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DOE OSTI2025

2024 Stor4Build Annual Meeting: Exploring Challenges and Opportunities in Thermal Energy Storage for Buildings

In late August 2024, Stor4Build brought nearly 80 stakeholders from the thermal energy storage industry to Oak Ridge National Laboratory (ORNL), including researchers, startups, electric utilities, nonprofits, implementers, state energy efficiency offices, and original equipment manufacturers. During the two-day Stor4Build Annual Meeting, participants engaged in vital discussions about the current challenges and opportunities for scaling thermal energy storage solutions in buildings. The event featured panel discussions led by leading technology experts and industry practitioners, as well as updates on Stor4Build–funded projects from national laboratories, highlighting advancements in the thermal energy storage field crucial to achieving the consortium’s mission.

25 ENERGY STORAGE↗
DOE OSTI2024

PV Performance Modeling and Stakeholder Engagement (Final Technical Report)

This core capability project’s objective is to increase the value of photovoltaic (PV) performance models by improving their functionality, demonstrating, and quantifying their validity, and offering a wide range of stakeholder engagement opportunities. In FY22-24, we developed new and improved modeling algorithms and functions to represent PV performance more accurately in a variety of environments and conditions. The “Model parameter toolkit” was developed and includes functions to translate between different module temperature models, incidence angle modifier models, and single-diode models. A new modeling capability named “PV Atlas” was also developed leveraging Sandia’s High Performance Computing resources. This capability allows us to investigate several questions and provide climate-specific best practices and geographic data files; all these are hosted on an interactive website on Sandia’s GitHub and can be used for training, system optimization, or to provide best practices for uncertainty reduction. For model validation, we published high-quality PV performance, and weather data; these data are well documented, filtered, and processed for quality and include examples on how to run PV simulations. We also developed well documented, standardized methods for validating PV models and ran independent model validation and 2 blind modeling intercomparisons engaging with 49 organizations from 17 countries. We co-led and contributed to a growing, well documented and maintained suite of open-source functions for PV modeling (i.e., the pvlib-python) and we outreached to the PV modeling stakeholders via the PVPMC workshops and web resources. In addition, this project supported US representation and leadership for the International Energy Agency (IEA) PVPS Task 13; specifically, members of our team led and supported 3 subtasks on: 1) Best practices for the optimization of bifacial photovoltaic tracking, 2) Extreme weather events and their multiple impact on PV power plants: Risks, failure mechanisms and mitigation strategies, and 3) Best practice guidelines for the use of economic and technical Key Performance Indicators (KPIs). This project resulted in the publications of 14 peer reviewed journal papers, 37 conference presentations, 6 SAND reports, 5 public datasets and 6 new webpages on the PVPMC website. It supported the release of 13 pvlib-python versions where 28 enhancements were from this PV Performance Modeling project. We co-organized 5 PVPMC workshops in FY22-24 with the participation of 214 unique institutions and around 700 participants. The PVPMC website was redesigned, and its reliability was improved; it receives over 50,000 visitors/year from 202 unique countries.

14 SOLAR ENERGY↗
DOE OSTI2025

Alaska Liquid Natural Gas Pipeline Front-End Engineering & Design (Final Technical Report)

