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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Final Scientific/Technical Report-FREE-piston Zero Emissions Refrigerator (FREEZER)

The FREE-piston Zero Emissions Refrigerator (FREEZER™) is a natural refrigerant Stirling-cycle cooler developed by AMSC in partnership with Heatcraft, targeted as a replacement refrigeration system for walk-in coolers or freezers found commonly in restaurants, convenience stores, supermarkets, etc. The FREEZER™, combined with a closed-loop CO2 heat-transfer system, had the goal to provides an efficient (Target COP = 1.4), zero ODP (Ozone Depletion Potential) and near zero GWP (Global Warming Potential) refrigeration solution with no synthetic, flammable, or toxic refrigerants. Other near zero GWP refrigeration systems do not exist at the scale and performance level of FREEZER. ARPA-E Continuation Funding enabled the design and fabrication of one Advanced Development Unit (ADU) cooler and two Field Test Unit (FTU) coolers, and a new revised Field Test Unit (new FTU). Heatcraft was to extensively test the various coolers at their facilities, which closely simulate real-world conditions. The original plan was to install and operate FREEZER FTUs alongside a traditional cooling solution at one or more customer locations to obtain data on direct performance comparisons with existing commercial refrigeration systems. Success in this FREEZER refinement and field-test project will establish the basis for a new class of environmentally friendly refrigeration systems that will revolutionize the industry. The hardware developed under the program is shown below in Figure 1. Five Stirling-cycle machines were built within the program, with a sixth cooler still under construction. The original DU and the ADU coolers met the performance target with a coefficient of performance (COP) of 1.2. The FTU was underperforming during the initial tuning of the free-piston Stirling cycle dynamics when there was a catastrophic failure of the fasteners on pressure boundary. This caused a pause to the program while the failure mechanism was investigated. The root cause was an inadequate flange design that allowed an excessive cyclic loading on the fasteners, leading to a fatigue failure. It was determined that existing FTU design could not be reasonably salvaged in a safe manner, and that fact, combined with the lower-than-expected performance of the new experimental heat exchanger modules lead to the design of the “new FTU” with a more conventional shell-and-tube heat exchanger design which should get close to the design target COP of 1.4, but have a higher overall machine cost. The program ran out of time before the fabrication of the new FTU was completed, but AMSC is still working on the cooler, with the majority of the parts fabricated, and hopes to have the unit under test sometime in early 2022, after which it will be shipped to Heatcraft for additional testing.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2021

Cost-effective, Thin-film SOFCs for Reliable Power Generation (Final Report)

The project was aimed at developing and demonstrating an advanced solid-oxide fuel cell (SOFC) technology to cost-effectively and reliably generate electricity directly from hydrocarbon fuels (e.g., natural gas and coal-derived syngas) for distributed and central generation applications. The studied technology was built on a planar, porous metal-supported SOFC (MS-SOFC) with a unique thin-film structure having its anode intimately supported on a metal substrate. The porous metal support with graded porosity was fabricated from a low-cost scalable phase-inversion tape casting method. Anode, thin-film electrolyte, and cathode were sequentially deposited on the porous metal substrate using atmospheric plasma spray (APS). In this study, it was shown that the composition of the casting slurry could significantly influence the morphology of the metal support fabricated using the phase-inversion tape-casting method. Increasing the solid loading in the slurry favored the formation and growth of finger-like pores to a point, but the presence of excessive solid loading increased the viscosity of the casting slurry, restraining the growth of finger-like pores. With the increase in the amount of the binder polyethersulfone (PESf) in the slurry, well grown finger-like pores and a thin sponge-like layer were formed. Since the parameters of the APS process have a significant effect on the microstructure of coatings, which in turn affects or determines the SOFC cell performance, a series of metal-supported solid oxide fuel cells with a four-layer cell configuration of 430L/Ni-ScSZ/ScSZ/LSCF have been fabricated by a combination of phase inversion tape casting and APS techniques. Electrochemical testing of the cells fabricated from different deposition APS conditions revealed significant differences in cell performance.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2024

