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All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Total Recycling of Copper Cable Scrap and Production of Carbon Using Fast Microwave Technology

The recycling of cable scrap, particularly from discarded electrical wiring, is gaining significant attention due to the rising demand for copper and the need for sustainable management of electronic waste. Traditionally, mechanical and thermal processings have been used to recover copper and plastic from cables. However, these approaches are often energy-intensive, time-consuming, and costly in terms of equipment and labor. In this study, we present a simple and effective method for recovering materials from cable scrap using a domestic microwave oven. Cable pieces (2–2.5 cm long) were exposed to 700 W of microwave irradiation under rotation for 30 s, enabling the rapid and efficient separation of high-quality copper metal from the core wire, and activated carbon from the carbonized plastic sheath. Microwaves facilitate this process through Ohmic heating, which induces electrical resistance in the metal, generating heat that mechanically loosens the metal and carbonized plastic components. The process demonstrates high efficiency, achieving an 80% reduction in energy consumption compared to conventional processings. This fast and energy-efficient method shows strong potential for scaling up to industrial recycling, offering a cost-effective and environmentally friendly way to recover high-quality materials for further use or repurposing.

Bourlinos, Athanasios B. (ORCID:0000000256165993)↗
DOE OSTI2022

Advanced Pt-Based Core–Shell Electrocatalysts for Fuel Cell Cathodes

Proton-exchange membrane fuel cells (PEMFCs) are highly efficient energy storage and conversion devices. Thus, the platinum group metal (PGM)-based catalysts which are the dominant choice for the PEMFCs have received extensive interest during the past couple of decades. However, the drawbacks in the existing PGM-based catalysts (i.e., high cost, slow kinetics, poor stability, etc.) still limit their applications in fuel cells. The Pt-based core–shell catalysts potentially alleviate these issues through the low Pt loading with the associated low cost and the high corrosion resistance and further improve the oxygen reduction reaction’s (ORR’s) activity and stability. This Account focuses on the synthetic strategies, catalytic mechanisms, factors influencing enhanced ORR performance, and applications in PEMFCs for the Pt-based core–shell catalysts. We first highlight the synthetic strategies for Pt-based core–shell catalysts including the galvanic displacement of an underpotentially deposited non-noble metal monolayer, thermal annealing, and dealloying methods, which can be scaled-up to meet the requirements of fuel cell operations. Subsequently, catalytic mechanisms such as the self-healing mechanism in the Pt monolayer on Pd core catalysts, the pinning effect of nitrogen (N) dopants in N-doped PtNi core–shell catalysts, and the ligand effect of the ordered intermetallic structure in L10-Pt/CoPt core–shell catalysts and their synergistic effects in N-doped L10-PtNi catalysts are described in detail. Additionally, the core–shell structure in the Pt-based catalysts have two main effects for enhanced ORR performance: (i) the interaction between Pt shells and core substrates can tune the electronic state of the surface Pt, thus boosting the ORR activity and stability, and (ii) the outer Pt shell with modest thickness can enhance the oxidation and dissolution resistance of the core, resulting in improved durability. We then review the recent attempts to optimize the ORR performance of the Pt-based core–shell catalysts by considering the shape, composition, surface orientation, and shell thickness. The factors influencing the ORR performance can be grouped into two categories: the effect of the core and the effect of the shell. In the former, PtM core–shell catalysts which use different non-PGM element cores (M) are summarized, and in the latter, Pt-based core–shell catalysts with different shell structures and compositions are described. The modifications of the core and/or shell structure can not only optimize the intermediate-binding energetics on the Pt surface through tuning the strain of the surface Pt, which increases the intrinsic activity and stability, but also offer a significantly decreased catalyst cost. Finally, we discuss the membrane electrode assembly performance of Pt-based core–shell catalysts in fuel cell cathodes and evaluate their potential in real PEMFCs for light-duty and heavy-duty vehicle applications. Even though some challenges to the activity and lifetime in the fuel cells remain, the Pt-based core–shell catalysts are expected to be promising for many practical PEMFC applications.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Technology Demonstration of a High-Pressure Swirl Oxy-Coal Combustor

