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DOE OSTI2025

Catalyst Development to Overcome Barriers for Commercialization of Synthetic High-Octane Hydrocarbons: Cooperative Research and Development (Final Report)

In recent years, researchers at the National Renewable Energy Laboratory (NREL) and the University of California Berkeley (UC Berkeley) have independently developed catalysts that convert methanol and dimethyl ether into alkylate-like hydrocarbons with a high-octane value, and both have developed intellectual property around these chemical transformations. Both UC Berkeley and NREL wish to see their technologies commercialized to address a number of domestic and international energy challenges. The technologies developed by NREL and UC Berkeley are complimentary but neither have moved beyond the laboratory scale due to remaining challenges with the catalyst activity and selectivity, and/or with the reaction engineering associated with maximizing the yield of the high-value product. NREL and UC Berkeley wish to collaboratively through a shared resources CRADA to solve issues related to the scale-up and process integration of their high-octane hydrocarbon technologies, thus enabling future licensing of the technology to an industry partner.

10 SYNTHETIC FUELS↗

DOE OSTI2026

The AWAKEN wind farm benchmark, Part 2: Modeling results

Accurately modeling wind farm performance in complex atmospheric flows remains a challenge. This paper presents the modeling results of the American WAKE experimeNt (AWAKEN) wind farm benchmark, a collaborative effort involving 16 research groups from academia and industry within the International Energy Agency Wind Technology Collaboration Programme Task 57. The study evaluates a diverse suite of simulation tools, ranging from fast-running engineering wake models to high-fidelity large-eddy simulations, against a diurnal case study observed during the AWAKEN campaign. The benchmark utilized a three-phase structure to progressively assess model performance as observational data availability increased. Initial blind predictions showed that higher-fidelity models did not uniformly outperform simpler simulation tools. A distinct spatial bias was observed where models struggled to resolve the interplay between a low-level jet, wakes, and terrain-induced flow acceleration. In subsequent phases, leveraging additional measurements for model improvement led to a reduction in mean absolute error across the model ensemble; however, this effect was most pronounced in engineering wake models, where targeted calibration reduced error by up to 40~\%. Overall, the study demonstrates that inflow characterization remains a primary prerequisite for accuracy, particularly for models relying on coarse forcing datasets. While the limited ability to resolve local terrain-flow interactions under single-day conditions represent a recognized constraint, the overall findings on wake modeling and real-world validation still provide valuable guidance for model application and for mitigating this limitation.

Bodini, Nicola↗

DOE OSTI2025

Roadmap on thermodynamics and thermal metamaterials

Thermal metamaterials represent a transformative paradigm in modern physics, synergizing thermodynamic principles with metamaterial engineering to master heat flow at will. As next-generation technologies demand multi-scale thermal control, this field urgently requires systematic frameworks to unify its multidisciplinary advances. Curated through a global collaboration involving over 50 specialists across 25 subdisciplines, this review primarily summarizes two decades of advancements, ranging from theoretical breakthroughs to functional implementations. The review reveals groundbreaking innovations in heat manipulation through the exploration of both classical and non-classical transport regimes, topological thermal control mechanisms, and quantum-informed phonon engineering strategies. By bridging physical insights like non-Hermitian thermal dynamics and valleytronic phonon transport with cutting-edge applications, we demonstrate paradigm-shifting capabilities: environment-adaptive thermal cloaks, AI-optimized metamaterials, and nonlinear thermal circuits enabling heat-based computation. Experimental milestones include 3D thermal null media with reconfigurable invisibility and thermal designs breaking classical conductivity limits. Here, this collaborative effort establishes an indispensable roadmap for physicists, highlighting pathways to quantum thermal management, entropy-controlled energy systems, and topological devices. As thermal metamaterials transition from laboratory marvels to technological cornerstones, this work provides the foundational lexicon and design principles for the coming era of intelligent thermal matter.

heat conduction control↗

DOE OSTI2024

OC6 Phase IV: Validation of CFD Models for Stiesdal TetraSpar Floating Offshore Wind Platform