End-Use Savings Shapes Measure Documentation: Window Film

This documentation focuses on a single end-use savings shape measure - window film. The window film studied in this analysis, called solar control film, is a passive retrofit solution for windows that does not involve window replacement. This type of film is composed of transparent, tinted, or metalized laminated polyester layers and can be attached to an existing window surface (either on the exterior or interior side of the window). The properties of the window film are designed to shift the thermal and optical performances of the overall glazing system in order to serve various needs the customer would have (e.g., heat, glare). While the practical goal of purchasing and installing a window film varies widely in the real market, this study only focuses on the goal of energy savings, and highlighting the corresponding emissions. Other important aspects that customers typically consider include visual comfort, privacy, aesthetics, ultraviolet protection, etc. Thus, in practice, customers often choose a window film product not only to save energy (or cost) but also to mitigate issues around glare, excessive light, daytime privacy, or inconsistent appearance of the building. Window film products that were modeled in this analysis significantly reduced the solar heat gain coefficient of the overall glazing system, resulting in better energy savings for buildings in hot climate regions. However, significantly reducing the solar heat gain coefficient that can block unfavorable heat during the summer can actually harm blocking favorable heat during the winter. By applying window films on a stock of buildings covering various load and weather conditions, this analysis highlights when (e.g., time of day) and where (e.g., geospacial location) we can save energy with window films.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Renewable hydrogen horizon: Geospatial techno-economic feasibility and life cycle greenhouse gas analysis in the Middle East and North Africa

Renewable hydrogen is receiving increasing attention for its potential as a flexible energy carrier in sectors such as transportation and industry. Specific cost and carbon intensity (CI) of renewable hydrogen production vary largely based on the location, owing to differences in renewable energy resources, as well as the supply chain dynamics. This study maps the techno-economic and life cycle greenhouse gas emissions of renewable hydrogen production in the Middle East and North Africa region, leveraging abundant solar and wind resources. The work investigates the variability in hydrogen costs and CI, optimally sizing proton-exchange membrane (PEM) electrolyzers to account for partial and cyclic loading, and explores standalone versus grid-connected systems. PEM capacity ratios of 52 %–63 % for photovoltaic (PV) systems and 28 %–82 % for wind systems were identified as optimal, with hydrogen production costs ranging from $\$3.8$-$\$4.8$/kg for PV and $2.0-$7.0/kg for wind. CIs span from 1.9 to 3.7 kg CO 2 ,eq /kg H 2 for PV and 0.4–7.7 kg CO 2,eq /kg H 2 for wind systems. The study highlights significant cost and CI reductions achievable with technological advancements and co-product revenue from oxygen and excess electricity sales.

Carbon Intensity↗
DOE OSTI2024

Wetlands Geoprocessor (v 1.0)

Wetlands have often been described as the “Earth’s kidneys” because wetlands have the ability filter pollutants and purify water. Based upon wetland storage capacity, average daily flow, and inflow nutrient loading this model estimates potential load reductions of nitrate and orthophosphate) from a constructed surface flow wetland (CW). The model relies upon equations, coefficients, and models provided by Cheng et al. 2020 and Cheng & Basu 2017. Nitrogen (N) and phosphorus are important nutrients to ecosystems, but high concentrations can lead to water quality issues. Major sources of these nutrients come from agricultural areas where fertilizer is applied in large quantitates and/or animal waste is present. Excess nitrate and phosphorus may result in overgrowth of algae, which can decrease the dissolved oxygen in water, thereby harming and killing fish and other aquatic species. This model evaluates water purification results and estimates cost to install a surface flow constructed wetlands.

