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At least 91 records · Page 5

U.S. Department of Energy Competitiveness Improvement Project (CIP) 2025 Prototype Manufacture Awardee: XFlow Energy

Vertical-axis wind turbines offer a compelling path to low-cost, reliable distributed energy that can compete with utility prices for businesses, landowners, and municipalities in rural areas. They generate power by using a main rotor shaft perpendicular to the ground to pick up wind from different directions without a yaw mechanism. However, previous commercialization attempts struggled to account for the unsteady aerodynamics of this design, leading to low power production and/or premature structural failure. To address these challenges, Competitiveness Improvement Project recipient XFlow Energy is building on work completed during three previous CIP funding awards to develop a 30-kW vertical-axis wind turbine that achieves both low costs and high energy output.

17 WIND ENERGY↗

Decentralized Voltage Control with Peer-to-peer Energy Trading in a Distribution Network

Utilizing distributed renewable and energy storage resources via peer-to-peer (P2P) energy trading has long been touted as a solution to improve energy system’s resilience and sustainability. Consumers and prosumers (those who have energy generation resources), however, do not have expertise to engage in repeated P2P trading, and the zero-marginal costs of renewables present challenges in determining fair market prices. To address these issues, we propose a multi-agent reinforcement learning (MARL) framework to help automate consumers’ bidding and management of their solar PV and energy storage resources, under a specific P2P clearing mechanism that utilizes the so-called supply-demand ratio. In addition, we show how the MARL framework can integrate physical network constraints to realize decentralized voltage control, hence ensuring physical feasibility of the P2P energy trading and paving ways for real-world implementations.

Feng, Chen↗

Market mechanism to enable grid-aware dispatch of Aggregators in radial distribution networks

This paper presents a market-based optimization framework wherein Aggregators can compete for nodal capacity across a distribution feeder and guarantee that allocated flexible capacity cannot cause overloads or congestion. This mechanism, thus, allows Aggregators with allocated capacity to pursue a number of services at the whole-sale market level to maximize revenue of flexible resources. Based on Aggregator bids of capacity (MW) and network access price ($/MW), the distribution system operator (DSO) formulates an optimization problem that prioritizes capacity to the different Aggregators across the network while implicitly considering AC network constraints. This grid-aware allocation is obtained by incorporating a convex inner approximation into the optimization framework that prioritizes hosting capacity to different Aggregators. We adapt concepts from transmission-level capacity market clearing, utility demand charges, and Internet-like bandwidth allocation rules to distribution system operations by incorporating nodal voltage and transformer constraints into the optimization framework. Simulation based results on IEEE distribution networks showcase the effectiveness of the approach.

Nazir, Mohammad Nawaf↗

Biochemical Process Modeling and Simulation (BPMS)

The Biochemical Process Modeling and Simulation project aims to reduce the cost and time of research by applying theory, modeling, and simulation to the most relevant bottlenecks in the biochemical process. We use molecular modeling, quantum mechanics, metabolic modeling, fluid dynamics, and reaction-diffusion methods in close collaboration with pretreatment, hydrolysis, upgrading, and TEA. The project's outcomes are increased yields and efficiency of the biochemical process, added value to products, and reduced price of fuels by specifically targeting catalytic efficiency, reactor design, enzyme efficiency, and microbial design. We work closely with experimental projects to identify problems and iterate with experiments to find and refine solutions. By working with experimentalists, we decide on problems that can be solved with simulation that could otherwise not be solved or would take too long with experiment alone to reach BETO's targets. Over the years, we have produced solutions that have resulted in determining the most likely fatty-acid derivative for passive transport out of bacteria that upgrade biomass, and we have also designed enzyme mutations for enhanced lignin upgrading. Metabolic models have been developed to tune the activity of 2,3 butanediol production for the 2030 target. A computational method to deliver understanding of how complex omics data can be interpreted in the metabolic pathways of organisms used in the Agile Biofoundry. We have found methods to overcome specific barriers and continue to develop those methods. Our reactor studies have guided the design of both the microbes and reactors for aerobic and micro-aerobic production at all scales and have been instrumental in improving the accuracy of techno-economic analysis models. This project is essential in the process of selecting the final processes for 2030 SAF production targets. More specifically, recently, we have: 1) Predicted the strength of the basic structural interactions in commodity plastics to provide guidance for plastics upcycling strategies. 2) Developed computational tool to improve the characterization of lignin-derived compounds 3) Developed new methodologies to enable Machine Learning-based Directed Evolution for protein engineering. 4) Developed Machine Learning methods to predict protein promiscuity and mutations to further improve microbial and enzymatic driven processes and demonstrated the utility of ML approaches to engineering proteins from sparse experimental datasets. 5) Developed new methods to enable high-fidelity simulation of aerobic fermentation at industrial scale and resolving mismatch of time scales through subcycling/operator splitting 7) Identified the difficulty in preventing local high-oxygen conditions in industrial bubble columns, which leads to less-desirable acetoin production, suggesting future research directions in alternative reactor configurations (e.g loop reactors, shallow-channel reactors).