This technical report presents the exploration of the design and prototyping of a High-Pressure Swirl Oxy-coal Combustor. Pressurized oxy-coal combustion systems have the potential to improve efficiency along with an increased carbon capture rate. Reduction of flue gas at higher pressure, smaller system size, and capital cost reductions render high-pressure oxy-coal systems particularly attractive as next-generation energy-producing systems. High-pressure oxy-coal combustion systems are a recent concept, and thus operability issues of combustor designs for such systems are not fully understood. Significant challenges exist to maintain oxy-coal combustion stability at elevated pressure and a high CO 2 diluent environment. Although a body of knowledge exists for high-pressure oxygen combustion in rocket engines (or similar applications), it is yet to be strategized how these fundamental concepts can be translated to low-temperature CO 2 diluent combustion regimes. The realization of the pressurized oxy-coal based systems requires combustor components to be designed and demonstrated for an operating pressure over 10 bar. However, pressurized oxy-coal combustor design information at this pressure range and scale relevant to validate those proposed systems is currently limited. Experimental data from MWth scale oxy-coal combustors are needed to identify the optimal trade-off between net efficiency and systems size. The proposed effort is aimed at demonstrating a 1 MWth down-fired swirl Oxy-Coal combustor and investigate the interrelation between combustor operating conditions (pressure; flame stability; flue gas recirculation ratio) and conversion efficiencies to minimize oxygen requirements. One of the key challenges is to configure burner design (i.e., swirl number and injector) and operating conditions for high-pressure oxy-coal combustion systems. These experiments differ from current systems partly due to the high theoretical flame temperature and related burner operability issues associated with oxy-combustion. An ASPEN PLUS® model study for 550 MWe TIPS and ENEL pressurized oxy-coal systems with CO 2 recirculation was performed to evaluate system design, subsystems sizing, and operating condition determination. The system analysis effort included TRL and technology gap determination of subsystems and critical components. This information was scaled to develop design requirements (design pressure and flue gas recirculation: RR Flue Gas = $\frac{m_{flue}}{m_{total}}$) for the 1 MWth combustor. The effects of a wide range of carbon dioxide recirculation ratios on the thermal efficiency of ENEL and TIPS cycles are studied. The pressure of 10 bar and 80 bar are used for ENEL and TIPS cycles, respectively. The thermal efficiency of ENEL is significantly higher than the efficiency of TIPS at a pressure of less than 10 bar. The insights from system analysis were then used to design a 1 MWth swirl oxy-coal combustor. Flame temperature analysis and material strength analysis was performed to determine the combustor thickness. The structural integrity of the combustor was validated by finite element analysis using Abacus® and Hypermesh®. Feasibility of igniters and secondary burners are investigated in successful high-pressure oxy-methane combustion. The secondary burners are designed in such a way that it can operate between 100 to 500 kW firing input. Three generations of the pintle injector were designed based on swirl numbers (S=0, 0.9, and 1.2). Key pintle injector parameters such as pintle size, pintle orifice size, spray pattern were investigated by cold flow tests. Information from these tests was used to modify injector design for smooth and successful operation. A 5 mm pintle orifice size was decided upon as the optimum size for oxy-coal operation for the combustor. Shadow sizing experiments were performed to identify the atomization rate of each injector. Different coal water slurry mixtures (30 – 50% coal by wt% in the mixture) at various total momentum ratios (TMR) were investigated for this purpose. These experiments provided decisive information to choose the best design of the injector. The injector with 1.2 swirl provided higher atomization in all cases than other designs. The mean equivalent droplet size of the jet was similar at different TMR and mixture ratios using this injector, thus making it suitable for use in most cases. Therefore, the 1.2 swirl-pintle injector was chosen for the shakedown test. The combustor and other sub-systems, including feed systems and control and data acquisition, have been manufactured, assembled, and integrated. The total system integration and installation began on July 1, 2020. The shake-down tests and initial operational capability demonstration are expected to be completed by September 30, 2020.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2023

