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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 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Microstructure development of novel composite heating elements for steel decarbonization

The iron and steel industry is critical for the modern world but is also responsible for 7% of the total energy sector CO2 emissions. It is a difficult industry to decarbonize due to the high temperature heat required for the production of steel, such as reheating steel slabs to ~1250 °C for hot rolling. Electrification of this process using resistive heating is currently not possible due to the poor creep resistance of MoSi2 heating elements, which need to be operated well below their maximum temperatures when mounted horizontally. To solve this problem, novel MoSi2 composite heating elements with SiBCN ceramic reinforcements are being developed using high energy ball milling and electric field assisted sintering (EFAS). The microstructure and density of the composites after sintering depends on the sintering parameters chosen. Herein we present the effects of EFAS sintering parameters on the microstructure and density of the MoSi2-SiBCN composites.

36 - MATERIALS SCIENCE↗
DOE OSTI2023

Heat Pumps in the United States: Market Potentials, Challenges and Opportunities

The US heat pump market has been affected by the socioeconomic impacts of the COVID-19 pandemic. However, the US administration’s electrification goal accelerates the deployment of heat pumps, and the US heat pump market has experienced steady growth since 2010. In 2020, heat pumps surpassed gas furnace shipments for the first time, and the trend maintained through 2022. The heat pump market share is expected to grow as policies, and financial incentives steer the building sector toward decarbonization. Here, this paper reviews the US heat pump market trends and discusses the challenges and opportunities in the current policy landscape.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2024

Equitable Strategies for Residential Building Energy Efficiency and Electrification in San José, California

Hotter summers, heat waves, wildfires, and droughts are already affecting San Jose residents, with historically marginalized communities impacted first and worst. The City of San Jose has ambitious goals to make the city climate-neutral by 2030 and serve as an example for cities to accelerate climate action around the world. Electrifying and decarbonizing residential buildings are important priorities to achieve San Jose's plans to reach carbon neutrality while enabling residents to live the "Good Life 2.0" - a vision that aligns with community-identified priorities of safety, health, freedom, community, and positive experiences. This technical assistance built upon the Electrify San Jose: Framework for Existing Building Electrification to identify actionable strategies to make single- and multi-family buildings both energy-efficient and all-electric. This report is intended to provide the San Jose Climate Smart team and their partners with relevant data, insights, and actionable analysis to aid in-depth and nuanced engagements with key stakeholders. In particular, the findings in this report highlight opportunities and challenges for San Jose City Council, residents, building owners, developers, financial institutions, and utility partners instrumental in building support and earning buy-in for energy efficiency and electrification upgrades in existing buildings.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2022

Alaska's First Thermalize Campaign: An Effort to Reduce Fuel Reliance in Juneau, AK

In 2018, the Bureau and City of Juneau set the goal of reaching 80% renewable energy in the sectors of transportation and space heating by 2045. This effort will minimize their reliance on fossil fuels, reduce their carbon footprint and increase their resilience in the event of a natural disaster as fuel oil reaches Juneau by boat and such shipments may be disrupted in a disaster. The community's resilience in the face of a disaster and lower carbon footprint goes hand-in-hand with public safety and health. The Cold Climate Housing and Research Center (CCHRC) partnered with several local and statewide groups, including Alaska Heat Smart and Information Insights, Inc, to lead Alaska's first thermalize campaign. Thermalize Juneau 2021 is an energy campaign working to lower the cost of heating homes in Juneau through beneficial electrification and increased energy efficiency. The goal of the campaign was to offer homeowners a streamlined and more affordable way to install heat pumps and energy efficiency improvements into their homes. Converting household heating from fuel to electricity also helps improve indoor and outdoor air quality and reduces maintenance requirements. The campaign had over 160 participants. As of Fall 2021, it is in its final stages of heat pump installations and energy efficiency improvements. In addition to tracking the energy savings and carbon reduction attributed to the campaign, the social equity was an important aspect. Thermalize Juneau attempted to include all the demographics present in Juneau in the campaign. The presentation will cover the goals and implementation of the campaign, current data on how it is improving community and household resilience, lessons learned, and next steps.

