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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 OSTI2025

Low Cost High-Performance HRE-Free 3-in-1 Electric Drive Unit

The project team completed work to expand upon American Axle & Manufacturing’s (AAM) baseline technology and develop a high-speed, AC induction electric drive unit (EDU) with total direct-oil-cooling and integrated power electronics. The project accelerated advancements in EDU technology by allowing AAM to build upon the progress made in developing the underlying baseline technologies. The following seven improvements to AAM’s baseline technology were implemented in this research and development program: 1) Increased speed (30k RPM) AC induction motor, 2) Silver-sintering of discrete silicon carbide (SiC) metal-oxide-semiconductor field-effect transistors (MOSFET) to heat sinks, 3) Electrically insulated rotor bars, 4) Optimized lamination steel, 5) EDU-integrated 650VDC inverter package, 6) Over-molded stator with molded liners, and 7) 650VDC power-dense stator design. The successful development of the technology resulted in a meaningful cost reduction for EDU systems in the market. Coupled with falling battery system costs, lower EDU costs will likely accelerate the market acceptance and related production scaling of battery electric vehicles. The objective of this project was to research, develop, and test a Heavy Rare Earth (HRE)-free 3-In-1 electric drive unit (EDU) that has class leading power density and cost. The key technologies to be developed were anticipated to meet or exceed the Department of Energy (DOE) targets of a cost ≤ $\$$7/kilowatt (kW), power density ≥ 12 kW/liter, and operating voltage ≥ 600 VDC.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

Marine Algae Industrialization Consortium (MAGIC): Combining biofuel and high-value bioproducts to meet the RFS

The Marine Algae Industrialization Consortium (MAGIC) was formed to address pressing challenges in the commercialization of microalgae as a source of biofuel. The “Marine Algae Industrialization Consortium (MAGIC): Combining biofuel and high-value bioproducts to meet the RFS” project formally addressed two US Department of Energy Bioenergy Technologies Office (BETO) goals: (1) Model the sustainable supply of 1 million metric tonnes ash free dry weight (AFDW) cultivated algal biomass and (2) Demonstrate valuable co-products produced along with biofuel intermediates to increase value of algal biomass by 30%. To achieve these goals, the project demonstrated and validated high-value co-products to drive down the cost of biofuel by increasing the value of algae “co-products” towards increasing the selling price of total algae biomass as one of the key drivers of economics and adoption. This was accomplished through five core, interdependent tasks including: (1) strain selection to identify and deliver strains for mass culture, (2) mass culture using a hybrid cultivation system and following key operating parameters for downstream applications to provide algae feedstock, (3) recovery and conversion to evaluate two alternative methods to separate dry algae biomass into oil and residuals for downstream testing, (4) product assessment to determine biofuel, aquafeed or poultry feed product efficacy using algae biomass fractions as well as to provide critical performance data for valuation and (5) commercialization to use technoeconomic and life cycle assessments (TEA/LCA) as iterative design and assessment tools including consideration of target markets, competitors, and distribution channels to guide product assessment, development and valuation. A total of 46 peer-review publications, many open-access, provide detail of much of the work carried out and the results of the tasks. Additional reports and presentations provide other technical and public engagement material. At a high level, using a variety of approaches, more than 1000 marine microalgae strains were evaluated to ultimately identify the seven winners that were down-selected to be grown in mass culture. Strain selection demonstrated that there were no ‘super strains’ and that each candidate had strengths and limitations for specific products, growth conditions or operational considerations. Mass culture growth of these seven strains at >5000 L / 29 m 2 scale found that four them were suitable for product assessment. More than 250 kg of biomass was produced across hundreds of pond runs along with thousands of cultivation entries on the growth and biomass characteristics as well as environmental parameters. In the process, dozens of standard operating procedures were generated as was custom software to process and analyze cultivation data. Recovery and conversion of algae biomass demonstrated that a hexane solvent based extraction protocol was most effective at recovering oil (biocrude) from algae and four strains were processed to produce oil and lipid extracted algae (residuals) for downstream testing. Membrane-based oil separation was less successful, but may still be applicable to other commercial applications in the future. Product testing demonstrated that algae biocrude is of high quality and hydrotreating generated numerous fractions of high quality composition for fuel and lubricate based applications. Aquafeed studies performed at a variety of scales showed that both whole and defatted (lipid extracted algae) microalgae were suitable as a feed ingredient, but that the specifics of the fed animal and biochemical composition of the algae are critical factors when determining formulation. Similarly, poultry studies on whole and defatted microalgae generally showed positive outcomes on animal growth and health, with some microalgae providing enhanced nutritional composition of the animal product. Economic and life cycle assessments covered a wide range of possible commercialization and sustainability scenarios. Replacement value, improved product value added, consumer values marketing added valuation and improved animal health were considered as alternatives for microalgae valuation. Using the open pond system, algae productivity was identified as the key driver of commercialization economics, but combination of co-products (e.g. animal feed) with biofuel production substantially increased the total selling price of algae. Modeled microalgae selling price exceeded $\$$1500/tonne and could generate competitive biofuel selling prices below $\$$5 gallon gas equivalents using realistic algal productivities. Short (process scale) and longer (decadal trends) sustainability assessments show that marine microalgae can enhance the sustainability of energy production and lead to other realized benefits in water, fertilizer and land use for other sectors (e.g. agriculture). This project successfully demonstrated all of the components of an end-to-end process from mass microalgae cultivation and dewatering, to recovery and conversion of algae biomass components, to final product demonstration and process valuation; the combined results provide a framework for future commercialization of algae based biofuels.

