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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 19 records

Estimating Electrification Potential for Class 8 Regional-Haul Trucks

This one-page highlight details the key takeaways from a project that utilized NREL's Fleet Research, Energy Data, and Insights (FleetREDI) data analysis pipeline. As part of the North American Council for Freight Efficiency's (NACFE's) Run on Less Depot data workshop, NREL sought to understand how Tesla semi-trucks would perform in real-world regional haul applications. Analysis reveals that the modeled Tesla trucks, with an average efficiency of 1.78 kWh/mi, struggle to achieve full operational coverage using current battery and charging configurations assuming operations remain unchanged. However, in an extreme case where ubiquitous charging exists, 100% EV coverage is possible for the given drive cycles. These findings highlight the trade-off between battery size and charge rate in electrification potential and emphasize the necessity for advancements in charging infrastructure to enable electric trucks for regional haul operations.

ADVANCED PROPULSION SYSTEMS↗

Characterization and Analysis of Insulated Metal Substrate-Based SiC Power Module for Traction Application

This paper presents the electrical characterization and drive cycle--based thermal analysis of an insulated metal substrate (IMS)--based silicon carbide power module for high-power traction inverters. The substrate was constructed using a thin layer of polymer--ceramic blend dielectric material with a thick copper core to improve transient thermal performance. The cooling performance of this module has already been validated with promising results. In this paper, an experimental test bed was set up to evaluate the dynamic and static electrical performance of the designed module under a wide range of operating conditions. The characterization results were then used to develop a drive cycle--based thermal model to validate the performance compared to the traditional direct bonded copper--based power module. The results indicate that the IMS-based power module is a suitable solution for high-power traction applications.

Chowdhury, Shajjad↗

Development of a Heavy-Duty Electric Vehicle Integration and Implementation (HEVII) Tool

As demand for consumer electric vehicles (EVs) has drastically increased in recent years, manufacturers have been working to bring heavy-duty EVs to market to compete with Class 6-8 diesel-powered trucks. Many high-profile companies have committed to begin electrifying their fleet operations, but have yet to implement EVs at scale due to their limited range, long charging times, sparse charging infrastructure, and lack of data from in-use operation. Thus far, EVs have been disproportionately implemented by larger fleets with more resources. To aid fleet operators, it is imperative to develop tools to evaluate the electrification potential of heavy-duty fleets. However, commercially available tools, designed mostly for light-duty vehicles, are inadequate for making electrification recommendations tailored to a fleet of heavy-duty vehicles. The main challenge is that light-duty tools do not estimate real-time vehicle mass, a factor that has a disproportionate impact on the energy consumption of large commercial vehicles. The Heavy-Duty Electric Vehicle Integration and Implementation (HEVII) tool advances the state of the art in evaluating electrification potential and infrastructure requirements for fleets of commercial vehicles. In this work, the HEVII tool is demonstrated with non-uniformly sampled telematics data from an existing fleet to assess the suitability for electrification of each individual vehicle, determine optimal locations for charging infrastructure to support a fleet of EVs and analyze associated costs. Payload mass is predicted using sparse ground-truth data for all input drive cycles and an initial data analysis is conducted to assess the characteristics driving behaviors and energy consumption of the fleet using an adaptable vehicle model. Battery size requirements are determined by applying a novel charger placement algorithm to maximize routes that are viable for EVs and balance time delays with infrastructure development costs. This work details and demonstrates the different aspects of the HEVII tool, presenting preliminary results from an example use case.

