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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Sizing ramping reserve using probabilistic solar forecasts: A data-driven method

Ramping products have been introduced or proposed in several U.S. power markets to mitigate the impact of load and renewable uncertainties on market efficiency and reliability. Current methods often rely on historical data to estimate the requirements of ramping products and fail to take into account the effects of the latest weather conditions and their uncertainties, which could lead to overly conservative or insufficient requirements. This study proposes a k-nearest-neighbor-based method to give weather-informed estimates of ramping needs based on short-term probabilistic solar irradiance forecasts. Forecasts from multiple sites are employed in conjunction with principal component analysis to derive numerical classifiers to characterize system-level weather conditions. In addition, we develop a data-driven method to optimize the model parameters in a rolling-forward manner. By using real-world data from the California Independent System Operator, we design two metrics to evaluate method performance: 1) frequency of shortage and 2) oversupply of ramping product. Our proposed method presents advantages in comparison with the baseline and a set of benchmark methods: without compromising system reliability, it reduces system ramping requirements by up to 25%, therefore improving both system reliability and economics.

14 SOLAR ENERGY↗
DOE OSTI2022

An economics-by-design approach to a radiant integrated thermophotovoltaic microreactor system

This paper presents an application of the economics-by-design approach to the Radiant Integrated Thermo-photovoltaic Microreactor System (RITMS). The RITMS design is unique in that it directly couples a critical fission reactor with thermo-photovoltaic (TPV) panels for high efficiency energy conversion. This significant shift from electric conversion using traditional dynamic heat pumps leads to a simpler and more reliable system without turbomachinery and high pressurization. In working towards wrapping up the early design work, the economics-by-design approach, which centers economic competitiveness as the optimization parameter, is well suited in making a final determination on viability. This paper describes the computational sequence that was developed to couple the radiative and conductive heat transfer and feed operational performance to cost estimation. The framework was applied to maximize the power of the system, while minimizing the fuel enrichment. This method is applied to a reference RITMS design as part of a parametric sensitivity study, which revealed that the system is under moderated and that single unit plants could produce power as low as 300 dollar/MWh. This price point supports the notion that early in the RITMS design implementation, adoption into niche markets as a first-of-a-kind technology is possible. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2022

A Novel Process for Converting Coal to High-Value Polyurethane Products

Battelle has demonstrated a patented process for making high-value, polyurethane (PU) foam from coal, based on preparing liquefied coal via direct liquefaction, converting it to polyols as an intermediate via ozonation, and then making PU foams from these polyols. This process represents a breakthrough in innovative utilization of U.S. coals, and is applicable to bituminous as well as sub-bituminous coals. The resulting PU foam products are projected to have an extremely high value (i.e., over $\$5,000$ /ton), with nearly 100% of carbon utilization from coalderived liquid feedstock, and 31.5% to 43.5% of the carbon in the PU foam polyol product being bio-based. The targeted products represent an extremely large (i.e., over $80 billion/year), existing PU foam market, which could expand into making coatings and adhesives. The process can further help reduce petroleum imports, while improving the economics of PU foam production. This work was completed with funding from the National Energy Technology Laboratory (NETL), with cost share from the State of Ohio’s Ohio Development Services Agency (ODSA) and others, and has advanced the process to 10 kg/day continuous scale and thus to Technology Readiness Level (TRL) 5. A total of 48 coal-based polyols were prepared and evaluated. The initial 28 polyols focused on range finding for ideal conditions. The later 20 polyols were produced as part of process optimizations. These optimizations were targeted around a continuous ozonolysis process to evaluate extended time reactions and to create the necessary intermediate for production of 1-gallon samples of polyol. The most unique attribute of Battelle’s polyol is in the utilization of coal’s aromaticity to gain final foam rigidity. Typically, polyols depend on the isocyanate fraction and cross-linking to gain rigidity. By utilizing coal, we were able to maintain rigidity while reducing the overall hydroxyl value of the polyol. This is important as lower hydroxyl value leads to greater percent weight of the coal-based polyol because less isocyanate is required for foaming. This leads to greater foam cost savings. This report provides the details, process, and process cost models of the conversion of coal to polyols and further to PU foams. Battelle’s process begins with coal liquids. These liquids can be obtained by two processes: coal coking or pyrolysis to produce coal tar, and Battelle’s biobased coal-to-liquids (CTL) process to produce heavy syncrude after liquifying >85% coal. After liquification, Battelle utilizes ozonolysis to create functionalization on the polyaromatic coal structure. The functionalization is then converted to the final polyester polyol through transesterification, or to hydroxyamide polyol through amidification. Equivalent or better standard properties have been obtained for 2 lb/ft 3 density rigid, water and freon-alternative blown foams, including compressive strength, density, R-value, and dimensional stability. Target applications for these foams are insulation, packaging, and energy-absorbing foams. Some exploratory testing also showed promise for adhesives applications. A detailed economic analysis showed that Battelle’s polyol process is economical, at a 140 metric tons per day (MTD) polyol production scale. An attractive return on investment (ROI) at competitive pricing validates the process is ready for a pilot-plant demonstration. A scale-up plan is provided.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2020