BIOMASS FUELS↗

Mineral-Ground Micro-Fibrillated Cellulose Reinforcement for Polymer Compounds

Additive Manufacturing (AM) is quickly becoming a mainstream, energy efficient manufacturing technique for complex and custom components. ORNL has taken polymer AM into the next level with Big Area Additive Manufacturing (BAAM). However, we need to develop the strength of AM materials (specifically polymers) to satisfy the mechanical requirements of structural parts. Also, it is crucial that the developed process can easily be scaled up to have a significant impact in the manufacturing industry of US. Furthermore, renewable, bio-derived AM materials are desirable from a sustainability perspective. In the first phase of this project the mechanical properties of polymer AM components were significantly improved developing a micro fibrillated cellulose (MFC)-reinforced composite material system that is derived from biomass and compatible with BAAM. Unfortunately, the improvements were observed only with freeze-dried MFCs, and freeze-drying is a very slow process and is not industrially scalable. Furthermore, MFCs were not available in large quantities at low cost. However, FiberLean has reached 12,000 tons/year capacity (60,000 tons/year including the minerals). FiberLean offers MFCs at a scale and order of magnitude lower price than current market participants. With their recently developed novel (patent pending) drying process FiberLean can achieve over 50% solid content commercially. In the 2nd phase of the project, the original objective was to investigate this new novel drying process along with compounding with different formulations to optimize and adapt to large scale additive manufacturing. However, the compounded materials prepared via this approach were very brittle and demonstrated poor mechanical performance. Therefore, the project was focused more on a scalable chemical surface modification of MFCs to enable their drying via conventional oven process with minimal agglomeration and better dispersion in PLA polymer matrix. Fiberlean and ORNL have worked together in this project to develop mineral-ground microfibrillated cellulose (MFC) - reinforced additive manufacturing feedstock materials with significantly improved mechanical properties. Properly surface modified and dried Fiberlean cellulose microfibrils led to tensile strength increases up to ~40% and elastic modulus increases up to 70% with the addition of 30% MFC into PLA matrix. The work has led to a high impact journal article and a provisional patent. Opportunities for a follow up work to demonstrate the technology in large scale and application of it to AM applications are currently being searched.

36 MATERIALS SCIENCE↗

Janus: A Python Package for Agent-Based Modeling of Land Use and Land Cover Change

Janus is an open source Python package for agent-based modeling (ABM) of land use and land cover change (LULCC). Many ABMs of LULCC have been created across platforms, some of which are not ideal for large scale, high resolution scenarios. This model provides a simple object-oriented framework for creating ABMs specific to LULCC. The organizational philosophy of the modeling framework is to create software objects (agents) that are associated with specific and contextual attributes which are isolated from where those agents exist in the spatial setting of the model, yet provide clear linkages between the agent, their environment, and other agents in the simulation. In this way, the framework allows for assembly of LULCC ABMs with low (programmatic) overhead, making the models extensible and providing clear mechanisms for integrating them with process-oriented biophysical models. Provided with Janus is a suite of geospatial data preprocessing tools that can use arbitrary land cover products as an input. Crop choice decisions are based on potential crop prices, these can be created synthetically, or drawn from integrated human-Earth systems models such as the GCAM. Janus is publicly accessible through GitHub and provides an example dataset for testing.

