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At least 577 records · Page 32

Review of Feasibility and Cost Drivers for Floating Offshore Wind Energy in Washington State

The state of Washington must double its clean electricity supply by 2050 to meet its clean energy goals and comply with the Clean Energy Transformation Act. With more than 6.6 GW of technical resource potential in federal waters where Bureau of Ocean Energy Management has leasing authority, offshore wind energy could play an important role in diversifying Washington State's clean energy mix, reducing dependence on out-of-state energy sources, and helping meet state decarbonization goals. Decision makers need technology-specific information to assist with long-term energy system planning, so the Bureau of Ocean Energy Management requested that the National Renewable Energy Laboratory provide an overview of several drivers of offshore wind energy feasibility and cost in Washington. This study summarizes some of the existing engagement efforts and perspectives on offshore wind energy in the region and quantifies the offshore wind resources in Washington as well as technology costs and performance of potential projects. Furthermore, this report reviews existing grid and port infrastructure and discusses infrastructure needs along with information gaps. This study also explores opportunities and barriers to Washington entities supporting the broader floating offshore wind energy supply chain along the U.S. West Coast. Note that this study is not part of a formal project planning process or official engagement effort, nor does it assess environmental or economic impacts from potential offshore wind energy development.

17 WIND ENERGY↗

Development of Industrial Scale Rare Earth Master Alloys from Their Native Oxides for Magnet Production

The objective of the project is to develop an energy-efficient, reduced cost, and single-step critical metal oxide reduction and alloying methodology for the production of NdFeB and SmCo magnets to facilitate the establishment of a sustainable domestic critical materials supply chain. The method consists of an immiscible molten salt flux layer and a higher density molten metal alloy pool (FeB or Co). The rare earth (RE) oxide and a reductant are added to the molten salt layer, where the reductant first strips the oxygen from the rare earth oxide. Subsequently, the separated RE metal diffuses into the molten metal pool below, creating a RE-saturated master alloy. Towards this end, thermodynamic calculations of the reactions between RE oxides, metallic reducing agent, and molten salt bath chemistry have been performed, and the ideal feeds and conditions for extraction and diffusion to produce master alloys were established. Small-scale and scaled experimentation was performed to validate and optimize the feasibility of viable reactions, temperatures, and process conditions with regards to yield, composition, and process efficiency. Finally, full-scale experiments for the production of NdFeB and SmCo magnets were performed, and their performance characteristics were established.

36 MATERIALS SCIENCE↗

Performance and Fabrication Status of TREAT LEU Conversion Conceptual Design Concepts

Resumption of transient testing at the TREAT facility was approved in February 2014 to meet U.S. Department of Energy (DOE) objectives. The National Nuclear Security Administration’s Global Threat Reduction Initiative Convert Program is evaluating conversion of TREAT from its existing highly enriched uranium (HEU) core to a new core containing low enriched uranium (LEU). This paper describes briefly the initial pre-conceptual designs screening decisions with more detailed discussions on current feasibility, qualification and fabrication approaches. Feasible fabrication will be shown for a LEU fuel element assembly that can meet TREAT design, performance, and safety requirements. The statement of feasibility recognizes that further development, analysis, and testing must be completed to refine the conceptual design. Engineering challenges such as cladding oxidation, high temperature material properties, and fuel block fabrication along with neutronics performance, will be highlighted. Preliminary engineering and supply chain evaluation provided confidence that the conceptual designs can be achieved.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NGNP Infrastructure Readiness Assessment: Consolidation Report

The Next Generation Nuclear Plant (NGNP) project supports the development, demonstration, and deployment of high temperature gas-cooled reactors (HTGRs). The NGNP project is being reviewed by the Nuclear Energy Advisory Council (NEAC) to provide input to the DOE, who will make a recommendation to the Secretary of Energy, whether or not to continue with Phase 2 of the NGNP project. The NEAC review will be based on, in part, the infrastructure readiness assessment, which is an assessment of industry's current ability to provide specified components for the FOAK NGNP, meet quality assurance requirements, transport components, have the necessary workforce in place, and have the necessary construction capabilities. AREVA and Westinghouse were contracted to perform independent assessments of industry's capabilities because of their experience with nuclear supply chains, which is a result of their experiences with the EPR and AP-1000 reactors. Both vendors produced infrastructure readiness assessment reports that identified key components and categorized these components into three groups based on their ability to be deployed in the FOAK plant. The NGNP project has several programs that are developing key components and capabilities. For these components, the NGNP project have provided input to properly assess the infrastructure readiness for these components.

