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DOE OSTI2023

Coal as Value-Added for Lithium Battery Anodes (Final Report)

Graphite is a basic material used for energy storage in lithium-ion (Li-ion) batteries. More than 70% of worldwide graphite production and nearly 50% of the annual graphite supply for the United States comes from China. Potential economic and national security concerns exist because Li-ion batteries are used not only for the fast-growing electrical vehicle market (15.6% compound annual growth rate [CAGR] from 2018 to 2028 in North America), but also for defense applications including unmanned aerial and ground vehicles. Development of an alternative formulation for Li-ion batteries is key. Building upon previous research confirming the ability of silicon alloys to improve the energy density of anodes, Semplastics developed a novel material based on our X-MAT® polymer-derived ceramic (PDC) technology. The X-MAT anode material is a composite of chemically tailored silicon oxycarbide (SiOC) and domestically sourced coal powder, designed to be a drop-in replacement for graphite within Li-ion battery anodes. Preliminary tests of this material showed more than twice the reversible capacity of graphite anodes (1,000 mAh/g vs. 372 mAh/g), with excellent stability and capacity retention, almost 100% coulombic efficiency, low voltage potential, and low thermal expansion. At full adoption in 2024, we expect the coal utilization to reach 27,300 tons. Through this project, Semplastics proposed to complete development and begin commercialization of this material. The objective was to determine the best formulation for technical performance and economic viability. At the end of the project, the X-MAT anode material is ready for implementation into existing battery manufacturing processes and can have a significant impact on the utilization of coal, with positive effects for the mining sector and the mitigation of carbon dioxide (CO 2 ) emissions.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2026

Evaluation of coal-associated sediments, wastes, and AMD sludge in the Southern Appalachian Basin as feedstock materials for REE and Li recovery

Critical minerals (CM) such as rare earth elements (REE+) and Lithium (Li) are essential to technological innovation, energy transitions, global economic and defense security, necessitating the search for unconventional resources and efficient recovery methods to avert supply chain disruptions. Here, this study evaluates coal-associated sediments (underclay and roof rock) and wastes from the Pennsylvanian Pottsville Formation of the Southern Appalachian Basin (SAB) as potential feedstocks for CM recovery. A total of 34 samples (15 underclays, 12 roof rocks, 5 Acid Mine Drainage (AMD) sludges, and 2 coal mining wastes) were characterized using XRD, XRF, ICP-MS, and μ-XRF analytical methods. The REE+ and Li concentrations of these materials ranged from 46.8 to 334.4 ppm and from 11.1 to 519 ppm, respectively, with one underclay sample (Hendrix 3456) yielding the highest values for both. Bulk mineralogy for all samples was dominated by aluminosilicate clay phases, particularly illite and kaolinite. All samples exhibited REY def, rel% values >26% and C outl indices that ranged from 0.69 to 0.94, classifying their REE ore potential as Category II (Promising) as defined by Seredin and Dai (2012). Extractability tests (EPA method 3051 A) yielded low REE+ and Li recoveries, with maximum values of 3.3% and 3.6%, respectively, suggesting associations with resistant minerals like clay and phosphates. Elemental mapping indicates that REE+ is associated with phosphate, whereas statistical analysis suggests that REE+ are associated with aluminosilicates, suggesting heterogeneous associations or minimal phosphate contribution. Li also correlated positively with Al 2 O 3 , indicating an aluminosilicate host. This study highlights the potential of coal-associated sediments in the SAB.

Clay minerals↗

DOE OSTI2026

Technology Impact and Resource Assessment of Existing and Planned U.S. Biofuel Production: Life Cycle Water Consumption, Water Stress, Land Use, and Criteria Air Pollutants

