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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 37 records · Page 2

Modeling Photovoltaics Innovation and Deployment Dynamics

PV’s historically rapid cost reduction is exceptional among technologies. Further cost reductions could play a major role in increasing deployment in the future. To enable such cost reductions, new modeling frameworks are needed to understand the determinants of innovation in PV. In this project, we study the mechanisms driving PV module and system cost reductions, delving deeply into the specific technological innovations that have occurred in the past and the policies that encouraged them, and also opportunities for future cost reduction and widespread deployment. The project contributes new fundamental insight on the determinants of technological innovation by developing novel methods and insights that are generalizable and can therefore be applied to other technologies. The results will allow policy makers, engineers, and other stakeholders to better prioritize their efforts and investments in the future. The project is organized around four journal articles as described below. The first article [1] identifies ‘low-level’ (e.g. conversion efficiency improvement) and ‘high- level’ (e.g. R&D efforts) mechanisms of cost reduction in PV systems (Tasks 1-4). This work builds on a previous DOE grant, where we developed a framework for technological innovation leading to PV module cost reduction [2]. We advance a method to disentangle the contributions of physical (‘hardware’) and non-physical (‘soft technology’) changes. Our results uncover reasons behind the relatively slow evolution of soft technology and can inform new innovation approaches to these technologies. The second article [3] identifies specific engineering or institutional innovations that enabled the low-level mechanisms of cost reduction in PV module and balance-of-systems (BOS) (Tasks 5, 9, 10). We identify 85 innovations and connect them to the cost variables they affected. By developing an innovations typology, this study shows the differences between the types of innovations affecting PV modules and BOS components. Finally, by analyzing the industry origins of innovations, this study also finds that PV was well-positioned within an ecosystem of continuously advancing technologies. The third article [4] studies prospective cost reduction opportunities (Task 10). We explore how design approaches that emphasize standardization and automation, such as plug-and-play PV systems, can create cost reduction opportunities by reducing interactions and speeding up activities with high process costs. We show that this can lead to cost reduction in cost components with the most untapped opportunity for improvement such as installation labor, overhead, electrical BOS, and customer acquisition. The fourth article [5] analyzes how various policies supporting PV deployment and R&D contributed to PV’s cost improvement by enabling high-level mechanisms, specific innovations, and ultimately low-level mechanisms of cost reduction (Tasks 8, 13, 14). We investigate examples from different countries and connect these policies to quantifiable cost change mechanisms. Our study sheds light on the roles that different nations played over time, through a diverse set of policy approaches.

14 SOLAR ENERGY↗

U.S. Solar Photovoltaic System and Energy Storage Cost Benchmarks: Q1 2021

Based on our bottom-up modeling, the Q1 2021 PV and energy storage cost benchmarks are: $\$2.65$ per watt DC (WDC) (or $\$3.05$/WAC) for residential PV systems, 1.56/WDC (or $\$1.79$/WAC) for commercial rooftop PV systems, $\$1.64$/WDC (or $\$1.88$/WAC) for commercial ground-mount PV systems, $\$0.83$/WDC (or $\$1.13$/WAC) for fixed-tilt utility-scale PV systems, $\$0.89$/WDC (or $\$1.20$/WAC) for one-axis-tracking utility-scale PV systems, $\$30,326$-$\$33,618$ for a 7.15-kWDC residential PV system with 5 kW/12.5 kWh nameplate of storage, $\$2.04$ - $\$2.10$ million for a 1-MWDC commercial ground-mount PV system colocated with 600 kW/2.4 MWhusable of storage, $\$166$ - $\$167$ million for a 100-MWDC one-axis tracker PV system colocated with 60 MW/240 MWhusable of storage. Between 2020 and 2021, there were 3.3% ($\$0.0$9/W), 10.7% ($\$0.19$/W), and 12.3% ($\$0.13$/W) reductions (in 2020 USD) in the residential, commercial rooftop, and utility-scale (one-axis) PV system cost benchmarks respectively. Balance of system (BOS) costs have either increased or remained flat across sectors, year-on-year, unlike in previous benchmark reports, which generally have reported declining BOS costs. The increase in BOS cost has been offset by a 17% reduction in module cost. Overall, modeled PV installed costs across the three sectors have declined compared to our Q1 2020 system costs.

