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All sources NASA NTRS DOE OSTI

DOE OSTI2024

Overcoming barriers to improved decision-making for battery deployment in the clean energy transition

Decarbonization plans depend on the rapid, large-scale deployment of batteries to sufficiently decarbonize the electricity system and on-road transport. This can take many forms, shaped by technology, materials, and supply chain selection, which will have local and global environmental and social impacts. Current knowledge gaps limit the ability of decision-makers to make choices in facilitating battery deployment that minimizes or avoids unintended environmental and social consequences. These gaps include a lack of harmonized, accessible, and up-to-date data on manufacturing and supply chains and shortcomings within sustainability and social impact assessment methods, resulting in uncertainty that limits incorporation of research into policy making. These gaps can lead to unintended detrimental effects of large-scale battery deployment. To support decarbonization goals while minimizing negative environmental and social impacts, we elucidate current barriers to tracking how decision-making for large-scale battery deployment translates to environmental and social impacts and recommend steps to overcome them.

25 ENERGY STORAGE↗

DOE OSTI2025

Assessing the deployment of solar-driven hydrogen from biomass at scale in the U.S.

Solar hydrogen from biomass gasification is a promising technology to sustainably produce hydrogen, responsibly dispose biomass waste, and reduce reliance on fossil fuels. However, its large-scale deployment faces challenges due to the geospatial misalignment between biomass resources and solar intensity, which introduces additional supply chain logistics costs. We analyze the logistics cost burden imposed by this misalignment and its impact on successful large-scale deployment of solar-driven hydrogen from biomass in the United States. We also consider associated carbon emissions and explore how the mix of deployed technologies evolves under externally imposed carbon penalties. Our findings show that while economies of scale are known to apply at the processing facility level, the reverse effect occurs at the broader systems-level, driven by logistics. Also, at current technology costs, high carbon penalties would be required to favor deployment of solar based technologies over conventional and hybrid alternatives. We further illustrate strategies and system-level changes to reduce logistics costs and enable sustainable, low-cost hydrogen for decarbonizing different industrial sectors.

Iloeje, Chukwunwike O. [Argonne National Laborator↗

DOE OSTI2021

Real-Time Evolution and Deployment of Neuromorphic Computing at The Edge

Extremely low power neuromorphic systems are well-suited for deployment to the edge for many applications. In many use cases of neuromorphic computing for control, a spiking neural network is trained off-line using a simulation and then deployed to a neuromorphic system at the edge, where it will operate without ongoing training or learning. However, it may be desirable to continue training or learning at the edge to refine or adapt to the real-world system. In this work, we propose an approach for performing real-time evolutionary optimization for spiking neural networks for neuromorphic deployment at the edge. In particular, we propose a combination of simulation and real-world evaluations, along with feedback from the real-world environment, to train spiking neural networks for continuous deployment to the edge. We show that the real-time evolution at the edge approach achieves comparable performance to an evolution approach that requires constant evaluation in the realworld environment.

Schuman, Catherine↗

DOE OSTI2022

Generating Sequential PV Deployment Scenarios for High Renewable Distribution Grid Planning

This paper introduces a novel approach for generating solar photovoltaic (PV) plant deployment scenarios for grid integration planning. The approach guarantees consistency among scenarios of the same deployment by ensuring that higher penetration scenarios contain PV units deployed in lower penetration scenarios. It also constrains the size and spatial distribution of the PV plants and considers three placement types. A case study on a real-world distribution system proves that the precepts of scenario consistency, deployment diversity, and placement are met. The study further investigates the impact of the resulting scenarios via a stochastic hosting capacity analysis. Results indicate that the ratio between PV and load sizes, referred to as the nodal PV penetration factor (NPPF), is a key driver of the grid integration impact. By reducing the NPPF from 5 to 2, the maximum hosting capacity increased by at least 112%. The study also reveals that scenarios under random placement can lead to higher hosting capacity values.