Biofuels have the potential to strengthen the U.S. energy supply, enhance energy security, and promote economic development. As the United States continues to expand biofuel production, quantifying resource requirements and location-specific constraints is crucial for planning, siting, and technology development to support long-term viability. Accordingly, this work assesses the life cycle resource consumption (water consumption, and land use), water stress and criteria air pollutants associated with expanded U.S. biofuel production over the 2020–2035 period, based on producers’ plans. We perform a bottom-up technology impact assessment and resource assessment by integrating facility-level production statistics with Argonne’s Research and Development (R&D) GREET model and county-level water-stress characterization factors from Available Water Remaining for the United States (AWARE-US) model. Results suggest that by 2035, biofuels could meaningfully contribute to U.S. energy demand, driven primarily by first-generation and waste-based feedstocks with plans for substantial capacity expansion, although cellulosic and e-fuel technologies remain limited. However, growth must be managed to minimize impacts on water resources and land use. These impacts vary by fuel type and facility location, specifically, projected expansion increases water consumption and can elevate water-stress impacts in certain regions like Nebraska, Kansas, Colorado, Idaho, California and North Texas. Direct land use also increases overall, particularly for first-generation feedstocks such as corn and soybeans. These findings underscore the need for continued technological improvements and innovative strategies to manage resource demands as the industry scales and to support complementary deployment within the evolving U.S. energy system.

09 BIOMASS FUELS↗

DOE OSTI2020

Exascale applications: skin in the game

As noted in Wikipedia, skin in the game refers to having ‘incurred risk by being involved in achieving a goal’, where ‘ skin is a synecdoche for the person involved, and game is the metaphor for actions on the field of play under discussion’. For exascale applications under development in the US Department of Energy Exascale Computing Project, nothing could be more apt, with the skin being exascale applications and the game being delivering comprehensive science-based computational applications that effectively exploit exascale high-performance computing technologies to provide breakthrough modelling and simulation and data science solutions. These solutions will yield high-confidence insights and answers to the most critical problems and challenges for the USA in scientific discovery, national security, energy assurance, economic competitiveness and advanced healthcare. This article is part of a discussion meeting issue ‘Numerical algorithms for high-performance computational science’.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2021

DOE Energy Frontier Research Centers Center for Direct Catalytic Conversion of Biomass to Biofuels (C3Bio)

New capabilities to predict, design and control the chemistries of carbon could answer a global imperative to transition from fossil-based to sustainable transportation fuels. While the use of inexpensive hydrocarbons has been an unparalleled achievement and enabler of economic prosperity for many nations, singular dependence upon crude oil has given rise to systemic vulnerabilities in climate, energy, economic, and national security. Lignocellulosic biomass, a renewable and carbon-neutral resource, has the potential to displace an estimated annual equivalent of three billion barrels of oil in the U.S. alone (National Research Council 2009, U. S. Department of Energy, 2011). However, biomass has only one-third the energy density of crude oil (Agrawal and Singh 2009, Richard 2010) and lacks petroleum’s versatility as a feedstock for fuels and chemicals. These limitations keep biomass conversion below the efficiency level needed for strategic impact while the scientific challenge of routing carbon from one molecular context to another remains unmet. In 2009, the Center for Direct Catalytic Conversion of Biomass to Biofuels (C3Bio) recognized the potential of chemical catalysis and fast pyrolysis to overcome such limitations by transforming the main components of biomass (cellulose, xylan, and lignin) from grasses and trees directly to liquid hydrocarbons and aromatic co-products. Enabled by the EFRC high-risk, high-reward approach to grand challenge science, C3Bio researchers have been key national players in disrupting the conventional paradigm of the cellulosic biorefinery into a new future of “no carbon left behind”—the full utilization of carbon from plant cell walls in energy-dense fuels (Fig. 1). We identified catalytic and fast-pyrolytic pathways that utilize cellulose, xylan and, most significantly, lignin. We developed catalytic processes that deoxygenate and transform monomers and isolated polymers into useful products and tested their use with intact biomass. We gained control of lignin synthesis within plants and initiated tailoring biomass to its end-use through the tools of plant molecular biology and genetic engineering. C3Bio breakthroughs have increased the energy density of biomass-derived substrates via catalytic and pyrolytic conversions into products such as benzoquinones, furfural and hydroxymethylfurfural, levoglucosan and levulinic acid, methoxypropylphenols and propylbenzene. Such advances in biomass conversion would not have been possible without simultaneous advances in analytical instrumentation and methodologies, and imaging technologies and applications. The legacy science developed by C3Bio enables design and control strategies for achieving a targeted product portfolio of fuel and chemical feedstocks from a diverse range of native and tailored biomass. Our research provides the knowledge base required for a bio-economy with product streams as diverse in functionality as those of the petrochemical industry. Coupling targeted computational modeling with experimentation, we achieved: (1) fundamental understanding of biopolymers and cell wall architecture assembly, (2) discovery of new chemistries that allow the development of highly selective pathways to fuels and desirable chemicals, and (3) an integrated systems-level understanding to control catalytic and pyrolytic pathways.

