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All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Organizational Influence on Supply Chain for Digital Energy Infrastructure: Business Models, and Policy Landscape

Significant investment is driving the essential modernization and digitization of U.S. energy infrastructure, but the United States faces a key challenge in this grid transformation: our renewable and clean energy supply chains have limited capacity to source necessary digital assets through U.S. or allied sources. Batteries and their associated power electronic interfaces are key components to delivering clean and more resilient energy delivery, providing much-needed fast ramping, emergency discharge, generation, and operations support to the electric grid. These services have grown to be invaluable over the past 10 years and will soon be an irreplaceable component of energy delivery. While there have been significant strides to move supply chains for raw and critical materials to U.S. and allied nations, the control and power electronic industry has lagged, in part because of lower cost margins. For example, the United States now has growing capacity to manufacture solar photovoltaic (PV) panels, but 90% of the inverters—which are essential to the conversion of DC to AC for grid connection and controls—are made in or source parts from the People’s Republic of China (PRC). While a global supply chain is beneficial for many economic and supply diversification reasons, presence of foreign entities of concern (FEOC) in a dominant role in this supply chain brings additional concerns for national security of infrastructure. The BESS relationship and new clean energy have features that warrant discussions and additional focus on impact for technology security, given their critical role. This review considers the impact and solutions for complex business and policy landscapes in clean energy supply chain, and the benefit trade-offs, focusing on the Battery Energy Storage System case study, and its complex organizational relationships across both the US, Allied countries and Foreign Entities of Concern. While many examples in this paper are presented on PRC focused manufacture, this could apply to any potentially adversarial relationship

25 - ENERGY STORAGE↗
DOE OSTI2022

A Technical-Economic Assessment of Brackish Water Treatment for Fossil Power Plant Cooling with Reduced Environmental Impact

The power sector accounts for approximately 40% of freshwater use in the U.S. Reusing non-traditional water resources is critical for alleviating water stress in the western United States. The purpose of this study is to conduct a techno-economic system analysis to evaluate the potential of brackish water treatment for wet cooling towers at existing thermo-electric generating units (EGUs). It aims to address current knowledge gaps in support of non-traditional water resources planning and the electric power industry's water decision- and policy making. An engineering-economic model was developed and combined with DuPont's water application value engine (WAVE) v1.82 to evaluate the viability of retrofitting reverse osmosis-based brackish water treatment systems to individual existing EGUs and then aggregating the unit-level results to the fleet level. In the base case, brackish water treatment can reduce freshwater consumption of electric generation units by 94–100% while increasing the cost of electric generation by approximately 10% and have marginal impacts on the units' parasitic loads. When zero liquid discharge systems are applied to brackish water brine treatment, the cost of electric generation and freshwater consumption savings and energy penalty to the power plant significantly increase. These costs are even higher than dry cooling deployment in lieu of wet cooling towers. The choice of freshwater savings between brackish water desalination and dry cooling deployment depends greatly on how the concentrated brines are managed. Multiple factors must be considered when supporting decision-making in water management and planning in power sectors, which include non-traditional water quantity and quality as well as trade-offs among technical performance, economics, and environmental impacts.

Wu, Zitao↗
DOE OSTI2021

Medium Voltage Converter Inductor Insulation Design Considering Grid Requirements

Medium voltage (MV) SiC devices facilitate direct (without 50-/60-Hz transformer) connection of the power electronics converter to the MV grid using simple topology. Compared to the insulation design of MV inductors that have been widely used in the power system, the insulation design of the MV converter filter inductors has new challenges. Particularly, the grid impact on insulation requirements on converter filter inductors is rarely discussed. This article introduces the insulation design of a grid-side filter inductor for a 13.8-kV power conditioning system converter. The grid insulation requirements, including the short-duration power frequency overvoltage and the lightning impulse voltage, are considered in the design. To meet the requirements, the layer-to-layer insulation, winding-to-core/ground insulation, the air gap discharge between the winding and the core, the local electric field, as well as the interturn transient voltage distribution are considered. Furthermore, the designed inductors are validated by the 46 kV (>1 min) dc hi-pot test, 12-kV ac partial discharge test, one-hour single-phase converter full rating test, as well as three-phase converter full rating test.