Electrons to Molecules by Engineering and Evolution: Biological Upgrading of Formate by Cupriavidus necator

Waste carbon from industrial point sources can be captured, stored, and/or transformed using electrochemical conversion or "electrons to molecules" technologies using low-cost renewable electricity. One such process involves electrocatalytic reduction of CO2 to generate formate/formic acid, a C1 carboxylic acid. Formate is a promising potential feedstock for microbial upgrading, as it is water soluble and can be consumed as the sole source of carbon and energy by some microbial species, such as the soil bacterium Cupriavidus necator. Here we will present progress toward improving C. necator as a host for biological conversion of formate to value-added products. Using the power of adaptive laboratory evolution, we were able to isolate mutants of C. necator with significantly faster growth rates on formate. We then sequenced the genomes of these strains, elucidated the metabolic role of the mutations we found, and then used these insights to build rationally engineered strains that outperform even the best evolved isolates. These results highlight the utility of "genome streamlining" as a route for generating platform strains with potential industrial applications.

adaptive laboratory evolution↗
DOE OSTI2025

Load-Shifting Strategies for Cost-Effective Emission Reductions at Wastewater Facilities

Significant hourly variation in the carbon intensity of electricity supplied to wastewater facilities introduces an opportunity to lower emissions by shifting the timing of their energy demand. This shift could be accomplished by storing wastewater, biogas from sludge digestion, or electricity from on-site biogas generation. However, the life cycle emissions and cost implications of these options are not clear. Here, we present a multiobjective optimization framework for comparing cost- and emission-minimizing load-shifting strategies at a California case study facility with a relatively low carbon intensity grid and high spread in peak and off-peak electricity prices. We evaluate cost and emission trade-offs from the optimal flexible operation of both existing infrastructure and optimally sized energy flexibility upgrades. We estimate energy-related emission reductions of up to 9.0% with flexible operation of existing infrastructure and up to 16.8% with optimally sized storage upgrades. Only a fraction of these potential savings are realized under actual industrial energy tariffs and the EPA’s recommended social cost of carbon. Energy flexibility may hold promise as a short-term emission-saving solution for the wastewater sector, but the extent of savings is heavily dependent on the cost of carbon, electricity tariffs, and emission intensity of the regional electricity grid.

climate↗
DOE OSTI2023

III-V PV Cell Core Capability (Final Technical Report)

This Core project developed III-V photovoltaics for terrestrial applications, focusing on high efficiency architectures and on cost-reduction. III-V cells have demonstrated the highest efficiencies of any photovoltaic materials system, reaching over 30% for two- junction tandems and over 47% for more complex concentrator cells. III-Vs have other characteristics that make them attractive to a range of terrestrial and near-terrestrial energy applications, such as being direct absorbers, lightweight and potentially flexible, having good thermal coefficient, good radiation hardness, and being very stable and durable. Cost is a key challenge with III-Vs, however, because of the high cost of epitaxy and processing.

14 SOLAR ENERGY↗
DOE OSTI2024

A Mid-Century Net-Zero Scenario for the State of Wyoming and its Economic Impacts