The Alaska Gasline Development Corporation (AGDC) is Alaska’s natural gas infrastructure development corporation established in 2013. AGDC’s mission is to maximize the benefit of Alaska’s vast North Slope natural gas resources for Alaskans through the development of infrastructure necessary to move the gas into local and international markets. AGDC was identified for a Congressionally Directed Spending (CDS) project for funding in the Energy and Water Development and Related Agencies Appropriations Act, 2023 under the heading: “Congressionally Directed Energy Efficiency and Renewable Energy Projects.” The CDS included $\$$4,000,000 of direct funding, with required match funds, to move the project forward. Alaska’s North Slope holds America’s largest proven and conventional natural gas supply. The integrated Alaska LNG Project will deliver 3.5 billion cubic feet of natural gas per day from Alaska’s North Slope gas fields to Alaskans as well as to a marine terminal located at tidewater in Cook Inlet. Alaska LNG is an integrated gas infrastructure project with three major components: a gas treatment plant (GTP) located at Prudhoe Bay, an 807-mile (1,287 km) gas pipeline (Mainline Pipeline) to Southcentral Alaska with interconnections for in-state gas use, and a natural gas liquefaction facility (LNG Facility) in Nikiski, Alaska. The integrated Alaska LNG Project has several strategic advantages including proven gas resources, existing upstream infrastructure, an advantageous arctic climate for LNG production, proximity to LNG markets, a track record of reliability from a state that first began exporting LNG to Japan in 1969, and broad support from Alaskans. North Slope natural gas is a conventional resource and can be produced with minimal drilling at a fraction of the carbon dioxide emissions of shale gas from the Lower 48 states. Through the development of the Alaska LNG Project, Alaska can provide energy security to Alaskans and a stable source of LNG to the Asia-Pacific region for generations. The Alaska LNG Project has been progressed through Pre-Front-End Engineering Design (Pre-FEED) and has obtained all major federal and State of Alaska permits and authorizations to construct the project, including the Federal Energy Regulatory Commission (FERC) Order Granting Authorization Under Section 3 of the Natural Gas Act. On September 5, 2024, the U.S. Department of Energy (DOE), National Energy Technology Laboratory (NETL) awarded Project No. DE-FE0032307 to AGDC with the objective to progress the project to Front-End Engineering Design (FEED) entry for the Alaska LNG Project Phase 1 Pipeline. The award Start Date was made effective July 1, 2023, with a Period of Performance through June 30, 2025. On March 27, 2025, AGDC announced the execution of definitive commercial agreements with Glenfarne Alaska LNG, LLC, an affiliate of Glenfarne Group, LLC, (together as “Glenfarne”), to lead the development of the Alaska LNG Project and enter FEED for the Phase 1 Pipeline. Project activities are now funded and directed by this private sector partner who holds a 75% interest in 8 Star Alaska, LLC (8 Star). 8 Star holds the assets of the Alaska LNG Project. As planned, AGDC continues to hold 25% minority interest in 8 Star and will play a governance role moving forward with Alaska LNG. This definitive commercial agreement milestone led to the successful completion of AGDC’s Statement of Project Objectives (SOPO) for FEED entry and led to the completion of DOE Project No. DE-FE0032307. At conclusion of the SOPO, AGDC also reached the award’s maximum federal cost share of $\$$4,000,000. AGDC is, therefore, providing Final Technical Report to close out DOE Project No. DE-FE0032307.

02 PETROLEUM↗
DOE OSTI2025

The Development of Catalysts for Upgrading of Pyrolysis Vapor for Refinery Feedstocks and Intermediates (CRADA Final Report)

Catalytic fast pyrolysis (CFP) is a versatile technology platform to convert biomass into fungible hydrocarbon transportation fuels and chemical co-products. Key technical barriers to reaching this goal include increasing the product yields and achieving the desired fuel properties for gasoline, diesel, and jet range fuels or blendstocks that would be suitable for introduction into existing refinery unit operations. Overcoming these barriers will require durable catalysts that are effective at upgrading and stabilizing biomass pyrolysis vapors. Towards these goals, this CRADA leveraged NREL experience as a leader in biomass pyrolysis research and Johnson Matthey's (JM) experience as a leader in the production of advanced catalytic materials. The scope spanned CFP catalyst development, characterization, multi-scale reaction testing, and computational modeling. CRADA benefits to DOE, Participant, and U.S. Taxpayer: Assists laboratory in achieving programmatic scope, Uses the laboratory’s core competencies. The purpose of this CRADA was to develop and deploy catalysts for biomass CFP to help achieve cost-competitive biofuels and bio-based products. This was accomplished through a close collaboration between biomass conversion researchers at NREL and catalyst development researchers at JM. Summary of Research Results: Focus Area 1. Foundational research on catalytic conversion and deactivation: Key interactions between pyrolysis vapors and heterogeneous catalysts were probed through catalyst characterization, model compound reaction testing, and atomistic-scale computational modeling. Catalyst development focused on multifunctional materials, which include zeolites, oxides, carbides, and nitrides. Computational modeling identified reaction mechanisms and elucidated surface chemistry to test hypotheses regarding mechanisms of deoxygenation, coupling, cracking, dehydration, coke formation, hydrogen transfer, and aromatic ring reactions. This information was used to design multifunctional catalysts to increase product yields, control product selectivity, and reduce deactivation during CFP and downstream processing steps. The results served to increase fundamental understanding of key catalyst attributes and durability features for the upgrading of biomass pyrolysis vapors. Model compound experiments confirmed the importance of metal-acid bifunctionality for the deoxygenation of lignin-derived phenolic species under hydrodeoxygenation conditions. This insight led to the development of catalysts such as Pt/TiO2 and Mo2C, which were confirmed as high-performing materials during subsequent bench-scale experiments using biomass-derived pyrolysis vapors. This focus area also led to the identification of important catalyst deactivation mechanisms associated with the deposition of inorganic contaminants such as potassium. The molecular-level insight from model compound experiments and computational modeling, shown in Figure 1, informed the development of regeneration procedures that have been shown to be effective for restoration of > 90% of initial catalyst activity. This understanding has subsequently been translated to other catalyst systems, including zeolite materials that can be operated without requirements for co-fed hydrogen.

