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All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Chloride Molten Salt Electrolysis Enables Integrated and Energy-Efficient Process for NdFeB Magnet Fabrication

Rare-earth elements (REEs) have been identified by NATO, the USDOE, and USGS as critical materials, i.e., materials which have significant demand yet pose supply-chain risks. Many of the existing processes for separations, metallization, and final parts production used across the REE supply chain involve energy intensive steps. For example, neodymium (Nd or NdPr) is produced using oxyfluoride electrolysis of Nd 2 O 3 , which requires hydrofluoric acid to produce a key electrolyte component (NdF 3 ) and generates undesired perfluorocarbon (PFC) gases. Such challenges make securing a resilient supply chain for NdFeB permanent magnets in countries like the United States prohibitively difficult. Here, we propose a chloride-based MSE process that circumvents these challenges, delivering high-purity NdPr from a (NdPr)Cl 3 feed from upstream REE separations. This eliminates environmentally-damaging steps of oxalate or carbonate precipitation and calcination, and enables superior production rates due to greater solubility of (NdPr)Cl 3 in chloride melts compared to Nd 2 O 3 . We show that CMSE generates high-purity NdPr (99.4 wt.%) while being energy-efficient (~ 6 kWh/kg-Nd). NdPr from CMSE was used to fabricate a NdFeB magnet with an excellent maximum energy product (> 40 MGOe), comparable to commercially available NdFeB magnets. This establishes CMSE as a leading approach for integrated, energy-efficient NdFeB magnet production.

Materials science↗
DOE OSTI2020

Combining Reclaimed PET with Bio-Based Monomers Enables Plastics Upcycling

Less than 30% of PET plastic is recycled in the United States. The low reclamation rate may be due to mechanical recycling accounting for the majority of commercial PET recycling. Mechanical recycling yields a lower-quality recycled plastic than the process of chemically recycling back to the monomer phase, which can be energetically and economically expensive. In this work, recently published in Joule, reclaimed PET bottles are chemically recycled and converted into higher-value fiberglass-reinforced plastics (FRPs).This presentation will focus on the supply-chain level energy and greenhouse gas emissions intensities associated with this novel upcycling route. The Materials Flows through Industry supply chain analysis tool, developed at NREL, is used to estimate these impacts. Depending on the extent and speed of adoption, this strategy for plastic upcycling could lead to significant energy usage and emissions reductions over the traditional FRP supply chain. Overall, this approach may provide an economic incentive for plastics recycling and renewable feedstock use through the creation of higher-value FRPs.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2025

Chelation ion chromatography as an automated, and cost-effective analytical technique for REE determination: method development and applications

Rare earth elements (REEs), as critical minerals, have important uses in modern energy and technologies, yet are vulnerable to potential supply chain disruptions. To establish domestic REE supply chain, efficient REE detection methods for resource characterization and mineral processing will be needed to accelerate innovations for domestic REE recovery. This study developed a rapid, novel, and cost-effective for REE detection method using ion chromatography (IC) for aqueous samples. Various REE-targeted eluent gradients and post-column agent compositions were tested on the chelation ion chromatography (CIC) with UV-vis detector for optimal separation and quantification of REEs within approximately 20 min. The single-channel pump to deliver the post-column solution to UV-vis detector was replaced with a 4-channel gradient pump, to increase operation and maintenance efficiencies. After method optimization, resulting calibration curves for more than ten REEs achieved high coefficients of determination (R2>0.999) and low relatively standard deviations (below 3.24%), demonstrating sub-ppm level detection limits (0.0897 to 0.1149 mg/L). The reliability of the CIC method was validated through comparison with inductively coupled plasma mass spectrometry (ICP-MS), showing strong agreement in REE recovery from certified standards. The impact of metal ions and salts on REE recovery using CIC was also systematically investigated. CIC consistently exhibited reliable performance in the presence of salt solutions such as NaCl and Na₂SO₄ (up to 10,000 mg/L). Our study also found the presence of high concentrations of Al ions (at 10,000 mg/L) significantly influenced REE determination, and elevated concentrations of Ca ions affected the recovery of specific REEs, including La, Ce, and Pr. The CIC method was further tested on REE-containing eluents from solvent extraction tests out of fly ash leachates. REE detection from these real processing fluids were reported to achieve 90% to 100% recovery rate from our IC method, compared to ICP-MS results. This study underscores the potential of CIC as a reliable and efficient alternative for REE determination in complex matrices. It also highlights the importance of minimizing select interfering metal ions in solutions to ensure accurate results. The REE CIC method presents a promising, low-maintenance, salt-tolerant, and cost-effective alternative to traditional analytical methods for REE analysis.