Clean hydrogen has the potential to help achieve 10% economy-wide emissions reductions by 2050 relative to 2005, promote energy security and resilience, and develop a new economy in the United States. In 2030, the hydrogen economy could create about 100,000 new jobs to build new capital projects and clean hydrogen infrastructure. The Wyoming Energy Authority recently announced the state’s energy strategy, which establishes a goal of net-zero emissions by 2050. Under all likely scenarios, achieving a mid-century net-zero target will pose challenges and create opportunities for Wyoming’s energy sector. If executed properly, the transition could favorably affect the state’s economy overall in the long term. This research program examines the economic impact of fossil energy production in Wyoming and provides various predictions for future energy mixes to achieve net-zero emissions. Preliminary work suggests that Wyoming-based hydrogen production could have significant economic benefits and job creation implications for Wyoming. This study further assesses Wyoming’s opportunities to create hydrogen-based industries, assess economic impacts, identify knowledge gaps and research needs, and create a Hydrogen Center of Excellence to accelerate commercialization and deployment. This project helped to understand Wyoming's areas of focus for research and development and identified its areas of strength and potential challenges in creating a hydrogen ecosystem. As a result of this study, we estimate that for blue hydrogen produced from coal and gas resources, the overall cost reduction will be driven mainly by the carbon-sequestration tax credit and the improvement in carbon capture. Mature technologies, like SMR and PSA, will make limited contributions. They have no or limited reductions from an additional capacity deployment in future costs. We also understand the importance of continued support from public and private sectors for Carbon Capture and Storage (CCS)-related research, development, and demonstration programs at federal and state levels. The successful and efficient production of blue hydrogen requires a unique blend of energy resources, geology, regulation, law, and infrastructure. Wyoming has the distinction of meeting all these demands. The team also estimates that the availability and command of water resources accessible for hydrogen production are crucial for developing new projects. Water treatment, use, and disposal after treatment will also make projects possible. Primarily, this is relevant for hydrogen made using renewable energy. Wyoming has one of the best wind resource capacity in the nation. Harnessing this resource is challenging due to limited transmission line availability. Hydrogen could become one of the solutions to the stranded resource problem, primarily if the water availability challenge is addressed. Using produced oil & gas water could help to solve the problem. A commonly cited barrier to the expansion of hydrogen markets is the cost associated with constructing new pipelines, which typically require large amounts of capital to develop. Wyoming already possesses much of the export infrastructure needed to connect Wyoming’s hydrogen production with major markets across the West Coast, Pacific Northwest, Midwest, and Front Range regions of the United States, where a large portion of Wyoming’s natural gas is already transported. In addition to transportation by pipeline, rail transportation of hydrogen has also proven feasible. Wyoming uses its extensive railway system to transport large amounts of coal to its export partners across the United States. By using cryogenic or compressed-gas cars, Wyoming has the potential to add hydrogen to its existing network of railroad energy exports. The same technology may also be applied to hydrogen transport via trucks traveling interstate highways. Wyoming’s workforce is ready to meet the demands of clean hydrogen development. Many of the skills and training needed for hydrogen production are the same skills already possessed by Wyoming’s oil & gas and coal workforce. Many government and industry leaders expect clean hydrogen and other low-carbon energy projects to generate significant job growth and to recruit many already-trained oil & gas and coal workers whose jobs may be displaced. As energy companies seek to penetrate the markets for Wyoming hydrogen production, there is a natural mutual benefit to Wyoming’s workers and companies seeking to launch projects with the assistance of a trained workforce. Wyoming’s university and community college system have adopted several programs to ensure that highly qualified engineers and other technically skilled employees continue to graduate with skills to support the development of hydrogen and other innovative energy projects moving forward. Throughout the project, stakeholder outreach and education took many forms, including meetings with several major companies in the industry, collaborating with local government organizations, educational organizations, and national laboratories, tribal outreach and engagement, the sponsoring of several hydrogen-focused projects in many departments throughout the University of Wyoming, and developing a collaboration with international universities. The products of these collaborations consist of working relationships with several companies in the industry, educational institutions, national labs, and local government, as well as strong connections with individuals who will play an essential role in the success of the Hydrogen Energy Research Center.

08 HYDROGEN↗
DOE OSTI2025

Application-specific machine-learned interatomic potentials: exploring the trade-off between DFT convergence, MLIP expressivity, and computational cost

