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DOE OSTI2023

FY19-FY21 Concentrating Solar Power Systems Analysis Final Report

This technical report summarizes work done by NREL over a 3-year period for the Concentrating Solar Power (CSP) Systems Analysis project for fiscal years 2019-2021 (FY19-FY21) in support of the Solar Energies Technology Office of the U.S. Department of Energy. The goal of the CSP Systems Analysis project is to provide timely and accurate CSP cost data to the U.S. Department of Energy's (DOE's) Solar Energy Technologies Office (SETO) and to project the performance and cost of emerging CSP technologies to inform research directions and industry investment.

14 SOLAR ENERGY↗
DOE OSTI2023

An Updated Review of the Solar PV Installation Workforce Literature

In order to develop a well-trained, equitable, and inclusive workforce with high quality jobs, the DOE Solar Energy Technologies Office (SETO) identified a need for analytical context around different PV project characteristics and labor aspects, and how they might impact workforce wellbeing and PV industry growth. To determine the most valuable novel analytical contributions, this work reviews existing literature on solar workforce topics to identify what areas have been studied previously and where gaps remain. Focus areas included the following topics: (1) metrics for solar workforce, deployment, costs, and associated studies capturing aspects such as demographics and regional distribution, (2) solar workforce wellbeing, including employee contracting mechanisms, compensation, occupational safety and health, and community impacts, (3) national and state policies most relevant to the U.S. solar workforce, and (4) ongoing efforts to expand solar workforce participation, including local staffing dynamics, challenges, and relevant strategies.

14 SOLAR ENERGY↗
DOE OSTI2023

Next Generation Integrated PV Products Cost and Workflow Analysis (Final Report)

Residential photovoltaic (PV) costs have fallen consistently for over a decade (Ardani et al. 2018). DOE has subsequently developed a new residential PV cost target for 2030 of $0.05/kilowatt hour (SETO 2023). Ardani et al. (2018) conclude that integrated roofing and PV (RIPV) products may be key to achieving the residential target for both new construction and retrofit residential PV. In RIPV, the PV product is incorporated into or replaces the roofing material. RIPV systems can use conventional crystalline or thin-film technologies, may be aesthetically attractive alternatives to traditional racked and mounted PV systems, and may increase building property values (Cook et al. 2023). These products also have the potential to provide customer acquisition, labor, and equipment cost savings over traditional, racked and mounted residential rooftop PV and several companies have recently introduced integrated roofing and PV (RIPV) products (Cook et al. 2023). In 2022, Tesla was the market leader, representing 94% of RIPV capacity installed in 2022 through its Solar Roof offering, while GAF Energy and its Timberline Solar product was second capturing 3% (Feldman et al. 2023). In this project, NREL analyzed three research questions: (1) How do current RIPV products compare to racked and mounted PV in terms of costs, install times and processes? (2) How are RIPV products installed and are there opportunities for cost savings? (3) What are the key barriers to expanding market opportunities for integrating solar and roofing products? In this project, we explored residential RIPV cost reduction opportunities by analyzing installation processes. Our study documented residential RIPV installations at two reroofing sites (20.52 kilowatts) and the equivalent of nine new construction sites (71.75 kW) in California through a methodology known as time and motion study. We also conducted 15 interviews with subject-matter experts to identify barriers and solutions to maximize these products' market penetration.

14 SOLAR ENERGY↗
DOE OSTI2023

Inventory for Crystalline Silicon Module Recycling: Cooperative Research and Development (Final Report)

A critical challenge for the continued expansion of photovoltaics (PV) is to develop technically feasible, inexpensive and environmentally friendly practices for handling and recycling modules at the end of their usable life. The National Renewable Energy Laboratory (NREL) is requested by the Electric Power Research Institute (EPRI) to collect primary data regarding the environmental performance of currently operational PV module recycling facilities in Europe. Very little has been published regarding crystalline silicon (C-Si) module recycling. Thus, much effort will be needed in direct industry outreach, collection of information and other business intelligence strategies similar to NREL's approaches for developing cost models for PV manufacturing. The goal of this work effort is to produce a detailed inventory that accounts for physical (e.g., energy, water, materials) flows through each step of a C-Si recycling process. The inventory (a life cycle inventory, or LCI) shall be designed so that it can be extended to include an accounting of costs for each process step, inputs, etc. This work effort shall leverage prior LCI data collection NREL performed for the United States Department of Energy, Solar Energy Technologies Office, under the auspices of the U.S. contribution to International Energy Agency's Photovoltaics Power Systems (PVPS) Task 12 (Environmental Health and Safety), which SETO nominated NREL to chair. The primary purpose of this work effort is to augment the prior data collection to increase the sample size of manufacturers' primary data in the LCI.

