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At least 343 records · Page 19

Flexible Perovskite-Perovskite PV for Mobile Power Applications (Final Technical Report)

This is the final report for the referenced TCF award which ran from Oct. 2019 through Jan. 2024 in conjunction with the industry partner Swift Solar. The long duration of the program was due to several factors including the pandemic and a technical work stoppage due to changes in the scope. Additionally, Swift’s business focus shifted during the course of the program. As a result of these factors, this program underwent two distinct modifications that dramatically changed the work scope. The following report is organized into three separate sections, each of which addresses a distinct work scope. Those scope changes, what necessitated them, and any new tasks/milestones are given, briefly, at the top of each section. The work performed was research on the hybrid halide perovskites (HHP), both the absorber material itself as well as other material layers that are required in a full device stack. At the start of the period of performance, there were two distinct challenges that we sought to address: (1) a wide band gap absorber (>1.6 eV), and (2) a recombination layer for tandem devices that provided good sequestration of the individual cell absorber materials in their respective device layers. NREL had previously published, and patented, advancements in both of these areas and they were the focus of much of the work throughout the program.

14 SOLAR ENERGY↗

Stakeholder-guided holistic, Adaptive Framework for enhancing community Energy Resilience (SAFER) (Final Technical Report)

The Stakeholder-guided holistic, Adaptive Framework for enhancing community Energy Resilience (SAFER) project advances resilience science and engineering by addressing challenges in rural Kansas communities where aging infrastructure, extreme weather, and socioeconomic disparities heighten vulnerability to energy disruptions. Traditional approaches often focus on technical performance while overlooking community concerns and priorities. SAFER responds by integrating community perspectives with advanced analytical frameworks to create a holistic model for measuring and improving resilience. Project objectives included developing novel resilience metrics, advancing modeling frameworks that capture interdependencies across infrastructures, and embedding community-centric indicators directly into planning processes for distributed energy resources. The key technical innovations included the creation of self-organizing map (SOM)-based indices for objective resilience quantification, hetero-functional graph theory (HFGT) models linking power, water, transportation, and community assets, and graph neural network (GNN) tools for identifying critical nodes in complex systems. Community-centric energy planning was demonstrated through optimal siting and sizing of (photovoltaic) PV and battery storage, ensuring resilience enhancements also addressed energy burden and energy insecurity. SAFER engaged community partners in Dodge City and Ford County through surveys, focus groups, and workshops, generating more than 600 responses that established baseline measures of energy burden, financial insecurity, and willingness-to-pay to avoid outages. This data, organized in terms of a community capitals framework, informed the development of weighted reliability indices that better reflect community costs than traditional utility metrics. SAFER’s GNN-based critical node identification framework identified expert-labelled critical nodes with over 99% accuracy, while also uncovering additional functionalities essential for proactive resilience planning. The project’s models demonstrated that optimal PV and storage deployment could improve resilience indices by over 11 percent, with dispatch strategies further enhancing outcomes, confirming both the technical effectiveness and economic feasibility of these approaches. Through its combined emphasis on rigorous modeling, community-focused planning, and community engagement, SAFER advances the state of resilience research while delivering direct benefits to rural communities. The project provides tools, guidelines, and resilience heatmaps that help utilities, local governments, and residents better anticipate disruptions, prioritize investments, and strengthen the capacity to withstand and recover from energy-related hazards. Furthermore, the developed HFG and GNN frameworks are designed for transferability, allowing them to be adapted for resilience planning in other communities with minimal retraining. This inductive learning capability provides a scalable pathway to extend the SAFER project’s impact. Thus, creating a foundation for a nationally applicable model of infrastructure resilience. Additionally, the HFG can also be extended to include other FEMA community lifelines.

14 SOLAR ENERGY↗

Stakeholder Training for IEEE 1547-2018 (Abbreviated Final Technical Report)

This project identifies and makes publicly available educational materials to assist stakeholders in adopting the revised IEEE Std 1547-2018, Standard for Interconnection and Interoperability of Distributed Energy Resources with Associated Electric Power Systems Interfaces. The new standard is significantly different than the previous 2003 version, contains new concepts and new technical requirements, and requires educational material on the application of these changes. NREL had a principal role in accelerating the revision process though its chairmanship of the IEEE Std 1547 working group to revise the standard and through technical support provided to the working group. Under this project, NREL and partners compiled and developed publicly available educational materials for IEEE Std 1547-2018, including webinars, white papers, and other resources on related topics.