09 BIOMASS FUELS↗
DOE OSTI2025

InfoRich VD&PT Controls Project Awarded Under the ARPA-E NEXTCAR Program (CRADA Final Report)

This CRADA supports the proposal led by General Motors LLC (GM) entitled "InfoRich VD&PT Controls" submitted under the Department of Energy (DOE) Advance Research Projects Agency-Energy (ARPA-E) NEXT-Generation Energy Technologies for Connected and Automated on-Road-vehicles (NEXTCAR) Program award DE-AR1564-1552. The project team is led by GM with sub-tier partners Carnegie Mellon University (CMU), and the National Renewable Energy Laboratory (NREL). The work under this NREL CRADA Joint Work Statement (JWS) is in support of GM's pending DOE Cooperative Agreement for DE-AR1564-1552 which extends through 04-01-2020.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2025

Enabling Next Generation Reaction Injection Molding (RIM) for Lightweight Structures

Replacing metal components in trucks, trailers, and buses with lightweight polymer composites is challenging due to high temperatures and complex manufacturing. The Reaction Injection Molding (RIM) process using Dicyclopentadiene (DCPD) resin offers a solution by producing robust parts with excellent stiffness, impact strength, and resistance properties. Simulations are essential for optimizing this process, predicting defects, and improving quality. However, most commercial software is tailored for thermoplastics, requiring thermoset users to generate their own datasets. In this project, a material data card for DCPD was developed to perform RIM simulations. Design of Experiments (DOE) was used to identify key factors affecting filling, curing, and warpage, aiming to minimize cycle time and defects. The simulations explored varying injection gate parameters (size, location, number) and process conditions (mold/resin temperature, injection/curing pressure). Results showed that gate design significantly impacts filling behavior and defects. A single central gate provided balanced flow with fewer defects, while two corner gates led to more defects. Additionally, lower injection pressure increased filling time, while higher mold temperature accelerated curing but led to more warpage. This optimization framework aims to enhance DCPD part performance and promote sustainable manufacturing by reducing waste and energy consumption. This research has been performed in collaborations with McClarin Composites. The research outcome has been submitted to the Journal of Manufacturing Processes.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Evaluation of LLM-Generated Kokkos Code Using Compile-Time and Run-Time Testing

Due to the growing use of large language models (LLMs) by developers and researchers, it has become essential to reliably evaluate their ability to generate code that uses specialized libraries. We explore the use of compile-time and run-time evaluation of LLM-generated Kokkos code through extending the methods used by OpenAI with the HumanEval dataset. Our evaluation framework is based on the first 40 prompts from the Kokkos138 dataset. We start by discussing two different forms of LLM prompting, using entirely plain English or providing pseudocode for added context. These two methods are used to generate Kokkos code with the Llama-3.1-8B-Instruct and CodeQwen1.5-7B-Chat models. We found that both forms of prompting led to high failure rates and difficulties with reliably parsing LLM-generated code, while prompts with pseudocode for context generally led to improved results on more complicated tests.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2025

