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Industrial Energy Storage Review

As the United States moves to net-zero carbon emission by 2050, a transition to renewable energy generation is required. However, the variable nature of renewable energy generation at high penetrations can cause imbalances in generation and transmission of electricity. These imbalances can be circumvented by the deployment of energy storage. Global industrial energy storage is projected to grow 2.6 times in the coming decades, from just over 60 GWh to 167 GWh in 2030. The challenge is to balance energy storage capabilities with the power and energy needs for particular industrial applications. Energy storage technologies can be classified by the form of the stored energy. The most common forms include thermal, chemical, electrochemical, and mechanical storage technologies. The most appropriate storage technology will depend on the unique energy needs of the industrial application. The purpose of this report is to provide a review of energy storage technologies relevant to the U.S. industrial sector, highlighting the applications in industry that will benefit from increased integration of energy storage, as well as the respective challenges and opportunities unique to integrating different storage technologies.

25 ENERGY STORAGE↗

Basic Energy Sciences Roundtable: Foundational Science to Accelerate Nuclear Energy Innovation

Energy security, availability, and reliability are among the greatest challenges facing the nation and the planet. An abundant potential source of energy resides in the fundamental atomic building blocks of the universe in the form of nuclear fission and fusion reactions. In fact, energy from nuclear fission currently provides the majority of the world’s zero-carbon electricity, and future fusion energy systems offer great promise; carbon-free nuclear energy technologies can be key to the world’s decarbonized energy future. Although contemporary fission systems use well-established technologies to supply safe and efficient baseload power, they could be more fuel efficient and less costly. Moving beyond massive light-water fission reactors to a variety of advanced nuclear systems—which will vary in size and operate in extremes of temperature, corrosivity, and other parameters—will place stringent conditions on materials and chemical systems. New demands will be placed on the coolants and solvents, the materials, and the monitoring tools used in these reactors. Fusion-based nuclear energy will require superior materials to withstand extremely high temperatures, plasma exposure, radiation damage, and implanted gases. The advantages associated with these new fission and fusion technologies will be realized only through continued advancements in the fundamental science underpinning our knowledge of the physics and chemistry of nuclear systems gained via improved experimental and computational methods. In July 2022, the U.S. Department of Energy’s Office of Basic Energy Sciences—in coordination with the Offices of Nuclear Energy, Fusion Energy Sciences, and Advanced Scientific Computing Research—held a virtual roundtable titled “Foundational Science to Accelerate Nuclear Energy Innovation” to discuss the scientific and technical barriers for advanced nuclear energy systems. Five priority research opportunities were identified to address these scientific and technical challenges and to accelerate progress toward the realization of next-generation fusion and fission energy systems. The foundational science gaps inhibiting the advancement of nuclear energy technologies are identified and tackled in five priority research opportunities. These opportunities pave the way to accelerate the development and ultimately the adoption of new nuclear energy systems. They include the fundamental aspects of ion-electron interactions; novel properties of next-generation coolants and solvents; interfacial dynamics, not only in solids, but in other aspects of nuclear reactors; novel operando and in situ monitoring and sensing; and artificial intelligence to accelerate condensed phases discovery. Building on the foundation established by previous Basic Energy Sciences workshops, these opportunities encompass recent advances in fundamental knowledge and focus on the experimental and computational methods needed to resolve major technical challenges for nuclear energy technologies. Through developing fundamental scientific insight as well as pushing the frontiers of modeling complex systems and probing the operation of materials and chemical systems in extreme environments, research motivated by the priorities identified here will further develop the promise, potential, and utilization of nuclear energy for a clean energy future.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Strategic Plan: Decrease Critical Minerals Waste Through Enabling Advanced Manufacturing Techniques

