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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Direct recycling of spent nickel-rich cathodes in reciprocal ternary molten salts

Lithium-ion batteries (LIBs) have revolutionized portable electronics and electric vehicles (EVs), but the growing accumulation of end-of-life (EOL) batteries poses environmental challenges. Recycling high-value cathodes from EOL LIBs can minimize waste and reduce the need for mining critical minerals. Here, this study focuses on the direct recycling of Ni-rich cathodes, particularly lithium-manganese-cobalt-oxide (NMC) 622 in a “reciprocal ternary molten salts (RTMS)" system. The ionothermal relithiation in the RTMS system successfully restores the layered structure, lithium content, and electrochemical performance of the NMC 622 cathode, comparable to the pristine material. The cost analysis reveals that cathode regeneration through ionothermal relithiation is more economical than virgin production or conventional recycling methods.

25 ENERGY STORAGE↗
DOE OSTI2022

A case study of high-temperature polyetherimide film capacitor fabrication

Capacitors, as the basic building block of power electronics and electrical systems, are the major constraint of the increasingly integrated power systems that require new capable polymer dielectric films operating at higher temperatures >125 °C. Despite tremendous research efforts on the lab scale, there remains a considerable barrier and knowledge basis for converting polymeric films to functioning capacitors desired in actual applications. Here, the authors tackled the polyetherimide (PEI) film scale up issues and developed various engineering processes for film de-wrinkling, optimal metallization, static elimination, and capacitor fabrication improvement. The authors discovered various fabrication challenges such as the electrostatic charge, metallization scheme, winding tension, and end electrode disconnects. To fabricate a high yield of PEI capacitor bobbins, it is necessary to utilize static eliminators (radioactive ionizers), moderately thick aluminum metallization (15–30 Ω/sq), and winding tension (60–100 g). It is also effective to evaluate capacitance, dielectric loss, equivalent series resistance, and thermal cycling stability of capacitors. This work sheds some light on converting PEI films and other polymeric films to capacitors on a scale up fabrication effort. The practical learning from film handling to capacitor fabrication in this work provided the necessary knowledge for manufacturing high-temperature polar film capacitors.

36 MATERIALS SCIENCE↗
DOE OSTI2020

A direct recycling case study from a lithium-ion battery recall

Direct recycling of lithium-ion is a promising method for manufacturing sustainability. It is more efficient than classical methods because it recovers the functional cathode particle without decomposition into substituent elements or dissolution and precipitation of the whole particle. This case study of cathode-healing™ applied to a battery recall demonstrates an industrial model for recycling of lithium-ion, be it consumer electronic or electric vehicle (EV) batteries. The comprehensive process includes extraction of electrolyte with carbon dioxide, industrial shredding, electrode harvesting, froth flotation, cathode-healing™ and finally, building new cells with recycled cathode and anode. The final products demonstrated useful capability in the first full cells made from direct recycled cathodes and anodes from an industrial source. The lessons learned on recycling the prototypical chemistry are preliminarily applied to EV relevant chemistries.

Sloop, Steve↗
DOE OSTI2021

Jianlin Li: Accelerating battery manufacturing and recycling

With continued penetration of consumer electronics and electric vehicles into the evergrowing marketplace, there is a critical need for an efficient and sustainable battery supply chain. This includes the production of raw materials, the design, development, and processing of cell materials and systems, and end-of-life product recycling. The Oak Ridge National Laboratory (ORNL) has established a research program dedicated to addressing many aspects of these key challenges. Here, we asked Jianlin Li, a Senior R&D Staff and leader of the Energy Storage and Conversion Manufacturing Group, his opinion on the role of chemistry and materials science in mitigating the impacts of critical materials in battery supply chains.

