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DOE OSTI2022

Single-column cryogenic air separation: enabling efficient oxygen production with rapid startup and low capital costs—application to low-carbon fossil-fuel plants

The rapid integration of intermittent renewable sources into the electricity grid is driving the need for more flexible, low-carbon fossil-fuel plants with lower capital costs. This then drives the need to improve the cryogenic air separation unit (ASU). To address this changing landscape, we explore a Praxair single-column ASU (PSC-ASU) design with the goal of reducing costs and improving flexibility, compared to a conventional double-column ASU. The PSC-ASU incorporates partial air condensation and air pre-separation in the bottom reboiler with a phase separator as well as N2-enriched vapor condensation in the upper reboiler to decrease energy consumption, as compared to Linde's single-column ASU. All three of the above-mentioned ASU designs are simulated in Aspen Plus and analyzed. An economic analysis is applied to evaluate the relative cost savings of the PSC-ASU compared to the double-column ASU. Results suggest that the specific energy consumption of the PSC-ASU is significantly lower than that of Linde's single-column ASU due to a drastically improved oxygen recovery rate. Although this improved oxygen recovery rate is still lower than that of the double-column ASU, the required pressure ratio of the main air compressor is 21% lower than that of the double-column ASU. As a result, the specific energy consumption of the PSC-ASU is only 1.9% greater than that of the double-column ASU for producing 95.1 mol% O2. However, the PSC-ASU reduces the hourly capital cost by 19% due to the elimination of a high-pressure column. This would effectively decrease the total hourly cost of the ASU, and thus the total hourly cost of low-carbon, fossil-fuel power plants that require oxygen.

Cheng, Mao↗

DOE OSTI2021

Rapidly ramp cryogenic air separation unit without loss of O2 product purity—application for low-carbon fossil-fuel plants

The rapid integration of intermittent renewable sources into the electricity grid is driving the need for low-carbon, fossil-fuel power plant capable of rapid ramping. Therefore, a cryogenic air separation unit (ASU) as part of low-carbon, fossil-fuel power plant should be capable of rapid ramping. However, highly integrated and nonlinear processes of the ASU would significantly restrict this rapid ramping. To overcome this fundamental issue, we study the basic dynamic process of a state-of-the-art double-column ASU. A flow-driven dynamic model was established in Aspen Plus Dynamics, assuming perfect flow controls, to capture the basic dynamics of ramping ASU. We find the vapor-liquid counter-current flow structure in the low-pressure column is critical to the air separation when rapidly ramping the ASU. This flow structure is established based on a complicated heat integration process. It is simplified as an apparent counter-current heat transfer process in this work, which greatly reduces the complexity for studying the dynamics of ASU. For keeping this basic flow structure, the heat integration is maintained as its heat duty follows the ASU load, through several basic feed-forward and feed-back controllers on the critical stream flowrates. Moreover, we find a fundamental issue of mismatched dynamics in the low-pressure column, resulting in a significant loss of O2 product purity when rapidly ramping down the ASU and an obvious fluctuation of O2 product purity. Based on these explorations, we propose a basic control method for rapidly ramping the ASU without loss of O2 product purity. Results show the ASU basic dynamic process successfully ramps at a rate up to 10%/min (40-100% load) while maintaining the O2 product purity within 95.2-95.6 mol%.

Cheng, Mao↗

DOE OSTI2025

WRPS Hanford Update [Slides]

The purpose of this report is to coordinate with the staff from WRPS, the current contract holder for operations at the Hanford site to better inform design decisions for the Autonomous systems for Hanford waste tank handling project. The project goals are to support risk reduction associated with monitoring, inspection and mapping of Hanford tank underground pits and includes: 1. A pit mock-up demonstration of Idaho National Laboratory’s (INL) Autonomous Pit Exploration System (APES) technology, which has two configurations: A. The Autonomous Robotic Arm, which is a proposed collaboration with Florida International University (FIU) and has capabilities to visually inspect, monitor, map and conduct simple tool manipulation tasks in the tank pits, and B. The robotic crawler configuration, which has capabilities to deploy to the bottom of the pits and conduct closer and bottom-up visual inspections. 2. An Implementation Plan that identifies Hanford site-wide application of the INL remote robotics technologies to enhance the performance of the tank farm systems and the characterization of the waste they contain to mitigate risk and optimize the overall waste mission. 3. A first-of-a-kind environmental digital twin will be produced. Digital twins to date require permanently installed sensors in order to produce asset specific predictions. This project will use the intermittent signals during inspections from deployed sensors on robotic systems to produce the data sets used by AI/ML to enable predictions of issues on tanks.

