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DOE OSTI2024

Carbon Ore-Derived Critical Materials for Clean Energy Technologies

Conference presentation at American Institute of Chemical Engineers (AIChE) Annual Meeting, San Diego, California, October 27–31, 2024. Trends in the manufacture of electric vehicles that use graphite-based LIBs are rising steeply in the United States and globally, but the U.S. domestic supply chains for graphite, the largest component in an LIB by mass, is severely limited and faces complicated geopolitical dynamics with foreign sources. Consequently, the United States has designated graphite as a critical mineral to focus attention and resources to develop technologies to meet the challenge of limited domestic graphite supply chains. Results obtained so far based on the UCOP process have successfully validated the technology at the laboratory scale, with the produced graphite material showing up to 95% degree of graphitization, high carbon purity of ~99.98%, residual ash content of ≤0.02%, negligible moisture, low trace elements, and high electrochemical stability. These results suggest that the emerging UCOP technology is a promising approach to effectively synthesize high-quality graphite from abundant coal and coal waste resources in the United States to create a sustainable domestic critical graphite supply chain. A brief description of the status of UCOP process development and representative results will be presented.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2022

Life-Cycle and Techno-Economic Assessment of Early-Stage Carbon Capture and Utilization Technologies—A Discussion of Current Challenges and Best Practices

The mitigation of climate change requires research, development, and deployment of new technologies that are not only economically viable but also environmentally benign. Systematic and continuous technology assessment from early technology maturity onwards allows assessment practitioners to identify economic and environmental characteristics. With this information, decision-makers can focus time and resources on the most promising technologies. A broad toolset for technology assessment exists—stretching from the well-established life cycle assessment (LCA) methodology to more loosely defined techno-economic analysis (TEA) methods and the increasingly popular principles of technology maturity assessment such as the concept of technology readiness levels (TRL). However, current technology assessment practice faces various challenges at early stages, resulting in a potential mismatch of study results and stakeholders' needs and an escalation of assessment effort. In this practice review, we outline current challenges in the interplay of LCA, TEA, and TRL and present best practices for assessing early-stage climate change mitigation technologies in the field of carbon capture and utilization (CCU). The findings help practitioners systematically identify the TRL of a technology and adapt technology assessment methodologies accordingly. We highlight the methodological challenges for practitioners when adapting the goal and scope, identifying benchmark technologies, creating a comprehensive inventory, comparing early stage to commercial stage, ensuring clarity of recommendations for decision-making under high uncertainty, and streamlining conventional LCA and TEA assessment approaches and provide actionable recommendations. Overall, this work contributes to identifying promising technologies faster and more systematically, accelerating the development of new technologies for climate change mitigation and beyond.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2023

Analysis of direct and indirect noise in a next-generation aviation gas turbine combustor

A large-eddy simulation (LES) of a next-generation combustor is performed to examine effects of this combustor concepts on direct and indirect combustion noise characteristics. Direct noise is computed considering the unsteady heat release predictions while entropy fluctuations in the downstream part of the combustor are used to estimate indirect noise through the transfer function of the outlet nozzle. A low-order acoustic reconstruction technique, which utilizes the Green’s function of the configuration, is developed to compute the acoustics inside the combustor. Comparisons to experimental results are reported, showing the reasonable accuracy of the LES and combustion noise computations. The direct noise spectrum peaks at frequencies around 3 kHz because of the fast timescales associated with the chemical reactions inside the combustor. In addition, the indirect noise is dominant at low frequencies, i.e., less than 400 Hz, because of the characteristics of the entropy spectrum at the outlet nozzle. Further, compared to a conventional rich-quench-lean (RQL) combustor configuration, significant differences in the acoustics are observed, and are explained by two specific technological novelties. Firstly, the direct noise spectrum peaks at significantly higher frequencies due to the combustor’s compactness. Secondly, the entropy inhomogeneties downstream of the combustion region are an order of magnitude smaller in amplitude due to the lack of dilution with cold air. This leads to a significant reduction in the indirect noise amplitude at low frequencies, where it is the dominant source of noise. These results suggest opportunities for advanced combustion technologies to achieve substantial reductions in combustion-related noise.