09 BIOMASS FUELS↗
DOE OSTI2020

Range cost-effectiveness of plug-in electric vehicle for heterogeneous consumers: An expanded total ownership cost approach

Plug-in electric vehicles (PEV) appears to have sales momentum in major personal vehicle markets but are still at the early market stage. Opportunities to accelerate PEV adoption can be discovered through comprehensive total cost of ownership (TCO) analysis. Understanding the cost-effective electric ranges of PEVs for consumers, manufacturers, and the society is critical for any discussion of PEV mass markets. This study expanded the traditional TCO approach by (1) fully considering heterogeneous consumer driving patterns, (2) quantifying the charging inconvenience and range anxiety cost of battery-electric vehicles (BEVs), and (3) monetizing both tangible and intangible PEV policies. Uncertainties were handled through Monte Carlo simulation. The results suggest that BEVs with an electric range of 250–350 km have the lowest TCO in cities with government-enacted purchase limitations, and internal combustion engine vehicles (ICEVs) have the lowest TCO in cities without purchase limitations, even when considering PEV subsidies. The lowest TCO for some consumer groups is obtained by BEVs with an electric range of 400–450 km, especially in northern China, where the weather is colder. The cost-effective all-electric range for BEVs in each city in 2025 will decrease due to improved battery performance in cold environments and an expanded charging infrastructure. Finally, based on TCO, plug-in hybrid electric vehicles (PHEVs) are currently more suitable for drivers with a high average daily mileage or a large mileage variance. However, by 2025, BEVs with a long driving range may become a more cost-effective choice for these drivers.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2026

Future Projections of Lifecycle Cost and Greenhouse Gas Emissions of Light-Duty Vehicles

Vehicles with electrified powertrains carry the promise of significant reductions in greenhouse gas (GHG) emissions from a lifecycle analysis (LCA) standpoint compared to conventional internal combustion engine (CICE) vehicles. However, trade-offs exist between different types of electrified powertrains in terms of cost, consumer acceptance, and GHG reduction efficacy for different operating conditions. The open-source tool CarGHG was developed with an aim to enable the exploration of a plethora of parametric study scenarios, including the cost of electrification technologies, different driving patterns and charging habits, and the cost and carbon intensity of electricity and fuel blends. This paper introduces the framework of CarGHG, then showcases total cost of ownership (TCO) and LCA GHG results for select models of light-duty vehicles. Another capability of CarGHG, which is the ability to estimate the performance of “virtual” vehicle models (perceived vehicle design specifications not yet on the market), is utilized to explore future scenarios of electrification and low-carbon fuel blends for Small Sports Utility Vehicles (SUVs), a popular light-duty vehicle segment in North America. With opportunities, but also uncertainties, in future scenarios, it is likely wise to continue pursuing multiple ways towards the reduction of LCA GHG.

