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DOE OSTI2025

Primary material supply configurations and domestic recycling for cost-effective battery material production in the US

Battery cathode active material costs hinge on regionally concentrated, price-volatile metal supply. Here. we construct a regional facility-level cost model based on over 80 global lithium, cobalt, and nickel mines, refineries, and battery-grade material plants. Our model yields aggregated lithium, nickel, manganese, and cobalt production material costs from 392 region-based supply configurations for five different cathode active materials. Focusing on the United States, all-domestic supply is 9–34% costlier than global average, increasing by cobalt content, while these shortfalls can be overcome by selective low-cost material imports. Furthermore, we analyze costs of two U.S.-based recycling facilities from primary data and techno-economic modelling and compare resulting cathode active material-level costs to primary supply. Although it is still significantly higher on cathode active material cost-level, rising end-of-life flows and lowered black-mass prices will, however, make secondary supply cost-competitive to domestic and foreign primary supply cost floors. Facility-level benchmarks reveal targeted import, scaling, and production cost optimization as levers for a resilient, cost-effective U.S. battery-material supply chain.

Energy↗

DOE OSTI2021

Influences of pH and substrate supply on the ratio of iron to sulfate reduction

Iron reduction and sulfate reduction often occur simultaneously in anoxic systems, and where that is the case, the molar ratio between the reactions (i.e., Fe/SO 4 2- reduced) influences their impact on water quality and carbon storage. Previous research has shown that pH and the supply of electron donors and acceptors affect that ratio, but it is unclear how their influences compare and affect one another. This study examines impacts of pH and the supply of acetate, sulfate, and goethite on the ratio of iron to sulfate reduction in semi-continuous sediment bioreactors. We examined which parameter had the greatest impact on that ratio and whether the parameter influences depended on the state of each other. Results show that pH had a greater influence than acetate supply on the ratio of iron to sulfate reduction, and that the impact of acetate supply on the ratio depended on pH. In acidic reactors (pH 6.0 media), the ratio of iron to sulfate reduction decreased from 3:1 to 2:1 as acetate supply increased (0-1 mM). In alkaline reactors (pH 7.5 media), iron and sulfate were reduced in equal proportions, regardless of acetate supply. Secondly, a comparison of experiments with and without sulfate shows that the extent of iron reduction was greater if sulfate reduction was occurring and that the effect was larger in alkaline reactors than acidic reactors. Thus, the influence of sulfate supply on iron reduction extent also depended on pH and suggests that iron reduction grows more dependent on sulfate reduction as pH increases. Our results compare well to trends in groundwater geochemistry and provide further evidence that pH is a major control on iron and sulfate reduction in systems with crystalline (oxyhydr)oxides. pH not only affects the ratio between the reactions but also the influences of other parameters on that ratio.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2022

Rare Earth Permanent Magnets: Supply Chain Deep Dive Assessment

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2022

Nuclear Energy: Supply Chain Deep Dive Assessment

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2022

Platinum Group Metal Catalysts: Supply Chain Deep Dive Assessment

The report “America’s Strategy to Secure the Supply Chain for a Robust Clean Energy Transition” lays out the challenges and opportunities faced by the United States in the energy supply chain as well as the federal government plans to address these challenges and opportunities. It is accompanied by several issue-specific deep dive assessments, including this one, in response to Executive Order 14017 “America’s Supply Chains,” which directs the Secretary of Energy to submit a report on supply chains for the energy sector industrial base. The Executive Order is helping the federal government to build more secure and diverse U.S. supply chains, including energy supply chains. This report focuses on the supply chain for catalysts, specifically platinum group metal (PGM) catalysts, used for decarbonizing energy technologies. Catalysts are substances that increase the rate, conversion, and selectivity of chemical reactions and are used in a variety of applications such as chemical manufacturing, petroleum refining, and catalytic converters. Catalysts containing PGMs (“PGM catalysts”) are particularly useful in widespread industrial applications, including the production of high-volume chemicals such as ammonia, acetic acid, nitric acid, and the refining of crude oil into petroleum products. The PGM metals possess extraordinary properties such as being active oxidation and hydrogenation catalysts; excellent electrical conductors and electrodes; and outstanding adsorbers of oxygen and hydrogen. Within the energy industrial base, PGM catalysts improve the energy and materials efficiency of petroleum refining and chemical industry processes and reduce energy consumption in manufacturing. In addition to their use in catalytic converters, PGM catalysts are important to maximizing the efficiency of emerging decarbonization technologies, specifically in proton exchange membrane (PEM) electrolyzers for green hydrogen production from water and PEM fuel cells for transportation and stationary energy storage. Green hydrogen is expected to play a significant role in decarbonization scenarios.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2021

