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DOE OSTI2024

2023 Peer Review Final Report

The U.S. Department of Energy’s Office of Energy Efficiency and Renewable Energy requires each of its programs to conduct periodic peer reviews to enhance EERE program planning. May 16–18, 2023, the Advanced Materials and Manufacturing Technologies Office (AMMTO) held an in-person peer review of its program activities in which an independent panel of experts provided AMMTO with feedback on how well the new office’s programs align with its overarching goals and mission statement, identified possible course correction, and shared information. This review marks AMMTO’s first in-person peer review since the Advanced Manufacturing Office evolved into AMMTO and the Industrial Decarbonization and Efficiency Office. A detailed summary of observations, findings, impact, and recommendations is contained in the following report.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2024

Overview and Status of the Long-Baseline Neutrino Facility Far Detectors Cryogenics System

The Sanford Underground Research Facility (SURF) will host the Far Detectors of the Deep Underground Neutrino Experiment (DUNE), an international multi-kiloton Long-Baseline neutrino experiment that will be installed about a mile underground in Lead, SD. Detectors will be located inside four cryostats filled with almost 70,000 metric tons of ultrapure liquid argon, with a level of impurities lower than 100 parts per trillion of oxygen equivalent. The cryogenics infrastructure supporting this experiment is provided by the Long- Baseline Neutrino Facility (LBNF). This contribution presents modes of operation, layout and main features of the LBNF Far Detectors cryogenics system, which is composed of the following subsystems: argon receiving facilities, nitrogen system, argon distribution system, argon purification and regeneration systems, argon circulation system, argon condensers system, internal cryogenics, miscellaneous items, and process controls. An international engin eering tea m is designing these systems and will manufacture, install, test, commission, and qualify them. This contribution describes the main features, performance, functional requirements, and modes of operation of the LBNF Far Detectors cryogenics system. It also presents the status of the design, along with present and future needs to support the DUNE experiment.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2024

Solar Energy Innovation Network 2017-2024: Abbreviated Final Technical Report

This material is based upon work supported by the U.S. Department of Energy's (DOE) Office of Energy Efficiency and Renewable Energy (EERE) Solar Energy Technologies Office under the Agreement/Award Number 32954 for Solar Energy Innovation Network (SEIN) Project, 2017-2024. SEIN is a dynamic program that assembles diverse teams of stakeholders to research solutions to real-world challenges associated with solar energy adoption. In conjunction with its partner organizations, NREL implemented the program by providing research, analysis, and technical expertise directly to project teams and groups of teams (cohorts), by facilitating networked learning through cohorts and peer exchange, and by facilitating dissemination and replication of solutions and lessons learned among stakeholders across the U.S. with similar challenges.

14 SOLAR ENERGY↗
DOE OSTI2024

Development of High-Fidelity and Efficient Modeling Capabilities for Enabling Co-Optimization of Fuels and Multi-Mode Engines

The objective of this closely coordinated research project is to develop improved physical sub-models and innovative numerical algorithms to enable accurate and efficient predictions of multi-mode combustion to support EERE’s Co-Optima program. To this end, a research pro-gram is proposed that seeks • to develop accurate submodels for predicting multi-mode combustion regimes, wall-heat transfer, non-equilibrium plasma ignition, and combustion-mode transition, • to develop dynamic load-rebalancing algorithms and efficient semi-implicit time-integration schemes for enabling exascale computing, • to validate the computational submodels against experiments and direct numerical simulation (DNS) data in conjunction with sensitivity analysis, and • to support the direct transition of the resulting sub-models into other engine-simulation tools through the development of self-contained modules. All sub-models will be integrated into the open-source exascale engine-simulation platform Nek5000.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Sandia Wind Energy Program - FY23 Accomplishments

This report summarizes Fiscal Year 2023 accomplishments from Sandia National Laboratories Wind Energy Program. The portfolio consists of funding provided by the DOE EERE Wind Energy Technologies Office (WETO), Advanced Research Projects Agency-Energy (ARPA-E), Advanced Manufacturing Office (AMO), the Sandia Laboratory Directed Research and Development (LDRD) program, and private industry. These accomplishments were made possible through capabilities investments by WETO, internal Sandia investment, and partnerships between Sandia and other national laboratories, universities, and research institutions around the world. Sandia’s Wind Energy Program is primarily built around core capabilities as expressed in the strategic plan thrust areas, with 29 staff members in the Wind Energy Design and Experimentation department and the Wind Energy Computational Sciences department leading and supporting R&D at the time of this report. Staff from other departments at Sandia support the program by leveraging Sandia’s unique capabilities in other disciplines.