Davis, Cleve↗
DOE OSTI2021

Cost-Optimized Cold Climate Heat Pump Development and Field Test

Cold climate heat pumps (CCHPs) expand the heat pump market to climates where heating demand is dominant. They can achieve more than 70% energy savings compared with electric resistance heating and operate at lower cost than using tank-stored propane to fuel a furnace. A high-efficiency heat pump with a heating seasonal performance factor (HSPF)—as defined by the Air-Conditioning, Heating, and Refrigeration Institute (AHRI 2008)—greater than 10.0 would be more efficient than gas heating in terms of source energy. However, developing a cost-effective CCHP involves some challenges. A typical single-speed, air-source heat pump (ASHP) with an HSPF of 7.7 Btu/Wh does not work well under cold outdoor temperature conditions typical of cold climate locations for four major reasons: 1. Discharge temperature is too high—The low suction pressure and high compression pressure ratio at low ambient temperatures causes high compressor discharge temperatures in excess of the maximum limit for many of the compressors on the market. Furthermore, system charge of a heat pump is usually optimized in the cooling mode, which leads to overcharge conditions in the heating mode, further increasing the discharge temperature. 2. Heating capacity is insufficient if sized to meet the building design cooling load— Heating capacity of a single-speed heat pump decreases with ambient temperature. The heating capacity at -13°F (-25°C) typically decreases to 20%–40% of the rated heating capacity at 47°F (8.3°C) (~equivalent to the rated cooling capacity at 95°F [35°C]). Therefore, a single-speed heat pump, typically sized to match the building design cooling load, cannot provide adequate heating capacity to match the building heating load at low ambient temperatures. The capacity deficit is filled by inefficient resistance heat, thus lowering the system efficiency and significantly increasing power demand. 3. Cyclic loss is significant if sized to meet the building design heating load—If a single-speed heat pump is sized to meet the heating load, it will be significantly oversized relative to the cooling load in many cold climates. This will cause excessive on/off cyclic loss during the cooling and heating operations at moderately low ambient temperatures. Thus, capacity modulation capability (e.g., using a variable-speed or multi-stage compressor) is necessary for a CCHP, which uses its full capacity to meet the peak heating load and partial capacity to meet the cooling and part-load heating loads. 4. Coefficient of performance (COP) is low—Heating COP degrades significantly at low ambient temperatures owing to the large temperature difference between the heat source and sink. A target CCHP should be sized to meet the building design heating load while minimizing the cyclic loss for the cooling and heating operations at moderate ambient temperatures.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

The Maintainable Fusion Pilot Plant

The US fusion community has coalesced around the goal of building an FPP as described by the National Academies of Science, Engineering, and Medicine (NASEM). In addition to demonstrating the viability of the technologies necessary to operate such a plant, including demonstration of net energy and electricity production, NASEM found that a “fusion pilot plant will need to demonstrate the ability to efficiently perform remote maintenance and replacement in support of the design of a power plant, taking into account details of the consequences of the fusion environment, such as material activation and tritium retention in components.” Current designs of fusion demonstration reactors do usually foresee a regular exchange of their first wall modules, including the tritium breeding blankets. In the European Power Plant Conceptual Studies, it is assumed that a fusion reactor will need to change its divertor every 2 years and its first wall blanket module every 5 to 6 years to reach acceptable availability. Underlying this capability are remote-handling technologies to keep the outage for the exchange of these components short. There are many uncertainties in the remote-handling schemes, and most schemes are at a preconceptual level at best. In addition, the exchange of these components would either produce an enormous rad-waste stream or would require an enormous refurbishment activity with huge cost-prohibitive hot-cells. Past Fusion Nuclear Science Facility (FNSF) preconceptual studies have led to hot cell dimensions of an unbelievable size, likely costing tens of billions of dollars. Already at The Way (previously International Thermonuclear Experimental Reactor, ITER), hot-cells have become cost-prohibitive, demanding redesigns of the ITER first wall to reduce the toxic rad-waste/inventory. In this in-situ PFC repair project, a concept for a long-life, maintainable first wall module concept is developed and tested. This first wall concept relies on innovative remote handling to repair the first wall modules in-situ, avoiding costly refurbishments outside of the tokamak vessel. This approach was highlighted in the Fusion Energy Sciences Advisory Committee (FESAC) report on Transformative Enabling Capabilities for Efficient Advance Toward Fusion Energy. In general, the damage of the first wall armor is due to particle and radiation exposures. Load conditions vary from one fusion reactor design to another. In tokamaks, first wall Plasma Facing Components (PFCs) are exposed to far-Scrape-Off-Layer plasma fluxes, electromagnetic radiation, energetic CX neutrals, and potentially runaway electron beams. Protecting the first wall to the worst-case load conditions would require the design of a very thick first wall armor. Transient heat and particle fluxes due to disruptions or edge localized modes can lead to excessive heat loads resulting potentially in melting PFCs down to the cooling channel. Catastrophic events like these need to be avoided by appropriate disruption mitigation systems. However, failure of these systems will still put a first wall at an unacceptable risk. Hence, a first wall design needs to accommodate the occasional transient heat loads by introducing sacrificial limiters, which will absorb these transients.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Digital Real-Time Simulation and Power Quality Analysis of a Hydrogen-Generating Nuclear-Renewable Integrated Energy System

