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DOE OSTI2025

Nature of innovations affecting photovoltaic system costs

Innovations improve technology costs through various kinds of engineering advancements, including changes to materials choices and device or process designs. Understanding how these innovations relate to cost change can reveal aspects of the process of technology evolution, yet developing such understanding is often not possible with a strictly quantitative approach due to data limitations. In this paper we develop a hybrid quantitative-qualitative framework for relating specific innovations to cost change by using the variables in a quantitative technology cost change model as an organizing principle. We demonstrate this framework by applying it to the cost decline in photovoltaic (PV) systems over the last five decades. This framework generates new understanding of a set of innovations that contributed to PV modules’ sustained cost decline and the more modest trends observed in balance-of-system (BOS) costs. The results show the great diversity of innovations that affected PV costs, drawing on wide-ranging fields of expertise within scientific research and practice. We find that there are differences in the characteristics of innovations that reduced the cost of PV modules compared to innovations influencing BOS costs. Numerous module innovations reduced costs by advancing manufacturing tools and processes that improved material quality. Many BOS innovations reduced costs through a combination of component design changes, integration, automation, digitalization, and standardization. Overall, most innovations in our sample affected PV hardware. However, some also target ‘soft technologies’ such as task durations through innovations like fast-track permitting, which require improved collaboration and process streamlining. This framework also provides insight into the nature of knowledge spillovers between technologies. Both module and BOS hardware innovations show the benefits of PV’s position within an ‘ecosystem’ of continuously advancing technologies in many industries, in particular semiconductors and electronics, and also point to the importance of public institutions for accelerating testing, permitting, and training.

14 SOLAR ENERGY↗

DOE OSTI2025

Wafer-Free Crystalline Silicon Solar Cells (CRADA Final Report)

This CRADA project, based on the DOE Solar Energy Technologies Office (SETO) Solar Prize Voucher program, helped Leap Photovoltaics to develop methodologies to immobilize Si particles by permanently attaching them to an Al-coated substrate and thereby forming carrier-selective electrical contacts to the Si particles. The bigger goal was to help Leap Photovoltaics develop these immobilized and contacted particle arrays into relatively efficient, inexpensive, and industrially relevant solar cells. By using Si particles instead of wafers in a solar cell absorber layer, one can avoid costs associated with growing monocrystalline Si ingots, then diamond-sawing them into wafers, then processing wafers into cells – a mainstream practice in today's high-efficiency Si cell and module technology. Monocrystalline or polycrystalline Si particles can be obtained in various ways: for example, Si kerf from wafer sawing is monocrystalline; recycled Si cell wafers can be ball-milled into particles; particles can be grown using various gas-phase techniques (mostly from SiH4). These Si particles can be assembled onto a substrate and serve as an absorber layer for the solar cell, absorbing photons to generate photocarriers. The challenge with this technique is to collect photocarriers from individual Si particles, with separation of photogenerated electrons to the negative cell’s electrode and positive photogenerated holes to the positive electrode. Therefore, each particle must have two isolated, carrier-selective contacts: one for electrons and one for holes. Plus, particles need to be immobilized onto a solid substrate. The goal of this work was focused on the immobilization of Si particles and creating hole-selective contact to them at the same time, using industrially relevant Si photovoltaic (PV) cell technology: screen printing of Al back-surface field electrodes. This is used in the mainstream Propane Education and Research Council (PERC) technology for hole-collecting contacts at the back of the cell. The work performed at NREL consisted of screen printing of Al metal paste on substrates, spreading Si particles onto it, and thermally processing the structures to form hole-collecting contacts. The final structures were investigated by scanning electron microscopy (SEM) after focused ion beam (FIB) cross-sectioning and polishing. The work was done jointly by NREL staff and Leap Photovoltaics (Leap PV) employees stationed at NREL. The samples were then taken to Leap PV for further processing. Training the Leap PV employee on various NREL techniques (laser cutting, screen printing, thermal processing, characterization) was part of the scope.

