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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 OSTI2024

Development of near-optimal advanced control sequences for chiller plants with water-side economizers in U.S. Climates (ASHRAE RP-1661)

Various advanced control sequences for chiller plants with water-side economizers (WSE) have been proposed in literature, but the evaluation and optimization of those controls is limited. It is possible to maximize energy savings by selecting different sequences and related parameters based on the plant configuration, load, and climate. This paper addresses this gap by developing near-optimal advanced control sequences for chiller plants with WSEs. First, advanced control sequences for chiller plants with WSEs are categorized into condenser water, chilled water, and hybrid controls and representative sequences from each category are identified. Next, 504 different scenarios are optimized. These scenarios represent all possible combinations of two plant configurations, a constant or variable load profile, three advanced control sequences, and seven optimization parameter combinations in six climate zones. The results show the recommended near-optimal sequences can reduce energy consumption by up to 15% relative to the baseline depending on the configuration, load profile, and climate. Specifically, the CW-CHW sequence is recommended for the majority of systems because it is often the most energy efficient and/or reduces the runtime of chillers. The methodology in this paper provides practical guidance for achieving energy savings through near-optimal control of chiller plants with WSEs.

42 ENGINEERING↗
DOE OSTI2021

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

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

14 SOLAR ENERGY↗
DOE OSTI2021

Grid-Scale Ternary-Pumped Thermal Electricity Storage for Flexible Operation of Nuclear Power Generation under High Penetration of Renewable Energy Sources

In this work, the integration of a grid-scale ternary-Pumped Thermal Electricity Storage (t-PTES) with a nuclear power generation to enhance operation flexibility is assessed using physics-based models and digital real time simulation. A part of the electricity from the nuclear power generation is delivered to the grid, and the balance is used to power a heat pump that can be augmented by an auxiliary resistive load element to increase the charging rate of the thermal storage. This increases the thermal potential between hot and cold thermal stores (usually solid materials or molten salts inside large storage tanks). The thermal energy is transformed back into electricity by reversing the heat pump cycle. Different transient scenarios including startup, shutdown, and power change for grid-connected operation are simulated to determine the behavior of the hybrid nuclear-t-PTES system operating under variable loads that constitute a departure from conventional, baseload nuclear plant operation schemes. Ternary refers to the three modes operation: (i) heat pump (including heating coil), (ii) heat engine, and (iii) simultaneous operation of heat pump (including heating coil) and heat engine during changeover from pumping to generation or vice-versa. The controllability of t-PTES in the short timescales as a dynamic load is used to demonstrate operational flexibility of hybrid nuclear plants for flexible operation through advanced load management. The integration of t-PTES into nuclear power systems enhances the system flexibility and is an enabler for high penetration of renewable energy resources.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2026

Public Reference Data for Megawatt-Scale Hydrogen Electrolysis - NLR Historical Solar PV