ADVANCED PROPULSION SYSTEMS↗

HOLISTIC ENERGY EFFICIENCY ANALYSIS OF ELECTRIFIED OFF-HIGHWAY MATERIAL HANDLER: FROM DRIVE CYCLE CHARACTERIZATION TO POWERTRAIN, HYDRAULIC, AND THERMAL SYSTEM PERFORMANCE

Three complexities surrounding the operation and testing of hybrid electric, heavy-duty nonroad machines have been addressed experimentally and using 1D simulation. Their resolutions have been intertwined with the development of a prototype machine that was proven to reduce fuel consumption in excess of 20%. A real-world drive cycle that leveraged hydraulic cylinder position was developed and utilized to ensure accurate reproduction of hydraulic work between the baseline and hybrid machines, while simultaneously maintaining less than 5% RMS error in position for main load handling functions. The newly developed, machine-specific drive cycle also contributed towards making equivalent comparisons in energy consumption between machine types through composite performance metrics that were extrapolated over a typical shift duration. Lastly, this work addressed thermal management energy consumption, a topic of increasing popularity when discussing electrified vehicles, by proposing a 1.4% energy savings through special mechanization and control of cooling system components.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DEVELOPMENT OF A LUMPED-PARAMETER THERMAL MODEL FOR ELECTRO-HYDRAULIC ACTUATORS

This paper describes a thermal-hydraulic modeling method of a closed-circuit electro-hydraulic actuator (EHA). Despite the high energy efficiency of EHAs, it is always important to assess their cooling requirements, to guarantee that the operating temperature remains within an acceptable range. The method proposed in this paper is based on a lumped parameter approach and simplifies some of the complex heat transfer processes by introducing empirical correction factors. The model is validated by means of temperature measurements on an EHA architecture developed by the author. The good match between the simulation results and experiments confirms the capability of the proposed methodology to predict the temperature performance of the reference EHA under different drive cycles. The paper presents a detailed analysis of the power losses and passive heat dissipation for the reference system. Based on this analysis, the cooling requirements of the EHA are studied.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Powertrain Performance and Total Cost of Ownership Analysis for Class 8 Yard Tractors and Refuse Trucks

Advanced powertrain technologies, specifically fuel cell electric powertrains, have gained attention as viable alternatives for medium- and heavy-duty (M/HD) vehicles. However, it is unclear how these alternative powertrain vehicles stack up against their diesel counterparts in terms of performance and total cost of ownership (TCO). Furthermore, there are vehicle segments within the M/HD sector that have remained unstudied for fuel cell electric applications. This analysis aims to provide a comparative scoping-level TCO and performance analysis for two heavy-duty vocation vehicles (Class 8 U.S. port-side yard tractor and Class 8 U.S.-based refuse truck) for both conventional diesel and heavy-duty fuel cell electric (HDFC) powertrains. The refuse truck analysis also considered compressed natural gas powertrains (CNG) for comparison. The analysis includes seven timeframes (2020, 2025, 2030, 2035, 2040, 2045, and 2050) for comparison. This simplified TCO analysis includes only direct costs (fuel price, glider purchase price, and operating & maintenance costs) and excludes any associated indirect cost (e.g., dwell time costs and other opportunity based costs). Representative drive cycles for each vehicle were based on on-board GPS logged data and chosen by the analysis team to represent average, non-extreme driving conditions. At the time the analysis was performed, the Inflation Reduction Act was not in effect and therefore any potential subsidies and future cost reductions enacted under the Inflation Reduction Act were not included. Based on the operational setpoints used in this analysis, HDFC powertrains for both yard tractors and refuse trucks have the potential to achieve TCO advantages over conventional diesel powertrains (and CNG for refuse truck applications) in the near- to mid-term future while meeting the necessary duty cycle performance requirements. Yard tractors and refuse trucks spend a significant amount of time operating at low speeds, with long durations of idling, and experience numerous start/stop occurrences. These operational characteristics favor fuel cell performance as fuel cells operate with higher efficiencies at lower percentages of total power output. Conversely, conventional diesel and CNG engines are most efficient at higher percentages of total power output. This helps HDFC powered yard tractors and refuse trucks realize improved fuel economy when compared to their diesel counterparts, which helps reduce total fuel costs and therefore, total TCO. The analysis demonstrates that fuel prices play a significant role in determining TCO for each vehicle and should remain an R&D focus area. Overall, under the analysis' specified conditions, HDFC yard tractors have the potential to achieve cost parity with diesel yard tractors as early as 2025. For refuse trucks, HDFC refuse trucks have the potential to achieve cost parity with diesel and CNG refuse trucks in 2030 and 2040, respectively.