Machine-learned interatomic potentials (MLIPs) are revolutionizing computational materials science and chemistry by offering an efficient alternative to ab initio molecular dynamics (MD) simulations. However, fitting high-quality MLIPs remains a challenging, time-consuming, and computationally intensive task where numerous trade-offs have to be considered, e.g., How much and what kind of atomic configurations should be included in the training set? Which level of ab initio convergence should be used to generate the training set? Which loss function should be used for fitting the MLIP? Which machine learning architecture should be used to train the MLIP? The answers to these questions significantly impact both the computational cost of MLIP training and the accuracy and computational cost of subsequent MLIP MD simulations. In this study, we use a configurationally diverse beryllium dataset and quadratic spectral neighbor analysis potential. We demonstrate that joint optimization of energy versus force weights, training set selection strategies, and convergence settings of the ab initio reference simulations, as well as model complexity can lead to a significant reduction in the overall computational cost associated with training and evaluating MLIPs. This opens the door to computationally efficient generation of high-quality MLIPs for a range of applications which demand different accuracy versus training and evaluation cost trade-offs.

36 MATERIALS SCIENCE↗
DOE OSTI2022

2021 Component Innovation Project Awardee: Bergey Windpower

In recent years, the cost of small wind turbines for homes, farms, and small businesses has decreased dramatically thanks to advances in American technology made possible by research and development support from the U.S. Department of Energy. But further reductions are needed to realize the gigawatt-scale potential of distributed wind energy to help electrify rural America, reduce carbon emissions, and create jobs. Currently, for residential- and farm-scale wind turbines with direct-drive, permanent-magnet alternators, the alternator is the highest-cost component of the wind turbine (excluding the tower). The Bergey Windpower Excel 15 wind turbine incorporates advanced technology in its rotor and controls and will soon incorporate advanced power electronics - but its alternator is based on technology that is more than a decade old. To help reduce capital expenditures of the Excel 15 wind turbine, Bergey Windpower is developing an advanced, lower- cost, permanent-magnet alternator.

CIP↗
DOE OSTI2023

Adopting occupancy-based HVAC controls in commercial building energy codes: Analysis of cost-effectiveness and decarbonization potential

Recent research has shown the energy-saving potential of occupancy-based HVAC controls (OBCs) in commercial buildings. However, building energy codes have not fully adopted this technology. This study aims to evaluate the cost-effectiveness and decarbonization benefits of OBCs and provide guidance for integrating occupancy sensors into building energy code development. To this end, a parametric simulation using EnergyPlus and a nationwide cost-effectiveness analysis are carried out considering three building types and 40 representative cities in the U.S. Here, the findings reveal that the current cost-effectiveness performance of OBCs is limited due to the high cost of occupancy sensors. However, incorporating the societal cost of carbon factor in future energy and environmental policy could greatly enhance the actual cost-effectiveness performance. Besides, a reduction in the cost of occupancy sensors to approximately 60% of the current price level could also greatly shorten the discounted payback period of OBCs. Additionally, OBCs demonstrate significant potential in building decarbonization, with potential CO 2 emissions savings of more than 5.56 million metric tons across the three building types and 40 selected cities. Finally, policy implications are provided to guide the incorporation of occupancy-based HVAC controls in future energy codes.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2026

Floating Photovoltaics in Hydropower Reservoirs in the United States

This report presents a comprehensive analysis of the feasibility of floating photovoltaics (FPV) in federally regulated reservoirs within the continental United States (CONUS) and to present a methodology for capturing the true costs of deployment, potential environmental impacts, and regulatory pathways for open-loop hydropower reservoirs. It is intended for stakeholders who may not be solar industry experts but who are interested in exploring the potential for FPV in their reservoirs. While there are promising opportunities, particularly in enhancing dissolved oxygen (DO) levels and potentially improving compliance with existing hydropower licenses, the current capital costs of FPV are not yet competitive with traditional land-based solar installations at the utility-scale when comparing the LCOE results. A competitive financial outlook is achievable when applying a 30% Investment Tax Credit (ITC) and considering a 5% reduction from the baseline capital expenditures (CapEx) at the Tuckertown Reservoir in North Carolina case study. The study is structured around three key pillars of research: technical potential, environmental impacts and regulatory considerations, and technoeconomic analysis. This report provides a nationwide assessment of the opportunities for FPV in terms of capacity, measured in direct current megawatts (MWDC), in reservoirs managed by the U.S. Bureau of Reclamation (USBR), the U.S. Army Corps of Engineers (USACE), and the Federal Energy Regulatory Commission (FERC). Additionally, the report introduces a heuristic model for estimating the CapEx of utility-scale FPV projects (1–100 MW), offering a baseline cost estimate for stakeholders. Finally, the report applies these models to a case study of a hydropower reservoir in North Carolina to present site-specific results.