25 ENERGY STORAGE↗
DOE OSTI2020

Impact of Residual Lithium on the Adoption of High-Nickel Layered Oxide Cathodes for Lithium-Ion Batteries

High-nickel layered oxide cathodes are becoming appealing for lithium-ion batteries employed in portable electronics and electric vehicles because of their higher energy density, low or no cobalt content, and ability to be manufactured with existing infrastructure. However, high-nickel layered oxides are plagued by the formation of residual lithium species, such as LiOH and Li 2 CO 3 , on the surface, which are detrimental to the manufacturing process and performance. Despite the problems residual lithium causes for the industry, academia mainly focuses on the safety risks and electrochemical impacts of residual lithium. In this Perspective, we examine the residual lithium problem through a lens of its impact on cathode slurry instability and large-scale manufacturing of high-nickel layered oxides. Additionally, methods of measuring residual lithium are discussed from the perspective of their accuracy as well as practicality in the manufacturing process. Furthermore, we hope that this Perspective would encourage the academic endeavor to consider the practical obstacles caused by residual lithium on the industrialization of high-nickel layered oxides and their mitigation, while attempting to improve their electrochemical performance and safety through doping, surface modifications, or other approaches.

25 ENERGY STORAGE↗
DOE OSTI2026

Sustainable Critical Minerals: Mining, Production, and Legacy

Critical minerals (CMs) are required in renewable energy systems, electric vehicles, electronics, and national defense. Global demand has increased rapidly due to energy and digital transitions, and the United States has become increasingly reliant on vulnerable supply chains. Geological scarcity, trade barriers, environmental hurdles, and processing challenges impede domestic CM production growth. Emerging strategies, including circular economy practices and advanced sustainable mining and processing techniques, can mitigate supply chain and economic risks. To advance these approaches, consistent research priorities, policy revisions, and technology investments are required to develop a resilient CM supply. Doing so with a focus on sustainability goals can simultaneously advance domestic economic and technological goals while limiting environmental impacts and supporting global environmental goals.

biomining↗
DOE OSTI2022

The Effects of Phosphate Impurity on Recovered LiNi 0.6 Co 0.2 Mn 0.2 O 2 Cathode Material via a Hydrometallurgy Method

From portable electronics to electric vehicles, lithium-ion batteries have been deeply integrated into our daily life and industrial fields for a few decades. The booming field of battery manufacturing could lead to shortages in resources and massive accumulation of battery waste, hindering sustainable development. Therefore, hydrometallurgy-based approaches have been widely used in industrial recycling to recover cathode materials due to their high efficiency and throughput. Further, impurities have always been a great challenge for hydrometallurgical recycling, introducing challenges to maintain the consistency of product quality because of potential unintended effects caused by impurities. Herein, after comprehensive investigation, we first report the impacts of phosphate impurity on a recycled LiNi 0.6 Co 0.2 Mn 0.2 O 2 ("NCM622") cathode via a hydrometallurgy method. We demonstrate that a passivation layer of Li 3 PO 4 is formed at grain boundaries during sintering, which significantly raises the activation barrier and hinders lithium diffusion. In addition, the distinct degradation of cathode electrochemical properties is observed from poor particle morphology and high cation mixing as a result of phosphate impurity. Cathode powders with 1 at. % phosphate impurity retain a capacity of 146 mAh/g after 100 cycles at 0.33C, 6% less than that of a virgin cathode. Furthermore, cathodes with higher phosphate concentrations perform even worse in electrochemical tests. Therefore, phosphate impurities are detrimental to the hydrometallurgical recycling of NCM cathode materials and need to be excluded from the recycling process.

25 ENERGY STORAGE↗
DOE OSTI2021

One-dimensional edge contact to encapsulated MoS 2 with a superconductor

Establishing ohmic contact to van der Waals semiconductors such as MoS 2 is crucial to unlocking their full potential in next-generation electronic devices. Encapsulation of few layer MoS 2 with hBN preserves the material’s electronic properties but makes electrical contacts more challenging. Progress toward high quality edge contact to encapsulated MoS 2 has been recently reported. Here, we evaluate a contact methodology using sputtered MoRe, a type II superconductor with a relatively high critical field and temperature commonly used to induce superconductivity in graphene. We find that the contact transparency is poor and that the devices do not support a measurable supercurrent down to 3 K, which has ramifications for future fabrication recipes.