In this report we developed a strategic outlook derived from previous findings by our Phase-2 Scorecard Report and the Critical Mineral Evaluation Report. In addition, Phase 2 Materials Scorecards have been developed in 2022 to provide a detailed justification and traceability for the adoption of additively manufactured structural materials and ceramics for nuclear deployment. The report provides a strategic vision to harvest the benefits of reduced material and energy demands by enhanced deployment of advanced manufacturing in nuclear technology. The objective of this report is to address the needs for imminent experimental/computational studies to optimize the deployment of advanced manufacturing for its energy-, cost-, and critical materials saving potentials. We display what further actions are needed to minimize supply risks of critical minerals and to lower the economic vulnerability when implementing the additional nuclear capacity projected by 2050, in support of the U.S. goal of net-zero carbon emission. The critical minerals essential for Gen-IV nuclear technology show either low disruption potential (supply risks) combined with high economic vulnerability, such as: copper, nickel, and chromium; or low supply risks combined with medium economic vulnerability, such as: manganese, molybdenum, tungsten, vanadium, tantalum, and zirconium. Enhancements in quality and yield of critical mineral recycling and the recovery of critical minerals from solid and industrial waste streams are needed to enhance supply security for stainless-steel production and to shift the time to scarcity for society to future years.

36 MATERIALS SCIENCE↗

Development Results on Replacement Materials for Current Scarce or High Supply Chain Risk Materials

In September 2020, the U.S. government issued an executive order to address the threat to the domestic supply chain from its reliance on critical minerals (CMs) from foreign competitors and to support the domestic mining and processing industry. The Advanced Materials and Manufacturing Technology (AMMT) program is addressing this executive order by evaluating advanced manufacturing (AM) and its impact on the demands of CMs for energy production in general and how the deployment of AM in nuclear energy will support the projected goals of the Paris Accord and further a net-zero carbon economy (NZE) by 2050. Three strategic reports were previously prepared by the AMMT program to date and identified two areas for more detailed exploration: (1) the replacement of high-risk CMs such as cobalt and niobium by more abundant minerals and (2) the minimization and utilization of CM waste streams. The design of nuclear materials without critical elements as alloying elements, is a part of the nuclear materials strategy to overcome the critical minerals scarcity. In this report, two approaches are evaluated namely (1) replacement of critical elements as alloying elements in nuclear materials, and (2) the design of a new alloys that does not contain critical minerals as an alloying element.

36 MATERIALS SCIENCE↗

Investigating Kinetic Mechanisms of Soot Formation in Plasma Pyrolysis of Methane via Active Learning (Final Technical Report)

Plasma pyrolysis of methane is an effective route for zero-carbon hydrogen production. Yet, soot generated from pyrolysis of hydrocarbons is detrimental to the climate and human health. There is ample experimental and theoretical evidence that suggests polycyclic aromatic hydrocarbons (PAHs) are the molecular precursors to soot particles. The reaction pathways of PAH formation are intricately dependent on a multitude of process parameters, whose kinetic mechanisms are not well-understood in plasma pyrolysis. This project aims to leverage advances in the kinetic modeling of soot formation in combustion, as well as in surrogate modeling and active learning, to systematically investigate the effects of process parameter on the kinetics of PAH formation in plasma pyrolysis of methane. To this end, we propose to use the PAH formation kinetics model developed by the PPPL/PU group based on the well-established ABF and HACA mechanisms, coupled with low-temperature plasma models. We will develop an active learning (AL) framework based on Bayesian optimization to systematically and data-efficiently explore the complex and multivariable parameter space of plasma pyrolysis in order to quantify the effects of plasma and feed parameters on the ABF and HACA kinetic pathways. AL is the branch of machine learning concerned with systematically querying samples from a system (experimental or computational) to train a data-driven model that maps design parameters to a performance criterion. We will use the data generated via AL to perform global sensitivity analysis, combined with uncertainty quantification, to elucidate the impact of different reaction pathways on minimizing formation of soot precursors. This study will result in an improved understanding of kinetics of PAH formation in plasma pyrolysis and can pave the way for more advanced mechanistic studies (e.g., soot nucleation mechanisms). Additionally, the findings will be useful for establishing practical strategies for increasing the pyrolysis efficiency and producing high-grade carbon for synthesis of nanomaterials.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Uncertainty Quantification of Fatigue Behavior of Rough AM Surfaces and Microstructures to Enable Hydrogen Gas Turbine