The U.S. Department of Energy and National Laboratory of the Rockies (NLR) demonstrate hydrogen electrolysis from variable sources, hydrogen compression and storage, and hydrogen fuel cell power production using megawatt-scale equipment at NLR’s Flatirons Campus as part of the Advanced Research on Integrated Energy Systems (ARIES) research platform. This dataset represents part of that effort and is intended for academic, national laboratory, industrial, and other stakeholders to plan, design, and validate models of megawatt-scale hydrogen technologies and diverse energy infrastructure nationwide. These data provide a baseline for how existing hydrogen electrolysis technologies perform when coupled with various energy technologies. Future datasets will demonstrate how existing hydrogen fuel cell technologies can provide controllable, dispatchable, and variable power output for artificial intelligence data centers and other variable loads. This dataset entry describes the behavior of a 1.25-MW proton exchange membrane MC250 electrolyzer system, manufactured by Nel Hydrogen , [1] when fed historical data generated by the 430-kW, fixed-axis solar photovoltaic (PV) array located at NLR’s Flatirons Campus. (While the electrolyzer balance of plant supports up to 2.5 MW of electrolysis, NLR only has a single 1.25-MW electrolysis stack.) Solar PV power output data for the 2020 calendar year were categorized on a daily basis by total energy generation and standard deviation. Each day was then ranked by these metrics, and the 25th, 50th, and 100th percentiles were selected. The 75th percentile day did not exhibit sufficient variability to make for a valuable experiment. A similar process was used for the related historical wind dataset . [2] The historical days in 2020 that represented these percentiles are Dec. 19, March 29, and May 4, respectively. The entire solar day’s power profile was then fed through the MC250 electrolyzer. Due to its length, the 100th percentile day experiment was split into two parts, and the final 3 hours of the solar day were not captured. These final 3 hours contained no spikes or dips of interest and simply represented a slow decay of input solar power. Also, a single timestamp (13:13:47 on Jan. 14, 2026) was lost in the hydrogen system supervisory control and data acquisition. Finally, during the 25th percentile experiment (solar day Dec. 19, 2020) data recording was lost from 11:00:13 to 11:14:45. The roughly 15 minutes of the solar profile were rerun at the end of the experiment and spliced into this time slot during post-processing. The electrolysis system controls hydrogen production by varying direct current applied to the stack, from a maximum of 3,000 A to a minimum safe operation of 300 A, or 10%. Because the current–voltage characteristic changes as the stack ages and efficiency degrades, the actual minimum safe operating power changes over time. The historical solar profiles were translated from power (kilowatts) to current (amperes) using a curve fit with calibration data and sent to the electrolyzer power supply at 1-Hz frequency. For more details on the statistical analysis process, see the slide deck “Public Reference Data for Megawatt-Scale Hydrogen Electrolysis: NLR Historical Solar PV Analysis and Profile Generation” accessible with this data entry. These datasets report relevant hydrogen balance-of-plant and system data, all captured at 1 Hz, including hydrogen mass production measured with an Emerson Coriolis flow meter. Each .zip file represents a single solar PV electrolysis experiment and is formatted as: {technology}_{percentile}_{scaling factor} For instance, “solarPV-430kW_25_2x.zip” reports the experiment using the 25th percentile solar data from the historical 2020 solar PV dataset, scaled to 200%. Scaling factors were applied to the generated solar PV power output files to more closely match the 1.25-MW capacity of the electrolyzer. Each .zip folder contains the following files: A .csv file containing raw data. An .xlsx file explaining all the fields in the raw data. A .png plot showing the time series of hydrogen production, electrolysis power consumption, and solar power input. A PDF file detailing the historical solar data statistical analysis used to generate the solar profile. An experiment labeled “characterization_200.zip” demonstrates the MC250 electrolyzer steady-state response with 30-minute load steps for a total duration of 5 hours. Finally, a .csv file is provided with all experiments combined into one dataset labeled "combined_solarPV_experiments.csv". [1] nelhydrogen.com/product/mc-series-electrolyser . [2] data.nlr.gov/submissions/316 .

08 HYDROGEN↗
DOE OSTI2026

Public Reference Data for Megawatt-Scale Hydrogen Electrolysis - NLR Historical Wind

