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DOE OSTI2024

Catalyst Layer Design, Manufacturing and In-line Quality Control

In this project we successfully demonstrated the capabilities of the Reactive Spray Deposition Technology (RSDT) to fabricate large-scale CCMs for advanced PEMWEs that have one-order of magnitude lower PGM loading in their catalyst layers, and performance comparable with the commercial state-of-the-art CCMs. The RSDT is a unique methodology that combines the catalyst synthesis and CCM fabrication in one step and reduces dramatically the time for CCM manufacturing. As fabricated large-scale CCMs with geometric area of 680 cm2 demonstrated excellent activity and durability performance, and the novel duo-recombination layer design paves the way for solving the safety concerns related to PEMWEs. In addition, excellent activity and durability performance has been demonstrated with RSDT fabricated CCMs with thinner membranes and duo RL design. This is a novel approach for further performance improvement of the MEAs for PEMWEs that has been successfully demonstrated for the first time in this project. The integration of the in-situ laser diagnostics system along with the in-line optical quality control system within the RSDT that has been achieved and demonstrated in this project, is an example for possibility of designing and building advanced manufacturing technologies that can meet the requirements of the future manufacturing. Therefore, the RSDT offers a precise real-time monitoring and control of the particles size, composition, loading, porosity, thickness, and defects in the catalysts’ layers, which render this technology as the best candidate for manufacturing of cost effective CCMs for PEMWEs. By using RSDT we successfully met all project’s milestones, Go/No-Go decision, objectives, goals, and deliverables.

08 HYDROGEN↗

DOE OSTI2022

Low-Cost, Easy-To-Integrate and Reliable Grid Energy Storage System with 2 nd Life Lithium Batteries

Batteries retired from electric vehicles have the potential to extend their service as low-cost stationary energy storage systems. However, disperse battery state of health (SOH) and nonuniform battery characters often lead to compromised battery performance and reliability, which greatly hinder their adoption. A Heterogenous Unifying Battery (HUB) system is proposed to stage 2 nd life battery bricks for a period, and enable them to attain improved SOH uniformity, performance, and reliability before being sold for 2 nd life applications, while simultaneously providing grid services. It may offer a technically and economically advantageous solution for the broad utilization of 2 nd use batteries. The goal of this project was to develop the hardware and software that enables the key functions of the HUB system. The first achievement of the project was the development of a 1kW scale proof-of-concept (POC) system, which comprises (i) a modular plug-n-play DC-DC power converter matrix with isolated series output connections to achieve fully independent control of energy flow to each of the connected battery units at low voltage; (ii) enhanced model based control that drives each batteries’ SOH towards uniformity while collectively providing grid energy storage services; and (iii) comprehensive procedures to perform battery diagnostics and prognostics. The second achievement was the development of a 100kW scale HUB system and demonstrated its performance of re-establishing battery SOH uniformity through a period of battery cycling operation. The final HUB system incorporates six DC-DC power converter matrices paired with six battery bricks. Hot swapping of a single battery brick while maintaining consistent system power was demonstrated and system operation was validated to be capable of implementing the approved grid duty cycle and of balancing and conditioning the battery bricks. Through the course of the project, the team optimized the building-block design, form-factors, and adjusted life balancing control. An up-sized 250kW Scale was developed and deployed in October 2022 with pack-level battery form factors, see photo in Figure 1 The third achievement of the project was to perform a techno-economic analysis in order to better understand the cost and revenue potentials in this new “recondition-then-resell" value proposition. The final TEA quantified the economics of new Li-ion batteries as well as second-life batteries processed via reconditioning and traditional binning. Results showed the reconditioned second-life batteries in this project to be economically favorable and viable in grid energy storage markets. The TEA results were published in the Applied Energy journal. The fourth achievement of the project was to deliver a tech-to-market plan for the HUB system that includes funding, IP, and manufacturing strategies. The final T2M plan outlines a business strategy in which the HUB provides a B2B service to EV companies as an alternative to battery recycling that can prepare batteries for 2nd life applications. A company named Smartville Inc. was founded to carry on the commercialization, funding, and technical IP licensing activities of the OPEN project.