33 ADVANCED PROPULSION SYSTEMS↗

Sources, seasonal cycling, and fate of plutonium in a seasonally stratified and radiologically contaminated pond

Unlike short-term laboratory experiments, studies at sites historically contaminated with radionuclides can provide insight into contaminant migration behavior at environmentally-relevant decadal timescales. One such site is Pond B, a seasonally stratified reservoir within Savannah River Site (SC, USA) has low levels (μBq L –1 ) of plutonium in the water column. Here, we evaluate the origin of plutonium using high-precision isotope measurements, investigate the impact of water column geochemistry on plutonium cycling during different stratification periods, and re-evaluate long-term mass balance of plutonium in the pond. New isotopic data confirm that reactor-derived plutonium overwhelms input from Northern Hemisphere fallout at this site. Two suggested mechanisms for observed plutonium cycling in the water column include: (1) reductive dissolution of sediment-derived Fe(III)-(oxyhydr)oxides during seasonal stratification and (2) plutonium stabilization complexed strongly to Fe(III)-particulate organic matter (POM) complexes. While plutonium may be mobilized to a limited extent by stratification and reductive dissolution, peak plutonium concentrations are in shallow waters and associated with Fe(III)-POM at the inception of stratification. This suggests that plutonium release from sediments during stratification is not the dominant mechanism driving plutonium cycling in the pond. Importantly, our analysis suggests that the majority is retained in shallow sediments and may become increasingly recalcitrant.

54 ENVIRONMENTAL SCIENCES↗

Diverse organic carbon dynamics captured by radiocarbon analysis of distinct compound classes in a grassland soil

Soil organic carbon (SOC) is a large, dynamic reservoir composed of a complex mixture of plant- and microbe-derived compounds with a wide distribution of cycling timescales and mechanisms. The distinct residence times of individual carbon components within this reservoir depend on a combination of factors, including compound reactivity, mineral association, and climate conditions. To better constrain SOC dynamics, bulk radiocarbon measurements are commonly used to trace biosphere inputs into soils and to estimate timescales of SOC cycling. However, understanding the mechanisms driving the persistence of organic compounds in bulk soil requires analyses of SOC pools that can be linked to plant sources and microbial transformation processes. Here, we adapt approaches, previously developed for marine sediments, to isolate organic compound classes from soils for radiocarbon ( 14 C) analysis. We apply these methods to a soil profile from an annual grassland in Hopland, California (USA), to assess changes in SOC persistence with depth (down to 1 m). We measured the radiocarbon values of water-extractable organic carbon (WEOC), total lipid extracts (TLEs), total hydrolyzable amino acids (AAs), and an acid-insoluble (AI) fraction from bulk and physically separated size fractions (< 2 mm, 2 mm–63 µm, and < 63 µm). Our results show that Δ 14 C values of bulk soil, size fractions, and extracted compound classes became more depleted with depth, and individual SOC components have distinct age–depth distributions that suggest distinguishable cycling rates. We found that AAs and TLEs cycle faster than the bulk soils and the AI fraction. The AI was the most 14 C-depleted fraction, indicating that it is the most chemically inert in this soil. Our approach enables the isolation and measurement of SOC fractions that separate functionally distinct SOC pools that can cycle relatively quickly (e.g., plant and microbial residues) from more passive or inert SOC pools (associated with minerals or petrogenic) from bulk soils and soil physical fractions. With the effort to move beyond SOC bulk analysis, we find that compound class 14 C analysis can improve our understanding of SOC cycling and disentangle the physical and chemical factors driving OC cycling rates and persistence.

