in this paper can be extended to many more opportunities.
Thermal Energy Storage Model Development within the Integrated Energy Systems Hybrid Repository
This publication details newly created energy storage models developed within the HYBRID Modelica repository as part of the Department of Energy Office of Nuclear Energy (DOE-NE) Integrated Energy Systems (IES) program, led by Idaho National Laboratory (INL). Model development to-date includes creation of dynamic systems-level models of concrete, latent heat, and packed-bed thermocline energy storage technologies for deployment in the IES-based HYBRID repository. Models are developed using the latest publicly available data and incorporate the possibility of control strategy inclusion for use with the existing IES modeling, analysis, and optimization toolset. Simulations showcase the abilities of each technology to cyclically charge and discharge when exposed to time-varying boundary conditions. In addition, low-level surrogate models for some of the thermal energy storage technologies were created using Python. These lower order Python files are much cheaper to run (i.e., computationally faster) and thus operate well when incorporated within the stochastic optimization problems run for the IES program. Moreover, economic data was collected for use within the INL-developed Framework for Optimization of ResourCes and Economics (FORCE). This information is incorporated within the FORCE platform. This work has resulted in creation of systems-level models for concrete, latent heat, and thermocline thermal energy storage systems with associated control systems. Now that these models are available, they can be utilized within different integrated energy park concepts to understand optimal system operation, control, and dispatching. Moreover, given the generic nature of the models, industrial partner technologies (e.g., Storworks Power, EnergyNest) can be quickly added to the repository using the existing models as a basis. Additional dynamic models for thermal energy storage concepts can be developed and added to the HYBRID repository as needed.
Status Report on FY2022 Model Development within the Integrated Energy Systems HYBRID Repository
This publication details newly created energy storage models developed within the HYBRID Modelica repository as part of the Department of Energy Office of Nuclear Energy (DOE-NE) Integrated Energy Systems (IES) program, led by Idaho National Laboratory (INL). Model development to-date includes creation of dynamic systems-level models of a pebble bed high temperature gas reactor (HTGR), liquid air energy storage (LAES), and compressed air energy storage (CAES) in the IES-based HYBRID repository. Models are developed using the latest publicly available data and incorporate the possibility of control strategy inclusion for use with the existing IES modeling, analysis, and optimization toolset. Simulations showcase the abilities of each technology to flexibly operate in ways consistent with IES operation expectations. When these models are available, they can be utilized within different integrated energy park concepts to understand optimal system operation, control, and dispatching. Moreover, given the generic nature of the models, industrial partner technologies can be quickly added to the repository using the existing models as a basis. Additional dynamic models for thermal energy storage concepts can be developed and added to the HYBRID repository as needed.
Hybrid renewable energy systems: the value of storage as a function of PV-wind variability
As shares of variable renewable energy (VRE) on the electric grid increase, sources of grid flexibility will become increasingly important for maintaining the reliability and affordability of electricity supply. Lithium-ion battery energy storage has been identified as an important and cost-effective source of flexibility, both by itself and when coupled with VRE technologies like solar photovoltaics (PV) and wind. In this study, we explored the current and future value of utility-scale hybrid energy systems comprising PV, wind, and lithium-ion battery technologies (PV-wind-battery systems). Using a price-taker model with simulated hourly energy and capacity prices, we simulated the revenue-maximizing dispatch of a range of PV-wind-battery configurations across Texas, from the present through 2050. Holding PV capacity and point-of-interconnection capacity constant, we modeled configurations with varying wind-to-PV capacity ratios and battery-to-PV capacity ratios. We found that coupling PV, wind, and battery technologies allows for more effective utilization of interconnection capacity by increasing capacity factors to 60%–80%+ and capacity credits to close to 100%, depending on battery capacity. We also compared the energy and capacity values of PV-wind and PV-wind-battery systems to the corresponding stability coefficient metric, which describes the location-and configuration-specific complementarity of PV and wind resources. Our results show that the stability coefficient effectively predicts the configuration-location combinations in which a smaller battery component can provide comparable economic performance in a PV-wind-battery system (compared to a PV-battery system). These PV-wind-battery hybrids can help integrate more VRE by providing smoother, more predictable generation and greater flexibility.
Efficient continuous Energy-Multigroup hybrid depletion scheme using the Shift Monte Carlo code. Part I: Energy condensation sensitivity analysis
Monte Carlo (MC) codes coupled to depletion solvers are increasingly used to provide high fidelity fuel cycle modeling capabilities. Here, these coupled depletion-MC tools produce accurate results in general but can experience nonphysical spatial oscillations when time steps are large or when a system’s dominance ratio approaches unity. Two substepping techniques have been developed previously to remedy and dampen these spatial oscillations without needing to reduce step sizes. The first approach relied on higher-order techniques to account for spectral changes within steps (extrapolation and interpolation techniques). The second approach used the first order perturbation (FOP) theory to account for the change in the one-group spatial flux distribution within steps. This paper develops a hybrid depletion methodology which, in a way, combines how the flux is handled in both substepping techniques. Specifically, the multigroup (MG) MC Shift code is used to update the flux distribution within steps rather than a one-group FOP solver. A fully reflected pincell is investigated, which is not spatially dependent in the MG representation. Thus, the analysis in this paper is an initial demonstration of hybrid depletion. An upcoming companion paper will focus on how the hybrid depletion dampens spatial oscillations. The hybrid depletion approach is verified to be consistent with previous constant extrapolation depletion (CED) methods. This paper finds that the hybrid CED exhibits some error in the eigenvalue and one group constants within macro steps. To address this discrepancy, a simple interpolation scheme (CELI) is investigated. This work found that CELI sufficiently addresses the discrepancy in spectrum for macro steps up to 100 days. Overall, this work demonstrates that the hybrid depletion method can significantly reduce the number of high fidelity MC executions in a MC-coupled depletion with an acceptable eigenvalue error.