2D materials↗
DOE OSTI2023

Quasiparticle Spectroscopy, Transport, and Magnetic Properties of Nb Films Used in Superconducting Qubits

Niobium thin films on silicon substrate used in the fabrication of superconducting qubits have been characterized using scanning and transmission electron microscopy, electrical transport, magnetization, the London penetration depth - based quasiparticle spectroscopy, and real-space real-time magneto-optical imaging. Here we study niobium films to provide an example of a comprehensive analytical set that may benefit superconducting circuits such as those used in quantum computers. The films have a superconducting transition temperature of T c = 9.35 K and a fairly clean superconducting gap. The estimated superfluid density is enhanced at intermediate temperatures. These observations are consistent with the recent theory of anisotropic strong-coupling superconductivity in Nb and indicate outstanding quality. However, the response to the magnetic field is complicated, exhibiting significantly irreversible behavior and insufficient heat dissipation (to a substrate), leading to thermomagnetic instabilities. This may present a challenge for further improvement of transmon quantum coherence. Possible mitigation strategies are discussed.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2025

What more can be done with XPS? Highly informative but underused approaches to XPS data collection and analysis

Because of the importance of surfaces and interfaces in many scientific and technological areas, the use of x-ray photoelectron spectroscopy (XPS) has been growing exponentially. Although XPS is being used to obtain useful information about the surface composition of samples, much more information about materials and their properties can be extracted from XPS data than commonly obtained. This paper describes some of the areas where alternative analysis methods or experimental design can obtain information about the near-surface region of a sample, often information not available in other ways. Experienced XPS analysts are familiar with many of these methods, but they may not be known to new or casual XPS users, and sometimes, they have not been used because of an inappropriately assumed complexity. The information available includes optical, electronic, and electrical properties; nanostructure; expanded chemical information; and enhanced analysis of biological materials and solid/liquid interfaces. Many of these analyses can be conducted on standard laboratory XPS systems, with either no or relatively minor system alterations. Topics discussed include (1) considerations beyond the “traditional” uniform surface layer composition calculation, (2) using the Auger parameter to determine a sample property, (3) use of the D parameter to identify sp 2 and sp 3 carbon information, (4) information from the XPS valence band, (5) using cryocooling to expand range of samples that can be analyzed and minimize damage, and (6) using electrical potential effects on XPS signals to extract chemically resolved electrical measurements including band alignment and electrical property information.

Baer, Donald R. [Pacific Northwest National Labora↗
DOE OSTI2022

GridDS: Data Science Toolkit for Energy Grid Data

According to the U.S. Energy Information Administration (EIA), the demand for energy is expected to increase 50% by the year 20501. While energy standards, such as the Institute of Electrical and Electronics Engineers (IEEE) Standard 1547, (Basso 2015) and monitoring with wide area management systems (WAMS) (Liu 2017, Zhou 2016) have enabled large scale data collection and storage, the application of this data in mitigating costs associated with increased consumer demand is an ongoing focus for energy research. This ubiquitous data collection presents a promising opportunity for machine learning and data science to improve efficiency of distributed energy resources (DERs). The GridDS software toolkit is designed to leverage advanced metering infrastructure (AMI), outage management systems data (OMS), Supervisory control Data Acquisition (SCADA), and geographic information systems (GIS) to forecast future energy demands and detect incipient grid failures. GridDS is a python software library designed to be modular and generalizable to data recorded by DERs. In adapting to disparate datasets recorded by various WAMS, GridDS provides a range of unique functionality not presently implemented in current WAMS which have highly specific software infrastructure by design. GridDS functionality ranges from data specification and preparation, to training and validation for state of the art machine learning, to interactive data visualization. For data intake, GridDS combines: Pandera: a library for creating data specifications. TimeScaleDB: a postgresSQL database infrastructure for efficient storage of timeseries data. Dataset class: A custom dataset class / interface that ensures modularity between a range of synthetic and live recorded datasets. Is

Ladd, Alexander↗
DOE OSTI2021

Challenges and needs for system-level electrochemical lithium-ion battery management and diagnostics

The desire for energy-dense and fast-charged battery technology in consumer-electronics, electric-vehicle, grid, and aviation applications is pushing the envelope on materials to cells and pack designs to use and operating conditions. However, some approaches could inherently decrease safety of the battery—thus requiring the development of advanced management and diagnostics. Safety of lithium-ion batteries (LiBs), particularly in multicell configurations, is highly variable and could evolve with use. Existing works primarily focus on cell life and safety diagnostics without considering module and pack-level uncertainties and sometimes imply that cell-level electrochemical diagnostics would work in modules or packs, a naive oversimplification. Using example case studies, we highlight the potential and challenges associated with extending single-cell diagnostics to multiple cells, note the challenge involved, and motivate the research and development and support communities to devote efforts to fill the gap by developing diagnostics at these levels for current- and future-generation LiBs.

