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At least 523 records · Page 29

Biomethanation to Upgrade Biogas to Pipeline Grade Methane

NREL is working closely with DOE, Electrochaea GmbH, and Southern California Gas Company (SoCalGas) to reduce costs of a biomethanation process capable of megawatt-scale deployment that upgrades organic biogas waste streams to produce pipeline quality renewable natural gas (RNG). Biomethanation is a two-step process using a single-celled methanogenic archaea that converts low-carbon low-cost hydrogen (H2) and waste carbon dioxide (CO2) to produce renewable methane (CH4). The process upgrades the biogenic CO2 - while allowing the CH4 to pass through - from biogas sources like dairies, wastewater treatment plants, and landfills. The CH4 produced is a drop-in direct replacement fuel and producers can participate in the growing number of carbon markets; like California's Low Carbon Fuel Standard and the Federal Renewable Fuel Standard. NREL and Argonne National Laboratory have completed a life cycle analysis using the GREET model to show that the biomethanation process produces RNG that is carbon negative even when H2 production via low-temperature water electrolysis is driven by the existing carbon intensity of California's electricity grid. And of course, even further carbon negative (-233 kg CO2e/kWh) when the electricity is produced from low-carbon sources like wind and solar. Leveraging lessons learned from operating SoCalGas' 700L 18-bar bioreactor system, NREL is designing and building a flexible RD&D platform that will enable field trials at biogas and other CO2 sources. A custom 16' long trailer will house a 20L 18-bar bioreactor, 3 - 25 kW proton exchange membrane electrolyzer, and dosing, thermal, and controls systems to support operations with only power, biogas, and water feedstocks required by the field locations. The end-of-project goal is to demonstrate pipeline quality RNG production (> 95% CH4, < 4% H2, <1% CO2, < 0.2% O2 and < 4 parts per million H2 sulfide) using real biogas feedstocks - thereby recycling both greenhouse gases for injection into the natural gas network or to be used onsite.

biogas upgrading↗

Advancing Energy Justice in Alaska

NREL works with remote and rural communities across Alaska and the world to develop energy and building technologies that enhance culture, strengthen economies, and improve resilience in a changing environment. Alaska and Arctic communities not only face one of the harshest climates on earth; they also pay some of the highest energy and housing costs in the nation. NREL's Alaska Campus collaborates with communities and tribes to develop affordable, culturally appropriate homes and buildings that combine traditional knowledge and twenty-first century technology. Demonstration homes deployed all over Alaska prove out new technologies in energy efficiency, foundations, indoor air quality, and clean energy. Local workforce development is incorporated into every project: new homes are built by local workers, often including the home's future occupant. With the Arctic warming twice as fast as the rest of the planet, coastal erosion and thawing permafrost are wreaking havoc on roads, buildings, and infrastructure across Alaska. With an inclusive approach to R&D, NREL is helping communities adapt to a changing environment and advancing energy justice in the world's extremes.

Alaska housing prototypes↗

Electric Motor Thermal Management

During FY 2022, NREL efforts focused on supporting collaborations with external research partners within the Electric Drive Technologies research consortium. The poster highlights collaborations with SNL, ORNL, and Georgia Tech. The collaboration with SNL utilized NREL's experimental capabilities to mechanically characterize SNL-provided material samples for motor applications. The collaboration with ORNL supported efforts to refine the design of a high-speed, non-heavy-rare-earth outer-rotor motor. The collaboration with Georgia Tech focused on a novel cooling technique for electric machines. NREL supported the effort by leading the thermal analysis and design of advanced machines.

ADVANCED PROPULSION SYSTEMS↗

MS4 - Municipal Separate Storm Sewer System

Stormwater refers to the rainwater or melted snow that flows over land surfaces - including streets, rooftops, and parking lots - that does not infiltrate into the ground. It is collected by storm drains and conveyed through a network of pipes and channels, eventually discharging into streams, rivers, lakes, or oceans. The storm sewer systems on NREL's South Table Mountain (STM) campus, distinct from the sanitary sewer systems, is known as a Municipal Separate Storm Sewer System (MS4).The Environmental Protection Agency (EPA) issued NREL an MS4 Permit for the STM campus to regulate stormwater operations within the boundaries of the STM campus. The STM campus is the only NREL campus to have an MS4 Permit.