Follow-On Status Report on FY2022 Model Development within the Integrated Energy Systems Hybrid Repository
This publication details newly created energy storage and reactor models developed within the HYBRID modeling repository as part of the Department of Energy Office of Nuclear Energy (DOE-NE) Integrated Energy Systems (IES) program, led by Idaho National Laboratory (INL). Model development to-date includes creation of dynamic systems-level models of a pebble bed high temperature gas reactor (HTGR), compressed air energy storage (CAES), and Modelica standard library based two-tank sensible heat storage (SHS) in the IES-based HYBRID repository. Models are developed using the latest publicly available data and incorporate the possibility of control strategy inclusion for use with the existing IES modeling, analysis, and optimization toolset. Simulations showcase the abilities of each technology to flexibly operate in ways consistent with IES operation expectations. When these models are available, they can be utilized within different integrated energy park concepts to understand optimal system operation, control, and dispatching. Moreover, given the generic nature of the models, industrial partner technologies can be quickly added to the repository using the existing models as a basis. Additional dynamic models for thermal energy storage concepts can be developed and added to the HYBRID repository as needed.
Hybrid renewable energy systems
In the pursuit of ecologically sustainable and resilient energy systems, increasingly more attention is being devoted to a diversity of energy generation and storage methods. As the landscape of generation technology gains nuance and complexity, a wide-ranging set of technical questions has emerged, touching on topics that range from control and optimization of hybrid systems to finance and economic viability to multi-fidelity modeling and scientific machine learning. In the context of this special issue, hybrid renewable energy systems are any systems that consider the combined dynamics of more than one form of generation, storage, or grid subsystem. Research endeavors have delved into improving the flexibility of energy systems by utilizing existing resources, introducing novel operational strategies, deploying enhanced renewable forecasts, and exploring emerging technologies. In conclusion, the interconnection among various sectors has garnered heightened attention, not only due to the provision of additional tradable energy products but also for furnishing flexible headroom to system operators.
Embedding ceramic components in metal structures with hybrid directed energy deposition
The combined benefit of both additive and subtractive manufacturing within the same gantry system enables hybrid directed energy deposition to create complex geometries with smooth surface finish and superior dimensional accuracy. Moreover, with layer-by-layer access to the structure during both the addition and subtraction of material, the insertion of components is now possible, assuming the components can survive the high temperatures associated with the subsequent metal deposition. Ceramic inserts are of interest for a variety of reasons including (1) to create complex interwoven ductile/brittle composites for ballistics or high-temperature applications or (2) to integrate high-temperature strain or temperature sensors protected within ceramic substrate subsumed into a larger metal structure. Here, in this work, stainless steel substrates were machined to create an internal cavity for the insertion of a ceramic component. During the investigation of several different over-the-ceramic deposition strategies, components were inserted, and different process sequences were allowed to continue to envelop the inserted ceramic with varying success. Unmelted powder was used to serve both as a thermal buffer and to provide a flush surface upon which the laser cladding could continue. Subsequent depositions were attempted with both dry and wet powder (addition of machining coolant to wet). The wet powder has previously been demonstrated to not significantly impact the mechanical properties of a final structure and provided a thermal barrier to protect the ceramic piece from the extreme temperatures of the final metal deposition. The wetting of the powder provided stability and minimized displacement caused by the powder flow from the laser cladding head. Finally, the use of an oblique angle for laser cladding allowed for the redirection of some fraction of the introduced thermal energy away from the ceramic component and, consequently, improved the survival of the ceramic inserts. With this combination of techniques, ceramic inserts survived full embedding within a 3D-printed stainless steel structure.
Data on temporal complementarity of hybrid renewable energy systems [SWR-23-09]
These datasets describe multiple facets of the temporal complementarity of co-located hybrid renewable energy systems throughout the United States. Several metrics characterizing the complementarity of generation profiles are provided on an annual and monthly basis (for both hourly and daily aggregations). These generation profiles are underpinned by hourly resource data (e.g., the WIND Toolkit and National Solar Radiation Database (NSRDB)) spanning the multi-year period 2007-2013. The data include complementarity results for greater than 1.76 million individual locations within the continental United States (CONUS). The data are intended to accompany two publications on the topic of temporal complementarity: 1) Harrison-Atlas, Dylan, Caitlin Murphy, Anna Schleifer, and Nicholas Grue. "Temporal complementarity and value of wind-PV hybrid systems across the United States." Renewable Energy 201 (2022): 111-123, doi:10.1016/j.renene.2022.10.060; and 2) Murphy, Caitlin, Harrison-Atlas, Dylan, Nicholas Grue, Vahan Gevorgian, Juan Gallego-Calderon, Shiloh Elliot and Thomas Mosier. “A Resource Assessment for FlexPower”. NREL Technical Report.