Hamza, Karim↗
DOE OSTI2024

Measurement of Wind Loading on Heliostats at the Crescent Dunes Power Plant: An Overview

The cost of solar collectors constitutes almost one third of the total cost of a CSP plant. One of the ongoing challenges in the design of these collectors is wind loading on mirrors, support structures, and drives. A particular challenge is dynamic wind loading, caused by the turbulent wind flow. To date, the design of solar collector structures has relied on wind tunnel experiments and numerical simulations that do not entirely capture the dynamic effects observed at scale. The CSP industry has shown increased interest in validating the idealized assumptions with measurements obtained in operational settings to improve wind load assumptions and increase reliability and cost-efficiency of the collector design. Further, performance models need realistic assumptions about wind loading and its impact on optical performance. In a parabolic trough field campaign, NREL successfully collected a wealth of long-term, high-resolution wind and loads data [2], that are publicly available and that can be used for the above-mentioned purposes. Heliostats are impacted differently by wind than parabolic troughs, due to their different shape, size, and field layout. To study the impact of wind and turbulence on heliostats, we initiated another field campaign in an operational power- tower plant, Crescent Dunes, in Nevada, USA. In this work, we present an overview of the measurements, first results, and potential implications of wind driven loads on Heliostats.

concentrated solar power↗
DOE OSTI2023

Wind Loading on Parabolic Trough Collectors: Wind and Structural Loads Measurements at an Operational Powerplant

Concentrated Solar Power (CSP) is a promising method for using solar power for electricity generation with thermal energy storage for industrial applications. Solar collectors constitute almost 1/3 of the total cost of the power plant. One of the primary drivers of unrealiability of these collectors is wind-driven loading of mirrors, support structures, and drives. To date, the design of the solar collector structures has relied on data from wind tunnels that do not adequately capture the dynamic effects observed at scale. NREL initiated a field measurement campaign at the operational Nevada Solar One (NSO) parabolic trough powerplant. At this plant, parabolic trough solar collectors track the sun from east to west in the course of a day and face varying wind loads depending on the wind properties and the angle of the troughs. The aim of the project is a detailed characterization of prevailing wind and turbulence conditions and resulting operational loads on parabolic troughs, providing insights into structural dynamic response, and generating a comprehensive wind-loading dataset for validating simulations of wind loading on collector structures. The measurements at NSO consist of sonic anemometers on masts at different heights to characterize the incoming flow and conditions at four trough rows at the edge of the trough field. In addition, a Doppler Lidar scans the horizontal plane above the troughs. The wind measurements at NSO have been continuously collecting data since October 2021 and are combined with structural load measurements that started in November 2022. The load measurements were installed on the same four outermost trough rows and include support structure bending moments, drive torque moments, dynamic accelerations of the spaceframe, mirror displacement, and tilt angles. Measurements are planned to continue until May 2023, providing a first-of-a-kind, high-resolution multi-month dataset of combined wind and load measurements. In this presentation, we show first results of the measurement campaign. Based on the measurements, we identified three main factors altering the flow over the parabolic troughs: Wind speed, wind direction, and the angle of the parabolic troughs. Most interactions between incoming wind and the trough field are observed when the wind blows perpendicular to the trough rows. In this case, the first rows experience the highest wind speed and block the downwind rows, creating conditions with decreased wind speed and enhanced turbulence within the trough field. Also, turbulent length scales are smaller after the first row. This leads to the highest static loads (bending and torque moments) at the first row but potentially increased dynamic loads within the field. We illustrate our findings with case studies focused on different wind conditions and will present fatigue analysis to highlight the impact of wind-driven loads on collector structures.