42 ENGINEERING↗
DOE OSTI2023

Prediction of Breakdown in Air and Solid Dielectrics: A Complete Plasma Model from Discharge Initiation to Flashover (Final Technical Report)

A major challenge for most of the technologies of today, and the technologies of the future, is the compact and reliable design of electrical insulation systems for their electrical components. Although controlled low-temperature plasmas (LTPs) or non-thermal plasmas in air at atmospheric pressure are of interest for a wide range of technologies, the appearance of such discharges is considered highly undesirable in insulation systems because they are precursors of a breakdown or flashover, where complete insulation failure takes place. For non-thermal plasmas, often only one mechanism, or the transition from one discharge mechanism to another, has typically been studied to date. On the other hand, in the case of thermal plasma applications, the conditions following the occurrence of an electric arc or flashover have always been considered. Here, there is a big technical gap: there is no paper describing a complete plasma model simulating all discharge mechanisms and their transitions from discharge initiation to electrical arc and flashover. To address this gap, a complete plasma model for both thermal and non-thermal plasmas should be developed using a hydrodynamic approach. The project aimed to build the model. The work has the potential to address industrial applications and is of great importance to higher voltage systems.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

Geophysical Characterization and Monitoring of the 200 Area Treated Effluent Disposal Facility to Support Permit Renewal; TEDF Geophysical Monitoring

The Treated Effluent Disposal Facility (TEDF), located in the 200 East Area of the Hanford Site, is a site where non-hazardous and non-radioactive liquid wastes are disposed into two state-permitted infiltration basins. In 2016, the Washington State Department of Ecology denied a permit renewal request for TEDF due to the inability to adequately assess the impact of TEDF discharge water on the underlying groundwater quality. TEDF overlies the relatively impermeable Ringold Lower Mud (RLM) unit, whose upper contact lies in the vadose zone approximately 30 m below ground surface and approximately 10 m above the water table boundary. The RLM is assumed to isolate TEDF discharge water from the natural groundwater aquifer, which is monitored using wellbores screened below the RLM. Therefore, samples collected from monitoring wells near TEDF are not considered representative of TEDF discharge water. Rather, TEDF discharge water is assumed to mound on top of the RLM to form a perched aquifer. To support permitting of the TEDF, a new monitoring well is required that can be used to sample water from the presumed perched water aquifer above the RLM. Ideally, the screened section of the well would be located at the peak of the perched water mound(s), which presumably occurs at the point of maximum vertical flux from TEDF to the RLM, or equivalently where the dominant infiltration flow paths reach the RLM. This report describes how time-lapse 3D electrical resistivity tomography (ERT) was used in conjunction with nominal TEDF discharge operations to image the dominant flow paths from each pond to the RLM. Results are summarized in Figure ES.1. Figure ES.1A shows a satellite image of the TEDF overlain by an array of surface ERT electrodes. The solid and dashed black circles denote the zones of maximum vertical flux at the RLM within the south and north ponds, respectively, and presumably the regions where perched water peaks during discharge. Figure ES.1B shows time-lapse difference imaging results approximately 15 days after switching discharge from the south pond to the north pond. Blue iso-surfaces beneath the north pond denote regions of increasing bulk electrical conductivity caused by increasing saturation due to infiltrating water. Red iso-surfaces beneath the south pond denote regions that were previously saturated during the south pond discharge and are now de-saturating, causing a decrease in bulk electrical conductivity. In both cases, the zones of maximum change mark the dominant flow paths to the RLM. Figure ES.1C shows time-lapse imaging results approximately 15 days after switching discharge from the north pond to the south pond. In this case, blue iso-surfaces mark the dominant flow paths to the RLM from the south pond. The red iso-surfaces mark the dominant flow paths that existed during discharge to the north pond. The regions of maximum change in bulk conductivity (due to saturation or desaturation) that mark the primary flow paths are equivalent in both cases and denoted by the dashed solid and black circles. If a perched water zone forms on the RLM, it is likely to mound within or near the dashed circle during discharge to the north pond, and in the solid circle during discharge to the south pond. In other words, if perched water mounding occurs, the circles mark the optimum locations suggested by the ERT imaging for monitoring boreholes to be placed, enabling samples to be collected that are representative of TEDF discharge impacts on groundwater quality.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2022