25 ENERGY STORAGE↗

DOE OSTI2023

Rapid Fabrication of High Frame Rate Multichannel FTIR Spectrometers

Spectrally resolved signals in the short- to mid-wave infrared (SWIR/MWIR) bands at high-temporal resolution are critical for many national security remote sensing missions. Currently available off the shelf technology can achieve either high temporal resolution or high spectral resolution, but rugged instruments that can achieve both simultaneously remain mostly in the realm of one-off R&D projects. This report documents efforts to demonstrate a new technique for designing and building high resolution, high framerate multichannel FTIR (MC-FTIR) spectrometers that operate in the SWIR/MWIR bands. The core optical element in a MC-FTIR spectrometer is an array of statically-tuned lamellar grating interferometers (LGI). In the original MC-FTIR work these arrays were fabricated using a synchrotron x-ray lithography method. We proposed to instead fabricate these LGI arrays using multiphoton lithography (MPL), a 3D printing technique that can fabricate meso-scale structures with sub-micron precision. Although we were able to fabricate LGI arrays of sufficient size using MPL, the realized optical surfaces had unsuitably high optical form errors, precluding their use in a fieldable instrument. Further advancement in MPL technology may eventually enable fabrication of interferometer-grade LGI arrays.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2024

Building on success in systems design of high yielding low‐input energycanes for marginal lands

Energycane and Miscanthus are highly sustainable and productive perennial grasses that produce a large annual crop of shoot biomass. Theoretical analysis of metabolism has suggested that these crops could be engineered to accumulate 20% of their harvestable biomass as oil. Given their much higher biomass yields than soybean and canola, this would yield several times more oil per acre. This could be converted to biodiesel or sustainable aviation fuel (SAF) by well‐established technologies. Energycane is well suited to the southeast quarter of the contiguous 48 states and Miscanthus to the northeast quarter. The objective of this award was to provide the foundation for converting these crops to oilcanes from DNA constructs and transformation to field trials and pilot plant development of oil extraction. Genetic engineering focused on development and implementation of improved constructs to increase oil levels, and increased photosynthesis to support the additional energy needed for oil production. The specific progress in each of our subtasks follows together with the products arising.

09 BIOMASS FUELS↗

DOE OSTI2025

Tunable Electrochemical Pathway for High-Purity REMs and CMs

This report details a comprehensive research initiative focused on developing a technical research plan for the efficient and sustainable production of rare earth elements (REEs) and critical materials (CMs) from coal-based resources, specifically lignite coal from the Williston Basin in North Dakota. The project’s methodology centers on the design and evaluation of a tunable electrochemical pathway (TEP), an innovative approach aimed at achieving high-purity rare earth oxides (REOs), rare earth salts (RES), and CMs. This research is crucial for addressing the growing demand for these materials in clean energy technologies, electric vehicles, and high-tech applications, while reducing the United States’ reliance on foreign supply chains. The project was structured into four key tasks, each designed to build upon the previous one and contribute to the overarching goal of developing a viable technical research plan.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2025

Edge at the Pier: EPCAPE Software-Defined Sensing Field Campaign Report

The Eastern Pacific Cloud Aerosol Precipitation Experiment (EPCAPE) was aimed to enhance the understanding of cloud and aerosol properties in the region surrounding La Jolla, California. To address challenges in data collection and processing from various instruments, an edge computing device known as Waggle Sage Node (WSN) was deployed at the Ellen Browning Scripps Memorial Pier. WSN is a distributed-sensing platform designed to collect and analyze environmental data at the edge. Sage is a multi-agency-supported project that designs and builds a new kind of national-scale reusable cyberinfrastructure to enable artificial intelligence (AI) at the edge based on the Waggle platform. Sponsors include the U.S. Department of Energy (DOE) Advanced Scientific Computing Research (ASCR), DOE National Nuclear Security Administration (NNSA), DOE Biological and Environmental Research (BER) through DOE Artificial Intelligence for Earth System Predictability (AI4ESP), Argonne Laboratory-Directed Research and Development (LDRD). Sage (https://sagecontinuum.org/) is funded as a National Science Foundation Mid-Scale Research Infrastructure (MSRI) project (https://www.nsf.gov/awardsearch/showAward?AWD_ID=1935984). This robust, multi-architecture edge computing platform facilitated environmental monitoring during the campaign. This report details the scientific objectives, deployment process, and key results of integrating Waggle into the EPCAPE field campaign.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2025