CSP collectors↗
DOE OSTI2022

A Comprehensive Approach towards Multi-Objective EMI Filter Design Optimization in High-Frequency SiC-Based Motor Drives

With rapid penetration of high-frequency, highdensity power electronics into the industry, controlling the system generated EMI becomes one of the major design challenges. Designing practical optimized EMI filters require simultaneous consideration of multiple aspects - including electromagnetic couplings, magnetic materials, practical component parasitics and their impacts at high-frequencies, and also the overall manufacturing costs. The multi-dimensional nature of the problem often results in overcompensated designs that hurt the system efficiency and power density. This paper focuses on a comprehensive design platform (developed in MATLAB) towards designing high-density, optimized, highly efficient EMI filters by analyzing the generated noise spectrum and evaluating a vast array of potential solutions before outputting an optimized filter solution. The proposed tool includes database-based component selection, optimal topology selection, multistage filter design, overall optimization for volume, mass, cost and total loss. The proposed filter has been thoroughly evaluated in a PSIM simulation environment emulating the hardware in CRD300DA12EXM3, a 300kW three-phase inverter from Wolfspeed with an RL load representing a motor drive application. Furthermore, a 20kHz switching frequency is chosen and impacts of the motor high-frequency characteristics on the generated EMI noise spectrum of the overall system have been analyzed.

42 ENGINEERING↗
DOE OSTI2020

The Power Reclamation of Utilizing Micro-Hydro Turbines in the Aeration Basins of Wastewater Treatment Plants

Upgrading the aeration basin technology can improve the oxygen transfer efficiency (OTE), while keeping the energy consumption at its minimum level. Therefore, this paper introduces a new idea of installing micro-propeller turbines in the aeration basin of a wastewater treatment plant (WWTP) to extract power from the high-velocity location in the water column. This extracted power can be used to operate a mixer at the top of the membrane to induce the mixing in that region, which will drive the less oxygenated wastewater into the water column. The rest of the extracted power will rotate microturbine rotors for electric power generation. By applying the proposed microturbines to the 13 audited facilities, it was demonstrated to achieve a gross annual energy-savings of 3,836.9 MWh, a gross annual cost-saving of $260,497, and total CO 2 emissions that would be reduced by 2,714 metric tons/year. Generally, the addition of the proposed microturbines can save up to 15.7% of the annual plant electricity consumption (1.3–12.8% of the plant annual electricity bills).

13 HYDRO ENERGY↗
DOE OSTI2020

Thermal Instability in the Manufacturing of Wind Turbine Blade Spar Caps

As wind turbine blades continue to scale in length and total mass, the acceptability of traditional approaches for the engineering of processes to build these products has reached a limit. The continued need to reduce the levelized cost of energy (LCOE) drives manufacturing cycle times lower and the net mass of critical components challenges even the most experienced fabricators to meet the quality requirements for safe operating performance over the 25-year design life of the blade. In trying to reduce cycle time for key components of wind turbines, manufacturers discovered occasional buckling of fibers in wind turbine blade spar caps. The cause of the buckling was unknown. The goal of this project was to show that a comprehensive simulation, which considered all of the physics of the VARTM process, could identify the cause of the fiber buckling in spar caps that has been observed during the manufacturing process. Ultimately, the simulation determined the manufacturing process and parameters could lead to significant compressive stresses in the fibers eventually causing buckling. Simulation results suggest that the stress introduced from friction is the largest source of compressive stress in the fibers, the stress from the weight of gravity is significant but secondary, and the compressive stress from cure shrinkage does not play a significant role in the buckling of fibers. This report provides details of the testing and simulation methodology used to identify the cause of the fiber buckling.