42 ENGINEERING↗

Supply Chain-Based Solution to Prevent Fuel Tax Evasion: Final Report

The primary source of funding for the United States transportation system is derived from motor fuel and other highway use taxes. Loss of revenue attributed to fuel-tax evasion has been assessed to be somewhere between 1 billion and 3 billion per year. Any solution that addresses this problem needs to include not only the tax-collection agencies and auditors, but also the carriers transporting oil products and the carriers customers. This report presents a system developed by the Oak Ridge National Laboratory (ORNL) for the Federal Highway Administration which has the potential to reduce or eliminate many fuel-tax evasion schemes. The solution balances the needs of tax-auditors and those of the fuel-hauling companies and their customers. The system has three main components. The on-board subsystem combined sensors, tracking and communication devices, and software (the on-board Evidential Reasoning System, or obERS) to detect, monitor, and geo-locate the transfer of fuel among different locations. The back office sub-system (boERS) used self-learning algorithms to determine the legitimacy of the fuel loading and offloading (important for tax auditors) and detect potential illicit operations such as fuel theft (important for carriers and their customers, and may justify the deployment costs). The third sub-system, the Fuel Distribution and Auditing System or FDAS, is a centralized database, which together with a user interface allows tax auditors to query the data submitted by the fuel-hauling companies and correlate different parameters to quickly identify any anomalies. Industry partners included Barger Transport of Weber City, Virginia (fleet); Air-Weigh, of Eugene, Oregon (and their wires and harnesses); Liquid Bulk Tank (LBT) of Omaha, Nebraska (three five-compartment trailers); and Innovative Software Engineering (ISE) of Coralville, Iowa(on-board telematics device and back-office system). ORNL conducted a pilot test with the three instrumented vehicles collecting real-world data during an eight-month period (October 2014 to June 2015). The vehicles logged a total of 375,000 miles and transported more than 7.5 million gallons of fuel. The drivers entered information on the telematics device about 77% of the time, with about 15% (10%) of the data showing at least one compartment with loading (offloading) valve activity, but not driver information entry for that compartment. Seven events (or about 0.7% of the trips) were identified by the boERS as having a missing fuel diversion number. The solution developed and tested in the pilot test had federal- and state-level tax auditors as its main audience. Nonetheless, the technology has to be adopted by the fuel carriers and therefore the solution had to address the needs of fuel-hauling companies and their customers (i.e., fuel theft and cocktailing). Sensors in the hatches allowed the obERS recognize when one of those were opened (always a suspicious activity, unless it happens at locations where maintenance is performed on the vehicle). The fuel-theft issue was addressed by a self-learning algorithm deployed on the boERS that continuously processed the data from the field to construct probability distributions of measures such as elapsed time of fuel loading and offloading by driver, vehicle, and compartment, valve actuation sequence, elapsed time between the first two valve actuations (by driver, compartment, and location), and other parameters. Probability thresholds, which can be set up by the carrier, determined how to classify the observed events. The boERS also kept track of valve sequencing at a given location and analyzed these actuations to help identify any suspicious activities. Technical and economic recommendations include: a) simplification of the driver data-entry task; b) reduction of system deployment cost; c) addition of capabilities that make the system more appealing to industry (i.e., identify and avoid fuel misdelivery); and d) incorporation of additional capabilities to the FDAS. Path to commercialization recommendations include: a) identify a company willing to further develop, test, and certify a hardened system with a price point the market will bear; b).transfer ERS to licensee; c) establish a fleet or fleets who want this technology for carrier benefits or trailer manufacturer who wants to offer it as optional technology; and d) identify a location for the deployment of FDAS.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Commercialization of New Carbon Fiber Materials Based on Sustainable Resources for Energy Applications