Accessibility and Availability of Gas Stations for Liquid Fuel Supply During Severe Weather Events

Energy infrastructure is a pivotal lifeline with wider inter-dependencies. Electric power is essential to the continued functioning of critical assets; liquid fuels and other physical primary energy commodities that are used to supply the local energy needs of these assets during extreme events when electricity infrastructure is compromised. During Superstorm Sandy, the disruption of fuel supplies in the Tri-state area necessitated increasing situational awareness about oil and natural gas (ONG) systems to redirect fuel supplies to first responders and for restoration efforts. During winter storm events over the past several years, the demand for ONG for heating and power generation has skyrocketed in the north-east, which subsequently had caused ONG price to hit their highest level in years. ONG is a major energy source for restoration and recovery activities. However, very little, if any, situational awareness information about ONG supply and demand is available to those coordinating emergency efforts. Often this lack of information is due to the decentralized nature of the ONG supply chain and proprietary data maintained by private entities. To understand the impact of fuel availability on response and recovery efforts, this research focuses on (i) determining the accessibility to gas stations for liquid fuel supply across space and time, and (ii) examining the spatio-temporal variation of fuel availability and demand during extreme weather events. The broader scope of the project focuses on providing spatio-temporal situational awareness information about ONG availability and demand across the fuel supply chain for positioning of resources for response activities.

Kar, Bandana↗

DOE OSTI2024

IBR Digital Supply Chain Gap Analysis and Recommendations

The adoption of clean energy technologies, including solar photovoltaics, continues to introduce non-traditional stakeholders to the operations and planning of the electric system. Stakeholders such as manufacturers, vendors, owners, aggregators, and others are enabling the adoption, integration, and optimum operations of solar technologies at accelerated rates. Inverters form the foundation of many digitally controlled energy sources for clean energy technologies, including Solar, Battery Energy Storage Systems, Hybrid Systems, and Hydrogen Fuel Cells. Their supply chain is complex, a series of microchips, electronic switches and other components making up its primary functions. The complexity of this space and the growing digitization associated with these components can create supply chain cyber risks. One measure to mitigate cybersecurity attacks is proper digital supply chain security. The U.S. Department of Energy (DOE) Solar Energy Technologies Office (SETO), in partnership with the Cybersecurity, Energy, Security, and Emergency Response (CESER) office, is hosting a workshop to bring together solar vendors and services providers to discuss digital supply chain security for solar systems and challenges and opportunities in the transitioning to a fully domestic supply chain for solar energy in the U.S. This workshop will support the Securing Solar for the Grid (S2G) and Energy Cyber Sense program activities. During the workshop, industry experts and researchers from DOE National Laboratories will discuss the current solar supply chain landscape and the transition to domestic manufacturing of solar components in the U.S. Tools and techniques to better manage and secure the digital supply chain of solar devices and systems will be discussed.

cybersecurity↗

DOE OSTI2025

Systems Analysis and Optimization of Circular PET Packaging Supply Chains in the United States: Environmental and Socioeconomic Impacts

Many actions are underway at global, national, and local levels to address the plastic waste problem and transition toward a circular economy of plastics. Studies evaluating environmental and socioeconomic impacts of such a transition are lacking. Here, the purpose of this study is to conduct a national systems analysis of polyethylene terephthalate (PET) packaging supply chains in the United States. Material flow data was combined with environmental and socioeconomic indicators to evaluate and compare the sustainability of the linear PET packaging supply chain, current (2019) supply chain, and possible future circular supply chain options in the United States. Environmentally optimal circular US PET packaging material flows showed 31% and 38% savings of GHG emissions and energy demand, respectively, with a circularity of 77% when compared with a linear supply chain. Additionally, the environmentally optimal system showed higher employment (29%) and wages (31%) than a linear system, but with a 5% decrease in revenue generation. A socioeconomically optimal circular PET supply chain showed increased employment (by 52%), wages (by 67%), and revenues (by 1%), with a circularity of 59% when compared with the linear system. However, it showed 14% higher GHG emissions than a linear system, indicating a trade-off between environmentally and socioeconomically optimal circular PET packaging systems. Overall, linear-to-circular material flow transition may not necessarily lead to increased revenues and decreased environmental impacts of the entire system, but it does benefit society due to increased employment and wages. Future systems analysis work should focus on improving data quality for environmental and socioeconomic dimensions.