This paper investigates the challenges and solutions associated with integrating a hydrogen-generating nuclear-renewable integrated energy system (NR-IES) under a transactive energy framework. The proposed system directs excess nuclear power to hydrogen production during periods of low grid demand while utilizing renewables to maintain grid stability. Using digital real-time simulation (DRTS) in the Typhoon HIL 404 model, the dynamic interactions between nuclear power plants, electrolyzers, and power grids are analyzed to mitigate issues such as harmonic distortion, power quality degradation, and low power factor caused by large non-linear loads. A three-phase power conversion system is modeled using the Typhoon HIL 404 model and includes a generator, a variable load, an electrolyzer, and power filters. Active harmonic filters (AHFs) and hybrid active power filters (HAPFs) are implemented to address harmonic mitigation and reactive power compensation. The results reveal that the HAPF topology effectively balances cost efficiency and performance and significantly reduces active filter current requirements compared to AHF-only systems. During maximum electrolyzer operation at 4 MW, the grid frequency dropped below 59.3 Hz without filtering; however, the implementation of power filters successfully restored the frequency to 59.9 Hz, demonstrating its effectiveness in maintaining grid stability. Future work will focus on integrating a deep reinforcement learning (DRL) framework with real-time simulation and optimizing real-time power dispatch, thus enabling a scalable, efficient NR-IES for sustainable energy markets.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Optimizing Hydronic Heating for Comfort and Performance in Multifamily Housing

Inefficient control settings in multifamily boilers often lead to substantial energy and cost penalties. To address this, a Fault Detection and Diagnostic (FDD) tool was developed to automate data analysis and identify operational faults such as suboptimal outdoor temperature sensor placement, misconfigured outdoor air reset (OAR) curves, excess boiler cycling, and domestic hot water (DHW) setpoint errors. By comparing pre- and post-implementation periods and applying engineering models, the tool quantifies energy savings and reduces manual analysis time by over 90%. Testing on over 100 monitored sites and a targeted subset of 12 buildings showed an average 11% energy savings from remote optimization; further validation across 19 OAR curve changes confirmed the tool’s accuracy, predicting actual savings within ±5% for most cases. Simple payback can be under three years for many multifamily buildings, though rising hardware, labor, and fuel costs create uncertainties, and decarbonization goals increasingly shift focus to electrification. The FDD tool remains invaluable for optimizing existing boilers, enhancing future electrification measures, and adapting to new technologies by refining building load estimates. In doing so, it supports both near-term efficiency and long-term transitions to low-carbon alternatives, ensuring buildings achieve substantial cost and energy benefits throughout their system lifecycles.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Multifunctional Heat Pump with Energy Storage Capability

