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DOE OSTI2022

Manufacturing Supply Chain Development for Modular Solar-Thermochemical Conversion Platform - CRADA 387 (Final Report)

Modular chemical process intensification (MCPI) is an emerging field where chemical processing is performed using small-scale modular equipment instead of conventional large centralized chemical plants. Conventional chemical plants benefit from economies of scale that encourage scale-up to ever larger plants. A goal of MCPI is to develop technology that intensifies processing so that equipment can be dramatically smaller and integrated into modular systems. Scale-up occurs by adding more modules in parallel rather than making the equipment larger. A key concept is that equipment and modules can ultimately be cheaper by leveraging economies of mass production, analogous to the automotive industry, in manufacturing the equipment. This project made significant progress toward this outcome by meeting the RAPID institute metric to reduce equipment cost by 20% for each doubling in manufacturing volume. The MCPI application was thermochemical technology that is being commercialized by STARS Technology Corporation, one of the CRADA partners. The technology converts solar and renewable power to chemical energy to produce renewable hydrogen, fuels, and chemicals. The benefit to the public is reduction in greenhouse gases that are contributing to climate change. The project transitioned the steam methane reforming (SMR) reactor from conventional fabrication methods to additive manufacturing (AM) direct metal laser sintering (DMLS) process. This is projected to reduce the cost of making a reactor by 58% when producing 100 reactors per year. Innovations in the DMLS process produced a patented design that reduces reactor weight by 60%. Reductions in material costs and processing time extend the DMLS advantage to higher production volumes. The new design promises to be 38% cheaper than the conventional processes at 1000 units per year. The resulting 87% reduction in the steam methane reforming (SMR) module cost in scaling from current costs meets the RAPID metric. The project was successful in producing and testing the first ever additively manufactured SMR reactors. A reactor achieved over 82% efficiency in converting electric power to chemical energy, which is a world record for an inductively heated SMR. The project has contributed to the design and assembly of a first demonstration plant that is headed to a hydrogen bus filling station in Thousand Palms, CA.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2020

Enhancing Chemical Stability and Suppressing Ion Migration in CH 3 NH 3 PbI 3 Perovskite Solar Cells via Direct Backbone Attachment of Polyesters on Grain Boundaries

Organic–inorganic halide perovskites feature excellent optoelectronic properties but poor chemical stability. While passivating perovskite grain boundary (GB) by polymers shows prospects on long-term performance of perovskite solar cells (PSCs), its detailed impact on the ion migration phenomenon, which largely deteriorates the PSC stability, remains less probed. In this work, we introduce a new polar polymer, polycaprolactone (PCL), to passivate GBs of methylammonium lead triiodide (MAPbI 3 ) perovskite with only 1–2 polymer monolayers via direct backbone attachment. The PSCs with passivated MAPbI 3 , using a classic but less stable Spiro-OMeTAD (2,2',7,7'-tetrakis[N,N-di(4-methoxyphenyl)amino]-9,9'-spirobifluorene) hole transport layer (HTL), exhibit improved power conversion efficiencies up to 20.1%, with 90% of the initial PCE being preserved after 400 h ambient storage, and 80% even after 100 h, 85 °C aging. The improved PSC stability indicates critical roles of PCL GB passivation in retarding moisture-induced decomposition and suppressing ion migration within the perovskite. Furthermore, time-of-flight secondary ion mass spectrometry reveals that I– ions can actively migrate into the electrode, HTL, and their interface in nonpassivated PSCs, even without an externally applied electric field, while such migration is significantly mitigated in PCL-passivated PSCs. This effective GB passivation by PCL suggests an important potential of polymer additives toward the development of stable high-performance PSCs.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Bidirectional LCC-LCC -Compensated 20 kW Wireless Power Transfer System for Medium-Duty Vehicle Charging