Design of Phase-Change Thermal Storage Device in a Heat Pump for Building Electric Peak Load Shaving: Preprint

Replacing carbon-intensive fossil fuel heating systems with electric heat pumps powered by renewables is a promising approach to decarbonize the building sector. However, one of the technical barriers of this approach is the large scale of heat demand, which will put excessive stress on the electricity grid. Integrating thermal energy storage (TES) into the heating systems can help alleviate this problem, by shifting thermal load and thus shaving peaks in the building electric load. Therefore, it is critical to understand how to design a thermal storage device in a heat pump for peak load shaving. In this study, we developed a numerical model for a cascaded vapor compression heat pump system integrating a phase change thermal storage device. This novel system can control the net thermal charging and discharging rate of the TES independently from the building's thermal load, which allows for precise control of electric power use. In the current study, we controlled the system to shave building electric peak load during a cold winter morning, and to charge TES during the relatively warm afternoon while still providing space heating. We used the model to evaluate the system performance with and without peak shaving. We also investigated the effect of PCM transition Tt on the peak reduction and electric energy saving potentials. The results show that peak shaving scheme effectively reduces the peak electric power consumption during a predefined discharge time window. When comparing to the no shaving case, for PCM Tt = 10 degrees C, the peak electric load reduction is 23.5%. When comparing to an air-source heat pump with back up electric heater, as Tt increases from 0 to 20 degrees C, the peak reduction increases from 46.1% to 50.9%. Integrating PCM Tt = 10 degrees C with peak shaving leads to the 45.5% of electric energy saving, which is the highest among the three transition temperatures.

electric energy saving↗
DOE OSTI2022

Single‐Crystal LiNi x Mn y Co 1− x − y O 2 Cathodes for Extreme Fast Charging

Abstract Ni‐rich layered LiNi x Mn y Co 1− x − y O 2 (NMCs, x ≥ 0.8) are poised to be the dominating cathode materials for lithium‐ion batteries for the foreseeable future. Conventional polycrystalline NMCs, however, suffer from severe cracking along the grain boundaries of primary particles and capacity loss under high charge and/or discharge rates, hindering their implementation in fast‐charging electric vehicular (EV) batteries. Single‐crystal (SC) NMCs are attractive alternatives as they eliminate intergranular cracking and allow for grain‐level surface optimization for fast Li transport. In the present study, the authors report synthetic approaches to produce SC LiNi 0.8 Co 0.1 Mn 0.1 O 2 (NMC811) samples with different morphologies: Oct‐SC811 with predominating (012)‐family surface and Poly‐SC811 with predominating (104)‐family surface. Poly‐SC811, representing the first experimentally synthesized NMC811 single crystals with (104) surface, delivers superior performance even at the ultra‐high rate of 6 C. Through detailed X‐ray analysis and electron microscopy characterization, it is shown that the enhanced performance originates from better chemical and structural stabilities, faster Li + diffusion kinetics, suppressed side reactions with electrolyte, and excellent cracking resistance. These insights provide important design guidelines in the future development of fast‐charging NMC‐type cathode materials.

Lu, Yanying↗
DOE OSTI2024

Interpretation of large‐scale, long‐term electrical geophysical monitoring guided by a process simulation

Abstract Surface electrical resistivity tomography (ERT) was used at a waste site to monitor vadose zone changes in electrical properties as a proxy for contaminant flux over a span of 17 years. The BC Cribs and Trenches (BCCT) site at the Hanford site contains 20 disposal trenches and six disposal cribs. Wastes include a large inventory of technetium‐99 and large masses of nitrate and uranium‐238. ERT data were collected along 41 profiles in 2005 to characterize regions of elevated bulk electrical conductivity (BEC) associated with past liquid waste discharges. Previous analyses performed on samples from four boreholes showed a high correlation between nitrate concentration and BEC. In 2022, ERT data were re‐collected along the same profiles and six additional profiles in an area not previously surveyed. Compared to background uncontaminated areas, BEC was higher in contaminated areas at the waste sites. Given the correlation between nitrate concentration and BEC previously found at this site, ERT images show the spatial distribution and relative ionic concentration of vadose zone contaminants at BCCT. Between 2005 and 2022, ERT difference images showed a decrease in BEC surrounding most waste sites, with exceptions where there were known anthropogenic surface changes. An evaluation of recharge‐driven nitrate migration using synthetic flow and transport simulations showed that downward migration causes a decrease in BEC from the decrease in ionic strength at the trailing end of the plume where contaminants migrated downward. From this, we interpret ERT difference images as showing the predominant regions of downward ion flux.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2022