detection of rare earth elements (REE)↗
DOE OSTI2024

Carbon intensity of mass timber materials: impacts of sourcing and transportation

Mass timber construction is widely considered a promising alternative construction method to reduce buildings’ total life-cycle carbon emissions because wood is a carbon sink. Cross-laminated timber (CLT) panels, manufactured by gluing lumber layers with grains at right angles, are potential low-carbon alternatives to carbon-intensive concrete and steel construction. However, most environmental impact assessment studies do not consider variation in transportation impacts within the CLT supply chain when calculating life-cycle impacts. This study investigates the embodied primary energy and the global warming potential (GWP) of CLT supply chain decisions regarding the type of timber species used, the U.S. region it is sourced from, and the location of the CLT mill. Longer transport distances in the supply chain for timber and CLT panels can contribute as much as 923 MJ/m 2 (20%) of the embodied primary energy of a CLT building, and the use of a higher-density timber species increases this contribution to 1246 MJ/m 2 (24%), with most of that energy derived from fossil energy sources. For perspective, the GWP of a building whose CLT panels and timber have been transported by truck over 6,000 km (252–270 kgCO 2 /m 2 ) is greater than the GWP of an equivalent reinforced concrete (RC) building (245 kgCO 2 /m 2 ). Thus, factors like the location of CLT processing facilities and the type of timber species can significantly impact the overall life-cycle assessment and, if chosen appropriately, can mitigate the environmental impacts of CLT construction.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2021

U.S. Industrial and Commercial Motor System Market Assessment Report Volume 1: Characteristics of the Installed Base