17 WIND ENERGY↗
DOE OSTI2022

Data-Driven Simulation-Based Planning for Electric Airport Shuttle Systems: A Real-World Case Study

Many airports are adopting battery electric buses in their shuttle fleets due to concerns over air quality and regulations. This study proposes a simulation-based optimization modeling framework to help airport shuttle operators effectively deploy electric buses. We evaluated a planned airport electric shuttle system with an event-driven simulator. Empirical data collected from existing systems were used to drive the simulations. We then proposed a simulation-based optimization model to determine the battery capacity, charging power, and number of chargers so that predefined objective(s) (e.g., minimizing total capital cost, minimizing emissions) are optimized. Compared to existing studies, the primary contribution of the proposed method is that it can model the real-world stochastic nature of operations in an electric bus system with much higher fidelity. To demonstrate the proposed modeling framework, we study a real-world shuttle system at the Dallas-Fort Worth International Airport, and present extensive numerical studies. When considering partial fleet electrification, the model can provide a set of Pareto optimal solutions. When considering full fleet electrification, the optimal solution requires a 50-kWh battery capacity and four 210-kW chargers, resulting in a total capital cost of $26,744,000. The results demonstrate that the proposed modeling framework can effectively optimize the planning of electric airport shuttle systems with partial or full fleet electrification.

ADVANCED PROPULSION SYSTEMS,ENERGY PLANNING, POLIC↗
DOE OSTI2025

Preliminary Techno-Economic Assessment of Gas Switching Reforming (GSR) of Natural Gas for Pure Hydrogen Production and Power Generation with Integrated CO2 Capture

The increasing demand for hydrogen and the CO2 intensity of natural gas (NG) reforming motivate the development of low-carbon-emission hydrogen production technologies. Gas Switching Reforming (GSR) is an advanced auto-thermal reforming technology that produces hydrogen or syngas from natural gas. It integrates inherent CO2 capture by utilizing a specialized oxygen carrier in a single fluidized bed reactor, eliminating the need for complex, energy-intensive post-combustion separation. GSR technology builds upon Chemical Looping Reforming (CLR), an experimentally proven technology with strong potential for scaling up. In this study, select oxygen carriers (OC) (NiO/Al2O3, Fe2O3-CeO2/Al2O3, and magnetite) were tested in methane steam reforming in a fixed bed reactor to determine their relative reactivities under relevant conditions for GSR (800 °C, 7 bar total pressure). Process models were then developed to perform techno-economic analysis (TEA) of GSR for hydrogen production (GSR-H₂) and a combined cycle (GSR-CC) in which high-purity H₂ is fired in a gas turbine to produce electricity. Operating at 10 bar and 1100 °C and with the additional recovery steps implemented increased H₂ production by ~30% and improved efficiency relative to prior studies. For GSR-H₂, the levelized cost of hydrogen (LCOH) is 1.61–1.64 $/kg-H₂, competitive with a reference SMR case, though operating and maintenance costs are higher due to increased electricity demand. GSR-CC has a significantly higher levelized cost of electricity (LCOE) than its reference NGCC (natural gas combined cycle) plant, suggesting it is less competitive; however, increasing production scale could make it more attractive. Life-cycle results for GSR-H2 indicate NG consumption drives ~75% of total global warming impacts (~2.3 kg CO2 eq/kg H2). An environmental, health, and safety screening suggests iron-based carriers are comparatively safer, whereas NiO may pose greater risks. Overall, GSR-H2 is a scalable, competitive option for hydrogen production using nickel and non-nickel OC.