42 - ENGINEERING↗

DOE OSTI2026

Flexible AI Models for Grid Resilience

The rapid growth in size and complexity of artificial intelligence (AI) and machine learning (ML) models has led to increased energy demands, posing a threat to the reliability of the existing power grid. This project addresses the challenge of highly intermittent and energy-intensive inference workloads by (1) developing fidelity-adaptive neural networks capable of dynamic response to grid conditions and (2) integrating these networks with power flow simulations to assess their impact on power grid reliability. We will explore both top-down and bottom-up approaches to create hierarchies of submodels that provide a controlled trade-off between power draw and prediction accuracy. The top-down method utilizes NN pruning to reduce a flagship model into progressively smaller, energy-efficient variants. The bottom-up approach employs geometrically principled weight setting strategies to construct depth-efficient models from the ground up. A real-time hardware-in-the-loop (HIL) platform will be developed to simulate a scaled AC power grid, integrating live AI workload power draw and enabling dynamic model switching in response to grid feedback. This work will provide a novel framework for evaluating the impact of flexible AI/ML workloads on grid performance and establish new methodologies for energy-aware computing in data centers. The outcomes will demonstrate that adaptive AI/ML can play a critical role in improving grid stability while advancing NREL's leadership in energy-efficient computing research.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2026

Persistent DynAMICS

Persistent DynAMICS is a lightweight software platform that enables distributed sensing systems to operate as a unified, responsive network. It integrates with existing sensors, data systems, and processing tools as an overlay, without requiring hardware replacement or increasing user burden. As data is collected, the system identifies situations that require additional attention and directs selected sensors to gather more information. For example, if a sensor detects an unusual condition along a pipeline, the system can task nearby sensors or different sensing modalities to confirm the event and focus data collection where it is needed. To support this, the platform forms temporary groups of sensors that work together to address specific objectives. Once complete, these groups are dissolved and resources are reassigned as needed. Communication is handled through an integrated messaging framework with client and server components, enabling reliable operation and data continuity even in low-bandwidth or intermittent connectivity environments.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2026

NLR CSP Optical Facilities: Illuminating the Path Forward Through Innovation and Impact: Agreement 38490

This initiative is a multi-faceted project at the National Laboratory of the Rockies (NLR) aimed at strengthening its Concentrating Solar Power (CSP) Optical Facilities to advance the development of low-cost, high-performance materials for solar and other applications. The project's strategy is built on three pillars: strategic stakeholder engagement, diligent facility maintenance and utilization, and the development of new research capabilities. The overarching goal is to ensure the facilities remain state-of-the-art resources for industry and academia, thereby accelerating the conversion of concentrated sunlight into energy. A key driver of the project is an international Advisory Board, which provides critical guidance on research priorities and industry needs, leading to new collaborations and secured funding. This external engagement, combined with proactive outreach to industry partners, ensures the lab's work remains aligned with real-world challenges, including materials durability and performance certification. Significant efforts in facility maintenance have addressed challenges with aging infrastructure. Notable achievements include the complete refurbishment of the hail-damaged Ultra-Accelerated Weathering System (UAWS) and the successful replacement of a failing 15-year-old Lambda 1050 spectrophotometer with a new-generation model, substantially upgrading material characterization capabilities. These maintenance activities were complemented by achieving a prestigious ISO 9001:2015 certification for the Advanced Optical Materials Labs, formally recognizing the quality and reliability of NLR's measurement capabilities. Despite these successes, challenges remain, including high demand for the High Flux Solar Furnace (HFSF) and intermittent failures of other key instruments. The project has delivered major advancements in research techniques and capabilities. At the Flatirons campus, a new indoor laboratory, was established to house advanced deflectometry and photogrammetry systems for heliostat characterization. For on-sun testing, a novel, actively cooled turning mirror was developed for the HFSF, enabling more realistic testing of particle receivers and components. A collaboration with Virginia Tech successfully demonstrated the high-temperature durability of a new solar absorber coating through extensive cyclic testing. Concurrently, new modeling took place to better predict material degradation on rough, fractal surfaces. In summary, this project has systematically enhanced NLR's CSP Optical Facilities through strategic upgrades, rigorous maintenance, and stakeholder-guided research. By overcoming equipment failures, budgetary constraints, and logistical hurdles, the project has reinforced NLR's role as a central hub for CSP innovation and materials testing. Future work will focus on securing diverse funding, expanding collaborations, and continuing to provide the critical infrastructure needed to accelerate the development and deployment of next-generation technologies.

