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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

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DOE OSTI2026

Heat Pump Retrofits for Central Plant Hydronic Heating Systems: A Software Toolkit for Screening and Design

Retrofitting existing central plants with high-efficiency heat pump technologies can play a crucial role in achieving long-term planning goals. Modern heat pump technologies are able to use waste heat recovery to meet a building's heating demand, but there is a lack of accessible tools designed for non-HVAC experts, such as building owners, to quickly and easily conduct what-if analysis, e.g., estimating retrofit costs and payback period for their partial or full equipment replacement. This paper introduces an open-source software toolkit designed to facilitate the initial screening and decision-making of heat pump retrofits in existing central plants using a building's yearly load profile from metered or utility bill data. The toolkit evaluates the technical and economic viability of replacing traditional central plant equipment with various options including water-to-water or air-to-water heat pumps, which can provide efficient and lower-cost heating and cooling. It allows users to compare current central plant configurations with retrofit scenarios, assessing energy consumption, life-cycle costs, and environmental impact. The toolkit offers (1) a web-based tool designed for user-friendly access by a broad audience and (2) Python-based source code for researchers and engineers conducting parametric studies and design parameter optimization. The toolkit compares a typical central plant configuration to a configuration that uses a heat pump to supply hydronic heating and cooling. The output metrics include energy consumption and output of each equipment, life-cycle cost analyses and metrics, and environmental impact of the system.

Excell, L↗

DOE OSTI2026

Drive Cycles, Battery Pack Scaling, and Usage Considerations for Long-Haul and Regional-Haul Electric Trucks

Electrifying Class-8 heavy-duty trucks presents a promising opportunity to enhance energy efficiency and reduce freight transport costs. Battery electric trucks (BETs), once considered niche, are gaining traction due to advancements in battery technology and cost reductions. However, accurately predicting battery lifespan under realistic usage conditions remains a key challenge. Understanding battery failure mechanisms and their links to design, operation, and management is essential for developers and fleet operators. This study introduces a method to develop simplified, lab-testable dynamic stress test (DST) cycles for regional and long-haul Class-8 BETs, derived from real-world diesel truck usage. These DSTs enable benchmarking of battery technologies, identification of aging stressors, and optimization of battery design, life, and cost. The approach supports evaluation of key metrics such as levelized cost of driving and total cost of ownership, aiding fair comparisons and adoption decisions. We also propose feasible battery pack sizes that meet current driving demands with strategic charging, and a method to scale pack-level DSTs to cell-level cycles for lab-based testing. These tools facilitate tradeoff analysis across battery chemistries, pack sizing, and charging strategies, while offering means to get insights into battery aging under realistic conditions-ultimately supporting informed BET deployment decisions.

25 ENERGY STORAGE↗

NASA NTRS1975

Statistical estimation of service cracks and maintenance cost for aircraft structures

A method is developed for the statistical estimation of the number of cracks to be repaired in service as well as the repair and the maintenance costs. The present approach accounts for the statistical distribution of the initial crack size, the statistical nature of the NDI technique used for detecting the crack, and the renewal process for the crack propagation of repaired cracks. The mean and the standard deviation of the cumulative number of cracks to be repaired are computed as a function of service time. The statistics of the costs of repair and maintenance, expressed in terms of the percentage of the cost of replacement, are estimated as a function of service time. The results of the present study provide relevant information for the decision of fleet management, the estimation of life cycle cost, and procurement specifications. The present study is essential to the design and cost optimization of aircraft structures.

Yang, J.-N.↗

NASA NTRS1980

Solar energy system economic evaluation for Solaron Akron, Akron, Ohio

The economic analysis of the solar energy system that was installed at Akron, Ohio is developed for this and four other sites typical of a wide range of environmental and economic conditions. The analysis is accomplished based on the technical and economic models in the f chart design procedure with inputs based on the characteristics of the installed parameters of present worth of system cost over a projected twenty year life: life cycle savings, year of positive savings and year of payback for the optimized solar energy system at each of the analysis sites. The sensitivity of the economic evaluation to uncertainties in constituent system and economic variables is also investigated. Results show that only in Albuquerque, New Mexico, where insolation is 1828 Btu/sq ft/day and the conventional energy cost is high, is this solar energy system marginally profitable.

Source record↗

NASA NTRS1993

Total systems design analysis of high performance structures

Designer-control parameters were identified at interdiscipline interfaces to optimize structural systems performance and downstream development and operations with reliability and least life-cycle cost. Interface tasks and iterations are tracked through a matrix of performance disciplines integration versus manufacturing, verification, and operations interactions for a total system design analysis. Performance integration tasks include shapes, sizes, environments, and materials. Integrity integrating tasks are reliability and recurring structural costs. Significant interface designer control parameters were noted as shapes, dimensions, probability range factors, and cost. Structural failure concept is presented, and first-order reliability and deterministic methods, benefits, and limitations are discussed. A deterministic reliability technique combining benefits of both is proposed for static structures which is also timely and economically verifiable. Though launch vehicle environments were primarily considered, the system design process is applicable to any surface system using its own unique filed environments.