14 SOLAR ENERGY↗

DOE OSTI2025

Electronic Structure Distortions in Chromium Chelates Impair Redox Kinetics in Flow Batteries

Aminopolycarboxylate chelates are emerging as a promising class of electrolyte materials for aqueous redox flow batteries, offering tunable redox potentials, solubility, and pH stability through careful selection of ligands and transition metal ions. Despite their potential, the impact of molecular structure modifications on the electronic and electrochemical properties of these chelates remains underexplored. Here, in this study, we examine how introducing a hydroxyl group, often employed for its solubilizing properties, to the backbone of CrPDTA, a reference chelate material, significantly changes the thermodynamics and kinetics of the chelate's redox process. We correlate changes in molecular and electronic structures to different electrochemical responses resulting from the hydroxyl addition and show that the introduction of this functional group leads to a distortion in the octahedral coordination of chromium. Furthermore, increased anisotropic spin density and nonintegral oxidation state changes in the Cr metal center result in a larger barrier for electron transfer in CrPDTA‐OH. It is demonstrated that preserving a hexacoordinate chelate structure across a broad pH range is crucial for efficient flow battery application and it is emphasized that ligand modifications must avoid distorting the octahedral coordination of the transition metal.

25 ENERGY STORAGE↗

DOE OSTI2023

Cleaner Chips: Decarbonization in Semiconductor Manufacturing

The growth of the information and communication technology sector has vastly accelerated in recent decades because of advancements in digitalization and Artificial Intelligence (AI). Scope 1, 2, and 3 greenhouse gas emissions data of the top six semiconductor manufacturing companies (Samsung Electronics, Taiwan Semiconductor Manufacturing Corporation, Micron, SK Hynix, Kioxia, and Intel) were gathered from the publicly accessible Carbon Disclosure Project’s (CDP) website for 2020. Scope 3 emissions had the largest share in total annual emissions with an average share of 52%, followed by Scope 2 (32%) and Scope 1 (16%). Because of the absence of a standardized methodology for Scope 3 emissions estimation, each company used different methodologies that resulted in differences in emissions values. An analysis of the CDP reporting data did not reveal information on strategies implemented by companies to reduce Scope 3 emissions. The use of renewable energy certificates had the largest effect on decarbonization centered on reducing Scope 2 emissions, followed by the deployment of perfluorocarbon reduction technologies to help reduce Scope 1 fugitive emissions. Technology-specific marginal abatement costs of CO2 were also estimated and varied between −416 and 12,215 USD/t CO2 eq., which primarily varied depending on the technology deployed.

42 ENGINEERING↗

DOE OSTI2023

Wave Energy Power Take-off Validation with a Hydraulicly Actuated Rotary Dynamometer and a Bi-Directional High-Power DC Supply

There are many organizations working towards the commercialization of wave energy converter technologies and are advancing their designs through the technology readiness levels (TRLs). A critical step before the field deployment of prototype wave energy converters is the validation of the subsystems and components that are contained in the wave energy converter through laboratory testing and performance characterization. In 2021, the National Renewable Energy Laboratory (NREL) developed and demonstrated a system for testing power takeoffs (PTO) with a low-speed, high-torque dynamometer and a grid-tied high-power DC power source and sink before field deployment. The hydraulic dynamometer allows for the simulation of PTO actuation from wave motion and is capable of a wide range of wave periods and heights which are represented as various speeds and torques from the dynamometer. The high-power bidirectional power supply allows for hardware in the loop and controller in the loop testing to be conducted on WEC power electronics. This presentation was made to describe the methods used by NREL research staff to test all components and sub-systems in the PTO of a novel wave energy converter before field deployment.

dynamometer↗

DOE OSTI2023

Wave Energy Power Take-Off Validation with a Hydraulicly Actuated Rotary Dynamometer and a Bidirectional High-Power DC Supply: Preprint

dynamometer↗

DOE OSTI2026

A Bis(arenesulfonyl) Peroxide, an Ambient-Stable Oxidant, Is a Strong p-Dopant for Organic Semiconductors