Motor systems are an integral part of our industrial and commercial facilities. They provide the motive force behind the fans, pumps, compressors, chillers, and conveyors in these facilities. Given their centrality to any facility’s operations, they are a critical energy end use to understand, particularly when developing technologies and policies to meet sustainability goals, improve productivity, and enhance resilience. In the late 1990s, the U.S. Department of Energy (DOE) conducted two seminal studies to better understand the installed stock and energy savings opportunities of industrial and commercial motor systems. In the industrial sector, The United States Industrial Electric Motor Systems Market Opportunities Assessment used primary data collected through onsite assessments and led to a greater understanding of the installed base of motor systems, their characteristics, and the opportunities for energy savings (U.S. Department of Energy, 2002). Notable findings included the following: Industrial motor systems consumed 679 billion kilowatt-hours (kWh) in 1994, representing 23 percent of U.S. electricity consumption. Cost-effective energy efficiency measures could result in 62-104 billion kWh of energy savings annually. Sixty-two percent of the energy savings potential was from fan, pump, and compressor end use equipment. Nearly half of motor system electricity consumption was attributable to approximately 3,500 facilities, or 1.5 percent of U.S. manufacturing facilities. Opportunities for Energy Savings in the Residential and Commercial Sectors with High Efficiency Electric Motors provided an evaluation of the installed stock of motor driven equipment in U.S. commercial and residential buildings and opportunities for utilization of high efficiency motors and variable speed technologies (Arthur D. Little, 1999). Notable findings included the following: Commercial motor systems consumed 343 billion kWh in 1995, with refrigeration and space conditioning constituting 93 percent of the total. Cost-effective energy efficiency measures could result in 51 billion kWh of energy savings annually. Due in no small part to these seminal studies, motor system technologies and usage characteristics have changed drastically since the late 1990s. Greater awareness of cost-effective strategies for reducing motor system electricity consumption have been developed and deployed. This includes several software tools, literature, and utility and government programs promoting energy efficiency improvements in motor driven systems. Additionally, several rounds of energy efficiency standards have been enacted, resulting in improved installed motor efficiency. The cost of variable speed drives has dropped substantially, and combined with utility rebate programs, has led to their greater adoption. Further, since these results were published, the U.S. manufacturing sector has undergone a massive transformation. Due to global competition, some sectors have relocated operations overseas. Others have brought operations onshore to avail low cost and abundant natural gas. Additionally, automation and robotics have pervaded the entire sector. Consequently, these two reports likely do not represent the current state of motor driven systems in U.S. industrial and commercial facilities. As cited in recent studies, the lack of current information on motor system electricity consumption and use characteristics limits the ability to conduct analysis on energy savings potential, develop technologies to address energy and productivity gaps, and develop programs to promote energy efficiency practices and technologies for motor systems (International Energy Agency, 2007; UNIDO, 2010; McKane and Hasanbeigi, 2011; Waide and Brunner, 2011). Specifically, the lack of information affects a range of stakeholders: Governments must rely on outdated information when setting research agendas, developing policies, and designing energy efficiency programs and offerings. Utilities and energy efficiency programs cannot identify the current market needs or potential impact when designing rebate and energy efficiency programs. Electric grid planners cannot identify motor system usage characteristics when developing plans to support the resilience of the electric grid. Manufacturers of motors, motor driven equipment, and drives are hampered when developing technologies to meet the needs of their market. Motor system end users are limited in their ability to identify energy saving opportunities within their own facilities because they do not have reliable benchmark information. In response to the lack of current information and analysis on industrial and commercial motor systems, the DOE initiated an update to these two studies. Launched in 2016 and led by Lawrence Berkeley National Laboratory (LBNL), the Motor System Market Assessment (MSMA) provides an updated, more comprehensive assessment of the installed stock of motor systems in both the industrial and commercial sectors, a review of the supply chains supporting motor and drives in the U.S., and the performance improvement opportunity available from using best available technologies and maintenance and operation practices. The outcomes of the MSMA are documented in three U.S. Industrial and Commercial Motor System Market Assessment reports, with this report being the first listed: 1. Volume 1: Characteristics of the Installed Base (this report) documents the findings on the installed base of motor systems in the U.S. industrial and commercial sectors. Quantification of energy savings potential is not documented in this report but in Volume 3. 2. Volume 2: Motors and Drives Supply Chain Review reviews the state of supply chains for motors and drives installed in U.S. industrial and commercial facilities, focusing on advanced motor and drive technologies and their constituent materials. 3. Volume 3: Energy Savings Opportunity analyzes the energy performance improvement opportunity for the installed base of U.S. industrial and commercial motor systems. This report has been prepared as a reference for motor system stakeholders. It provides factual information as could be best determined by the assessment results and avoids speculating on any findings.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2022

A green closed-loop process for selective recycling of lithium from spent lithium-ion batteries

As the economy started to recover from the COVID pandemic, the price of Li 2 CO 3 skyrocketed to its highest. This situation has aggravated concerns about the supply chain for lithium-ion batteries (LIBs). Recycling spent LIBs is a potential solution to alleviate the bottleneck of the supply chain and prevent environmental pollution, and has attracted lots of attention. However, lithium recycling is generally disregarded because of the complex recycling process and its low recycling efficiency. Here, in this work we developed a sustainable lithium recovery process, which can selectively leach and recover lithium with formic acid before recycling valuable metals. With the reported method, lithium can be 99.8% recovered from layered oxide cathode materials with 99.994% purity. In addition, this lithium recovery process is affordable, compared to the typical hydrometallurgical process, by saving 11.15% per kilogram of spent LIBs. Therefore, this research provided a new solution to eliminating the effects of lithium ions on valuable metal separation and the co-precipitation reaction and precluding the influence of other metal ions on lithium recovery. Finally, this simplified lithium recovery process provides new opportunities for sustainable recycling of LIBs and economical restoration of the lithium supply chain.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