Replacing gas furnaces with heat pumps on a large scale can pose challenges to the electrical grid. It will significantly increase the demand, strain the electrical grid, especially during peak usage times. To ensure that heat pumps contribute to reducing emissions, it's essential to increase the share of renewable energy in the grid. However, the supply of renewable energy is unstable. Large scale of electrification must address the concern of grid resilience to meet necessary heating/cooling demands and shift peak electric load. All these require future heat pumps having energy storage capability. These systems can store excess energy during low-demand periods and release it during high-demand periods, reducing stress on the grid. This paper will introduce an innovative configuration, control, and laboratory investigations of a multifunctional packaged heat pump. In addition to the original indoor and outdoor air coils, the heat pump has a parallel hydronic loop with a brazed plate heat exchanger (BHP). The hydronic loop circulates hot/chilled water to store heating/cooling energy in phase change material (PCM). It is capable of space cooling, space heating, cooling energy storage/defrosting, water heating/heating energy storage with outdoor air source or indoor air source, and cooling/heating energy free discharge. The laboratory studies and breadboard unit are presented. Additionally, building energy simulation demonstrates utility cost reduction potential via charging PCM panels/ceilings during off-peak hours and releasing the energy during peak hours to mitigate the peak power consumption.

Shen, Bo↗
DOE OSTI2025

A scoping study of far-SOL main-wall protection limiters for steady-state operation of compact pilot plant tokamaks

We present a novel method for handling steady-state heat fluxes incident on the main wall of pilot plant-scale magnetic fusion devices, based on the utilization of protection limiters in the far scrape-off layer (SOL). This method helps avoid large plasma-wall gaps, without excessively compromising blanket performance. We present an optimization algorithm for determining the appropriate size and scale of these protection limiters given (1) probability distributions of SOL plasma parameters and (2) assumed risk tolerance. As part of this optimization, we have developed an analytic description of parallel heat fluxes across limiter shadows, and an objective cost function (the ‘Far-SOL Marginal Cost’) to quantify the impact that different main-wall thermal management design choices have on reactor capital cost. Applying the model to a midscale fusion pilot plant concept shows that making use of far-SOL protection limiters can reduce capital costs on the order of $500 M, relative to naively increasing the plasma-wall gap. Our analysis demonstrates that the far-SOL power decay length is the highest-leverage plasma assumption for thermal loading of the first wall, and the primary cost driver for main wall thermal management. The relative cost efficiency of protection limiters increases as assumptions on the far-SOL heat flux become more pessimistic. The concepts described in this paper motivate the further development of far-SOL protection limiters as part of larger efforts to design economical core-edge-wall compatible solutions for a fusion pilot plant.

Design under uncertainty↗
DOE OSTI2026

Novel thermal energy storage component: Development, performance, and phase transition diagnosis

Thermal energy storage (TES) using phase change materials (PCMs) is a promising technology for capturing and storing excess thermal energy for later use. However, challenges such as poor heat transfer efficiency and a lack of modular, scalable designs have limited widespread adoption of TES in real-world applications. This study developed and evaluated modular brick-type and blade-type TES prototypes featuring an aluminum housing, an embedded serpentine coil for active or passive thermal exchange, and a cost-effective metal mesh to enhance PCM thermal conductivity. The blade-type TES achieved notable geometric efficiency, with a thickness-to-length ratio of 0.03 and a thickness-to-width ratio of 0.08, enabling highly compact and modular thermal storage suitable for space-constrained applications. The paper presents a detailed evaluation of the TES prototypes’ performance. The comparative analysis indicated that the TES prototypes provide a highly cost-effective, thermally optimized alternative for compact energy storage and load shifting. A novel diagnostic technique was also introduced: using a portable endoscope to capture real-time visualizations of PCM phase transitions inside the TES. This method provides critical insights into internal heat transfer mechanisms, identifies potential issues, and offers valuable support for optimizing the TES design and developing the control algorithm. Overall, the modular brick-type and blade-type TES designs demonstrated in this work provide a scalable, efficient, and economically viable solution for advancing TES across residential, commercial, and industrial sectors. The designs’ compact structure, enhanced thermal performance, and integrated diagnostic capabilities make them strong candidates for future deployment in energy-efficient systems.

