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At least 235 records · Page 13

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DOE OSTI2026

High‑performance cold‑climate heat pump using tandem compressors with and without vapor injection: Laboratory investigation and field demonstration

Cold‑climate air‑source heat pumps must maintain heating capacity and stable operation at low ambient temperatures for residential applications. This study adapts tandem single-speed compressors—proven in commercial systems —for residential CCHPs, integrating VI and validating performance across laboratory and extreme field conditions to achieve cold-climate targets. That is to achieve ≥75% of the rated heating capacity at −25.0 °C relative to 8.3 °C and heating coefficient of performance (COP) greater than 4.0 at 8.3 °C. Laboratory testing confirmed that both configurations met these targets while operating within acceptable discharge‑temperature limits. Relative to the non‑VI configuration, the VI system provided up to 15% higher heating capacity and up to 9% higher heating COP under identical conditions, yielding a 5.6–9.1% increase in heating seasonal performance factor (HSPF). Field tests in Ohio and Alaska, with minimum outdoor temperatures of −25.0 °C and −34.0 °C, respectively, showed stable operation, minimal supplemental heating (<3.2%), low defrost penalties, and consistent output. Tandem‑compressor architectures proves promising for cold-climate residential heating.

Hu, Yifeng [ORNL] (ORCID:0000000242875185)↗

DOE OSTI2021

Evaluation of hybrid evaporative-vapor compression air conditioners for different global climates

Currently, a majority of global residential air-conditioning requirements are met using cooling systems based on the vapor compression cycle (VCC). To meet the future demand for space cooling and to reduce the corresponding environmental impact, there is a need for alternative cooling systems which require less resources and exhibit a higher coefficient of performance (COP). One of proposed alternatives is called the hybrid evaporative-vapor compression (HEVC) cycle, which utilizes adiabatic latent cooling in combination with the VCC. In this paper, we conducted a feasibility analysis of a HEVC system by comparing its performance to that of VCC for various global climates. To accomplish this, we developed and validated models to simulate the performance of residential VCC and HEVC systems. ASHRAE weather data and design conditions were then used to compare the performance of the two systems. In general, HEVC systems are best suited for hot arid climates with energy reduction greater than 20%. Conversely, humid climates are not suitable for HEVC adoption due to degraded performance of evaporative coolers in these climates. In addition to comparing the energy savings from HEVC systems, it is also critical to analyze their water consumption. Generally, climates that benefit the most from HEVC technology tend to also experience water scarcity issues. Thus, both the energy savings and water consumption of HEVC systems must be analyzed to guide the discussion on their adoption.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2026

Multi-Objective design of interlocking metasurfaces using conditional diffusion models

Unit cell design remains a major challenge for interlocking metasurfaces, a promising joining technology for dissimilar materials, due to the complex, competing, multivariate design space and the need for rapid adaptation to varying performance requirements. This study explores Conditional Diffusion Models as a design optimization tool for interlocking metasurfaces. Given the complex, competing, multivariate design space for interlocking metasurfaces, unit cell design remains a major challenge for this joining technology. We trained a conditional diffusion model on 25,000 finite element analysis-simulated interlocking metasurface unit cells to generate designs with tailored thermo-mechanical properties (tensile strength, shear strength, and thermal conductivity) based on specified performance criteria. The model demonstrated a success rate of approximately 72 % in producing designs that met specified property bounds. The conditional diffusion model generated both thermally resistive and conductive designs, revealing clear trends in design characteristics: taller, dendritic structures were advantageous for tensile loads, while shorter, robust designs excelled in shear applications. Our findings indicate that the model's performance is more influenced by the breadth of the design space than by the quantity of training data, highlighting the importance of expansive design domains for generating innovative solutions. This work establishes conditional diffusion models as a highly efficient and adaptable tool for rapid interlocking metasurface unit cell design, paving the way for advancements in multi-material joining technologies, as well as highlighting the justification to leverage conditional diffusion models as design tools across complex design domains.