14 SOLAR ENERGY↗

Potential Infrastructure Cost Savings at Hybrid Wind Plus Solar PV Plants

This report documents the creation of NREL's Balance of System model for Hybrid Renewable Energy Systems (HybridBOSSE). Balance of System (BOS) costs account for approximately 30% of the capital expenditure required to install a land-based wind plant, and as much as 40% of the cost of installing a solar PV plant. Hybrid Renewable Energy systems present an opportunity to combine balance of system components to achieve cost savings, and HybridBOSSE aims to provide a component-level model to determine the associated BOS costs in a hybrid renewable energy system. Prior BOS models for hybrid systems (at NREL and elsewhere) have relied on empirical curve fits of legacy industry data, limiting their utility and their predictive ability for new technology combinations and configurations, such as those found in Hybrid Plants. Hybrid plants at the utility scale have considerably more interest in the last number of years, with ever-growing capacities in the interconnection queues, and many large developers pivoting to only consider hybrid plants going forward. As these plants become a commercial reality, the need for a detailed analysis of costs in a hybrid plant to fully exploit the available cost savings grows. The tool developed and documented in this work, HybridBOSSE, provides an open-source, python-based method of assessing the costs in hybrid plants. This analysis capability unlocks greater certainty in hybrid plant costs, as well as the ability to examine scenarios of hybridization and glean combinations that offer the greatest flexibility and cost reduction.

14 SOLAR ENERGY↗

The Future of Renewable Energy Generation: Photovoltaic Materials

There are myriad ways to harness solar energy, including, but not limited to: solar thermal, solar fuels, and photovoltaics (PV). Across the portfolio of solar energy technologies, PV is unique in that collected photons are directly converted to electricity. Traditionally, the dominant materials in PV are also the dominant semiconductor and optoelectronic materials. The cost of solar energy from PV is a product of a complex combination of non-material related factors, known as soft costs, e.g., permitting, zoning, and of balance-of-systems (BOS) costs, like inverters or other components needed to utilize cells and modules. While the soft costs are due to administrative/regulatory concerns, BOS costs are driven by details of cell/module fabrication, mounting, power electronics, and other concerns, which touch on a range of basic material science issues. There is some overlap of BOS and soft cost, as a lighter weight solar panel can reduce installations costs, as an example. At the PV-system level, the materials considerations span both electronic and structural components. The focus of this paper is the solar cell, which is the minimum operational unit device that converts light into electricity.

30 DIRECT ENERGY CONVERSION↗

Background-Oriented Schlieren Velocimetry of Helium Coolant Flow in Additively Manufactured Channels

High-pressure helium gas cooling is an attractive solution for thermal management of the fusion blanket first wall, as this coolant is chemically and neutronically inert and separable from hydrogenic species. However, due to the low thermal mass of helium, geometric optimization of these channels is required to provide sufficient cooling at manageable flow rates and pumping burdens. Increasingly, analysis and optimization of these coolant channels rely on computational fluid dynamics (CFD) simulations, and these require relevant experimental data for turbulence model validation. Toward this end, a high-pressure helium gas flow visualization system has been employed to image the flow of helium in flow channels with one-sided heating, mimicking the blanket first wall environment. Flow of helium at 4 MPa pressure and flow rates up to 68 g/s (Reynolds number 57 000) is supplied to rectangular channel test sections, with uniform heating applied to the bottom wall of the channel at heat fluxes varied between roughly 50 and 130 kW/m2. A high-speed camera is used to image index of refraction (IOR) gradients in the fluid via background-oriented schlieren (BOS), and temperature and pressure instrumentation are used to characterize thermal-hydraulic performance of each channel. Cross correlation of time-resolved BOS images is then used to calculate time-averaged 2-D helium velocity fields. Flow in additively manufactured (AM) channels is examined in this manner, including both featureless channels and those containing baffling as a heat transfer enhancement. The flow distribution seen in the featureless case differs significantly from that seen in prior simulations, whereas the flow in the baffled case shows the predicted behavior of flow forced along the heated wall. This augmented flow distribution is seen to increase the heat transfer coefficient in the baffled test section. Here, strategies are discussed for ongoing and future validation of these simulations, with the aim of model deployment for blanket cooling design and optimization.