13 - HYDRO ENERGY↗
DOE OSTI2021

Improving the performance of first- and last-mile mobility services through transit coordination, real-time demand prediction, advanced reservations, and trip prioritization

Socio-demographic trends and recent economic development patterns have resulted in travel behavior changes that call for more flexible and accessible public transit options. Because flexible transit services vary in scope, size, and service type, new data-informed methods are useful to optimize services based on the specific needs of local communities and riders. In this study, real-world demand and vehicle trajectory data were used to evaluate and optimize system performance for an existing first-mile–last-mile (FMLM) service in Robinson Township, PA. A general FMLM model for arbitrary demand and service supply was then developed to quantify system performance—both travel time costs and day-to-day reliability—for various operational polices considering spatio-temporal demand variation and transportation network dynamics. Heuristics were used for optimal real-time vehicle routing in sizable real-world networks accommodating various service types and scopes. In this case study, total user costs were reduced by 18.6% when rides were coordinated with mainline fixed-route transit. Predictive routing strategies were shown to marginally improve system performance under sparse and variable spatio-temporal demand. The case study also highlights potentially large travel time and user reliability improvements—reductions of 51% and 53.8%, respectively—when trip requests were made in advance of their desired pickup time. Finally, we show that travel time reliability can be improved for time-inflexible trips with trip prioritization without increasing total user costs. These results were stable to changes in demand density.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2025

Life Cycle Emissions and Health Cost Impacts of Producing Ethanol and Electricity from Willow and Switchgrass in the Riparian Buffers of Mid-Atlantic United States

The United States (US Mid-Atlantic Region (MAR) has the potential to grow a variety of perennial feedstocks such as switchgrass and shrub willow to increase domestic energy production. These cellulosic feedstocks have also shown improved ecosystem services, such as soil carbon sequestration, nitrate leaching reduction, and flood mitigation along rivers and streams as partially harvested riparian buffers. To examine the effects on greenhouse gases (GHGs) and criteria air pollutants (CAPs) from using these feedstocks to produce ethanol or electricity, we conducted a comprehensive life cycle assessment (LCA) and estimated the impact on human health costs when land use is changed from corn production for ethanol. Results indicate up to 54% reduced GHG per hectare from using willow and switchgrass feedstock sources to produce ethanol instead of corn. However, there was a trade-off in terms of CAP emission, as grass-based energy emitted more NO x and SO x compared to the corn ethanol pathway, except for SO X emissions from willow-based electricity. Electricity from cellulosic biomass had higher particulate matter (PM) emission compared to that from corn ethanol. Estimates for health cost to society ranged from $2498 ha –1 for electricity from switchgrass to a net benefit of $448 ha –1 for ethanol production from willow, depending on varying biomass yield under different market scenarios. Although using cellulosic feedstocks to produce bioenergy has great potential to reduce GHG emissions, CAP control measures are needed to manage CAP-induced health costs.

Bioenergy↗
DOE OSTI2025

Optimizing Control for Efficient Load Shifting with Thermal Energy Storage in Existing HVAC Systems