Conditional diffusion models↗

DOE OSTI2022

Communication breakdown: Energy efficiency recommendations to address the disconnect between building operators and occupants

As technology advances, progressive building performance goals are met with ease and occupant behavior plays an increasingly significant role in preventing building operators from achieving those goals. However, removing occupants from participating in building control and operation is counterintuitive to the purpose of building operation. Occupant-centric control (OCC) has been suggested as a means of incorporating the occupant while simultaneously reducing the negative impact their behavior can have on building performance. As a result, operators are now tasked with incorporating OCC into their daily operation. The relationship between building occupants and operators is a critical component to OCC, and balancing occupant comfort and building performance. In this paper, we present findings from an international qualitative study of building operators with a focus on the operator and occupant relationship. This paper identifies the role operators play in OCC, how these relationships develop, and how these relationships impact building operation through two key research questions: What factors influence the quality of relationships between occupants and operators? How can the relationships between operators and occupants be improved? Subsequently, these questions revealed this relationship becomes strained when building performance is prioritized over comfort, occupants are ignored or uneducated, and feedback is negative or sparse. In short: there is a disconnection between operators and occupants. Here we propose several solutions including modifying job requirements to prioritize occupant comfort, educating occupants to make autonomous decisions that are not detrimental to operation, and creating effective communication channels for instances where operator intervention is required.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2026

Reduced-order CFD modeling of cryogenic hydrogen isotope extrusion for pellet fueling

This study presents a reduced-order model (ROM) for computational fluid dynamics (CFD) simulations of cryogenic hydrogen isotope extrusions, focusing on protium (H₂) and deuterium (D₂) piston extruders. Using a 2D axisymmetric ROM in ANSYS-Polyflow, significant computational savings were achieved (runtime reduced from 9∼24 h to 3∼5 min), with extrusion force discrepancies between the 2D ROM and 3D models being on the order of 1%. Parametric studies identified optimal cutoff shear rates in the viscosity model (0.01/s for H₂ and 0.001/s for D₂), providing recommendations for future simulations. Finally, a comprehensive comparison of ROM results with experimental data was performed across varying geometries, cryogenic materials, temperatures, extrusion lengths, and piston velocities. Predictions at low extrusion temperatures met the objective of providing quick and efficient solutions with an acceptable extrusion force error of approximately 10% or less, validating the effectiveness of the 2D ROM approach. However, at high temperatures closer to the triple point, extrusion force error grows, which necessitates developing an improved model that accounts for temperature effects, e.g. melting. Nevertheless, the findings still represent a significant improvement in efficiency of CFD modeling of cryogenic hydrogenic extrusion. The ROM framework can also be extended to tritium (T2) and screw extruders, which will ultimately provide a fast and effective tool for optimizing pellet injector design for ITER and future reactor systems.

Fan, Joy [ORNL] (ORCID:0000000229751735)↗

DOE OSTI2024

Material analysis of metal hydrides for bulk hydrogen storage

The United States Department of Energy (DOE) Hydrogen Storage Engineering Center of Excellence (HSECoE), 2009–2014, was established to evaluate the viability of material-based hydrogen storage for light duty vehicles. The HSECoE concluded that there were no metal hydrides that simultaneously met the DOE targets for gravimetric and volumetric capacity, and rate of onboard refueling. However, it was noted by the DOE that potential applications existed for stationary hydrogen storage systems. An application of particular interest is using a metal-hydride to store a hydrogen supply for fuel cell backup power to a 5 MWe data center. A generalized numerical model that coupled mass and energy conservation, chemical kinetics and thermodynamics was developed to simulate the discharge process for a given metal-hydride. The model was applied to an interstitial and a complex metal-hydride. In conclusion, it was found that the interstitial metal-hydride, which is discharged by a pressure swing is preferrable in a practical sense to the complex metal-hydride, which requires a temperature swing discharge process.