This paper presents the design and demonstration of a bidirectional 20 kW wireless charging system (WCS) with a significantly large airgap (11 inches) and asymmetrical input-output voltage levels. Analytical and experimental sensitivity analyses of the WCS resonant tank were conducted to verify the optimal operating region under the load and frequency variation. The inverter and rectifier were designed with switching components, the charging pads were designed with double-D (DD) coils, and the tuning networks were designed with an LCC-LCC tuning circuit. The grid and vehicle side tuning circuits were designed separately to achieve a ~1:2 gain for the asymmetrical input (800 V dc ) and output (350 V dc ) voltage. The proposed WCS was designed, simulated, and tested to verify the efficiency, power transfer capacity, and sensitivity under load variation. The experimental results show that, at 20-kW output power, the achieved grid to vehicle dc-dc efficiency was 96.1%, and vehicle to grid dc-dc efficiency was 96.2%. The proposed system is the largest-airgap bidirectional WCS with the highest efficiency and power density.

33 ADVANCED PROPULSION SYSTEMS↗

NASA NTRS2000

Conceptual Design Study of a Closed Brayton Cycle Turbogenerator for Space Power Thermal-To-Electric Conversion System

A conceptual design study was completed for a 360 kW Helium-Xenon closed Brayton cycle turbogenerator. The selected configuration is comprised of a single-shaft gas turbine engine coupled directly to a high-speed generator. The engine turbomachinery includes a 2.5:1 pressure ratio compression system with an inlet corrected flow of 0.44 kg/sec. The single centrifugal stage impeller discharges into a scroll via a vaned diffuser. The scroll routes the air into the cold side sector of the recuperator. The hot gas exits a nuclear reactor radiator at 1300 K and enters the turbine via a single-vaned scroll. The hot gases are expanded through the turbine and then diffused before entering the hot side sector of the recuperator. The single shaft design is supported by air bearings. The high efficiency shaft mounted permanent magnet generator produces an output of 370 kW at a speed of 60,000 rpm. The total weight of the turbogenerator is estimated to be only 123 kg (less than 5% of the total power plant) and has a volume of approximately 0.11 cubic meters. This turbogenerator is a key element in achieving the 40 to 45% overall power plant thermal efficiency.

Hansen, Jeff L.↗

DOE OSTI2018

Techno-economic analysis of high-efficiency natural-gas generators for residential combined heat and power

Residential combined heat and power (CHP) systems produce electricity onsite while utilizing waste heat to supplement home heating requirements, which can lead to significant reductions in CO 2 emissions and primary energy consumption. However, the current deployment of such CHP systems in the U.S. residential sector is extremely low primarily due to their high cost, short system life, and low system efficiency. Based on an analysis of average energy consumption of representative single-family homes in 10 U.S. cities across 7 different climate zones, it is concluded that there is no one-size-fits-all residential CHP system, but that a range of products are more likely to reflect consumer preferences. It is further identified via a systematic techno-economic analysis (TEA) that high-efficiency (e.g., 30% - 40% fuel to electricity), long-life (e.g., 15 years), low-cost (preferably less than U.S. $2,500 installed price), and low emissions are key requirements to enable widespread deployment of CHP systems in the U.S. residential sector. This article analyzes how the payback period would change for each city by varying nearly a dozen parameters and concludes with an evaluation on maximum market penetration based on a given set of parameters, and the resulting energy and emissions savings that can be practically achieved in some scenarios.

03 NATURAL GAS↗

DOE OSTI2015

Side chain engineering of poly-thiophene and its impact on crystalline silicon based hybrid solar cells

The influence of ether groups in the side chain of spin coated regioregular polythiophene derivatives on the polymer layer formation and the hybrid solar cell properties was investigated using electrical, optical, and X-ray diffraction experiments. The polymer layers are of high crystallinity but the polymer with 3 ether groups in the side chain (P3TOT) did not show any vibrational fine structure in the UV-Vis spectrum. The presence of ether groups in the side chains leads to better adhesion resulting in thinner and more homogeneous polymer layers. This, in turn, enhances the electronic properties of the planar c-Si/poly-thiophene hybrid solar cell. We find that the power conversion efficiency increases with the number of ether groups in the side chains, and a maximum power conversion efficiency of η = 9.6% is achieved even in simple planar structures.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