Additive manufacturing↗

Knowledge acquisition and innovation quality: The moderating role of geographical characteristics of technology

Acquiring and absorbing knowledge at different geographic levels is an important step in the technological learning and innovation processes for firms. Geographically bounded knowledge searching and spillover have been shown in various network formats, industries, geographic scopes, and country contexts. This study finds evidence of localized learning in citation networks in the solar photovoltaic balance-of-systems (PV BOS) innovations, and that the levels of localized learning vary based on the degree to which technologies are relevant to local contexts. Thus, this study proposes that the value of local and non-local knowledge on patent quality is contingent on technological characteristics. Further, leveraging the different degrees of local dependence on four types of technologies in the PV BOS industry, we find that the impact of local knowledge on innovation quality is higher for technologies that are more rooted in local contexts and that the impact of non-local knowledge is higher for technologies that are less relevant to local contexts.

99 GENERAL AND MISCELLANEOUS↗

Design Overview of a High-Pressure Helium Flow Visualization Apparatus for Blanket Cooling Studies

Cooling of the fusion blanket first wall remains a significant challenge given the adverse conditions of heat and particle flux encountered near the plasma. Helium emerges as an attractive cooling candidate because of its chemical and neutronic inertness and separability from hydrogenic species (e.g. tritium). Because of the low thermal mass of helium, optimization of these coolant channels is warranted to provide high heat transfer performance at low pumping costs. Increasingly, computational fluid dynamics (CFD) simulations are employed to model and optimize these flow channels, and accompanying experimental data are needed to validate the predictions of these models. To provide the aforementioned experimental data, a high-pressure helium flow visualization upgrade has been designed for the Helium Flow Loop Experiment facility. This apparatus was built to American Society of Mechanical Engineers boiler and pressure vessel standards to withstand operating pressure of 4 MPa and mated to high-pressure glass windows. Seedless flow visualization is performed via high-speed background oriented schlieren (BOS), with image correlation used for time-resolved two-dimensional velocimetry at frequencies in excess of 60 kHz. Rectangular flow channel test articles are additively manufactured via laser powder bed fusion and installed into this visualization apparatus, with one-sided heating supplied by resistive heaters. In conclusion, the chosen test geometries were informed by prior CFD simulations, and the helium flow structures observed via BOS (detachment, recirculation, etc.) will be used for the validation of these accompanying models, in support of the design and optimization of blanket cooling channel configurations.

Helium flow↗

Development of Fixtures and Methods to Assess the Durability of Balance of Systems Components

The degradation of photovoltaic (PV) balance of systems (BoS) components is not well studied, but the consequences include offline modules, strings, and inverters; system shutdown; arc faults; and fires. A utility provider experienced a ~30% failure rate in their power transfer chain, originally attributed to branch connectors. Field-failed specimen assemblies were, therefore, examined, consisting of cable connector, branch connector, and discrete fuse components. In this study, unused field-vintage specimens are examined using a benchtop prototype fixture to identify the most influential environmental stressors on BoS components as well as the effect of external mechanical perturbation. The prototype fixture was used to develop a perturbation capability for future use in the combined-accelerated stress testing chamber. The benchtop experiments were also used to develop the in-situ data acquisition of specimen current, voltage, and temperature. A significant increase in operating temperature (~100 °C from ~40 °C) and a different failure mode (arcing at the metal pins rather than overheating of the fuse filament) were observed promptly once periodic mechanical perturbation was applied. The current at failure was decreased from 35 A (measured for static specimens, with failure occurring in the fuses) to 15 A (for tests with mechanical perturbation, with failure at the male/female metal pin connection). After initial examination using X-ray computed tomography, the external plastic was machined away from failed specimens to allow for failure analysis, including the extraction of the internal convolute springs for morphological examination (optical and electron microscopy). Chemical composition analysis included energy-dispersive X-ray spectroscopy, differential scanning calorimetry, and Fourier transform infrared spectroscopy.