ABSTRACT With only a few floating offshore wind turbine (FOWT) farms deployed anywhere in the world, FOWT technology is still in its infancy, building on a modicum of real‐world experience to advance the nascent industry. To support further development, engineers rely heavily on modeling tools to accurately portray the behavior of these complex systems under realistic environmental conditions. This reliance creates a need for verification and validation of such tools to improve reliability of load and dynamic response prediction and analysis capabilities of FOWT systems. The Offshore Code Comparison Collaboration, Continued with Correlation and unCertainty (OC6) project was created under the framework of the International Energy Agency to address this need and considers a three‐sided verification and validation between engineering level models, computational fluid dynamics (CFD), and experimental results. In this paper, a novel floating offshore wind platform, the Stiesdal TetraSpar, is simulated using CFD under the load conditions defined by Phase IV of the OC6 project. The comparison of these CFD results against the experimental results demonstrated the ability to predict the platform response to waves when imposing the measured wave signals as input. Although validation versus experiment was largely successful, the damping behavior was impacted by uncertainties likely originating from the mooring system and sensor umbilical cable. This extensive comparison effort with multiple CFD practitioners offers insight into best practices to achieve reliable results.

17 WIND ENERGY↗

DOE OSTI2024

Summary of FY 2024 A709 Code Case testing at ANL, INL and ORNL

A collaborative research and development effort in support of the Alloy 709 Code Case qualification in the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code, Section III, Division 5, High Temperature Reactors is being carried out at Oak Ridge National Laboratory (ORNL), Idaho National Laboratory (INL), and Argonne National Laboratory (ANL). Key testing data for the Alloy 709 100,000-hr near-term Code Case submittal to ASME is expected to be completed by the end of 2024, with design parameters anticipated to be finalized in FY 2025. This report summarizes the testing results for three commercial heats of Alloy 709 conducted across three laboratories, reviews the current testing status, and outlines the remaining data needed to support the first Alloy 709 Code Case submittal to ASME. The Alloy 709 Code Case plan remains on schedule.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2025

eMosaic: Electrification Mosaic Platform for Grid Informed Smart Charging Management (Final Scientific/Technical Report)

ABB (Prime Contractor), in collaboration with its partners at the Utah State University (USU), Idaho National Laboratory, Rocky Mountain Power (RMP), and Electric Power Engineers (EPE), have performed research, development, and wide scale demonstration of a scalable and resilient Electrification Mosaic (eMosaic) platform for Smart Charge Management (SCM) for Electric Vehicle Infrastructure. Work was completed under DE EE0009194, titled “eMosaic Electrification Mosaic Platform for Grid Informed Smart Charging Management”, funded by the US Department of Energy. The project members developed algorithms that provide localized and bulk grid services and that reduce and stabilize costs all the way down the supply chain to the PEV owner through SCM. This platform aggregates telemetry from multiple data sources as pieces of the larger picture including personal, private fleet or transportation EVs, fast chargers and other supply equipment, weather service information, and geographically distributed charging sites such as public lots, garage and retail, and private or shared usage depots. ABB and the project team designed, tested, and improved a charging management system at local/edge and cloud levels. The ultimate objective of the project was to convincingly demonstrate that the developed secure eMosaic plat-form can be readily and favorably adopted by diverse utilities and site owners at scale. This was achieved through a demonstration plan with field deployment at several physical sites across 4 states and additional scalable simulation from high fidelity charging models.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2025

PCOR partnership initiative to accelerate CCCUS deployment

The Plains CO 2 Reduction (PCOR) Partnership Initiative, led by the Energy & Environmental Research Center (EERC), was a 5-year collaborative effort under the U.S. Department of Energy’s Regional Initiative to Accelerate CCUS (carbon capture, utilization, and storage). With support from the University of Wyoming School of Energy Resources (UW SER), the University of Alaska Fairbanks Institute of Northern Engineering (UAF INE), and a broad network of public and private stakeholders, the program focused on overcoming regional challenges to CCUS across ten U.S. states and four Canadian provinces. This report summarizes the notable findings of the EERC and its collaborators through the 5-year PCOR Partnership Initiative phase. The EERC developed and demonstrated a risk-based area of review (AOR) workflow for U.S. Environmental Protection Agency Class VI carbon dioxide (CO 2 ) storage permitting.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2024