NASA NTRS1982

Development of a polysilicon process based on chemical vapor deposition, phase 1 and phase 2

High-purity polycrystalline silicon was produced in an experimental, intermediate and advanced CVD reactor. Data from the intermediate and advanced reactors confirmed earlier results obtained in the experimental reactor. Solar cells were fabricated by Westinghouse Electric and Applied Solar Research Corporation which met or exceeded baseline cell efficiencies. Feedstocks containing trichlorosilane or silicon tetrachloride are not viable as etch promoters to reduce silicon deposition on bell jars. Neither are they capable of meeting program goals for the 1000 MT/yr plant. Post-run CH1 etch was found to be a reasonably effective method of reducing silicon deposition on bell jars. Using dichlorosilane as feedstock met the low-cost solar array deposition goal (2.0 gh-1-cm-1), however, conversion efficiency was approximately 10% lower than the targeted value of 40 mole percent (32 to 36% achieved), and power consumption was approximately 20 kWh/kg over target at the reactor.

Plahutnik, F.↗

DOE OSTI2018

Basic Research Needs for Microelectronics

Since the invention of the integrated circuit in 1958, advances in microelectronics have followed Moore’s law and other scaling laws. These have led to over a billion-fold increase in the number of transistors on a chip. The Department of Energy’s Office of Science (DOE-SC) programs have always been at the cutting edge of microelectronics, making major contributions to the scientific understanding, materials, and advanced instrumentation that enabled innovations to promote scaling. This has driven transformative advances in microelectronics for the challenging demands of DOE’s high performance computing and science facilities. Now, strong evidence exists that scaling is approaching its physical and economic limits, and yet, the growth of data-centric computing and sensor networks is redefining computing workloads and microelectronics needs. In addition, greatly improved microelectronics are needed for the nation’s electricity grid if it is to be energy-efficient, resilient to natural phenomena and intentional attack, and agile in adapting to fluctuations in demand and power generation. Sustained and rapid progress in microelectronics science and technology from millivolt to megavolt scales is thus essential if we are to continue pushing the boundaries of science within DOE, and more significantly, to continue to lead the global information and power technology revolution. In October 2018, DOE-SC convened a workshop to address Basic Research Needs for Microelectronics by a “co-design” approach. Participants focused on scientific issues associated with advanced microelectronics technologies for applications relevant to the DOE mission, including computing, power grid management, and science facility workloads. (Topics of direct relevance to quantum information science and quantum computing were outside the scope of this workshop.) The workshop was organized around microelectronics needs for three areas: 1) future DOE-SC facilities, 2) high performance computing beyond exascale (a billion billion calculations per second), and 3) power control, conversion, and detection for a modernized electrical grid and related high power applications. Panels were formed around each of these areas, with a fourth panel formed to address Crosscutting Research. Workshop participants were asked to focus on a co-design innovation ecosystem in which materials, chemistries, devices, systems, architectures, algorithms, and software are researched and developed in a closely integrated fashion, with feedback and interdisciplinary collaboration at each interface in this microelectronics technology hierarchy. The panels identified the five Priority Research Directions on the following page.