14 SOLAR ENERGY↗

Inclusive Shared Solar Initiative (ISSI) (Final Technical Report)

Between 2020 and 2024, the Inclusive Shared Solar Initiative (ISSI) served as a forum for three states to navigate the design and development of LMI-accessible community solar projects. A collaboration between the National Association of State Energy Officials (NASEO) and National Energy Assistance Directors Association (NEADA), ISSI provided financial and technical assistance to teams of State Energy Offices and State LIHEAP Agencies in Minnesota, Wisconsin, and the District of Columbia. The key goals guiding ISSI were to develop four new community solar frameworks in three new states and create greater momentum among state governments, community solar developers, and the finance community in scaling and investing in community solar projects that are affordable and accessible to LIHEAP households. Ultimately, in addition to developing and launching four new shared solar projects serving LMI subscribers, the ISSI state partners pioneered community solar policy and program design strategies that increased protections for low-income consumers, reduced barriers to enrollment and project development, and fostered inter-program coordination.

14 SOLAR ENERGY↗

Final Technical Report for U.S.-Japan Hadronic Physics Exchange Program for Studies of Hadron Structure and QCD

Nuclear physics explores the fundamental properties of matter -- how protons and neutrons emerge as quantum systems of elementary particles, how they form the atomic nuclei, and how they give rise to the wide variety of phenomena and applications at biological, technical, and astronomical scales. It is a global scientific effort centered around large-scale experimental user facilities (particle accelerators and detectors), advanced theoretical methods and concepts, and computational techniques and resources. Exchange of knowledge and ideas, scientific collaboration, and workforce development on a global scale are essential for the future of the field. The nuclear physics program envisaged in the 2023 DOE/NSF NSAC Long-Range Plan and pursued at the U.S. National Labs has strong synergies with programs at other facilities worldwide and will realize significant benefits from international collaboration. Nuclear physics is also recognized for promoting international cooperation in the broadest sense through joint construction and operation of experimental equipment, personal contacts between scientists, and education and training. The U.S.-Japan Hadronic Physics Exchange Program (USJPHE) supported collaborative scientific research in hadronic physics and quantum chromodynamics. USJHPE focused on subject areas related to the programs at current and future experimental facilities in the U.S.\ and Japan and supported both experimental and theoretical studies. USJHPE particularly aimed to realize synergies between the hadronic physics programs at Jefferson Lab 12 GeV and J-PARC resulting from the complementarity of electromagnetic and hadronic probes in the multi-GeV energy range. Subject areas of common interest included the quark-gluon structure of hadrons and nuclei, meson and baryon spectroscopy, strangeness and hypernuclear physics, and other related topics. USJHPE also supported research in hadronic physics and nuclear-physics-enabled tests of fundamental symmetries related to the programs at Brookhaven National Lab, Fermilab, KEK, Spring-8, and university-based facilities in the U.S. and Japan. USJHPE especially promoted collaboration between the U.S. and Japanese nuclear physics communities in developing the physics program and instrumentation for the future Electron-Ion Collider. USJHPE was intended to provide travel grants to U.S.-based scientists (primary institutional affiliation with a U.S.\ university, national laboratory, or other research center) to visit Japanese institutions and conduct collaborative research there. The program supported senior researchers, postdoctoral fellows, and students. Continuing the setup of the preceding grant period, J-PARC served as the Japanese “hub” for U.S. physicists for short- and long-term visits, and JLab served as the corresponding U.S. “hub”. The program was officially managed through the U. of Connecticut in Storrs, CT. Support for Japanese physicists visiting the U.S. was provided through funds from Japanese funding agencies. The USJHPE program promoted the scientific exchange and the collaborative spirit in hadronic physics between the two countries.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

Ion Channel Laser Based on Direct Laser Acceleration of a Shaped Beam Driver (Final Technical Report)