17 WIND ENERGY↗
DOE OSTI2023

Sandia Wind Energy Program: FY22 Accomplishments

This report summarizes Fiscal Year 2022 accomplishments from Sandia National Laboratories Wind Energy Program. The portfolio consists of funding provided by the DOE EERE Wind Energy Technologies Office (WETO), Advanced Research Projects Agency-Energy (ARPA-E), Advanced Manufacturing Office (AMO), and the Sandia Laboratory Directed Research and Development (LDRD) program. These accomplishments were made possible through capabilities investments by WETO, internal Sandia investment, and partnerships between Sandia and other national laboratories, universities, and research institutions around the world. Sandia’s Wind Energy Program is primarily built around core capabilities as expressed in the strategic plan thrust areas, with 29 staff members in the Wind Energy Design and Experimentation department and the Wind Energy Computational Sciences department leading and supporting R&D at the time of this report. Staff from other departments at Sandia support the program by leveraging Sandia’s unique capabilities in other disciplines.

17 WIND ENERGY↗
DOE OSTI2022

Batteries (2021 Annual Progress Report)

This document summarizes the progress of VTO battery R&D projects supported during the fiscal year 2021 (FY 2021). In FY 2021, the DOE VTO battery R&D funding was approximately $\$$115 million. Its R&D focus was on the development of high-energy batteries for EVs as well as very high-power devices for hybrid vehicles. The electrochemical energy storage roadmap (which can be found at the EERE Roadmap web page2) describes ongoing and planned efforts to develop electrochemical storage technologies for EVs. To advance battery technology, which can in turn improve market penetration of PEVs, the program investigates various battery chemistries to overcome specific technical barriers, e.g., battery cost, performance, life (both the calendar life and the cycle life), its tolerance to abusive conditions, and its recyclability/sustainability. VTO R&D has had considerable success, lowering the cost of EV battery packs to $\$$185/kWh in 2019 (representing more than 80% reduction since 2008) yet even further cost reduction is necessary for EVs to achieve head-to-head cost competitiveness with ICEs (without Federal subsidies). In addition, today’s batteries also need improvements in such areas as their ability to accept charging at a high rate, referred to as extreme fast charging (XFC) (15 minute charge) – to provide a “refueling” convenience similar to ICEs, and the ability to operate adequately at low temperatures. Research into “next-gen lithium-ion” batteries which would provide such functionalities is one of the R&D focus areas. VTO is funding research on both “next gen” chemistries (which employ an alloy anode and/or a high voltage cathode) and beyond lithium-ion (BLI) chemistries (which can, for example, employ a lithium metal anode).

25 ENERGY STORAGE↗
DOE OSTI2025

Circularity Futures Workshop Series: Summary Report

The aim of this report is to synthesize key feedback received from the three-part Circularity Futures workshop series held in Spring 2024. The workshop series was conducted by the National Renewable Energy Laboratory (NREL) on behalf of U.S. Department of Energy, Office Energy Efficiency and Renewable Energy (EERE), and was broken into three workshops: Workshop 1 - Circularity Analysis Needs and Priorities; Workshop 2 - Circularity Metrics and Indicators; and Workshop 3 - Circularity Data. Together, the workshops focused on identifying the existing priorities and gaps in the circularity modeling space, understanding different stakeholders' use and interpretation of circularity metrics and indicators, identifying common data gaps and data quality challenges, and assessing the robustness of available solutions. The workshop series brought a diverse group of stakeholders - including representatives from U.S. government offices, national labs, nonprofit organizations, industry, and academia - to collect first-hand feedback on needs, priorities, challenges and opportunities in the circularity modeling and analysis space. The workshop discussions highlighted numerous common needs, priorities and challenges among the interviewed groups. Several topics were frequently discussed, including: 1) Circularity as a pathway for sustainable economic growth: While circularity is generally defined in terms of resource conservation and reducing wasteful disposal of materials, participants agreed that circular strategies should serve broader economic, environmental, and social goals. It is therefore crucial for circularity analysis to look beyond waste reduction and instead evaluate a variety of impact metrics such as cost savings, job creation, air quality, and pollutant emissions. Mutli-criteria decision-making frameworks may be useful for making sense of disparate metrics and evaluating tradeoffs between impact categories.; 2) Economic and social factors are not well understood: Underdevelopment of existing end-of-life (EOL) management infrastructure, inconsistent standardization codes and policy space in reusing recycled content, and suboptimal collection and sorting strategies collectively contribute to uncertainty about the economic potential of circular pathways. The latter observation is consistent among all technologies but more emphasized for renewable energy systems. Social impacts of circularity practices are less understood and less researched than other sustainability aspects.; 3) Inconsistent methods for assessing emerging technologies: LCA and TEA results vary widely depending on the assumptions made with regards to market adoption of new technologies. Emerging technologies suffer limited availability of data needed to conduct a robust circularity analysis. Yet, understanding projected impacts of proposed nascent technology is a key need for different stakeholder groups.; and 4) Lack of temporally and geospatially explicit data: There is a need for open data that represents variations in circularity technologies over time and location. The lack thereof leads to aggregated and potentially misrepresented results in circularity analysis. Sensitivity analyses should be included to verify whether options perceived as more sustainable align with real-world practices.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2025