The U.S. Department of Energy and the National Laboratory of the Rockies (NLR) demonstrate hydrogen electrolysis from variable sources, hydrogen compression and storage, and hydrogen fuel cell power production using megawatt-scale equipment at NLR’s Flatirons Campus as part of the Advanced Research on Integrated Energy Systems (ARIES) initiative. This dataset represents part of that effort and is intended for academic, national laboratory, industrial, and other stakeholders to plan, design, and validate models of megawatt-scale hydrogen technologies and diverse energy infrastructure nationwide. These data provide a baseline for how existing hydrogen electrolysis technologies perform when coupled with various energy technologies. Future datasets will demonstrate how existing hydrogen fuel cell technologies can provide controllable, dispatchable, and variable power output for artificial intelligence (AI) data centers and other variable loads. This dataset entry describes hydrogen production by conducting a statistical analysis of historical wind data over a five-year period (2020-2025) from a single 1.5MW turbine manufactured by General Electric (GE) located at NLR’s Flatirons Campus, to generate an experimental test profile that was deployed on a 1.25-MW proton exchange membrane type MC250 electrolyzer system manufactured by Nel Hydrogen . [1] While the electrolyzer balance-of-plant supports up to 2.5 MW of electrolysis, NLR only has a single 1.25-MW electrolysis stack. The historical wind data provided several metrics, however, the analysis particularly focused on the measured power output by the wind turbine. The power output time series of data for each day was categorized by total energy generation and standard deviation, and the day that represented the highest combination of these two metrics was chosen – December 25th, 2022. This process was then repeated for a moving four-hour window within this day to identify the most statistically variable period. Finally, this four-hour period was scaled by 65% to match the 1.25 MW electrolyzer. The electrolysis system controls hydrogen production by varying DC current applied to the stack, from a maximum of 3000 A to a minimum safe operation of 300 A, or 10%. Because the current – voltage characteristic changes as the stack ages and efficiency degrades, the actual minimum safe operating power changes over time. The historical wind profiles were translated from power (kilowatts) to current (amperes) using a curve fit with calibration data and sent to the electrolyzer power supply at 1 Hz frequency. For more details on the statistical analysis process, see the presentation labeled “ Public Reference Data for Megawatt-Scale Hydrogen Electrolysis” provided with each data entry. These datasets report relevant hydrogen balance-of-plant and system data, all captured at 1 Hz, including hydrogen mass production measured with an Emerson Coriolis flow meter. Each .zip file represents a single wind turbine electrolysis experiment and is formatted as follows: {technology}_{scaling factor}-{electrolyzer ramp rate in amperes/second} For instance, “wind-GE1.5MW_0.65-400.zip” represents the hour-long experiment using historical data from the wind-GE1.5MW turbine, scaled to 65%, with the electrolyzer power supply set to a maximum ramp rate (gain and slew) of 400 A/s. Each .zip folder contains the following files: A .csv file containing raw data An .xlsx file explaining all the fields in the raw data. A .png plot showing the time series of hydrogen production, electrolysis power consumption, and wind power input. A PDF file detailing the historical wind data statistical analysis used to generate the wind profile. An experiment labeled “characterization_200.zip” demonstrates the MC250 electrolyzer steady-state response with 30-minute load steps for a total duration of 5 hours. Finally, a .csv file is provided with all simulated wind experiments combined into one dataset labeled "combined_historical_wind_experiments.csv". NLR also built an AI/machine-learning predictive model based on these datasets. The model ingests the electrolyzer current command in amperes, as well as various pressures and temperatures across the system, and predicts hydrogen output in kilograms per hour. The complete model can be found at https://huggingface.co/NatLabRockies/ptmelt-hydrogen-electrolysis [1] nelhydrogen.com/product/mc-series-electrolyser .

08 HYDROGEN↗
DOE OSTI2024

A data-driven sensor placement approach for detecting voltage violations in distribution systems

Stochastic fluctuations in power injections from distributed energy resources (DERs) combined with load variability can cause constraint violations (e.g., exceeded voltage limits) in electric distribution systems. To monitor grid operations, sensors are placed to measure important quantities such as the voltage magnitudes. Here, in this paper, we consider a sensor placement problem which seeks to identify locations for installing sensors that can capture all possible violations of voltage magnitude limits. We formulate a bilevel optimization problem that minimizes the number of sensors and avoids false sensor alarms in the upper level while ensuring detection of any voltage violations in the lower level. This problem is challenging due to the nonlinearity of the power flow equations and the presence of binary variables. Accordingly, we employ recently developed conservative linear approximations of the power flow equations that overestimate or underestimate the voltage magnitudes. By replacing the nonlinear power flow equations with conservative linear approximations, we can ensure that the resulting sensor locations and thresholds are sufficient to identify any constraint violations. Additionally, we apply various problem reformulations to significantly improve computational tractability while simultaneously ensuring an appropriate placement of sensors. Lastly, we improve the quality of the results via an approximate gradient descent method that adjusts the sensor thresholds. We demonstrate the effectiveness of our proposed method for several test cases, including a system with multiple switching configurations.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2021

Characterization of multiterminal tandem photovoltaic devices and their subcell coupling

Three-terminal (3T) and four-terminal (4T) tandem photovoltaic (PV) devices using various materials have been increasingly reported in the literature, but measurement standards are lacking. Here, multiterminal devices measured as functions of two load variables are characterized unambiguously as functions of three device voltages or currents on hexagonal plots. We demonstrate these measurement techniques using two GaInP/GaAs tandem solar cells, with a middle contact between the two subcells, as example 3T devices with both series-connected and reverse-connected subcells. Coupling mechanisms between the subcells are quantified within the context of a simple equivalent optoelectronic circuit. Electrical and optical coupling mechanisms are most clearly revealed using coupled dark measurements. These measurements are sensitive enough to observe very small luminescent coupling from the bottom subcell to the top subcell in the prototype 3T device. Quick simplified measurement techniques are also discussed within the context of the complete characterization.