36 MATERIALS SCIENCE↗

DOE OSTI2017

Building America Case Study: Multifamily Central Heat Pump Water Heaters, Davis, California

Although heat pump water heaters (HPWHs) have gained significant attention in recent years as a high efficiency electric water heating solution for single family homes, central HPWHs for commercial or multi-family applications are not as well documented in terms of measured performance and cost effectiveness. To evaluate this technology, the Alliance for Residential Building Innovation team monitored the performance of a 10.5 ton central HPWH installed on a student apartment building at the West Village Zero Net Energy Community in Davis, California. Monitoring data collected over a 16-month period were then used to validate a TRNSYS simulation model. The TRNSYS model was then used to project performance in different climates using local electric rates. Results of the study indicate that after some initial commissioning issues, the HPWH operated reliably with an annual average efficiency of 2.12 (Coefficient of Performance). The observed efficiency was lower than the unit's rated efficiency, primarily due to the fact that the system rarely operated under steady-state conditions. Changes in the system configuration, storage tank sizing, and control settings would likely improve the observed field efficiency. Modeling results suggest significant energy savings relative to electric storage water heating systems (typical annual efficiencies around 0.90) providing for typical simple paybacks of six to ten years without any incentives. The economics versus gas water heating are currently much more challenging given the current low natural gas prices in much of the country. Increased market size for this technology would benefit cost effectiveness and spur greater technology innovation.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2022

Recent Advancements and Prospects of Chemical Heat Pumps for Temperature Amplification for Nuclear Process Heat Applications

The energy economy is continually evolving, particularly in terms of primary energy sources, their conversions to useful forms such as electricity and heat, and their utilization in different sectors, in response to socio-political factors. Because nuclear energy source is a clean and non-carbon-emitting energy source, it is crucial to consider its role in the evolution of the energy economy. Integrated Energy Systems (IES) are collaboratively controlled systems that can dynamically apportion thermal and/or electrical energy to promote the production of various energy products and have the potential to reduce greenhouse gas (GHG) emissions, improve energy efficiency, improve electrical grid dependability, and enhance energy economics. To realize the benefits of IES with the current reactor fleets, selection and development of a complimentary temperature upgrading technology are necessary for providing process heat and improving economics.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

Electrically interfaced Brillouin-active waveguide for microwave photonic measurements

New strategies for converting signals between optical and microwave domains could play a pivotal role in advancing both classical and quantum technologies. Traditional approaches to optical-to-microwave transduction typically perturb or destroy the information encoded on intensity of the light field, eliminating the possibility for further processing or distribution of these signals. In this paper, we introduce an optical-to-microwave conversion method that allows for both detection and spectral analysis of microwave photonic signals without degradation of their information content. This functionality is demonstrated using an optomechanical waveguide integrated with a piezoelectric transducer. Efficient electromechanical and optomechanical coupling within this system permits bidirectional optical-to-microwave conversion with a quantum efficiency of up to -54.16 dB. Leveraging the preservation of the optical field envelope in intramodal Brillouin scattering, we demonstrate a multi-channel microwave photonic filter by transmitting an optical signal through a series of electro-optomechanical waveguide segments, each with distinct resonance frequencies. Such electro-optomechanical systems could offer flexible strategies for remote sensing, channelization, and spectrum analysis in microwave photonics.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2025

Multifunction Hydrophobic Ligand Engineered Cd(S, Se)/ZnS Quantum Dots for Stabilizing Highly Efficient Carbon‐Based Perovskite Solar Cells

The long-term operational stability of perovskite solar cells (PSCs) remains a key challenge impeding their commercialization, particularly due to ambient environments (e.g., moisture, oxygen, heat)-induced degradation. Carbon electrode-based PSCs have emerged as cost-effective and relatively stable alternatives to metal electrode-based devices due to carbon materials' hydrophobic behavior, yet they still lag in both long-term durability and power conversion efficiency (PCE). In this work, an ultrathin hydrophobic ligand-modified core–shell Cd(S,Se)/ZnS quantum dots (QDs) capping layer is introduced as a multifunctional interfacial modifier for carbon-electrode-based PSCs. This oleic acid ligand-modified QDs capping layer exhibits inherent hydrophobicity, effectively serving as a moisture barrier to retard perovskite degradation under ambient conditions. Furthermore, the strong interfacial bonding between the QDs and perovskite halide surfaces leads to efficient trap state passivation, reducing trap density and creating a more uniform electrical contact. The modified QDs/perovskite interface also features an elevated conduction band edge, promoting improved charge extraction. As a result, devices incorporating this quantum dot capping layer retain 98% of their initial PCE after 450 h of ambient aging and achieve a champion efficiency of 20.74%. As a result, this strategy highlights the potential of hydrophobic ligand-modified chalcogenide QDs as surface modifiers to enhance both the stability and performance of carbon-based PSCs, offering a promising route toward scalable fabrication of durable perovskite solar modules.