clean energy↗
DOE OSTI2024

Development and field demonstration of residential air source integrated heat pump using a three-stage compressor

To promote decarbonization and all electrification at residential sectors, it is necessary to use air source heat pumps (ASHPs) to replace natural gas for space heating and water heating. ASHPs are widely utilized for residential space cooling, heating, and water heating due to their simplicity and cost-effectiveness. However, their performance can be compromised in cold climates, where they may experience reduced heating capacity. A multi-functional heat pump, using a single compressor, to meet all home space conditioning and water heating demands, is an emerging technology. To address this limitation, we have developed and demonstrated an air source integrated heat pump to fulfill comprehensive home comfort requirements. This system employs a three-stage compressor and a single set of heat exchangers and valves, optimizing functionality while minimizing costs. The performance of the developed system was rigorously evaluated in both laboratory and field settings. In laboratory conditions, the system achieved a Seasonal Energy Efficiency Ratio of 17.0 (average COP of 4.98) and a Heating Seasonal Performance Factor of 11.0 (3.22). Additionally, in its most efficient operational mode—combining space cooling and water heating—the unit attained a total energy efficiency exceeding 7.0 seasonal COP in the field and could heat a 189-liter tank of water in just 25 min. The field study corroborated the laboratory findings, validating the system’s performance in real-world conditions. Here, this integrated heat pump represents an ideal solution for decarbonizing homes in northern climates by providing efficient space heating and water heating, thereby replacing the need for natural gas.

Integrated heat pump↗
DOE OSTI2025

Glass Furnace Decarbonization Technology Stack (Final Technical Report)

This report summarizes the objectives, approach, and outcomes of the Glass Furnace Decarbonization Technology Stack project undertaken by Owens-Brockway Glass Container Incorporated under award number DE-CD0000093. The project aimed to implement a pioneering combination of furnace technologies at the Zanesville, OH manufacturing site to reduce carbon intensity (CI) by 20–40% compared to baseline operations. The proposed Furnace Technology Stack included a Gas/Oxy-fuel system, OPTIMELT™ Heat Recovery System, raw material pre-heating, electric boosting, and forehearth electrification—designed to demonstrate commercial feasibility and drive industry-wide decarbonization.

42 ENGINEERING↗
DOE OSTI2026

Sand-Based Thermal Storage for Building Heating Applications: A District Energy Case Study

Buildings account for 40% of global energy consumption and contribute to 30% of global carbon emissions. As energy from renewable sources increases in availability and building designers push for increased electrification, thermal energy storage (TES) systems will play a crucial role in extending the usable time horizon of renewable energy. While water, molten salt, and phase change materials are typically used for building TES heating applications, silica-sand has emerged as an alternative medium for concentrated solar power applications due to its low cost, wide availability, and comparable system efficiency. This paper proposes a new silica-sand particle-based TES system for building heating applications. In this work, a novel steam plant for district heating applications is first designed to utilize silica-sand TES, which can be used for different district energy systems. To demonstrate the silica-sand TES plant performance, the design is modelled in Modelica based on a case study on the University of Colorado Boulder’s campus. The simulation results show that the sand TES plant is more costly to operate than a gas-boiler based plant due to the low cost of natural gas, while the site EUI and carbon intensity can be improved. This novel system shows initial promise as a low-carbon alternative to conventional natural gas steam boilers but will require further modelling and follow-up research to improve its energy efficiency. An eventual rise in natural gas prices, and reduction of electricity prices, could improve the economic viability of this system.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

Home Energy Upgrades as a Pathway to Home Decarbonization in the US: A Literature Review