14 SOLAR ENERGY↗
DOE OSTI2023

High Temperature Ceramic Heat Exchangers for the Gen3 Concentrated Solar Power Systems

As part of the Department of Energy’s Solar Energy Technology Office (SETO), the Concentrated Solar Power (CSP) Gen3 Demonstration Roadmap outlined the various technology pathways, goals, and technology needs/gaps to integrate CSP to a supercritical CO 2 (sCO 2 ) power cycle that operates at temperatures >700 °C. It is envisioned that the higher temperature power cycle will enhance the overall system efficiencies and reduce the levelized cost of electricity (LCOE) to meet a 2030 cost target of $0.05/kWhe for baseload CSP plants with ≥12 hours of storage. In this regard, there is a need for heat exchangers (HXs) that can operate at high sCO 2 pressures and temperatures >700 °C. Since current high-temperature alloys degrade at high temperatures, as part of this project, advanced ceramic materials, HX designs, and low-cost additive manufacturing approaches were developed to fabricate and evaluate the performance of the lab-scale ceramic HX prototypes.

14 SOLAR ENERGY↗
DOE OSTI2023

Operation and Maintenance of PV Systems: Data Science, Analysis, and Standards

This effort improves the effectiveness and reduce uncertainty in O&M cost through four primary objectives/tasks: 1) institutionalize standards for reliability and availability reporting for large PV power plants; 2) bridge systemic O&M knowledge gaps around important topics affecting O&M; 3) characterize systemic failure modes and patterns and accelerate O&M experiential learning cycles using field data; and 4) establish a baseline understanding of UPVS O&M cost drivers. Key results of this effort include publication of IEC standards, published topical papers on O&M topics, training, and characterize field data for climate- and service-related patterns (additional details below). Integrating these results serves to reduce performance risk and facilitate improvement in the way solar projects are operated and maintained. Results are well received and two publications are among the most successful SETO publications at NREL ("Model of Operation and Maintenance Costs for Photovoltaic Systems with over 40,000 downloads and "Best Practices in Operation and Maintenance of PV Systems, 3rd Ed." with over 90,000 downloads).

14 SOLAR ENERGY↗
DOE OSTI2022

Accelerated Scaling to Rapid Open-Air Fabrication of Durable Perovskite Solar Modules

The goals of this SETO project (DE-EE0008559, Accelerated Scaling to Rapid Open-Air Fabrication of Durable Perovskite Solar modules) are to address the principal challenges towards the successful commercialization of perovskite solar modules utilizing scalable, high-throughput open-air spray deposition. The successful outcome of the project will provide the foundation of an all open-air spray deposited perovskite solar module with hole transport layer (HTL), perovskite, electron transport layer (ETL), and barrier layer development while establishing a fundamental understanding of perovskite device behavior under accelerated aging conditions. Through this program, we have made significant progress towards a commercializable pathway for perovskites. (1) We’ve demonstrated the successful open-air deposition of perovskite and transport layer materials. These deposition methods were chosen for their inherent scalability, and open-air processing enables a significant reduction in processing costs. These methods are also compatible with high throughputs, demonstrating the fastest perovskite film deposition at these performance levels. (2) Development of a unique all-fiber laser scribing procedure provides a high-performance, low-cost method for further improvements in scalability. (3) Our group has also placed a unique emphasis on device stability. The development of testing standards for perovskite modules is required to thoroughly evaluate potential candidates for commercialization, and we’ve taken inspiration from current industry standards to provide an honest insight into the performance and reliability of our devices. (4) An extensive cost model detailing the specific contributions of each device layer and production component provides the most thorough evaluation of any perovskite technology against conventional silicon and compound semiconductor solar devices. The cost model is a critical advancement that will provide the foundation for evaluating the levelized cost of energy (LCOE) of this technology.