Verderaime, V.↗

DOE OSTI2025

Robot-based Additive Manufacturing of Lego-type Modular Molds for Wind Blades

The objective of this project is to reduce the cost and lead time of horizontal wind turbine blade mold tooling and blade transportation, while maintaining the highest standards of blade quality. The solution involves a smart-design family of modular molds that are easily transportable to fabrication sites near the place of service. Key innovations include the use of additive manufacturing (AM) to integrate conformal thermal management channels, offering enhanced control over the thermal profiles tailored to specific blade materials. This approach enables in-situ quality assurance during mold fabrication, significantly improves mold life, and allows for reuse across multiple production cycles. Ultimately, the solution aims to optimize both tooling and transportation costs, contributing to the scalability of wind turbine blade production. A significant barrier to scaling up the production of large wind turbine blades lies in the high costs associated with tooling and the transportation of blades. Traditional molds are expensive, bulky, and difficult to transport, adding considerable lead time and cost to the overall manufacturing process. Additionally, transporting blades to distant locations for final assembly further exacerbates these challenges. The project aims to address these inefficiencies by demonstrating a modularized, additive-manufactured mold that meets all necessary blade specification requirements, specifically for blade lengths between 120m and 150m.

17 WIND ENERGY↗

DOE OSTI2024

Levelized cost of charging of extreme fast charging with stationary LMO/LTO batteries

Extreme DC fast charging for electric vehicles (EVs) could be competitive with the internal combustion engine refueling experience and enable longer-distance travel, which could help with EV adoption and decarbonization, but these systems have high capital costs and extremely variable high-power demands. Behind-the-meter systems (BTMS) could support extreme-fast-charging (XFC) stations to increase nationwide adoption of EVs. Here, this study examines the optimal break-even levelized cost of charging (LCOC) across 96 BTMS scenarios to enable low-wait XFC stations providing 200 miles of charge in 10 min. This research simulates LCOC via synthetic XFC-capable EV loads, machine-learned battery life models from testing data, and nonlinear optimal controls, co-minimizing complex utility costs and battery replacements. An aggregate optimal BTMS design treating each EV load as equal likely gives an optimal LCOC per utility rate, the average of which is $\$$0.59/kWh. In addition, the sensitivity of optimal and off-optimal design factors, the long-life LMO/LTO chemistry, and optimized controls are analyzed. The battery control model, based on battery stressors to compare chemistries, optimizes LMO/LTO resting state of charge and cycle depth without compromising cost reduction, which enables greater flexibility in operation. The LCOC savings due to replacement reduction are small, up to $\$$0.035/kWh (6%), with an average of $\$$0.02/kWh (3.5%). Compared with gasoline stations, the aggregate XFC station design achieves comparable speed, experience of service, and cost at $\$$3.81/gal gasoline, showing that EVs can replace gasoline vehicles even for longer-distance travel.

25 ENERGY STORAGE↗

DOE OSTI2025

Load-Shifting Strategies for Cost-Effective Emission Reductions at Wastewater Facilities

Significant hourly variation in the carbon intensity of electricity supplied to wastewater facilities introduces an opportunity to lower emissions by shifting the timing of their energy demand. This shift could be accomplished by storing wastewater, biogas from sludge digestion, or electricity from on-site biogas generation. However, the life cycle emissions and cost implications of these options are not clear. Here, we present a multiobjective optimization framework for comparing cost- and emission-minimizing load-shifting strategies at a California case study facility with a relatively low carbon intensity grid and high spread in peak and off-peak electricity prices. We evaluate cost and emission trade-offs from the optimal flexible operation of both existing infrastructure and optimally sized energy flexibility upgrades. We estimate energy-related emission reductions of up to 9.0% with flexible operation of existing infrastructure and up to 16.8% with optimally sized storage upgrades. Only a fraction of these potential savings are realized under actual industrial energy tariffs and the EPA’s recommended social cost of carbon. Energy flexibility may hold promise as a short-term emission-saving solution for the wastewater sector, but the extent of savings is heavily dependent on the cost of carbon, electricity tariffs, and emission intensity of the regional electricity grid.

climate↗

NASA NTRS1978

Life cycle costing with a discount rate

This article studies life cycle costing for a capability needed for the indefinite future, and specifically investigates the dependence of optimal policies on the discount rate chosen. The two costs considered are reprocurement cost and maintenance and operations (M and O) cost. The procurement price is assumed known, and the M and O costs are assumed to be a known function, in fact, a non-decreasing function, of the time since last reprocurement. The problem is to choose the optimum reprocurement time so as to minimize the quotient of the total cost over a reprocurement period divided by the period. Or one could assume a discount rate and try to minimize the total discounted costs into the indefinite future. It is shown that the optimum policy in the presence of a small discount rate hardly depends on the discount rate at all, and leads to essentially the same policy as in the case in which discounting is not considered.