PET↗

DOE OSTI2022

Material Flow Analysis and Life Cycle Assessment of Polyethylene Terephthalate and Polyolefin Plastics Supply Chains in the United States

Plastics are useful and beneficial materials that contribute to an improved quality of life, yet they generate significant solid wastes and emissions and consume significant energy resources. Systems analysis is incomplete on current linear production systems of plastics supply chains and their associated processes. Our study combines material flow and life cycle assessment data sets of polyethylene terephthalate (PET) and the main polyolefin polymers in the United States, comprising over 70% of plastics flows. This study estimates the total greenhouse gas (GHG) emissions and energy consumption of these supply chains, including transportation and end-of-life processes, lacking in prior studies. Here we calculate annual GHG emissions and energy consumption of these plastic supply chains to be 101 MMT CO 2 -eq and 3248 PJ in 2019, respectively. The GHG emissions of these supply chains represented 1.5% of the total U.S. emissions and 5% of the total U.S. industry-related GHG emissions. The total energy consumption of these supply chains represented 3.1% of the total U.S. energy consumption in 2019. Transportation of PET and polyolefin plastic materials contributes 5% and 2% to the total supply chain GHG emissions and energy consumption, respectively. This baseline study provides a benchmark and enables a comparison to future circular production systems for plastics in the United States.

09 BIOMASS FUELS↗

DOE OSTI2023

The evolution of symbiotic innovation, water, and agricultural supply chains

Abstract The water literature has mainly investigated the diversion and distribution of water from the source to the end users or the utilization of water at the farm level in crop production. This paper presents a supply chain perspective that links the innovation supply chain of water delivery and irrigation with the complete water supply chain to the crop and the crop supply chains. These supply chains are symbiotic. Changes in the demand for crops, agronomic technology, and knowledge about water will modify the water infrastructure, irrigation technology, land‐use and crop production patterns, and the pricing of water and related commodities. The parameters that guide investment in water innovation and the design of the water supply chain depend on political, economic, and technological considerations that have coevolved over time with water and crop systems. Evidence from California and elsewhere supports the findings of the paper.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2021

Planning for a Resilient Home Electricity Supply System

Resilience of power systems is already a key issue that is getting frequent attention all over the world. It is useful to analyze resilience issues not only for bulk supply, but at all levels including at a customer level. This is because distributed energy resources can play a prominent role in enhancing resilience. Although the literature on planning models, tools and data for bulk supply and distribution systems have expanded in recent years, customer-centric planning, e.g., for an individual household, is yet to receive adequate attention. Although solar PV and battery storage at a household level have been analyzed, how these resources can be optimally combined, together with grid supply, from a resilience perspective is the focus of this study. The study demonstrates how a conceptual framework can be developed to show the trade-off between system costs and resilience including its dimensions such as duration, depth and frequency of service outages. A planning model is developed that incorporates multiple facets of resilience and individual customer preferences. The model considers power system resilience explicitly as a constraint. The model is implemented for a household level case study in Miami, Florida. The results show there are complex trade-offs among different dimensions of resilience. The study demonstrates how combined resilience metrics can be formulated and evaluated using the proposed least-cost planning model at a household level to optimize grid supply together with solar, battery storage and diesel generators. The model allows a planner to directly embed a resilience standard to drive the optimal supply mix. These concepts and the modeling construct can also be applied at other levels of planning, including community level and bulk supply system planning.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2022

Aluminum Electrolytic Capacitor Vulnerability Evaluation in DC Power Supplies at the Spallation Neutron Source