ENERGY PLANNING, POLICY, AND ECONOMY,SOLAR ENERGY↗

DOE OSTI2023

Transactive Energy System Deployment Over Insecure Communication Links

Here, in this paper, the privacy and security issues associated with the transactive energy system (TES) deployment over insecure communication links are addressed. In particular, it is ensured that 1) individual agents’ bidding information is kept private throughout hierarchical market-based interactions; and 2) any extraneous data injection attack can be quickly and easily detected. An implementation framework is proposed to enable the cryptography-based enhancement of privacy and security for the deployment of any general hierarchical systems including TESs. Under the proposed framework, a unified cryptography-based approach is developed to achieve both privacy and security simultaneously. Specifically, privacy preservation is realized by an enhanced Paillier encryption scheme, where a block design is proposed to significantly improve computational efficiency. Attack detection is further achieved by an enhanced Paillier digital signature scheme, where a stamp-concatenation mechanism is proposed to enable detection of data replace and reorder attacks. Simulation results verify the effectiveness of the proposed cyber-resilient design for transactive energy systems. Note to Practitioners—This paper is motivated by addressing the issues of cyber resiliency for practically deploying transactive energy system (TES) but it is also applicable to the problem of enhancing the privacy and security for any general hierarchical control systems. TES is an emerging control approach that engages energy suppliers and customers through market operations and uses the price to optimally allocate energy resources. While it has been shown to be promising for power system applications, the underlying market-based interactions raise significant concerns of privacy (data leakage) and security (data tampering). However, existing TES works only focus on the coordination mechanism instead of privacy and security issues. This paper proposes a new cryptography-based TES design for practical deployment. Specifically, to protect privacy, individual supply and demand amounts to be exchanged are all encrypted in a particular way such that the original amounts cannot be inferred from the encrypted amounts, while the desired computation for setting the market clearing price can be carried out over the encrypted amounts, thus generating an encrypted result which, when decrypted, matches that of the same computation over the original amounts. To achieve security, for each exchanged data, its sender generates a particular digital signature which is exchanged together with the data. This enables the receiver to automatically detect the integrity by checking whether a mathematical relationship holds for the pair of data and signature. In our future research, we will investigate more challenging scenarios where some suppliers and customers themselves could be corrupted and purposely submit distorted amounts.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2025

Field expedient stool collection methods for gut microbiome analysis in deployed military environments

ABSTRACT Field expedient devices and protocols for the collection, storage, and shipment of stool samples in deployed settings are needed for the advancement of microbiome research in military health. Relevant assessments include the evaluation of microbiome signatures associated with susceptibility to travelers’ diarrhea and recovery of gut function following infection. However, inherent biases in microbial measurements due to preservatives and sampling methods are unclear and should be assessed for an accurate evaluation of the microbiome. We performed shotgun metagenomic sequencing and compared the microbiome composition in paired fecal samples collected using Flinters Technology Associates (FTA) cards and OMNIgene (OG) Gut tubes, prior to and during international travel, from 49 adult participants, 39 of whom remained asymptomatic and 10 experienced travelers’ diarrhea. Higher concentrations of nucleic acid and sequencing libraries were observed in OG samples. A majority of genera (82.9%) were detected with both methods, and detections of genera limited to one collection method were not highly prevalent across samples and were present in extremely low relative abundances (<0.01%). Differences in beta diversity were largely explained by inter-individuality of microbiome composition, followed by the effect of collection method and timepoint-disease states. Differential abundance analysis indicated that Corynebacterium and Blautia were consistently higher in abundance across all groups with FTA and OG collection, respectively. The observed differences in microbiome composition between methods suggest the need for consistent and standardized protocols within a study. Overall, the data presented here could help guide the future design of fecal microbiome study protocols in field and military deployment settings. IMPORTANCE The assessment of field-deployable methods for fecal sample collection and storage is required to reliably capture samples collected in remote and austere locations. This study describes a comparative metagenomics analysis between samples collected by two different commercially available methods in a military-deployed setting. The results presented here are foundational for the future design of fecal microbiome study protocols in an operational context.

field study↗

DOE OSTI2025

Distributed Acoustic Sensing for Whale Vocalization Monitoring: A Vertical Deployment Field Test