Grid-Ready Energy Analytics Training with Data (“GREAT with Data”)

GridEd is a collaborative educational initiative consisting of the Electric Power Research Institute (EPRI), 5 Partner Universities (Stony Brook University, The University of Texas at Austin, University of California – Riverside, Virginia Tech, Washington State University), and participating industry sponsors. This educational initiative focuses on developing and training the next generation of power engineers so they can help shape the electric grid of the future by anticipating and fulfilling the needs of changing electric industry requirements. GridEd is leveraging electric industry research to educate a future electric grid workforce by empowering new and continuing education students, not only to become competent and well-informed engineers, but also to participate and influence major technological, social, and policy decisions that address critical global challenges. GridEd’s activities are centered around four core pillars: Enhancement of university power systems engineering curricula; Professional development and training for a diverse electric industry workforce; Stimulating students to join the movement for the next generation of power engineers, and; Improve workforce development efforts in the electric utility industry. Major accomplishments over the course of the project were: Over 50 unique professional short courses were delivered by more than 30 instructors across the GridEd network; Over 3,600 unique learners, many who took multiple courses, received more than 27,000 professional development hours (PDH) and over 1,000 certificates of completion; Approximately 2,900 unique learners undertook a course that was offered LIVE online or in-person; Approximately 700 unique learners undertook a course that was offered as computer-based training (CBT); Over 35 unique university courses were delivered by more than 30 instructors to 1,500 university students across the GridEd network; One-hundred-and-fifty-seven (157) students were funded to completed 43 student projects in topics of power systems and data science, and; Six (6) Historically Black Colleges and Universities (HBCUs) recruited as Affiliate Universities via Utility Partners. The professional training initiative and workforce development activities launched by this project will be sustained through EPRI’s collaborative business model with industry. Stimulating students to join the power engineering workforce of the future and the enhancement of tertiary training may continue to need government support.

14 SOLAR ENERGY↗

DOE OSTI2025

Visolis Microbial Chemical Intermediate Library Screening (CRADA Final Report)

Visolis is developing a commercial process for the bioproduction of a chemical intermediate, towards the derivative production of a portfolio of bio-based chemicals with large application potential, from drop-in commodity chemicals, to innovative specialty chemical offerings, to materials for multiple end markets and industries, which will ultimately benefit consumers and the public. Visolis already has several variants of a microbe that produce the chemical intermediate at distinct levels (i.e. high, medium, and low). They are currently pursuing transcriptomics analysis for some of these strains, towards a better understanding of the biology behind what makes certain strains perform better than others. There exist genome-scale library approaches for the microbe that could be used to screen gene disruption, overexpression, or repression candidates for perturbations to the production of the chemical intermediate. These approaches often reveal opportunities for further production improvement that are not otherwise accessible using hypothesis-driven metabolic engineering approaches. However, Visolis, while it could generate or procure such genome-scale libraries, does not have the automated strain engineering workflows required to screen thousands of variants, obtaining a production phenotype and a genotype for each. The purpose of this collaboration is to use LBNL and SNL capabilities to enable Visolis to effectively screen thousands of genome-scale library strain variants for phenotype/genotype relationships that will complement Visolis’ transcriptomic investigations.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2026

Evaluation of Bio-Intermediates and Other Biofuels for use in Marine Engines

This paper presents an overview of the DOE Marine Biofuel Feasibility Study to evaluate the potential of biofuels for ocean-going vessels. These vessels operate on low-cost residual fuel oils (also known as heavy fuel oils or HFO), which require significant heating and purification onboard vessels. The industry is looking at economical alternative fuels that can enhance performance from combustion/emissions, rheology, and other perspectives. Four U.S. national laboratories are collaborating to evaluate a variety of biofuels, including bio-intermediates (pyrolysis and hydrothermal liquefaction oils), biodiesel (fatty acid methyl esters or FAME), bio-residuals (FAME byproducts) for their suitability as fuels for marine diesel engines. Bio-intermediates in particular are of interest because large marine engines that operate on HFO can tolerate lowerquality, more viscous fuels and may be able to utilize these fuels with less upgrading than other applications, presenting economic advantages. The test fuels of interest are examined to determine the minimum level of upgrading required for blend compatibility with market HFOs containing high levels of asphaltenes as well as their impact on the viscosity, polymerization tendency, and combustion properties (particularly cetane number) of the fuel blends in preparation for future evaluation in engine studies.