14 SOLAR ENERGY↗
DOE OSTI2024

Investigation of Defect Physics for Efficient, Durable and Ubiquitous Perovskite Solar Modules (Final Technical Report)

Organometal halide perovskite solar cells have experienced eye-catching improvements in its recent few years. It serves as one of the most promising candidates to replace the currently widely used silicon-based solar modules. To implement its final step to the real application, functional longevity becomes the dernier continent to conquer. As a polycrystalline material, defect plays critical role in the efficiency and stability of the perovskite solar cells. Thus, the investigation of the defect physics of the perovskite layer is indispensable in this research field. However, hard evidence and a consensus are still lacking in terms of the specific nature of the defects and their effects on performance and hysteresis, and perhaps even more importantly, there is absence of fundamental understanding of the correlations between the defects and long-term operational stability of the device. A more fundamental understanding of the nature of defects in perovskite materials is of paramount importance to progress their efficiency and durability. In this work we propose in-depth studies of correlations of defects with performance and stability of perovskite solar cells. Our project aimed 1) to investigate the defects physics in perovskite solar cells, and 2) to develop a comprehensive understanding and physical model of defects and its influence on performance and stability of perovskite solar cells. With the support from program manager, Peter Lobaccaro, and the Solar Energy Technologies Office of U.S. Department of Energy, the project ends with impact achievements. Our research results have systematically provided strategies to analyze the influences of constructive molecular configurations to the charged defects in the perovskite lattices and developed in-depth understanding of chemical additive approach to improve the perovskite solar cell performance and stability. As history has shown us, control over defect properties of semiconductor materials is the key to achieving high performance and low cost devices. Therefore, the potential impact of unlocking the understanding and manipulation of defects in perovskites is great, enabling this technology to realize SETO goals. The research project is highly productive with 18 published papers in three years in top-level journals such as Science, Nature, Nature Materials, Nature Communications, Journal of American Chemistry Society, Joule, Advanced Materials, and Nano Letters. These works have drawn great attention nationwide with notable total citations over 700 times from 2020 to 2022.

14 SOLAR ENERGY↗
DOE OSTI2024

Rooftop Photovoltaics and Electric Vehicle Co-Adoption: Attitudes, Norms, Diffusion, and Economics

The overall objectives of the project were to (1) Identify personal and social norms, peer effects, demographics and contextual factors (such as household energy expenditures, experience with outages, charging infrastructure availability) that may facilitate or hinder Solar-EV co-adoption; (2) outline strategies for the design of programs and practices that will enable reasoned RPV and EV adoption and their co-adoption; and (3) assemble a dataset comprised of survey responses of RPV-EV co-adopters, RPV-only adopters, EV-only adopters, and non-adopters. These objectives were only partially fulfilled given the decision to terminate the project. The research team was able to complete the semi-structured interviews, the core BY1 task and summarize the results below. As well, once the team learned of the research project’s fate, it sought and obtained the DOE SETO Technical Manager’s approval to repurpose funds for BY2 tasks to the extent feasible. Rather than invest further resources in expanding the pool of potential survey respondents and having no budget to survey, the research team repurposed funds subject and undertook a more limited (geographically) survey, but also expanded to it to include contingent valuation questions. The analysis of the survey data will necessarily be delayed given the lack of budget support, although some information on the respondent sample is in the results. Given a lack of attention to co-adoption previously, the insights generated in this project should assist decision-makers and industry actors in the development of programs and practices that enable reasoned RPV adoption and EV adoption and their co-adoption.

14 SOLAR ENERGY↗
DOE OSTI2024

Adaptive Protection and Control for High Penetration PV and Grid Resilience (Final Technical Report)

The report summarizes the work and accomplishments of DOE SETO funded project 36533 “Adaptive Protection and Control for High Penetration PV and Grid Resilience”. In order to increase the amount of distributed solar power that can be integrated into the distribution system, new methods for optimal adaptive protection, artificial intelligence or machine learning based protection, and time domain traveling wave protection are developed and demonstrated in hardware-in-the-loop and a field demonstration.

14 SOLAR ENERGY↗
DOE OSTI2024

Heliostat Consortium Annual Report: 2024

In 2021, the U.S. Department of Energy's (DOE's) Solar Energy Technologies Office (SETO) funded the formation of the Heliostat Consortium (HelioCon), a five-year consortium designed to advance U.S. heliostat technologies by engaging industry, subject matter experts, and general stakeholders for direct project-level collaboration, external consulting, and mission-specific panels and workshops. HelioCon is led by the National Renewable Energy Laboratory (NREL) and Sandia National Laboratories, in partnership with the Australian Solar Thermal Research Institute. This report describes HelioCon's activities and impact in fiscal year 2024.