14 SOLAR ENERGY↗

High Contrast Pattern Projection To Enable Background Oriented Schlieren Based Air Leak Detection Through Any Interior Or Exterior Building Surface

Air leakage in buildings wastes an estimated 4 quads of energy per year in the United States. Finding and sealing leakage sites is critical in existing buildings. Previous work has shown that background oriented Schlieren (BOS) imaging can be used to visualize air leakage but requires the leak to exit through a high contrast surface like a brick wall. To remedy this, different techniques of projecting various high contrast patterns on low contrast building surfaces like interior gypsum walls or vinyl siding were investigated. For each technique, the background quality was measured and compared to an ideal printed random dot background. The background quality metrics were correlated with the measured visualization metrics to understand which metrics are most important for maximizing air leak visualization performance. In this work, leakage visualization performance is presented for these various projected backgrounds with an aim to expand the building surfaces suitable for the BOS leak detector.

Jatana, Gurneesh [ORNL] (ORCID:0000000288903225)↗

Q1-2024 Solar Cost Benchmarks

Each year, the U.S. Department of Energy’s (DOE) Solar Energy Technologies Office (SETO) and its national laboratory partners develop cost benchmarks for U.S. solar photovoltaic (PV) systems. These benchmarks track progress toward reducing solar costs and guide R&D priorities. Unlike typical studies that report only $/W, SETO uses intrinsic units (e.g., $/m² for mounting structures) to better capture how technology improvements such as module efficiency would impact system costs. This allows flexible modeling where inputs can vary significantly to assess cost sensitivity. Costs are reported in two ways: Minimum Sustainable Price (MSP): Long term, financially viable price under stable market conditions. Modeled Market Price (MMP): Actual market price, influenced by short term distortions such as tariffs or subsidies. Three national labs collect cost data from industry stakeholders, ensuring no duplication in outreach to stakeholders. Data reflects real transactions (primarily from Q1) and is weighted based on the number of sources per cost element. The PV System Cost Model (PVSCM) divides total installed system cost into eight categories: 1. Module (PV) 2. Inverter 3. Energy Storage System (ESS) 4. Structural BOS (SBOS) 5. Electrical BOS (EBOS) 6. Fieldwork 7. Office work 8. Other (developer/EPC costs) The first five are hardware costs, while the last three are soft costs. Each category includes fixed and variable cost components, where “size” depends on context (e.g., manufacturing capacity for modules vs. system capacity for installation costs). Variable costs are expressed using appropriate intrinsic units. The model reflects the owner’s upfront overnight capital cost, excluding tax credits. Tariffs and subsidies are treated as temporary market distortions affecting MMP but not MSP. PVSCM is implemented in Excel, where cost elements are aggregated into total system cost. Additional sheets handle unit conversions and operation & maintenance (O&M), with O&M costs levelized over the system’s lifetime.

14 SOLAR ENERGY↗

Using online tools at the Bovine Genome Database to manually annotate genes in the new reference genome

With the availability of a new highly contiguous Bos taurus reference genome assembly (ARS-UCD1.2), it is the opportune time to upgrade the bovine gene set by seeking input from researchers. Furthermore, advances in graphical genome annotation tools now make it possible for researchers to leverage sequence data generated with the latest technologies to collaboratively curate genes. For many years the Bovine Genome Database (BGD) has provided tools such as the APOLLO genome annotation editor to support manual bovine gene curation. The goal of this paper is to explain the reasoning behind the decisions made in the manual gene curation process while providing examples using the existing BGD tools. We will describe the sources of gene annotation evidence provided at the BGD, including RNAseq and Iso-Seq data. We will also explain how to interpret various data visualizations when curating gene models, and will demonstrate the value of manual gene annotation. The process described here can be applied to manual gene curation for other species with similar tools. With a better understanding of manual gene annotation, researchers will be encouraged to edit gene models and contribute to the enhancement of livestock gene sets.

59 BASIC BIOLOGICAL SCIENCES↗

Technology Innovation Pathways for Distributed Wind Balance-of-System Cost Reduction

This exploratory analysis characterizes the balance-of-system (BOS) cost reduction opportunity for small, commercial, medium, and large distributed wind systems. To do this, we used the National Renewable Energy Laboratory’s (NREL’s) Land-based Balance of System Systems Engineering (LandBOSSE) model (Eberle et al. 2019). This model calculates the capital expenditures (CapEx) associated with installation and the system components (e.g., foundation and electrical infrastructure) other than the rotor nacelle assembly and tower. Then, building on the cost reduction potential assessment, we provide a more qualitative evaluation of prospective technology innovation concepts that may enable realization of those cost reductions for distributed wind systems.