Biomass carbon removal can help sustainable aviation fuels achieve on-time arrival

Biofuels, including sustainable aviation and marine fuels, and biomass carbon removal and storage (BiCRS) are often viewed as potentially competing pathways for advancing climate and energy goals. Their comparative economic, environmental, and temporal advantages remain debated. Rather than identifying a “best-use” for biomass, we show that the relative economic advantages of BiCRS versus biofuels exist along a continuum shaped by energy- and decarbonization-focused market conditions. These pathways need not be adversarial: BiCRS can enable, rather than displace, future biofuel deployment. While the lignocellulosic biofuel sector continues to face barriers associated with underdeveloped supply chains and technologies that have not yet been commercialized at scale, emerging BiCRS approaches are comparatively feedstock-flexible, rapidly deployable, and responsive to carbon removal markets. Early BiCRS deployment can help establish reliable biomass supply chains, reducing investment risk for future lignocellulosic biorefineries. By easing initial supply chain constraints, BiCRS can serve as a practical stepping stone toward meeting both near-term carbon removal needs and long-term sustainable fuel objectives under uncertain future market and policy conditions.

bioenvironmental engineering↗
DOE OSTI2024

Large-scale spatially explicit analysis of carbon capture at cellulosic biorefineries

The large-scale production of cellulosic biofuels would involve spatially distributed systems including biomass fields, logistics networks and biorefineries. Better understanding of the interactions between landscape-related decisions and the design of biorefineries with carbon capture and storage (CCS) in a supply chain context is needed to enable efficient systems. Here we analyse the cost and greenhouse gas mitigation potential for cellulosic biofuel supply chains in the US Midwest using realistic spatially explicit land availability and crop productivity data and consider fuel conversion technologies with detailed CCS design for their associated CO 2 streams. Optimization methods identify trade-offs and design strategies leading to systems with attractive environmental and economic performance. Strategic and operational decisions depend on underlying spatial features and are sensitive to biofuel demand and CCS incentives. US CCS incentives neglect to motivate greenhouse gas mitigation from all supply chain emission sources, which leverage spatial interactions between CCS, electricity prices and the biomass landscape.

09 BIOMASS FUELS↗
DOE OSTI2024

Component Criticality in BESS for Cybersecurity

Battery energy storage systems (BESS), inverters, and associated digital equipment are integral pieces of interdependent energy delivery systems. When considering the supply chain security of such systems, there is often a misplaced focus on the origin of energy generation and storage materials like battery cells, overlooking the more significant cyber risks that stem from digital power electronics control systems. Part of this misplaced focus is due to the relative costs of these components, with more attention given to expensive raw materials rather than the impactful digital elements themselves. The Idaho National Laboratory (INL) is addressing this gap in supply chain security through a systems-of-systems approach that considers the impact various components in digital energy systems can have should misoperation occur. Therefore, INL assigns a cyber criticality score based on quantitative analysis, which enables informed prioritization of mitigations and allows operators to reduce risk in light of the prevalence of a BESS and associated systems foreign supply chain.