Radioisotope Science and Technology Division FY 2025 Core R&D Summary Report: Competitive Projects, Postdoctoral Researchers, and Student Interns

R&D efforts in support of the Oak Ridge National Laboratory (ORNL) Isotope Program Radioisotope Portfolio are led by the Radioisotope Science and Technology Division (RSTD). In addition to supporting the ORNL Isotope Program Radioisotope Portfolio, RSTD supports a portfolio of research related to fundamental properties of radioisotopes and radioisotope applications, including diagnostic and therapeutic uses of medical radioisotopes, radioisotopes for national security, and the production of 238 Pu for the National Aeronautics and Space Administration (NASA) and US Department of Energy (DOE) Office of Nuclear Energy. RSTD is organized into functional science and engineering groups, with most staff members supporting multiple programs. The goal of this organization is to enable synergy between programs such that R&D advances coming from other programs may provide benefit to the ORNL Isotope Program. R&D within RSTD is focused around addressing five grand challenges, as documented in the strategic plan for the DOE Office of Isotope R&D and Production, or DOE Isotope Program (IP), Radioisotope Production R&D activities at ORNL: 1. Maximizing the scientific output of radioisotope transmutation resources, 2. Maximizing the scientific output of radioisotope processing resources, 3. Minimizing waste and having optimal waste disposition, 4. Focusing on product quality and reliability, and 5. Expanding the use of beneficial isotopes. The ORNL Core R&D program, one of the primary R&D components within the ORNL Isotope Program Radioisotope Portfolio, ranges from benchtop to demonstration activities, with a focus on researching enhanced production techniques, developing emerging isotopes, and developing the talent pipeline for radioisotope science and technology. Projects within the Core R&D Program are led primarily by RSTD staff members. In supporting enhanced production techniques, the Core R&D program presents an opportunity to fund novel R&D that might not be tied to a specific radioisotope product but still presents a high potential for broad applicability in the longer term. In supporting the development of emerging isotopes, the Core R&D program develops high-priority isotopes that are not able to be fully supported through production funds.

07 ISOTOPE AND RADIATION SOURCES↗
DOE OSTI2025

Securing Solar for the Grid (S2G) (Final Project Report) [Slides]

This is the final technical report for the SETO-funded project Securing Solar for the Grid (S2G) from FY22-24. The project scope included development and dissemination of standards' requirements, best practices, equipment testing procedures, assessment tools, as well as education and training materials for cyber defense, posture and maturity tailored to solar technologies. The outcomes for this work include: co-led the development of cybersecurity certification standard (UL2941), co-led the development of cybersecurity guide (IEEE1547.3), development of recommendations for supply chain cybersecurity, and development of cybersecurity risk profiles and recommendations for DERMS.

14 SOLAR ENERGY↗
DOE OSTI2025

Port Gamble S'Klallam Tribe Strategic Energy Plan

The Port Gamble S'Klallam Tribe's Strategic Energy Plan (SEP) details the outcomes and efforts of a 1.5-year Energy Technology Innovation Partnership Program (ETIPP) project. This collaboration involved the Port Gamble S'Klallam Tribe, Spark Northwest, the Pacific Northwest National Laboratory (PNNL), and the National Renewable Energy Laboratory. Project partners supported the Tribe in identifying key energy research focus areas and the Tribe's energy vision. As the technical lead on the project, PNNL led a series of research initiatives to evaluate potential pathways for the Tribe to achieve its energy goals, subsequently providing associated recommendations. The SEP offers a comprehensive analysis encompassing several critical aspects including: -The Tribe's current energy landscape -Availability of renewable resources -Potential microgrid designs, developed by Säzän Group -Critical infrastructure analysis -Electric vehicle integration -An energy workforce development framework, led by Spark Northwest The analysis results come with recommended next steps, categorized by implementation timeframe (short-term, medium-term, long-term) and priority.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2026

History of the Chemical Stockpile Emergency Preparedness Program – Volume 2: Lessons Learned (Final Report 2026)