Strong p-dopants are required to dope high-ionization energy organic semiconductors for a variety of potential applications, but strong, simple one-electron oxidants are typically sensitive to reduction by atmospheric moisture and thus challenging to store or handle. Here we show that bis(3,5-bis(trifluoromethyl)benzenesulfonyl) peroxide─a dimer formed by two highly oxidizing radicals─can function as a water-stable yet powerful oxidant, cleanly reacting with some organic semiconductors to form two radical cations and two 3,5-bis-(trifluoromethyl)benzenesulfonate anions, although in other cases sulfonylation reactions can also occur. Notably, this peroxide is capable of p-doping the high-ionization energy polymer poly[(9,9-dioctylfluorene-2,7-diyl)- alt -(benzo[2,1,3]thiadiazol-4,7-diyl)] (F8BT) to afford electrical conductivities of up to 0.03 S cm –1 , while its use with electron-rich poly(3,4-dialkoxythiophene-2,5-diyl) derivatives can afford values up to 100 S cm –1 . Quantum-chemical calculations reveal the peroxide oxidant behaves in a fashion mirroring that of relatively oxygen-stable, but highly reducing, n-dopants that have been developed based on dimers of organic radicals or organometallic sandwich compounds.

doping↗

DOE OSTI2025

Epitaxial Growth Development: CRADA Final Report

The purpose of this CRADA is to assist Trumpf Photonics in developing a procedure to grow ZnSe epilayers on the (110) facets of AlGaAs/InGaAs laser diodes that will provide high degrees of electronic passivation and performance reliability. Work will be divided into four tasks: 1) characterization of material growth at Trumpf Photonics, 2) development of a highly effective AlGaAs facet cleaning procedure at NREL, 3) development of a ZnSe epitaxy procedure at NREL, and 4) transfer of the procedures developed at NREL to the Trumpf Photonics site. This CRADA is designed to last 3 years total.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Advancing Photo(Electro)Chemical Water Splitting: The Promise of Atomically Dispersed Single‐, Dual‐, and Alloy‐Site Catalysts

Single-atom catalysts (SACs) have rapidly gained prominence as an emerging class of electrocatalysts for water splitting, owing to their uniform and precisely defined active sites. By maintaining uniform reaction pathways, SACs minimize the formation of unwanted byproducts, thus exhibiting extremely high selectivity and atomic efficiency. A key determinant of SAC performance lies in the interfacial interaction between the isolated metal atoms and the supporting material under strong metal–support coordination, which is vital for maintaining long-term activity. However, despite these benefits, reproducibly synthesizing SACs with high metal loadings while retaining uniform dispersion remains a significant challenge. To address the intrinsic challenges of SACs, recent research has expanded into dual-atom catalysts (DACs) and single-atom alloy catalysts (SAACs), providing synergistic active sites and combining the benefits of SACs with bimetallic systems. Furthermore, this review systematically explores the latest advancements in synthesis methods and innovations for SACs for electrochemical water splitting. Additionally, it examines the evolution of catalyst design, emphasizing the unique structural and electronic characteristics of single-site, dual-site, and alloyed SAC systems and highlighting their critical roles in accelerating water-splitting reaction kinetics as well as the prevailing challenges and outlining promising directions for advancing hydrogen production via water electrolysis.

08 HYDROGEN↗

DOE OSTI2021

Tandem Electrocatalytic CO 2 Reduction with Efficient Intermediate Conversion over Pyramid-Textured Cu–Ag Catalysts