Oak Ridge National Laboratory (ORNL) and GrafTech International have collaborated to develop and demonstrate the performance of high temperature thermal insulation prototypes made from lignin-based carbon fibers. This project will potentially lead to the first commercial application of lignin-based carbon fibers (LBCF). The goal of the commercial application is to replace expensive, Chinese-sourced isotropic pitch carbon fibers with lower cost carbon fibers made from a domestically sourced, bio-derived (renewable) feedstock. LBCF can help recapture jobs that were previously exported to China while resolving a supply chain vulnerability and reducing the production cost for GrafTechs high temperature thermal insulation. The performance of the LBCF prototypes was measured and found to be comparable to that of the current commercial product. During production of the insulation prototypes, ORNL and GrafTech demonstrated lignin compounding/pelletization, fiber production, heat treatment, and compositing at scales far surpassing those previously demonstrated in LBCF R&D or production. A plan was developed for the commercialization of LBCF thermal insulation, with key milestones including qualification of multiple scalable lignin sources in 2013, tons-scale production and field testing by customers in 2014, and product launch as soon thereafter as production capabilities can be constructed and commissioned.

carbon fiber↗

Medium Duty Electric Vehicle Demonstration Project

The Smith Electric Vehicle Demonstration Project (SDP) was integral to the Smith business plan to establish a manufacturing base in the United States (US) and produce a portfolio of All Electric Vehicles (AEV’s) for the medium duty commercial truck market. Smith focused on the commercial depot based logistics market, as it represented the market that was most ready for the early adoption of AEV technology. The SDP enabled Smith to accelerate its introduction of vehicles and increase the size of its US supply chain to support early market adoption of AEV’s that were cost competitive, fully met the needs of a diverse set of end users and were compliant with Federal safety and emissions requirements. The SDP accelerated the development and production of various electric drive vehicle systems to substantially reduce petroleum consumption, reduce vehicular emissions of greenhouse gases (GHG), and increase US jobs.

Mackie, Robin J. D.↗

Start Up Application Concerns with Field Programmable Gate Arrays (FPGAs)

This note is being published to improve the visibility of this subject, as we continue to see problems surface in designs, as well as to add additional information to the previously published note for design engineers. The original application note focused on designing systems with no single point failures using Actel Field Programmable Gate Arrays (FPGAs) for critical applications. Included in that note were the basic principles of operation of the Actel FPGA and a discussion of potential single-point failures. The note also discussed the issue of startup transients for that class of device. It is unfortunate that we continue to see some design problems using these devices. This note will focus on the startup properties of certain electronic components, in general, and current Actel FPGAs, in particular. Devices that are "power-on friendly" are currently being developed by Actel, as a variant of the new SX series of FPGAs. In the ideal world, electronic components would behave much differently than they do in the real world, The chain, of course, starts with the power supply. Ideally, the voltage will immediately rise to a stable V(sub cc) level, of course, it does not. Aside from practical design considerations, inrush current limits of certain capacitors must be observed and the power supply's output may be intentionally slew rate limited to prevent a large current spike on the system power bus. In any event, power supply rise time may range from less than I msec to 100 msec or more.

Katz, Richard B.↗

Cyber-Informed Engineering (CIE) Guide for States

The Cyber-Informed Engineering (CIE) Guide for States provides state energy offices, public utility commissions, and partner organizations with a structured framework for integrating cyber-resilient engineering practices into energy planning, grantmaking, interconnection processes, and workforce development. As grid digitalization and the adoption of distributed energy resources accelerate, states face expanding cyber-physical risks that traditional cybersecurity measures alone cannot fully address. CIE offers a proactive, consequence-focused engineering methodology that emphasizes eliminating or mitigating high-impact failure modes through design, physical controls, and operational safeguards. The guide outlines the 12 core CIE principles, demonstrates their application through state-focused use cases—including grant evaluation rubrics, interconnection reviews, allow-list development, and training programs—and provides practical tools such as scoring frameworks, impact assessment methods, and implementation checklists. It also highlights pathways for state–utility collaboration and opportunities for technical assistance from national laboratories. By adopting CIE, states can enhance grid reliability, reduce lifecycle costs, strengthen supply-chain assurance, and foster a security-aware engineering culture that aligns with broader resilience and modernization goals. November 2025

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Securing Critical Materials for the U.S. Electric Vehicle Industry: A Landscape Assessment of Domestic and International Supply Chains for Five Key Battery Materials

This study explores the prospective supply of upstream critical materials, providing insights into the U.S.'s capacity to meet its Electric Vehicle (EV) and Energy Storage System (ESS) deployment targets for 2035. It evaluates the proportion of critical materials demand that can be met by domestic upstream sources and the amount that will require non-U.S. sources. The analysis considers geological resources and current international development activities, contributing to the understanding of mineral supply security as the global community strives for net-zero emissions by 2050. The study focuses on five materials assessed in the 2023 DOE Critical Materials Assessment – Lithium, Nickel, Cobalt, Graphite, and Manganese.