14 SOLAR ENERGY↗
DOE OSTI2026

Encapsulation in a Bacterial Microcompartment Shell Improves Thermal Stability of a Glycolytic Enzyme

Selective encapsulation of target enzymes is an increasingly well-studied field, with a host of potential applications for biotechnology. Natively, many bacteria utilize bacterial microcompartments (BMCs) for enzyme encapsulation to enhance catalysis. BMCs are protein shells that enable selective localization of targeted metabolic enzymes and may improve catalytic rates by colocalizing pathway enzymes and/or serve to sequester toxic or volatile intermediates. The microcompartment shell of Haliangium ochraceum (HO) is a notable BMC chassis because of its modularity and versatility; it is easily expressed and assembled outside its native host and can accept a wide array of cargo. Recently, it was demonstrated that assembly of HO BMC shells can be easily achieved in vitro. Following up on our previous work on in vivo assembly of HO-BMCs with triose phosphate isomerase (TPI) as a model enzyme cargo, here we have demonstrated the advantages of in vitro assembly (IVA) for targeted enzyme encapsulation. We achieved variable loading of BMC shells with targeted amounts of TPI and demonstrated enhanced thermal stability of encapsulated TPI versus free TPI up to 62 °C.

assays↗
DOE OSTI2026

Uniformity, performance, and durability of roll-to-roll-coated iridium oxide electrolyzer catalyst layers

This work investigates the use of roll-to-roll coating methods for the production of iridium oxide catalyst layers for proton exchange membrane water electrolyzers. Catalyst layers were produced using two coating methods: slot die and gravure. By varying the solids content of the catalyst ink and coating process variables loadings between 0.08 and 0.64 mg Ir cm −2 were prepared with relatively high spatial uniformity. However, at loadings below 0.2 mg Ir cm −2 microscopy reveals voids in the catalyst layer due to similar length scales of catalyst agglomerates and overall layer thickness. Electrochemical testing shows that these voids do not impact initial membrane electrode assembly performance but lead to increased performance losses after potential cycling compared to spray coated catalyst layers.

08 HYDROGEN↗
DOE OSTI2026

Statistical Analysis of Inter-Area Oscillations in the U.S. Eastern Interconnection: A 2017-2023 Perspective

Recent advancements and the accumulation of high-resolution, long-term phasor measurement unit (PMU) data have provided detailed insights into inter-area oscillations in power grids. This study conducts a comprehensive statistical analysis of inter-area oscillations within the United States Eastern Interconnection from 2017 to 2023. Utilizing data captured by the advanced wide-area Frequency Monitoring Network (FNET/GridEye), this investigation examines the occurrence patterns, dominant frequencies, damping ratios, and excitation mechanisms of these oscillations. Our analysis sheds light on the evolving statistical behaviors of inter-area oscillations, offering updated and critical information for grid operators and planners. The insights gained from this study can be instrumental in enhancing the operational resilience of the power network and guiding strategic developments in grid infrastructure to accommodate future challenges. Additionally, the study discusses emerging challenges associated with the modernization of the power grid, including increased renewable penetration, dynamic load variability, and cyber-physical vulnerabilities that complicate oscillation monitoring and control.

Inter-area oscillations↗
DOE OSTI2025

Interoperable, Inverter - Based Distributed Energy Resources Enable 100% Renewable and Resilient Utility Microgrids

As microgrids transition away from use of conventional generating resources and increasingly rely on renewable resources towards decarbonization goals, it is crucial to evaluate the capability inverter-based resources to provide microgrid stability and resilience. Particularly, microgrids with a high contribution of intermittent solar photo voltaic generation and higher load variability present unique challenges requiring fast voltage and frequency support. At the San Diego Gas & Electric Company(R) (SDG&E(R)) Borrego Springs Microgrid, a battery inverter was upgraded with grid-forming (GFM) capability to serve as island leader, transitioning responsibility away from diesel generators. An interoperable microgrid control scheme was developed, coordinating GFM and grid-following (GFL) inverters. Hardware-in-the-loop (HIL) simulations using relevant power and controller HIL interfaces between real-time simulators and field equipment are being conducted to de-risk field deployment.