14 SOLAR ENERGY↗

DOE OSTI2016

Effects of Cd Diffusion and Doping in High-Performance Perovskite Solar Cells Using CdS as Electron Transport Layer

Perovskite solar cells with stabilized power conversion efficiency exceeding 15% have been achieved, using a methylammonium lead iodide (MAPbI 3 ) absorber and CdS as the electron transport layer. X-ray photoelectron spectroscopy reveals a small presence of Cd at the surface of most perovskite films fabricated on CdS. In this work, perovskite films were deliberately doped with Cd to understand the possible impacts of Cd diffusion into the perovskite absorber layer. Doping substantially increases the grain size of the perovskite films but also reduces device performance through the formation of an electrical barrier, as inferred by the S-shape of their $J–V$ curves. Time-resolved photoluminescence measurements of the doped films do not indicate substantial nonradiative recombination due to bulk defects, but a secondary phase is evident in these films, which experiments have revealed to be the organic–inorganic hybrid material methylammonium cadmium iodide, (CH 3 NH 3 ) 2 CdI 4 . It is further demonstrated that this compound can form via the reaction of CdS with methylammonium iodide and may form as a competing phase during deposition of the perovskite. Buildup of this insulating compound may act as an electrical barrier at perovskite interfaces, accounting for the drop in device performance.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2015

Room-temperature, solution-processable organic electron extraction layer for high-performance planar heterojunction perovskite solar cells

Here in this work, we describe a room-temperature, solution-processable organic electron extraction layer (EEL) for high-performance planar heterojunction perovskite solar cells (PHJ PVSCs). This EEL is composed of a bilayered fulleropyrrolidinium iodide (FPI)-polyethyleneimine (PEIE) and PC 61 BM, which yields a promising power conversion efficiency (PCE) of 15.7% with insignificant hysteresis. We reveal that PC 61 BM can serve as a surface modifier of FPI-PEIE to simultaneously facilitate the crystallization of perovskite and the charge extraction at FPI-PEIE/CH 3 NH 3 PbI 3 interface. Furthermore, the FPI-PEIE can also tune the work function of ITO and dope PC 61 BM to promote the efficient electron transport between ITO and PC 61 BM. Based on the advantages of room-temperature processability and decent electrical property of FPI-PEIE/PC 61 BM EEL, a high-performance flexible PVSC with a PCE ~10% is eventually demonstrated. Lastly, this study shows the potential of low-temperature processed organic EEL to replace transition metal oxide-based interlayers for highly printing compatible PVSCs with high-performance.

14 SOLAR ENERGY↗

DOE OSTI2015

Gate tunable monolayer MoS{sub 2}/InP heterostructure solar cells

We demonstrate monolayer molybdenum disulfide (MoS{sub 2})/indium phosphide (InP) van der Waals heterostructure with remarkable photovoltaic response. Furthermore, benefiting from the atomically thin and semiconductor nature of MoS{sub 2}, we have designed the gate tunable MoS{sub 2}/InP heterostructure. Applied with a top gate voltage, the Fermi level of MoS{sub 2} is effectively tuned, and the barrier height at the MoS{sub 2}/InP heterojunction correspondingly changes. The power conversion efficiency of MoS{sub 2}/InP solar cells has reached a value of 7.1% under AM 1.5G illumination with a gate voltage of +6 V. The tunable MoS{sub 2}/InP heterostructure may be promising for highly efficient solar cells.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2018