Modifying fossil-fueled industrial gas turbines to utilize low or zero-carbon fuels, such as hydrogen or hydrogen-natural gas blends, is a complex endeavor. The successful implementation of this technology hinges on three key design criteria: (1) developing new fuel injectors capable of efficiently burning alternative fuels, (2) ensuring manufacturability to meet cost and time-to-market goals, and (3) achieving component durability in the demanding environment of an operating gas turbine. Additive manufacturing (AM) accelerates product development, yet concerns persist regarding the durability of parts with rough AM surfaces. A fully experimental approach to quantify the fatigue performance of rough AM microstructures is both costly and labor-intensive. To address this, ORNL and Solar Turbines Incorporated (Solar) employed a crystal plasticity finite element (CPFE) model to identify the factors influencing AM surface fatigue behavior. These CPFE findings, combined with targeted experimental data, were used to develop a computationally efficient surrogate model suitable for assessing the lifespan of gas turbine engine components.

08 HYDROGEN↗

Low-Temperature Plasma-Based Metrology of Lithium-Ion Battery Electrode Materials (CRADA Final Report)

As part of the Cyclotron Road program, SirenOpt Inc. evaluated its low-temperature plasma-based metrology sensor prototype for measuring multiple critical properties of lithium-ion battery electrode materials in parallel and in real-time. Cost-effective, minimal-waste manufacturing of high-performance battery electrode materials will be vital for achieving society’s net-zero carbon emission goals. Because existing electrode metrology sensors cannot operate within most sections of manufacturing lines, manufacturers often complete hundreds of processing steps before they can test their products and detect problems. When manufacturers perform these offline tests, they typically only test a small portion of the manufactured products. Current electrode manufacturing thus often yields many low-quality products, or off-spec products that must be thrown away all together. For example, at least 6% of the total lithium-ion battery manufacturing cost (i.e., over $250 million/year for the average gigafactory) is devoted to processing defective electrodes that are not scrapped until performance tests are failed during late-stage quality control checks. Electrode variability also leads manufacturers to build extra cells into battery packs to reduce the risk of poor performance. For example, many electric vehicle (EV) manufacturers include up to 10% more cells than needed, which substantially increases the cost and weight of the final EV product. The SirenOpt sensor can potentially enable early detection of poorly manufactured electrodes and allow them to be removed earlier from manufacturing lines, which can save battery manufacturers (hundreds of) millions of dollars per year. The sensor can further be used to improve product quality by accelerating R&D and process optimization, improving quality control, and enabling real-time process control. Overall, a real-time, in-situ metrology strategy can create unprecedented opportunities for implementation of smart manufacturing practices and advanced quality and process control solutions to realize higher battery electrode throughput and performance.

25 ENERGY STORAGE↗

Using Additives to Control the Decomposition Temperature of Sodium Borohydride

Hydrogen (H 2 ) shows great promise as zero-carbon emission fuel, but there are several challenges to overcome in regards to storage and transportation to make it a more universal energy solution. Gaseous hydrogen requires high pressures and large volume tanks while storage of liquid hydrogen requires cryogenic temperatures; neither option is ideal due to cost and the hazards involved. Storage in the solid state presents an attractive alternative, and can meet the U.S. Department of Energy (DOE) constraints to find materials containing > 7 % H 2 (gravimetric weight) with a maximum H 2 release under 125 °C. While there are many candidate hydrogen storage materials, the vast majority are metal hydrides. Of the hydrides, this review focuses solely on sodium borohydride (NaBH 4 ), which is often not covered in other hydride reviews. However, as it contains 10.6% (by weight) H 2 that can release at 133 ± 3 JK -1 mol -1 , this inexpensive material has received renewed attention. NaBH 4 should decompose to H 2 (g), Na(s), and B(s), and could be recycled into its original form. Unfortunately, metal to ligand charge transfer in NaBH 4 induces high thermodynamic stability, creating a high decomposition temperature of 530 °C. In an effort make H 2 more accessible at lower temperatures, researchers have incorporated additives to destabilize the structure. This review highlights metal additives that have successfully reduced the decomposition temperature of NaBH 4 , with temperatures ranging from 522 °C (titanium (IV) fluoride) to 379 °C (niobium (V) fluoride). We describe synthetic methods employed, chemical pathways taken, and the challenges of boron derivative formation on H 2 cycling. Though no trends can be found across all additives, it is our hope that compiling the data here will enable researchers to gain a better understanding of the additives’ influence and to determine how a new system might be designed to make NaBH 4 a more viable H 2 fuel source.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Design and Operation of Energy Systems with Large Amounts of Variable Generation: IEA Wind TCP Task 25 (Final Summary Report)