A nuclear-hydrogen hybrid energy system with large-scale storage: A study in optimal dispatch and economic performance in a real-world market

Here a study in optimal dispatch and economic analysis of a novel nuclear hybrid energy system (NHES) with large-scale hydrogen storage and a novel control scheme is conducted. The control scheme makes charge and discharge decisions by using the real-time electricity price relative to the historical price distribution. The pricing data is taken from the ERCOT Houston and West load zones with different price oscillations. Six case control studies with different levels of aggressiveness were chosen for each load zone for a total of 12 case studies. It is found that in a high price volatility load zone, a more aggressive control strategy maximizes revenue, while in a less oscillatory load zone, a moderate control strategy performs better. The NHES can store energy when the price is low and sell additional electricity when the price is high, as well as participate in the ancillary services market. Due to these advantages, the NHES can generate 10–40 million USD more revenue annually than a stand-alone nuclear plant. Due to higher costs, the NHES has a higher LCOE (81.36 USD/MWh) than a stand-alone plant (68.66 USD/MWh); however, the LCOE of the NHES is still comparable to other new forms of electricity generation. It is found that both the NHES and the stand-alone plant are not economical in the existing electricity market. Due to the extra revenue generated, the hybrid system has a positive annual cashflow whereas the stand-alone plant does not. It is found that the hybrid plant needs less cost subsidy than a stand-alone plant to become economical.

08 HYDROGEN↗
DOE OSTI2021

Effect of ionization waves on dust chain formation in a DC discharge

An interesting aspect of complex plasma is its ability to self-organize into a variety of structural configurations and undergo transitions between these states. A striking phenomenon is the isotropic-to-string transition observed in electrorheological complex plasma under the influence of a symmetric ion wake field. Such transitions have been investigated using the Plasma Kristall-4 (PK-4) microgravity laboratory on the International Space Station. Recent experiments and numerical simulations have shown that, under PK-4-relevant discharge conditions, the seemingly homogeneous direct current discharge column is highly inhomogeneous, with large axial electric field oscillations associated with ionization waves occurring on microsecond time scales. here, a multi-scale numerical model of the dust–plasma interactions is employed to investigate the role of the electric field in the charge of individual dust grains, the ion wake field and the order of string-like structures. Results are compared with those for dust strings formed in similar conditions in the PK-4 experiment.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

Hardware Design of Medium Voltage SiC-Based Modular Multilevel Converters for Grid-Tied Applications

This paper presents a design of a 10 kV silicon carbide (SiC) MOSFET based modular multilevel converter (MMC). The MMC functions as the interconnection between a 24 kV dc bus and a 13. SkV distribution grid. This paper focuses on the hardware design of the MMC and its submodules. The gate driver, auxiliary power supply and bus bur in submodules are major components that need to meet high dv/dt immunity and high insulation voltage requirements. The gate driver achieves over 200 kV/us common mode transient immunity (CMTI). Its associated auxiliary power supply is based on an on-board transformer with over 30 kV insulation capability and 1.4 pF barrier capacitance. The busbar achieves less than 11 kV/cm electric field in the air to avoid partial discharges. Validation tests of the MMC submodule were performed by double pulse tests at 5 kV and buck converter tests at3 kV, 52A (peak). Reliable operations were achieved in validation tests.

auxiliary power supply↗
DOE OSTI2021

Plasma generation by household microwave oven for surface modification and other emerging applications