25 ENERGY STORAGE↗
DOE OSTI2024

Mapping Support for Targeted Critical Minerals Exploration and Extraction

The United States’ dependency on imported minerals poses significant risks to economic stability and national security due to potential supply disruptions. Recognizing the strategic importance of critical minerals, the Department of Energy (DOE) emphasizes the need for a secure and resilient supply chain to support emissions reduction, technology development, and capitalization on clean energy opportunities. The DOE’s Office of Manufacturing and Energy Supply Chains (MESC), in collaboration with the Office of Policy (OP), addresses these vulnerabilities by focusing on upstream domestic critical minerals production, balancing extraction with social and environmental goals, including conservation, environmental justice, and respect for Tribal sovereignty. This report showcases a collaborative effort involving Idaho National Laboratory (INL), Argonne National Laboratory (Argonne), National Renewable Energy Laboratory (NREL), and the U.S. Geological Survey (USGS) to map mineral development potential along with key social and environmental datasets. A geographical information system (GIS)-based web map application was developed as a preliminary tool for environmental analysis, integrating 158 geospatial data layers such as critical habitat, land ownership, economic indicators, and environmental concerns. Data were sourced from agencies like the Bureau of Land Management (BLM) and USGS and processed using GIS technology to enhance visualization and analysis. The proposed analysis framework categorizes areas into high, mid, and low concern based on withdrawn lands, special status species, the Economic Development Capacity Index (EDCI) Mining Composite Index, and the Climate and Economic Justice Screening Tool (CEJST). While the application provides broad visualizations, it is not a substitute for detailed environmental reviews required under the National Environmental Policy Act (NEPA). Users must conduct further analyses and engage with tribal entities and other stakeholders for comprehensive planning. A case study of the Idaho Cobalt Belt (ICB) in Lemhi County, Idaho, has been provided in the report to illustrate the tool's practical use. This report introduces a GIS application and framework to support stakeholders in identifying and prioritizing areas for critical mineral exploration, promoting secure supply chains, and advancing the nation's energy independence through responsible resource stewardship.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

An Updated Life Cycle Assessment of Utility-Scale Solar Photovoltaic Systems Installed in the United States

Given the high deployment targets for solar photovoltaics (PV) needed to meet U.S. decarbonization goals, and the limited carbon budget remaining to limit global temperature rise, accurate accounting of the energy-use and greenhouse-gas emissions over the life-cycle of PV systems is needed. In the United States, most PV systems are large utility-scale systems which use single-axis trackers and central inverters, which are not commonly examined in existing life-cycle assessment (LCA) literature. In this study, we present a cradle-to-grave LCA of a typical silicon U.S. utility PV (UPV) installation which is consistent with the utility system features documented in the annual NREL PV system cost benchmark reports. We analyze and present results for four main metrics: cumulative energy demand (CED), greenhouse gas (GHG) emissions, energy payback time (EPBT), and carbon payback time (CPBT). We consider six primary manufacturing options: three based on an imported PV module supply chain (comparing low-carbon imports, high-carbon imports, and average imports), and three based on a potential domestic PV module supply chain (comparing low-carbon U.S. regions, high-carbon U.S. regions, and average U.S. regions). These manufacturing options were then paired with installation locations to create six main cases: low-carbon options were installed in Phoenix (Arizona), high-carbon options were installed in Seattle (Washington), and average options were installed in Fredonia (Kansas). These locations were selected to represent a range of irradiance and grid mixes in the United States, in order to illustrate the likely range of EPBTs and CPBTs possible across the United States. For all six cases, a sensitivity analysis for end-of-life (EOL) handling was explored to capture current and future management options: landfilling, partial recycling, and high-quality recycling. For the purposes of this report, the benchmark system was defined to use an average imported supply chain with partial recycling, installed in Fredonia (Kansas). CED results show ratios at or below 0.1 MJ oil-eq /MJgenerated which demonstrates efficient use of primary energy resources (below a 1:1 ratio), and represents a slight improvement over previous results in literature. GHG emissions per kWh range from 10-36 g CO 2 e, which are consistent with or lower than previous results published by NREL and IEA-PVPS. We use a graphical approach for calculating EPBT and CPBT in this report, which improves upon methods typically used in literature by accounting for non-linearity and avoiding data quality issues associated with long-term projections. EPBT was determined to vary from 0.5 to 1.2 years, with a benchmark EPBT of 0.6 years; CPBT was shown to vary from 0.8 to 20 years, with benchmark CPBT of 2.1 years, which is lower than other estimates from recent literature (typically >2 years).