08 HYDROGEN↗

DOE OSTI2022

Development and performance of INCONEL® alloy 740H® seam-welded piping

INCONEL® alloy 740H® is an age-hardenable nickel-based alloy approved for pressure vessels and piping within ASME Section I, VIII, and B31.1. Currently, the code applies a weld strength reduction factor (WSRF) of 0.7 to the allowable stresses for longitudinal seam welds in the time dependent creep regime. In this work, a full-scale seam weld was successfully produced using typical industrial practices. The component was solution heat-treated and aged after fabrication to improve the performance of the weldment. Tensile, bend, impact, and low-cycle fatigue tests showed the component met all the specification requirements and elevated temperature properties were within base metal expectations with failures predominately in the weld metal. Long-term creep tests, including large samples more representative of the entire weldment, were fabricated and tested to times in excess of 10,000 h at multiple temperatures. Analysis of the creep data supports a WSRF of 0.9 for the solution annealed + aged weldments in contrast to the WSRF of 0.7 currently applied to welded + aged weldments. Metallurgical analysis shows that the solution annealing causes recrystallization of the weld metal and reduces the chemical compositional and microstructural gradients in the weldments resulting in acceptable short-term performance. In long-term creep, evidence for coarsened zones in the weldments due to discontinuous coarsening reactions were identified as the mechanism leading to accelerated creep damage formation in the weld metal and sample failure.

14 SOLAR ENERGY↗

DOE OSTI2021

Molecular insights and future frontiers in cell photosensitization for solar-driven CO 2 conversion

The conversion of CO 2 to value-added products powered with solar energy is an ideal solution to establishing a closed carbon cycle. Combining microorganisms with light-harvesting nanomaterials into photosynthetic biohybrid systems (PBSs) presents an approach to reaching this solution. Metabolic pathways precisely evolved for CO 2 fixation selectively and reliably generate products. Nanomaterials harvest solar light and biocompatibly associate with microorganisms owing to similar lengths scales. Although this is a nascent field, a variety of approaches have been implemented encompassing different microorganisms and nanomaterials. To advance the field in an impactful manner, it is paramount to understand the molecular underpinnings of PBSs. In this perspective, we highlight studies inspecting charge uptake pathways and singularities in photosensitized cells. We discuss further analyses to more completely elucidate these constructs, and we focus on criteria to be met for designing photosensitizing nanomaterials. As a result, we advocate for the pairing of microorganisms with naturally occurring and highly biocompatible mineral-based semiconductor nanomaterials.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Decomposing sources of value for electricity and negative emissions technologies in net-zero power systems

Deep decarbonization of the US power system would require rapid deployment of variable renewable energy (VRE) resources, which are projected to provide a substantial share of electricity generation at the time of net-zero emissions. However, the exact share of generation met by VRE and the roles of other technologies in supplying key electricity services—energy and firm capacity—remain uncertain. This study employs a detailed model of the US power sector to decompose the provision and value of electricity services, including negative emissions, by technology across a range of deep decarbonization scenarios. Results indicate that while technology deployment and the share of services provided by each technology vary significantly depending on future technological and market conditions, the value composition and future roles of individual technologies remain consistent. These findings offer guidance for research and development priorities and provide insights to inform electricity policy and planning.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2026

Perovskite design principles for efficient microwave dry reforming with noble metal free catalysts

Microwave absorbing catalysts have the potential to electrify high-temperature thermal reactions such as the dry reforming of methane process (DRM: CO 2 + CH 4 → 2CO + 2 H 2 ). However, microwave catalysts present unique challenges due to their dual requirements of maintaining microwave absorption in both oxidative and reductive environments and stability across a range of temperatures in inherently non-isothermal reactors. Here, catalyst candidates from the La 0.8 Sr 0.2 CoO 3 -La 0.8 Sr 0.2 NiO 3 -La 0.8 Sr 0.2 MnO 3 perovskite systems were screened (28 total) to identify promising microwave catalysts free of noble metals for dry reforming methane. The best performing candidates met two main criteria. First, they occurred at crystal phase boundaries, giving rise to a pseudocubic perovskite structure. The combined use of Goldschmidt tolerance factor and octahedral tolerance factors appeared to be suitable for predicting pseudocubic perovskites. Second, they provided a balance of reducible metal sites with an irreducible metal oxide support. The best performing catalyst was found to exsolve Ni-Co alloy particles as active sites for the DRM reaction which offered superior resistance to coking for excellent reforming efficiency and stability.

