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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 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Recovery of High Value Anode Materials for a Closed Loop Li-ion Battery Recycling Process (Final Report)

Battery Resourcers’ goal with this Small Business Innovative Research Phase 1 project was to produce high quality and high purity graphite generated from its Li-ion battery recycling technology. Battery Resourcers’ technology recovers cathode material from a broad spectrum of Li-ion battery regardless of size, shape or chemistry. In Battery Resourcers existing model, the graphite is recovered to be used as a reductant and therefore the battery materials cost or recycling cost is not lowered by the recovery of the graphite. Currently, Battery Resourcers is piloting its lithium ion battery recycling process and the recovered LiNi 0.33 Mn 0.33 Co 0.33 O 2 (NMC111) or LiNi 0.6 Mn 0.2 Co 0.2 O 2 (NMC111) cathode materials have shown that they can outperform existing commercial NMC111 cathode materials while being produced at a projected lower cost. Battery Resourcers and its subcontractor WPI have demonstrated the same success with the recovered graphite for anode materials. The success of this award will enable Battery Resourcers offer lowest cost anode materials while reducing the carbon footprint of the battery industry. This will potentially lower the cost of EV by lowering the upfront cost of the battery and the end of life disposal costs. The technical objectives of this Phase 1 research project are to purify the recovered graphite from Battery Resourcers leaching process and demonstrate it is viable to be used in new electric vehicle lithium ion batteries. This project demonstrated that Battery Resourcers can recover graphite with less than 2% impurities. To separate the graphite from other materials Battery Resourcers will employed new filtering techniques and chemical processing methods.

25 ENERGY STORAGE↗
DOE OSTI2022

Techno-economic analyses of several redox flow batteries using levelized cost of energy storage

Development of inexpensive long-duration energy storage supports widespread deployment of variable renewable energy resources onto the electricity grid. Flow batteries are a promising class of devices for long-duration energy storage. Techno-economic modeling is needed to evaluate commercial feasibility of existing technologies and to help guide research and development of new technologies. Levelized cost of storage is a useful metric that accounts for capital and operating costs and energy throughput over the life of a project. This metric is used to compare the economic prospects of lithium ion to eight aqueous and two hypothetical nonaqueous flow batteries in four use cases. Finally, flow batteries with inexpensive active materials are favored in long-duration applications.

25 ENERGY STORAGE↗
DOE OSTI2023

U.S. Solar Photovoltaic System and Energy Storage Cost Benchmarks, With Minimum Sustainable Price Analysis: Q1 2023

The U.S. Department of Energy's (DOE's) Solar Energy Technologies Office (SETO) aims to accelerate the advancement and deployment of solar technology in support of an equitable transition to a decarbonized economy no later than 2050, starting with a decarbonized power sector by 2035. Its approach to achieving this goal includes driving innovations in technology, hardware, and soft cost reductions to make solar affordable and accessible for all. As part of this effort, SETO must track solar cost trends so it can focus its research and development (R&D) on the highest-impact activities. The benchmarks in this report are bottom-up cost estimates of all major inputs to PV and energy storage system installations. Bottom-up costs are based on national averages and do not necessarily represent typical costs in all local markets. Like last year's report, this year's report includes two distinct sets of benchmarks: minimum sustainable price (MSP) benchmarks and modeled market price (MMP) benchmarks. MSP benchmarks can be interpreted as the minimum price a company needs to charge to remain financially solvent in the long term based on the minimum sustainable prices of all inputs including minimum sustainable profit margins. MMP benchmarks can be interpreted as the actual cash sales price a company charges in the given benchmark period. These simplified estimates are useful for tracking technological progress, but they do not reflect all experiences. In fact, no individual estimate under any approach can reflect the diversity of the PV and storage manufacturing and installation industries. Our residential MMP benchmark ($2.90 per watt direct current [Wdc]) is 24% higher than the MSP benchmark ($2.34/Wdc) and 9% lower than our MMP benchmark ($3.18/Wdc) from Q1 2022 in 2022 U.S. dollars (USD). For community solar, our MMP benchmark ($1.75/Wdc) is 18% higher than our MSP benchmark ($1.49/Wdc). Our Q1 2022 benchmark report has no community solar system for comparison. For utility-scale systems with one-axis tracking, our MMP benchmark ($1.17/Wdc) is 22% higher than our MSP benchmark ($0.96/Wdc) and 10% higher than its counterpart ($1.07/Wdc) in Q1 2022 in 2022 USD.