battery energy storage↗
DOE OSTI2023

Optimal Power Sharing Speed Compensation in On-road Wireless EV Charging Systems

Dynamic wireless charging of electric vehicles (EV) is an emerging technology with the potential to address range anxiety and reduce the size of batteries or provide charge-sustaining operation. Charging demand for dynamic wireless charging systems (DWCS) varies greatly in response to location-specific traffic behaviors including the number and speed of vehicles. This paper highlights the potential reduction of load variation with speed compensation and simulates opportunities to maximize the number of cars charged concurrently through “power sharing” or altering power output to slower cars while maintaining a maximum delivered energy. An improved sub-minute model for synthetic traffic is proposed to effectively model DWCS load on high speed roadways and a power electronics model is created based on an existing prototype developed by ORNL to investigate the potential for power sharing. Reductions in the average speed of traffic can greatly increase instantaneous DWCS load by as much as 26%, complicating capacity sizing. Parametric studies with a LCC-S power electronics model shows feasible power reduction of more than 20%, while maintaining a maximum achievable efficiency greater than 90%. Speed compensation on a roadway with large speed variation can reduce average power expected by 21% and increase the maximum number of cars charged simultaneously by 30%. The application of power sharing may significantly reduce load variability due to speed, allow for increased car hosting capability, and guarantee a maximum energy delivered.

Lewis, Donovin D.↗
DOE OSTI2021

Optimal Power Flow in DC Networks with Robust Feasibility and Stability Guarantees

With high penetrations of renewable generation and variable loads, there is significant uncertainty associated with power flows in DC networks such that stability and operational constraint satisfaction are of concern. Most existing DC network optimal power flow (DN-OPF) formulations assume exact knowledge of loading conditions and do not provide stability guarantees. Here, in contrast, this paper studies a DN-OPF formulation which considers both stability and operational constraint satisfaction under uncertainty. The need to account for a range of uncertainty realizations in this paper's robust optimization formulation results in a challenging semi-infinite program (SIP). The proposed solution algorithm reformulates this SIP into a computationally tractable problem by constructing a tight convex inner approximation of the stability set using sufficient conditions for the existence of a feasible and stable power flow solution. Optimal generator set-points are obtained by optimizing over the proposed convex stability set. The validity and effectiveness of the propose algorithm is demonstrated through various DC networks adapted from IEEE test cases.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2025

Speed Variation Based Power Regulation Concept for Dynamic Wireless Charging

On-road wireless charging of electric vehicles (EVs) in-motion could potentially reduce range anxiety or battery size with wide-spread deployment. The planning and implementation of such systems are greatly complicated due to their susceptibility to load variation inherent to traffic flow. Here, this paper proposes a method for derisking the potential for traffic slowdowns by compensating for reduced vehicle speed and investigates how implementation may affect system performance. A load modeling case study is presented at 200kW for a mile of high-speed roadway employing speed-based power regulation with results indicating average power usage and maximum car hosting capability can be reduced by 20% and increased by 30% respectively. An 85kHz power electronics model is developed based on designs and prototypes for an 11kW, 190m airgap static system and a 200kW dynamic wireless track. The simulation is validated in the 11kW experimental prototype and modified for 200kW operation to compare with simulated performance. Sensitivity studies are performed in MATLAB/Simulink to evaluate how parameters influence system performance and confirm the capability to reduce output power and maintain efficiency at 11 and 200kW. The static 11kW experimental system operates at 93.6% efficiency and multiple options exist to reduce power while maintaining efficiency greater than 90%. The capability to dynamically modify power output from WPT coils, in an experimentally validated simulation, enables techniques to significantly mitigate load variability due to reductions in vehicle speed.