09 BIOMASS FUELS↗

DOE OSTI2024

Near Net Shape Workshop Report

In 2021, President Biden issued Executive Order (EO) 14017, spurring the federal government to build more secure and diverse U.S. supply chains, including energy supply chains, to ensure economic prosperity and national security (White House 2021). In response to EO 14017, the U.S. Department of Energy (DOE) published America’s Strategy to Secure the Supply Chain for a Robust Clean Energy Transition (Igogo 2022) to outline the challenges and opportunities facing the energy supply chain along with key strategies to secure America’s position as a clean energy superpower in the years and decades to come. The expansion of domestic manufacturing capabilities is identified as one of the common risks and vulnerabilities for which DOE should develop comprehensive strategies to secure supply chains for the clean energy transition. The report states that “examples of manufacturing capabilities of concern include … large iron and steel castings for wind turbines, hydropower turbines, and nuclear reactor components.”

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2022

WBG-Enabled Current-Source Inverters for Integrated PM Motor Drives

This project takes advantage of the special capabilities of wide-bandgap (WBG) power semiconductor devices to develop innovative power electronics in the form of new current-source inverters (CSIs) that offer promising advantages over the dominant voltage-source inverter (VSI) topology. These CSIs, in turn, are extremely well-suited for integration into the housings of permanent magnet synchronous machines (PMSMs) to form integrated motor drives (IMDs). These new IMDs offer great promise for achieving major energy savings in a wide variety of applications that benefit from adjustable-speed control, including air conditioners, laundry appliances, industrial pumps/compressors, electric vehicles, and aerospace drives. WBG devices play a critical enabling role in these new IMDs because of their transformative features including much higher switching frequencies, lower losses, and compatibility with high operating temperatures. When incorporated into new CSI-based IMDs with PM machines, these WBG switches open the door to achieving major increases in power density, drive system efficiency, and fault tolerance, as well as substantial reductions in electromagnetic interference (EMI), manufacturing cost, and temperature-induced failures. The higher operating temperature capability of WBG devices compared to conventional silicon power devices is very appealing in IMD applications because the power electronics is mounted in close proximity to the motors which typically operate at temperatures well above the maximum limits of today’s silicon-based power electronics. This project has succeeded in designing, building, and testing multiple prototype versions of this CSI-IMD that have overcome many technical challenges in order to demonstrate the impressive performance improvements that can be achieved by the WBG-enabled CSI-IMD. The preliminary demo and bench-top versions of the current-source inverter developed during the first two years of the project were critical to laying the technical foundations for the 3 kW prototype CSI-IMD unit that was successfully built and tested during the third year. This prototype CSI-IMD unit was designed to fit within the housing envelope of the original permanent magnet (PM) synchronous machine in order to meet the demanding power density requirements that were set at the beginning of the project. All of the remaining performance objectives set for the prototype CSI-IMD unit including efficiency and electromagnetic interference (EMI) were also met. The last 18 months of the project were devoted to developing further enhancements of the WBG-enabled CSI-IMD technology that better prepare it for commercial production. More specifically, an upgraded version of the prototype CSI-IMD unit was developed that moved the power electronics into the same machine housing chamber as the motor, substantially raising the thermal demands on the power electronics. Tests with five different combinations of motor enclosure types and air cooling configurations were evaluated. Importantly, this work confirmed that the power electronics can deliver its full rated power and still operate well within its maximum temperature limits even for worst-case conditions when the housing is “totally-enclosed” without any openings for air to enter or exit the enclosure, and no blower/fan is provided to blow air over the outside surface of the enclosure. Reaching the full performance and energy-savings potential of this disruptive CSI-IMD motor drive technology is highly consistent with ARPA-E’s stated mission to “enhance the economic and energy security of the United States” while also supporting its commitment to “ensure that the U.S. maintains a technological lead in developing and deploying advanced energy technologies”. Follow-on projects are under way to explore the scalability of WBG-enabled CSI-IMD technology to 100 kW (peak) electric vehicle traction drives and fault-tolerant modular motor drives for future electrified aircraft propulsion applications.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2023

Clean Cities Coalitions: Advancing Affordable, Efficient, and Clean Transportation Fuels and Technologies

A collaborative network of more than 75 Clean Cities coalitions boosts the country's economic vitality, energy security, and quality of life by advancing the deployment of affordable, efficient, and clean transportation fuels and technologies. Coalitions provide the technical expertise local decision makers and fleets need to understand and implement alternative and renewable fuels, electric vehicles, idle-reduction measures, fuel economy improvements, new mobility choices, and emerging transportation technologies.

ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2023

Clean Cities Coalitions: Advancing Affordable, Efficient, and Clean Transportation Fuels and Technologies

This fact sheet provides an overview of the U.S. Department of Energy's (DOE's) Vehicle Technologies Office Clean Cities Coalition Network, which boosts the country's economic vitality, energy security, and quality of life by advancing the deployment of affordable, efficient, and clean transportation fuels and technologies. Coalitions provide the technical expertise local decision makers and fleets need to understand and implement alternative and renewable fuels, electric vehicles, idle-reduction measures, fuel economy improvements, new mobility choices, and emerging transportation technologies.

accomplishments↗

DOE OSTI2023

Clean Cities Coalitions: Advancing Affordable, Efficient, and Clean Transportation Fuels and Technologies

ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2024

A Path to Navigating the Storm: Load Forecasting and Increasing Resilience in Puerto Rico

Puerto Rico Grid Resilience and Transitions to 100% Renewable Energy Study (PR100) provided a comprehensive analysis of pathways for Puerto Rico to achieve its goal of 100% renewable energy by 2050, based on extensive stakeholder input. The study illuminates immediate and longer-term investments needed to achieve reliability while pursuing Puerto Rico's energy goals and addressing critical energy needs. Expected benefits of these investments include improvements in safety, security, health, and economic opportunity.

ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2024

GLIMPSE of Future Power Grid Models

Power grid is one of the critical national infrastructures with social, economics, and national security impacts. Particularly, power distribution systems represent part of the infrastructure between power distribution substations and customers such as residential, commercial, and industrial. To address various grid modernization challenges, state-of-the-art algorithms and methodologies have been developed to deploy, operate, and expand a secure and resilient power grid. At the same time, there is a need to develop capabilities to assist power grid stakeholders to quickly get insight into the design and structure of the grid. Data visualization is a key approach to comprehend and understand complex systems such as the power grid. We present GLIMPSE Grid Layout Interface for Model Preview and System Exploration), a graph-based semantic-aware application to visualize and update distribution power grid models. The GLIMPSE can be used with standard IEEE models to search and highlight power grid objects such as generators, loads, overhead lines, etc. Additionally, it supports updating attributes and model export to integrate with GridLAB-D simulations.

Cybersecurity, power grid, visualization↗

DOE OSTI2025

Clean Energy for the Battery-to-EV Supply Chain: A Roadmap for Indonesia - Summary Brief

Indonesia has a unique opportunity to support the clean energy transition, enhance energy security, and spur economic growth with local battery manufacturing, bridging from the material supply all the way to pack designs and, ultimately, the manufacturing of electric cars. Following the elevation of United States and Indonesia relations to a Comprehensive Strategic Partnership, leaders of both countries highlighted the importance of Net Zero World support for Indonesia's energy transition, including collaboration on low-carbon battery supply chains. In support of this agreement, Net Zero World has partnered with Indonesia's Ministry of Energy and Mineral Resources and other Indonesian partners to chart actionable steps for establishing a clean, resilient battery supply chain and circular economy. This partnership aims to position Indonesia as a regional leader in clean energy and can help attract investment in the domestic battery and electric vehicle (EV) sectors.

batteries↗

DOE OSTI2022

Evaluating the regional risks to food availability and access from land-based climate policies in an Integrated Assessment Model

Mitigating greenhouse gas (GHG) emissions is necessary to reduce the overall negative climate change impacts on crop yields and agricultural production. However, certain mitigation measures may generate unintended consequences to food availability and food access due to both land use competition and economic burden of mitigation. Integrated assessment models (IAM) are generally used to evaluate these policies; however, currently these models may not capture the importance of income and food prices for hunger and overall economic wellbeing. Here, we implement a measure of food security that captures the nutritional and economic aspects as the total expenditures on staple foods divided by income and weighted by total caloric consumption in an IAM, the Global Change Analysis Model (GCAM4.0). We then project consumer prices and our measure of food security along the Shared Socioeconomic Pathways (SSPs). Sustained economic growth underpins increases in caloric consumption and lowering expenditures on staple foods. Strict conservation policies affect food accessibility in a larger number of developing countries, whereas the negative effects of pricing terrestrial emissions is more concentrated on the poor in Sub-Saharan Africa, by substantially replacing their cropland with forests and affecting the production of key staples.