Energy transduction ferroic materials

Ferroic materials and multiferroics, characterized by their ferroic orders, provide an efficient route for the coupling control of magnetic, mechanical, and electrical subsystems in energy transduction, which aims at converting one form of energy into another. A surge of interest in the ferroic coupling effect has stemmed from its potential use as a new versatile route for energy transduction. Here, the recent progress on the use of (multi)ferroic materials is reviewed, with special emphasis on the fundamental mechanisms that dictate the energy transduction process, including piezoelectricity, pyroelectricity, electrocaloric, magnetostriction, magnetocaloric, elastocaloric, magnetoelectricity, and emerging spin-charge conversion. Research on energy transduction ferroic materials paves the way for ubiquitous energy harvesting through magneto-mechano-electric-thermal coupling mechanisms. Lastly, a summary and the future prospective directions of this field are discussed.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Strategy for Ultranarrow Light Down-Conversion for Displays Based on Bicolor-Emitting 2D Colloidal Heterostructures

The demand for ultranarrow spectral emission below 10 nm is critical for next-generation displays. Although current colloidal nanocrystals are successful in light down-conversion applications, they fall short in matching the stringent color purity requirements set by standards like Rec. 2020. Achieving such narrow linewidths through material engineering alone remains elusive, necessitating innovative light management strategies that avoid optical losses and maintain device efficiency. Here, in this work, we present a novel 2D colloidal heterostructure design, combining a CdSe core nanoplatelet, a CdS crown, and a CdZnS shell, to achieve bright bicolor emission in the solid state (green/red) emission with tunable intensity ratios controlled by excitation power (either optical or electrical). Integration of these nanoplatelets into a dielectric cavity further narrows the emission linewidth to sub-2 nm while enhancing the photoluminescence intensity by up to 200 times, meeting the Rec. 2020 color purity targets. This approach paves the way for a strategy avoiding complex laser-based solutions.

2D nanocrystals↗

DOE OSTI2016

Generation and Use of Thermal Energy in the U.S. Industrial Sector and Opportunities to Reduce its Carbon Emissions

The industrial sector was the third-largest source of direct U.S. greenhouse gas (GHG) emissions in 2014 behind electricity generation and transportation and accounted for roughly 20% of total emissions (EPA 2016). The Energy Information Administration (EIA) projects that total U.S. energy consumption will grow to about 108 exajoules (1 EJ = 10 18 J) or 102 quads (1 quad = 10 15 British thermal units) in 2025, with nearly all of the growth coming from the industrial sector (DOE 2015b). Energy consumption in the industrial sector is forecast to increase to 39.5 EJ (37.4 quads)—a 22% increase, exceeding 36% of total energy consumption in the United States. Therefore, it is imperative that industrial GHG emissions be considered in any strategy intent on achieving deep decarbonization of the energy sector as a whole. It is important to note that unlike the transportation sector and electrical grid, energy use by industry often involves direct conversion of primary energy sources to thermal and electrical energy at the point of consumption. About 52% of U.S. industrial direct GHG emissions are the result of fuel combustion (EPA 2016) to produce hot gases and steam for process heating, process reactions, and process evaporation, concentration, and drying. The heterogeneity and variations in scale of U.S. industry and the complexity of modern industrial firms’ global supply chains are among the sector’s unique challenges to minimizing its GHG emissions. A combination of varied strategies—such as energy efficiency, material efficiency, and switching to low-carbon fuels—can help reduce absolute industrial GHG emissions. This report provides a complement to process-efficiency improvement to consider how clean energy delivery and use by industry could reduce GHG emissions. Specifically, it considers the possibility of replacing fossil-fuel combustion in industry with nuclear (specifically small modular reactors [SMRs]), solar thermal (referred to herein as solar industrial process heat [SIPH]), and geothermal energy sources. The possibility of applying electrical heating and greater use of hydrogen is also considered, although these opportunities are not discussed in as much detail.

08 HYDROGEN↗