54 ENVIRONMENTAL SCIENCES↗

Acetolysis for Epoxy-Amine Carbon Fibre-Reinforced Polymer Recycling

Carbon fibre-reinforced polymers (CFRPs) are used in many applications in the global energy transition, including for lightweighting aircraft and vehicles and in wind turbine blades, shipping containers and gas storage vessels1,2,3,4. Given the high cost and energy-intensive manufacture of CFRPs5,6,7, recycling strategies are needed that recover intact carbon fibres and the epoxy-amine resin components. Here we show that acetic acid efficiently depolymerizes both aliphatic and aromatic epoxy-amine thermosets used in CFRPs to recoverable monomers, yielding pristine carbon fibres. Deconstruction of materials from multiple sectors demonstrates the broad applicability of this approach, providing clean fibres from 2 h reactions. The optimal conditions were scaled to 80.0 g of post-consumer CFRPs, and demonstrative composites were fabricated from the recycled carbon fibres, which were recycled two more times, maintaining their strength throughout. Process modelling and techno-economic analysis, with feedstock cost informed by wind turbine blade waste generation8, indicates this method is cost effective, with a minimum selling price of US$1.50 per kg for recycled carbon fibres whereas life cycle assessment shows process greenhouse gas emissions around 99% lower than virgin carbon fibre production. Overall, this approach could enable recycling of industrial CFRPs as it provides clean, mechanically viable recycled carbon fibres and recoverable resin monomers from the thermoset.

09 BIOMASS FUELS↗

Low-Cost Electrochemical Compressor (ECC) Utilizing Green Refrigerants for HVAC Applications [Slides]

HVAC systems account for approximately 14 Quads or primary energy annually, or nearly 30% of all energy used in the U.S. commercial and residential buildings. Electrochemical compression (ECC) is a transformative solid-state technology and ECC based HVAC systems could result in 40% less energy use. The goal of the project was to develop the most efficient, noiseless, and most environmentally friendly cooling system based on integrating 2 (two) technologies: a) electrochemical compressors (ECC) to replace mechanical compressors for use in building heating, ventilation, and air conditioning (HVAC) applications and b) Ionic Liquid Desiccant Systems. The overall objective was to develop and build a scalable ILD/ECC-based air conditioning system operating with a COP of 4.5, with a price premium of $70 installed per kBTU/hr.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Hydrogen Production Cost from Proton-Conducting Solid Oxide Electrolysis

Rigorous stakeholder-vetted techno-economic analysis (TEA) was conducted to estimate the cost of hydrogen (H 2 ) production using Proton-Conducting Solid Oxide (PSO) electrolysis. The analysis evaluates Current (2025) and Future (2035) technology cases at centralized plant scales of 50 and 500 metric tonnes per day (MTD), assuming electricity, water, and air as the only system inputs. Untaxed, unsubsidized levelized cost of hydrogen (LCOH) is projected to range from 2020 $\$$1.81 to $\$$2.47/kg H 2 at an electricity price of $\$$0.03/kWh and 97% capacity factor under Nth-of-a-kind (NOAK) deployment assumptions. Total installed capital cost was developed using bottom-up Design for Manufacture and Assembly (DFMA) stack cost modeling and detailed balance-of-plant estimates, including mechanical and electrical subsystems, installation, site preparation, engineering, and contingency. Stack performance assumptions include thermoneutral operation, degradation over time, and periodic replacement. LCOH was calculated using the Hydrogen Analysis (H2A) discounted cash flow model in constant 2020 dollars. Results indicate PSO electrolysis has potential for competitive hydrogen production costs under low-cost electricity and mature manufacturing conditions.

08 HYDROGEN↗

Knowledge Spillovers and Cost Reductions in Solar Soft Costs

Despite the commonly acknowledged importance of knowledge spillovers in reducing solar soft costs, we are only beginning to answer a fundamental question: who learns what (knowledge acquisition), from whom (knowledge production), and how (spillover mechanisms)? Until recently, this important topic has been largely unexplored in the case of solar soft costs. Thus, this project set out to identify how knowledge spillovers affect soft costs in the U.S. photovoltaic (PV) installation industry, specifically how important spillovers are, what types of knowledge are most likely to spillover, and how networks of actors affect spillovers. Our findings offer insights for designing solutions that address problems associated with knowledge spillovers and that leverage spillovers to reduce solar soft costs. Recognizing the ambiguity in the definition of soft costs, i.e., “non-hardware costs,” and variability in soft cost categories, we developed the Solar Soft Cost Ontology (SSCO) to systematically identify key concepts related to soft costs, network actors, learning processes, and the relationships between them. This ontology served as a foundational organizational structure for the methodology of the remaining tasks: case studies, surveys, pricing analysis, patent analysis, network analysis, and project integration across tasks. While there is substantial learning among installers that is reducing the soft costs for PV installations, most of that learning is retained by firms rather than spread across the industry. The positive relationship between experience accumulation and cost reductions is typically explained as learning by doing (LBD), but we find that LBD effects are mediated by other learning mechanisms, including learning by searching and learning by interacting. Knowledge spillovers have significant potential to reduce solar PV soft costs, but successful knowledge spillover pathways are complex and non-trivial. There are a wide variety of ways to construct an installation business, thus categories of firms that can effectively cross-learn directly are small and what knowledge is relevant to whom is challenging and costly for firms to assess. This fragmentation limits the critical mass needed for spillover related soft cost reductions. Knowledge does not flow directly between installers. Indirect knowledge transfer pathways are critical: distributors, software providers, collaboratives, and hiring. Furthermore, diverse, more integrated knowledge networks tend to promote successful learning by organizations and across the system as a whole. Accordingly, we find the need to supporting the whole ecosystem using an integrated policy and programmatic approach to support installers, distributors, complementary sector, and facilitators. Overall, a deliberate policy-mix design is needed to reduce the solar PV deployment barrier in terms of installation cost reductions, because deployment policies could potentially interact with policies that facilitate network-building and technological innovation. A combination of deployment policies, innovation-support policies, and network-facilitating policies could potentially lead to a more desired market outcome through achieving higher joint learning rates from firms’ cumulative experiences developed in a more integrated production and deployment ecosystem.