Kaul, Brian [ORNL] (ORCID:0000000184813620)↗

DOE OSTI2025

Cyber-Informed Engineering (CIE) Guide for States

The Cyber-Informed Engineering (CIE) Guide for States provides state energy offices, public utility commissions, and partner organizations with a structured framework for integrating cyber-resilient engineering practices into energy planning, grantmaking, interconnection processes, and workforce development. As grid digitalization and the adoption of distributed energy resources accelerate, states face expanding cyber-physical risks that traditional cybersecurity measures alone cannot fully address. CIE offers a proactive, consequence-focused engineering methodology that emphasizes eliminating or mitigating high-impact failure modes through design, physical controls, and operational safeguards. The guide outlines the 12 core CIE principles, demonstrates their application through state-focused use cases—including grant evaluation rubrics, interconnection reviews, allow-list development, and training programs—and provides practical tools such as scoring frameworks, impact assessment methods, and implementation checklists. It also highlights pathways for state–utility collaboration and opportunities for technical assistance from national laboratories. By adopting CIE, states can enhance grid reliability, reduce lifecycle costs, strengthen supply-chain assurance, and foster a security-aware engineering culture that aligns with broader resilience and modernization goals. November 2025

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2025

Cyber-Informed Engineering (CIE) Guide for States

29 - ENERGY PLANNING, POLICY AND ECONOMY↗

DOE OSTI2025

Advances and Challenges of SCAN and r 2 SCAN Density Functionals in Transition‐Metal Compounds

ABSTRACT Transition‐metal compounds (TMCs) with open‐shell d ‐electrons are characterized by a complex interplay of lattice, charge, orbital, and spin degrees of freedom, giving rise to various fascinating applications. Often exhibiting exotic properties, these compounds are commonly classified as correlated systems due to strong inter‐electronic interactions called Hubbard U . This inherent complexity presents significant challenges to Kohn‐Sham density functional theory (KS‐DFT), the most widely used electronic structure method in condensed matter physics and materials science. While KS‐DFT is, in principle, exact for the ground‐state total energy, its exchange‐correlation energy must be approximated in practice. The mean‐field nature of KS implementations, combined with the limitations of current exchange‐correlation density functional approximations, has led to the perception that DFT is inadequate for correlated systems, particularly TMCs. Consequently, a common workaround involves augmenting DFT with an on‐site Hubbard‐like U correction. In recent years, the strongly constrained and appropriately normed (SCAN) density functional, along with its refined variant r 2 SCAN, has achieved remarkable progress in accurately describing the structural, energetic, electronic, magnetic, and vibrational properties of TMCs, challenging the traditional perception of DFT's limitations. This review explores the design principles of SCAN and r 2 SCAN, highlights their key advancements in studying TMCs, explains the mechanisms driving these improvements, and addresses the remaining challenges in this evolving field.

Zhang, Yubo [Minjiang Collaborative Center for The↗

DOE OSTI2024

Preliminary Experimental Results in Support of the Development of EPP and SMT Design Methods and Viscoplastic Model for A709

The ASME code qualification effort for Alloy 709 (A709) is currently underway to qualify it for Class A construction in the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code, Section III, Division 5. The United States (U.S.) Department of Energy (DOE) national laboratories are collaborating in the advanced materials development initiative to investigate the mechanical performance of A709 in support of its code qualification. As part of the A709 code qualification effort, this report summarizes ORNL’s initial experimental findings that support the integration of A709 into the elastic-perfectly plastic (EPP) strain limits code case. It also covers thermomechanical fatigue testing conducted to develop viscoelastic material models, along with the preliminary results of creep-fatigue experiments at 816°C using the Simplified Model Test (SMT) method.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Advanced Computing Annual Report 2024