14 SOLAR ENERGY↗
DOE OSTI2021

A market-oriented database design for critical material research

Material databases are important tools to provide and store information from material research. Rising concerns about supply-chain risks to raw materials presents a need to incorporate raw-material market and end-use application data, beyond basic chemical and physical properties, into a material database. One key challenge for researchers working on critical materials is information scarcity and inconsistency. This paper introduces, as a result of a two-year project, a critical-material commodity database (CMCD) incorporated with a low-code web-based platform that allows easy access for users and simple updates for the authors. The main goal of this project was to educate material scientists on the applications having the most impact on the supply chain and current industrial specifications/markets for each application. The objective was to provide material researchers with harmonized information so that they could gain a better understanding of the market, focus their technologies on an application with a high potential for commercialization, and better contribute to supply-chain risk reduction. While the goal was met with high receptivity, several limitations stemmed from query design, distribution platform, and quality of data source. To overcome some of these limitations and expand on CMCD's potential, we are building a public webpage with an improved interface, better data organization, and higher extensibility.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Williston Basin CORE-CM Initiative Final Report

The University of North Dakota Energy & Environmental Research Center (EERC) is leading the Williston Basin Carbon Ore, Rare Earth, and Critical Minerals (CORE-CM) Initiative to drive the expansion and transformation of coal and coal-based resource usage within the Williston Basin to produce rare-earth elements (REEs), CMs, and nonfuel carbon-based products (CBPs). This project is the first phase in a long-term program and set the stage for future work by assessing resource, market, technology, and infrastructure knowledge; identifying knowledge gaps; developing a series of plans to be carried out in future work; and initiating stakeholder engagement. Composed of several tasks, the project sought to identify, characterize, and assess several necessary aspects vital to make this future work a reality. The project’s fundamental task was to characterize the Williston Basin CORE-CM resources. Over 2500 samples from multiple sources were utilized to begin the assessment. Several locations were identified in western North Dakota where sample analysis identified the total REE (TREE) concentration as being over 500 parts per million (ppm), which is at a concentration level that would be suitable to consider for mining and extraction. Current operating coal mines have sufficient concentrations of TREEs for consideration. However, the current data across the basin are still not adequate to fully characterize REE and CM content nor give reliable estimates of the total resource potential. Waste stream reuse was also considered, and several streams were identified which ranged from potential energy sources to chemicals to material wastes. This includes streams that result from oil and gas production. These streams are not fully characterized, and further data are needed before they can be accurately assessed. Infrastructure within the Williston Basin is suitable for expansion of a new industry to mine, extract, and concentrate REEs and CMs. The development of this industry will not only preserve many existing jobs in the coal-mining industry but produce many new jobs. The supply chain for REEs and CMs is currently controlled outside of the United States in nations such as China, but the potential to develop the supply chain within the basin is considered possible. Processing of the mined materials for REEs and CMs needs further research. The technology and knowhow exist outside of the United States, and within the country much of the knowledge has been lost and must be regained. To develop the supply chain and regain lost processing technology, the creation of technology innovation centers (TICs) is crucial. The Williston Basin contains several similar centers and entrepreneurial assistance for other industries that can be applied in the development of REE and CM innovation centers. Education to develop the new skill sets required is also needed. Outreach is important for the development of the REE and CM industry within the basin. Understanding throughout federal and state governments, state agencies, industry, and resource end users is vital for the industry to form and grow. Through this project these groups have been contacted through bulletins, presentations, webinars, and annual symposiums. The report is a summary of the work conducted and throughout refers to a series of appendixes which contain more thorough and specific information about each section.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2023

The Port of Los Angeles Zero- and Near-Zero-Emission Freight Facilities Shore to Store Project