14 SOLAR ENERGY↗
DOE OSTI2020

Low-cost & Energy Dense Batteries for Transportation

The project sought to explore development of novel polymer separator materials and additives for Li-S and Li-ion batteries that would solve critical failure modes and performance bottlenecks for these chemistries. This technology presented significant advanced manufacturing challenges and opportunities in getting to scale, including materials synthesis scale-up, large-area polymer processing techniques, electrode formulation, and the development of coin and pouch cells for electrochemical energy storage. Specific accomplishments included synthesis of organic molecular and polymer materials designed to solve outstanding challenges in electrochemical cells. The primary focus of new materials design was aimed at improving longevity, power, cost reduction, and environmental sustainability of said electrochemical devices. The project also involved assembly and characterization of electrochemical devices with standard galvanostatic and potentiostatic techniques as well as electrochemical impedance spectroscopy.

25 ENERGY STORAGE↗
DOE OSTI2020

FASTSim™ (Future Automotive Systems Technology Simulator) [SWR-20-101 and SWR-12-07]

The Future Automotive Systems Technology Simulator (FASTSim™) provides a simple way to compare powertrains and estimate the impact of technology improvements on light-, medium-, and heavy-duty vehicle efficiency, performance, cost, and battery life. This extremely fast simulation tool features a streamlined user interface and can rapidly perform a variety of tasks using basic computing resources: • less than 0.1 second to simulate second-by-second standard duty cycles • less than 10 seconds to estimate vehicle efficiency, fuel economy, acceleration, battery life, and cost • less than 5 minutes to perform powertrain comparisons of efficiency and cost. FASTSim models a variety of vehicle powertrains and fuel converter types: • Conventional vehicles - spark ignition, Atkinson, diesel, and hybrid diesel • Electric-drive vehicles - hybrid, plug-in hybrid, and all-electric • Hydrogen fuel cell vehicles. The default model includes a variety of vehicles and duty cycles and an option for adding additional vehicles and custom cycles: • Packaged with more than 20 vehicles • User interface enables addition of more vehicles • Includes standard U.S. drive cycles as well as European and Japanese cycles. FASTSim is available for download in Microsoft Excel and Python formats here: https://www.nrel.gov/transportation/fastsim.html

Baker, Chad↗
DOE OSTI2025

Spin‐State and Clustering Effects in Fe‐Complex Negolytes for Near‐Neutral Aqueous Redox Flow Batteries

Cost-effective redox-active materials are essential for advancing redox flow batteries (RFBs). Iron, with its abundance and suitability as a redox couple, is a promising candidate; however, achieving stable and fast redox reactions in aqueous RFBs remains a challenge. Here, this study presents an Fe-based negolyte stabilized by a hexadentate ligand, where Fe–ligand bonds are enhanced through intermolecular interactions. The sulfonate-substituted Fe complex exhibits a formal potential of −0.44 V versus Ag/AgCl and an exceptionally high rate constant of 0.69 cm s −1 . Near-neutral RFBs incorporating 0.5 M Fe complex show excellent cycling stability, with no discernible capacity fading over 300 cycles. This performance is attributed to intermolecular hydrogen bonds that reinforce Fe–ligand coordination and promote the formation of stable trimeric clusters. Operando electrochemical Raman spectroscopy and density functional theory reveal that π-backdonation from Fe(II) to the imino-phenolate moiety further stabilizes the complex after reduction. In contrast, the hydroxyl-substituted complex exhibits inferior stability due to weaker hydrogen bonding and less pronounced π-backdonation. These findings underscore the importance of ligand design and intermolecular interactions in developing cost-effective, high-performance redox-active materials for aqueous RFBs.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Assessing the cost-effectiveness of carbon neutrality for light-duty vehicle sector in China