Emerging Technologies for Improved Plug Load Management Systems: Learning Behavior Algorithms and Automatic and Dynamic Load Detection

Plug loads are responsible for a significant portion of the energy consumed in commercial buildings, yet their distributed and ever-changing nature makes them one of the most challenging building end uses to manage. Plug load management systems exist today that utilize smart plugs to meter and control devices at the outlet level, however, their uptake has been relatively slow in part due to the significant labor required for installation and maintenance. Learning behavior algorithms and automatic and dynamic load detection have been identified as two technology areas that could accelerate the adoption of plug load management systems by reducing these labor demands and providing additional energy efficiency and non-energy benefits. Learning behavior algorithms learn occupant behavior and adjust plug load management systems accordingly, allowing for the automatic creation of optimized control schedules. Automatic and dynamic load detection allows a plug load management system to identify devices as they are plugged in to a building and keeps the system up to date as devices are moved throughout a building. In this paper, we present our findings with respect to the current state of these two technologies based on a review of existing research and patents, as well as a series of interviews with companies working in the plug load space. We have found that, as of now, no commercialized solutions exist for these plug load technologies and that more work is needed to bring them to market. In addition, we summarize our findings related to the technology challenges, market barriers, drivers, and opportunities for these technologies moving forward.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2021

Recent Developments in the Design of Vertical Borehole Ground Heat Exchangers for Cost Reduction and Thermal Energy Storage

Ground source (geothermal) heat pumps (GSHPs) can meet the thermal demands of buildings in an energy-efficient manner. The current high installation costs and long payback period limit the attractiveness of GSHP installation in the United States. Vertical borehole ground heat exchangers (VBGHEs), which are commonly used in GSHP systems, contribute most to the cost premium of GSHPs. Reducing the cost of VBGHEs could help increase market penetration of GSHP systems. This paper reviews recent developments for VBGHEs, including improvements in borehole heat transfer and borehole field layout, integration with thermal energy storage, and new design tools. Improvements in the borehole design and materials are more likely to be justified when the ground has high thermal conductivity. Integrating thermal energy storage can provide additional value to the GSHP system, especially when flexible electric demand at buildings becomes more valuable. Here, advanced design tools for VBGHEs that account for the thermal response of irregularly shaped borehole fields and that are more closely integrated with whole-building energy simulation programs may facilitate more innovations and optimization of GSHP system designs.

15 GEOTHERMAL ENERGY↗
DOE OSTI2023

Coal-based Bricks & Blocks (CBBs): Process Development to Prototype Fabrication Coupled with Techno-Economic Analysis and Market Survey

