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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
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

White Paper on Case Study of Safe Installation of Second-Life Energy Storage System

This technical report provides for a case study for the safe installation of a second-life, or repurposed, battery, that has been reconfigured for use as a stationary energy storage systems (ESS). Driven by legislative requirements such as California Senate Bill 615 and projections that retired EV batteries could meet a substantial portion of U.S. grid ESS needs beginning in 2035, the repurposing of EV batteries is anticipated to grow significantly. However, safety concerns arise from the effects of aging, unknown prior usage history, and changes in thermal runaway behavior, which may increase failure risks compared to new batteries. NFPA 855, the predominant U.S. standard for ESS installation, mandates that second-life batteries meet all requirements for new batteries, with repurposers complying with UL 1974 in addition to obtaining UL 9540 and UL 1973 listings. These are certifications that few repurposers have achieved and represent a regulatory barrier to entry for the market as a whole.

47 OTHER INSTRUMENTATION↗
DOE OSTI2025

QuESt PCM

SAND2025-14369O QuESt PCM is a tool for modeling power system production cost. It is designed for high-fidelity representation of energy storage systems (ESS) and is part of QuESt 2.0: Open-source Platform for Energy Storage Analytics. Sandia National Laboratories is a multimission laboratory managed and operated by National Technology & Engineering Solutions of Sandia, LLC, a wholly owned subsidiary of Honeywell International Inc., for the U.S. Department of Energy’s National Nuclear Security Administration under contract DE-NA0003525.

Nguyen, Tu Anh [Sandia National Lab. (SNL-CA), Liv↗
DOE OSTI2025

Diversifying the Materials and Technologies for the Future of Energy Storage

It is increasingly important to meet the growing global energy demand driven by factors such as population growth, electrification, and the rapid development of emerging economies, while minimizing the environmental harm caused by carbon dioxide emissions. Although fossil fuels remain an abundant and inexpensive energy source, there is a global consensus on the critical importance of addressing climate change and an increasing urgency to reduce carbon dioxide emissions without hindering economic growth. This challenge is particularly daunting due to the significant transformations required in electricity generation systems, transportation, and industrial processes. A significant portion of our energy still comes from burning fossil fuels, which poses harmful effects on the environment. Transitioning to renewable energy sources like solar and wind is essential, as these sources provide a low-carbon pathway for power generation and have become increasingly cost-competitive with fossil fuels. However, they face the inherent challenge of intermittency. Thus, energy storage systems (ESS) are essential not only to address this issue but also to accommodate the increasing adoption of electric vehicles (EVs). Lithium-ion batteries (LIBs) are still the predominant ESS used for these applications; however, they suffer from issues related to scarce and harmful resources, safety, and socio-economic impacts. This underscores the need for alternative energy storage systems beyond LIBs. Here, in this review, we discuss the diversification, repurposing, and recycling of ESS to meet the projected energy demand while minimizing environmental harm.

batteries↗
DOE OSTI2022

Lithium-Ion Battery Design for Grid-Scale Energy Storage App

A software that delivers parameters from energy storage system (ESS) to container, rack, module and single cell design, as well as data analysis on arbitrage energy and frequency regulation of ESS in different regions, has been developed. The Lithium-ion Battery Design for Grid-scale Energy Storage App V1.0 has the capability to output the system, module and cell design with the energy, power, capacity, group method, cost of single cell, and single cell test protocol which break down from input energy storage system data in different regions. The default chemistry of the battery is LiFePO4 and graphite. The energy density of the graphite/LiFePO 4 pouch cell ranges from 100 Wh/kg to 200 Wh/Kg in the software. Graphite/LiFePO 4 pouch cell (up to 1Ah in lab) manufacturing line is also built and can be used to evaluate the test protocol, moreover, for electrolyte evaluation in other ESMI seedling projects. The software enables rapid prototyping to accelerate energy storage research, development, and manufacturing.