This report summarizes findings on wind integration from the 17 countries or sponsors participating in the International Energy Agency Wind Technology Collaboration Program (IEA Wind TCP) Task 25 from 2006-2020. Both real experience and studies are reported. Many wind integration studies incorporate solar energy, and most of the results discussed here are valid for other variable renewables in addition to wind. The national case studies address several impacts of wind power on electric power systems. In this report, they are grouped under long-term planning issues and short-term operational impacts. Long-term planning issues include grid planning and capacity adequacy. Short-term operational impacts include reliability, stability, reserves, and maximizing the value of wind in operational timescales (balancing related issues). The first section presents the variability and uncertainty of power system-wide wind power, and the last section presents recent studies toward 100% shares of renewables. The appendix provides a summary of ongoing research in the national projects contributing to Task 25 for 2021-2024. The design and operation of power and energy systems is an evolving field. As ambitious targets toward net-zero carbon energy systems are announced globally, many scenarios are being made regarding how to reach these future decarbonized energy systems, most of them involving large amounts of variable renewables, mainly wind and solar energy. The secure operation of power systems is increasingly challenging, and the impacts of variable renewables, new electrification loads together with increased distribution system resources will lead to somewhat different challenges for different systems. Tools and methods to study future power and energy systems also need to evolve, and both short-term operational aspects (such as power system stability) and long-term aspects (such as resource adequacy) will probably see new paradigms of operation and design. The experience of operating and planning systems with large amounts of variable generation is accumulating, and research to tackle the challenges of inverter-based, nonsynchronous generation is on the way. Energy transition and digitalization also bring new flexibility opportunities, both short and long term.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Environmental life-cycle analysis of hydrogen technology pathways in the United States

Hydrogen is a zero-carbon energy carrier with potential to decarbonize industrial and transportation sectors, but its life-cycle greenhouse gas (GHG) emissions depend on its energy supply chain and carbon management measures (e.g., carbon capture and storage). Global support for clean hydrogen production and use has recently intensified. In the United States, Congress passed several laws that incentivize the production and use of renewable and low-carbon hydrogen, such as the Bipartisan Infrastructure Law (BIL) in 2021 and the Inflation Reduction Act (IRA) in 2022, which provides tax credits of up to $3/kg depending on the carbon intensity of the produced hydrogen. A comprehensive life-cycle accounting of GHG emissions associated with hydrogen production is needed to determine the carbon intensity of hydrogen throughout its value chain. In the United States, Argonne’s R&D GREET ® (Greenhouse Gases, Regulated emissions, and Energy use in Technologies) model has been widely used for hydrogen carbon intensity calculations. This paper describes the major hydrogen technology pathways considered in the United States and provides data sources and carbon intensity results for each of the hydrogen production and delivery pathways using consistent system boundaries and most recent technology performance and supply chain data.

Elgowainy, Amgad↗

Underground Hydrogen Storage: Transforming Subsurface Science into Sustainable Energy Solutions