The main focus of our research was to understand the synergies between an electron bunch and a laser pulse when the two co-propagate through the plasma. We have clearly demonstrated using theoretical and computational modeling that the propagation distance of both the bunch and the laser pulse could be extended. The ability of the combined bunch/pulse system to extend the propagation distance and the size of the plasma bubble enables highly-efficient sources of relativistic electrons. As pointed out by the Plasma Decadal Study, such electron sources can be used for generating extremely bright x-rays for a variety of applications can serve as probes and diagnostics for other plasma experiments: high energy density (HED) sciences, inertial confinement fusion (ICF), and potentially Fusion Materials and Technology (FM&T). Development of advanced diagnostics of plasma-based accelerators is yet another key area identified by recent reports. Even broader security and medical applications of compact accelerator-based radiation sources, such as very high energy electron (VHEE) sources for FLASH radiobiology, have been identified by a recent multi-agency panel. A number of key technical issues were considered and successfully resolved during the course of the grant. Those include: beam loading effect of both the driver and witness bunches on the wake, laser channeling by the bunch, and the direct laser acceleration (DLA) of the driver bunch by the laser pulse. To demonstrate clear synergy, we were able to ascertain that the total energy gain of a witness bunch in the wake of the combined bunch/laser complex is large than the sum of the energy gains in the wake of the laser pulse alone, and the driver bunch alone. We have also demonstrated that not only the energy gain is improved, but the energy spread is not sacrificed. To carry out these simulations, we have to develop a range of in-house computational tools, including a fully-3D code WAND-PIC.

43 PARTICLE ACCELERATORS↗

Mitigating Phase Unbalance for Distribution Systems with High Penetrations of Solar PV (Final Technical Report)

Distribution system operators have traditionally limited unbalance among phases by maintaining similar loadings on each phase. High penetrations of distributed solar PV continually change the net loading on each phase, resulting in time-varying phase unbalances that can damage three-phase devices such as three-phase motors, violate grid codes, and increase technical losses. This project has developed several control strategies for the reactive power outputs of solar PV inverters in order to mitigate power quality issues related to phase unbalance. These control strategies include a decentralized approach that is solely based on local measurements, distributed and grouped approaches that consider subsets of loads and PV generators, and a centralized approach that leverages measurements from a variety of locations in order to compute optimal reactive power setpoints for each inverter. Variants of the controllers handle challenges relevant to practical implementations, including noisy measurements, delayed communications, and reactive power limits. Moreover, the project developed theory that provides convergence guarantees for systems with multiple interacting controllers as well as “balanceability” certificates that ensure satisfaction of phase unbalance requirements with variable loading. The controllers were integrated with NRECA’s Open Modeling Framework (omf.coop) and evaluated using actual distribution system models obtained from several NRECA member utilities. Application of the controllers results in significant improvements to phase unbalance in these test cases with decreases from base case levels of over 3% to under 0.5%, which is within the 2% IEC phase unbalance standard.

14 SOLAR ENERGY↗

5G-TSN Architecture Capable of Providing Real-time Situational Awareness to Fossil-Energy (FE) Generation Systems (Final Technical Report)

This final report highlights the comprehensive achievements of the project focused on developing and validating a 5G-Time Sensitive Networking (TSN) architecture tailored for real-time operational awareness in fossil energy systems. The initiative successfully advanced through a series of technical milestones, including the integration of EMI-aware network models, deployment of advanced simulation frameworks, and real-world performance characterization at key sites such as UTEP and Fabens. Through the strategic use of NetSim® software, the team created and validated network configurations for wired and wireless environments, tested under varying congestion conditions, and verified network slicing implementations for URLLC-specific applications. Major accomplishments include the migration of simulation tools to the latest NetSim® version to support accurate modeling of TSN and network slicing, extensive EMI measurement campaigns, and the development of a robust simulation model for end-to-end SCADA system integration. Simulations compared both TDD and FDD duplexing modes, revealing insights into their performance under congested conditions. The wireless network was benchmarked for throughput, jitter, and delay metrics, aligning with 3GPP Release 15/16 and IEEE 802.1-TSN standards. A peer-reviewed conference paper was accepted and published, contributing to the broader academic and industrial discourse on 5G-TSN integration in energy systems, in addition to a journal article. Despite minor delays due to software limitations, the project achieved its objectives and delivered validated architecture ready for deployment in advanced energy network environments.