The CSEP Program involved multiple federal agencies, multiple states, and numerous local units of government. The involvement of diverse agencies at different levels of government led to conflict and difficulty in resolving issues. That, in turn, led to slow progress in achieving program goals. Program management was criticized repeatedly by the U.S. General Accounting Office (GAO). After other mechanisms for interagency coordination had failed to give the desired results, FEMA and the Army agreed to form site-specific and national-level IPTs. The IPTs worked well to break the logjam and accelerate implementation of the program. Key elements of the IPTs’ success included constant interagency communication, solving problems at the lowest level, and obtaining buy-in from higher authority. The IPT technique could be applied to other emergency management and homeland security programs that require interagency coordination.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗
DOE OSTI2026

Powering Progress: Increasing capacity for State Agency participation in the development of solar guidelines

This project supported State Fish and Wildlife Agencies (SFWAs) in their participation in an industry-led process to develop nationwide utility scale solar energy wildlife guidelines intended to mitigate the impacts of large-scale solar development on wildlife and natural habitats. Led by the Association of Fish and Wildlife Agencies (AFWA), the project focused on documenting and communicating SFWA priorities, providing logistical and technical support for state engagement, and disseminating early outcomes to promote adoption and use.

14 SOLAR ENERGY↗
DOE OSTI2026

High-Torque Heavy-Rare-Earth-Free Electric Motor Thermal Management

This project is part of a multi-lab Next-Generation Reliable Electric Drive Systems for Medium and Heavy-Duty Vehicles (NEXT-DRIVE) project led by Oak Ridge National Laboratory (ORNL), and including NREL, Sandia National Laboratories (SNL), and Ames Laboratory that leverages research expertise and facilities of these national labs to develop tools and approaches for reducing the design and development time of new electric drive technologies for medium and heavy-duty vehicles (MHDVs) and their associated costs while increasing reliability and asset utilization. The Next-Drive project aligns with the DOE's goals by introducing high-fidelity multi-physics and AI/ML-based modeling to design low-cost, highly reliable, and longer-lifetime drivetrains, aiming to achieve 25 years of progress in 5 years. The efforts of this project will focus on NEXT-DRIVE Task 4 (led by ORNL, NREL, and AMES) - developing high-fidelity modeling framework and identifying technologies enabling heavy-rare-earth-free electric motors for medium- and heavy-duty vehicles to achieve 1 million miles of operation. Contrary to conventional approaches that optimize the motor for power density, the focus will be to identify motor designs that achieve the best trade-off between motor power density and durable operation. NREL tasks include development of high-fidelity motor thermal models incorporating rotor windage losses and identification, evaluation and measurement of motor interface materials in key thermal pathways. The poster summarizes NREL's accomplishments for the first half of FY 2025 and outlines future plans.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2026

Fast-ion confinement in LHD and W7-X (Final Technical Report)

This project was the PhD thesis project for Wataru Hayashi, who graduated in December 2025. In work performed prior to the award while Heidbrink was a Guest Professor at NIFS, we had established conditions for the study of fast-ion confinement in the Large Helical Device (LHD) with fast-ion D-alpha (FIDA) diagnostics. Subsequently, we proposed new sightlines that could augment the existing FIDA measurements with ones that were more sensitive to the highest energy ions. During the project period, the new sightlines were installed by the LHD team and showed the expected enhanced sensitivity to high-energy ions. Many LHD experiments were led by UCI scientists remotely during the pandemic and in-person afterward. One of these, which was led by one of Professor Zhihong Lin’s PhD students (Ethan Green) in collaboration with Hayashi and Heidbrink, resulted in a Nuclear Fusion article on the effect of radial electric fields on fast-ion confinement. The main output of the project, however, is two detailed experimental papers by Hayashi et al. The first of these is a study of neoclassical fast ion confinement in MHD-quiescent plasmas, a key issue in stellarator research. The second is an initial study of the effect of Alfven eigenmodes on fast-ion confinement. In addition to these studies, the project also helped partially support stellarator research with the GTC code by members of Prof. Lin’s group.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2026

Advancing Artificial Intelligence with Liquid Argon Neutrino Experiments (Technical Report)