China’s progress in decarbonizing its transportation, particularly vehicle electrification, is notable. However, the economically effective pathways are underexplored. To find out how much cost is necessary for carbon neutrality for the light-duty vehicle (LDV) sector, this study examines twenty decarbonization pathways, combining the New Energy and Oil Consumption Credit model and the China-Fleet model. We find that the 2060 zero-greenhouse gas (GHG) emission goal for LDVs is achievable via electrification if the battery pack cost is under CNY483/kWh by 2050. However, an extra of CNY8.86 trillion internal subsidies is needed under pessimistic battery cost scenarios (CNY759/kWh in 2050) to eliminate 246 million tonnes of CO 2 -eq by 2050 ensuring over 80% market penetration of battery electric vehicles (BEVs) in 2050. Moreover, the promotion of fuel cell electric vehicles is synergy with BEVs to mitigate the carbon abatement difficulties, decreasing up to 34% of the maximum marginal abatement internal investment.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2026

Next-generation anodes for high-energy and low-cost sodium-ion batteries

Sodium-ion batteries (NIBs) are increasingly becoming commercially viable alternatives to lithium-ion batteries (LIBs), driven by sodium’s lower cost and greater resource availability. However, current NIB technology still falls short of established LIB systems, such as those based on LiFePO 4 , in both cost efficiency and energy density. Although since the early 2020s, industrial advances have raised NIB energy densities to around 175 Wh kg −1 , performance remains limited by the relatively low specific capacity (typically 200–350 mAh g −1 ) and low tap density (0.3–1.0 g cm −3 ) of the prevailing hard carbon anodes. This Review analyses emerging anode materials that could unlock higher-energy and lower-cost NIBs, with a focus on high-capacity hard carbon and alloy-based systems. We discuss the latest progress, fundamental challenges and future directions in these anode materials across the key themes of electrode design, structure–property engineering and characterization. Here, by offering forward-looking insights into the rational design and optimization of anode materials, this Review aims to accelerate the research and development of commercially viable NIBs and support the broader advancement of energy storage technologies.

Batteries↗
DOE OSTI2026

Amorphous ZrCl 4 -Based Superionic Conductor as a Cost-Effective Solid Electrolyte for Batteries

Developing highly conductive and cost-effective solid electrolytes is essential for the commercialization of all-solid-state batteries (ASSBs). Zr-based halide electrolytes hold great promise due to their low estimated cost and high oxidation stability. However, the ionic conductivities of most of them are not high enough to enable moderate- and high-rate cycling of ASSBs. Here, fast ion transport is achieved in a group of cost-effective ZrCl 4 -based electrolytes via a design strategy to create highly disordered amorphous structures. Amorphous Li 0.8 ZrCl 4 (SO 4 ) 0.4 , with a low estimated cost of $21 kg –1 , achieves an ionic conductivity of 1.86 mS cm –1 at 25 °C. It also shows a high oxidation limit of 4.5 V vs Li/Li + and good compatibility with high-voltage cathodes, as demonstrated by the stable cycling of ASSBs (73.7% capacity retention after 1000 cycles at 1 C). Synchrotron X-ray diffraction, pair distribution function analysis, and electrochemical impedance spectroscopy reveal that the outstanding conductivity of these amorphous electrolytes is closely related to their short-range and medium-range ordering, revealing new insights for designing high-performance, cost-effective solid electrolytes.

Zhang, Guangxing [Georgia Institute of Technology,↗
DOE OSTI2021

Battery Storage for Resilience

As the capital costs of battery storage systems are decreasing, new opportunities to cost-effectively deploy the technology, often paired with renewable energy technologies, are emerging. At the same time, the duration and frequency of natural disasters is increasing. As a result, a growing number of institutions are deploying battery storage systems as a resilient energy solution because traditional back-up power solutions, like diesel generators, are not always sufficient, especially during longer-duration and larger-scale disasters. This fact sheet describes how battery storage, along with additional generation sources, can be used both to provide cost savings while grid-connected and to provide backup power when the grid goes down.