42 ENGINEERING↗

DOE OSTI2023

The 2023 terahertz science and technology roadmap

Abstract Terahertz (THz) radiation encompasses a wide spectral range within the electromagnetic spectrum that extends from microwaves to the far infrared (100 GHz–∼30 THz). Within its frequency boundaries exist a broad variety of scientific disciplines that have presented, and continue to present, technical challenges to researchers. During the past 50 years, for instance, the demands of the scientific community have substantially evolved and with a need for advanced instrumentation to support radio astronomy, Earth observation, weather forecasting, security imaging, telecommunications, non-destructive device testing and much more. Furthermore, applications have required an emergence of technology from the laboratory environment to production-scale supply and in-the-field deployments ranging from harsh ground-based locations to deep space. In addressing these requirements, the research and development community has advanced related technology and bridged the transition between electronics and photonics that high frequency operation demands. The multidisciplinary nature of THz work was our stimulus for creating the 2017 THz Science and Technology Roadmap (Dhillon et al 2017 J. Phys. D: Appl. Phys. 50 043001). As one might envisage, though, there remains much to explore both scientifically and technically and the field has continued to develop and expand rapidly. It is timely, therefore, to revise our previous roadmap and in this 2023 version we both provide an update on key developments in established technical areas that have important scientific and public benefit, and highlight new and emerging areas that show particular promise. The developments that we describe thus span from fundamental scientific research, such as THz astronomy and the emergent area of THz quantum optics, to highly applied and commercially and societally impactful subjects that include 6G THz communications, medical imaging, and climate monitoring and prediction. Our Roadmap vision draws upon the expertise and perspective of multiple international specialists that together provide an overview of past developments and the likely challenges facing the field of THz science and technology in future decades. The document is written in a form that is accessible to policy makers who wish to gain an overview of the current state of the THz art, and for the non-specialist and curious who wish to understand available technology and challenges. A such, our experts deliver a ‘snapshot’ introduction to the current status of the field and provide suggestions for exciting future technical development directions. Ultimately, we intend the Roadmap to portray the advantages and benefits of the THz domain and to stimulate further exploration of the field in support of scientific research and commercial realisation.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2025

Closing the Accuracy Gap in Tandem Photovoltaic Testing: An Accessible and Efficient Spectral Tuning Method Using LED-Based Simulators for Research Laboratories and Industry

Accurate performance calibration of multijunction (MJ) solar cells is critical for advancing this technology toward large-scale terrestrial application, yet existing testing methods developed by photovoltaics calibration laboratories remain prohibitively complex and resource intensive for most research laboratories. Current approaches rely on expensive multisource simulators and/or intricate spectral tuning algorithms, limiting accessibility and hindering standardized comparisons of emerging MJ technologies such as perovskite-based tandems. This paper introduces a streamlined spectral irradiance adjustment method for light-emitting diode (LED)-based solar simulators, which are increasingly adopted in the photovoltaics community due to their versatility and cost-effectiveness. The method we present bins LED channels into groups based on the number of junctions of the MJ photovoltaic device under test (DUT) and their corresponding band gaps and incorporates an automated tuning algorithm that eliminates the need to adjust each channel’s irradiance individually. This tuning algorithm requires the relative spectral responsivities of both the DUT and a broadband reference cell, as well as a calibrated spectroradiometer. Measurement validation across various MJ devices, including III-V and perovskite/silicon tandems, demonstrates excellent agreement within 1% with well-established xenon-tungsten multisource simulators and associated tuning algorithms. By enabling precise spectral tuning with readily available equipment and a simple tuning algorithm, our approach bridges the measurement accuracy gap between research laboratories and accredited testing facilities, fostering more reliable device comparisons and accelerating the translation of MJ technologies into real-world energy systems.