This project developed the integration of a direct-contact heat exchanger (DCHX) based thermal energy storage (TES) system with a chiller–air handling unit (AHU) plant to evaluate its potential for reducing building energy costs. Detailed physical models of the TES unit, building envelope, and HVAC components were developed alongside simplified control-oriented models to support both high-fidelity simulation and real-time optimization. Two control strategies were implemented and compared: a rule-based control (RBC) aligned with utility time-of-use (ToU) rates, and a model predictive control (MPC) framework leveraging forecasts of building load, weather, and internal gains.Simulation results show that the RBC strategy reduced daily electricity costs by around 30% by shifting cooling production from on-peak to off-peak hours. In contrast, the MPC strategy achieved significantly greater performance, reducing daily operating costs by up to 44% and peak-hour costs by more than 60%. Both strategies maintained indoor thermal comfort within acceptable limits, with MPC further improving load distribution and reducing equipment cycling.The outcomes confirm that TES integration, particularly when coordinated with advanced predictive control, can provide substantial cost savings and on-peak demand reduction. . These findings directly support the U.S. Department of Energy’s goals for grid-interactive efficient buildings and demonstrate the potential of TES-enabled HVAC systems for scalable deployment across the commercial building.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2025

Optimizing Control for Efficient Load Shifting with Thermal Energy Storage in Existing HVAC Systems

This project developed the integration of a direct-contact heat exchanger (DCHX) based thermal energy storage (TES) system with a chiller–air handling unit (AHU) plant to evaluate its potential for reducing building energy costs. Detailed physical models of the TES unit, building envelope, and HVAC components were developed alongside simplified control-oriented models to support both high-fidelity simulation and real-time optimization. Two control strategies were implemented and compared: a rule-based control (RBC) aligned with utility time-of-use (ToU) rates, and a model predictive control (MPC) framework leveraging forecasts of building load, weather, and internal gains. Simulation results show that the RBC strategy reduced daily electricity costs by around 30% by shifting cooling production from on-peak to off-peak hours. In contrast, the MPC strategy achieved significantly greater performance, reducing daily operating costs by up to 44% and peak-hour costs by more than 60%. Both strategies maintained indoor thermal comfort within acceptable limits, with MPC further improving load distribution and reducing equipment cycling. The outcomes confirm that TES integration, particularly when coordinated with advanced predictive control, can provide substantial cost savings and on-peak demand reduction. . These findings directly support the U.S. Department of Energy’s goals for grid-interactive efficient buildings and demonstrate the potential of TES-enabled HVAC systems for scalable deployment across the commercial building.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2020

Valuation and cost reduction of behind-the-meter hydrogen production in Hawaii

A 250kW hydrogen electrolysis facility was recently installed at the Natural Energy Laboratory of Hawaii Authority's (NELHA's) campus. This facility that will begin operation in 2020 to produce hydrogen for fuel cell buses on the island to demonstrate of the application of hydrogen to decarbonize transportation. Given the size of the electrolysis station, it has the potential to significantly increase electricity costs for the campus, which is subject to energy and peak demand charges from the local utility. In this paper, we analyze the cost of hydrogen production at NELHA given the rate structure options available from the utility. Production costs are estimated using optimal versus constant scheduling of the facility to meet the buses’ demand. A model of the electrolysis station is used to capture changes in production efficiency over the power range in the optimization routine. The effects of combining the station and campus load versus standalone operation and increasing solar generation are also explored. The analyses surrounding this scenario show the importance of multiple factors on the potential profitability of hydrogen production in behind-the-meter applications and show trends that could have implications for other similar installations.

08 HYDROGEN↗
DOE OSTI2023

Exploring the Impact of Near-Term Innovations on the Technical Potential of Land-Based Wind Energy

Land based wind may play a critical role in reaching emissions reductions goals and high renewable contribution scenarios with capacity expansion modeling results estimating over 1 terawatt of land-based wind by 2035 to reach 100% clean electricity. Deployment of land-based wind at this magnitude may require significant investments in transmission infrastructure and will require significant land area for new wind and transmission. Cost reductions via technological advancements in wind turbine design, construction, and maintenance will have a major role in enabling the scale of deployment required. Since 1998, the levelized cost of wind energy has fallen by over 60% due to improvements in capacity factors, advancements in turbine controls, and cost reductions in installation, operation, and maintenance. These cost reduction pathways, generally referred to as wind technology "innovations", have enabled significant increases in the capacity and electric generation share of wind power in the United States. Nevertheless, achievements of past wind innovations have not led to widespread wind deployment outside of high wind speed geographies. This study evaluates the potential of near-term innovations to expand the geographic range of economically viable land-based wind power production in the United States. Many challenges to future deployment of wind power can be associated with increasing concentration in high-wind areas. As more wind power is deployed in these same areas, it is likely that residential and regulatory resistance to further deployment will increase, access to transmission will diminish, and options for distant companies and governments with renewable energy goals will remain limited. Therefore, this analysis aims to emphasize the potential for innovations to enable land-based wind in regions with limited wind deployment and with lower wind resource and better access to transmission.