03 NATURAL GAS↗
DOE OSTI2025

Preliminary techno-economic assessment of gas switching reforming (GSR) of natural gas for pure hydrogen production and power generation with integrated CO2 capture

The increasing demand for hydrogen and the CO2 intensity of natural gas (NG) reforming motivate the development of low-carbon-emission hydrogen production technologies. Gas Switching Reforming (GSR) with integrated CO2 capture, a technology based on Chemical Looping Reforming (CLR), has been experimentally proven and shows potential for scale-up. In this study, select oxygen carriers (OC) (NiO/Al2O3, Fe2O3-CeO2/Al2O3, and magnetite) were tested in methane steam reforming in a fixed bed reactor to determine their relative reactivities under relevant conditions for GSR (800 °C, 7 bar total pressure). Process models were then developed to perform techno-economic analysis (TEA) of GSR for hydrogen production (GSR-H2) and a combined cycle (GSR-CC) in which high-purity H2 is fired in a gas turbine to produce electricity. Operating at 10 bar and 1100 °C and with the additional recovery steps implemented increased H2 production by ∼ 30% and improved efficiency relative to prior studies. For GSR-H2, the levelized cost of hydrogen (LCOH) is 1.61–1.64 $/kg-H2, competitive with a reference SMR case, though operating and maintenance costs are higher due to increased electricity demand. GSR-CC has a significantly higher levelized cost of electricity (LCOE) than its reference NGCC (natural gas combined cycle) plant, suggesting it is less competitive; however, increasing production scale could make it more attractive. Life-cycle results for GSR-H2 indicate NG consumption drives ∼ 75% of total global warming impacts (∼2.3 kg CO2 eq/kg H2). An environmental, health, and safety screening suggests iron-based carriers are comparatively safer, whereas NiO may pose greater risks. Overall, GSR-H2 is a scalable, competitive option for hydrogen production using nickel and non-nickel OC.

03 NATURAL GAS↗
DOE OSTI2022

A method for determining optimal electric range by considering electric vehicle lightweighting on perceived ownership cost

The limited driving range due to high costs and low energy densities of batteries constraints the battery electric vehicle (BEV) market growth. Lightweighting in theory can reduce energy consumption rate and extend the driving range. The knowledge gap is to quantitatively link the cost-effectiveness of light-weight technologies with range extension and consumer acceptance of BEVs. In this study, a physics-based energy consumption model of BEVs is constructed and associated with a statistics-based model on the basis of travel surveys. A perceived cost of ownership (PCO) is then developed by adding intangible costs to traditional total cost of ownership models. We estimate, at the disaggregate vehicle model and driver level and the aggregate market level, 1) the extended range due to lightweighting for a given battery size; and 2) the optimal electric range based on lightweighting decisions. The cost-effectiveness of lightweighting for BEV range extension is found to vary with income-dependent daily range limitation value, driving patterns and lightweighting technology costs. In general, adopting lightweighting in BEVs is more cost-effective for consumers with higher daily limitation value, as well as for those with higher driving intensity or suitable daily driving patterns. When the lightweighting involves a higher vehicle production cost, less lightweighting could reduce the overall PCO for BEV owners. 4 of the selected top ten BEV models are found to benefit from additional 2.09%–4.45% lightweighting. Finally, the method built in this study can guide automakers in planning R&D investments in battery and lightweighting technologies.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2026

From Cell to System: Accelerated hpc Simulations of BESS Aging under Frequency Regulation and Arbitrage use cases

Lithium-ion battery energy storage systems (BESS) packs have emerged as a leading solution for grid-scale energy storage, enhancing resiliency and balancing load fluctuations. Yet, experimental characterization of large-format LIB packs-particularly to assess performance and degradation over hundreds of cycles - demands substantial hardware investment and multi-year testing campaigns. In this work, we couple a hierarchical, physics-based modeling framework agnostic to electrode chemistries with high-performance computing to accelerate systems level evaluation by upto two orders of magnitude. Building on the open-source liionpack platform, we implement cell, module, and pack-scale electrochemical models enriched with mechanistic aging mechanisms and deploy them on an HPC cluster to simulate 150−200kWh systems over 500 - 1,000 cycles with in days. We subject these virtual B ESS to both constant-current cycling and realistic grid service profiles spanning frequency regulation, ramp-rate support, and energy arbitrage-and quantify the resulting degradation patterns. Our results reveal that localized cell aging can induce substantial nonuniformity at module and pack levels, with service-specific cycling protocols driving distinct aging modes. This rapid, multiscale modeling approach provides a powerful design-space exploration tool for optimizing electrical architecture, control strategies, and operational schedules to prolong pack lifetime and lower total cost of ownership.