Liu, Dianying [Pacific Northwest National Laborato↗
DOE OSTI2024

A Neural Network-Based Power Mismatch Elimination Strategy for Integrated Solar and ESS AC/DC Systems (MARS)

The multiport autonomous reconfigurable solar power plant (MARS) is a promising concept for the integration of photovoltaic (PV) and energy storage system (ESS) to the transmission ac grid and a high-voltage direct current (HVdc) link. The presence of PV and ESS in each arm of the MARS results in uneven distribution of active power among different submodules (SMs), thereby leading to unbalanced SM capacitor voltages and potentially compromising the system stability. Moreover, in the case of partial shadings, shaded PV SMs will suffer from decreased power injections causing power mismatch in the MARS system. To address this issue, a neural-network-based power mismatch elimination (NNPME) strategy is proposed in this article. The proposed NNPME strategy optimizes ESS usage and leverages both dc and ac circulating currents to facilitate power transfer among the SMs, arms, and phases of the MARS system. Simulation and control hardware-in-the-loop (cHIL) experiments demonstrate the effectiveness of the proposed NNPME strategy. Compared with the traditional approaches, the proposed NNPME strategy can significantly enhance system efficiency and ensure stable and continuous operation, even in the presence of uneven power distribution within the MARS system.

14 SOLAR ENERGY↗
DOE OSTI2025

Development and Experimental Validation of a High-Power DC Distribution Testbed for Advanced Charging Infrastructure and Energy Management

This paper presents the development of a hardware testbed for DC-distributed high-power charging (HPC) stations. As DC distributed solutions emerge as a viable solution to optimize HPC site operations, challenges such as interoperability, protection, and seamless integration of distributed energy resources (DER) persist. These issues underscore the need for a robust testing facility to investigate compliance of available commercial off-the-shelf (COTS) market devices. The developed testbed features a DC-distributed charging hub including a charger, emulated energy storage system (ESS), and site level communication and controller implementation. It facilitates the testing of COTS hardware, charger prototypes, standards validation and site energy management system (SEMS) controllers at rated power. This paper details the development of the charging infrastructure platform, implementation of communication system, validation of different SEMS algorithms, and understanding improvements required for future expansion. Using the developed testbed, interoperability gaps for SEMS implementation with multi-vehicle concurrent charging via a multi-port charger are experimentally observed. Aimed at supporting the transition to large-scale EV charging infrastructure deployment and DER integration, this testbed plays a crucial role in conformity testing of COTS device interoperability.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2025

A Safe Response to Renewable Energy Hazards

The International Association of Fire Fighters (IAFF) and Underwriters Laboratories, LLC (UL) in conjunction with UL Solutions initiated a joint project in 2022 under an agreement with the United States Department of Energy-Office of Energy Efficiency and Renewable Energy (DOE-EERE). This project focused on two separate and important initiatives related to energy efficiency in residential buildings. Initiative 1: Fire Performance on Energy Efficient Exterior Walls. Initiative 2: Firefighting Tactics in Residential Properties with Building Energy Storage Systems (BESS). The project’s first initiative addresses concerns surrounding new technologies with enhanced, energy-efficient exterior walls installed on residential properties. The concerns of fire rapidly traveling vertically up the exterior of these walls were examined. This addressed a growing concern from the first responder community that many times, the fires on the exterior of residential buildings have already evolved into an attic fire by the time of arrival – making it problematic to address the fire scenario. The test plan for Initiative 1 incorporated a modified version of an American Society for Testing and Materials (ASTM) test method, ASTM E2707, Standard Test Method for Determining Fire Penetration of Exterior Wall Assemblies Using a Direct Flame Impingement Exposure, as the foundation of the research. The test method involved a wall structure intended to represent retrofit construction to evaluate how fire would spread vertically or laterally. The second aspect of the UL-IAFF Project focuses on the fire service response to Residential Battery Energy Storage System (RBESS) incidents. These simulation tests were constructed in the large-scale fire test facility at UL Solutions’ Northbrook, IL campus. A baseline test was conducted that involved a test structure with no batteries—shelving units populated with standardized commodities, representing a typical garage with cellulosic and plastic contents. Three additional tests have been conducted to generate data with the contribution of energy storage system (ESS) batteries to compare fire and explosion hazards against the baseline test. Through this work, fire service tactical considerations can be explored. From the data, the team can determine 1) the visual indicators of a residential fire that has involved an RBESS (or, potentially, other large batteries) and 2) the impact of fire service-initiated ventilation of the structure on the fire conditions and explosion risks.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2026