14 SOLAR ENERGY↗
DOE OSTI2024

DOE’s National Solar Thermal Test Facility Operations and Maintenance

This report details operations and maintenance (O&M) activities performed across Fiscal Years 2022 through 2024 in support of the continued capabilities of the National Solar Thermal Testing Facility (NSTTF) at Sandia National Laboratories. The NSTTF O&M project is funded by the U.S. Department of Energy Solar Energy Technologies Office (SETO) to support research activities and testing on behalf of external customers at the facility under award number CPS 38491. During the project period, the NSTTF made progress in the areas of site metrics, site maintenance and utilization tracking, and customer engagement. The O&M project also supported special initiatives including procurement of a heat exchanger for particle concentrating solar thermal processes and a scoping and cost study for refurbishment and repair of component in the NSTTF heliostat field.

14 SOLAR ENERGY↗
DOE OSTI2024

Evaluating Microchannel Heat Exchanger Lifetime for Concentrating Solar Power Applications FY24Q4 (RPPR-1)

Microchannel heat exchanger technology is being pursued for next generation CSP concepts for primary power cycle heat addition and power cycle heat recuperation due to the high heat transfer coefficients and pressure containment advantages of small sCO 2 channels. The economics of future CSP plants as dictated by the SETO 2020 or 2030 targets depend on a heat exchanger with a 30-year lifetime (resisting creep, fatigue, corrosion, erosion) and operational characteristics such as fast ramping and the ability to withstand thermal shock. However, the lifetime and operational limits of microchannel heat exchangers operating at high-temperatures, particularly those constructed from high-nickel alloys, are not well known. This uncertainty has resulted in heat exchanger vendors not being able to accurately forecast heat exchanger lifetime as required by customers, specify operational limits as required by process engineers to prevent premature heat exchanger failure, or overdesign heat exchanger which leads to higher cost than necessary. Our goal is to evaluate heat exchanger lifetime and operational limits for the manufacturing and prototype design for next-generation CSP heat exchanger technology through a combination of collecting experimental data and modeling studies.

14 SOLAR ENERGY↗
DOE OSTI2025

Equitable Resilience: Opportunities to Advance Solar Paired with Battery Storage in Historically Marginalized Communities

This report was produced as part of the Equitable Solar Communities of Practice program through the U.S. Department of Energy (DOE) Solar Energy Technologies Office (SETO). Clean Energy Group (CEG) managed the Resilience, Storage, and Grid Benefits Community of Practice, which aimed to research, evaluate, and identify opportunities to scale the meaningful benefits of solar paired with battery storage in historically marginalized communities. The report is designed to 1) educate a broad audience on the benefits of solar paired with battery storage, 2) identify barriers to deploying solar paired with battery storage in historically marginalized communities, 3) amplify early-adopters and innovative programs that support battery storage access across the nation, and 4) recommend best practices for programs and policies to adopt in advancing equitable access to solar and battery storage technologies.

14 SOLAR ENERGY↗
DOE OSTI2025

Evaluating Microchannel Heat Exchanger Lifetime for Concentrating Solar Power Applications Research Performance Progress Report (RPPR-1)

Microchannel heat exchanger technology is being pursued for next generation CSP concepts for primary power cycle heat addition and power cycle heat recuperation due to the high heat transfer coefficients and pressure containment advantages of small sCO 2 channels. The economics of future CSP plants as dictated by the SETO 2020 or 2030 targets depend on a heat exchanger with a 30-year lifetime (resisting creep, fatigue, corrosion, erosion) and operational characteristics such as fast ramping and the ability to withstand thermal shock. However, the lifetime and operational limits of microchannel heat exchangers operating at high temperatures, particularly those constructed from high-nickel alloys, are not well known. This uncertainty has resulted in heat exchanger vendors not being able to accurately forecast heat exchanger lifetime as required by customers, specify operational limits as required by process engineers to prevent premature heat exchanger failure, or overdesign heat exchanger which leads to higher cost than necessary.