14 SOLAR ENERGY↗

Machine Learning Reduced Order Model for Cost and Emission Assessment of a Pyrolysis System

Biomass pyrolysis is a promising approach for producing economic and environmentally-friendly fuels and bioproducts. Biomass pyrolysis experiments show that feedstock properties have a significant impact on product yields and composition. Scientists are developing detailed chemical reaction mechanisms to capture the relationships between biomass composition and pyrolysis yields. These mechanisms can be computationally intensive. In this study, we investigate the use of a machine learning reduced order model (ROM) for assessing the costs and emissions of a pyrolysis biorefinery. Here, we developed a Kriging-based ROM to predict pyrolysis yields of 314 feedstock samples based on the results of a detailed chemical kinetic pyrolysis mechanism. The ROM is integrated into a chemical process model for calculating mass and energy yields in a commercial-scale (2000 tonne/day) biorefinery. The ROM estimated biofuel yields of 65 to 130 gallons per ton of dry biomass. This results in biofuel minimum fuel-selling prices of $2.62 to $5.43 per gallon and emissions of -13.62 to 145 kg of CO 2 per MJ. The ROM achieved an average mean square error of 1.8e-20 and a mean absolute error of 0.53%. These results suggest that ROMs can facilitate rapid feedstock screening for biorefinery systems.

09 BIOMASS FUELS↗

Protecting pilots, law enforcement and others from lasers [Slides]

Laser lights are being shined into the eyes of law enforcement officers, first responders, and pilots to harass, distract or harm them. Over the last 10 years, there has been a 148% increase in reported aviation laser events in the US. The availability of powerful lasers has increased and the price has decreased over time. Retroreflector prisms return laser light to the origin. This solution is both protective and helps identify the location of the source.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

Toward Rational Design of Nickel Catalysts for Thermocatalytic Decomposition of Methane for Carbon Dioxide-Free Hydrogen and Value-Added Carbon Co-Product: A Review

Thermocatalytic decomposition of methane provides opportunities for hydrogen (H2) production with no emission of carbon dioxide. However, high-value carbon products need to be produced for economic deployment of thermocatalytic decomposition and to achieve a minimum H 2 selling price below the U.S, Department of Energy target of $ 1/kg H 2 . In this review, we re-evaluate data on catalyst development reported in the literature and propose correlations between catalyst characteristics, catalytic stability, and properties of carbon co-products. In the first part of the review, growth mechanisms for carbon nanotubes using state-of-the-art chemical vapor deposition are reviewed to catalog the effects of catalyst characteristics, the influence of carbon sources, interactions between metal particles and supports, and metal particle sizes on carbon growth. In the second part, representative developments in mono-, bi-, and tri-metallic nickel catalysts are highlighted. We present kinetic analysis of reactions catalyzed by mono-metallic nickel catalysts, which generates a correlation between metal particle size and catalyst stability. Rational design of Ni-based catalysts for TCD of methane requires attention to the size of the metal particle and effective normalization of the reaction rates. Further attention to the distribution of the metal particle sizes may help identify catalyst properties that contribute longevity and selectivity to processes that use them. While it is tempting to focus on the highest valued carbon products (e.g., CNTs and CFs), analysis of the markets for other carbon products suggests that a more flexible approach may generate comparable returns without the risk associated with specialization.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Environmentally Sound One-Step Solar Silicon From Natural Quartzite