Hybrid Fuel Cell Systems for Heavy-Duty Trucks: Configuration, Heat Rejection, and Performance

Low-temperature polymer electrolyte membrane fuel cell systems can achieve higher efficiency than diesel engines, but heat rejection remains a major challenge in class-8 heavy-duty fuel cell trucks. For the same rated power, the radiator heat load is greater than that in a diesel engine, while the allowable operating temperatures are lower. This work proposes and evaluates 400 kWe fuel cell–battery hybrid (FCH) platforms and operating strategies that manage heat rejection without enlarging the radiator frontal area. Three FCH platforms are identified, each varying in fuel cell system (FCS) rated power, battery energy storage system (ESS) capacity, and maximum stack coolant exit temperature (T h1 ). All three satisfy key system and vehicle requirements, including 175 kWe FCS power at top sustained speed, 400 kWe FCH power on a 6% grade climb, a target stack power density (PD) of 750 mW e /cm 2 , and heat rejection constraints. The first FCH has the smallest FCS, the largest ESS, and a T h1 of 90 °C. The second achieves the highest PD of 840 mW e /cm 2 at a T h1 of 95 °C. The third has the largest FCS, the smallest ESS, and a T h1 of 102 °C. At a Th1 of 115 °C, the platform can be configured as a stand-alone 400 kWe(net) FCS without hybridization, but the achievable PD drops to 460 mW e /cm 2 .

25 ENERGY STORAGE↗
DOE OSTI2025

Hybrid Energy Management with Real-Time Control of a High-Power EV Charging Site

Decarbonization of transportation systems is driving higher capacity energy storage and faster charging power requirements in electric vehicles (EVs). Given the potential advantages - such as increased efficiency, reduced inverter capacity, and less total cable mass - there is a demand in the industry for more DC distribution for high-power charging (HPC) hubs. However, the cost-effective, adaptive, and robust operation of the DC-coupled HPC hub necessitates a robust site energy management system (SEMS). Validating SEMS operation using a digital twin of an HPC hub in a real-time simulator (RTS) platform is crucial before field deployment. In this study, we propose a hybrid energy management site controller designed to achieve high-level, long-term operational objectives while managing low-level power sharing control between hub assets. We develop a centralized model predictive controller (MPC) to optimize hub operating points and use these points to update the droop parameters of the site energy storage system (ESS). This approach ensures the hub follows an optimal operating point while maintaining the flexibility to respond to load surges. We tested and verified our proposed approach both offline and on a Controller Hardware-in-the-loop (C-HIL) simulation platform integrated with a SEMS framework, demonstrating real-time site operation and validating a cost-effective and robust site controller.

ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2025

Q1-2024 Solar Cost Benchmarks

Each year, the U.S. Department of Energy’s (DOE) Solar Energy Technologies Office (SETO) and its national laboratory partners develop cost benchmarks for U.S. solar photovoltaic (PV) systems. These benchmarks track progress toward reducing solar costs and guide R&D priorities. Unlike typical studies that report only $/W, SETO uses intrinsic units (e.g., $/m² for mounting structures) to better capture how technology improvements such as module efficiency would impact system costs. This allows flexible modeling where inputs can vary significantly to assess cost sensitivity. Costs are reported in two ways: Minimum Sustainable Price (MSP): Long term, financially viable price under stable market conditions. Modeled Market Price (MMP): Actual market price, influenced by short term distortions such as tariffs or subsidies. Three national labs collect cost data from industry stakeholders, ensuring no duplication in outreach to stakeholders. Data reflects real transactions (primarily from Q1) and is weighted based on the number of sources per cost element. The PV System Cost Model (PVSCM) divides total installed system cost into eight categories: 1. Module (PV) 2. Inverter 3. Energy Storage System (ESS) 4. Structural BOS (SBOS) 5. Electrical BOS (EBOS) 6. Fieldwork 7. Office work 8. Other (developer/EPC costs) The first five are hardware costs, while the last three are soft costs. Each category includes fixed and variable cost components, where “size” depends on context (e.g., manufacturing capacity for modules vs. system capacity for installation costs). Variable costs are expressed using appropriate intrinsic units. The model reflects the owner’s upfront overnight capital cost, excluding tax credits. Tariffs and subsidies are treated as temporary market distortions affecting MMP but not MSP. PVSCM is implemented in Excel, where cost elements are aggregated into total system cost. Additional sheets handle unit conversions and operation & maintenance (O&M), with O&M costs levelized over the system’s lifetime.