Abstract There is growing interest in floating offshore wind turbine (FOWT) technology, where turbines are installed on floating structures anchored to the seabed, allowing wind energy development in areas unsuitable for traditional fixed-platform turbines. Responsible development requires monitoring the impact of FOWTs on marine wildlife, such as whales, throughout the operational lifecycle of the turbines. Distributed acoustic sensing (DAS)—a technology that transforms fiber-optic cables into vibration sensor arrays—has been demonstrated for acoustic monitoring of whales using seafloor telecommunications cables. However, no studies have yet evaluated DAS performance in dynamic, engineered environments, such as floating platforms or moving vessels with complex, dynamic strain loads, despite their relevance to FOWT settings. This study addresses that gap by deploying DAS aboard a boat in Monterey Bay, California, where a fiber-optic cable was lowered using a weighted and suspended mooring line, enabling vertical deployment. Humpback whale vocalizations were captured and identified in the DAS data, noise sources were identified, and DAS data were compared to audio captured by a standalone hydrophone attached to the mooring line and a nearby hydrophone on a cabled observatory. This study is unique in: (1) deploying DAS in a vertical deployment mode, where noise from turbulence, cable vibrations, and other sources posed additional challenges compared to seafloor DAS applications; (2) demonstrating DAS in a dynamic, nonstationary setup, which is uncommon for DAS interrogators typically used in more stable environments; and (3) leveraging looped sections of the cable to reduce the noise floor and mitigate the effects of excessive cable vibrations and strain. This research demonstrates DAS’s ability to capture whale vocalizations in challenging environments, highlighting its potential to enhance underwater acoustic monitoring, particularly in the context of renewable energy development in offshore environments.

Saw, Jaewon↗

DOE OSTI2021

FTS3: Data Movement Service in containers deployed in OKD [Slides]

The File Transfer Service (FTS3) is a data movement service developed at CERN which is used to distribute the majority of the Large Hadron Collider's data across the Worldwide LHC Computing Grid (WLCG) infrastructure. At Fermilab, we have deployed FTS3 instances for Intensity Frontier experiments (e.g. DUNE) to transfer data in America and Europe, using a container-based strategy. In this article we summarize our experience building docker images based on work from the SLATE project (slateci.io) and deployed in OKD, the community distribution of Red Hat OpenShift. Additionally, we discuss our method of certificate management and maintenance utilizing Kubernetes CronJobs. Finally, we also report on the two different configurations currently running at Fermilab, comparing and contrasting a Docker-based OKD deployment against a traditional RPM-based deployment.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2022

Michigan Hydrogen and Fuel Cell Electric Vehicle Deployment Plan: H2 FCEV Roadmap 2022

This report describes a roadmap for hydrogen fuel cell electric vehicles in the state of Michigan. This plan provides links to relevant information to assess, plan, and initiate hydrogen and FCEV deployment to help meet the energy, economic, and environmental goals for the State of Michigan. Policies and incentives that support hydrogen and fuel cell technology will increase deployment, thus increasing production and creating jobs throughout the supply chain. As deployment increases, an economy of scale will develop and manufacturing costs will decline, positioning hydrogen and fuel cell technology to compete more effectively in a global market without incentives. Policies and incentives to purchase and support the deployment of FCEVs, FCEBs, and hydrogen refueling can be coordinated regionally to maintain this advanced clean transportation sector as a global exporter for long-term growth and economic development. Overall, the execution of this plan will maintain Michigan's role as a global showcase for regionally manufactured transportation technology while reducing NOx and CO 2 emissions and as new jobs are created for businesses and industry.

08 HYDROGEN↗

DOE OSTI2023

Deployment of Dynamic Neural Network Optimization to Minimize Heat Rate During Ramping for Coal Power Plants (Final Technical Report)

Much success was achieved throughout the course of this project. A successful implementation of Dynamic Neural Network Optimization (D-NNO) was coupled with Adaptive Predictive Controls (APC) and a novel hardware installation comprised of an advanced sensor network (ASN) measuring mass-weighted averages of flue gas constituents above the horizontal superheater of a coal-fired utility boiler. From 2019 through 2023 (including an extension due to COVID delays), the team was able to prototype, evaluate, deploy, iterate, and ultimately finalize an advanced closed-loop control D-NNO system which demonstrated the ability to: •improve unit efficiency ~2.0% relative to unoptimized operation (represented as total fuel fired per MWh generated) •improve unit NOx emission rates 10%+ beyond static optimization baselines •improve unit temperature stability as much as 58% and on average 12% •improve operating load stability as much as 35% The culmination of this project has generated an advanced methodology of deploying specially designed recurrent neural networks (long short-term memory, gated recurrent unit, encoder-decoder networks, transformers, etc.), customized trajectory planning and closed-loop optimization modules capable of adapting to live electric grid responses and demands, self-tuning and adaptive expert controls constantly adjusting prediction parameters to real-time unit behavior, and a hardware/software package able to reliably calculate net unit heat rate (NUHR) in real-time using flue gas constituents, machine learning, and known combustion relationships. Through this real-time NUHR value, immediate feedback on system adjustments relative to operating efficiency was available, allowing for rapid improvements to system performance. In addition to development and deployment of the advanced D-NNO system, the approach methodology has been readily commercialized through the project platform Griffin Open Systems, LLC, the D-NNO software platform host. Similar methodologies to those developed by this project have already been deployed at 5 other units across the United States, with another 6 implementations scheduled, and more expected. Over the course of the project, multiple academic papers were submitted and accepted for publication within esteemed academic journals, and PhD students were trained and graduated, as well as undergraduate students becoming involved and participating to project objectives.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2024