The service life of electrolytic capacitors is a concern for long-term reliable operation of power supplies. The Power Conversion Group at the Spallation Neutron Source (SNS) facility of Oak Ridge National Laboratory is responsible for more than 500 power supplies with over 1000 electrolytic capacitors installed in these power supplies. Most of the electrolytic capacitors have been in operation since 2007 and are either well over or close to the manufacturer provided lifetime. This paper addresses this vulnerability to ensure continued reliable operation of the SNS. The power supply circuit is simulated in a MATLAB/Simulink environment to quantify the capacitor ripple current and operating voltage. Combined with manufacturer data, this information is used to estimate capacitor lifetime. Utilizing the simulation results and lifetime projections of the capacitors, capacitor replacements for the power supplies is prioritized. To assess end-of-life, the ambient temperature and ripple current of the capacitor is used. Based on the manufacturer's data and scientific literature review, capacitor end-of-life is established. The results of the simulations and analysis is presented. Data on the highest priority supplies will also be presented, and statistics on the capacitor performance, reliability and remaining lifetime will be shown.

Harave, Sudarshan↗

DOE OSTI2022

Evolutionary Game and Simulation Research of Blockchain-Based Co-Governance of Emergency Supply Allocation

Recently, with the spread of COVID-19 pandemic, emergency supply allocation system is drawing more and more social attention. Emergency supply allocation system is an important part of emergency governance system. It reflects social organizations’ credibility, public safety, and the modernization level of social governance. However, emergency supply allocation system still has some problems, such as information asymmetry, different desires of participants, unreasonable allocation, and so on. At present, it is widely accepted that the advantage of blockchain in co-governance could be of great help in solving above problems. And in order to distinguish the effect of blockchain to the emergency supply allocation, the paper builds a tripartite evolutionary game model among the government, social organizations, and the public to analyse the impact of blockchain platform on emergency supply allocation. The simulation analysis shows the following: (1) The strategy choices of the government have a crucial impact on the evolution and stability of social organizations’ strategies. It needs a long-term process to guide social organizations practicing active allocation, and the government should accelerate to build the blockchain platform to promote this process. (2) With the help of blockchain platform, the increment of penalty intensity of the government is conductive to increasing the probabilities that social organizations practice active allocation and the government practices strict supervision. (3) Blockchain platform has a significant impact on social organizations’ choice for active allocation in many aspects, such as the positive and negative effects of social organizations, effect’s increasing multiple, and the cost of the public informing. In the end, some suggestions are presented to improve the co-governance of emergency supply allocation.

Zhao, Huawei↗

DOE OSTI2022

Electric Grid Supply Chain Review: Large Power Transformers and High Voltage Direct Current Systems

The report “America’s Strategy to Secure the Supply Chain for a Robust Clean Energy Transition” lays out the challenges and opportunities faced by the United States in the energy supply chain as well as the federal government plans to address these challenges and opportunities. It is accompanied by several issue-specific deep dive assessments, including this one, in response to Executive Order 14017 “America’s Supply Chains,” which directs the Secretary of Energy to submit a report on supply chains for the energy sector industrial base. The Executive Order is helping the federal government to build more secure and diverse U.S. supply chains, including energy supply chains. The need to modernize and increase the capacity of the U.S. power grid is increasing due to growing population, aging infrastructure, grid resilience requirements, operational flexibility needs, and a growing portfolio of renewable energy. As part of the Paris Climate Agreement the United States has committed to reducing its net greenhouse gas emissions by 50 to 52 percent below 2005 levels in 2030 and has set a goal of 100 percent carbon pollution free electricity by 2035 (The United States of America Nationally Determined Contribution, 2021). Meeting these targets will require a significant expansion of the power system to integrate a large amount of new renewable resources (United States Department of State & United States Executive Office of the President, 2021). However, many critical components supporting the power grid have limited to no domestic manufacturing capacity and face complex challenges in supporting a rapid expansion of the grid to meet multiple objectives, including decarbonization goals. This report focuses on two key grid components: large power transformers (LPTs) and high-voltage direct current (HVDC) transmission.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2022