14 SOLAR ENERGY↗
DOE OSTI2025

SNL NSTTF Heliostat Refurbishment Project Final Report

This document provides an overview of re-start efforts at Sandia National Laboratories (SNL), National Solar Thermal Test Facility (NSTTF), for the DOE SETO SNL Heliostat Refurbishment project. Sandia continues to pursue innovative concentrating solar power (CSP) and thermal (CST) research in order to enhance commercial performance and reduce LCOE and LCOH of concentrating solar energy.

14 SOLAR ENERGY↗
DOE OSTI2025

Scribe and Interface Modification for Stable Halide Perovskite Modules (CRADA Final Report)

This project provided funding to NREL/Tandem PV by EERE-SETO and has the goal of improving perovskite module stability by at least a factor of 2 without sacrificing initial efficiency. This will be demonstrated using 3"x3" minimodules and will be tested according to the Innovation and Entrepreneurship Center (IEC) standards and demonstrated using outdoor testing. A CRADA was established between NREL and Tandem PV to address the goals for the funded effort.

14 SOLAR ENERGY↗
DOE OSTI2025

Impacts of PV Module Connector Failures on Cost and Performance of Utility Scale Photovoltaic Systems

The reliability, cost and performance of electrical connectors are a concern in all types of electrical systems, and demands on connectors used on photovoltaic (PV) systems include that connectors maintain electrical conductivity and physical strength, endure ultraviolet sunlight and high ambient temperature, and resist moisture and chemical intrusion over a very long (>25 year) performance period. Connector failures increase operation and maintenance (O&M) costs and reduce plant production, but connector failure can also cause safety and liability problems, which are of greater concern. This work results from a three-year collaboration between Sandia National Laboratories (SNL), the Electric Power Research Institute (EPRI), and the National Renewable Energy Laboratory (NREL) and funded by the U.S. Department of Energy (DOE) Solar Energy Technology Office (SETO) under Agreements #39035 and #38531 "Connector Reliability Across the US Solar Sector." a multi-pronged investigation of PV connector health across the US (see https://energy.sandia.gov/pvconnectors/). This report presents derivation of a Techno-Economic Analysis (TEA) that models failure modes and frequencies (how often failure occurs), estimates O&M costs and lost production associated with connector failures, and then calculates the effect that PV module connectors can have on Levelized Cost of Energy (LCOE). The model is informed with initial data from quantitative assessment of failure rates, root causes and mechanisms, in-situ diagnostics and data collection, lab-based forensics, and interviews with PV connector manufacturers and plant operators. SNL conducted site inspections at multiple utility-scale sites in different climates and subjected field samples of new, used, and degraded connectors to visual and electrical characterization. EPRI conducted metallurgical analysis of the pin and sleeve conductors to study failure-induced morphological and compositional changes. There is in general a shortage of statistically valid data, but data from PVROM database maintained by SNL was sufficient to ascertain failure rates and lost production as well as provide qualitative insight in its curated maintenance records. This report details the structure of the mathematical model but the sources of data to inform the model will continue to evolve. Analysis of a 100 MW PV plant is provided as an example of the use of the model, with results indicating that connectors are responsible for Annualized O&M Costs of $\$$71,933/year; Annualized Unit O&M Costs of $\$$0.72/kW/year; that a Reserve Account of $\$$187,220 should be available to fund repairs related to connectors; that connectors add $\$$1,494,004 to the Net Present Value of the O&M Costs (project life); and that O&M related to connectors adds about $\$$0.00088/kWh to the Levelized Cost of Energy. The impact of this model is to provide a tool to make the US solar sector more robust by quantifying and monetizing the reliability risks to utility-scale PV systems posed by poorly installed, mismatched and/or poorly designed and manufactured connectors. The TEA provides a model incorporating failure statistics, O&M cost data, and lost production into a single figure of merit, informing decisions and enabling practitioners to optimize cost and performance trade-offs. Stakeholders include connector manufacturers, system designers and equipment specifiers, standards bodies, installers and O&M providers, investors and insurance underwriters. This report supports continued growth of PV predicated on assurances that properly installed and maintained PV system connectors are safe and reliable. The project team is proposing future work including accelerated testing of connectors and expanding the approach taken here to other PV system components, such as TEA for rapid shut-down devices.

14 SOLAR ENERGY↗