Posner, E. C.↗

DOE OSTI2021

Resilience and economics of microgrids with PV, battery storage, and networked diesel generators

Current designs and assessments of microgrids have ignored component reliability, leading to significant errors in predicting a microgrid’s performance while islanded. Existing life cycle cost studies on hybrid microgrids—which combine photovoltaics (PV), battery storage and networked emergency diesel generators—also have not identified all the potential economic opportunities. Reducing the number of emergency diesel generators through reliance on PV and battery, retail bill savings, and demand response and wholesale market revenue streams are all important. This paper provides a new statistical methodology that calculates the impact of distributed energy reliability and variability on a microgrid’s performance and a novel use of the optimization platform REopt to explore multiple cost savings and revenue streams. We examine the impacts for microgrids in California, Maryland, and New Mexico and show that a hybrid microgrid is a more resilient and cost-effective solution than a diesel-only system. Under realistic conditions, a hybrid microgrid can provide higher system reliability when islanded and have a lower life cycle cost under multiple market conditions than a traditional diesel generator-based system. The improved performance of the hybrid system is resilient to conditions experienced over the last 20 years in solar irradiance and sees little degradation in performance immediately after a hurricane. The cost savings to provide this more resilient backup power system as compared to a diesel-only microgrid are significant. The net present cost for a hybrid microgrid is 19% lower in New Mexico and 35% lower in Maryland than a diesel-only microgrid. In California, the net present cost of the hybrid microgrid is negative because, unlike a diesel-only microgrid, a hybrid microgrid has lower life cycle costs than the power costs without a microgrid.

25 ENERGY STORAGE↗

NASA NTRS1980

Solar energy system economic evaluation for Seeco Lincoln, Lincoln, Nebraska

The economic analysis of the solar energy system that was installed at Lincoln, Nebraska is developed for this and four other sites typical of a wide range of environmental and economic conditions in the continental United States. This analysis is accomplished based on the technical and economic models in the f chart design procedure with inputs based on the characteristics of the installed system and local conditions. The results are expressed in terms of the economic parameters of present worth of system cost over projected twenty year life: life cycle savings, year of positive savings and year of payback for the optimized solar energy system at each of the analysis sites. The sensitivity of the economic evaluation to uncertainties in constituent system and economic variables is also investigated.

Source record↗

DOE OSTI2023

Optimization of a Residential Air Source Heat Pump using Refrigerants with GWP <150 for Improved Performance and Reduced Emission

Using low-GWP refrigerants can reduce the Green House Gas (GHG) emission of heat pump systems. Heat exchangers and compressors are the key components and have a prominent impact on system performance, significant research is devoted to reducing the cost of the heat exchangers while achieving the same or better system performance with refrigerant charge reduction.To better understand the environmental impacts of optimized systems with low-GWP refrigerants, Life Cycle Climate Performance (LCCP) evaluation method was used to evaluate the direct and indirect emissions of the system over the course of its lifetime from manufacturing to disposal. The DOE/ORNL Heat Pump Design Model (HPDM) is used to evaluate the performance of heat pumps. Multi-objective optimizations using Particle Swarm Optimization (PSO) algorithm are performed on a 3-ton R410A residential air source heat pump on market. Seven R410A alternatives, i.e., R32, R454B, R454C, R455A, R457A, R1234yf and R1234ze(E) are investigated. The last five fluids have GWP lower than 150.As a result, 5.5%-12.8% seasonal energy efficiency ratio 2 (SEER2) improvement is achieved, and the optimized systems reduce life cycle CO2 emission by 8.5%-28.6% with GWP lower than 150 refrigerants. The optimal heat exchangers can fit into the original R410A fan-coil units; therefore, the proposed design method establishes a production and installation path to produce cost-effective low-GWP heat pumps easily accepted by end users.