58 GEOSCIENCES↗

Development of Ionic Liquid-Additized, GF-5/6 Compatible Low-Viscosity Oils for Automotive Engine and Rear Axle Lubrication for 4% Improved Fuel Economy

This joint project among ORNL, GM, and DRO successfully developed ionic liquid-additized low viscosity lubricants, SAE 0W-12 and 70W-80, for both IC engine and rear axle lubrication, respectively, and demonstrated combined vehicle fuel economy improvement (FEI). Phosphonium-alkylphosphate ILs have been found to be the most effective among the candidates in protecting surface damage from both sliding wear and rolling contact fatigue, and optimal IL concentrations have been determined. The IL’s impact on three-way catalyst seems to be significantly less adverse than the conventional ZDDP. Oil formulations were optimized for both energy efficiency and wear protection. Tribological bench testing of the IL-additized low-viscosity oils showed at least 40% lower boundary friction, more than 60% lower elastohydrodynamic friction, and greater than 50% less wear compared with commercial baselines. IL-additized lubricants have demonstrated FEI by 9.9% in engine dynamometer tests under extreme conditions and 6.9% increased power output in gear rig tests. Prototype IL-additized engine oil and rear axle fluid exhibited combined FEI of 1.39% and 3.24% benchmarked against the state-of-the-art baselines in vehicle testing of fresh oils under the Federal Test Procedure (FTP) city cycle and Highway Fuel Economy Driving Schedule (HWFET), respectively. Used oil analysis suggested that the IL-additized low-viscosity oils produced less wear than the commercial baselines. The gained fundamental understanding and demonstrated FEI in this work pave the way for future development and implementation of the ionic liquid technology.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Information and Collaboration Levels in Vehicular Strings: A Comparative Study

The potential safety, productivity, and energy benefits of automated vehicles have driven a surge of research interest in their algorithms. Even within single-lane driving, control engineers now have a profusion of approaches available to them. Algorithm classes include classical controllers, receding horizon controllers, and constrained eco-driving formulae based on Pontryagin’s Minimum Principle. Differing connectivity architectures and collaboration levels further differentiate algorithms from one another. This study evaluated six controllers in two drive cycle-based scenarios using an electric powertrain model for energy analysis. Individual-vehicle and string performance were examined, including string stability and length. Algorithms with greater access to information generally performed best. Although collaboration affected energy use only slightly, it made a greater impact on string length.

Dollar, R. Austin↗

A Comparative Analysis of Waste-as-a-Feedstock Accounting Methods in Life Cycle Assessments

Global waste generation is a ubiquitous challenge, driving a paradigm shift towards viewing waste as a valuable resource for a circular economy across diverse sectors. While innovative waste-to-resource pathways are crucial, rigorous Life Cycle Assessment (LCA) is essential to ensure the pathways are an important part of current practices. However, LCA application to waste valorization varies, leading to incomparable results due to differing methodological choices. This paper examines three key nuances in waste-as-resource LCAs: the zero-burden assumption, the biogenic carbon neutrality assumption, and the benchmark assumption for emissions avoidance. Using a waste gasification to hydrogen case study, we demonstrate how these methodological decisions impact LCA outcomes. Our findings reveal that waste composition significantly influences the results and highlight challenges associated with biogenic carbon accounting under various system boundary assumptions. Emissions avoidance accounting requires multi-functional unit perspectives and robust benchmark selection. This paper clarifies these accounting approaches, empirically illustrates their influence, and discusses broad implications for accurate sustainability assessment, emphasizing the critical role of transparent LCA choices for effective policy and investment in circular economy solutions.