The decline of coal use for energy production provides an abundance of local feedstock for new innovative uses and value-added products. Expanding the U.S. coal-value chain to manufacture high-value carbon products can strengthen the nation’s energy and mineral security, enhance the U.S. national defense security, increase the United States’ economic prosperity, while achieving U.S. environmental objectives. The primary project goal is a relatively light-weight composite product with superior (or comparable) compressive strength. Both virgin and, where available, post-consumer recycled thermoplastic versions are tested for each thermoplastic species. A useful attribute of thermoplastics as binders is that they can be heated to their melting point, cooled, and reheated again without significant degradation. A key advantage of thermoset CBBs is that they require only mixing and molding. CBB advantages include low cost, availability, binding ability and processability. Coal-based bricks and blocks (CBBs) weigh about 50% less than clay bricks and can be manufactured with an interlocking design to promote ease of use for the novice builder. CBB formulation is evaluated according to a design-of-experiments (DoE) approach. DoE variables are a) relative weight fractions of binder, b) relative proportions of large versus small (milled) anthracite size fractions, and c) additive percentage. Fabrication methods include hot-press molding and extrusion, the later being the most commercially viable. CBBs are tested for compressive strength, modulus of rupture (by flexure test) and water absorption per ASTM C67, with density determined by the Archimedes drainage method. Fractured interfaces are examined by SEM (Scanning Electron Microscopy) to resolve fracture dynamics and interior microstructure uniformity. Differential scanning calorimetry (DSC) is used to compare plastic transition temperatures i.e., glass and melting temperatures to contrast virgin with post-consumer recycled thermoplastics and optimize their usage. These results are used in the DoE analysis to identify the binder and relative weight percentages for optimum strength, density, and porosity. Overall, CBBs possess strength comparable to clay-based bricks but are non-permeable and hydrophobic, and hence resistant to degradation by freeze-fracturing, corrosion, and efflorescence. The strongest composites have been made with the following thermoplastic binders (in order of strength): thermoset, high-density polyethylene crosslink resin, high-density polyethylene, nylon 6/6, and polypropylene. Results from a techno-economic analysis TEA show economy of scale for CBBs by modularization and reveal the binder as the cost driver for material costs. Ideally, the incorporation of post-consumer recycled thermoplastic will decrease material acquisition costs and increase product sustainability. Notably, CBBs do not require the high temperature calcination needed to produce cement, nor do they require firing in the 1600-2400 °F range for three days using natural gas, as do clay brick equivalents. Instead, CBBs are heated to a modest <600 °F according to the melt flow index of the thermoplastic binder. Existing anthracite mines can be expanded to produce CBBs to reduce aggregate transportation costs and emissions that exist for clay bricks. TEA reflects this reduced energy cost while a comparative CO2 emission analysis quantifies the reduced environmental footprint. The market survey identifies several commercialization opportunities, dependent upon the brick classification.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2022

Marine Renewable Energy Applications for Restorative Ocean Farming: Kelp

Kelp farming and kelp forest restoration have both been proposed as a solution to locally decrease the impacts of ocean acidification and eutrophication, often with co-benefits to other forms of aquaculture and mariculture. Compared to global markets, the kelp industry in the United States is still in its early phases, with the first commercial kelp farm founded in Casco Bay, Maine in 2010. Since then, interest and effort in kelp production has been increasing, with farms now present in Maine, New Hampshire, Connecticut, Rhode Island, Massachusetts, New York, Washington, and Alaska. Many research projects are underway in the United States to explore benefits of 3D ocean farming, tackle logistical problems of working in the ocean, autonomous farming, and explore viable end uses for kelp products. In seaweed farming, to remove the stored carbon or excess nutrients from the system, the biomass needs to be harvested at the optimal time to avoid the release of CO 2 that comes with decomposition. Timing of the harvest is also important for maximum crop yield, which can vary based on the final product. Additional monitoring needs can include a variety of water quality metrics, growth measurements, and visuals to ensure the health of the farm, comply with permits, support operations and maintenance functions. The variables measured may vary by desired end use of the product, location of farm, and operational design. Monitoring all of these parameters requires specialized devices that can be costly and challenging to maintain. Monitoring devices often face power and logistical constraints that could prevent kelp farmers from adopting these technologies or receiving accurate, efficient monitoring to assess ecosystem benefits and valuation. Marine energy has been identified as a possible power source for these devices. This project investigates the power needs for conducting kelp farm environmental monitoring compared with the available marine energy resource to evaluate if locally generated ocean energy could provide a solution to these monitoring challenges and benefit kelp farmers. This process was structured as follows: 1. Define what data is needed for farmers and their communities through desk research and interviews with end users. 2. Identify sensors and power requirements currently in use or available for commercial purchase. 3. Analyze current kelp and other mariculture farm locations for the potential marine energy resource. 4. Analyze farm designs and associated structures to make recommendations for marine energy design. 5. Quantify value that investment in sensors could provide in terms of carbon credit possibilities.