Li, Zhenning↗

NASA NTRS1980

Solar energy system economic evaluation: IBM System 2, Togus, Maine

The economic analysis of the solar energy system, is developed for Torgus and four other sites typical of a wide range of environmental and economic conditions in the continental United States. This analysis is accomplished based on the technical and economic models in the f-chart design procedure with inputs taken on the characteristics of the installed system and local conditions. The results are expressed in terms of the economic parameters of present worth of system cost over a projected twenty year life, life cycle savings, year of positive savings and year of payback for the optimized solar energy system at each of the analysis sites. The sensitivity of the economic evaluation to uncertainties in constituent system and economic variables is also investigated. Results demonstrate that the solar energy system is economically viable at all of the five sites for which the analysis was conducted.

Source record↗

NASA NTRS1980

Solar energy system economic evaluation final report for SEMCO-Loxahatchee, Loxahatchee National Wildlife refuge, Palm Beach County, Florida

Economic analysis of the solar energy system installed at Loxahatchee, was developed for Loxahatchee and four other sites typical of a wide range of environmental and economic conditions in the continental United States. This analysis was accomplished based on the technical and economic models in the f Chart design procedure with inputs based on the characteristics of the installed system and local conditions. The results are expressed in terms of the economic parameters of present worth of system costs over a projected twenty year life, life cycle savings, year of positive savings and year of payback for the optimized solar energy system at each of the analysis sites. The sensitivity of the economic evaluation to uncertainties in constituent system and economic variables was also investigated. The results demonstrate that the solar energy system is economically viable at all of the five sites for which the analysis was conducted.

Source record↗

NASA NTRS1980

Solar energy system economic evaluation for Elcam-Tempe, Tempe, Arizona and Elcam-San Diego, San Diego, California

The long term economic performance of the solar energy system at its installation site is analyzed and four additional locations selected to demonstrate the viability of the design over a broad range of environmental and economic conditions. The economic analysis of the solar energy systems that were installed at Tempe, Arizona and San Diego, California, is developed for these and four other sites typical of a wide range of environmental and economic conditions in the continental United States. This analysis is accomplished based on the technical and economic models in the f Chart design procedure with inputs based on the characteristics of the installed system and local conditions. The results are expressed in terms of the economic parameters of present worth of system cost over a projected twenty year life: life cycle savings; year of positive savings; and year of payback for the optimized solar energy system at each of the analysis sites. The sensitivity of the economic evaluation to uncertainites in constituent system and economic variables is also investigated. The results demonstrate that the solar energy system is economically viable at all of the sites for which the analysis was conducted.

Source record↗

NASA NTRS1980

Solar energy system economic evaluation for IBM System 3, Glendo, Wyoming

This analysis was based on the technical and economic models in f-chart design procedures with inputs based on the characteristics of the parameters of present worth of system cost over a projected twenty year life: life cycle savings, year of positive savings, and year of payback for the optimized solar energy system at each of the analysis sites. The sensitivity of the economic evaluation to uncertainties in constituent system and economic variables was also investigated.

Source record↗

NASA NTRS1985

Second-generation mobile satellite system. A conceptual design and trade-off study

In recent years, interest has grown in the mobile satellite (MSAT) system, a satellite-based communications system capable of providing integrated voice and data services to a large number of users. To explore the potential of a commercial mobile satellite system (MSS) beyond the horizon of the first generation, using technologies of the 1990's and to assist MSAT-X in directing its efforts, a conceptual design has been performed for a second-generation system to be launched around the mid-1990's. The design goal is to maximize the number of satellite channels and/or minimize the overall life-cycle cost, subject to the constraint of utilizing a commercial satellite bus with minimum modifications. To provide an optimal design, a series of trade-offs are performed, including antenna sizing, feed configurations, and interference analysis. Interference is a serious problem for MSAT and often an overlapping feed design is required to reduce interbeam interference. The trade-off studies will show that a simple non-overlapping feed is sufficient for the second-generation system, thus avoiding the need for the complicated beam-forming network that is associated with the overlapping feed designs. In addition, a system that operates at L-band, an alternative frequency band that is being considered by some for possible MSAT applications, is also presented.

Sue, M. K.↗

DOE OSTI2021

Sizing Energy Storage System for Energy Arbitrage in Extreme Fast Charging Station

This paper proposes a non-linear programming (NLP) model to optimally size the energy storage system (ESS) and obtain an optimal energy management for energy arbitrage of an extreme fast charging station (XFCS) for electric vehicles (EVs), with minimized total cost of XFCS operation and ESS investment. Different from most reported work on sizing the ESS for EV charging stations, this paper proposes a pragmatic approach to model the ESS life degradation and accurately count the ESS cycles. Moreover, this work incorporates the peak demand charges in the operational cost of the charging station which are often overlooked in the literature. The proposed model is formulated and solved using AIMMS. Finally, a thorough sensitivity analysis is performed to offer insights into how different input parameters impact the ESS sizing and savings from the energy arbitrage perspective.

25 ENERGY STORAGE↗