As the global economy moves toward net-zero carbon emissions, large-scale energy storage becomes essential to tackle the seasonal nature of renewable sources. Underground hydrogen storage (UHS) offers a feasible solution by allowing surplus renewable energy to be transformed into hydrogen and stored in deep geological formations such as aquifers, salt caverns, or depleted reservoirs, making it available for use on demand. This study thoroughly evaluates UHS concepts, procedures, and challenges. This paper analyzes the most recent breakthroughs in UHS technology and identifies special conditions needed for its successful application, including site selection guidelines, technical and geological factors, and the significance of storage characteristics. The integrity of wells and caprock, which is important for safe and efficient storage, can be affected by the operating dynamics of the hydrogen cycle, notably the fluctuations in pressure and stress within storage formations. To evaluate its potential for broader adoption, we also examined economic elements such as cost-effectiveness and the technical practicality of large-scale storage. We also reviewed current UHS efforts and identified key knowledge gaps, primarily in the areas of hydrogen–rock interactions, geochemistry, gas migration control, microbial activities, and geomechanical stability. Resolving these technological challenges, regulatory frameworks, and environmental sustainability are essential to UHS’s long-term and extensive integration into the energy industry. This article provides a roadmap for UHS research and development, emphasizing the need for further research to fully realize the technology’s promise as a pillar of the hydrogen economy.

25 ENERGY STORAGE↗

Design of a SMART Valve Testbed for Nuclear Thermal Dispatch

By the year 2050, the United States aims to achieve net-zero carbon emissions. To achieve this target, the licensing of the Light Water Reactor (LWR) fleet has been extended for 20 more years. To stay economically competitive with other power sources such as renewable and fossil-fuel power plants, the U.S. Department of Energy has introduced a plan to modernize the existing LWR fleet and diversify the revenue stream. One of the plans is to dispatch thermal energy to endothermic industrial processes. SMART valves will play an important role in this initiative by efficiently balancing the load by regulating valves in a coordinated manner while monitoring the thermal-hydraulic systems to enhance safety and maintain the integrity of the power plant. This research aims to develop a facility to test the coordinated control algorithm and produce various test results for training the monitoring system. The constructed facility is capable of simulating various operational and accidental scenarios by coordinating all the valves (positions) and pump (flowrate). The facility is developed with an Internet of Things (IoT)-based custom system and a python-based valve position control and coordination mechanism. It has achieved stable sensor outputs, pump control, and coordinated valve regulation in all three valves with minimum obstruction in the system.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

Impact of Materials Properties on Higher-Temperature Engine Operation

Here, we examine the effects on materials temperatures and engine efficiency via simulations of engines operating at temperatures which exceed the thermal limits of today’s materials. Potential focus areas include high-speed, high-load operation (in the fuel-enrichment zone) as well as conditions of selective cooling at lower speeds and loads. We focus on a light-duty DISI and a heavy-duty CI engine using GT-Power. Temperature distributions within the head, block, piston, and valves were obtained from 3D FEA simulations coupled with 1D GT-Power representations of the engine’s gas flow and combustion regions. We use experimentally measured thermal properties of current commercial alloys for specific engine components, as well as candidate developmental alloys with improved temperature tolerance, to gauge the effects of materials properties on engine performance, particularly focusing on operating areas where materials which can withstand higher temperatures can enable intensified combustion conditions and increased specific output. The outcome of this work is guidance on materials selection targets and benefits as OEMs meet engine-performance needs in the coming decades, to include Class 8 line-haul freight vehicles with reduced emissions, as well as design of future near net zero-carbon light-duty range extenders for more rapid electrification of medium- and heavy-duty vehicles.

36 MATERIALS SCIENCE↗

Beneficial CHP – Is that a Thing? Considering CHP in the Context of Beneficial Electrification

For decades, combined heat and power (CHP) has been promoted and embraced as a cost-effective technology for meeting on-site thermal and electric needs more efficiently and with fewer emissions than separate procurement of those resources. But climate change concerns are leading to a reevaluation of CHP’s benefits. Significantly, natural gas, the most common fuel for CHP and until recently regarded as an environmentally preferable “bridge fuel” in the energy transition to renewables, is increasingly being reexamined amid calls for deep decarbonization and emerging clean energy policies that limit the use of natural gas. Given this trend, electrification has gained traction as a net zero carbon energy strategy. With natural gas being a preferred fuel for CHP, policymakers and others are beginning to question CHP’s role in a cleaner, more electrified future. However, CHP fueled by low carbon fuels such as renewable natural gas and hydrogen may be a more viable path to decarbonizing industrial processes that are difficult to electrify due to technology limitations or cost, and for applications where energy resilience is a critical requirement. This paper seeks to add clarity to a complex issue. It offers a framework for assessing industrial applications where natural gas CHP will provide significant GHG reductions in the near term and provide a more economic and practical path to deep decarbonization in the long term through a transition to low carbon fuels.