Journey Mapping Distributed Wind Deployment: Installer Perspectives

This work uses journey maps to assess the deployment of distributed wind technologies through the perspective of installers. Journey mapping is a human-centered design method that chronologically traces processes from the perspective of those who participate in them. The journey map will be leveraged to identify deployment pain points (i.e., manifestations of generic deployment barriers) that the Strategize, Engage, Network and Deploy (SEND) Distributed Wind project team will seek to address in future work.

17 WIND ENERGY↗

DOE OSTI2024

Adaptive Protection and Validated Models to Enable Deployment of High Penetrations of Solar PV (PV-MOD)

The availability and validation of various PV models in commercial tools differ, with some models not yet thoroughly validated for advanced inverter functionalities and reliable performance under weak system conditions. Many existing models do not fully incorporate new inverter control functions, which can affect system stability. The increasing deployment of solar PV and other inverter-based resources (IBRs), including distributed energy resources (DERs), is influencing the reliable operation of protection schemes in distribution systems and microgrids. Emerging adaptive protection schemes (APS) offer new opportunities for protecting these systems during varying configurations and DER operating conditions, though their demonstration and validation remain limited. Adaptive protection schemes face similar challenges, as they are typically designed for specific configurations. There is a growing need for tools and methodologies to streamline the deployment of adaptive protection for safe and reliable DER integration. The project main objective was to develop and validate high-fidelity generic models of solar PV facilities for stability, protection, EMT, and QSTS analyses. This objective was achieved, and these models can now be integrated into commercial software tools, enabling utilities, vendors, and developers to study high-penetration PV systems more confidently. The project also demonstrated advanced applications of these models, including the design and deployment of adaptive protection schemes in high-penetration field applications and microgrids, supporting grid safety and reliability. Several milestones were reached by the end of the project. A sophisticated inverter test plan was developed, and inverters representative of the North American marketplace were selected. EPRI and NREL tested various inverters, conforming to IEEE standards. Improvements were made to existing generic models of IBR units, IBR plants, and aggregated feeders for various analyses. The first generic electromagnetic transient (EMT) model for a solar PV plant was developed, conforming to IEEE Std 2800™-2022 and validated against laboratory measurements of a 2.2 MVA large-scale battery energy storage system (BESS) inverter. That model was then used to produce reference responses illustrating examples of validated and verified IBR plant models that pass or fail tests for technical minimum capability and performance as specified in the IEEE standard. The developed, tested, and validated generic models can be used for transmission planning, stability assessments, expansion planning, and evaluating potential future IBR interconnection requirements. They can also support interconnection screens and conformity assessments of IBR plants, including solar PV. The project significantly contributed to the ongoing standardization and model-based representation and verification of IBR responses. The project further addressed challenges of common distribution protection schemes with increasing deployment of DER by developing, validating, and demonstrating adaptive protection schemes (APS) that can improve the reliable and safe integration of DER into distribution systems. New APS were designed using improved DER models for three common distribution systems: a radial feeder, a meshed network, and a microgrid. Modeling and hardware-in-the-loop (HIL) testing of the APS were conducted, successfully showing their effectiveness and selectivity. Proof-of-concept field demonstration was achieved for two APS, i.e., one on a radial feeder and another one in a microgrid. Field demonstration could not be achieved for the APS on a meshed network, primarily due apprehension of one utility partner and also due to limited access to the protective algorithms in the network protectors. Guidelines developed from the lessons learned in the project lay out the general process followed in the design, installation, and commissioning of APS for various distribution systems. Distribution utility partners’ apprehension about field demonstration of the new APS were addressed—with varying success—by taking a stepped risk-management approach of modeling of a wide range of sensitivities first, performing in-depth proof-of-concept testing in the laboratory including HIL next, and finally deliberately implementing and commissioning the actual protection equipment and algorithms into parts of—or in parallel operation to—the three real distribution systems. Future work should include pilot projects that further show the acceptable performance of the developed APS before these schemes be rolled out more widely. Inclusion of both utility and original equipment manufacturers (OEMs) in future projects could increase chances of successful field demonstration. Despite challenges in achieving the field demonstration goal of the project for all three APS, the research significantly contributed to the innovation of adaptive protection solutions for scalable and reliable DER integration into distribution systems. This project significantly enhances the understanding of the impact of using appropriate inverter models on distribution and transmission (T&D) systems. By addressing the limitations of existing generic models, the project introduces high-fidelity models for stability, protection, electromagnetic transient (EMT), and quasi-static time series (QSTS) analyses. These models, integrated into commercial software tools, enable utilities, vendors, and developers to confidently study high-penetration PV systems. The project also demonstrates advanced applications, including adaptive protection schemes (APS) for distribution systems and microgrids, ensuring grid safety and reliability. The technical effectiveness and economic feasibility of the methods are evident through the development and validation of sophisticated inverter test plans and the selection of representative inverters. Testing by EPRI and NREL on retail, commercial, and utility-scale inverters, conforming to IEEE standards, underscores the robustness of the models. Improvements to existing generic models for various analyses further enhance their validity and applicability. The project also identifies gaps in common distribution protection schemes and designed new APS using improved DER models, demonstrating their effectiveness through modeling and hardware-in-the-loop (HIL) testing. The project’s benefits to the public are manifold. By advancing the standardization and model-based representation of IBR response, it supports transmission planning, stability assessments, and future IBR interconnection requirements. The generic models can facilitate better communication between transmission planners and developers, supporting expected IBR plant capability and performance. Additionally, the development of APS for radial feeders, meshed networks, and microgrids supports the integration of distributed energy resources (DERs) into distribution systems, enhancing grid reliability and safety. The project’s emphasis on thorough testing and simplicity in design ensures practical and scalable solutions for DER integration.