14 SOLAR ENERGY↗
DOE OSTI2025

NFPA Distributed Energy Resources Safety Training (DERST) For Emergency Responders

The National Fire Protection Association, with support from the Department of Energy, executed a multi-year initiative to develop, enhance, and disseminate Distributed Energy Resources Safety Training (DERST) tools for U.S. emergency responders. As Distributed Energy Resources (DER)—such as solar photovoltaics, battery energy storage systems (ESS), electric vehicles (EVs), and associated infrastructure—become increasingly prevalent, the NFPA identified a critical need for up-to-date standardized, accessible, and effective safety training tailored for the fire service and related public safety professionals. The project delivered a comprehensive suite of educational resources to improve responders’ abilities to safely manage DER-related incidents. This included: • Revised Modular Training Courses: Updated classroom-based DER safety courses, now modular and accessible nationwide through fire academies and the North American Fire Training Directors (NAFTD) network. • Live Burn Testing & Research: A full-scale controlled burn of a DER-equipped residential structure provided real-world data and insights, forming the basis for updated best practices. • A Gamified Simulation Tool – Firefighters Incident Response Simulation Tool (FIRST): A first-of-its-kind, multiplayer, scenario-based simulation using the Unreal Engine 5.0 to train responders in a realistic virtual, multi-DER incident environment. • Field Familiarization Software Tools & Prop Guide: Digital DER field familiarization evolutions software guide and a prop development manual to support field-based DER training exercises, enhancing responders' hands-on familiarity with DER infrastructure and collaboration on virtual incident responses. • National Dissemination Strategy: Strategic partnerships with NAFTD, Vector Solutions, and others enabled wide-scale distribution, with over 5,000 departments accessing resources and 1,100+ departments adopting the simulator in the first seven months. Also provided a web portal for easy access to all training and simulation programs developed under this grant for the U.S. responder community. Key findings from the project—particularly from the burn test—led to paradigm shifts in fire response tactics. For example, traditional approaches to garage fires may be hazardous if DERs are present, due to explosive off gassing and thermal runaway risks. The new training emphasizes scene assessment, stand-off approaches, thermal imaging verification, and careful post-incident cooling of DER components to prevent reignition. This initiative has had a significant national impact, raising awareness, enhancing preparedness, and supporting safer DER incident response practices. Significant engagement from the media, public safety organizations, and PBS coverage has further amplified the reach and adoption of NFPA’s DER safety training, tools, and simulations.

14 SOLAR ENERGY↗
DOE OSTI2026

Examination of entrainment, combustibility, and heat transfer due to cell venting inside simplified battery energy storage enclosures

Battery energy storage systems (ESS) assembled of modules containing lithium-ion batteries can pose fire and explosion hazards during thermal runaway because vented gases may accumulate, combust, or escape enclosures. Here, we propose a prototypical configuration composed of the main components of an ESS rack, where modules are represented as rectangles within an enclosure and vent gas is injected steadily through the top of a module. This idealized geometry allows for exploration of how rack-level characteristics can influence smaller single-cell or module-level scales. Through this geometry, we conduct numerical simulations to understand how variations in the vent velocity, temperature, and vertical location affect entrainment rates, fraction of uncombusted fuel, rich-gas coverage, and heat flux to other modules. At lower vent velocities and vertical positions, buoyancy drives enough entrainment and mixing to react with most of the vent gases on the converging plenum. As jet momentum increases and/or buoyancy decreases via higher vent position in the rack, vent gases can propagate into and burn in the divergence plenum. Heat flux to the impinged module scales strongly with vent momentum and temperature, while heat transfer to upper modules peaks when flames in the diverging plenum reach the surface and declines when combustion is suppressed.