ENERGY PLANNING, POLICY, AND ECONOMY↗

Creating the National Renewable Energy Laboratory: Implications for New National Energy Research Institutes

The history of the design and development of the National Renewable Energy Laboratory (NREL) in the United States illustrates how the plans for a new institute can be realized and evolve over four decades. This history summarizes the process of planning and developing NREL as a new research institute to meet its mandated mission, including creating a research agenda and plans for R&D management, human resources, financial sustainability, and facilities. The NREL origin story, informed by the development of similar institutions around the world, also reveals generalized principles useful for decision makers across the globe who are designing their own research institute. These principles are described in this publication.

energy institute↗

Post-Deployment Characterization of Glass Fiber-Reinforced Thermoset and Thermoplastic Composite Tidal Turbine Blades: Preprint

In 2021, the National Renewable Energy Laboratory (NREL) supported Verdant Power with the most successful tidal energy deployment in U.S. history. Three of their tidal turbines were deployed as part of the Roosevelt Island Tidal Energy project. Initially, the three rotors were manufactured from glass fiber-reinforced epoxy composites. Midway through the deployment, one rotor was replaced with one manufactured at NREL. Instead, it was infused with a novel, infusible thermoplastic resin system. Since the deployment, one epoxy rotor and one thermoplastic rotor were returned to NREL for continued materials and manufacturing research. The two rotors underwent full-scale structural testing before being sectioned and cut into specimens for a variety of manufacturing quality tests, thermos-mechanical characterization, and evaluation of material performance in marine environments, to understand the key differences between the fiberglass reinforced epoxy and Elium composites used for the respective rotors. Matrix burnoff tests showed that the Elium blades had a considerably higher fiber volume fraction compared to the epoxy blades (61% vs. 49%). Environmental aging of the specimens showed that the epoxy laminates absorbed more water over the conditioning period, however, it was determined that the Elium laminates had higher diffusion coefficients, so initially absorbed water faster. Finally, one full epoxy blade and one full Elium blade were conditioned at ambient temperatures for up to 11 months, while taking periodic mass measurements. The datasets were extrapolated out to assume a full 20 year operational life span and it was determined that the blades would not reach full saturation during that time span.

composite manufacturing↗

Post-Deployment Characterization of Glass Fiber-Reinforced Thermoset and Thermoplastic Composite Tidal Turbine Blades

In 2021, the National Renewable Energy Laboratory (NREL) supported Verdant Power with the most successful tidal energy deployment in U.S. history. Three of their Gen5d 5 m turbines were deployed as part of the Roosevelt Island Tidal Energy project. Initially, the three deployed rotors were manufactured from glass fiber-reinforced epoxy composites. Midway through the deployment, one rotor was replaced with one manufactured at NREL. The new rotor utilized a novel infusible thermoplastic resin system (Elium from Arkema). Since the deployment, one epoxy rotor and one thermoplastic rotor were returned to NREL for continued materials and manufacturing research. The two rotors underwent full-scale structural testing before being sectioned and cut into specimens for a variety of manufacturing quality tests, thermomechanical characterization, and evaluation of material performance in marine environments to understand the key differences between the fiberglass-reinforced epoxy and Elium composites used for the respective rotors. Matrix burn-off tests showed that the Elium blades had a considerably higher fiber volume fraction compared to the epoxy blades (61% vs. 49%). Environmental aging of the specimens showed that the epoxy laminates absorbed more water over the conditioning period; however, it was determined that the Elium laminates had higher diffusion coefficients, so they initially absorbed water faster. Finally, one full epoxy blade and one full Elium blade were conditioned at ambient temperatures for up to 11 months, while periodic mass measurements were taken. The datasets were extrapolated to assume a full 20-year operational life span, and it was determined that the blades would not reach full saturation during that time span.