42 ENGINEERING↗
DOE OSTI2026

Analyzing SCM Grid Benefits from Electric Transportation [Slides]

Increasing adoption of EVs and expanding unmanaged charging loads could increase the cost of transportation energy due to increasing load variability and shrinking infrastructure capacity. The actual cost of transportation energy, such as charging an EV, depends on several factors including energy costs, charging infrastructure costs, and applicable grid upgrades. Based on studies from past DOE projects; RECHARGE, DirectXFC, FUSE and 21st Century Truck Partnership (21CTP) the EV-CENTS project will develop a transportation energy cost metric to better quantify these factors and provide a framework for assessing the value potential of new technology solutions, such as smart charge management (SCM), which could reduce these costs for all stakeholders. The initial assessment will focus on the cost of charging, which will vary across vehicle classes such as light-duty vehicles (LDV) or medium and heavy-duty vehicles (MHDV), as well as across different vocations resulting in many different use cases for this metric. Cost of charging results will be developed for each use case in both uncontrolled and controlled scenarios to understand the value potential of different SCM objective functions and their ability to optimize the cost of energy and delay or eliminate the need for electrical upgrades.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2025

Integrated Multi-Fidelity Model and Co-Simulation Platform for Distribution System Transient and Dynamic Analysis—DistribuDyn

As inverter-based, distributed energy resources (DERs) and variable loads continue to proliferate across distribution systems, it is increasingly important to understand their impacts on system stability and reliability. However, most commercially available simulation tools for distribution planning primarily focus on steady-state and quasi-steady state analysis, offering limited capabilities to study transient and dynamic behaviors.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2025

Public Reference Data for Megawatt-Scale Hydrogen Electrolysis – Simulated Wind

The U.S. Department of Energy and the National Laboratory of the Rockies (NLR) demonstrate hydrogen electrolysis, hydrogen compression and storage, and variable hydrogen fuel cell power production using megawatt-scale equipment at NLR’s Flatirons Campus as part of the Advanced Research on Integrated Energy Systems (ARIES) initiative. This dataset represents part of that effort and is intended for academic, national laboratory, industrial, and other stakeholders to plan, design, and validate models of megawatt-scale hydrogen technologies and diverse energy infrastructure nationwide. These data provide a baseline for how existing hydrogen electrolysis technologies perform when coupled with various energy technologies. Future datasets will demonstrate how existing hydrogen fuel cell technologies can provide controllable, dispatchable, and variable power output for artificial intelligence (AI) data centers and other variable loads. This dataset entry describes hydrogen production using a single, simulated wind turbine. The electrolyzer is a 1.25-MW proton exchange membrane type MC250 system manufactured by Nel Hydrogen . While the unit supports up to 2.5 MW of electrolysis, NLR only has a single 1.25-MW electrolysis stack. For the simulated wind energy profiles, NLR used OpenFAST to simulate a 3.4-MW International Energy Agency (IEA) reference wind turbine. The hour-long wind energy profiles varied over wind turbulence intensity (Class A or Class C) and average wind speed (5, 7, or 9 m/s). To match the power limits of the 1.25-MW electrolyzer and 3.4-MW IEA wind turbine most effectively and to maximize the efficiency of hydrogen production at a given average wind speed, the profiles were sometimes scaled by two times. This means that, in some cases, the experimental setup assumed two 1.25-MW electrolyzers were coupled with the wind turbine, representing a total maximum electrolysis load of 2.5 MW. Finally, NLR experimented with two settings for the electrolyzer power supply minimum and maximum current ramp rates (gain and slew): 200 and 400 amperes per second. The simulated profiles were translated from power (kilowatts) to current (amperes) using a curve fit with calibration data and sent to the electrolyzer power supply at 1-Hz frequency. These datasets report relevant hydrogen balance-of-plant and system data, all captured at 1 Hz, including hydrogen mass production measured with an Emerson Coriolis flow meter. Each .zip file represents a single wind turbine electrolysis experiment and is formatted as follows: {technology}-{average wind speed}-{turbulence class}_{number of 1.25 MW electrolyzers connected}-{electrolyzer ramp rate in amperes/second} For instance, “windIEA3.4-5ms-C_2-400.zip” represents the hour-long experiment using the IEA 3.4-MW turbine, subjected to an average wind speed of 5 m/s and Class C wind turbulence, and connected to two 1.25-MW electrolyzers with the power supply set to a maximum current ramp rate (gain and slew) of 400 A/s. Each .zip folder contains the following files: A .csv file containing raw data. An .xlsx file explaining all the fields in the raw data. A .png plot showing the time series of hydrogen production in kilograms per hour, electrolysis power consumption, and input wind turbine power. An experiment labeled “characterization_200.zip” demonstrates the MC250 electrolyzer steady-state response with 30 minute load steps for a total duration of 5 hours. Finally, a .csv file is provided with all simulated wind experiments combined into one dataset labeled "combined_wind_experiments.csv". NLR also built an AI/machine-learning predictive model based on these datasets. The model ingests the electrolyzer current command in amperes, as well as various pressures and temperatures across the system, and predicts hydrogen output in kilograms per hour. The complete model can be found at https://huggingface.co/NatLabRockies/ptmelt-hydrogen-electrolysis .