01 COAL, LIGNITE, AND PEAT↗

Development and Bench-Scale Testing of a Novel Biphasic Solvent-Enabled Absorption Process for Post-Combustion Carbon Capture (Final Technical Report)

A new class of biphasic solvents was developed, and the concept of the enabled carbon dioxide (CO 2 ) absorption process was tested for post-combustion carbon capture in our previous lab-scale research. The primary goals of this project were to advance the development of the novel biphasic CO 2 absorption process (BiCAP) and validate its technical advantages by testing the integrated technology at a 40 kWe bench-scale with actual coal-derived flue gas in a power plant environment. The project was led by the University of Illinois at Urban-Champaign (UIUC), and Trimeric Corporation served as a sub-awardee providing support in basic design and techno-economic studies. To achieve the project goals and objectives, solvent management studies, process modeling and optimization, bench-scale equipment design, construction and testing, and technical, economic and environmental assessments have been conducted. The two top-performing biphasic solvents developed in our previous research were used in this project. Biphasic solvent emissions and control were investigated in the laboratory. The emissions of the biphasic solvents from the absorber were comparable to or lower than the reference 30 wt% monoethanolamine (MEA) solution, while they could be more effectively removed in the water wash column. Lab-scale testing of solvent degradation reclamation has revealed that vacuum distillation was feasible for biphasic solvent reclamation. Aspen Plus models were used to optimize the BiCAP, and a CO 2 stripping configuration introducing a secondary cold solvent feed to the stripper was identified to be the most energy efficient. A 40 kWe bench-scale, integrated BiCAP system was successfully designed, fabricated, and installed at the UIUC’s Abbott Power Plant. Parametric testing with synthetic flue gas has demonstrated that the two biphasic solvents required a more than 40% lower heat duty for CO 2 desorption as compared to the reference MEA tested on the same bench-scale skid. Slipstream testing with actual coal flue gas for a total of 31 days in two test campaigns has further demonstrated stable operation of the bench-scale skid. During the first campaign targeting 90% CO 2 removal, the heat duty averaged at 2,183 MJ/tonne of CO 2 captured and during the second campaign targeting 95% removal, the heat duty averaged at 2,450 MJ/tonne of CO 2 captured. A techno-economic analysis has revealed that for integration of the BiCAP into a 650-MWe pulverized coal-fired power plant, the parasitic power loss was reduced by ~20%, and the cost of CO 2 capture was reduced by ~21% ($36.3/tonne on a December 2018 dollar basis) compared to the U.S. Department of Energy (DOE)’s baseline Case B12B. As progression from this bench-scale development effort, a new project “Engineering-Scale Testing of the Biphasic Solvent Based CO 2 Absorption Capture Technology at a Covanta Waste-to-Energy Facility” was awarded by the DOE, launched in February 2023, to allow the team to further test the technology and demonstrate its technical and economic advantages at a pilot scale.

20 FOSSIL-FUELED POWER PLANTS↗

Development of Advanced Solid Sorbents for Direct Air Capture (Final Technical Report – Unlimited)

RTI Team, proposes an approach for demonstrating carbon-neutral methanol (MeOH) produced from carbon dioxide (CO 2 ) removed from air by direct air capture (DAC) and green hydrogen (H 2 ) from water (H 2 O) electrolysis using renewable electricity. The proposed project will include completing a feasibility study that informs a conceptual design of an integrated process that meets technical and economic targets set forth.