17 WIND ENERGY↗

Anomalously strong viscosity behavior in mixed oxy-sulfide Na 4 P 2 S 7-x O x invert glasses

In this paper, the first observations have been made of anomalously strong viscosity behavior and correspondingly strong bulk glass formation and resistance to crystallization in a melt quenched (MQ) prepared series of invert, modifier content greater than the glass former content, mixed oxy-sulfide Na 4 P 2 S 7-x O x , 0 ≤ x ≤ 5, (NaPSO) glasses. We find that these glasses even with 67 mole % modifier, Na 2 S, and only 33 mole% glass former P 2 S 5-x O x , exhibit a calorimetric fragility index, m cal , as small as 29 compared to typical values of ~ 60 to 80 for alkali silicate glasses with > 50 mole% SiO 2 and the theoretical minimum m cal of ~ 15. The m cal values were converted to kinetic viscosity fragility, m vis , values and used with the measured glass transition temperatures, T g s, to produce viscosity curves for the glasses using the Mauro-Yue-Ellison-Gupta-Allan (MYEGA) model. The viscosity of the glass with a minimum m cal value of x = 2.5 was then shown to exhibit a viscosity that was as strong as, and for some compositions stronger than, the viscosity of alkali aluminosilicate glasses which have three dimensional network structures compared to the one dimensional chain structures observed in these MOS invert glasses. Consistent with these small values of fragility indices and therefore predicted higher viscosity above the glass transition temperature, T g , in the supercooled liquid regime, these glasses are also particularly resistant to crystallization. For example, the x = 2.5 glass composition exhibits a crystallization temperature, T C , more than 150K above its T g . We find that the calorimetric fragility of these glasses varies systematically with the extent of network forming bridging oxygens (BOs) in the glasses. The structural change caused by incrementally replacing sulfur with oxygen has been found to have consistent, large effects on the thermal properties.

36 MATERIALS SCIENCE↗

Sarcocystis cruzi (Hasselmann, 1923) Wenyon, 1926: redescription, molecular characterization and deposition of life cycle stages specimens in the Smithsonian Museum

Currently, 7 named Sarcocystis species infect cattle: Sarcocystis hirsuta, S. cruzi, S. hominis, S. bovifelis, S. heydorni, S. bovini and S. rommeli; other, unnamed species also infect cattle. Of these parasites of cattle, a complete life cycle description is known only for S. cruzi, the most pathogenic species in cattle. The life cycle of S. cruzi was completed experimentally in 1982, before related parasite species were structurally characterized, and before the advent of molecular diagnostics; to our knowledge, no archived frozen tissues from the cattle employed in the original descriptions remain for DNA characterization. Here, we isolated DNA from a paraffin-embedded kidney of a calf experimentally infected with S. cruzi in 1980; we then sequenced portions of 18S rRNA, 28S rRNA, COX1 and Acetyl CoA genes and verified that each shares 99–100% similarity to other available isolates attributed to S. cruzi from naturally infected cattle. We also reevaluated histological sections of tissues of calves experimentally infected with S. cruzi in the original description, exploiting improvements in photographic technology to render clearer morphological detail. Finally, we reviewed all available studies of the life cycle of S. cruzi, noting that S. cruzi was transmitted between bison (Bison bison) and cattle (Bos taurus) and that the strain of parasite derived from bison appeared more pathogenic than the cattle strain. Based on these newfound molecular, morphological and physiological data, we thereby redescribed S. cruzi and deposited reference material in the Smithsonian Museum for posterity.