Gao, Zhiming [ORNL] (ORCID:0000000271397995)↗
DOE OSTI2022

Irrigation Modernization Task 4: Accelerating Energy Solutions (FY2022 Final Report)

This report offers insights on energy solutions for irrigation modernization that serve the needs of farmers as well as residents and industry in the local community. Solutions are found in the irrigation districts where local generation from renewable energy sources – solar, hydro, and wind – can be combined with energy storage and customer loads. These combined resources configured in microgrids can lower costs during peak loads and provide resiliency by maintaining electricity supply during outages. The goal of this project, as stated in the FY2022 AOP, is to promote realization of energy solutions that are tailored to physical location, community, infrastructure, and energy value streams. Further, it is to develop examples of how to increase value of, and overcome barriers to, energy solutions in the context of irrigation modernization. In pursuit of that goal, the project looked at options for: 1) Reducing the cost of energy consumed in irrigation systems, 2) Increasing the revenue from surplus power generation, and 3) Deploying new power generation configured as part of a local microgrid. Potential solutions to reducing energy costs and increasing surplus power revenue revolve around addressing regulatory and legal constraints tied to how power is purchased by and sold to the irrigator or irrigation district. Some headway was made in identifying barriers and ways to push utilities to be more accommodating to distributed energy sources; however, for the most part, real progress hinges on changes at the regulatory and legislative level. Deployment of local, renewable generation systems can be implemented provided the economics of the project and the location are favorable. In concert with Famers Conservation Alliance and Energy Trust of Oregon, a number of approaches were studied in the past year, including off-grid solar powered pumps, grid-tied community solar projects, and in-conduit canal hydropower systems. Ultimately three viable projects were identified: 1) North Unit Irrigation District/City of Redmond, Oregon Critical Facility Microgrid – offers combined in-conduit hydro and solar power generation. 2) Wallowa County/Joseph, Oregon Irrigation System Upgrades – centered on upgrades to a non-powered dam that will add a turbine as well as in-conduit power in canal feeders downstream. 3) Medford, Oregon Wastewater Treatment Plant Biogas Cogeneration System – centered on building out biogas storage and grid upgrades to power the plant, sell excess power, and provide emergency backup power (supplanting a diesel generator). Each of these projects has characteristics that broaden the understanding of the value of microgrids employing renewable energy to achieve resiliency and net-zero carbon goals. The first two projects are centered on new hydropower systems. Although the Medford project is only tangentially tied to an irrigation district, it was selected for study analysis as it was the only one mature enough (with sufficient data) to complete an analysis within this project year. Thus, we chose to move forward developing a case study, in concert with the Community Water-Power Resilience project, to demonstrate a method for evaluating such projects. Essentially, this case study serves as a template for studies to be carried out next year that more directly involve irrigation system hydropower, e.g., the project at the Wallowa County/Joseph, Oregon Irrigation System. Lastly, it is recognized that the locations and case studies in this report are all located in Oregon. We recognize this as a limitation. While the intent is not to ignore other states or regions, this result is driven by the fact that we have cultivated a collaboration with non-profit entities in Oregon that focus on these topics – Farmers Conservation Alliance and Energy Trust of Oregon. These partners were central to identifying projects that may be good fits for this program. A goal in the coming year is to establish collaboration with entities in other states/regions that, similarly, can connect us to potential projects in their geographic area. The potential benefits from the WPTO’s support for demonstration projects as energy solutions in irrigation districts include: (1) Alternative power supplies for communities and farms using renewable, carbon-free energy resources, (2) Cost savings for electricity for communities and farms, (3) Resiliency of power supplies for critical loads when electricity from the grid is not available, (4) Resiliency of power supplies for critical infrastructure in the event of catastrophic events, and (5) Demonstration of irrigation modernization projects that provide resilience and a reduced carbon footprint to irrigation districts and nearby communities. These deployments can serve as vanguards/archetypes spurring similar projects in other districts and states.