10 SYNTHETIC FUELS↗

Final Technical Report

Statement of the problem or situation that is being addressed in your application. The DOE and its national laboratories developed the Home Energy Score™ (HES) to encourage homeowners to improve their energy performance, lower costs and to share energy information through the MLS listing, appraisal, and financing channels. While the HES is an instrumental tool, it is currently underutilized and consists of technical, structural and sector barriers which need to be addressed in order to scale and many energy efficiency contractors are understandably overwhelmed by the added time and effort and lack of incentive to sell and deliver deep retrofit projects while simultaneously meeting the DOE HES program requirements; consequently, contractors may decide to forgo participation. Home Energy Rating System (HERS) Raters have the opportunity to play the critical Assessor role in producing a Home Energy Score (HES); this role has immense potential but currently is unfulfilled. Lastly, while utilities are interested in their customer base achieving greater energy efficiency, especially to help offset growing residential loads in states like California that are accelerating electrification, utilities do not have access to the market actors who are on the front line of influence to homeowners or review and approve their permits: HERS Raters, assessors, contractors and building departments. General statement of how this problem is being addressed: ConSol will integrate the Home Energy Score™ (HES) to its State of California, approved home energy rating services (HERS) platform (CHEERS) to develop a single tool for contractors nationwide to assess, record and install recommended cost, energy, and emissions saving measures to the 140 million single-family homes throughout the U.S. and 14 million homes in California (CHEERS+HES). The CHEERS high fidelity energy code permitting data will be integrated with HES for simple, accurate, easy-to-use home energy estimation and analysis and will directly gain access to the retrofit and renovations markets with the same upgraded platform. This innovative project will assist the utilities in supporting existing homes in their jurisdictions with HES and develop measures to improve energy efficiency and reduce emissions. How is this problem being addressed? What is the overall project approach? In effort to expand the Home Energy Score™ (HES) by increasing the use of aggregable home energy asset data, ConSol proposes to integrate the DOE HES via Application Programming Interface (API) to its State of California approved home energy rating services platform (CHEERS). Once the CHEERS platform and HES are integrated (CHEERS+HES), this enhanced platform will be instantly available and actively deployed via Phase 1 pilot to HERS Raters, assessors and contractors in California to market-test the solution, understand the rate of adoption and identify opportunities for improvement prior to scaling nationally. The CHEERS high fidelity energy code permitting data will be integrated with HES for simple, accurate, easy-to-use home energy estimation and analysis and will directly gain access to the retrofit and renovations markets with the same upgraded platform. This innovative project will assist the building industry and homeowners with an easy-to-use assessment if energy and carbon impacts of existing homes, and assist the utilities in supporting existing homes in their jurisdictions with HES to improve energy efficiency and reduce emissions. What is to be done in Phase I? During Phase I of this proposed project, ConSol will (1) design software architecture that links CHEERS to the Home Energy ScoreTM via API, (2) solicit partnership from one or more California utilities for a regional pilot, (3) test the new software with its HERS Raters and contractor network in the partnership utility jurisdiction, (4) launch a pilot version of the newly developed software with HERS Raters and contractors in the utility territory, and (5) explore California’s GoGreen energy efficiency homeowner lending program in parallel with the pilot. Commercial Applications and Other Benefits. Summarize the future applications or public benefits if the project is carried over into Phase II or Phase III and beyond. The CHEERS+HES commercialized product will be ready for national market scale following a successful Phase 1 performance. The CHEERS+HES adoption is estimated to reach a 5% adoption growth rate versus the 110,000 baseline, starting in Year 1 after Phase I completion, and continuing each year. As a direct benefit to the DOE, CHEERS will set a goal of 100,000 Home Energy Score assessments for existing home alterations within the first 10 years following Phase 1 performance. The technical benefits of this proposed project include the harmonized, automated, and seamless integration of the DOE HES into the widely used and market leading California energy registry, CHEERS. The social benefits include the aggregate energy, cost and GHG savings by allowing the broader public streamlined access to the CHEERS+HES measurement and the energy efficiency recommended measures that may result. Key Words: Home Energy ScoreTM (HES); Application Programming Interface (API); Home Energy Rating Services (HERS); HERS Raters; contractors; assessors; existing homes, energy asset data; cost, energy, and emissions saving measures; energy code (Title 24) compliance; document repository; utilities; pilot; newly developed software; energy efficiency; homeowner. Summary for Members of Congress: The DOE Home Energy Score™ (HES) is a tool to encourage homeowners to improve their energy performance, lower costs and share energy information but is underutilized and consists of barriers which need to be addressed in order to scale. In effort to expand the HES, CHEERS, Inc. will integrate the HES to its State of California, approved home energy rating services (HERS) platform (CHEERS) to develop a single tool for contractors nationwide to assess, record and install recommended cost, energy, and emissions saving measures to the 140 million single-family homes throughout the U.S. and 14 million homes in California.