Hedman, Bruce↗

Transforming Energy Through Computational Excellence: High-Performance Computing for Energy Innovation

The challenges associated with energy efficiency of manufacturing and advanced materials often cannot be addressed through experimentation alone, whether because of scale, complexity, or practicality. High-performance computing (HPC) enables fast tackling of these challenges in the manufacturing sector - vital to achieving net-zero carbon emissions by 2050. The National Renewable Energy Laboratory (NREL) and industry partners leverage HPC to apply advanced modeling, simulation, and data analysis to improve manufacturing efficiency, explore new materials for energy applications, and develop technologies to manage carbon across the life cycle. From improving additive manufacturing processes to increasing the energy efficiency of jet-engine components, advanced computing can help manage emissions produced by manufacturing in a wide variety of ways.

advanced materials↗

The Lab-Embedded Entrepreneurship Program (LEEP)

Addressing climate change, sustainability, and social justice cannot be based solely on deployment of existing technologies. New innovations, derived from massive U.S. investments in basic and applied energy research at universities and the national labs, are critically needed to achieve net-zero carbon missions by 2050.

LEEP, Chain Reaction Innovations, Innovation Cross↗

Analyzing Foreign and Domestic Policy to Determine a Pathway to Achieving the US' NDC with a Focus on Advanced Reactors and Hydrogen

The United states in 2021 released a nationally determined contribution indicating goals to reach 50-52% reduction in CO2 emissions by 2030 compared with 2005 and to achieve zero carbon electricity by 2035. Current policy does not put us on course to achieve these goals, so we investigated policies that could form a pathway to achieve these goals in the US. We focused on the use of advanced nuclear reactors and hydrogen, but analyzed all relevant sectors to achieve our goals. This report also focuses on analyzing existing foreign policies and determining the most effective policies in each sectors. By combining the most effective policies from around the world in each sector, we find that we can set policies that form a pathway that is ambitious enough to meet the NDC goals.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Life Cycle Assessment for Closed-Loop Pumped Hydropower Energy Storage in the United States

The federal government has initiated an aggressive set of policies to achieve a net-zero carbon emission goal for the electricity sector by 2050. As a result, rapid growth in deployment of renewable energy technologies is expected. Most commercially mature technologies are temporally variable and do not provide grid inertia, while renewable technologies with high projected deployment have intermittent generation methods. Energy storage technologies are needed to both dispatch power on-demand and help provide the needed grid inertia. Pumped storage hydro (PSH) is a well-established technology that has gained renewed interest in recent years offering energy-balancing, grid stability, control of electrical network frequency, and large-scale storage capacity. For widespread adoption of PSH, more information is needed regarding its current life cycle environmental impacts. The objective of this study is to perform a full life cycle assessment (LCA) of new closed-loop PSH in the U.S. The functional unit for this study is 1 kWh of electrical power delivered to the grid and the base case project lifetime is 80 years. The life cycle inventory for this project accounts for all material and energy flows associated with the green-field construction, operation, maintenance, and decommissioning of a closed-loop PSH plant in the U.S. Collected data represents a range of potential PSH specifications and geographic locations coming from all prospective closed-loop PSH installations in the U.S. with data available. In addition, existing PSH installations are used to provide assumptions for inventory inputs. Results presented will include the global warming potential (GWP IPCC 100a) and Energy Return on Investment (EROI) from our base case (average PSH installation) as well as from scenario analyses and model sensitivity. These results will be compared to the impacts from existing PSH sites and alternate storage technologies. Methods align with the assumptions and guidelines put in place by previous PSH LCAs to ensure an accurate comparison with the results from this report.

ENERGY PLANNING, POLICY, AND ECONOMY,HYDRO ENERGY↗