14 SOLAR ENERGY↗

DOE OSTI2023

Storing Electricity with Salt and Iron (CRADA Final Report)

As part of the Cyclotron Road program, Inlyte Energy, Inc. investigated low-cost energy storage for the electricity grid via batteries manufactured from abundant materials. Low-cost energy storage can solve the problem of the intermittency of wind and solar power, thereby allowing these sources of energy to scale more rapidly. The project team explored development of a Na-FeCl 2 battery—which had as its starting redox-active materials the abundant materials table salt (NaCl) and iron—that can operate safely and efficiently over a long lifetime, and be produced at very low-cost. The Na-FeCl 2 battery is architecturally similar to the commercialized Zebra (Na-NiCl 2 ) batteries, which have demonstrated safety, efficiency, and long lifetime. This project explored and assessed key design changes, including the use of planar Na-β’’-alumina solid electrolyte and lower temperatures (~200 °C) with polymer seals aimed at decreasing costs.

25 ENERGY STORAGE↗

DOE OSTI2026

DAOS Benchmarks and Findings

We benchmark DAOS on a 127-node, 4,064-target pool using fio, IOR, IO500, and mdtest, comparing the DFS API against DFuse+POSIX. Single-client fio sweeps show larger block sizes and writes yield higher bandwidth, with similar random/sequential performance. Multi-node IOR (1–32 nodes, 6–48 tasks/node) shows bandwidth saturating around 32 tasks/node, with large transfer sizes hurting read throughput at high concurrency and write latency growing faster than read latency. An 8-node IO500 run shows DFS achieving ~5x higher bandwidth and ~190x higher IOPS than POSIX. We also detail operational issues: SCM target-filling under mdtest, intermittent NA_HOSTUNREACH errors, fio CPU-affinity failures, and a pool error storm resolved by recreation.

George, Rebecca [Thomas Jefferson National Acceler↗

DOE OSTI2026

Cloud-Based Demonstration of the Eastern Interconnection Situational Awareness Monitoring System (ESAMS)

This report describes a cloud-based implementation and field demonstration of the Eastern Interconnection Situational Awareness and Monitoring System (ESAMS). ESAMS was developed to support the detection and source localization of forced oscillations using synchrophasor measurements from tie-lines connecting areas served by different reliability coordinators (RCs), so that RCs could better coordinate their response to wide-area events. A previous effort had identified deployment barriers associated with hosting shared situational awareness tools at a single RC. To address these barriers, ESAMS was migrated to Amazon Web Services and evaluated in a six-month field demonstration. ISO New England (ISO-NE) and PJM streamed data to the platform using AWS Direct Connect and a site-to-site VPN, respectively. The resulting multi-utility measurement footprint enabled regional source localization across major portions of the U.S. Eastern Interconnection and supported routine identification of oscillation events. During the final three months of the trial, 24 events above 2 MW/MVAR were detected. The largest detected oscillation approached a 25 MW peak-to-peak amplitude, and the longest persisted intermittently for more than 11 hours. The demonstration also assessed operational considerations—including data transfer volumes, end-to-end latency, and cloud computing costs—and found that network and compute requirements were modest relative to typical cloud capabilities while providing performance comparable to prior on-premises deployments. Overall, the results indicate that cloud hosting can provide a practical path to shared interconnection-wide oscillation monitoring. The cloud ESAMS demonstration establishes a foundation for broader utility participation and for building future wide-area analytics that leverage measurements across organizational boundaries.