Cui, Ryna↗

DOE OSTI2022

Cross-Layered Distributed Data-Driven Framework for Enhanced Smart Grid Cyber-Physical Security

Smart Grid (SG) research and development has drawn much attention from academia, industry and government due to the great impact it will have on society, economics and the environment. Securing the SG is a considerably significant challenge due the increased dependency on communication networks to assist in physical process control, exposing them to various cyber-threats. In addition to attacks that change measurement values using False Data Injection (FDI) techniques, attacks on the communication network may disrupt the power system's real-time operation by intercepting messages, or by flooding the communication channels with unnecessary data. Addressing these attacks requires a cross-layer approach. In this paper a cross-layered strategy is presented, called Cross-Layer Ensemble CorrDet with Adaptive Statistics(CECD-AS), which integrates the detection of faulty SG measurement data as well as inconsistent network inter-arrival times and transmission delays for more reliable and accurate anomaly detection and attack interpretation. Numerical results show that CECD-AS can detect multiple False Data Injections, Denial of Service (DoS) and Man In The Middle (MITM) attacks with a high F1-score compared to current approaches that only use SG measurement data for detection such as the traditional physics-based State Estimation, Ensemble CorrDet with Adaptive Statistics strategy and other machine learning classification-based detection schemes.

cyber-physical security↗

DOE OSTI2024

How to Create, and Sustain, R&D Leadership A blueprint for international collaboration

How the United States can compete in the twenty-first century is one of the most vexing challenges for policy makers and academics today. Many studies have shown that most impactful science and technology advances happen in open and diverse environments, under excellent research conditions, with sufficient funding. Since the end of World War II, the United States has been the most attractive country for open research and commercialization of new discoveries. This strategy—partly articulated in science administrator Vannevar Bush’s Endless Frontier report of 1945—leverages federal government investments in research and development (R&D) to enhance economic competitiveness and national security. The combination of a dynamic, open research ecosystem and world-leading science infrastructure provided an exciting work environment leading to groundbreaking discoveries, and propelled economic growth through the second half of the twentieth century.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2025

NREL is Delivering Integrated Solutions for an Affordable and Secure Energy Future

The National Renewable Energy Laboratory (NREL) is the U.S. Department of Energy's primary national laboratory for energy systems research and development. As the energy systems laboratory, NREL's unique strength lies in developing and integrating a broad array of energy technologies into robust, resilient systems - bridging foundational research with practical applications to lower energy costs, drive economic growth, bolster national security, and deliver abundant and reliable energy.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2025

Driving Economics and Reducing Risks: The Business Case for Security-by-Design in Nuclear Power

This report provides an analysis of the financial, operational, and strategic advantages of incorporating Security-by-Design (SeBD) early in the lifecycle of nuclear power plant projects. By framing security as a foundational design element rather than a late-stage add-on, owners, vendors, and operators can reduce budget overruns, strengthen regulatory compliance, and increase revenue opportunities. The report details key lifecycle phases, highlighting the strategic imperative for organizations (including project developers, investors, vendors, and regulators) to adopt SeBD. Drawing on industry estimates, real-world case studies, and comparative cost analyses, the findings underscore that even a modest upfront investment in SeBD can yield substantial long-term returns by preventing costly retrofit activities, minimizing regulatory delays, and positioning nuclear vendors for the ability to adapt in the evolving security market. By avoiding excessive retrofit expenses and positioning security as a built-in feature rather than an afterthought, nuclear projects can protect their financial performance, enhance public trust, and secure a competitive edge in an increasingly complex global energy market. The authors advocate for SeBD’s strategic implementation, supported by established quality management methodologies, thereby promoting continuous improvement and defect avoidance. Ultimately, early SeBD integration represents a strategic investment, yielding significant returns by preventing costly retrofits and positioning nuclear projects for enhanced competitiveness and public trust.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