25 ENERGY STORAGE↗
DOE OSTI2020

Support for the 2019 IEEE Symposium on Fusion Engineering

This award provided financial support to help cover program-related expenses for the 2019 IEEE Symposium on Fusion Engineering (SOFE-2019), which was held 2-6 June 2019 near Jacksonville, FL. The SOFE is a biennial conference that enables fusion engineers from around the world to report on their work and stay current with the latest developments in fusion R&D, both physics and engineering. The symposium was sponsored by the Nuclear and Plasma Sciences Society (NPSS) of the Institute of Electrical and Electronics Engineers (IEEE), an international professional society whose members today span a wide range of disciplines. The IEEE Fusion Technology Standing Committee (FTC), most of whose members are involved in DOE Fusion Energy Sciences (FES) sponsored work, were responsible for organizing the SOFE. The SOFE has been the leading conference of choice for U.S. fusion engineers since its founding in 1965. In recent years, attendance has been growing as the conference has attracted greater participation of fusion researchers from other countries, especially from Asia but also from Europe and from the international ITER project, both central team and domestic agencies. This trend benefits U.S. participants by providing a forum to learn about the world’s most advanced fusion engineering activities and to strengthen collaborative ties with colleagues.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

Recommendations for Data-in-Transit Requirements for Securing DER Communications

With the adoption of Distributed Energy Resource (DER) interoperability standards, common communication protocols are now being deployed between power system operators and DER devices. In 2018, a revision to the US interconnection and interoperability standard, Institute of Electrical and Electronics Engineers (IEEE) Std. 1547, required DER equipment to have an IEEE 2030.5, IEEE 1815, or SunSpec Modbus communication exchange interface. This change supports the future transition to secure connection and exchange of information between the DER equipment and implementing parties, such as grid operators. Adoption of standardized communication protocols and associated information models is a critical step toward interoperability between power system operators and DER, such as photovoltaic (PV) and energy storage systems. However, security requirements for these standardized communication protocols are not comprehensive, resulting in non-standard and vendor-specific implementation that may leave DER equipment susceptible to cyberattacks. This paper examines the data-in-flight security requirements for standardized DER communication protocols, per IEEE 1547-2018 revision, as it relates to device authentication, key management, and encryption. The state of the art for these security features is also explored, addressing their impact on communication and performance of low-cost single board computers, which are typical of DER devices. In conclusion, a recommendation is provided to adopt a common set of communication requirements, which are intended to achieve interoperability and implement data security over DER network pathways, while ensuring reliable, secure, and real-time information delivery.

42 ENGINEERING↗
DOE OSTI2021

Fabricating Diamond-like Amorphous Carbon

Using a magnetically confined hot hollow cathode PE-CVD, hydrocarbon gas is decomposed under a diluent gas to deposit hydrogenated amorphous carbon onto a sample holder. During the fabrication of the hydrogenated amorphous carbon, the electric potential, electron temperature, and electron density of the plasma are measured with a Langmuir probe. Raman spectroscopy is used to determine the structural and electronic characterization of the final hydrogenated amorphous carbon solid.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2021

Validation and Verification for INL Modelica-based TEDS models Via Experimental Results