Follum, James D.↗

DOE OSTI2022

Environmental Flow Requirements from FERC Licenses Across the US

Environmental flow requirements included in Federal Energy Regulatory Commission (FERC) hydropower licenses are important for balancing natural properties and benefits of river ecosystems (e.g., healthy species, recreation, water supply, flood control) supporting hydropower production. In some cases, environmental flow requirements may limit operational flexibility given current operational schemes and make a hydropower plant less able to provide power to the electric grid on demand. Hydropower plants may gain some flexibility as hydropower scheduling time periods are made to be more responsive to the short-term needs of an energy grid increasingly reliant on intermittent renewables. However, many flow requirements focus on the daily, monthly, or seasonal flow fluctuations which matches the time scale of most paradigms linking flow alterations to the health of river ecosystems. This dataset seeks to provide a greater understanding of how flexibility in environmental requirements can be leveraged to create positive outcomes for both the power system and the environment. It contains information on environmental flow requirements from the Protection, Mitigation, and Enhancement section of 50 randomly selected FERC licenses: 25 issued from 1998-2013 that were also included in the ORNL Mitigation Database (Schramm et al. 2015) and 25 issued from 2014-present. The information on environmental flow requirements was extracted from the PM&E section of 50 randomly selected FERC licenses: 25 issued from 1998-2013 that were also included in the ORNL Mitigation Database (Schramm et al. 2015) and 25 issued from 2014-present. The flow requirements were then categorized into flow augmentation categories based on whether the license stated a specific water management purpose for the given requirement called augmentation categories (i.e., fisheries or habitat, recreation or boating, industry, and general or unspecified; Table B). Requirements were also grouped into flow type categories (e.g., minimum flow rate, maximum flow rate, ramping rate). Additional information related to flow requirements such as the augmentation time-period and whether the flow rate was continuous (i.e., condition must be present at all-times) or instantaneous (i.e., condition present at a point in time) was also extracted from the licenses. Some licenses had specific flow requirements based on whether the project was in a wet, dry, or normal water year. If that information was presented in the license, it was also included in the data set. The location within the project was noted, hereafter, zone, in the dataset for flow requirements relating to specific areas of hydropower projects (Dam, Powerhouse, Bypass Reach). Maximum discharge capacities of hydropower facilities were also extracted from both the Existing Hydropower Assets (EHA) data set and the National Inventory of Dams (NID) databases. Each facility was coded with project identification codes from the EHA dataset to facilitate cross-referencing between datasets.

13 HYDRO ENERGY↗

DOE OSTI2022

Experimental performance analysis of a dual source heat pump integrated with thermal energy storage

To mitigate disturbances to the electric grid resulting from the growing penetration of intermittent and decentralized renewable generation, a dual-source (air source and ground source) heat pump (DSHP) integrated with thermal energy storage (TES) was developed. The DSHP can use either ambient air or the shallow subsurface of the ground to provide space heating or space cooling to the building as the conventional heat pump and produce hot/cold water for charging TES. Using dual sources (air and ground) can reduce the required size of the expensive ground heat exchangers while retaining high energy efficiency. During the off-peak period, the DSHP cools/heats the TES with low-cost electricity or overproduced renewable power. The stored cooling/heating energy in the TES is released during peak hours of the electric grid to meet the thermal demands of the building without consuming electricity to run the DSHP. A 2-ton (7 kW) prototype DSHP was developed and integrated with a 50-gallon (189 L) TES tank filled with a phase change material. Field tests were conducted to characterize the performance of the integrated system operating in various operation modes.

Wang, Lingshi↗

DOE OSTI2020

State-Constrained Grid-Forming Inverter Control for Robust Operation of AC Microgrids

The control of grid-forming inverters has become an important problem to achieve high efficiency, reliability, and resilience of the future power grid. The distributed control that utilizes a sparse communication network has been proposed for AC microgrids, in which each DG only has access to the information of a small number of its neighboring DGs, reducing the computational complexity and improving the resiliency to faults and unknown parameters. However, these approaches have not provided a clear analysis of the coupling between active/reactive power injections and the voltage magnitude/frequency or a distributed updating law with a solid theoretical foundation. Additionally, in the existing approaches, tracking the references from the secondary control may violate operational constraints.