If combined with renewably generated electricity, electrochemical CO 2 reduction (E-CO 2 R) could be used as a sustainable source of chemicals and fuels. Tandem catalysis approaches are attractive for providing the product selectivity, which would be required for commercial applications. Here, we demonstrate a two-step tandem electrocatalytic E-CO 2 R with efficient conversion of the intermediate species. The catalyst scaffold is Si(100), which is etched to form a textured surface consisting of micron-sized pyramid structures with the {111} facets. Two metals are used in the electrocatalytic cascade: Ag is employed to perform a two-electron reduction of CO 2 to the intermediate CO, and Cu performs conversion to more reduced products. Using high-angle physical vapor deposition, we form separated, micron-scale areas of the two electrocatalysts on opposite sides of the pyramids, with their relative surface coverages being tunable with the deposition angle. Compared to the textured scaffolds with blanket Ag and Cu used as controls, bimetallic pyramid tandem catalysts have higher current densities and much lower faradic efficiencies (FE) for CO. These effects are due to efficient conversion of the CO formed on Ag to more reduced products on Cu. Methane is the main product to be enhanced by the cascade pathway: a bimetallic catalyst with approximately equal coverages of Ag and Cu produces methane with a FE of 62% at -1.1 V RHE , corresponding to a partial current density of 12.7 mA cm -2 . We estimate an intermediate conversion yield for the CO intermediate of 80-90%, which is close to the mass-transport limited value predicted by reaction-diffusion simulations.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Charge accumulation and solvation in $β$-NiOOH: Surface chemistry of an OER catalyst from ML-aided simulations

Electrochemical water splitting is a key technology for a sustainable energy transition, providing a route to store surplus electricity from renewable sources. A central bottleneck is the sluggish oxygen evolution reaction (OER), which drives the search for catalysts that are active, stable, and inexpensive enough for large-scale deployment. Within this context, pure and doped NiO x H y combine high activity with low cost, making them prime candidates for alkaline OER. Yet, despite extensive study, the atomistic structure of NiOOH under operando conditions and the associated reaction mechanisms remain debated. Here, we investigate the structural complexity of pure β-NiOOH, the scaffold for its doped derivatives. We systematically investigate the oxidation of the surface adsorbates via proton-coupled electron transfer steps across relevant facets and sites, identifying the most probable sequence of deprotonation events. Our results reveal asymmetric charge accumulation on Wulff-relevant surfaces and show how applied potential can promote morphological restructuring. Explicit solvation is included through machine-learning interatomic potential molecular dynamics of the NiOOH/water interface, which allows us to resolve the hydrophobic and hydrophilic character of different surfaces and the associated interfacial water structure. Together, these insights demonstrate how surface chemistry and solvation jointly govern the stability of NiOOH and the accumulation of surface charge, with possible implications for catalytic performance.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2020

A Review of Sandia Energy Storage Research Capabilities and Opportunities (2020 to 2030)

Large-scale integration of energy storage on the electric grid will be essential to enabling greater penetration of intermittent renewable energy sources, modernizing the grid for increased flexibility security, reliability, and resilience, and enabling cleaner forms of transportation. The purpose of this report is to summarize Sandia's research and capabilities in energy storage and to provide a preliminary roadmap for future efforts in this area that can address the ongoing program needs of DOE and the nation. Mission and vision statements are first presented followed by an overview of the organizational structure at Sandia that provides support and activities in energy storage. Then, a summary of Sandia's energy storage capabilities is presented by technology, including battery storage and materials, power conversion and electronics, subsurface-based energy storage, thermal/thermochemical energy storage, hydrogen storage, data analytics/systems optimization/controls, safety of energy storage systems, and testing/demonstrations/model validation. A summary of identified gaps and needs is also presented for each technology and capability.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2025

Fundamental Research Aimed at Diverting Excess Reducing Power in Photosynthesis to Orthogonal Metabolic Pathways