33 ADVANCED PROPULSION SYSTEMS↗

ORBIT: Offshore Renewables Balance-of-System and Installation Tool

This report describes the Offshore Renewables Balance-of-system Installation Tool ("ORBIT"), a new model developed by the National Renewable Energy Laboratory (NREL) to evaluate the balance-of-system (BOS) costs associated with offshore wind projects. In the context of wind energy projects BOS costs encompass all expenses required to construct a project other than the capital expenditures (CapEx) of the turbines and towers, including the procurement costs for all other components (such as substructures, cables, and electrical infrastructure), offshore and land-based construction costs, port costs, site surveying fees, permitting fees, and leasing fees are all categorized as BOS costs. BOS costs significantly contribute to the levelized cost of energy (LCOE) for offshore wind, typically comprising over 50\% of the CapEx for a fixed-bottom offshore wind project and 60\% for a floating project. In addition, technology solutions and installation methods vary drastically between projects as they are impacted by factors such as vessel availability, geographic considerations and site geotechnical conditions. These effects require a model with appropriate fidelity to understand how these costs scale as turbine rating increases and the offshore wind supply chain, particularly offshore construction vessels, is expanded. For offshore wind, cost savings attributed to increased turbine rating are primarily realized through BOS procurement and project installation as fewer substructures and less cable are required. BOS costs represent both a modeling challenge, as well as an opportunity, for project developers to optimize solutions to reduce costs. It is critical to understand how these costs are affected by novel technologies, innovative installation processes, and operational constraints in order identify meaningful cost reductions for offshore wind energy.

17 WIND ENERGY↗

Laboratory-Directed Research and Development 2016 Summary Annual Report

The Laboratory-Directed Research and Development (LDRD) Program at Idaho National Laboratory (INL) reports its status to the U.S. Department of Energy (DOE) by March of each year. The program operates under the authority of DOE Order 413.2C, “Laboratory Directed Research and Development” (April 19, 2006), which establishes DOE’s requirements for the program while providing the laboratory director broad flexibility for program implementation. LDRD funds are obtained through a charge to all INL programs. This report includes summaries of all INL LDRD research activities supported during Fiscal Year (FY) 2016. INL is the lead laboratory for the DOE Office of Nuclear Energy (DOE-NE). The INL mission is to discover, demonstrate, and secure innovative nuclear energy solutions, other clean energy options, and critical infrastructure with a vision to change the world’s energy future and secure our critical infrastructure. Operating since 1949, INL is the nation’s leading research, development, and demonstration center for nuclear energy, including nuclear nonproliferation and physical and cyber-based protection of energy systems and critical infrastructure, as well as integrated energy systems research, development, demonstration, and deployment. INL has been managed and operated by Battelle Energy Alliance, LLC (a wholly owned company of Battelle) for DOE since 2005. Battelle Energy Alliance, LLC, is a partnership between Battelle, BWX Technologies, Inc., AECOM, the Electric Power Research Institute, the National University Consortium (Massachusetts Institute of Technology, Ohio State University, North Carolina State University, University of New Mexico, and Oregon State University), and the Idaho university collaborators (i.e., University of Idaho, Idaho State University, and Boise State University). Since its creation, INL’s research and development (R&D) portfolio has broadened with targeted programs supporting national missions to advance nuclear energy, enable clean energy deployment, and secure and modernize critical infrastructure. INL’s research, development, and demonstration capabilities, its resources, and its unique geography enable integration of scientific discovery, innovation, engineering, operations, and controls into complex large-scale testbeds for discovery, innovation, and demonstration of transformational clean energy and security concepts. These attributes strengthen INL’s leadership as a demonstration laboratory. As a national resource, INL also applies its capabilities and skills to the specific needs of other federal agencies and customers through DOE’s Strategic Partnership Program.