composite manufacturing↗

Wind Energy Accomplishments and Year-End Performance Report: Fiscal Year 2024

As the largest source of clean, renewable power generation in the United States and one of the fastest growing sources of new electricity supply, wind energy will play a large role in the nation's energy future. In Fiscal Year (FY) 2024, scientists, engineers, analysts, and support professionals at the U.S. Department of Energy's (DOE's) National Renewable Energy Laboratory (NREL) worked to accelerate the pace of innovation in wind energy science and technology, advance grid systems integration, and develop sustainable solutions to deployment challenges. Much of NREL's research, development, and deployment work aligns with addressing the Grand Challenges of Wind Energy. Beginning in 2019, DOE's Wind Energy Technologies Office partnered with the International Energy Agency to identify the barriers to greater wind energy deployment and related research gaps. The world's leading wind energy scientists and engineers identified five research areas as critical to advancing wind energy deployment: wind atmospheric science, wind turbine systems, wind plants and grid, environmental co-design, and social science. In FY 2024, NREL's accomplishments helped narrow the research gaps in these critical areas. This report provides details on those accomplishments.

accomplishments↗

Geothermal Power Systems Analysis: Outcome of Industry Stakeholders Workshop

Geothermal cost and performance evaluation implemented via techno-economic assessment (TEA) modeling is critical for the U.S. Department of Energy (DOE) and other geothermal industry stakeholders in assessing the current state of geothermal technologies and to identify existing hurdles to commercially viable geothermal development. The Geothermal Electricity Technology Evaluation Model (GETEM) is a major TEA tool used in estimating the economic feasibility and levelized cost of energy (LCOE) of conventional hydrothermal systems and enhanced geothermal systems (EGS). Since 2021, GETEM has been transitioning from an intricate spreadsheet model to a user-friendly tool within the System Advisor Model (SAM) developed by the National Renewable Energy Laboratory (NREL). Apart from enabling an expanded visibility of the geothermal model among other renewable resources, having GETEM in SAM has the advantage of simulation automation, better usability, updates tracking, active user inputs/feedback, and extended financial modeling. GETEM is used in developing supply curves for NREL's Annual Technology Baseline (ATB), which provides inputs to the Renewable Energy Potential (reV) and the Regional Energy Deployment System (ReEDS) models. The geothermal module in NREL's reV model assesses the geothermal energy potential in the conterminous United States by defining the geospatial intersection of geothermal resources with existing grid infrastructure within the constraint of land use characteristics. The ReEDS model is a capacity expansion model used for simulating the long-term build-out and operation of the U.S. generation and transmission system based on current energy costs and policies. To ensure enhanced representation of current industry trends in our model transitions and development, we organized a two-day virtual workshop to elicit geothermal industry stakeholder input and recommendations on our current approaches and assumptions on techno-economic, resource assessment, and deployment scenarios modeling of geothermal technologies. Participants included developers, operators, investors, regulatory agencies, system modelers, national laboratory researchers, consultants, and other stakeholders. In this workshop, we gained stakeholder insights on current geothermal plant performance (i.e., capacity factors), updated drilling costs and learning curves, and next-generation technologies such as closed-loop and superhot rock geothermal. Other outcomes from this workshop and its impact on future geothermal development feasibility, resource availability, and capacity expansion studies are compiled and discussed.

annual technology baseline↗

Development and Preliminary Analysis of a U.S. Geothermal Heat Pump Installation Database

This paper seeks to addresses the significant gap in the literature regarding the installation and adoption of geothermal heat pump (GHP) systems in the United States. While the "2021 U.S. Geothermal Power Production and District Heating Market Report" published by the National Renewable Energy Laboratory (NREL) focused on direct-use geothermal district heating systems, it did not include an analysis of GHP installations (Robins et al. 2021). To bridge this gap, NREL has compiled a novel database currently containing 70,470 records of GHP installations, primarily sourced from state well permits and small-scale studies. Our methodology emphasizes the collection, cleaning, and standardization of data, addressing challenges such as inconsistent reporting formats and privacy concerns. Despite limitations in data on capacity, costs, and performance, our preliminary geospatial analysis reveals insights into the distribution of GHP systems across urban and rural areas and climate zones. The paper highlights the importance of publicly accessible data for advancing GHP technology adoption with a discussion of existing data sources and their limitations, advocating for improved collaboration between NREL and industry stakeholders.