The grant allowed two main contributions: 1) The development of a first successful demonstration of the employment of Optimal Transport in liquid argon time projection chamber neutrino detectors. Optimal Transport, used in other contexts and specifically with LHC calorimetric data, was adapted to address a key particle identification challenge in LArTPCs: the separation of pi0 backgrounds from single-electrons produced in charged-current electron neutrino interactions. The work, leveraging ML methods such as k-nearest-neighbor (kNN) and support-vector-machine (SVM), showed an increase in background rejection of a factor of two or more. Work is now ongoing to incorporate this development in physics analyses for LArTPC experiments and more broadly expand the use of OT in LArTPC detectors including DUNE. This work was done in collaboration with the phenomenology group led by Nathaniel Craig at UCSB. 2) The deployment of NuGraph2, a graph neural network developed for LArTPC reconstruction, in the MicroBooNE experiment. NuGraph2 uses novel graph-neural-network methods on the rather simple LArTPC inputs of reconstructed hits, greatly simplifying the workflow compared to the use of waveform or signal-deconvolved wire ROIs. The network performed particle classification and was shown to address many challenging problems in LArTPC imaging including track-shower separation and the identification of protons and charged pions from primary muons. Our group collaborated with Giuseppe Cerati (FNAL scientist) who is one of the core developers of NuGraph2 to integrate this tool in MicroBooNE’s analysis framework. This consisted in tow key contributions: a) Studying performance on real data, which came with several months of iterations because the MC-trained version of the network was found to show significant bias that our group investigated and addressed. b) Integrating the output hit labeling of NuGraph2 into the existing particle tracking and shower reconstruction code. As a result of this work led by our team NuGraph2 is now enabling a suite of new analyses which benefit from enhanced capabilities and thus broader physics reach. The grant supported primarily the salary of UCSB graduate student Chuyue “Michaelia” Fang as well as partial summer salary support for PI Caratelli. Some funds were used for travel by Michaelia to ML related schools and conferences.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2026

PACT Center: Perovskite PV Accelerator for Commercializing Technologies (Final Technical Report)

The Perovskite PV Accelerator for Commercializing Technologies (PACT) center was established in July 2021 as a national resource to accelerate the commercialization of perovskite photovoltaic (PV) technology in the United States. Since its inception, PACT has been led by Sandia National Laboratories (Sandia) in partnership with the National Laboratory of the Rockies (NLR), formerly known as NREL. From FY20-FY23, Los Alamos National Laboratory (LANL), CFV Labs, Black & Veatch (B&V), and the Electric Power Research Institute (EPRI) were part of the project team. LANL brought expertise in perovskite PV device designs and processing, CFV Labs (now GroundWork Renewables) provided initial indoor and outdoor measurement hardware technology, B&V led the initial effort on perovskite PV bankability, and EPRI worked on reviewing testing standards, identifying commercialization gaps, and helping to run PACT’s Industry Advisory Board, a group including representatives from commercial testing labs, independent engineering firms, insurance companies, state regulators, and electric utilities. To source perovskite PV module samples, PACT contracted with the University of North Carolina (UNC), the University of Toledo, the University of Washington, and SLAC/Stanford University to provide a steady stream of research-grade perovskite mini modules, enabling protocol development in advance of commercial module availability. The project period ran from July 1, 2021, through December 31, 2025, including a No Cost Extension. Starting in FY25, the project was continued as a Core Capability in the Lab Call portfolio and continues at a reduced budget with only Sandia and NLR as funded recipients. Notably, starting in FY25 PACT expanded its scope beyond MHP modules to accept all emerging PV mini module technologies for testing, including organic PV (OPV) and all-thin-film tandems, with the aim of supporting commercialization across the broader emerging PV ecosystem. With this change in scope the program was renamed the PV Accelerator for Commercializing Technologies, dropping perovskite from the name.