99 GENERAL AND MISCELLANEOUS↗

Minimum GHG emissions and energy consumption of U.S. PET and polyolefin packaging supply chains in a circular economy

There is a wide agreement on the urgency of transforming linear management of plastics towards a circular economy model. However, no clear pathways exist as to required recycling technologies involved and system-wide environmental impacts. This study explores such pathways in the U.S. for the most commonly used packaging plastics through a combination of mechanical and emerging advanced recycling technologies. A system optimization model aimed at minimizing environmental impacts was developed to determine optimal end-of-life (EOL) management and locations of existing and emerging U.S. recycling infrastructures. Our study includes material flows from virgin resin production through semi-manufacturing processes to existing EOL disposal and recycling processes. An optimized circular plastics packaging system achieved greenhouse gas (GHG) emission savings of up to 28% and cumulative energy demand (CED) savings of up to 46%, compared to the linear economy. Moreover, these savings of GHG emissions and CED impacts represent a reduction of 0.16% and 0.49% compared to annual U.S. GHG emissions and energy consumption in 2022, respectively. The optimal recycling rates and systems-level circularity ranged from 78–99% and 57–75%, respectively. Increased energy savings led to increased GHG emissions showing a potential trade-off between GHG emissions and energy. Analysis of 40 scenarios showed the importance of material collection distances, blend limit of mechanically recycled resins, process yields, and mandated recycling rates for achieving a sustainable circular economy of plastics.

09 - BIOMASS FUELS↗

Cis-Lunar Base Camp

Historically, when mounting expeditions into uncharted territories, explorers have established strategically positioned base camps to pre-position required equipment and consumables. These base camps are secure, safe positions from which expeditions can depart when conditions are favorable, at which technology and operations can be tested and validated, and facilitate timely access to more robust facilities in the event of an emergency. For human exploration missions into deep space, cis-lunar space is well suited to serve as such a base camp. The outer regions of cis-lunar space, such as the Earth-Moon Lagrange points, lie near the edge of Earth s gravity well, allowing equipment and consumables to be aggregated with easy access to deep space and to the lunar surface, as well as more distant destinations, such as near-Earth Asteroids (NEAs) and Mars and its moons. Several approaches to utilizing a cis-lunar base camp for sustainable human exploration, as well as some possible future applications are identified. The primary objective of the analysis presented in this paper is to identify options, show the macro trends, and provide information that can be used as a basis for more detailed mission development. Compared within are the high-level performance and cost of 15 preliminary cis-lunar exploration campaigns that establish the capability to conduct crewed missions of up to one year in duration, and then aggregate mass in cis-lunar space to facilitate an expedition from Cis-Lunar Base Camp. Launch vehicles, chemical propulsion stages, and electric propulsion stages are discussed and parametric sizing values are used to create architectures of in-space transportation elements that extend the existing in-space supply chain to cis-lunar space. The transportation options to cis-lunar space assessed vary in efficiency by almost 50%; from 0.16 to 0.68 kg of cargo in cis-lunar space for every kilogram of mass in Low Earth Orbit (LEO). For the 15 cases, 5-year campaign costs vary by only 15% from 0.36 to 0.51 on a normalized scale across all campaigns. Thus the development and first flight costs of assessed transportation options are similar. However, the cost of those options per flight beyond the initial operational capability varies by 70% from 0.3 to 1.0 on a normalized scale. The 10-year campaigns assessed begin to show the effect of this large range of cost beyond initial operational capability as they vary approximately 25% with values from 0.75 to 1.0 on the normalized campaign scale. Therefore, it is important to understand both the cost of implementation and first use as well as long term utilization. Finally, minimizing long term recurring costs is critical to the affordability of future human space exploration missions. Finally minimizing long term recurring costs is critical to the affordability of future human space exploration missions.