42 ENGINEERING↗

DOE OSTI2024

Ensuring Σ s Y s = 1 in transport of species mass fractions

When transporting species mass fractions in reacting flow simulations, there are physical constraints that must be met. Unfortunately, nonlinear transport schemes such as weighted essentially non-oscillatory (WENO) schemes do not ensure that the sum of mass fractions equals 1. In detonation simulations, errors in the sum of mass fractions are observed to worsen over time when the standard WENO scheme is used. To prevent this, typically one species is forced to absorb all or most of the error in the sum of mass fractions. Here, this work presents an alternative method for correcting the WENO-interpolated mass fractions such that inert species do not change. The method is demonstrated for both argon and nitrogen-diluted hydrogen detonations in one dimension. Using the modified WENO interpolations, the error in the sum is reduced significantly. In addition, the new approach is better able to capture the physical instability expected for nitrogen-diluted detonations.

74 ATOMIC AND MOLECULAR PHYSICS↗

DOE OSTI2020

Uranium nitride tristructural-isotropic fuel particle

A summary of activities around concept development, design, manufacturing, and early irradiation testing of a novel coated fuel particle, uranium nitride tristructural-isotropic fuel is provided. This fuel particle offers significantly higher uranium density over historic manifestations of coated fuel particles and may be more optimal for a range of advanced reactor applications. After reviewing the design process, steps involving production of this fuel form are discussed. Low burnup irradiation data on this fuel particle are now available, indicating that performance metrics have been met to date based on the original design expectations.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2021

Perspectives on multiscale modelling and experiments to accelerate materials development for fusion

Prediction of material performance in fusion reactor environments relies on computational modelling, and will continue to do so until the first generation of fusion power plants come on line and allow long-term behaviour to be observed. In the meantime, the modelling is supported by experiments that attempt to replicate some aspects of the eventual operational conditions. In 2019, a group of leading experts met under the umbrella of the IEA to discuss the current position and ongoing challenges in modelling of fusion materials and how advanced experimental characterisation is aiding model improvement. This review draws from the discussions held during that workshop. Topics covering modelling of irradiation-induced defect production and fundamental properties, gas behaviour, clustering and segregation, defect evolution and interactions are discussed, as well as new and novel multiscale simulation approaches, and the latest efforts to link modelling to experiments through advanced observation and characterisation techniques.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2025

Energy innovation in the US buildings sector: Setting the stage and mapping the future

Jared Langevin is a staff scientist at Lawrence Berkeley National Laboratory, where he leads modeling of US buildings sector innovation and its implications for energy demand, consumer costs, and the power grid. Eric Wilson is a senior research engineer in the Building Technologies and Sciences Center at the National Renewable Energy Laboratory (NREL). Much of his 15-year career at NREL has revolved around modeling and analysis of the US building stock. Jared and Eric co-led the development of a National Blueprint for buildings sector innovation while serving as advisors to the US Department of Energy’s Deputy Assistant Secretary for Buildings and Industry.

Langevin, Jared↗

DOE OSTI2022

Development and validation of a quantitative proton NMR method for the analysis of pregnenolone

Pregnenolone (PREG) is an endogenous steroid frequently sold as an over-the-counter dietary supplement touted to promote neurological and immunological health. While the PREG dietary supplement is added to the diet for health benefits, there are no FDA approved PREG drugs. However, compounded PREG drug products are available to U.S. patients. The FDA works with state regulatory authorities on the oversight of compounding activities, including developing 503A and 503B lists of bulk substances that compounders are permitted to use. PREG is one of the substances publicly nominated to be included on the 503B list. Compounded hormone therapies such as those using PREG are of interest given the lack of standardization in compounded drug products which may increase the possibility of underdosing, overdosing, or contamination. However, no USP monograph currently exists to evaluate the quality of PREG drug substance or product. To address knowledge gaps and assist in quality control, a simple and rapid quantitative proton nuclear magnetic resonance spectroscopy (qNMR) method for the identification and assay of PREG in different types of PREG products was developed and validated. PREG samples were characterized using 1D 1 H and 2D 1 H– 13 C HSQC NMR spectra. The qNMR assay method (taking approximately 10 min per NMR spectrum) was validated for precision, accuracy, specificity, robustness and linearity per ICH Q2(R1) guidance. The method was validated in a range from 0.032 to 3.2 mg/mL. As a proof of concept, seven PREG bulk substance samples, three tablet and two capsule PREG dietary supplements were assessed by the qNMR analytical procedure. NMR data from all tested samples met the expected criteria for identification and assay. The results demonstrate the potential of qNMR for the quality assessment of different types of PREG samples.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2022