In fiscal year (FY) 2024, the National Renewable Energy Laboratory (NREL) took a major leap forward with the completed full buildout of Kestrel, the Office of Energy Efficiency and Renewable Energy's newest high-performance computing (HPC) system. Kestrel is already supporting science across the portfolio, bringing roughly 44 petaflops of computing power, which is more than five times the capacity of our previous supercomputer, Eagle. By delivering greater GPU capacity, Kestrel enables faster progress in artificial intelligence (AI) and opens new avenues in energy research - from defining long-term planning scenarios to accommodate a growing power system to material discovery to improving energy efficiency in photovoltaics (PV). Across the portfolio, research is being accelerated by Kestrel's impressive power. During FY24, 427 projects and more than 700 researchers used NREL's HPC, supporting the U.S. Department of Energy's Office of Energy Efficiency and Renewable Energy across 13 funding areas. Through these collaborations, researchers produced more than 450 technical outputs, including 195 articles in peer-reviewed publications, pushing the boundaries of science and engineering. This year's report features new sections spotlighting the expanding roles of Artificial Intelligence and Accelerated Computing. We also introduce an early career section to celebrate the accomplishments of our up-and-coming researchers, whose pioneering work is shaping the future of energy. We hope you enjoy the new insights and discoveries highlighted in these pages.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2025

Scintillating Bubble Chambers for Rare Event Searches

The Scintillating Bubble Chamber (SBC) collaboration is developing liquid-noble bubble chambers to detect sub-keV nuclear recoils, allowing the search for low-mass (GeV-scale) dark matter and coherent elastic neutrino-nucleus scattering from low-energy (MeV-scale) neutrinos. The scintillating bubble chamber detectors benefit from the energy reconstruction that the scintillation signal gives in addition to the superior electron-recoil insensitivity that bubble chambers naturally provide. The high level of superheat achievable in noble liquids while being electron-recoil insensitive allows for lower nuclear recoil thresholds than in existing freon-based bubble chambers, potentially reaching the 100 eV threshold desired for reactor CEvNS measurements. To validate this lower threshold, the SBC collaboration is constructing two 10 kg detectors that are functionally identical. The SBC-LAr10, which is being commissioned at Fermilab, is intended for engineering and calibration research and has additional possibilities in assessing coherent elastic neutrino-nucleus scattering in argon. SBC-SNOLAB, the second detector for a low-background dark matter search, will be run at SNOLAB underground.

Pyda, Daniel [Unlisted, US]↗

DOE OSTI2025

Recovery and Refining of Rare Earth Elements from Lignite Mine Wastes

The University of North Dakota (UND), in collaboration with a comprehensive team of technical, business and host-site partners, built on prior technology development to complete a front-end engineering and design (FEED) and business planning study to recover and refine rare earth elements (REE) and critical minerals (CM) from North Dakota (ND) lignite mine wastes. The end of project goal was to have an investment quality project and a committed team ready to commercialize the proposed technologies in a future construction and operations phase.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2025

CRADA Number NFE-22-09375 with Vitriform3D, Inc. (CRADA Final Report)

Each year, roughly 8 million tons of glass are landfilled in the United States. Vitriform3D, in collaboration with Oak Ridge National Laboratory through the Innovation Crossroads program, is developing an additive manufacturing approach to transform post-consumer glass into engineered stone building materials. A custom UV-curable binder jetting system was commissioned to enable recycled glass printing without energy-intensive oven curing. While this printer is still under development, the team pursued a parallel research track using ORNL equipment and a polyethyleneimine (PEI) binder. Printed parts were thermally post-cured and infiltrated with epoxy, with the resulting material exceeding fiber cement board performance. Silane treatment of the glass particles further improved glass–epoxy adhesion, yielding an additional 24% strength gain over the epoxy-glass composite, achieving nearly 3x the fiber cement benchmark. Ongoing research is focused on reducing epoxy content to improve cost and recycled content while retaining mechanical performance. This work demonstrates a scalable, low-carbon pathway to convert glass waste into high-value, locally produced construction materials.

36 MATERIALS SCIENCE↗