59 BASIC BIOLOGICAL SCIENCES↗

Evaluating the Durability of Balance of Systems Components Using Combined-Accelerated Stress Testing

The degradation of photovoltaic (PV) balance of systems (BoS) components is not well-studied, but the consequences include offline modules, strings, and inverters; system shutdown; arc faults; and fires. A utility provider experienced a ~30% failure rate in their power transfer chain, originally attributed to branch connectors. Field-failed specimen assemblies were therefore examined, consisting of cable connector, branch connector, and discrete fuse components. In this study, unused field-vintage specimens are examined using combined-accelerated stress testing (C-AST) to clarify the most influential environmental stressors as well as the effect of external mechanical perturbation. A benchtop prototype fixture was used to develop the perturbation capability for the C-AST chamber. The benchtop experiments were also used to develop the in-situ data acquisition of specimen current, voltage, and temperature. A significant increase in operating temperature (~100 degrees C from ~40 degrees C) and a different failure mode were observed promptly once periodic mechanical perturbation was applied. The current at failure was decreased from 35 A (with failure in the fuses) to 15 A (failure at the male/female metal pin connection). After initial examination using X-ray computed tomography, the external plastic was machined away from failed specimens to allow for failure analysis, including the extraction of the internal convolute springs for morphological examination (optical and electron microscopy).

balance of systems↗

Inelastic relaxation processes in amorphous sodium silicates

During fracture amorphous oxides exhibit irreversible processes, including inelastic and nonrecoverable relaxation effects in the process zone surrounding the crack tip. Here, classical molecular dynamics simulations were used with a reactive forcefield to evaluate inelastic relaxation processes in five amorphous sodium silicate compositions. Overall, the 20% Na 2 O-SiO 2 (NS20) composition exhibited the most inelastic relaxation, followed by the 15% Na 2 O-SiO 2 (NS15) composition, the 25% Na 2 O-SiO 2 (NS25) composition, and finally the 10% (NS10) and 30% (NS30) Na 2 O-SiO 2 compositions. Coordination analysis of the Na + ions identified that during inelastic relaxation the Na+ ions were increasingly coordinated by nonbridging oxygens (NBOs) for the NS10 and NS15 compositions, which was supported by radial analysis of the O-Na-O bond angles surrounding the crack tip. Across the sodium silicate compositional range, two different inelastic relaxation mechanism were identified based on the amount of bridging oxygens (BOs) and NBOs in the Na+ ion coordination shell. At lower (NS10) and higher (NS30) sodium compositions, the entire structured relaxed toward the crack tip. In contrast at intermediate sodium concentrations (NS20) the Na + ion migrates toward the crack tip separately from the network structure. By developing a fundamental understanding of how modified silica systems respond to static stress fields, we will be able to predict how varying amorphous silicate systems exhibit slow crack growth.

36 MATERIALS SCIENCE↗

Photovoltaic Cable Connectors: A Comparative Assessment of the Present State of the Industry [Slides]

The consequences of failure for balance of systems (BoS) components (such as PV cable connectors) include offline module string(s); low system voltage; arc, ground, insulation, and over-temperature faults; triggered fuse(s); system shutdown; and fire. The degradation modes for connectors are studied here through an industry survey and its subsequent examination, which are compared to field-degraded specimens. 117 specimens were obtained from a variety of locations and climates or accelerated tests. A failure analysis for connectors from PV installations was developed (and applied to 54 specimens) including nondestructive examinations (photography, a custom resistance-current scan, and X-ray computed tomography) and destructive examinations (featuring milling of the external plastic, extraction of the internal convolute spring, and potting and polishing in cross-section). Surface and through-thickness composition of the metal pins and springs was quantified using scanning electron microscopy with energy-dispersive X-ray spectroscopy. Fourier-transform infrared spectroscopy was used to verify the base polymer materials and compare the chemical structure of the connector body, bushing, end nut, and o-ring. Thermogravimetric analysis and differential scanning calorimetry were used to further verify the degradation of the same polymeric components. Updated from 2023 NIST/UL Workshop on Photovoltaic Materials Durability (website: https://events.ul.com/WPMogn?rt=aAuoWsl4E0KaORLCMeOgfA) and 2024 PVRW workshop (https://pvrw.nrel.gov/past-proceedings).

14 SOLAR ENERGY↗

Annual Supply Chain for Photovoltaics (ASC-PV) in the United States: 2024 in Review

This report analyzes U.S. PV and BESS supply chains and costs in 2024, for PV module and battery technologies, structural and electrical balance of system (BOS) components, as well as PV recycling. The report concludes with an analysis of technology installation trends, government support for domestic manufacturing, manufacturing jobs, and the domestic content of PV systems installed in the United States in 2024.

14 SOLAR ENERGY↗