The City of Los Angeles Harbor Department (Harbor Department, Port of Los Angeles) partnered with Equilon Enterprises LLC (d/b/a Shell Oil Products US) (Shell), Toyota Motor North America (Toyota), and Kenworth Truck Company (Kenworth) partnered with the Port of Hueneme, United Parcel Service, Total Transportation Services Inc., Southern Counties Express, Toyota Logistics Services, Air Liquide, National Renewable Energy Laboratory, Coalition For A Safe Environment, and the South Coast Air Quality Management District to introduce hydrogen fuel into the Southern California drayage truck market by demonstrating near-commercial heavy-duty hydrogen fuel cell electric trucks at and between freight facilities throughout the region, while continuing to lay the groundwork for battery-electric operations. The Shore to Store project built on project team experience to help realize our vision of zero-emission freight operations in the future. Ten Kenworth zero-emission Class 8 fuel cell electric trucks, integrated with Toyota’s fuel cell drive technology, were operated by United Parcel Service, Total Transportation Services Inc., Southern Counties Express, and Toyota Logistics Services in commercial service. The demonstration fleet fueled at the Shore to Store hydrogen fueling stations that were built in Ontario, California, and Wilmington, California. An additional station at the Port of Long Beach (Portal Station) was available for fueling the fleet. Portal Station was supported by grants from the California Energy Commission and South Coast Air Quality Management District and used as match funding for the Shore to Store project. The Port of Hueneme demonstrated two battery-electric yard tractors, and Toyota Logistics Services demonstrated two zero-emission forklifts at their warehouse facility, showcasing elements of the entire supply chain operating with zero emissions. This project showcased a snapshot of the zero-emission supply chain of the future, providing a model by which freight facilities can support zero-emission operations. The Shore to Store project: Demonstrated the technical feasibility of zero-emission hydrogen fueled Class 8 heavy-duty trucks and electric cargo handling equipment in rigorous goods movement operation throughout the Southern California region. Cumulatively completed 59,212 miles of zero-emission operation, with 21,650 miles driven in-service with the fleets, using hydrogen fuel cell electric Class 8 heavy-duty trucks. Operated zero-emission yard tractors for a total of 2,749.6 hours. Created direct localized emission reductions in designated disadvantaged communities, including those in zip codes 90220, 90247, 90248, 90731, 90744, 90802, and 91761. For the 59,212 miles of zero-emission operation, reduced emissions by an estimated total of 15.5 kg NOX (0.163 g/km), 1.01 kg SOX (0.0106 g/km), and 304.8 metric tonnes of CO2e (3.2 kg/km) compared to diesel baseline vehicles including both tailpipe emissions and the emissions from producing the fuel sources.

08 HYDROGEN↗
DOE OSTI2023

Observations and Lessons Learned From Installing Residential Roofing-Integrated Photovoltaics