Furthering Advancements to Shorten the Time (FAST) to Commissioning for Pumped Storage Hydropower (PSH) Prize: Cooperative Research and Development (Final Report)

The National Renewable Energy Laboratory initiated a Prize with support from Argonne National Laboratory (ANL), Oak Ridge National Laboratory (ORNL), and Pacific Northwest National Laboratory (PNNL), and sponsored by the U.S. Department of Energy Water Power Technologies Office (DOE WPTO) to encourage ideas to reduce the time to commissioning for PSH projects. As a result, nine finalists have been chosen to develop their concepts in advance of the FAST Prize Pitch Contest to be held on October 7, 2019. The National Labs will provide technical and business advisement to the noted FAST Prize finalists in preparation for this Pitch Contest.

16 TIDAL AND WAVE POWER↗

DOE OSTI2025

Designing FAIR Workflows at OLCF: Building Scalable and Reusable Ecosystems for HPC Science

High Performance Computing (HPC) centers, such as the Oak Ridge Leadership Computing Facility (OLCF), provide advanced infrastructure that enables scientific research at extreme scale. These centers operate with unique hardware configurations, specialized software environments, and elevated security re quirements that differ substantially from what most users encounter on their local systems. As a result, users often develop customized digital artifacts that are tightly coupled to the specific configuration of a given HPC center. Although necessary, this practice can lead to significant duplication of effort as multiple users independently create similar solutions to common problems.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2026

Carbon Capture Pilot at Vicksburg Containerboard Mill (Final Technical Report)

This is the final technical report for the DOE-OCED project DE-CD0000051. The report provides the progress at the close of the project. The objective of the project is to design and build a large pilot plant for carbon dioxide (CO 2 ) capture from a pulp and paper (P&P) mill using RTI’s non-aqueous solvent (NAS) technology at a capacity of 120,000 t-CO 2 /year, with >90% CO 2 captured. The pilot plant will be used for testing and evaluating the NAS capture process using real flue gas from the P&P mill’s power boiler for a minimum of 1 year of parametric testing and a minimum of 2,000 hours of continuous long-term testing. The testing will provide data for process optimization and scale-up for the P&P industry, provide information on interaction of flue gas contaminants on solvent performance and degradation, and inform strategies for emission control. At the end of the project, the pilot plant will be managed by International Paper (IP), the host site owner, which will continue to capture CO 2 , sequester the captured CO 2 , and be eligible for the 45Q credit.

42 ENGINEERING↗

DOE OSTI2024

ANSI/ASHRAE/IES Standard 90.1-2022 Performance Rating Method Reference Manual

This document is intended to be a reference manual for the Appendix G Performance Rating Method (PRM) of ANSI/ASHRAE/IES Standard 90.1-2022 (Standard 90.1-2022). The PRM can be used to demonstrate compliance with the standard and to rate the energy efficiency of commercial and high-rise residential buildings with designs that exceed the requirements of Standard 90.1. Use of the PRM for demonstrating compliance with Standard 90.1 was a new feature of ANSI/ASHRAE/IES Standard 90.1-2016 (Standard 90.1-2016). The procedures and processes described in the PRM reference manual (PRM-RM) are designed to provide consistency and accuracy by filling in gaps and providing additional details needed by users of the PRM.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2023