14 SOLAR ENERGY↗

DOE OSTI2021

Deployment of salt sample extraction system at an engineering-scale electrorefiner

The goal of the salt sampling program at Argonne is to develop and deploy automated molten salt sampling approaches for interfacing relevant unit operations with salt analysis to improve the timeliness of sampling-based accountancy measurements. Two technologies under development in support of this goal are a vacuum sampling loop module and a high-throughput pneumatic sample generator module. Compared to traditional point sampling approaches (i.e., dip probes), the vacuum sampling loop facilitates the collection of a larger cross-section of the bulk salt in order to collect more representative samples. The vacuum sampling approach also eliminates the risk of dross contamination of samples and avoids the use of moving parts in the salt. The pneumatic sample generator module is used to facilitate high-throughput sample analysis to improve the measurement precision of any given analytical technique by averaging out random sampling and measurement errors. In FY21, two methods for integrating these two modules were tested including direct fluidic coupling and coupling using a solid salt transfer mechanism. Solid salt transfer was ultimately selected over fluidic coupling, primarily to enable the transport of samples over longer distances to support automated at-line integration with high-precision techniques (such as microcalorimetry) that cannot withstand the conditions near an electrorefining process. To facilitate rapid solid salt coupling, new mechanisms were developed for rapidly charging and discharging salt sample tubes at the vacuum sampling loop and pneumatic sample generator modules, respectively. While the charging mechanism will be deployed in FY22, the discharge mechanism was tested in FY21 and is described here. The solid salt tube transfer method was deployed at one of Argonne’s engineering-scale electrorefiners to implement at-line high-throughput pneumatic micro-sample generation capabilities. The approach was used to generate precise uranium- and lanthanide-bearing electrorefiner micro-samples with the specific dimensions requested by researchers at Los Alamos National Laboratory for use in testing their novel microcalorimeter x-ray techniques. The solid salt transfer mechanism proved not only to be an effective means of integrating the precision sample generator with vacuum sampling, but also improved the performance of the sampler generator. To discharge salt from the sample tubes at the sampler generator, tube segments were inserted directly into the sample generator’s Helmholtz chamber and pressure pulse actuations were used to generate precision molten salt samples directly from the tube segments. The direct insertion of sample tubes into the sample generator enabled rapid loading of the salt and prevented salt from contacting most of the interior surfaces of the sample generator, which eliminated cross-contamination between runs. The vacuum sampling-loop tube charging mechanism will support high-throughput tube sampling operations by employing a dynamic vacuum filling process to fill short charge tubes that are configured to be rapidly connected and disconnected from the loop. The dynamic vacuum sampling operation will be automated, and sample tube handling can be executed with simple overhead actuation. Because the modular sampling approach described here eliminates the need for new high-radiation sample handling capabilities, salt-wetted seals, salt-wetted moving parts, and heated transfer lines outside the electrorefiner, it will address most of the remaining technical challenges for the at-line deployment of high-precision analytical techniques which will enable significant reductions in the time delay for sampling-based high-precision accountancy measurements.