14 SOLAR ENERGY↗
DOE OSTI2026

Coalition for Community-Supported Affordable Geothermal Energy Systems (C2SAGES)

The C2SAGES project evaluated the feasibility of a community geothermal system for the planned Windy Ridge affordable housing development in Hinesburg, Vermont. Led by GTI Energy with Vermont Gas Systems, LN Consulting, NREL, and Frontier Energy, the work assessed technical design, energy performance, costs, business models, community engagement, maintenance, workforce development, and permitting. The proposed system was designed to serve 100% of the development’s heating, cooling, and domestic hot water loads. Compared with a baseline using air-source heat pumps and natural gas water heating, the geothermal system was estimated to reduce HVAC and domestic hot water energy use by about 45% to 48%, lower operating and maintenance costs, and reduce 30-year life-cycle costs by 37% for Phase 1 and 10% for Phase 2. Technical testing and modeling indicated that the Windy Ridge site is suitable for a community-scale geothermal system. The project also developed borehole field layouts, piping concepts, pump house designs, controls, maintenance plans, and supporting engineering drawings. The business model analysis found that first cost, ownership structure, and customer affordability remain major deployment challenges. Utility-led maintenance and operation were viewed favorably, but traditional utility cost-recovery models may require subsidy or revised financing structures to be practical for affordable housing. Community engagement highlighted the need for clear public education, transparent financing, reliable long-term maintenance, trained technicians, and the potential to pair geothermal systems with weatherization. Overall, the report concludes that community geothermal is technically feasible and offers meaningful energy, emissions, and life-cycle cost benefits, but broader deployment will depend on workable financing models and workforce readiness.

15 GEOTHERMAL ENERGY↗
DOE OSTI2026

Gear Test Assembly - Experimental Testing and Analysis of Gears and Bearings - FY2026

The Gear Test Assembly (GTA) is an experimental test apparatus built and installed in the Mechanisms and Engineering Test Loop (METL) at Argonne National Laboratory (ANL). While designed to accommodate a variety of components intended for use in advanced compact in-vessel transfer machine, the focus of GTA been the testing of large radial spur gears. The performance of the components used in GTA motivates the choices made in the design, components, and material choices for the forthcoming METL test articles; the Gripper Test Assembly (GrTA), and the Bearing Test Assembly (BTA). To date, GTA has completed nine experimental testing campaigns and achieved over 21 million revolutions under prototypic sodium fast reactor loads and operating conditions. This report provides an overview and results for the two most recent experiments Campaign #8 and Campaign #9. `Campaign #8 was the first campaign to make use of a set of nickel alloy radial spur gears, made from Hastelloy C-22HS, and combined with heat-treated tapered roller bearings. The bearings and torque profile used allowed Campaign #8 to be directly compared with Campaign #1 where Inconel 718 gears were used instead. Campaign #8 attained 1,058,880 shaft revolutions within 23% of the 1,314,855 revolutions achieved in Campaign #1. These results demonstrate that the heat-treated tapered roller bearings show consistent increased lifetimes, approximately three times longer than for non heat-treated taper rollers, and that the particular material of the gear does not play a substantial role in performance. Similar to Campaign #7 where bearing failure resulted in fragmentation and transport of bearing material into the gear teeth led to tooth damage in the Inconel gears, a similar process led to the damage of the Hastelloy gears. Subsequent NDE analysis showed that the damage was only limited to the tooth surface and does not extend into the gear interiors. Based on the NDE reports, the Hastelloy gears can be reconditioned and put back into service for future campaigns as was done for the Inconel gears. Reconditioned Inconel 718 gears damaged in Campaign #7 were returned to service in Campaign #9 and paired with non heat-treated tapered roller bearings. In Campaign #9 a novel set of operating conditions were implemented whereby the gears and bearings were cycled between hot, submerged refueling conditions where fuel handling operations occurred and cold, dry, and inert conditions where the sodium was drained and the vessel was allowed to cool simulating long, ex-vessel storage of the fuel handling machine. A total of eight of these operating cycles were achieved before a bearing failure occurred after the accumulation of 475,692 shaft revolutions were achieved. During Campaign #9, one of the drive motors was damaged and over the course of a 240 day standby period, the entire GTA drive system was upgraded from a 480VAC system to a 240VAC system that provided the opportunity to consolidate wall-space in the METL facility and provide more space for additional test articles being installed in the coming year. The over 475,000 shaft revolutions achieved in Campaign #9 eclipses the previous record for lifetime of non heat-treated tapered roller bearings held by Campaign #3 of 392,000 shaft revolutions. Further analysis and future campaigns hope to shed light on the cause of this approximately 17% increase in lifetime.

42 ENGINEERING↗