A simple and inexpensive method to generate plasma using a kitchen microwave oven is described in this paper. The microwave-generated plasma is characterized by spectroscopic analysis and compared with the absorption spectra of a gas discharge tube. A Paschen-like curve is observed as the microwave plasma initiation time is plotted as a function of the pressure of the plasma chamber. We have also demonstrated that this microwave-generated air plasma can be used in a multitude of applications such as: (a) surface modification of a substrate to change its wettability; (b) surface modification to change electrical/optical properties of a substrate; and (c) enhancement of adhesive forces for improved bonding of polymeric microfluidic molds, such as bonding polydimethylsiloxane (PDMS) chips to glass covers. These simple techniques of plasma generation and subsequent surface treatment and modification applications may bring new opportunities leading to new innovations not only in advanced labs, but also in undergraduate and even high school research labs.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Modeling Losses in a Three Electrode System Towards Fast Charge Control

In this work we demonstrate the applicability of a versatile separator-reference mounted electrode in a three-electrode setup to accurately capture the primary current pathway in the battery cell during operation, calibrate a porous electrode model to the individual anode and cathode potential signals, and assign the various resistances to electrochemical phenomena in the battery cell. This calibrated electrochemical model is validated using continuous rate discharges associated with highway driving scenarios in an electric vehicle, and in turn utilized to predict the local anode potential and proximity to lithium plating onset. Finally, we demonstrate the strategy associated with utilization of the model to estimate constant anode potential charging during fast charge scenarios at various rates and starting conditions as a future look to fast charge calibration development and controls.

Garrick, Taylor R. (ORCID:0000000322518129)↗
DOE OSTI2022

Effects of inter-pulse coupling on nanosecond pulsed high frequency discharge ignition in a flowing mixture

This work numerically investigates the effects of non-equilibrium nanosecond plasma discharge pulse rep- etition frequency, pulse number, and flow velocity on the critical ignition volume, minimum ignition energy, and chemistry in a plasma-assisted H 2 /air flow at 300 K and 1 atm using a multi-scale adaptive reduced chemistry solver for plasma assisted combustion (MARCS-PAC). The interactions between discharges/ignition kernels spanning decoupled, partially-coupled and fully-coupled regimes in a pulse train are studied. For a single pulse discharge, increased flow velocity increases the minimum ignition energy required due to the increase of convective heat loss and flame stretch. The results show that the minimum ignition kernel prop- agation speed at the critical ignition kernel volume increases with the flow velocity. The minimum critical ignition volume decreases with the increase of plasma discharge energy. For sequential two-pulse discharges, ignition fails at both decoupled and partially-coupled regimes even when the total discharge energy is above the minimum ignition energy, but succeeds only in the fully-coupled regime at a shorter inter-pulse time. Overlap of the OH radical pool between the sequential two-pulse discharges and the increase of the chemistry effect due to the increase of reduced electric field in the fully-coupled regime contribute to the ignition enhancement. In addition, for two-pulse discharges in the fully-coupled discharge regime, the mixture can be ignited at a total energy below the minimum ignition energy of a single pulse with the same flow conditions. Moreover, for a given total discharge energy with multiple pulsed discharges, the enhancement of the ignition kernel volume has a non-monotonic dependence on discharge frequency and pulse number. The effective ignition enhancement can be achieved with an optimal pulse repetition frequency and pulse number. Furthermore, this work provides a new understanding of the mechanism for repetitive plasma ignition and insights for the optimization of plasma ignition in a reactive flow.

42 ENGINEERING↗
DOE OSTI2023

Unintended gas breakdowns in narrow gaps of advanced plasma sources for semiconductor fabrication industry

Occurrence of unintended gas breakdown in the narrow gaps of plasma processing chambers is one of the critical challenges in developing advanced plasma sources. Here, we present a combined experimental and theoretical study of unintended discharges in the narrow gaps of plasma processing chambers and report significant drop of the gas breakdown voltage in the presence of a background plasma facing the gap. Experimentally measured breakdown voltages decrease in subsequent breakdown events due to wall erosion caused by the discharge. Therefore, preventing and mitigating the first discharge is of paramount importance. An analysis of kinetic simulation results indicates that the charged particle influx from the background plasma in the processing chamber into the gap is responsible for the onset of early breakdown: higher charged particle density within the gap modifies the electric field profile, allowing unintended breakdowns to occur at a significantly reduced threshold voltage.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