Application Programming Interface (API)↗

Advances on CHP District Energy and Microgrids Deployment: Simplified Tool for Rapidly Deploying Feasibility Analytics for the Non-Technical User (Final Technical Report)

Community energy systems have proven to have the potential to improve cost efficiency, resilience, and decarbonize. However, investing in community energy systems such as community microgrids or district energy systems is a complex decision due to the high initial investment and the uncertainties associated with the long development time and lifecycle of the project. Tools that make feasibility assessments accessible to non-technical users like investors, policymakers, and other stakeholders will result in more feasibility analyses completed, more candidate projects identified, and more community energy systems deployed. The pilot tool developed under this award is named Energy Fellow. Energy Fellow allows technical and non-technical users to complete feasibility analyses for district energy systems and community microgrids. This is the first software tool of its kind designed for non-technical users and available at no cost. Its scope was adjusted to a 25x25-mile region within the Houston area in Texas to make its development compatible with the funding available. However, the findings and models developed make this pilot tool easily scalable to the US. The lessons learned during the design, implementation, and testing stages have helped find trade-off solutions to software and hardware challenges related to implementing 3D models in online tools. Green software strategies has been successfully applied to the design and operations of the tool, and the team has researched the aspects of the (non-technical) user experience that will make commercial developments of this tool even more impactful.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Energy recovery from solid waste. Volume 2: Technical report

A systems analysis of energy recovery from solid waste demonstrates the feasibility of several current processes for converting solid waste to an energy form. The social, legal, environmental, and political factors are considered in depth with recommendations made in regard to new legislation and policy. Biodegradation and thermal decomposition are the two areas of disposal that are considered with emphasis on thermal decomposition. A technical and economic evaluation of a number of available and developing energy-recovery processes is given. Based on present technical capabilities, use of prepared solid waste as a fuel supplemental to coal seems to be the most economic process by which to recover energy from solid waste. Markets are considered in detail with suggestions given for improving market conditions and for developing market stability. A decision procedure is given to aid a community in deciding on its options in dealing with solid waste, and a new pyrolysis process is suggested. An application of the methods of this study are applied to Houston, Texas.

Huang, C. J.↗

Turnaround operations analysis for OTV. Volume 2: Detailed technical report

The objectives and accomplishments were to adapt and apply the newly created database of Shuttle/Centaur ground operations. Previously defined turnaround operations analyses were to be updated for ground-based OTVs (GBOTVs) and space-based OTVs (SBOTVs), design requirements identified for both OTV and Space Station accommodations hardware, turnaround operations costs estimated, and a technology development plan generated to develop the required capabilities. Technical and programmatic data were provided for NASA pertinent to OTV round and space operations requirements, turnaround operations, task descriptions, timelines and manpower requirements, OTV modular design and booster and Space Station interface requirements. SBOTV accommodations development schedule, cost and turnaround operations requirements, and a technology development plan for ground and space operations and space-based accommodations facilities and support equipment. Significant conclusion are discussed.

Source record↗

SPERLU Selective Process for Efficient Removal of Lignin and Upgrading (Final Technical Report)

To meet the growing demand for bio-based chemicals and improve the profitability and efficiency of the emerging biorefinery industry, lignin is an abundant and attractive feedstock. Spero Renewables has developed a proprietary and patent-pending technology, the Selective Process for Efficient Removal of Lignin and Upgrading (SPERLU). The technology is a catalytic deconstruction and upgrading of lignin in lignocellulosic biomass or commercially available technical lignin to produce multi-functional phenol (MFP) products. The SPERLU process has been demonstrated and vetted on a lab scale to convert commercially available technical lignin to MFPs in yields of 60-90% (based on lignin). The MFP products can be separated and further upgraded through catalytic or biological means. Spero performed a detailed kinetic study of the SPERLU process and used the resulting kinetic data to design and construct a mini-pilot-scale reactor for routine production of hundreds of grams of MFP products. Spero’s lignin-based MFPs have been demonstrated for use as a drop-in replacement for bisphenol A (BPA) in the synthesis of thermoset polymers. Spero’s lignin-based thermoset polymers exhibit excellent mechanical properties and can be used in many applications. Additionally, a collaboration with the National Renewable Energy Lab (NREL) was used to evaluate the feasibility of upgrading SPERLU products through biological means into valuable chemicals. A comprehensive technoeconomic analysis (TEA) and Life-cycle analysis (LCA) have been completed and support the case for commercialization of the SPERLU technology. Through this project Spero has significantly de-risked the SPERLU technology and is actively planning larger scale pilot projects.