Effect of porous transport layer properties on the anode electrode in anion exchange membrane electrolyzers

Anion exchange membrane water electrolyzers (AEMELs) have recently received significant attention due to their potential advantages over existing commercial water electrolysis technologies. However, AEM electrolyzers have not yet met performance and durability targets. One of the critical components in achieving high AEMEL performance is the porous transport layer (PTL) which serves many critical functions in the oxygen evolution reaction (OER) electrode. In this study, several OER PTL attributes were investigated, including: material of construction, fabrication method, feature size, porosity/density, and thickness. It was found that higher porosity helped facilitate multiphase (O 2 , H 2 O, etc.) transport; however, as the porosity increased, the catalyst layer adhesion to the PTL decreased, the contact resistance with the bipolar plate increased and the cell operating voltage increased. It was found that nickel-based PTLs allowed for lower operating voltages than similarly-structured stainless steel PTLs. Improved operating voltages were achieved with both fiber felts and sintered structures by porosity optimization. Furthermore, an increase in thickness did not affect transient voltage response, however, it had a negative effect on performance stability. As a result, the experimental findings presented here provide important insights for development of PTL materials and structures for efficient and low-cost water electrolysis.

08 HYDROGEN↗

DOE OSTI2025

Property optimized energy absorber for automotive bumpers utilizing multi-material and structural design strategies

This study proposes a novel design for automotive bumper using optimized lattice structures and multi-materials to balance low-speed collision and high-speed pedestrian impact performance. Different blends of 20 % carbon fiber-reinforced acrylonitrile butadiene styrene with thermoplastic polyurethane were used to tailor material properties. The energy absorber features lattice structures with customized mechanical responses, created by varying the incline angle θ from 0 to 180°. We conducted 576 finite element simulations on a half-scale model to optimize energy absorption and stiffness, leading to 66 optimized designs that met both low-speed and high-speed impact criteria. Two sub-scale optimized energy absorbers with different peak forces—both meeting low-speed impact requirements—were 3D printed and validated through drop-weight testing. The one with lower peak stress demonstrated a more compliant response, exhibiting approximately 90 % lower initial peak force and an increase in energy absorption of around 33 % (from 24 J to 32 J). Compared to the baseline triangular lattice, the optimized absorber increased energy absorption by 68 % from (19 J to 32 J) and reduced peak stress by 70 %. It also showed near-complete recovery with minimal fractures, making it suitable for repeated use. This design improves safety while offering a lightweight, durable, and cost-effective bumper system.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Enhancing membrane performance for CO 2 capture from flue gas with ultrahigh MW polyvinylamine

Membranes for post-combustion CO 2 capture are required to have a high CO 2 permeance due to the limited driving force. For facilitated transport membranes synthesized with polyvinylamine (PVAm), a defect-free selective layer of <200 nm is usually required to render sufficient permeance with high CO 2 /N 2 selectivity. In order to meet such a demand through the knife-coating process, the coating solution needs to have a high viscosity at a relatively low concentration to minimize its penetration into the substrate. The demand was met by synthesizing PVAm with an ultrahigh molecular weight (MW) via inverse emulsion polymerization (IEP) in this study. Compared to solution polymerization, IEP isolates the reaction in inverse micelles suspended in a continuous organic phase, which allows excellent dissipation of the heat generated by the reaction and reduces gel formation drastically. The polymerization parameters, including monomer concentration, initiator concentration, and reaction temperature, were investigated to obtain the optimal MW of PVAm for membrane performance. As compared to solution polymerization, IEP enhanced the MW of PVAm from 1.2 to 12.7 MDa, which minimized the penetration of the coating solution into the substrate and hence the extra mass transfer resistance. The effect of MW and degree of hydrolysis of PVAm on the membrane transport properties were studied. Furthermore, by employing PVAm with a MW of 12.7 MDa to strengthen the polymer matrix, the loading of piperazine glycinate in the membrane was increased up to 85 wt.%. In conclusion, the resultant membrane achieved a CO 2 permeance of 839 GPU and a CO 2 /N 2 selectivity of 161 at the typical flue gas temperature of 57°C.

20 FOSSIL-FUELED POWER PLANTS↗