Computational fluid dynamics↗
DOE OSTI2025

Development of copper thiolate organometallic compound as thermal sensitive coating for energy storage system safety

Safety and reliability are primary concerns for the deployment of lithium-ion batteries, especially in electric vehicles (EV) and larger-scale energy storage systems (ESS). Current technology in battery management systems (BMS) includes cell voltage monitoring and positioning temperature sensors in selected locations. For a system with hundreds to thousands of individual batteries, single-point temperature monitoring is inadequate to detect hot spots and cell overheating, which could lead to thermal runaway. Here, we have developed a temperature-sensitive copper-thiol compound that can be directly coated onto battery pouch foils to enable early detection of thermal runaway. Upon reaching specific temperatures, this compound releases a sulfur-containing detectable gas, which can be identified using chemically specific gas sensors to trigger an early warning signal. Such a signal propagate through air offers broad signal coverage and enables a more comprehensive approach to large-area temperature monitoring. The Cu-ethanethiol coating is designed to release volatile gases when the substrate surface temperature exceeds 70 °C, with continuous outgassing as the temperature increases. The compound is composed of Cu, S, Cl, hydrocarbons and trace amounts of oxygen. Upon heating, the oxidation state of Cu(I) transitions to Cu (II), accompanied by gas release. Thermogravimetric analysis coupled with mass spectrometry correlated well with the onset of gas release temperature and emission of sulfur-containing volatile gases. Additionally, an acrylic overcoat is applied to enhance the adhesion of the thermally sensitive compound film to the battery pouch foil. This coating is expected to offer an additional safety layer for ESS, alerting possible thermal runaway events before a failure occurs, thereby allowing sufficient time to implement a mitigation plan.

Early warning systems↗
DOE OSTI2025

Coordination of Energy Storage and Distributed Generation for Voltage Control and Peak-valley Filling

The increasing penetration of distributed energy resources (DERs) in distribution network (DN) poses challenges on voltage control. In addition, the growing integration of DERs also reshapes the traditional load profile. To comprehensively address the voltage control and peak-valley filling in DN, this paper proposes a model predictive control (MPC) based optimization framework. The proposed method can achieve coordinated voltage control and peak-valley filling by adjusting the reactive power output from distributed generations (DGs) and the charging/discharging of energy storage systems (ESS). The performance of the proposed method is demonstrated by simulations on a modified IEEE-123 bus system.

Zhang, Zhengfa [University of Tennessee, Knoxville↗
DOE OSTI2026

Safe Deep Reinforcement Learning for Active Distribution System Model Predictive Control with EVs and DERs

The temporal and spatial mismatch between PV generation and electric vehicle (EV) charging and discharging may cause voltage violations in active distribution networks. Despite the widespread use of deep reinforcement learning (DRL) in power system optimization and control, it lacks guarantees on constraint satisfaction during both training and deployment. This paper proposes a Lagrangian-based safe DRL approach for model predictive control (MPC) of active distribution systems with large-scale integration of PVs, EVs, and energy storage systems (ESSs). A Transformer-LSTM time-series model is proposed to forecast EV charging demand, which is then formulated as a constraint to ensure charging requirements are met. Using this prediction, a Lagrangian-based safe soft actor-critic (SAC) framework is developed for real-time control in a three-phase unbalanced distribution system, enforcing voltage safety constraints while optimizing the cumulative net reward. By integrating the forecasting model with multi-period constraints, the proposed framework jointly coordinates PV systems, EV charging and discharging, and ESS scheduling within the MPC horizon. Numerical experiments on a modified IEEE 123-bus system with real-world data show that, under a high PV penetration scenario, the proposed method increases the net reward by 30.74% and reduces average voltage violations from 0.0011 p.u. to 0.0002 p.u. compared with standard SAC. Compared with the optimal power flow (OPF) approach, it achieves similar voltage security while yielding lower line losses. It also maintains real-time control capability, reducing operation latency to 53.21 ms per 15-minute control interval. The proposed method remains effective under varying PV/EV penetrations and load conditions.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2025