17 WIND ENERGY↗
DOE OSTI2020

Production of Biocrude in an Advanced Photobioreactor-Based Biorefinery

Algenol Biotech, the National Renewable Energy Laboratory (NREL), Georgia Institute of Technology, Arizona State University, and Reliance Industries formed a team to advance the state of the art in algal biomass production and downstream processing technologies, with the end goal of a sustainable, economically viable biofuel intermediate (BFI, biocrude) product. The project included examination of high value co-product production as a market entry strategy and for enhancing the economics of a biorefinery for BFI production. The project targeted innovations in biology, operations, and engineering. The goals of the project were: BFI productivity greater than 4,000 gal-BFI/acre-yr on an annualized basis; energy efficient innovations in downstream operations resulting in an energy expenditure less than 10% of the BFI energy content and a carbon footprint reduction of more than 60% compared to fossil alternatives; and a comprehensive Techno-Economic Analysis (TEA) that identifies limiting factors for commercial viability of a photobioreactor (PBR)-based biofuel product. The project achieved the overall objectives. Strain development efforts led to the identification of a strain (Cyanobacterium sp. AB1166) that, relative to the previous best strain (Cyanobacterium sp. AB1), exhibited a ~10% increase in productivity under commercially-relevant cultivation conditions and also resulted in cultures with a >50% reduction in viscosity such that harvesting efficiency was improved; these results represent achievement of key project milestones. Progress was also made at NREL in altering the biochemical composition of algal biomass to improve the yield of BFI produced via HTL. These strain enhancements coupled with improved outdoor cultivation practices, including semi-continuous operation, increased areal biomass productivity by nearly 80% over the established baseline productivity. The annualized productivity achieved (26.8 g/m2-d), paired with HTL conversion yields realized at NREL and RIL (38% ± 2% BFI), translates to 4,100 gal-BFI/acre-yr, exceeding the FY20 BETO goal of 3,700 gal-BFI/acre-yr. Significant progress was also demonstrated in large scale PBR-based production system design, operability, and cost reduction. A 24,000-L production module comprised of 240 interlinked PBRs was constructed and successfully operated outdoors for over one year in Fort Myers, Florida. Aided by a state-of-the-art productivity model, the productivities achieved convincingly demonstrated scalability of laboratory results determined at the mL to L scale to large-scale outdoor operations exceeding 20,000 L. The system was used to cultivate Arthrospira platensis (Spirulina), an industrially-relevant cyanobacterium and source for phycocyanin, an approved blue food colorant that Algenol is developing as a risk reduction strategy for future biofuel projects and as a potential business opportunity. A key project milestone to develop phycocyanin extraction and purification technologies was achieved ahead of schedule, and product samples received positive feedback from potential customers. The production and downstream operations data generated in this project were used to conduct and refine Techno-Economic and Life Cycle Assessments to provide research guidance for reducing the costs and environmental footprint of algal biofuel and co-product manufacturing plants. Several CO 2 supply scenarios for an algal biorefinery were identified as being capable of providing a large (>60%) reduction in carbon footprint in comparison to gasoline. The TEA assessments incorporated detailed comparisons of PBR versus open pond production systems, yielding a 3-fold higher areal productivity for PBRs and suggesting overall production cost parity for the two systems. The progress in this ABY2 project addressed many of the the barriers identified for the Advanced Algal Systems R&D Program and are directly relevant to achieving the established BETO goals associated with large scale biofuel production and cost reduction.

09 BIOMASS FUELS↗