This work aims to characterize how home energy upgrade projects and programs in the US have evolved over the past decade. It also identifies what changes are needed to drive expansion of the US energy retrofit market in such a way that addresses carbon emissions from buildings, improves resilience and upgrades the housing stock. This review focuses on whole-home energy upgrades, targeting deep energy retrofit savings of >30%. The topics we cover include trends in home electrification, US and European home energy upgrade programs, energy upgrade measure costs, business economics, and health effects. Key changes in project design noted in this review include: (1) the electrification of dwellings with rapidly improving heat pump systems and low-cost solar photovoltaic technology; and (2) a shift away from high-cost building envelope strategies and towards more traditional home performance/weatherization envelope upgrades. Promising program design strategies covered include: (1) end-use electrification programs; (2) novel financing approaches; (3) the use of carbon-based program and project metrics; and (4) “one-stop shop” programs. Based on the existing market barriers, we suggest that the industry should adopt new project performance metrics. Additionally, market drivers are needed to spur widespread energy upgrades in the US housing stock. Costs must be reduced, and projects designed to appeal to homeowners and contractors.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Equitable Strategies for Residential Building Energy Efficiency and Electrification in San José, California [Slides]

Hotter summers, heat waves, wildfires, and droughts are already affecting San Jose residents, with historically marginalized communities impacted first and worst. The City of San Jose has ambitious goals to make the city climate-neutral by 2030 and serve as an example for cities to accelerate climate action around the world. Electrifying and decarbonizing residential buildings are important priorities to achieve San Jose's plans to reach carbon neutrality while enabling residents to live the "Good Life 2.0" - a vision that aligns with community-identified priorities of safety, health, freedom, community, and positive experiences. This technical assistance built upon the Electrify San Jose: Framework for Existing Building Electrification to identify actionable strategies to make single- and multi-family buildings both energy-efficient and all-electric. This report is intended to provide the San Jose Climate Smart team and their partners with relevant data, insights, and actionable analysis to aid in-depth and nuanced engagements with key stakeholders. In particular, the findings in this report highlight opportunities and challenges for San Jose City Council, residents, building owners, developers, financial institutions, and utility partners instrumental in building support and earning buy-in for energy efficiency and electrification upgrades in existing buildings.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2025

Advanced defrosting techniques in air source heat pumps: A review of vapor injection, thermal energy storage, and experimental frost accumulation data

Electrification is a critical step for reducing greenhouse gas emissions from heating. Air source heat pumps (ASHPs) are a promising alternative to fossil fuel-based systems due to their high coefficients of performance (COP), dual heating and cooling capability, and lower carbon footprint. However, for ASHPs to achieve widespread adoption, they must operate reliably across all climates, including cold regions. Additionally, defrosting techniques should be energy efficient and minimally disruptive to indoor comfort. Vapor injection (VI) technology can address the high-pressure and high-temperature lift challenges encountered in low ambient conditions. More recently, in addition to enhancing heating performance, VI has also been shown to improve the speed and efficiency of reverse cycle defrosting. Likewise, thermal energy storage (TES) has steadily gained attention for its ability to serve as an auxiliary heat source during both normal operation and defrosting. This review analyzes the benefits and limitations of VI- and TES-assisted defrosting approaches. While both technologies show strong potential individually, no studies to date have explored their combined use in ASHP systems. Additionally, to support continued development of defrosting strategies, both in modeling and experimental work, it is critical to establish frost accumulation data under a range of operating conditions. By compiling the available data from the literature, this paper also highlights the limited availability of such experimental data and the wide variation in frosting and defrosting durations and termination criteria, which are often influenced by system design and test setups.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

Peak Reduction Using Mode Adjustment of Heat Pump Water Heaters in a Residential Neighborhood

Building electrification is putting pressure on distribution grid worldwide. Peak reduction is an important concern that can help reduce the growing stress and allow to defer investments in new capacity. Water heaters represent a convenient way of reducing peak because they are less dependent on weather, and their storage volume allows for asynchronous water heating and hot water use. Previous empirical studies investigated the ability of water heaters to reduce peak through the adjustment of the temperature setpoint. However, not all equipment vendors offer this option. This study aims at understanding the feasibility of peak reduction with an alternative configuration available in the market - by adjusting the device mode rather than temperature setpoint. The peak reduction methodology is tested in an occupied 46-townhome neighborhood located in Atlanta, GA. We find that peak shifting is possible with the adjustable mode approach, with the change in the peak load by 30-60%.