Building-sited solar photovoltaics (PV) could play a key role in decarbonizing the building sector either through racked and mounted PV or through Building-integrated PV (BIPV). BIPV is installed into the building envelope itself, with solar cells and/or modules forming the outer layer of a building structure, thus transforming a single-purpose structure into one that serves the dual purposes of the building envelope and electricity. BIPV can be applied to building roofs, facades, awnings, pergolas, windows, skylights, balustrades, and other external surfaces. Given BIPV products vary widely, the focus of this research is residential roofing integrated PV (RIPV), where solar is incorporated into or otherwise replaces the roofing material. Previous research suggests that residential RIPV could reduce customer acquisition, labor, supply chain, and equipment costs. These products have yet to realize these cost savings and deployment remains significantly less than conventional rooftop PV as a relative share of the addressable market in the US. One potential barrier to broader residential roofing integrated PV deployment may be higher costs relative to conventional rooftop PV, primarily because the design and installation of these products is still evolving. Here, we explore residential RIPV cost-reduction opportunities by analyzing installation processes. Our study documents residential RIPV installations at 2 reroofing sites and the equivalent of 9 new construction sites in California through a methodology known as time and motion study. We also conducted interviews with subject-matter experts to identify barriers and solutions to maximize these products' market penetration. Our time and motion study breaks the RIPV installation process into four steps: 1) staging, unloading, and roof preparation; 2) fire resistant underlayment(s) (synthetic material laid between roof shingles and roof deck); 3) flashings and PV installation; and 4) wiring and monitoring. We measure the time required for each step in terms of worker-hours, representing an hour of labor from a single worker. We further normalize process time by dividing worker-hours by kilowatt (kW) of system capacity. The most time-intensive step was flashings and PV installation, taking around 2.4 worker-hours per kW on average and accounting for around 60% of the process time for an average installation. The total installation process took on average about 6.4 and 3.5 worker-hours per kW at the reroofing sites and new construction sites, respectively. For comparison, a previous time and motion study documented a time of 6.9 worker-hours per kW for conventional rooftop PV. The shorter RIPV installation times are consistent with previous studies suggesting that RIPV could be installed faster than conventional rooftop PV. The time and motion results and feedback from interviewees provide insights into potential residential RIPV cost reduction opportunities. Several interviewees suggested that these products would be more efficient if PV installation was more fully integrated into the roofing/construction industries, which currently use separate supply chains and skillsets. Further integration could reduce supply chain delays and labor force redundancies. Future research could explore specific ways to integrate these industries to help realize the cost savings potential of RIPV.

14 SOLAR ENERGY↗
DOE OSTI2025

GridSTIX

SF-25-112 Grid-STIX is a comprehensive extension of the STIX (Structured Threat Information Expression) 2.1 ontology specifically designed for electrical grid cybersecurity applications. This ontology provides a standardized, machine-readable framework for modeling grid assets, operational technology devices, threats, vulnerabilities, supply chain risks, and security relationships in electrical power systems. ## Key Features - **Comprehensive Grid Coverage**: Physical assets, OT devices, grid components, sensors, and energy storage systems - **Zero Trust Architecture**: Policy decision points, enforcement points, trust brokers, and continuous monitoring - **AMI Infrastructure**: Advanced metering networks, head-end systems, mesh gateways, and MDM systems - **Advanced Security Modeling**: Attack patterns, vulnerabilities, mitigations, and supply chain risks - **Critical Grid Relationships**: Power flow, protection, control, and synchronization relationships - **Supply Chain Security**: Supplier modeling, country of origin tracking, and risk assessment - **Protocol Support**: DNP3, Modbus, IEC 61850, IEC 60870-5-104, OPC-UA, and IEEE standards - **Python Code Generation**: Automated STIX-compliant Python class generation from ontologies - **Interactive Visualization**: Enhanced HTML network graphs with grid-specific categorization - **STIX 2.1 Compliance**: Full compatibility with STIX threat intelligence ecosystem

Blakely, Benjamin [Argonne National Laboratory (AN↗
DOE OSTI2026

System-Level Integration of Modular Language Models for Real-Time Risk Assessment in Third-Party Risk Management Systems

Large enterprises typically rely on dedicated teams to govern and implement security measures throughout their supply chains, ensuring compliance with enterprise security procedures. There is a significant reliance on Third-Party Risk Management (TPRM) platforms, which often require complete, highly structured information from potential vendors. The review and compliance assurance processes are time- and labor intensive, often requiring several rounds of review between the supply chain security risk management teams, business users, and potential vendors, leading to delays in the supply chain processing and consumer experience. Significant challenges in the risk management paradigm include handling unstructured data in various formats and providing real-time feedback to users to reduce the required review time. This paper presents a novel solution to these challenges. A modular multi-step system architecture is proposed using advances in language processing, specifically for unstructured responses and provides real-time feedback (i.e., 3 seconds) so that users can improve their responses before the TPSRM team review. This novel system architecture will increase information accuracy and significantly reduce time and labor during the review process.

99 - GENERAL AND MISCELLANEOUS↗