ANSI/ASHRAE/IES Standard 90.1-2019 Performance Rating Method Reference Manual

This document is intended to be a reference manual for the Appendix G Performance Rating Method (PRM) of ANSI/ASHRAE/IES Standard 90.1-2019 (Standard 90.1-2019). The PRM can be used to demonstrate compliance with the standard and to rate the energy efficiency of commercial and high-rise residential buildings with designs that exceed the requirements of Standard 90.1. Use of the PRM for demonstrating compliance with Standard 90.1 was a new feature of ANSI/ASHRAE/IES Standard 90.1-2016 (Standard 90.1-2016). The procedures and processes described in the PRM reference manual (PRM-RM) are designed to provide consistency and accuracy by filling in gaps and providing additional details needed by users of the PRM.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

Adaptive variational simulation for open quantum systems

Emerging quantum hardware provides new possibilities for quantum simulation. While much of the research has focused on simulating closed quantum systems, the real-world quantum systems are mostly open. Therefore, it is essential to develop quantum algorithms that can effectively simulate open quantum systems. Here we present an adaptive variational quantum algorithm for simulating open quantum system dynamics described by the Lindblad equation. The algorithm is designed to build resource-efficient ansatze through the dynamical addition of operators by maintaining the simulation accuracy. We validate the effectiveness of our algorithm on both noiseless simulators and IBM quantum processors and observe good quantitative and qualitative agreement with the exact solution. We also investigate the scaling of the required resources with system size and accuracy and find polynomial behavior. Our results demonstrate that near-future quantum processors are capable of simulating open quantum systems.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2022

A Review of the Use of Wearables in Indoor Environmental Quality Studies and an Evaluation of Data Accessibility from a Wearable Device

An understanding of indoor environmental quality (IEQ) and its effects on occupant well-being can inform building system design and operation. The use of wearables in field studies to collect subjective and objective health performance indicators (HPIs) from a large number of occupants could deliver important improvements in IEQ. To facilitate the use of wearables in IEQ studies, there is a need to identify which HPIs should be collected and to evaluate data accessibility from these devices. To address this issue, a literature review of previous IEQ studies was conducted to identify relationships between different IEQ factors and HPIs, with a focus on HPIs that were collected using wearables. A preliminary assessment of data accessibility from a selected wearable device (Fitbit Versa 2) was performed and documented. The review suggested the need to further investigate and collect sleep quality parameters, heart rate, stress response, as well as subjective ratings of comfort using wearables. The data accessibility assessment revealed issues related to missing data points and data resolution from the examined device. A set of recommendations is outlined to inform future studies.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2021

3D Printing of High Viscosity Reinforced Silicone Elastomers

Recent advances in additive manufacturing, specifically direct ink writing (DIW) and ink-jetting, have enabled the production of elastomeric silicone parts with deterministic control over the structure, shape, and mechanical properties. These new technologies offer rapid prototyping advantages and find applications in various fields, including biomedical devices, prosthetics, metamaterials, and soft robotics. Stereolithography (SLA) is a complementary approach with the ability to print with finer features and potentially higher throughput. However, all high-performance silicone elastomers are composites of polysiloxane networks reinforced with particulate filler, and consequently, silicone resins tend to have high viscosities (gel- or paste-like), which complicates or completely inhibits the layer-by-layer recoating process central to most SLA technologies. Herein, the design and build of a digital light projection SLA printer suitable for handling high-viscosity resins is demonstrated. Further, a series of UV-curable silicone resins with thiol-ene crosslinking and reinforced by a combination of fumed silica and MQ resins are also described. The resulting silicone elastomers are shown to have tunable mechanical properties, with 100–350% elongation and ultimate tensile strength from 1 to 2.5 MPa. Three-dimensional printed features of 0.4 mm were achieved, and complexity is demonstrated by octet-truss lattices that display negative stiffness.

36 MATERIALS SCIENCE↗

DOE OSTI2020

U.S. Department of Energy Solar Decathlon Competition Guide 2019-2020

This Solar Decathlon will offer collegiate teams a unique experience to develop critical career skills, learn from both national experts and peers, and gain valuable insights from world-class thought leaders. This document details the Rules for the Design Challenge and Build Challenge.