09 BIOMASS FUELS↗
DOE OSTI2024

Innovating the next generation of commercial smart building software

Nearly 30% of commercial building energy use is wasted due to equipment faults and HVAC controls problems. The result is increased emissions, compromised comfort and productivity, and less reliable coordination of building power needs with a clean grid. The energy impact alone represents $17 billion in potential savings. Today’s smart building software provides a robust solution to address these operational deficiencies. Energy management and information systems (EMIS) are saving up to 9% on average, with two-year paybacks. They are being incorporated into energy management processes, commissioning services, and utility programs. As effective as they are, two barriers prevent even deeper benefits; limited personnel to fix problems once they are identified, and the expense and time to manually implement changes in control systems. In partnership with the research community, the EMIS industry is developing new capabilities to overcome these barriers. Moving beyond siloed products for either fault detection and diagnostics, or optimal control, these new capabilities empower users to not only automatically identify faults, but also to push corrective action, and control improvements to their buildings. In this paper, several areas for enhancements are documented: ‘one-time’ correction of faults such as setpoints, schedules, and economizer lockouts; short-term active testing for automated proportional integral derivative (PID) loop tuning and functional testing; and continuous supervisory control for demand flexibility and year-round efficiency. Results are presented from a pair of partner implementations out of a dozen providers integrating these enhancements into their products, including field tests from across the country, and insights into operator acceptance and integration into operations and maintenance practices.

Casillas, Armando↗
DOE OSTI2024

High-Efficiency and Low-Carbon Energy Storage and Power Generation System for Electric Aviation

This report summarizes the work performed by University of California San Diego (UCSD) – Honeywell Aerospace (Honeywell) team for the U.S. Department of Energy/Advanced Research Projects Agency-Energy (DOE/ARPA-E) under Phase 1 (April 2021 – October 2023) project, Cooperative Agreement DE-AR0001347 entitled “High-Efficiency and Low-Carbon Energy Storage and Power Generation System for Electric Aviation”. The main objective of this project is to develop and demonstrate an energy storage and power generation (ESPG) system operating on bio liquid natural gas (LNG) for electric aviation applications. The ESPG system concept in this project is a fuel cell, battery, and gas turbine hybrid system that incorporates an innovative solid oxide fuel cell (SOFC) technology. This SOFC technology has two main novel elements: (i) a lightweight and compact stack architecture that consists of cells and cell modules in electrical parallel and series connections (the module design) and (ii) exceptionally high performance, direct methane thin-film cells on porous substrate made by sputtering deposition process. This fuel cell has the specific power and volumetric power density suitable for electric aviation applications. Based on the current status of the SOFC technology, the Phase 1 work focused on the following activities: (i) ESPG System Modeling – to design and optimize an aircraft SOFC-based ESPG system concept that met the performance, weight and cost targets; (ii) Cell Material Development and Scaleup – to demonstrate scalability of the sputtering process for manufacture of thin-film SOFC cells of practical sizes, confirm the exceptional performance of sputtered cells, improve cell stability and durability for operation with hydrogen and methane fuel, and develop a suitable electrically conducting porous substrate to replace the current non-conducting ceramic substrate; (iii) Stack Development – to design and manufacture stack components for the stack architecture, evaluate and select a suitable sealant, and build and operate multi-cell stacks to demonstrate stack operation, and (iv) Technology to Market – to develop business models and commercialization plans, conduct various market and technology analysis and estimate SOFC and ESPG system costs.