A Shared Understanding and Paths Forward for Community Benefit Mechanisms: Workshop Summary Report

On October 7-8, 2024, the U.S. Department of Energy's Office of Energy Efficiency and Renewable Energy (EERE) and the National Renewable Energy Laboratory hosted an in-person workshop focused on research needs and strategies for community benefit mechanisms (CBMs) used in the deployment of renewable energy infrastructure. Community benefit mechanisms (such as community benefit agreements, funds, and donations) are used to provide increased benefits and/or mitigate negative impacts of energy development for the communities that are impacted. The workshop aimed to assess the current state of knowledge, tools, practices, and lessons learned, as well as to identify research and other work needed to improve the impact and effective implementation of CBMs. This report describes the purpose and structure of the workshop and summarizes key themes, questions, issues, and ideas that arose from the workshop.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2025

A Safe Response to Renewable Energy Hazards

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

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

Intermediate Temperature Proton‐Conducting Solid Oxide Electrolysis Cells with Improved Performance and Durability

Technical understanding: A high-performance and stable intermediate temperature proton-conducting solid oxide electrolysis cell (PCEC) will add significantly to the hydrogen roadmap of EERE. However, the low electrocatalytic activity of the air electrode and the instability of the electrolyte are technical barriers. In this research, we utilized computational fluid dynamic modeling and materials/microstructure engineering to investigate the complex reaction chain and to improve the performance and reliability of the protonic ceramic electrochemical cells. An active and stable Pr 1.8 Ba 0.2 NiO 4+δ -BaZr 0.1 Ce 0.7 Y 0.1 Yb 0.1 O 3-δ (BZCYYb) scaffold conformal coating electrode was rationally designed where the robust Pr 1.8 Ba 0.2 NiO 4+δ functions both as a catalytic active and a protective layer. The PCECs with porosity-optimized scaffold conformal coating electrodes demonstrate 1.46 Acm -2 under 1.3 V at 600°C, which is among the highest in recent years. The final optimization by computational fluid dynamic modeling and conformal coating technique was applied to evolve the PCEC air electrode from Pr 2 NiO 4+δ to Pr 1.8 Ba 0.2 NiO 4+δ -BaZr 0.1 Ce 0.7 Y 0.1 Yb 0.1 O 3-δ scaffold conformal coating. The electrolysis current was boosted from 0.445A/cm 2 to 1.46A/cm 2 at 600°C and 1.3V. A superior low degradation rate of 1mV/kh was achieved in a 5000-hour of operation. Technical effectiveness and economic feasibility: The effectiveness of this TCO conformal coating on electrolyte backbone as air electrode has been proven by long-term demonstration. Based on the highly conductive BZCYYb electrolyte and the TCO steam electrode PNO, this project rationally took advantage of the existent materials to structure a PCEC device with high TRL and low risk. The solution infiltration method used to structure the conformal coating is a standard method used by the solid oxide cell community. Very minimal adoption is needed in the current SOC fabrication process. It is a cost-effective, scalable method for manufacturing, and brings up remarkable impact on the current technical status of PCEC. Benefit to the public: The findings in the research showed the industry that the severe challenge in PCEC can be overcome in a practical way. A various energy-hydrogen ecosystem is not beyond reach. The success of this technology provides sustainable and affordable H 2 to society. It will stimulate investment from the governmental and private sectors in response to the device manufacture and deployment, and the related infrastructure construction. It will generate high-pay domestic jobs and environmental benefits to the general public in the United States.