LCA method↗

Metaproteomics-informed stoichiometric modeling reveals the responses of wetland microbial communities to oxygen and sulfate exposure

Abstract Climate changes significantly impact greenhouse gas emissions from wetland soil. Specifically, wetland soil may be exposed to oxygen (O 2 ) during droughts, or to sulfate (SO 4 2- ) as a result of sea level rise. How these stressors – separately and together – impact microbial food webs driving carbon cycling in the wetlands is still not understood. To investigate this, we integrated geochemical analysis, proteogenomics, and stoichiometric modeling to characterize the impact of elevated SO 4 2- and O 2 levels on microbial methane (CH 4 ) and carbon dioxide (CO 2 ) emissions. The results uncovered the adaptive responses of this community to changes in SO 4 2- and O 2 availability and identified altered microbial guilds and metabolic processes driving CH 4 and CO 2 emissions. Elevated SO 4 2- reduced CH 4 emissions, with hydrogenotrophic methanogenesis more suppressed than acetoclastic. Elevated O 2 shifted the greenhouse gas emissions from CH 4 to CO 2 . The metabolic effects of combined SO 4 2- and O 2 exposures on CH 4 and CO 2 emissions were similar to those of O 2 exposure alone. The reduction in CH 4 emission by increased SO 4 2- and O 2 was much greater than the concomitant increase in CO 2 emission. Thus, greater SO 4 2- and O 2 exposure in wetlands is expected to reduce the aggregate warming effect of CH 4 and CO 2 . Metaproteomics and stoichiometric modeling revealed a unique subnetwork involving carbon metabolism that converts lactate and SO 4 2- to produce acetate, H 2 S, and CO 2 when SO 4 2- is elevated under oxic conditions. This study provides greater quantitative resolution of key metabolic processes necessary for the prediction of CH 4 and CO 2 emissions from wetlands under future climate scenarios.

59 BASIC BIOLOGICAL SCIENCES↗

DriveSense: A Noise-Resilient Framework for Driving Mode Identification

Accurate drive mode classification is essential for enhancing the reliability and predictive maintenance of heavy-duty electric trucks. This study proposes a novel fuzzy logic-based framework, DriveSense, for real-time drive mode classification, addressing key challenges such as sensor noise, transitional behaviors, and computational efficiency. The proposed approach integrates a two-stage filtering pipeline, combining adaptive outlier removal and a dynamic Kalman filter to enhance data quality. A fuzzy inference system with smoothened trapezoidal membership functions is then applied to classify driving modes into standstill, constant speed, acceleration, and deceleration while mitigating the effects of noise and edge cases. Performance evaluation using real-world and simulated drive cycles demonstrates significant improvements in classification accuracy (up to 97.8%), F1-score (up to 0.97), and robustness against noise, while reducing false positives. Comparative analysis against baseline models, demonstrates DriveSense’s superior accuracy and generalizability across diverse driving patterns. The framework’s lightweight and interpretable fuzzy inference engine operates with low computational latency, ensuring compatibility with real-time embedded systems typical of heavy-duty electric trucks. Moreover, DriveSense models transitional behaviors through overlapping fuzzy sets and adaptive borderline classification logic, enabling smooth identification of subtle shifts such as rolling stops or gradual deceleration. These results highlight DriveSense’s potential to enhance predictive maintenance strategies, reduce downtime, and support scalable, fleet-wide diagnostics.

Kumar, Praveen [Oak Ridge National Laboratory (ORN↗

Asymmetric daytime and nighttime surface temperature feedback induced by crop greening across Northeast China

Mid-high latitude Northeast China witnessed significant crop greening from 2001 to 2020, as evidenced by satellite records and field observations. The land surface temperature of croplands during the growing season showed a decreasing trend, suggesting negative surface temperature feedback to crop greening of agricultural ecosystems in mid-high latitude Northeast China. Here, using time-series remote sensing products and long-term scenario simulations, the present study highlights that crop greening can slow climate warming. Our study noted a stronger surface cooling effect induced by crop greening during the growing season in the day than at the night, which contributed to asymmetric diurnal temperature cycle changes in Northeast China. In addition, our biophysical mechanism analysis revealed aerodynamic and surface resistances as the major driving factors for the daytime land surface temperature (LST) cooling effect induced by crop greening, while the ground heat flux and ambient temperature feedback as the major attributes of the nighttime LST cooling impact due to crop greening.