Solar Photovoltaics: Supply Chain Deep Dive Assessment

This is one of a series of reports and deep dive assessments produced in response to Executive Order 14017 “America’s Supply Chains,” which directs the Secretary of Energy to submit a report on supply chains for the energy sector industrial base. The Executive Order is helping the federal government to build more secure and diverse U.S. supply chains, including energy supply chains. Over the past decade, solar power has gone from an emerging, niche technology to a mature energy industry. By 2035, solar power could supply 40% or more of U.S. electricity demand, dramatically accelerating the decarbonization of buildings, transportation, and industry; and, if current technology trends continue, it could do so without increasing the price of electricity. The rapid expansion of solar energy has the potential to yield broad benefits in the form of economic activity and workforce development. The solar industry already employs roughly 230,000 people in the United States, at an average wage that is higher than the national average for most comparable positions. By decarbonizing the electricity sector by 2035, the U.S. solar industry could employ 500,000–1,500,000 people by 2030. The components that are assembled to install a photovoltaic power system are produced by a global supply chain. Photovoltaic (PV) modules (also called panels) are made of cells that use a variety of technologies. There are two leading types of solar modules used in the United States, with crystalline silicon (c-Si) modules representing 84% of the market and cadmium telluride (CdTe) modules representing 16% of the market. Modules of either type require mounting structures to provide mechanical support (racking), which may be configured to follow the sun (tracking). The output of any PV module is direct current (dc), which is almost always converted to alternating current (ac) by an inverter.

14 SOLAR ENERGY↗

DOE OSTI2024

Power Supply Options for the Marpi Landfill, Saipan: Addendum to 2023 Feasibility Study

The Marpi Landfill (Marpi or the landfill), located on the northern end of the island of Saipan in the Commonwealth of the Northern Mariana Islands (CNMI), is powered by an on-site diesel generator that only operates when the landfill is open and staffed. The CNMI Office of Planning and Development (OPD) aspires to provide the Marpi Landfill with 24-hour power availability despite its remote location and to increase sustainable energy consumption within the CNMI. Pacific Northwest National Laboratory (PNNL) authored a feasibility study in 2023 that explores alternative power supply options for the landfill. This feasibility study (hereafter referred to as Phase I of this study) culminated in a report named “Power Supply Options for the Marpi Landfill, Saipan.” In Phase I, the project team investigated and prioritized seven different power supply scenarios (Table ES-1) for the landfill according to Solid Waste (SW) Taskforce priorities. The project team found that Scenario 4 (100 kW of solar photovoltaic [PV] generation, a 75 kW/300 kWh battery energy storage system [BESS], and 160 kW of diesel generation) ranked highest. Following the Phase I feasibility study, the SW Taskforce secured additional funding for PNNL to assess additional considerations regarding power supply options for Marpi. The purpose of Phase II of this study is to investigate these additional considerations, as compiled in this addendum. Some of the findings compiled here replace findings from the original report. The project team evaluated additional considerations regarding power supply options for the landfill, including modified operations to account for 24/7 power supply, electrified landfill equipment, new and replacement distribution line costs, and the social cost of carbon.

14 SOLAR ENERGY↗

DOE OSTI2024

Summary: Nuclear Energy Critical Material Waste Reduction and Supply Chain Solutions Enabled by Advanced Manufacturing

In September 2020, the U.S. government issued an executive order to address the threat to the domestic supply chain from its reliance on critical minerals (CMs) from foreign competitors and to support the domestic mining and processing industry. A national strategy on CMs with impact on the U.S. Department of Energy’s (DOE’s) vision for 2021–2031 was developed. This vision embraces science and technology to re-establish U.S. competitiveness in the CM and material supply chains by (a) scientific innovation and technologies to ensure resilient and secure CMs and maintain a domestic material supply chain, (b) building a long-term minerals and materials innovation ecosystem to foster new capabilities to mitigate CM supply chain challenges, (c) increasing private sector adoption for sustaining the domestic CM supply chain, and (d) coordinating with international partners and federal agencies to diversify global supply chains and ensure the adoption of best practices for sustainable mining and processing (DOE 2021).

36 MATERIALS SCIENCE↗

DOE OSTI2021

Supply voltage decoupling circuits for voltage droop mitigation

Circuits and methods are provided for utilizing decoupling capacitors to mitigate voltage droop on power supply lines of a power distribution network. A power supply line is capacitively decoupled using a first decoupling capacitor connected to the power supply line and charged to a first voltage level of the power supply line. A second decoupling capacitor is pre-charged to a second voltage level greater than the first voltage level and held in standby. A control circuit determines or predicts an occurrence of a droop event in which the first voltage decreases to a level which is at or below a droop threshold voltage level, and selectively connects the pre-charged second decoupling capacitor to the power supply line to source additional boosting current through discharging of the second decoupling capacitor and thereby capacitively decouple the power supply line using the higher second voltage and additional boosting current.

Zhang, Xin↗