25 ENERGY STORAGE↗
DOE OSTI2025

Stable cycling of high-mass loaded MnO 2 electrodes for sodium-ion batteries

Achieving cost-effective, sustainable solutions for large-scale energy storage are critical for advancing the global clean energy transition. In view of the challenges posed by limited lithium reserves, low-cost sodium-ion batteries (SIBs) have emerged as a promising direction, especially for grid-level energy storage. Among the various battery electrode materials, manganese dioxide (MnO 2 ) stands out as a favorable choice for such large-scale applications due to its earth abundance, cost-effectiveness, and non-toxic nature. Although MnO 2 is known as a pseudocapacitive material with superior cycling stability in aqueous electrolytes, its dissolution in non-aqueous electrolytes has restricted its use in long-lifetime batteries. In this study, we address two issues which have limited the use of MnO 2 electrodes in non-aqueous electrolytes. First, using electrochemical quartz crystal microbalance measurements in combination with other electrochemical methods, we demonstrate that diglyme (bis(2-methoxyethyl) ether) electrolyte can achieve stable cycling of electrodeposited ε-MnO 2 . These results enable us to tackle a second objective, that is increasing the mass loading of the MnO 2 electrode, since achieving high areal energy density is a significant factor in reducing manufacturing costs. Using 3D printed graphene aerogel (GA) as a scaffold, our studies show that the electrodeposited MnO 2 /GA electrodes possess scalable properties with mass loadings from 20 to 80 mg cm −2 . The resulting electrodes exhibit areal energy densities as high as 4.4 mA h cm −2 at a current density of 10 mA cm −2 . The high mass loaded MnO 2 electrodes were incorporated as a cathode in a SIB which used TiO 2 as the anode. The SIB device exhibited excellent performance with power densities in excess of 70 mW cm −2 . These studies highlight the promise of MnO 2 electrodes for use in a low-cost technology for large-scale energy storage.

25 ENERGY STORAGE↗
DOE OSTI2021

Electrochemical implications of modulating the solvation shell around redox active organic species in aqueous organic redox flow batteries

Significance The development of cost-effective batteries for long-duration grid scale energy storage will be accelerated using frameworks to rapidly screen and select battery components. Herein, we show that the solvent reorganization energy calculated from the Born equation (with reference to an electrolyte’s composition) is predictive of the electrolytes’ device level performance. This descriptor was found to correlate with key transport and kinetic properties over a range of electrolyte compositions and pH values, succinctly capturing the multicomponent interactions between the electrolyte salts and solvent. This enables the initial high-throughput screening of electrolyte candidates with minimal experimentation. Applied to aqueous redox flow batteries employing organic redox active species, we predict high-performance electrolyte compositions, enabling significantly enhanced device performance.

Sharma, Kritika↗
DOE OSTI2021

Comparing total cost of ownership of battery electric vehicles and internal combustion engine vehicles

The technological advance of electrochemical energy storage and the electric powertrain has led to rapid growth in the deployment of electric vehicles. The high cost and the added weight of the batteries have limited the size (energy storage capacity) and, therefore, the driving range of these vehicles. However, consumers are steadily purchasing these vehicles because of the fast acceleration, quiet ride, and high energy efficiency. The higher pack-to-wheel efficiency and the lower energy cost per mile, as well as the lower expense for maintenance and repair, translate to operating savings over conventional vehicles. Here we compare battery electric vehicles with internal combustion engine vehicles based on the total cost of ownership. It is seen that the higher initial cost of electric vehicles can be recovered in as little as 5 years. This is especially true for electric vehicles with shorter driving ranges. Specifically, a vehicle with an electric driving range under 200 miles may achieve cost parity with an equivalent internal combustion engine vehicle in 8 years or less.

33 ADVANCED PROPULSION SYSTEMS↗