14 SOLAR ENERGY↗

DOE OSTI2022

Clean Cities Coalitions: Advancing Affordable, Domestic Transportation Fuels and Technologies Across the Country

This fact sheet provides an overview of the U.S. Department of Energy's (DOE's) Vehicle Technologies Office Clean Cities Coalition Network, which advances affordable, domestic transportation fuels and technologies nationwide. More than 75 active coalitions serve as the foundation of Clean Cities, working in communities across the country to help local decision makers and fleets understand and implement alternative and renewable fuels, idle-reduction measures, fuel economy improvements, new mobility choices, and emerging transportation technologies. At the national level, VTO develops and promotes publications, tools, and other unique resources to support coordinators. At the local level, coalitions leverage these resources to create networks of stakeholders.

accomplishments↗

DOE OSTI2022

Clean Cities Coalitions: Advancing Affordable, Domestic Transportation Fuels and Technologies Across the Country

accomplishments↗

DOE OSTI2022

Clean Cities Coalitions: Advancing Affordable, Domestic Transportation Fuels and Technologies Across the Country

accomplishments↗

DOE OSTI2025

Environmental and socio-economic Pareto-front trade-off analysis of U.S. PET packaging material in a circular economy

Various recycling technologies are emerging to implement circular economy in plasticssupply chain systems. However, the environmental and socio-economic trade-offs of in circular economy are not well understood at a systems level. Particularly, quantifying these trade-offs as a function of end-of-life (EOL) management decisions, including transition of recycling technologies, systems level metrics such as circularity, recycled content, and the need for fossil-derived plastics are not well understood. Here, the present study addressed these research gaps by applying a systems analysis modeling approach that utilizes material flow analysis, life cycle assessment, socioeconomic data, and system optimization techniques for polyethylene terephthalate (PET) packaging supply chains in the United States. Pareto-front trade-offs between conflicting environmental and socio-economic impacts as well as those between socioeconomic impacts and circularity were explored using the epsilon constraint method. The Pareto-front trade-off analysis revealed the transition of EOL management strategies for PET packaging systems, including changes in selection of recycling technologies, to aid decision making process by quantifying studied system metrics. Transitioning from environmentally optimal to socio-economically optimal systems led to increased employment (by 17%), wages (by 26%), and revenues (by 6%) but also led to increased global warming potential (GWP; by 65%), energy consumption (by 59%), and reliance on fossil PET in the system (by 78%). Finally, the results show that there is not a unique set of recycling technologies to achieve a sustainable circular economy of PET packaging system, instead it depends on the decision maker’s objectives and targeted metrics of the system.

54 - ENVIRONMENTAL SCIENCES/GLOBAL CLIMATE CHANGE ↗

DOE OSTI2020

Smart Contract-Defined Secondary Control and Co-Simulation for Smart Solar Inverters using Blockchain Technology

This paper proposes a cooperative control approach using blockchain technology for solar inverters in a photovoltaic system. Moreover, a co-simulation method for smart inverters and a blockchain network is studied. The blockchain assisted-smart inverter (BASI) consists of a solar inverter and an internet of things device as a client node of a blockchain network, which can fully utilize emerging blockchain technologies such as distributed ledger, security functions, and smart contract. The control includes a primary-level droop control in a BASI and smart contract-defined secondary-level supervisory control in a secured blockchain network. The concept of the proposed smart contract-defined control approach is validated by simulation studies using the cyber-physical co-simulation testbed built-in MATLAB/Simulink in a PC interfacing with a Hyperledger-Fabric blockchain software implemented in a PC.