This report provides an overview on the verification and validation (V&V) of the Thermal Energy Distribution System (TEDS) model developed in the Modelica process modeling ecosystem using experimental data. Model development has led to the creation of a dynamic process model of the experimental TEDS facility housed within the Energy Systems Laboratory (ESL) at Idaho National Laboratory (INL). The model was then used during the preconstruction phase of the experimental effort to inform experimental design (e.g., insulation requirements, bypass line placement, expected performance of components) and to test innovative control schemes prior to the initial operation. The TEDS model developed in Modelica includes the primary components of the TEDS experimental unit: a 200kW Chromalox heater; a single-tank packed-bed thermal energy storage system filled with 0.125-inch alumina (Al2O3) beads; an ethylene-glycol-to-Therminol-66 heat exchanger; system piping; five control valves; and all associated temperature, pressure, and volumetric flow sensors. Using the Institute of Electrical and Electronics Engineers (IEEE) V&V methodologies, considered the gold standard in the engineering field, the model was verified using a combination of static analysis, spatial convergence, and regression tests. Then using dynamic time warping (DTW) initial runs to validate and tune the TEDS model versus the experiment were conducted. This tuning method was accomplished using the INL Risk Analysis Virtual ENvironment (RAVEN) software package. Tuning is required to account for physical phenomena that are less understood within the empirical heat transfer correlations. Through the commencement of this work, a systems-level model of TEDS with associated control systems, sensors, piping diameters, and component capabilities has been created. This model was utilized in the pre-experimental phase to inform system design, insulation thicknesses, and potential control schemes to operate the system effectively and safely. Then, initial experimental startup and operational data were used to demonstrate the validation and tuning methodology. This process demonstrates the classical two-step approach of a model informing experimental design followed by the experiment validation and tuning the model.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Energy Resilient Recovery in Puerto Rico: Hurricane Maria Recovery Support

This report covers microgrids as a special application of distributed energy resources (DERs) in Puerto Rico. This is one of a series of reports describing the U.S. Department of Energy (DOE) multi-laboratory efforts undertaken. To ensure the sustainable, long-term recovery of Puerto Rico's electric power grid from hurricanes Maria and Irma and to build capacity to manage future potential natural disasters in the most secure and resilient way, DOE convened experts from multiple national laboratories to develop a comprehensive set of data, models, analytic tools, and studies, considering inputs from a wide variety of stakeholder groups, to support technically sound recommendations for Puerto Rico's energy investment decisions. In Phase 1 of the multi-laboratory effort to support Puerto Rico's recovery, the National Renewable Energy Laboratory (NREL) provided the utility company Puerto Rico Electric Power Authority (PREPA) recommendations for a new framework of interconnection standards to accelerate the integration of utility-scale, transmission-connected, renewable electrical generation and energy storage that ensure cross-technology compatibility and enable high deployment levels without compromising grid reliability, safety, or security (https://www.nrel.gov/docs/fy19osti/73848.pdf). In Phase 2, NREL published a report focused on the interconnection of distributed energy resources (DERs) to the electric distribution system in Puerto Rico (https://www.nrel.gov/docs/fy21osti/77127.pdf). This report familiarized the reader with Puerto Rico's distribution infrastructure and operational practices and procedures that are relevant to DER interconnection. The report also provided considerations for streamlining the interconnection process given the expected increase in deployments resulting from Puerto Rico's renewable portfolio standard goal of 100% renewables by 2050. Accordingly, the report identifies considerations and concerns associated with the increase in intermittent generation, strategies for DER interconnection best practices, and the potential use of the latest technological solutions identified in the latest revision of the Institute of Electrical and Electronics Engineers 1547-2018 interconnection standard. Additionally, the report identified ways to improve the physical resiliency of installed DERs. This task describes how distributed energy systems may participate in and contribute to improving the resiliency of Puerto Rico's energy infrastructure in the future. This report presents an analysis of the Puerto Rico grid to illustrate the possible different microgrid and minigrid scenarios. The capability to form sustained microgrids and minigrids has the potential to provide a high level of resiliency during disturbances on the grid. DERs, on the other hand, have the capability to aid in the microgrid operation by providing grid support as well as grid-forming functionality. Other tasks in Phase 3 include voltage regulation in distribution networks using DERs and transmission-and-distribution co-simulation.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2022

Providencia Island White Papers: Overview of Technical Requirements for Interconnection

This issue brief provides an overview of key technical requirements for inverter-based resources - including distributed energy resources (DERs) - to support the reliable and safe operation of the Providencia Island electrical grid, and other island or isolated area mini-grid applications. With the planned increase in inverter-based resources and the introduction of energy storage, adopting Institute of Electrical and Electronics Engineers (IEEE) Std 1547-2018, including the more advanced performance capabilities for voltage and frequency ride-through, will simplify interconnection as well as help to maintain a safe, reliable grid on Providencia Island.

24 POWER TRANSMISSION AND DISTRIBUTION↗