14 SOLAR ENERGY↗

DOE OSTI2021

BETO 2021 Peer Review - Biomethanation to Upgrade Biogas to Pipeline Grade Methane WBS 5.1.3.102

We are developing, innovating and de-risking a biomethanation process capable of megawatt-scale deployment that upgrades biogas waste streams to produce pipeline quality renewable natural gas (RNG). Biomethanation is a two-step process using a methanogenic microorganism to convert renewable hydrogen (H2) and waste carbon dioxide (CO2) to renewable methane (CH4) - the primary component in natural gas. Using biogenic CO2 from biogas sources like dairies, wastewater treatment plants, and landfills allows production of this drop-in direct replacement fuel to participate in the growing number of carbon markets; like California's Low Carbon Fuel Standard and the Federal Renewable Fuel Standard. The end-of-project goal is to demonstrate pipeline quality RNG production (> 95% CH4, < 4% H2, <1% CO2, < 0.2% O2 and < 4 parts per million hydrogen sulfide) using real biogas feedstocks. We will accomplish this goal by designing and building a pressurized (18 bar) mobile lab-scale (20L) bioreactor research platform, including integrated electrolyzer system, based on lessons learned from operating the 700L pilot system from Southern California Gas Company. In collaboration with Electrochaea, natural gas utilities and Argonne National lab, will provide the data to establish a preliminary range of carbon intensity to help accelerate the deployment of utility-scale H2 production and qualify the biomethanation pathway process for RNG production.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2021

Energy Efficient, Cost-Effective Power and Co-Generation Technologies: Techno-Environmental Analysis

Development of energy solutions for addressing grid resiliency and energy efficiency while lowering greenhouse gas emissions is critical in today’s energy scenario. Chemical energy provides on demand power. Cogeneration technologies offer numerous benefits in meeting the growing energy demand while lowering the impact on environment. Utilization of waste heat from prime movers in conjunction with energy efficient heat pumps and renewable photovoltaics is an attractive approach. Efficient utilization of available resources to support current and future building energy needs targeting grid resiliency, energy and environmental security via co-generation approaches is the focus of this study. A detailed techno-environmental analysis of hybrid system configurations consisting of conventional and emerging technologies utilizing natural gas, electric grid, and renewable power resources along with heat recovery systems and heat pump technologies are analyzed and presented. The key objective is to present integrated system configurations and thermodynamic analysis of various co-generation systems suitable for providing building energy. Design solutions targeting low carbon footprint and high energy efficiency are presented.

Cheekatamarla, Praveen↗

DOE OSTI2022

Life after 30 years - a PV system in Colorado

The PV system consisted of 155 monocrystalline Si Arco M53 panels, installed in 1987. 80 were installed on a fixed tilt rack, and 75 on 5 separate dual-axis passive trackers. The system was decommissioned in 2017 due a campus re-design and building expansion at the Platte River Power Authority (PPRA) site. Prior to decommissioning a site visit established the following failure type observations: EVA browning (100%), cracked cells (60%), and cracked wires or grommets (9%, or more if replacements were made selectively on cracked parts). EVA browning is typical in modules of this vintage, whereas the occurrence of so many cracked cells is surprising and is likely weather-related. The fairly frequent occurrence of cracked wires and grommets serves as a reminder that accelerated testing of these components is important for goals of low-cost 50-year energy generation. In smaller numbers, thermal effects (7%), bent frames (1%), and cell corrosion (<1%) were observed. A sample of 20 modules was selected and brought to NREL for in-depth characterization. Because baseline measurements were not available using the nameplate rating, which can be inaccurate, revealed a mean module sample degradation of 0.7 %/year. Sporadic production data during the 30 years determined a system degradation rate closer to 1.2 %/year. Subsequently, four of these modules were re-mounted outdoors at NREL and are now approaching a total lifetime of 34 years.

durability↗