25 ENERGY STORAGE↗
DOE OSTI2023

Liquid Air Combined Cycle TM for Power and Storage

Liquid Air Combined Cycle (LACC) is a hybrid liquid air energy storage (LAES) system combining energy storage with a combustion turbine to enable large-scale, long-duration energy storage (LDES) while reducing fuel intensity compared to the current state-of-the-art. The LACC technical approach employs proven equipment (cryogenic refrigeration, storage, tanks, pumps, gas turbines, exhaust heat recovery equipment, and turbines) to limit technical risk to a novel organic Rankine cycle (ORC), which was evaluated during this project and found to be feasible. Moreover, LACC storage is safe and relatively compact, to facilitate siting close to loads and within metropolitan regions. The air storage medium is freely available and eliminates supply chain constraints. LACC uses cryogenic air as a storage medium and a gas turbine as the source of heat to drive the discharge process. LACC is distinguished from other LAES technologies by several factors. The charge and discharge processes are decoupled so that cryogenic liquid air is the only storage medium. Other systems also store the higher temperature thermal energy from the liquefaction process in an additional medium. Subsequently, LACC focuses on maximization of the discharge energy and power. LACC also permits the use of commercially available cryogenic refrigeration and storage technologies to increase competition. This project identified product requirements to support market entry and commercialization of the LACC in modular units of approximately 117 MW, each drawing liquid air from customary cryogenic storage tanks capable of storing 75 GWh of dispatchable energy, more than pumped storage hydro or compressed air energy storage technologies. An economic analysis identified the specific liquid air consumption (quantity of liquid air per unit of discharge energy) as a critical parameter. Minimizing the air consumption reduces the specific capital cost ($\$ $/kW) for charging and discharging equipment by reducing the size of piping and turbomachinery. Likewise, the specific cost of energy capacity ($\$ $/kWh) is reduced by increasing the energy deliverable from a given size tank. The cycle was analyzed to identify the optimal equipment selection and operating conditions, which in turn were combined with quotes and cost estimates to calculate the cost of energy from an LACC system. A substantial effort was focused on the ORC, which draws low-temperature heat from the gas turbine exhaust and condenses at low temperature using the cryogenic liquid air as a heat sink. Alternative turbomachinery arrangements were evaluated for feasibility and cost. A technology maturation plan lays out a low-risk approach to development of the novel ORC components and demonstration of LACC technology at pilot scale.

25 ENERGY STORAGE↗
DOE OSTI2021

Optimization of Localized High Concentration Electrolytes (LHCE) for Li||LiCoO 2 and Si|| LiCoO 2 Batteries used in Consumer Electronics Applications (Final Report for I3T Project 75934)

This project will optimize localized high concentration electrolyte (LHCE) for Li/LCO and Si/LCO batteries for consumer electronics applications, including select the best solvent and diluent, optimize the ratios of the solvents and the salt concentration. Results will be demonstrated not only in both coin cells, but also in pouch cells, which is required for large-scale commercial applications. This work can provide better understanding that would also benefit other LMB projects, including Li/NMC and Li/S batteries for electric vehicle applications. In the history of rechargeable batteries, all batteries have been first used in small scale consumer electronics, then eventually penetrate to large scale applications such as electrical vehicle or grid. We believe this development route will also be true for LMBs. By developing the best electrolyte for Li/LCO and Si/LCO chemistry, we will not only get the early market entry in consumer electronics, but we can also accumulate experience on the practical application of LMBs which can be used to further develop other types of LMBs for EV and other large-scale applications pursued by DOE.

25 ENERGY STORAGE↗
DOE OSTI2025

Variable Curvature Pultruded Vertical Axis Wind Blades

XFlow Energy is developing a floating offshore vertical-axis wind turbine (VAWT) enabling a 70% reduction in the levelized cost of energy compared to floating horizontal-axis wind turbines (HAWTs). While the wind industry has historically been successful at lowering the cost of terrestrial wind systems, there are no scalable, economically viable floating wind solutions on the market with the levelized cost of energy (LCOE) of current floating offshore solutions is $200/MWh (Musial 2022). Low-cost blade production is one of the key technologies for realizing this target LCOE reduction. The proposed design uses a constant cross-section blade, enabling the use of pultrusion, a continuous, automated, mold-free production method. By employing blades with variable curvature, XFlow can minimize the bending stresses in the blades, allowing for light-weighting. Constant curvature pultrusion has been demonstrated on hollow sections. Variable curvature pultrusion has been demonstrated on solid sections. This project aims to develop a method of variable curvature pultrusion for hollow sections, as required for mass-optimal VAWT blades.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2025