13 HYDRO ENERGY↗
DOE OSTI2023

Systems Biology-Based Optimization of Extremely Thermophilic Lignocellulose Conversion to Bioproducts

This was a collaborative project involving researchers at the University of Georgia, North Carolina State University, Sanford‐Burnham‐Prebys Med. Discovery Institute and the University of Rhode Island. The over-arching goal was to demonstrate that non-model microorganisms, specifically extreme thermophiles, can be a strategic metabolic engineering platform for industrial biotechnology. We engineered the most thermophilic lignocellulose-degrading organism known, Caldicellulosiruptor bescii (Cbes) , which grows optimally near 80°C, and the most thermophilic fermentative organism known, Pyrococcus furiosus (Pfu) , which grows optimally at 100°C, to produce several key industrial chemicals. This work leveraged recent breakthrough advances in the development of molecular genetic tools for these organisms, complemented by a deep understanding of its metabolism and physiology gained over the past decade of study in the PIs’ laboratories. We applied the latest metabolic reconstruction and modeling approaches to optimize biomass to product conversion. Bio-processing above 70°C can have important advantages over near-ambient operations. Highly genetically-modified microorganisms usually have a fitness disadvantage and can be easily overtaken in culture when contaminating microbes are present. The high growth temperature of extreme thermophiles precludes growth or survival of virtually any contaminating organism or phage. This reduces operating costs associated with reactor sterilization and maintaining a sterile facility. In addition, at industrial scales, heat production from microbial metabolic activity vastly outweighs heat loss through bioreactor walls such that cooling is required. Extreme thermophiles have the advantage that non-refrigerated cooling water can be used if needed, and heating requirements can be met with low-grade steam typically in excess capacity on plant sites. We assembled a highly interdisciplinary team that brought together all of the expertise for the project to have successful outcomes. This project also built upon and utilized extensive information already available in the PIs’ labs for both Cbes and Pfu to develop models that provide a comprehensive description of these organisms’ physiology and metabolism that were utilized to inform metabolic engineering strategies. The models were validated with experimental data and the results demonstrated that unpretreated lignocellulose has the potential to be converted into value-added industrial chemicals at high loading at bioreactor scale. The data generated from this research were published in twenty-one peer-reviewed papers in international journals with online access.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2026

Performance Assessment of a Heat Pump Integrated with Thermal Energy Storage in Cooling & Heating Modes

Thermal Energy Storage (TES) systems have demonstrated significant potential to manage the fluctuating nature of energy demand and shifting peak loads. This technology has made significant recent advances, including new research on the integration of TES with residential and commercial Heating, Ventilation, and Air-Conditioning (HVAC) systems. In this paper, we present the use of a novel laboratory assessment framework for a prototype heat pump system integrated with latent heat phase change material-based TES. The assessment framework consists of 22 total test points (11 heating, 11 cooling) using psychrometric conditions from AHRI Standard 210/240 and includes transient conditions to evaluate TES charging and discharging modes. In addition, both continuous mode and cyclic mode were evaluated for charging and discharging to explore the benefits to TES heat transfer from repeated transient operation. The ambient conditions evaluated include heating mode charging at cold-climate heat pump conditions when winter-peaking utilities may most require demand reduction (H4Full conditions, 5°F/-15°C) and cooling mode charging at high ambient temperature that may occur during times of day when excess solar power generation results in low-cost electricity (105°F/40.6°C). The work demonstrates the demand reduction capabilities of integrating TES with HVAC, including up to 44% in cooling mode and 60% in heating mode compared to conventional HVAC equipment without TES.