14 SOLAR ENERGY↗

DOE OSTI2024

Ducted Fuel Injection and Cooled Spray Technologies for Particulate Control in Heavy-Duty Diesel Engines

Heavy-duty diesel engine manufacturers are continually seeking simple, low-cost technologies to reduce emissions. Ducted Fuel Injection (DFI) and Cooled Spray (CS) technologies have emerged as promising solutions, offering the potential for nearly sootless operation. These innovations could significantly decrease harmful Particulate Matter (PM) emissions while enabling further optimization to reduce Nitrogen Oxides (NOx) and increase efficiency. While initial experiments across various engine types have shown promise, uncertainties remain regarding the ideal geometry, scaling properties, and effectiveness of these technologies across different operating conditions. This project aims to address these knowledge gaps through experiments in both optical and metal single-cylinder engines.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2025

Magnet-superconductor hybrid quantum systems: a materials platform for topological superconductivity

Magnet–superconductor hybrid (MSH) systems have recently emerged as one of the most significant developments in condensed matter physics. This has generated, in the last decade, a steadily rising interest in the understanding of their unique properties. They have been proposed as one of the most promising platforms for the establishment of topological superconductivity, which holds high potential for application in future quantum information technologies. Their emergent electronic properties stem from the exchange interaction between the magnetic moments and the superconducting condensate. Given the atomic-level origin of such interaction, it is of paramount importance to investigate new magnet–superconductor hybrids at the atomic scale. In this regard, scanning tunneling microscopy (STM) and spectroscopy are playing a crucial role in the race to unveil the fundamental origin of the unique properties of MSH systems, with the aim to discover new hybrid quantum materials capable of hosting topologically non-trivial unconventional superconducting phases. In particular, the combination of STM studies with tight-binding model calculations have represented, so far, the most successful approach to unveil and explain the emergent electronic properties of MSHs. The scope of this review is to offer a broad perspective on the field of MSHs from an atomic-level investigation point-of-view. The focus is on discussing the link between the magnetic ground state hosted by the hybrid system and the corresponding emergent superconducting phase. This is done for MSHs with both one-dimensional (atomic chains) and two-dimensional (atomic lattices and thin films) magnetic systems proximitized to conventional s-wave superconductors. We present a systematic categorization of the experimentally investigated systems with respect to defined experimentally accessible criteria to verify or falsify the presence of topological superconductivity and Majorana edge modes. The discussion will start with an introduction to the physics of Yu–Shiba–Rusinov bound states at magnetic impurities on superconducting surfaces. This will be used as a base for the discussion of magnetic atomic chains on superconductors, distinguishing between ferromagnetic, antiferromagnetic and non-collinear magnetic ground states. A similar approach will be used for the discussion of magnetic thin film islands on superconductors. Given the vast number of publications on the topic, we limit ourselves to discuss works which are most relevant to the search for topological superconductivity.

Majorana states↗

DOE OSTI2024

Multidimensional perspectives of geo-epidemiology: from interdisciplinary learning and research to cost–benefit oriented decision-making

Research typically promotes two types of outcomes (inventions and discoveries), which induce a virtuous cycle: something suspected or desired (not previously demonstrated) may become known or feasible once a new tool or procedure is invented and, later, the use of this invention may discover new knowledge. Research also promotes the opposite sequence—from new knowledge to new inventions. This bidirectional process is observed in geo-referenced epidemiology—a field that relates to but may also differ from spatial epidemiology. Geo-epidemiology encompasses several theories and technologies that promote inter/transdisciplinary knowledge integration, education, and research in population health. Based on visual examples derived from geo-referenced studies on epidemics and epizootics, this report demonstrates that this field may extract more (geographically related) information than simple spatial analyses, which then supports more effective and/or less costly interventions. Actual (not simulated) bio-geo-temporal interactions (never captured before the emergence of technologies that analyze geo-referenced data, such as geographical information systems) can now address research questions that relate to several fields, such as Network Theory. Thus, a new opportunity arises before us, which exceeds research: it also demands knowledge integration across disciplines as well as novel educational programs which, to be biomedically and socially justified, should demonstrate cost-effectiveness. Grounded on many bio-temporal-georeferenced examples, this report reviews the literature that supports this hypothesis: novel educational programs that focus on geo-referenced epidemic data may help generate cost-effective policies that prevent or control disease dissemination.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2025