08 HYDROGEN↗
DOE OSTI2025

Public Reference Data for Megawatt-Scale Hydrogen Electrolysis - Simulated Wave

The U.S. Department of Energy and the National Laboratory of the Rockies (NLR) demonstrate hydrogen electrolysis, hydrogen compression and storage, and variable hydrogen fuel cell power production using megawatt-scale equipment at NLR’s Flatirons Campus as part of the Advanced Research on Integrated Energy Systems (ARIES) initiative. This dataset represents part of that effort and is intended for academic, national laboratory, industrial, and other stakeholders to plan, design, and validate models of megawatt-scale hydrogen technologies and diverse energy infrastructure nationwide. These data provide a baseline for how existing hydrogen electrolysis technologies perform when coupled with various energy technologies. Future datasets will demonstrate how existing hydrogen fuel cell technologies can provide controllable, dispatchable, and variable power output for artificial intelligence (AI) data centers and other variable loads. This dataset entry describes hydrogen production using a single, simulated wave energy conversion device. The electrolyzer is a 1.25-MW proton exchange membrane type MC250 system manufactured by Nel Hydrogen. While the unit supports up to 2.5 MW of electrolysis, NLR only has a single 1.25-MW electrolysis stack. For the wave energy, NLR used a wave energy converter model from PacWave. These devices can be equipped with accumulators and pressure relief values to smooth the power output by storing and releasing hydraulic energy. Using a peak power output of 10 MW, the model created two 25-minute profiles: one with and one without the accumulators and pressure relief valves. To down select the profile data from the native resolution of 20 Hz to 1 Hz, NLR took the mean of every 20 data points. NLR experimented with two simulated wave energy power plants: one that peaks at 10 MW, and one that peaks at 5 MW. These profiles were scaled for the physical 1.25 MW electrolyzer by multiplying the original profiles by one eighth and one quarter, respectively. The first profile matches the capacity rating of eight of the 1.25 MW electrolyzers, while the second matches four electrolyzers. Finally, NLR experimented with two settings for the electrolyzer power supply minimum and maximum current ramp rates (gain and slew): 200 and 400 amperes per second. The simulated profiles were translated from power (kilowatts) to current (amperes) using a curve fit with calibration data and sent to the electrolyzer power supply at 1-Hz frequency. These datasets report relevant hydrogen balance-of-plant and system data, all captured at 1 Hz, including hydrogen mass production measured with an Emerson Coriolis flow meter. Each .zip file represents a single wave electrolysis experiment and is formatted as follows: {technology}-{accumulator?}_{number of 1.25 MW electrolyzers connected}-{electrolyzer ramp rate in amperes/second} For instance, “wavePacWave-Noacc_4-400.zip” represents the 25 minute-long experiment using the PacWave’s wave energy converter model, equipped with no accumulator, connected to four 1.25-MW electrolyzers with their power supplies set to a maximum current ramp rate (gain and slew) of 400 A/s. Each .zip folder contains the following files: A .csv file containing raw data. An .xlsx file explaining all the fields in the raw data. A .png plot showing the time series of hydrogen production in kilograms per hour, electrolysis power consumption, and input wave power. An experiment, labeled “characterization_200.zip”, demonstrates the MC250 electrolyzer steady-state response with 30 minute load steps for a total duration of 5 hours. Finally, a .csv file is provided with all wave profiles combined into one dataset labeled "combined_wave_experiments.csv". NLR also built an AI/machine-learning predictive model based on these datasets. The model ingests the electrolyzer current command in amperes, as well as various pressures and temperatures across the system, and predicts hydrogen output in kilograms per hour. The complete model can be found at https://huggingface.co/NatLabRockies/ptmelt-hydrogen-electrolysis.

08 HYDROGEN↗