25 ENERGY STORAGE↗
DOE OSTI2025

An Application of Molecular Recognition for the Efficient Removal of Cesium from Hanford Nuclear Waste by Modular Solvent Extraction

In this work, experimental results leading to flowsheet design are presented showing how a calixarene-crown ether based solvent-extraction process can meet the challenge of cesium removal from nuclear tank wastes stored at the US Department of Energy Hanford site. Cleanup of legacy Cold War nuclear waste stored in underground tanks represents one of the greatest environmental challenges facing the US Department of Energy in terms of risk, cost, and effectiveness of applicable science and technology. Planning for the cleanup at the Hanford Site calls for the removal of the radioactive fission product 137Cs from its alkaline salt waste, including the use of modular processes that can be deployed near the tank farms. To meet the resulting need for extremely high selectivity, the Next-Generation Caustic-Side Solvent Extraction (NG-CSSX) process employing a calix[4]arene-crown ether in modified kerosene has been adapted to remove sub-millimolar cesium in competition with molar sodium and potassium in a high-nitrate alkaline matrix. Potassium loading in the solvent was determined in extraction, scrubbing, and stripping, leading to an empirical model closely approximating cesium distribution ratios for a variety of Hanford waste types. Process chemistry has been developed based on this molecular-recognition approach, focusing on the competitive effect of potassium loading and the mitigating process modifications needed, including extending the scrub section. The result is a modular flowsheet design that can achieve cesium decontamination factors well in excess of 15,000 even for the worst-case Hanford waste.

Williams, Neil [ORNL] (ORCID:000000023159226X)↗
DOE OSTI2022

Site demonstration and performance evaluation of MPC for a large chiller plant with TES for renewable energy integration and grid decarbonization

Thermal energy storage (TES) for a cooling plant is a crucial resource for load flexibility. Traditionally, simple, heuristic control approaches, such as the storage priority control which charges TES during the nighttime and discharges during the daytime, have been widely used in practice, and shown reasonable performance in the past benefiting both the grid and the end-users such as buildings and district energy systems. However, the increasing penetration of renewables changes the situation, exposing the grid to a growing duck curve, which encourages the consumption of more energy in the daytime, and volatile renewable generation which requires dynamic planning. The growing pressure of diminishing greenhouse gas emissions also increases the complexity of cooling TES plant operations as different control strategies may apply to optimize operations for energy cost or carbon emissions. This paper presents a model predictive control (MPC), site demonstration and evaluation results of optimal operation of a chiller plant, TES and behind-meter photovoltaics for a campus-level district cooling system. The MPC was formulated as a mixed-integer linear program for better numerical and control properties. Compared with baseline rule-based controls, the MPC results show reductions of the excess PV power by around 25%, of the greenhouse gas emission by 10%, and of peak electricity demand by 10%.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2022

Towards Energy-Positive Buildings through a Quality-Matched Energy Flow Strategy

Current strategies for net-zero buildings favor envelopes with minimized aperture ratios and limiting of solar gains through reduced glazing transmittance and emissivity. This load-reduction approach precludes strategies that maximize on-site collection of solar energy, which could increase opportunities for net-zero electricity projects. To better leverage solar resources, a whole-building strategy is proposed, referred to as “Quality-Matched Energy Flows” (or Q-MEF): capturing, transforming, buffering, and transferring irradiance on a building’s envelope—and energy derived from it—into distributed end-uses. A mid-scale commercial building was modeled in three climates with a novel Building-Integrated, Transparent, Concentrating Photovoltaic and Thermal fenestration technology (BITCoPT), thermal storage and circulation at three temperature ranges, adsorption chillers, and auxiliary heat pumps. BITCoPT generated electricity and collected thermal energy at high efficiencies while transmitting diffuse light and mitigating excess gains and illuminance. The balance of systems satisfied cooling and heating demands. Relative to baselines with similar glazing ratios, net electricity use decreased 71% in a continental climate and 100% or more in hot-arid and subtropical-moderate climates. Total EUI decreased 35%, 83%, and 52%, and peak purchased electrical demands decreased up to 6%, 32%, and 20%, respectively (with no provisions for on-site electrical storage). Decreases in utility services costs were also noted. These results suggest that with further development of electrification the Q-MEF strategy could contribute to energy-positive behavior for projects with similar typology and climate profiles.

54 ENVIRONMENTAL SCIENCES↗