data collection↗

A Novel High-Temperature Generator/Motor Design: With Applications in Geothermal Drilling and Other Industries

The National Renewable Energy Laboratory (NREL), in partnership with Tetra Corporation and TPL Inc, has an ongoing ARPA-E project related to an advanced high-temperature geothermal drilling system, and the power electronics necessary for this system. As part of this work, NREL designed, built and tested a high-temperature generator for power generation in a 250 degrees Celsius downhole drilling environment. This design exceeded initial performance targets at elevated temperature. NREL is investigating alternative applications for this design, as either a generator or motor capable of efficient performance at high temperature.

alternator↗

Strengthening U.S. National Security Through Advanced Energy Innovation

NREL's work in strategic energy security is focused on keeping the United States secure and its citizens safe by applying expertise in advanced energy systems and technologies to prevent energy system disruptions from any source, natural or human. NREL pursues national security objectives by providing partners an accurate understanding of national and international security implications of global energy trends; novel installation, facility, and operational energy solutions; access to NREL R&D capabilities to incorporate advanced energy technologies and biomaterials into mission requirements; and the ability to test future technologies using large-scale grid modeling.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Advancing Geothermal Research: Fiscal Year 2025 Accomplishments Report

This is a summary of geothermal work done at the National Renewable Energy Laboratory (NREL) in Fiscal Year 2025. This year brought increased attention to the geothermal industry and NREL's geothermal research portfolio. With more than 70 active projects, NREL research spanned the areas of resource exploration and characterization; conventional and next-generation geothermal technologies; subsurface thermal energy storage; heating and cooling; co-production of geothermal with critical minerals and oil and gas; modeling and analysis leveraging expertise in data science and machine learning; and more.

15 GEOTHERMAL ENERGY↗

Demonstrating the data center as a flexible grid asset using a C-HIL setup

Increasing data center demand is outpacing grid infrastructure development. Artificial intelligence workloads and hyperscale cloud growth are creating unprecedented demand for power, while traditional grid expansion faces multiyear development timelines. Verrus is developing an innovative datacenter solution for this challenge, data centers that act as active grid-supportive assets rather than passive loads. Our approach integrates a novel grid-aware power flow management system with battery energy storage systems(BESS) into a microgrid-controlled, medium-voltage power distribution architecture that delivers critical capabilities, such as: * Fast response to grid disturbances such over/ under voltage or over/ under frequency * Demand flexibility that can service requests from the utility within 10 s * Uninterrupted transition to islanded operation during grid outages * Continuous uptime assurance for compute loads while maintaining all customer service level agreements. Through Verrus' strategic partnership with the National Renewable Energy Laboratory (NREL), these capabilities were validated using NREL's Advanced Research on Integrated Energy Systems (ARIES) virtual emulation environment to model a 70-MW grid-interactive data center. This paper outlines the design, methodology, and results of this emulated deployment, demonstrating that data centers can provide both critical load resilience and ancillary grid support without compromising uptime requirements. Specifically, we present a digital real time simulation of a 70 MW data center integrated with a physical microgrid controller, and demonstrate the data center response in the event of a grid voltage and frequency event, utility demand response request and utility outage.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Renewable Hydrogen to Vehicle (RH2V) – Operation Verification and Risk Mitigation Studies: Original Agreement (Modification 0) (CRADA Final Report)

Toyota has announced plans for commercial fuel cell vehicle deployment in 2015. To fully realize the benefits of fuel cell vehicles (zero emission with no performance loss in terms of vehicle range and capability), hydrogen produced efficiently from renewable sources is necessary. Most of the hydrogen fueling stations today utilize hydrogen reformed from natural gas (produced onsite or delivered). This enables more stations to be deployed cost-effectively within a network. Producing and using cost-effective renewable hydrogen in fuel cell vehicles will enable realization of the full potential. A viable option of green hydrogen that reliably delivers on the full suite of benefits for Toyota fuel cell vehicle drivers is needed. NREL is in a unique position to analyze and optimize renewable hydrogen production scenarios using the Energy Systems Integration Facility (ESIF), a facility that is specifically designed to evaluate renewable energy integration technologies. As the U.S. Department of Energy's (DOE) primary national laboratory for renewable energy and energy efficiency research and development, NREL has extensive knowledge of photovoltaic systems as well as alternative renewable technologies for efficient and reliable production of green hydrogen.