demand response↗
DOE OSTI2024

Clean Industry in China: A Techno-Economic Comparison of Electrified Heat Technologies, Barriers, and Policy Options

China’s manufacturing sector generates 61% of the country’s CO 2 emissions, nearly three-quarters of which is related to industrial process heating. To meet China’s climate targets and attain a zero-carbon industrial sector, decarbonizing these industrial heating processes is a necessity. If China’s electricity grid is similarly decarbonized, direct electrification is the most practical means of supplying this heat efficiently at the required scale.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2025

Low-Cost Sulfur Thermal Storage for Solar Industrial Process Heat Applications

Industrial process heat (IPH) is one of the largest energy demands in U.S., representing about 10% of all domestic energy consumption. Fuel costs to generate this industrial process heat are generally a top three cost for industry, a major component in American manufacturing competitiveness. Roughly 60% of US IPH demand (about 6,500 TBtu annually) falls in the medium-temperature range of 100–250 °C. While concentrated solar thermal (CST) technologies can provide a cost-effective source of heat in this temperature range, solar intermittency limits their adoption in industries that operate 24/7. Element 16 Technologies, Inc. developed a low-cost sulfur thermal energy storage (TES) technology to bridge this gap by capturing excess solar heat during the day and dispatching it reliably during non-solar hours. The core innovation is the use of sulfur, an abundant, industrial waste byproduct that costs ten times less than molten salt used in commercial TES systems. The overall goal of the project was to advance the design and development of molten sulfur TES to a manufacturing-relevant prototype stage for solar industrial process heat applications, while establishing and validating a realistic pathway to commercial success. Key tasks included corrosion and mechanical durability testing to identify cost-effective materials, design investigations using physics-based simulation tools, techno-economic evaluations of system lifetime costs, and pilot-scale testing for performance verification. Corrosion testing of steel alloys under cyclic molten sulfur conditions showed that austenitic stainless steels in the 300 series performed particularly well, with no structural degradation of welds or joints. Thermal cyclic testing of pilot sulfur TES units up to 1.5 MWh quantified charge/discharge rates, heat losses, round-trip efficiency and validated the system's capability to operate effectively under intermittent charging conditions. A techno-economic model, informed by sulfur TES performance model validated using pilot test data, showed that hybrid solar+sulfur TES+NG boiler systems are economically competitive with incumbent natural gas boilers for multiple locations in the southwest US. In summary, this project established molten sulfur TES as a technically viable pathway to improve economic competitiveness of American manufacturing by lowering the cost of solar industrial process heat.

14 SOLAR ENERGY↗
DOE OSTI2023

Solar+Storage for Household Back-up Power: Implications of building efficiency, load flexibility, and electrification for backup during long-duration power interruptions [Slides]

The study analyzes the evolving role of solar+storage for home backup power during long-duration power interruptions. In particular, it evaluates how required storage sizing is impacted as homes become more efficient, flexible, and electrified. The study relies on NREL’s ResStock building modeling platform to create statistically representative distributions of the existing building stock in ten locations across the United States. It then shows how the amount battery storage required for backup power rises or falls as a series of building envelope efficiency, load flexibility, and electrification measures are applied across the building stock in each region. The study also includes sensitivities to show how backup power requirements are impacted by the timing and duration of power interruptions, and explores variation in backup power requirements across the building stock within each study location. The results demonstrate the value of pairing solar+storage with efficiency upgrades, smart home controls, and (in mild winter climates) efficient heat pump retrofits. That value comes in the form of reducing the amount of storage required and/or extending the range of interruption conditions over which a given system can provide backup power (i.e., more extreme weather and/or longer interruptions). Heat pumps in cold-weather climates can pose a challenge for solar+storage backup power, given the amount of storage required, though are a vast improvement over electric-resistance heating. Retaining existing fossil-based heating systems for occasional use during power interruptions, as either the primary or supplementary source of heat, can mitigate this challenge. Other forms of building electrification (e.g., cooking and water heating) generally have marginal impacts on backup battery sizing, given their relatively small energy demand.