Improved PV System Control Strategies to Reduce Power Management Costs in Nanogrids

An improved PV system control method is proposed to reduce nanogrid operation costs in this paper. A model including it various components such as photovoltaic (PV) systems, energy storage systems (ESSs), gateways, and household loads is considered with the constraints of the ESS, PV irradiance from real data, and household load. We designed an optimal economic dispatch strategy with an improved PV system control method. Combining the proposed optimal economic dispatch and PV system control strategies, it can improve the control performance for both transient and steady-state responses thereby enabling the maximum power to be extracted from the PV. Consequently, the PV power is maximized, which allows the ESS to use less power and sell the surplus to external power sources, which means the proposed method decreases the nanogrid operation costs. Furthermore, this performance is verified via nanogrid simulations and PV experimental kit.

PV system control↗
DOE OSTI2026

Flow dynamics and heat transfer in simplified battery energy storage systems with heated battery modules

Large-scale energy storage systems (ESSs) composed of batteries show promise in addressing current energy challenges, but dissipation of generated heat is important. Here, this paper focuses on buoyant convective flows in simplified ESS battery racks. Natural convection is not generally the primary cooling strategy but can be important in abnormal scenarios where there is module overheat or potentially thermal runaway. We use computational fluid dynamics to investigate the flow dynamics and heat transfer mechanisms in a simplified parameterized rack design. Despite its simplicity, this configuration produces many of the relevant features expected in real ESSs without details of module geometry or hardware, allowing broad conclusions independent of manufacture-specific designs. We start by providing visualizations of the flowfield and measurements of entrainment, heat flux, and pressure. To characterize the dependence on the system parameters, we develop an integral-scale analysis of the average temperature equation to highlight the dominant source terms. We use results from this analysis to derive a steady network model composed of simple algebraic expressions to provide first-order predictions of entrainment through the rack. The network model leads to a linear scaling of the Reynolds number based on convective mass flux with respect to the Grashof number based on the heat source. We deduce empirical relationships that relate the heat exchanged between modules using a surface-averaged Nusselt number as a function of the local Reynolds and Rayleigh numbers. Lastly, we investigate how space between the modules and rack in the spanwise direction creates flow bypass, resulting in different flow pathways.

Battery thermal management↗
DOE OSTI2026

From Cell to System: Accelerated hpc Simulations of BESS Aging under Frequency Regulation and Arbitrage use cases

Lithium-ion battery energy storage systems (BESS) packs have emerged as a leading solution for grid-scale energy storage, enhancing resiliency and balancing load fluctuations. Yet, experimental characterization of large-format LIB packs-particularly to assess performance and degradation over hundreds of cycles - demands substantial hardware investment and multi-year testing campaigns. In this work, we couple a hierarchical, physics-based modeling framework agnostic to electrode chemistries with high-performance computing to accelerate systems level evaluation by upto two orders of magnitude. Building on the open-source liionpack platform, we implement cell, module, and pack-scale electrochemical models enriched with mechanistic aging mechanisms and deploy them on an HPC cluster to simulate 150−200kWh systems over 500 - 1,000 cycles with in days. We subject these virtual B ESS to both constant-current cycling and realistic grid service profiles spanning frequency regulation, ramp-rate support, and energy arbitrage-and quantify the resulting degradation patterns. Our results reveal that localized cell aging can induce substantial nonuniformity at module and pack levels, with service-specific cycling protocols driving distinct aging modes. This rapid, multiscale modeling approach provides a powerful design-space exploration tool for optimizing electrical architecture, control strategies, and operational schedules to prolong pack lifetime and lower total cost of ownership.

Ayalasomayajula, Surya [ORNL] (ORCID:0009000860788↗