This project aimed to demonstrate a new molten salt electrodeposition process to go straight from low-cost silica at $200/tonne ($40¢/kg Si basis) to polysilicon in a single step using less than 30 kWh/kg. This would eliminate the carbothermic reduction step and all direct greenhouse emissions, along with 90% of the energy. It would also eliminate the chemical hazards of chlorosilane handling which have resulted in multiple fatalities in the polysilicon industry – in Japan, the US and China. This project had the following major accomplishments: Stakeholder engagement indicated that the solar silicon market is very sensitive to price, provided quality is sufficient. The most important measure of silicon quality is not purity but carrier lifetime, as many impurities can reduce performance at concentrations too small to measure; Experiments set a baseline of current efficiency which is too low for commercial application (~3%), with electronic current ruled out as a mechanism for reduced current efficiency; A scale-up plant narrative narrative described a potential plant and formed the basis for the TEA components; TEA showed that current efficiency, large cell size, and zirconia membrane lifetime are key factors which determine capital and operating costs for the process.

14 SOLAR ENERGY↗

Repowering and Retrofitting of Solar Inverters: A Field Case Study [Slides]

A handful of large-scale photovoltaic (PV) plants have undergone retrofitting and/or repowering of inverters for a variety of reasons, such as rapid product life-cycle innovations with lack of reverse compatibility, original equipment manufacturers (OEMs) exiting the inverter business, weather damage, more lucrative revenue opportunities driven by high contractual offtake price, and so on. Insights has been collected via expert elicitation and relevant staff involved in these retrofitting/repowering at the case study site. Selecting and installing inverters from a different OEM at the commercially operating PV plant provides a unique opportunity to thoroughly document inverter retrofitting/repowering. The case study describes compatibility of mechanical, electrical, communications, and other important aspects. The goal is to provide a public case study that improves the general knowledge of the solar industry about what is involved in repowering/retrofitting a PV plant and how others can best prepare.

14 SOLAR ENERGY↗

A Combined Water and CO2 Direct Air Capture System (CRADA 521)

The primary objective of this project is to demonstrate the outstanding technical and economic performance of a transformational Hybrid DAC (HDAC) technology that simultaneously captures CO2 and water from the air. Air is passed over a CO2 selective sorbent to remove ≥85% of the CO2 from the air stream. The atmospheric water extraction (AWE) section of the unit utilizes a novel isothermal pressure swing regeneration cycle with desiccant beds thermally coupled by heat pipes that provide a passive heat transfer mechanism to “cancel” the heat of water vapor adsorption. By proving system performance through this demonstration project, our initial technoeconomic analysis (TEA) will be validated, showing that HDAC technology: 1) is deployable in many more locations with limited water resources, 2) improves the financial returns, and 3) reduces risks from volatility in the price of CO2.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Effective Kitchen Ventilation for Healthy Zero Net Energy Homes with Natural Gas

Past studies indicate that kitchen ventilation that minimally complies with California’s Residential Building Code is inadequate at controlling combustion pollutants from natural gas burners and particulate matter produced during cooking. Effectiveness is further limited by misperceptions that kitchen ventilation is infrequently needed. This project developed the technical basis for updating kitchen ventilation requirements to protect health in new California homes, especially in smaller homes common among low-income renters. Tasks included (1) a field study of ventilation equipment performance and indoor air quality in 23 low-income apartments at four sites; (2) analysis of range hood use related to cooking time and household parameters using data from 54 houses and 17 low-income apartments; (3)a measurement-based study to quantify performance of over-the-range microwave ovens with integrated exhaust fans;and (4) pollutant exposure simulations to inform capture efficiency standards.The field study found operational deficiencies with mechanical ventilation systems in a substantial fraction of low-income apartments that affected performance, resulting in higher exposures to pollutants generated indoors. Using gas cooking burners produced high short-term and weekly time-averaged nitrogen dioxide in apartments.Range hoods were used more frequently with cooking in houses (36percent) than apartments (28percent); use increased with overall cooking frequency in a home and with duration of cooktop but not oven events; actual use was correlated to, but lower than,self-reported use;and use was more frequent in houses when cooking generated any fine particulate matter (PM2.5)or when high PM2.5resulted from cooking in apartments. Performance of over-the-range microwaves with integrated exhaust fans was similar to that of range hoods of comparable price. Simulation analysis found that performance standards need to be updated to ensure that kitchen exhaust ventilation adequately protects for substantial cooking in new California residences.

03 NATURAL GAS↗