08 HYDROGEN↗

Vulcan Test Platform: Demonstrating the Data Center as a Flexible Grid Asset

Explosive data center demand is outpacing grid infrastructure development. AI workloads and hyperscale cloud growth are creating unprecedented power requirements, while traditional grid expansion faces multi-year development timelines, regulatory hurdles, and decarbonization challenges. Sidewalk Infrastructure Partners recognized this impending crisis years ago and founded Verrus to develop an innovative solution: data centers that function as grid assets rather than passive loads. The Verrus approach integrates proprietary grid-aware controls with battery energy storage systems (BESS) in a medium-voltage architecture that delivers three critical capabilities: Fast-responding demand flexibility that can service requests from the utility within 10 seconds, Uninterrupted transition to islanded operation during grid disturbances, Continuous uptime assurance while maintaining all customer service level commitments Through Verrus' strategic partnership with the National Renewable Energy Laboratory (NREL), we validated these capabilities on Vulcan, a 70 MW utility-scale test platform powered by NREL's ARIES Virtual Emulation Environment. This deployment-ready technology has successfully demonstrated that Verrus data centers can deliver meaningful grid services while maintaining mission-critical reliability. This technical report outlines the design, methodology, and results of this emulated deployment, demonstrating that data centers can play a pivotal role in enhancing grid flexibility and reliability, without sacrificing service level guarantees.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Electric Vehicle Supply Equipment (EVSE) Study for Vernon County, Wisconsin [Slides]

Viroqua is a town in Wisconsin with a population of approximately 4,500. The Vernon County Energy district is a local nonprofit in Viroqua that provides energy education, individualized energy consulting and coaching to residents and businesses. They have a very good relationship with our county government and wish to support their efforts. The Vernon County government is currently working on a comprehensive plan and would like to include planning for electric vehicle (EV) charging infrastructure in the plan. They are seeking guidance on logical phases for implementation and identifying the best locations for Level 2 and Level 3 EV chargers. NREL provided technical input on strategic planning for electric vehicle (EV) adoption and electric vehicle supply equipment (EVSE) expansion in Vernon County through the Clean Energy to Communities (C2C) Expert Match technical assistance program. NREL provided strategic planning support for EV expansion planning in Vernon County and siting considerations for locating EVSE.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Development of High-Quality, Very Large-Grained Cd(Se,Te) Thin Films for CdTe Solar Modules (Final Technical Report)

TCF-21-25048 is a one-year project to quantify the potential attributes of recent NREL inventions where CdTe devices with grain sizes exceeding 100's of microns in lateral dimension can be fabricated using a novel seeded-epitaxial process. A CdSe0.1Te0.9 film is evaporated on commercially available transparent conducting oxide (TCO) where the latter surface roughness (Ra) has been reduced to < 1-nm. After NREL's colossal grain growth (CGG) process, the grain size of this "seed" layer is increased to 100-1000 um. CdTe is then deposited epitaxially resulting in a large-grain CdTe device structure without use of CdCl2. As of this report, we have: Demonstrated the feasibility of using Tec-15 substrates after surface roughness (Ra) reduction (nexTC); Developed reproducible CGG processes for this commercially available substrate; Developed a close-spaced sublimation (CSS) process for CdTe epitaxy using these substrates; Demonstrated that large-grain CdTe films have less sub-band (band tail) absorption than conventional, small-grain CdTe; Demonstrated that large-grain CdTe films (no CdCl2) have carrier lifetimes up to 1.5 ns; Demonstrated that carrier lifetimes in epi-CdTe films (no CdCl2) have comparable lifetimes when compared to the best pX-CdTe films (FSLR) treated with CdCl2; Started making large-grain CdTe devices using CGG templates and epitaxially deposited CdTe.

14 SOLAR ENERGY↗