09 BIOMASS FUELS↗

Organic Rankine Cycle Integration and Optimization for High Efficiency CHP Genset Systems (Final Technical Report)

This project successfully advanced the integration of Organic Rankine Cycle (ORC) technology with reciprocating engine–based combined heat and power (CHP) systems to improve electrical efficiency, total CHP efficiency, and grid-responsive operation. Over three budget periods, the work progressed from high-temperature ORC component development and thermodynamic model validation to next-generation system design, working fluid transition, and techno-economic analysis. Key technical accomplishments include development and validation of a thermodynamic model capable of accurately predicting ORC performance across an expanded temperature and pressure envelope; successful identification and validation of low-global-warming-potential (GWP) working fluids—most notably R1233zd(E)—as viable replacements for R245fa; and demonstration of scalable ORC architectures suitable for integration with 1–20 MW class reciprocating engines. These advances enable flexible CHP configurations that can increase electrical output while maintaining high overall utilization of available thermal energy. The project also produced a clean-sheet design for a next-generation ORC system targeting substantially higher power output per unit, supported by detailed component selection, heat exchanger evaluation, and system-level modeling. Techno-economic analyses indicate that ORC-enabled flexible CHP systems can meet or exceed Department of Energy (DOE) efficiency targets while providing value to both facility operators and the electric grid.. Late-stage testing of the largest next-generation ORC prototype identified limitations related to pump net positive suction head (NPSH) requirements and condenser flooding under certain operating conditions. Although these issues constrained full validation of that configuration within the project timeframe, they provided clear and actionable design guidance for future system refinements. Importantly, validated modeling, smaller-scale testing, and working fluid evaluations confirmed the technical viability of the overall approach. In aggregate, this project met its core objectives by establishing validated design tools, de-risking key ORC technologies for CHP applications, and defining a credible pathway toward commercialization of flexible, high-efficiency CHP systems. The results form a strong foundation for continued development and deployment beyond the conclusion of the DOE-funded effort.

20 FOSSIL-FUELED POWER PLANTS↗

Reducing Energy Use and Making Energy More Efficient in the Native Village of Kiana (Final Technical Report)

The goal of the Remote Alaska Community Energy Efficiency (RACEE) Competition was to advance the implementation of affordable, resilient, and clean energy-efficient solutions for remote Alaska communities. RACEE assisted Kiana with its unique challenges, mostly the remote nature of their location paired with the harsh temperatures and isolated electrical grid resulting in high energy costs. In addition to the assistance from DOE, the Alaska Energy Authority (AEA) provided direct technical assistance to RACEE recipients throughout their projects. Before Kiana started work, AEA conducted energy audits in public buildings and facilities to identify which energy measures would be most effective for the community’s energy goals.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Public – Private Partnership to Promote Efficient Manufacturing and Workforce Development (IAC Final Technical Report)

Through delivering ninety (90) energy assessments to small- and medium-sized manufacturing facilities in and around Tennessee, significant understandings were gained through providing detailed energy assessment reports to manufacturers and training seventy-seven (77) engineering students in which thirty-five (35) certified IAC students were recognized by DOE. The robust involvement of Tennessee Valley Authority (TVA), local utility and Tennessee Tech’s Cybersecurity Education, Research, and Outreach Center (CEROC) in majority of assessments made the technical operation very effective where leaded to 40.5% implementation rate of energy recommendations. Other benefits of the award to the public are a dynamic modeling tool capable of analyzing existing cooling towers for energy use optimization was developed and presented to DOE IAC, providing technical assistance to non-participating manufacturers in the form of workshop and training, publishing fifteen (15) peer-reviewed conference and journal papers as well as a book chapter in the area of industrial energy efficiency field, assisting the TVA Magnolia Combined Cycle Power Plant to become the First 50001 Ready Certified Power Plant in the U.S. through briefing them on ISO 50001 and 50001 Ready as well as providing an energy assessment to the plant, assisted the new IAC center at Clemson University with on-site and remote support, and provided assessment and training in unique areas of water, waste water, cyber security and smart manufacturing to our clients, students and community.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