Xu, Ying↗

DOE OSTI2021

An experimental database of cell performance for vanadium redox flow battery

The continual growth in energy demand has resulted in the deployment of renewable energy generators to reduce the impact of fossil fuel dependence. However, these generators often suffer from intermittency and require energy storage when there is over-generation and the subsequent release of this stored energy at high demand. One promising energy storage technology which can provide a solution to improve energy management and grid stability, is the redox flow battery. Among the numerous flow battery systems, vanadium redox flow battery is the most iconic solution to large scale energy storage, giving a more efficient link between energy production, especially from renewables, and energy demand. The aim of the current database is to characterize the performance of the cell design and to provide training/validation data for physical model or data-driven model. The database includes hundreds of experimental cell performance data of vanadium redox flow battery with various current densities for multiple charge-discharge cycles. All the cell parameters, chemical parameters, material parameters, operation parameters and thermodynamic parameters of the cell system are listed. Coulomb, voltaic and energy efficiencies are also provided. The database will be helpful for researchers in the field of redox flow batteries.

Gao, Peiyuan↗

DOE OSTI2021

Error-Level-Controlled Synthetic Forecasts for Renewable Generation

Renewable energy resources, including solar and wind energy, play a significant role in sustainable energy systems. However, the inherent uncertainty and intermittency of renewable generation pose challenges to the safe and efficient operation of power systems. Recognizing the importance of short-term (hours ahead) renewable generation forecasting in power systems operation, it becomes crucial to address the potential inaccuracies in these forecasts. To systematically evaluate the performance of controllers in the presence of imperfect forecasts, we generate synthetic forecasts using actual renewable generation profiles (one from solar and one from wind). These synthetic forecasts incorporate different levels of statistical error, allowing us to control and manipulate the accuracy of the predictions. The primary objective is to employ synthetic forecasts with controlled yet realistic error levels to systematically investigate how controllers adapt to variations in forecast accuracy, providing valuable insights into their robustness and effectiveness under real-world conditions.

Array↗

DOE OSTI2024

Molten sodium batteries: advances in chemistries, electrolytes, and interfaces

The need for clean, renewable energy has driven the expansion of renewable energy generators, such as wind and solar. However, to achieve a robust and responsive electrical grid based on such inherently intermittent renewable energy sources, grid-scale energy storage is essential. The unmet need for this critical component has motivated extensive grid-scale battery research, especially exploring chemistries “beyond Li-ion”. Among others, molten sodium (Na) batteries, which date back to the 1960s with Na-S, have seen a strong revival, owing mostly to raw material abundance and the excellent electrochemical properties of Na metal. Recently, many groups have demonstrated important advances in battery chemistries, electrolytes, and interfaces to lower material and operating costs, enhance cyclability, and understand key mechanisms that drive failure in molten Na batteries. For widespread implementation of molten Na batteries, though, further optimization, cost reduction, and mechanistic insight is necessary. In this light, this work provides a brief history of mature molten Na technologies, a comprehensive review of recent progress, and explores possibilities for future advancements.

25 ENERGY STORAGE↗

DOE OSTI2022

Aqueous titanium redox flow batteries—State-of-the-art and future potential

Market-driven deployment of inexpensive (but intermittent) renewable energy sources, such as wind and solar, in the electric power grid necessitates grid-stabilization through energy storage systems Redox flow batteries (RFBs), with their rated power and energy decoupled (resulting in a sub-linear scaling of cost), are an inexpensive solution for the efficient electrochemical storage of large amounts of electrical energy. Titanium-based RFBs, first developed by NASA in the 1970s, are an interesting albeit less examined chemistry and are the focus of the present review. Ti, constituting 0.6% of the Earth’s crust and an ingredient in inexpensive white paints, is amongst the few elements (V and Mn being some others) which exhibit multiple soluble oxidation states in aqueous electrolytes. Further, the very high (approaching 10 M) solubility of Ti in low pH solutions suggests the possibility of developing exceptionally high energy density aqueous Redox Flow Batteries systems. With these advantages in mind, we present the state-of the-art in Ti-RFBs with a focus on Ti/Mn, Ti/Fe and Ti/Ce couples and systems that use Ti as an additive (such as Ti/V/Mn). The inherent advantages of inexpensive Ti actives and relatively high energy density is contrasted with potential side-reactions resulting in reduced energy efficiency. Technological pathways are presented with a view to overcoming critical bottlenecks and a vision is presented for the future development of Ti-RFBs.