14 SOLAR ENERGY↗
DOE OSTI2024

End-Use Savings Shapes Measure Documentation: Heat Pump Rooftop Units with Original Fuel Backup

This documentation focuses on a single end-use savings shape measure—heat pump rooftop units with supplemental heat that matches the original fuel type of the replaced system; if the existing system used electric resistance heating, the supplemental heating source is electric resistance. If it was a natural gas furnace, the supplemental system is modeled as natural gas. This is a modification to the heat pump rooftop unit with electric supplemental heat measure from the Commercial EUSS 2023 Release 1 dataset. This document will primarily discuss the supplemental heating change for the heat pump RTU measure. For a comprehensive overview of the fundamental modeling methodology and background of the heat pump RTU measure, including performance curves and other key assumptions, please review the documentation for the original heat pump rooftop unit with electric supplemental heat.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2021

Opportunities for Solar Industrial Process Heat in the United States

This presentation summarizes the first national analysis of opportunities for solar technologies to provide industrial process heat (IPH) in the United States. The industrial sector is a major end-user of energy and IPH constitutes a majority of industrial fuel energy. New disaggregations of IPH demands are made at the temporal, geographic, and operational levels. Solar heat generation by seven solar thermal technologies and PV-connected electrotechnologies are modeled using county solar resources and land availability and matched to relevant IPH demands. Parabolic trough collectors (PTC), when combined with thermal energy storage (TES), not only have the largest opportunity in terms of distribution over geography and time, but also in terms of applicable IPH demands. PTC with TES represents the displacement of nearly 2,500 trillion Btus of combustion fuels, which corresponds to 137 million metric tons of CO2, or about 15% of all industrial combustion CO2 emissions. TES, along with site-level analysis, are identified as areas of further analysis.

41 EE - Solar Energy Technologies Office (EE-4S)↗
DOE OSTI2026

Design Considerations for Phase Change Material-Incorporated Heat Exchangers in Water Heating

In recent years, the buildings sector has seen major pushes towards decarbonization through innovations that promote deep electrification. 20% of an average household's energy use comes from water heating, and in the US, over half of all households still use gas water heaters. Of those that use electricity for water heating, the majority use resistive elements rather than heat pump water heaters (HPWHs), the latter of which use 60-70% less energy than the former. However, HPWHs tend to have larger dimensions, preventing current 50-80-gallon tanks on the market from fitting into smaller utility closets sized for 30-40 gallons, such as those found in manufactured housing. Additionally, these smaller HPWHs tend to underperform relative to their larger counterparts. One solution that addresses both space and performance concerns is thermal energy storage, and in particular, phase change materials (PCMs). This study outlines the design process used to produce novel PCM heat exchangers for use in small-volume HPWH tanks, including the identification of design constraints and performance targets relevant to real-world applications. To ensure optimal PCM utilization and tank storage capacity, this works seeks to co-maximize surface area and PCM volume; therefore, this research targets triply periodic minimal surface (TPMS) lattices, which boast enhanced heat transfer capabilities compared to traditional heat exchanger geometries. Starting with a suite of TPMS lattices, we demonstrate a systematic approach for narrowing down feasible designs that comply with identified constraints while meeting PCM performance objectives. Our current results indicate that tuning lattice properties can effectively produce geometries that provide enough energy storage to achieve a 50-gallon capacity out of a 40-gallon HPWH, even when placing the PCM heat exchanger inside the tank. Additionally, we demonstrate successful fabrication of lattices with these tuned properties.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