Variable Curvature Pultruded Vertical Axis Wind Blades

XFlow Energy is developing a floating offshore vertical-axis wind turbine (VAWT) enabling a 70% reduction in the levelized cost of energy compared to floating horizontal-axis wind turbines (HAWTs). While the wind industry has historically been successful at lowering the cost of terrestrial wind systems, there are no scalable, economically viable floating wind solutions on the market with the levelized cost of energy (LCOE) of current floating offshore solutions is $\$$200/MWh (Musial 2022). Low-cost blade production is one of the key technologies for realizing this target LCOE reduction. The proposed design uses a constant cross-section blade, enabling the use of pultrusion, a continuous, automated, mold-free production method. By employing blades with variable curvature, XFlow can minimize the bending stresses in the blades, allowing for light-weighting. Constant curvature pultrusion has been demonstrated on hollow sections. Variable curvature pultrusion has been demonstrated on solid sections. This project aims to develop a method of variable curvature pultrusion for hollow sections, as required for mass-optimal VAWT blades.

17 WIND ENERGY↗
DOE OSTI2020

A comparison study on trading behavior and profit distribution in local energy transaction games

With the increasing integration of distributed energy resources, localized peer-to-peer energy transactions are receiving more attention since they could absorb more distributed renewables locally and stabilize the power grid. To better study the trading behavior and provide guidance for a viable local market design, different game-theoretical frameworks including cooperative and non-cooperative games are established and compared here. For the cooperative grand coalition, the maximum social welfare is guaranteed, the Shapley value and bargaining based approaches are implemented for further profit redistribution. It is shown that the asymmetrical bargaining power can be critical in the final payment clearing and it is equivalent to the Shapley value allocation if prosumers bargain based on their marginal contributions. Non-cooperative trading is formulated by using a Stackelberg bilevel model in which the upper level has the privilege in internal price setting. However, system optimum is not obtained due to competition, and the selfish leader could take away 89% of the collective benefit by price-gap based arbitraging. Aiming for a long-lasting trading market, a virtual benevolent leader and a uniform price structure in which purchase price equals selling price are tested. Experimental results indicate that maximum social welfare and a fairer profit allocation can be achieved with a uniform price structure, regardless of the selfish or benevolent attitude.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2022

Commercial Building Sensors and Controls Systems - Barriers, Drivers, and Costs

Optimized building sensors and controls systems could lead to 29% annual energy savings in commercial buildings and are integral to the growth of grid-interactive efficient buildings. However, only 8% of small commercial buildings have installed sensors and controls systems-which is largely due to cost barriers. This publication seeks to increase the transparency of system costs and identify specific barriers and drivers for increased adoption. Qualitative interview data was collected from 20 interviews with industry and qualitative cost data was collected from invoices during the interviews. The greater understanding of costs and barriers associated with commercial building sensors and controls systems lays the groundwork for future steps in increasing system adoption, reducing energy consumption, and market transformation.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2022

Low-Cost, Easy-To-Integrate and Reliable Grid Energy Storage System with 2 nd Life Lithium Batteries