Photosystems are incredible biological machines that use sunlight to drive the conversion of carbon dioxide to sugar. The amount of sunlight available for photosynthesis sometimes exceeds the amount of energy plants can use. This excess energy has to be safely dissipated through non-productive biological processes. The ultimate goal of this project is to understand whether we can utilize that otherwise unused excess energy. In our previous work, we showed that, in principle, it is possible to attach a catalyst to photosystem I and generate H2 using light. Our current strategy is to genetically fuse parts of the photosystem I complex with a recently discovered oxygen-tolerant [FeFe] hydrogenase. Our rationale is that such chimeric proteins may potentially result in the natural incorporation of the photosystem I-hydrogenase link using the inherent genetic machinery of the cell. In this project, we aim to verify that light-driven hydrogen production in this construction is possible. Throughout the project, we designed nanoconstructs that showcase the plausibility of this technology, at least in vitro. We take advantage of these constructs to investigate details of the coupling between photosystem I and a H2-producing enzyme called [FeFe] hydrogenase. This part of the project reveals details of the electron transfer between photosystem I and the attached hydrogenase, providing information that can lead to new strategies for improved biological photocatalysis. We also researched efficient and robust tethering of the [FeFe] hydrogenase to photosystem I in cyanobacteria. This work will highlight successful design strategies to guide the future development of photosynthetic biohybrids. Uncovering the principles governing the utilization of otherwise unusable energy significantly further our understanding of cyanobacterial photosynthesis. The work proposed establishes the feasibility of diverting excess energy under high light conditions to orthogonal enzymatic pathways and set design rules for efficient utilization of such a strategy for scientific and industrial applications in biosensing, renewable energy, and high-value chemicals production. The work addresses the DOE-BES Photosynthetic Systems program goal to develop a multidimensional understanding of photosystems that would provide specific metrics that instruct strategies for improving biological photosynthesis and for guiding the future development of bioreactors and biomimetic energy systems.

Photosynthetic systems, hydrogenase, cyanobacteria↗

DOE OSTI2026

Polywell Revisited

The Polywell fusion concept, originally proposed by Robert W. Bussard in 1985, has been investigated for over four decades as a potential solution for achieving net fusion energy in a compact and economically viable reactor. It combines two distinct approaches: high-beta magnetic cusp confinement of electrons using polyhedral coil configurations and electrostatic ion confinement via a potential well formed by injected electron beams. While the hybrid nature of the Polywell system offers advantages in plasma stability and engineering simplicity, previous efforts have been limited by persistent challenges in achieving sufficient plasma confinement required to generate a net energy gain. Here, in this study, we examine previous works and identify limitations of several Polywell embodiments that have historically impeded progress. We present an updated Polywell physics model incorporating experimental findings and recent first-principles particle-in-cell simulations. This updated model outlines a credible path toward overcoming confinement losses and achieving net energy gain using deuterium-tritium (D-T) fuels. Our findings provide a renewed scientific basis for the continued development of the Polywell fusion concept as a practical and scalable approach to fusion energy.

Electrostatic potential well↗

DOE OSTI2022

Machine learning prediction and experimental verification of Pt-modified nitride catalysts for ethanol reforming with reduced precious metal loading

Ethanol is the smallest molecule containing C–O, C–C, C–H, and O–H bonds present in biomass-derived oxygenates. The development of inexpensive and selective catalysts for ethanol reforming is important towards the renewable generation of hydrogen from biomass. Transition metal nitrides (TMN) are interesting catalyst support materials that can effectively reduce precious metal loading for the catalysis of ethanol and other oxygenates. Herein theoretical and experimental methods were used to probe platinum-modified molybdenum nitride (Pt/Mo 2 N) surfaces for ethanol reforming. Computations using density-functional theory and machine learning predicted monolayer Pt/Mo 2 N to be highly active and selective for ethanol reforming. Temperature-programmed desorption (TPD) experiments verified that ethanol primarily underwent decomposition on Mo 2 N, and the reaction pathway shifted to reforming on Pt/Mo 2 N surfaces. Additionally, high-resolution electron energy loss spectroscopy (HREELS) results further indicated that while Mo2N decomposed the ethoxy intermediate by cleaving C–C, C–O, and C–H bonds, Pt-modification preserved the C–O bond, resulting in ethanol reforming.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2024