54 ENVIRONMENTAL SCIENCES↗

Drive Cycles, Battery Pack Scaling, and Usage Considerations for Long-Haul and Regional-Haul Electric Trucks

Electrifying Class-8 heavy-duty trucks presents a promising opportunity to enhance energy efficiency and reduce freight transport costs. Battery electric trucks (BETs), once considered niche, are gaining traction due to advancements in battery technology and cost reductions. However, accurately predicting battery lifespan under realistic usage conditions remains a key challenge. Understanding battery failure mechanisms and their links to design, operation, and management is essential for developers and fleet operators. This study introduces a method to develop simplified, lab-testable dynamic stress test (DST) cycles for regional and long-haul Class-8 BETs, derived from real-world diesel truck usage. These DSTs enable benchmarking of battery technologies, identification of aging stressors, and optimization of battery design, life, and cost. The approach supports evaluation of key metrics such as levelized cost of driving and total cost of ownership, aiding fair comparisons and adoption decisions. We also propose feasible battery pack sizes that meet current driving demands with strategic charging, and a method to scale pack-level DSTs to cell-level cycles for lab-based testing. These tools facilitate tradeoff analysis across battery chemistries, pack sizing, and charging strategies, while offering means to get insights into battery aging under realistic conditions-ultimately supporting informed BET deployment decisions.

25 ENERGY STORAGE↗

A novel triple power cycle featuring a gas turbine cycle with supercritical carbon dioxide and organic Rankine cycles: Thermoeconomic analysis and optimization

In this study, a novel triple power cycle is proposed where waste heat from a gas turbine cycle is utilized to drive a supercritical carbon dioxide (s-CO 2 ) recompression cycle and a recuperative organic Rankine cycle (ORC) in sequence. A detailed thermoeconomic model is developed and implemented in MATLAB to evaluate the performance of the proposed cycle under different operating conditions. Optimization using a particle swarm optimization (PSO) algorithm is performed to minimize the levelized cost of electricity (LCOE) and determine the optimum design conditions of the cycle. The optimization results show that for a 100 MW cycle, the overall thermal efficiency and LCOE are 0.521 and $\$52.819$/MWh, respectively. The turbine inlet temperature of the gas turbine and s-CO 2 cycles are found as the most influential parameters on the thermoeconomic performance of the triple cycle. The proposed triple cycle shows an excellent waste energy recovery potential and superiority over a very thermodynamically efficient cycle from the literature, which included a gas turbine topping cycle and a complex cascade s-CO 2 power cycle used a bottoming cycle. As a result, the proposed triple cycle shows up to 0.9% points higher efficiency while it has fewer heat exchangers and turbomachinery than the cycle from the literature.

30 DIRECT ENERGY CONVERSION↗

The Department of Energy and IDEA team up to document industry best practices

This article describes a collaboration between the U.S. Department of Energy and the International District Energy Association (IDEA) to document best practices in district energy systems. The initiative focuses on analyzing real-world performance data and highlighting effective strategies for improving efficiency, integrating renewable energy, and supporting decarbonization efforts. It highlights case studies from the University of California, Davis, and Princeton University to show how long-term master planning, phased project implementation, and strong financial analysis can drive successful transitions to more sustainable energy systems. U.C. Davis emphasizes incremental, results-driven planning and pilot projects, while Princeton focuses on aligning climate goals with financially viable infrastructure investments and life-cycle cost analysis. Overall, the article demonstrates that combining strategic planning, data-driven decision-making, and financial accountability is essential for advancing sustainable district energy systems.

96 KNOWLEDGE MANAGEMENT AND PRESERVATION↗