08 HYDROGEN↗
DOE OSTI2024

Cost-effective Conductor, Cable, and Coils for High Field Rotating Electric Machines

The purpose of the DOE-AMMTO-funded project was to significantly reduce industrial energy intensity through manufacturing innovations. The project focused on superconducting technology for industrial motors to dramatically increase efficiency. The bottleneck in deploying high temperature superconducting (HTS) motors was high cost and low yield of the conductor manufacturing process. The process yield is low because of the defects in the conductor, forcing the manufacturers to cut off defective sections after characterizing each millimeter. Additionally, the piece lengths tend to be low because of the defects. The project tackled the low-yield manufacturing process challenge by devising an innovative method to use defective conductors in bundled cables without losing performance by engineering current sharing among the conductors. The innovation not only lowers the cost of the conductor but also enhances the reliability of HTS motors and other devices to mitigate the defects that might form during the fabrication and operation of the device. With the increasing interest in REBa2Cu3O7-x (REBCO)-coated conductors for various power, energy, and magnet applications, ensuring the reliability of HTS devices is of significant interest. The EERE funding allowed us to make significant progress in understanding the defects in manufactured conductors and the implications of the defects in superconducting electric motors and other superconducting power and energy applications.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

High Efficiency Reversible Solid Oxide System (Final Technical Report)

This report was generated based upon work supported by the U.S. Department of Energy’s Office of Energy Efficiency and Renewable Energy (EERE) under the Hydrogen and Fuel Cell Technologies Office, H2@Scale Initiative, Award Number DE-EE0008847. In this project, FuelCell Energy studied the design and performance of a system rated for 15kWe Charge/3 kWe Discharge energy storage system based on reversible solid-oxide technology.

08 HYDROGEN↗
DOE OSTI2022

I.3.4.1.1 Overview of Advanced Characterization Within the Powertrain Materials Program (Task 4A1) (Oak Ridge National Laboratory); (Task 4A2) (Argonne National Laboratory); and (Task 4A3) (Pacific Northwest National Laboratory)

This report describes the activities performed during the third year of Thrust 4A, “Advanced Characterization,” within the DOE-EERE VTO PMCP. The goal of the PMCP, which was launched in October 2018, has been to accelerate design, development, demonstration, and deployment of new, cost-effective advanced alloy solutions via a modern ICME approach. The properties of these new materials are targeted to enable improvements in engine efficiency, lightweighting, and durability enhancement over the full range of on-road vehicle classes (e.g., Classes 1-8), including range extenders for future electric HD freight vehicles.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2025

Scribe and Interface Modification for Stable Halide Perovskite Modules (CRADA Final Report)

This project provided funding to NREL/Tandem PV by EERE-SETO and has the goal of improving perovskite module stability by at least a factor of 2 without sacrificing initial efficiency. This will be demonstrated using 3"x3" minimodules and will be tested according to the Innovation and Entrepreneurship Center (IEC) standards and demonstrated using outdoor testing. A CRADA was established between NREL and Tandem PV to address the goals for the funded effort.

14 SOLAR ENERGY↗
DOE OSTI2025

Decarbonizing Solvent Chemistry Through Microwave Processing [Abstract]

National Energy Technology Laboratory and Covestro LLC. will collaborate on a project titled, “Decarbonizing Solvent Chemistry Through Microwave Processing”, which was selected for funding by DOE’s Office of Energy Efficiency and Renewable Energy (EERE) Industrial Efficiency and Decarbonization Office (IEDO) FOA DE-EE0002997. The project aims to develop a microwave-based approach for low-heat aqueous-based industry-relevant reactions currently conducted using a conventional fossil-energy fueled hydrothermal reactor. The team has combined expertise in the areas of polymer production, microwave assisted reactions and scale-up, and life cycle analysis to perform the tasks proposed.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Abstract for CRADA between NETL and West Virginia University Research Corporation

The National Energy Technology Lab (NETL) will collaborate with West Virginia University to develop and demonstrate a dynamically operated modular, microwave-enhanced catalytic process for the co-production of ammonia and olefins. Ammonia and olefins (e.g., ethylene) are the most widely produced chemicals in the U.S. by volume, but their processes are also the most carbon and energy intensive as they rely on fossil-based feedstocks and combustion of fossil fuels for heating. The project will leverage the unique ability of microwaves to intensify process heating by providing pulsed, targeted energy to active sites of a mixed catalyst bed to convert a mixture of CH 4 /N 2 into ethylene and ammonia. The collaboration will facilitate the development of microwave technology that has the potential to utilize distributed waste resources like shale gas or biogas as well as renewable electricity to produce these valuable chemicals. It is expected that the results will decarbonize chemical production by using renewable energy and waste feedstocks, improve efficiency by reducing unit operations (H 2 production), and de-risk microwave technology for chemical production by demonstrating long-term and dynamic operability. This project was funded by an award from the Department of Energy’s EERE IEDO.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