Ayalasomayajula, Surya [ORNL] (ORCID:0009000860788↗
DOE OSTI2022

Valuing Residential Energy Efficiency: Analysis for a Prototypical Southeastern Utility [Slides]

The increasing amount of variable renewable energy resources and shifts towards more end-use and vehicle electrification suggests profound changes to power system planning and operation. Specifically, renewable energy is expected to shift net peak demand from late afternoon to early evening and end-use electrification may significantly increase winter peak demand. Residential energy efficiency is likely to align well with these shifts as it tends to produce savings in the early evening (e.g., from lighting measures) and coincident with heating loads (e.g., from envelope and space conditioning measures). Despite the opportunity to decrease system costs and emissions, residential energy efficiency is often limited by static valuation methods and its economic potential is considerably less than its technical potential. Using hourly residential energy efficiency characterizations, utility program cost data, and a capacity expansion model, we estimate the benefits of residential energy efficiency for a prototypical, summer-peaking utility in the Southeastern region. We first establish the cost-effective residential energy efficiency portfolio through “competition” with supply-side resources in a forward-looking capacity expansion model. Importantly, we then evaluate several scenarios intended to drive an increasing amount of cost-effective residential energy efficiency through measure cost reductions, increased customer adoption, policy goals (e.g., carbon price), and delivery of an integrated package of measures. The results quantify total system cost and emissions reductions, fossil-fuel plant retirements, and peak demand reductions. Results suggest the design and prioritization of policies and programs to access the untapped amount of cost-effective residential energy efficiency.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2026

Comparative assessment of new oxygen carrier materials for gas switching reforming of natural gas: Techno-economics assessment, life cycle analysis, and experimental insights

The increasing demand for hydrogen and the CO 2 intensity of natural gas (NG) reforming motivate the development of low-carbon-emission hydrogen production technologies. Gas Switching Reforming (GSR) with integrated CO 2 capture, a technology based on Chemical Looping Reforming (CLR), has been experimentally proven and shows potential for scale-up. In this study, select oxygen carriers (OC) (NiO/Al 2 O 3 , Fe 2 O 3 -CeO 2 /Al 2 O 3 , and magnetite) were tested in methane steam reforming in a fixed bed reactor to determine their relative reactivities under relevant conditions for GSR (800 °C, 7 bar total pressure). Process models were then developed to perform techno-economic analysis (TEA) of GSR for hydrogen production (GSR-H 2 ) and a combined cycle (GSR-CC) in which high-purity H 2 is fired in a gas turbine to produce electricity. Operating at 10 bar and 1100 °C and with the additional recovery steps implemented increased H 2 production by ∼ 30% and improved efficiency relative to prior studies. For GSR-H 2 , the levelized cost of hydrogen (LCOH) is 1.61–1.64 $/kg-H 2 , competitive with a reference SMR case, though operating and maintenance costs are higher due to increased electricity demand. GSR-CC has a significantly higher levelized cost of electricity (LCOE) than its reference NGCC (natural gas combined cycle) plant, suggesting it is less competitive; however, increasing production scale could make it more attractive. Life-cycle results for GSR-H 2 indicate NG consumption drives ∼ 75% of total global warming impacts (∼2.3 kg CO 2 eq/kg H 2 ). An environmental, health, and safety screening suggests iron-based carriers are comparatively safer, whereas NiO may pose greater risks. Overall, GSR-H 2 is a scalable, competitive option for hydrogen production using nickel and non-nickel OC.