Merrill, Raymond G.↗

X-ray absorption spectroscopy of lanmodulin-derived peptides bound to rare earth elements

A sustainable and robust supply chain of rare earth elements (REEs) is necessary to meet our consumer, national security and clean energy goals. However, current intra-REE separation technologies (e.g. solvent extraction) are costly and carry a heavy environmental burden. Therefore, the development of new aqueous based ligands that are selective for individual REEs will be integral in future REE production systems. To develop these ligands, an understanding of how ligand coordination structure relates to selectivity is imperative. We used X-ray absorption spectroscopy (XAS) to observe the local structure around four lanthanide (Ln) ions (La, Ce, Pr and Nd) complexed by water and several relevant chelating ligands [lanmodulin EF-hand 1 peptides (LanM1), ethyl­enedi­amine­tetra­acetic acid (EDTA), amino­tris­(methyl­ene­phospho­nic acid) (ATMP) and citric acid]. To collect these liquid-phase XAS spectra, we developed a new flow cell that prevents bubble interference and beam damage to the samples. In the X-ray absorption near-edge structure (XANES), we observed energy shifts in the white line, white line broadening and differences in the white line intensity of different Ln–ligand complexes between ligands. In the extended X-ray absorption fine structure (EXAFS), we distinguished differences in peak intensity and distance between coordinating ligands. Differences in the local coordination structure between Ln–LanM1 peptide complexes were more subtle compared with the other ligands (La–water, La–EDTA, La–ATMP and La–citric acid complexes). Further XANES and EXAFS studies, in combination with modelling and other techniques, could greatly improve our structural knowledge of how these aqueous ligands bind Ln ions and how they can be used to design more selective ligands for more efficient and sustainable REE separations.

EDTA↗

Photovoltaics (Fact Sheet)

The fact sheet summarizes the goals and activities of the DOE Solar Energy Technologies Program efforts within its photovoltaics subprogram.

14 SOLAR ENERGY↗

PowerAmerica (Final Technical Report)

The U.S. Department of Energy’s Advanced Manufacturing Office (predecessor to AMMTO) established PowerAmerica in December 2014 to develop and accelerate the adoption of wide bandgap (WBG) semiconductor chips and power electronics in manufacturing. The objective was to spark early commercialization of energy efficient products; educate and train the workforce; create high-tech jobs; and nurture the growth of the U.S. WBG semiconductor manufacturing industry. PowerAmerica isled by North Carolina State University by way of a five-year, $140M cooperative agreement with DoE. This private-public partnership with DoE includes member companies ranging from startups and small-medium enterprises to large system integrators, world-class universities, and national labs. The WBG power electronic ecosystem formed by our diverse membership is focused on using advanced manufacturing to 1) lower the cost of silicon carbide and gallium nitride semiconductor devices to be comparable to silicon devices; 2) demonstrate the system benefits and energy efficiency advantages of WBG semiconductor power electronics through system demonstrations that validate their effectiveness; and 3) build an education pipeline for a skilled workforce to meet the future demand for emerging WBG semiconductor markets — and enhance U.S. economic competitiveness globally. PowerAmerica was initially funded in six budget periods, each lasting 12 to 18 months. By the end of Budget Period 6 (August 2023), PowerAmerica had achieved its major objectives in technology development, semiconductor device cost reduction, ecosystem growth and engagement, and education and workforce development. Through strategic foundry investments, we helped to establish the first U.S. SiC foundry (X-FAB) and supported a lab (Microchip) to start SiC volume production. We’ve helped bring together companies from different parts of the supply chain, resulting in several successful new partnerships and business relationships. Through projects with some of the largest manufacturers of energy-intensive equipment in the U.S. — John Deere, GE, United Technologies, Raytheon, Carrier, Toshiba, and others — we have successfully demonstrated the energy and system benefits of WBG technology. We have also harnessed the unique capabilities and facilities of national labs — the Naval Research Laboratory, National Renewable Energy Laboratory, and Argonne National Laboratory — to help solve challenging technical problems for industry. Thanks to our many webinars, tutorials, annual events, and presence at major energy and electronics conferences around the world, the PowerAmerica name has become synonymous with WBG technology advancement. The commercial interest in WBG technology is higher than ever; companies and governments around the world have announced hundreds of millions of dollarsin future investment to build capacity — and compete with silicon in many markets and applications. We have trained hundreds of engineering students, from universities across the U.S., through hands-on projects and WBG coursework. Working professionals have also benefited through the years from our many targeted short courses, tutorials, and technical webinars. In short, PowerAmerica has made great strides in each of our key objectives, and the organization has been operating without government or NC State

14 SOLAR ENERGY↗