Improvements to the High-Field-Side Transient CHI System on QUEST

Transient coaxial helicity injection (CHI) is a promising candidate for solenoid-free plasma current start-up in a low-aspect-ratio tokamak in support of developing fully non-inductive scenarios. The aim of the transient CHI research on QUEST is to develop a reactor-relevant CHI design. On QUEST, a CHI discharge is initiated by driving current along magnetic field lines that connect an electrically insulated electrode plate (which is referred to as a bias electrode) to a vessel component at the bottom region of the spherical tokamak. In the first application of CHI on QUEST, the electrically insulated electrode plate was biased with respect to the outer vessel in a configuration referred to as low-field-side (LFS) injection. To maintain a narrow injector flux footprint width throughout the discharge, QUEST is now developing a high-field-side (HFS) injection configuration, in which the electrically insulated electrode plate is biased with respect to the inner vessel components. Through the implementation of a CHI-dedicated gas injection system, studies in the HFS injection configuration have now demonstrated good magnetic flux evolution into the vacuum vessel. Toroidal currents up to 43 kA have been achieved, and the generated current has increased in proportion to the magnetic flux connecting the electrodes. Finally, these results which show agreement with the CHI-scaling suggest that much higher levels of toroidal current can be generated on QUEST in an optimized CHI system in which the magnetic flux connecting the CHI electrodes is further increased.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Modeling Structured Electrodes and Graded Porosity for Improving Discharge Rate Capability in Ultra-Thick Graphite|LiNi 0.6 Mn 0.2 Co 0.2 O 2 Batteries

Long-range electric vehicles (EVs) require high-energy-density batteries that also meet the power demands of high current charge and discharge. Ultra-thick (>100 μm) Lithium-ion battery electrodes are critical to enable this need, but slow ion transport in conventional uniform electrodes (UEs) reduces battery capacity at increasing charge/discharge rates. We present a 3D computational analysis on the impact of structured electrode (SE) and graded electrode (GE) geometries on the discharge rate capability of ultra-thick graphite|LiNi 0.6 Mn 0.2 Co 0.2 O 2 (NMC-622) battery cells based on the footprint of a commercial EV pouch cell. SE cathodes with either a “grid” or “line” geometry and GEs with two layers of porosity were modeled. Based on the results of 230 models, we found that the electrolyte volume fraction is a key parameter that impacts capacity improvements in UEs, GEs, and SEs at 2 C–6 C discharge rates. SEs have the greatest discharge rate capability, outperforming GEs and UEs due to reduced Lithium-ion concentration gradients across the electrode thickness, which mitigates electrolyte depletion at high rates. The best SE model has a “grid” geometry with gravimetric and volumetric energy density improvements of 0.9%–4% at C/2–2 C and 18%–24% at 4 C–6 C relative to UEs.

25 ENERGY STORAGE↗
DOE OSTI2021

Designing the Insulation System for Motors in Electrified Aircraft: Optimization, Partial Discharge Issues and Use of Advanced Materials

Designing the insulation system for motors to be used in electrical aircraft requires efforts for maximizing specific power, but, in parallel, particular attention to achieve high reliability. As a major harm for organic insulation systems is partial discharges, design must be able to infer their likelihood during any operation stage and handle their potential inception. This paper proposes a new approach to carry out optimized or conservative insulation system designs which can provide the specified life at the chosen failure probability as well as look at the option of possibly reducing the risk of partial discharges to zero, at any altitude. Examples of designing turn, phase to ground and phase-to-phase insulation systems are reported, with cases where the design can be optimized and other cases where the optimized design does not pass IEC testing standard. Therefore, the limits for design feasibility as a function of the required level of safety and reliability are discussed, showing that the presence of partial discharges cannot be always avoided even through conservative design criteria. Therefore, the use of advanced, corona-resistant materials must be considered, in order to reach a higher, sometimes redundant, level of reliability.

Ramin, Robin (ORCID:0000000211455006)↗