Advancing Development of Emissions Detection (Final Report)

This document is the final report to the U.S. Department of Energy (DOE for contract DE-FE0031873) awarded to Colorado State University (CSU). CSU and partners at Harrisburg University of Science and Technology, University of Texas Arlington, and University of Texas at Austin organized several testing rounds to provide knowledge focused on advancing the detection capabilities of emissions monitoring devices. With this funding opportunity the research group began by establishing the Advancing the Development of Emission Detection (ADED) program, with the goal focused on enhancing the accuracy, reliability, and field applicability of methane detection technologies. This effort aimed to address the critical challenges of identifying and quantifying methane emissions while enabling industry stakeholders to meet regulatory compliance and environmental sustainability goals. The program engaged with industry, government, and technology stakeholders to promote adoption and consensus on testing techniques for methane detection solutions. Methane, a potent greenhouse gas, contributes significantly to global warming, and the oil and natural gas (O&G) sector is a primary source of methane emissions. Regulatory measures such as leak detection and repair (LDAR) programs have been implemented to address emissions. However, traditional LDAR approaches, reliant on handheld and component-level measurements, are resource-intensive. To address these limitations and move with evolving regulations, advanced methane technologies are emerging. These solutions include ground-based sensors, mobile systems (e.g., drones, vehicles, and aircraft), and satellite-based platforms. They offer innovative capabilities for autonomous monitoring, larger spatial coverage, and emission quantification using methods such as tracer gas techniques and inverse modeling with Gaussian plume analysis. The ADED program began with creating protocols for methane controlled release (CR) testing these continuous monitoring (CM) and survey technologies that detect and monitor methane emissions at O&G facilities. The protocols were then implemented throughout testing of CM and survey devices at CSU’s Methane Emissions Technology Evaluation Center (METEC) facility from 2021 through 2024. As apart of the protocol, solutions that tested under the ADED program installed their solutions at METEC, documented their system under test, and provided detection reports to the METEC team for analysis. The METEC team would provide the solutions with analyzed reports of their emissions and ground truth data of the releases conducted during their testing session. Under the ADED program, CMs were also tested at O&G facilities for a six week test run of challenge release (ChR) releases. The findings from the ADED program underscore the critical role of collaborative research and innovation in tackling methane emissions, offering a pathway for the oil and gas sector to achieve significant environmental and economic benefits. Results from METEC testing saw improvement of performance and accuracy across all solutions over the extent of the ADED experiments. The results also showed a variance in CM solution performance between CRs and ChRs. That variance pushed the team to further analyze the differences between CR testing environments and field conditions. With the drive from regulations and that variance in field conditions, the ADED team began designing a new CR testing protocol and additions to the METEC testing facility. The METEC team is furthering the progress made through the ADED program with awarded funding from DE-FE0032276. This funding pushes the development of METEC’s addition with new equipment, allowing for an updated facility layout. METEC still facilitates for traditional facilities, with a legacy pad, while expanding an new design based on how O&G infrastructure has Final Report - Contract Number: DE-FE0031873 been changed over the last decade. Throughout the ADED program the team has also been working with international partners to ensure staying in the trend globally. International partners have been essential in moving the new protocol forward to implement into CR testing at the METEC facility in Spring 2025.

42 ENGINEERING↗

DOE OSTI2023

Beyond 15 MW: A cost of energy perspective on the next generation of drivetrain technologies for offshore wind turbines