03 NATURAL GAS↗
DOE OSTI2022

Cooling Egypt: Cost and benefits of room air conditioner efficiency improvement in Egypt

Egypt is one of the largest countries in the Middle East and North Africa region with a population of a total of 106 million (as of July 2022). Increasing urbanization, population growth, and increasing temperatures will likely continue to drive demand for electricity from air conditioning, with corresponding negative impacts on the peak load, air quality, and greenhouse gas emissions from refrigerant use and energy consumption. Since 2003, Egypt has adopted a standards and labeling program for various appliances, and has improved its room air conditioner (RAC) energy efficiency requirements in 2016 and 2017. However, its market is still dominated by inefficient fixed-speed drive (FSD) RACs due to a price-sensitive market. Seasonal metrics such as Cooling Season Performance Factor (CSPF) measure the energy efficiency of FSD and variable-speed drive (VSD) RACs on the same scale. Leading markets, most notably China, have already adopted a new MEPS in 2020 and 2022, which align largely with the United for Efficiency (U4E) Model Regulations Guidelines. India has also adopted a CSPF metric. Both India and China are now experiencing (1) increased demand and consumption of higher efficiency VSD RACs, as well as (2) a corresponding drop in prices from the economies of scale of production of these higher efficiency RACs. Because China is a leading manufacturer in the global air conditioner (AC) market, its adoption of the model U4E regulations have effectively raised the energy efficiency of the ACs in the global market. To achieve the benefits of taking a similar approach to Egypt’s market, we offer the following recommendations: 1. Adopt a common metric to measure the efficiency of both FSD and VSD RACs 2. Raise the stringency of MEPS to the level of the U4E Model Regulation Guidelines 3. Restructure the labeling program from the “A++” labeling scheme to a simpler A through E or a star-rating program 4. Strengthen the compliance regime governing the Egyptian AC MEPS 5. Assist small and medium AC manufacturers in Egypt to transition manufacturing lines to produce low-cost, high-efficiency VSD RACs. Adopting these recommendations would reduce Egypt’s electricity consumption to 11 TWh in 2030 and 89 TWh in 2050—with corresponding carbon dioxide (CO2) emissions reductions and avoided generation capacity requirements compared to the baseline.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2022

Effect of modeled time horizon on quantifying the need for long-duration storage

Long-Duration Energy Storage (LDES) has gained interest due to its key role in attaining a decarbonized, low-cost, and stable grid driven by variable renewable electricity (VRE). Currently, there is a wide range of LDES technologies being developed to provide electricity with 8+ hours of consecutive discharge. However, current capacity expansion models used in long-term planning processes rarely consider low cost LDES as a candidate technology. If they do, the storage balancing horizon (SBH) of the model usually only considers non-consecutive 1-day periods that do not capture the potential of LDES to shift energy across multiple days or even seasons. Addressing these limitations in existing models, this work explores the ways in which the optimal energy storage changes when increasing the number of consecutive days in the SBH and how these changes will impact planners who are determining the future roles of energy storage. Our analysis uses SWITCH, an open-source capacity expansion model with a high spatial resolution for the entire Western Electricity Coordinating Council (WECC) in a zero-carbon scenario in 2050. We find that the number of consecutive days in the SBH changes both the total selected power and energy capacity of LDES when storage energy and power capacity overnight costs are $\$$13 USD/kWh (or less) and $113 USD/kW, respectively. We also find that the amount of required energy in storage to drive a future VRE-driven WECC grid ranges from 2.5 TWh to 16.0 TWh depending on the length of the SBH. The optimal storage duration (energy to power ratio) we obtain ranges from 10 h to 620 h among all the scenarios. Furthermore, depending on the storage cost assumption, we observe different charge/discharge patterns when varying the length of the SBH. Given our results, we anticipate that as more LDES technologies become commercially available, it will be critical to increase the length of the SBH to fully capture the benefits of LDES assets in long-term planning processes of high VRE-driven grids.

42 ENGINEERING↗