25 ENERGY STORAGE↗

DOE OSTI2020

Gambusia holbrooki Survive Shear Stress, Pressurization and Avoid Blade Strike in a Simulated Pumped Hydroelectric Scheme

Pumped hydroelectric energy storage (PHES) projects are being considered worldwide as a means of achieving political renewable energy targets in a way that stabilises baseload energy supply from often intermittent renewable energy sources. Unlike a conventional hydroelectric system that only pass water in a downstream direction, a feature of PHES is that it relies on the bi-directional flow of water. In some cases this flow can be across different waterbodies or catchments, posing a risk of inadvertently expanding the range of aquatic animals like fish. The risk of this happening depends on the likelihood of survival of individuals, which remains poorly understood for turbines that are pumping rather than generating. This study quantified the survival of a globally widespread and invasive poeciliid fish, Eastern gambusia (Gambusia holbrooki) when exposed hydraulic stresses characteristic of what would be experienced through a PHES during the pumping phase. A shear flume and hyperbaric chamber were used to expose fish to different strain rates and rapid and sustained pressurisation. A blade strike model was also used to predict survival of fish passing through a Francis dual turbine / pump. The ranges simulated were based on design and operational conditions provided for a PHES scheme being proposed in south-eastern Australia. All gambusia tested survived extremely high (up to 7600 kPa gauge pressure) pressurisation, high levels of shear stress (up to 1853 s -1 ), and the majority (> 93 %) were unlikely to be struck by a turbine blade. Given their tolerance to these extreme simulated stresses, we conclude that gambusia will likely survive passage through a PHES scheme. Therefore, where a new PHES poses the risk of inadvertently expanding the range of gambusia or similar poeciliid species, measures to minimise their spread or mitigate their ecosystem impacts should be considered.

25 ENERGY STORAGE↗

DOE OSTI2022

Cryptic Methane-Cycling by Methanogens During Multi-Year Incubation of Estuarine Sediment

As marine sediments are buried, microbial communities transition from sulfate-reduction to methane-production after sulfate is depleted. When this biogenic methane diffuses into the overlying sulfate-rich sediments, it forms a sulfate-methane transition zone (SMTZ) because sulfate reducers deplete hydrogen concentrations and make hydrogenotrophic methanogenesis exergonic in the reverse direction, a process called the anaerobic oxidation of methane (AOM). Microbial participation in these processes is often inferred from geochemistry, genes, and gene expression changes with sediment depth, using sedimentation rates to convert depth to time. Less is known about how natural sediments transition through these geochemical states transition in real-time. We examined 16S rRNA gene amplicon libraries and metatranscriptomes in microcosms of anoxic sediment from the White Oak River estuary, NC, with three destructively sampled replicates with methane added (586-day incubations) and three re-sampled un-amended replicates (895-day incubations). Sulfate dropped to a low value (∼0.3 mM) on similar days for both experiments (312 and 320 days, respectively), followed by a peak in hydrogen, intermittent increases in methane-cycling archaea starting on days 375 and 362 (mostly Methanolinea spp. and Methanosaeta spp., and Methanococcoides sp. ANME-3), and a methane peak 1 month later. However, methane δ 13 C values only show net methanogenesis 6 months after methane-cycling archaea increase and 4 months after the methane peak, when sulfate is consistently below 0.1 mM and hydrogen increases to a stable 0.61 ± 0.13 nM (days 553–586, n = 9). Sulfate-reducing bacteria (mostly Desulfatiglans spp. and Desulfosarcina sp. SEEP-SRB1) increase in relative abundance only during this period of net methane production, suggesting syntrophy with methanogens in the absence of sulfate. The transition from sulfate reduction to methane production in marine sediments occurs through a prolonged period of methane-cycling by methanogens at low sulfate concentrations, and steady growth of sulfate reducers along with methanogens after sulfate is depleted.

59 BASIC BIOLOGICAL SCIENCES↗