Leading wind turbine manufacturers are racing to build larger and more powerful offshore machines. Drivetrain configurations often use a permanent-magnet synchronous generator (PMSG), in either a direct-drive configuration or coupled to a gearbox. With increasing demand for critical rare-earth magnets, new generator technologies are emerging to ensure a stable and secure supply chain. We evaluate three different topologies of radial flux synchronous generators employing high field magnets with reduced or no rare-earth content: a direct-drive interior PMSG (DD-IPMSG), a geared drivetrain combining a medium speed gearbox with a PMSG (MS-PMSG), and a direct-drive low-temperature superconducting generator (DD-LTSG). We develop a conceptual design module for each of these technologies within a larger framework for full turbine design. This provides the fairest comparison between technologies at nominal power ratings from 15-25 MW, which represent the next generation of offshore wind turbines. The analyses show that if operational expenditures (OpEx) are constant across the technologies, MS-PMSG results in the lowest LCOE with reductions of up to 7% relative to DD-IPMSG. DD-LTSG also yields lower LCOE values by 2%-3% for fixed-bottom turbines and 3%-5% with a floating platform. However, results are sensitive to OpEx assumptions, with a mere 10% increase causing the conclusions to shift.

17 WIND ENERGY↗

DOE OSTI2025

An infrared, Raman, and X-ray database of battery interphase components

Further improvements to lithium-ion and emerging battery technologies can be enabled by an improved understanding of the chemistry and working mechanisms of interphases that form at electrochemically active battery interfaces. However, it is difficult to collect and interpret spectra of interphases for several reasons, including the presence of a variety of compounds. To address this challenge, we herein present a vibrational spectroscopy and X-ray diffraction data library of ten compounds that have been identified as interphase constituents in lithium-ion or emerging battery chemistries. The data library includes attenuated total reflectance Fourier transform infrared spectroscopy, Raman spectroscopy, and X-ray diffraction data, collected in inert atmospheres provided by custom sample chambers. The data library presented in this work (and online repository) simplifies access to reference data that is otherwise either diffusely spread throughout the literature or non-existent, and provides energy storage researchers streamlined access to vital interphase-relevant data that can accelerate battery research efforts.

25 ENERGY STORAGE↗

DOE OSTI2023

A Comparison of Generator Technologies for Offshore Wind Turbines

Leading wind turbine manufacturers are racing to build larger and more powerful offshore machines. Drivetrain configurations often use a permanent-magnet synchronous generator (PMSG), in either a direct-drive configuration or coupled to a gearbox. With increasing demand for critical rare-earth magnets, new generator technologies are emerging to ensure a stable and secure supply chain. We evaluate three different topologies of radial flux synchronous generators employing high field magnets with reduced or no rare-earth content: a direct-drive interior PMSG (DD-IPMSG), a geared drivetrain combining a medium speed gearbox with a PMSG (MS-PMSG), and a direct-drive low-temperature superconducting generator (DD-LTSG). We develop a conceptual design module for each of these technologies within a larger framework for full turbine design. This provides the fairest comparison between technologies at nominal power ratings from 15-25MW, which represent the next generation of offshore wind turbines. The analyses show that if operational expenditures (OpEx) are constant across the technologies, MS-PMSG results in the lowest LCOE with reductions of up to 7% relative to DD-IPMSG. DD-LTSG also yields lower LCOE values by 2-3% for fixed-bottom turbines and 3-5% with a floating platform. However, results are sensitive to OpEx assumptions, with a mere 10% increase causing the conclusions to shift.

direct drive↗

DOE OSTI2021

On the progress of 3D-printed hydrogels for tissue engineering

Additive manufacturing or more commonly known as 3D printing, is currently driving innovations and applications in diverse fields such as prototyping, manufacturing, aerospace, education, and medicine. Recent technological and materials research breakthroughs have enabled 3D bioprinting, where biomaterials and cells are used to create scaffolds and functional living tissues (e.g. skin, cartilage, etc.). This prospective focuses on the classification and applications of hydrogels, and design considerations in their production (i.e. physical and biological parameters). Herein, the materials for 3D printing of hydrogels, such as biopolymers, synthetic polymers, and nanocomposites, are mainly discussed. More importantly, future perspectives on 3D printing hydrogels including new materials, 4D printing, emerging printing technologies, etc. and their importance in biomedical and bioengineering applications are discussed.

36 MATERIALS SCIENCE↗