Batteries retired from electric vehicles have the potential to extend their service as low-cost stationary energy storage systems. However, disperse battery state of health (SOH) and nonuniform battery characters often lead to compromised battery performance and reliability, which greatly hinder their adoption. A Heterogenous Unifying Battery (HUB) system is proposed to stage 2 nd life battery bricks for a period, and enable them to attain improved SOH uniformity, performance, and reliability before being sold for 2 nd life applications, while simultaneously providing grid services. It may offer a technically and economically advantageous solution for the broad utilization of 2 nd use batteries. The goal of this project was to develop the hardware and software that enables the key functions of the HUB system. The first achievement of the project was the development of a 1kW scale proof-of-concept (POC) system, which comprises (i) a modular plug-n-play DC-DC power converter matrix with isolated series output connections to achieve fully independent control of energy flow to each of the connected battery units at low voltage; (ii) enhanced model based control that drives each batteries’ SOH towards uniformity while collectively providing grid energy storage services; and (iii) comprehensive procedures to perform battery diagnostics and prognostics. The second achievement was the development of a 100kW scale HUB system and demonstrated its performance of re-establishing battery SOH uniformity through a period of battery cycling operation. The final HUB system incorporates six DC-DC power converter matrices paired with six battery bricks. Hot swapping of a single battery brick while maintaining consistent system power was demonstrated and system operation was validated to be capable of implementing the approved grid duty cycle and of balancing and conditioning the battery bricks. Through the course of the project, the team optimized the building-block design, form-factors, and adjusted life balancing control. An up-sized 250kW Scale was developed and deployed in October 2022 with pack-level battery form factors, see photo in Figure 1 The third achievement of the project was to perform a techno-economic analysis in order to better understand the cost and revenue potentials in this new “recondition-then-resell" value proposition. The final TEA quantified the economics of new Li-ion batteries as well as second-life batteries processed via reconditioning and traditional binning. Results showed the reconditioned second-life batteries in this project to be economically favorable and viable in grid energy storage markets. The TEA results were published in the Applied Energy journal. The fourth achievement of the project was to deliver a tech-to-market plan for the HUB system that includes funding, IP, and manufacturing strategies. The final T2M plan outlines a business strategy in which the HUB provides a B2B service to EV companies as an alternative to battery recycling that can prepare batteries for 2nd life applications. A company named Smartville Inc. was founded to carry on the commercialization, funding, and technical IP licensing activities of the OPEN project.

25 ENERGY STORAGE↗
DOE OSTI2021

Current research in low temperature proton exchange membrane-based electrolysis and a necessary shift in focus

While hydrogen has limited use in energy markets today, significant growth is possible in grid storage and as an energy carrier in other sectors. Along with lower electricity prices, further hydrogen cost reduction can enable electrochemical water splitting, particularly as the use of intermittent, renewable power sources increases and the quantity and duration of storage requirements limit electrical storage options. With the improved viability of large-scale hydrogen production, research in low temperature electrolysis has dramatically increased. The overwhelming majority of research efforts within proton exchange membrane-based systems has focused on catalyst development, although a smaller set have developed transport layers as well. As proton exchange membrane-based electrolysis shifts into higher technology readiness levels, however, there is a growing need for work optimizing materials integration, developing component-specific and device-level accelerated stress tests, and addressing manufacturing considerations. These areas directly impact electrolyzer performance, durability, and cost, and are critical to advancing hydrogen’s value and electrochemical water splitting.

08 HYDROGEN↗
DOE OSTI2021

A Review on Bioinspired Proton Exchange Membrane Fuel Cell: Design and Materials

With the climate crisis gathering recognition, there has been significant interest in clean energy. As a reliable and clean energy solution, markets transitioning toward sustainable energy have identified polymer electrolyte membrane fuel cells (PEMFCs) as a critical technology. The increasing interest in PEMFCs is primarily due to their high energy density, high efficiency and zero greenhouse gas emission. However, additional development is required to overcome the current barriers associated with fuel cell component design, high manufacturing cost, and insufficient stability. Bioinspired designs have the potential to provide new and valuable insights using novel techniques for extracting design inspirations from biological structures. Applying these design concepts to develop materials and structures for various fuel cell components can be transformative. The well–adapted structures and functional features of biological systems have been proven to greatly enhance the performance of current designs through novel and optimized pathways. Bioinspired designs have indeed lived up to performance expectations and even exceed them. Herein, the potential and value of using these bioinspired designs are discussed. Recent studies and advancements based on nature–inspired structures for components of PEMFCs and how these design considerations substantiate their claim as an attractive alternative to conventional designs are discussed.

25 ENERGY STORAGE↗