Reduction of CO to Methanol with Recyclable Organic Hydrides

We report the reaction steps for the selective conversion of a transition metal carbonyl complex to a hydroxymethyl complex that releases methanol upon irradiation with visible light have been successfully quantified in acetonitrile solution with dihydrobenzimidazole organic hydride reductants. Dihydrobenzimidazole reductants have been shown to be inactive toward H 2 generation in the presence of a wide range of proton sources and have been regenerated electrochemically or photochemically. Specifically, the reaction of cis-[Ru(bpy) 2 (CO) 2 ] 2+ (bpy = 2,2'-bipyridine) with one equivalent of a dihydrobenzimidazole quantitatively yields a formyl complex, cis-[Ru(bpy) 2 (CO)(CHO)] + , and the corresponding benzimidazolium on a seconds time scale. Kinetic experiments revealed a first-order dependence on the benzimidazole hydride concentration and an unusually large kinetic isotope effect, inconsistent with direct hydride transfer and more likely to occur by an electron transfer-proton-coupled electron transfer (EΤ-PCET) or related mechanism. Further reduction/protonation of cis-[Ru(bpy) 2 (CO)(CHO)] + with two equivalents of the organic hydride yields the hydroxymethyl complex cis-[Ru(bpy) 2 (CO)(CH 2 OH)] + . Visible light excitation of cis-[Ru(bpy) 2 (CO)(CH 2 OH)] + in the presence of excess organic hydride was shown to yield free methanol. Identification and quantification of methanol as the sole CO reduction product was confirmed by 1 H NMR spectroscopy and gas chromatography. The high selectivity and mild reaction conditions suggest a viable approach for methanol production from CO, and from CO 2 through cascade catalysis, with renewable organic hydrides that bear similarities to Nature's NADPH/NADP + .

14 SOLAR ENERGY↗

DOE OSTI2025

Microscopic analysis of irradiated UN–Mo–W for space nuclear propulsion

Nuclear propulsion is an effective method of providing thrust in deep space, allowing for shorter mission duration for long-term surface missions to Mars. The fuel for nuclear propulsion systems must exhibit superior mechanical and thermal properties, to decrease the possibility of fuel failure and to increase reactor efficiency. Here, the objective of the Sirius project is to fabricate and irradiate cermet fuels at the Idaho National Laboratory Transient Reactor Facility to determine the properties of the fuel after irradiation at prototypical nuclear propulsion start-up conditions. The Sirius project featured 3 test capsules, Sirius-1 featured uranium nitride fuel dispersed in a matrix of tungsten and rhenium, while Sirius-2A and -2B featured uranium nitride-molybdenum-tungsten fuel (UN-Mo-W). The fuel samples from the Sirius-2A and -2B capsules were examined after irradiation using optical microscopy, scanning electron microscopy, and X-ray diffraction analyses. The mechanical properties of the fuel from Sirius-2A and -2B are discussed in a previous work. In this study, the results of the optical microscopy, scanning electron microscopy, and X-ray diffraction analyses are discussed.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

Station Impact Analysis 2025

As part of the U.S. DOE EVs@Scale consortium, the NextGen Profiles (NGP) project presents analysis and results from the study of High Power Charging Electric Vehicles and Battery Charging Infrastructure. High Power Charging equipment is capable of recharging electric vehicle traction batteries at power levels of 200KW and above. The intent of the project is to further understand the most recent technological capabilities of the electric mobility industry related to charging performance. The project aims to develop EV, EVSE, and Fleet characterization testing practices and comprehensive analysis with inputs from key industry stakeholders. The results published in this NextGen Profiles project report provide data and insight for use by numerous entities including modeling and simulation organizations, policy makers, fleet planners, industry stakeholders and the general public involved with the development, deployment and operation of electrified transportation technologies. The factors influencing Electric Vehicle (EV) Direct Current Fast Charging (DCFC), including EV battery specifications, temperature effects on lithium-ion battery and power electronics performance, lithium-ion battery SOC bounding and charging station design considerations are specifically investigated to analyze their impacts on charging station operation and recommendations are made to minimize charge station dwell time, reduce charging costs and mitigate electric grid and charge station congestion. Additional high-power charging results are anticipated in future publications in support of the U.S. DOE EVs@Scale consortium NextGen Profiles project.

33 ADVANCED PROPULSION SYSTEMS↗