42 ENGINEERING↗

DOE OSTI2025

ThunderDOEME: A Seismoacoustic Deployment at Langmuir Observatory

This report documents a two-month deployment of seismoacoustic instrumentation at the Langmuir Observatory, located outside Socorro, New Mexico. A total of eleven Fairfield Nodal Seismometers and fifteen GEM infrasound loggers were deployed from June 2 to August 5, 2025. The nodal seismometers recorded data for an average of 34 days, while the GEMs had variable operational durations throughout the deployment period. The primary objective was to capture thunder signals using seismoacoustic instrumentation, contributing to a better understanding of the acoustic and seismic phenomena associated with thunder. Coinciding with this deployment, optical and electric field sensors were present, providing information regarding the timing and location of lightning strikes in the region. Additionally, triggered lightning strikes were conducted, serving as a ground truth for validating the captured thunder signals. Preliminary analysis of the data reveals clear thunder signals in both the seismic and infrasound recordings, with peak frequencies observed across a range of 4 to 40 Hz, depending on the event.

47 OTHER INSTRUMENTATION↗

DOE OSTI2022

Generating Sequential PV Deployment Scenarios for High Renewable Distribution Grid Planning: Preprint

ENERGY PLANNING, POLICY, AND ECONOMY,SOLAR ENERGY↗

DOE OSTI2022

Licensing, Regulations and Developing Guidance for Nuclear Technology Deployment for Embarking countries in Africa

The African region is witnessing an increased number of countries at different stages of implementing or considering the introduction of peaceful nuclear power programs to meet the demand of their rapidly growing economies as well as clean energy needs. Grid size, cost, licensing, and regulations will be some of the challenges to deploying larger power reactors. A key element of the regulatory framework will be the inclusion of nuclear security information and assurance that security is integrated into the license review process.As each country continue to implement and consider different reactor designs from several vendors, the significance of customer knowledge of licensing, Regulations, and guidance document to facilitate the deployment and operational needs for nuclear technology cannot be over-emphasized. This special session will bring together a selected panel of key stakeholders and policymakers from embarking countries in Africa to participate in a panel discussion to share their experience in the licensing, regulations, and development of guidance for power plant deployment. The session will also consider and identify potential gaps that may affect the licensing and regulatory applications for the future nuclear infrastructure. As well, the panel will promote regional networking and communication to increase capacities in readiness for the potential deployment of additional technology, such as Small Modular Reactors.

Dahunsi, Stephen↗

DOE OSTI2024

Ad-Mat: Adaptations of Mature Manufacturing Strategies for Accelerated Redox Flow Battery Deployment

The concept of the Ad-Mat approach is to leverage existing adjacent markets across a broad scope of technologies in order to reduce the manufacturing learning curve and ultimately accelerate redox flow battery (RFB) deployment at scale. Lithium-ion batteries (LIBs) are currently the dominant energy storage technology, and they came to technological maturity under unique market conditions when there was no meaningful competition in the consumer electronic and electric vehicle (EV) space. Today, alternative chemistries that may be technologically better-suited for long-duration storage applications are experiencing a high barrier to entry. This is in large part due to the substantial bias towards the scaled-up production and supply chain that now exists for LIBs. In the case of RFBs in particular, numerous analyses have suggested that RFBs should theoretically have a much lower system cost than LIBs - however, this relies on a mature and competitive manufacturing landscape, which has been extremely challenging to achieve for both flow batteries and other LIB competitors. At the moment, LIB alternatives tend to have isolated small-scale manufacturing pathways, which preclude the economies of scale that would be required to compete with the mature LIB industry. In the present state of the industry, niche manufacturing tools and approaches have evolved to support each alternative technology, such that there is substantial replication and duplication in effort. Continuing to pursue a strategy of isolated manufacturing processes/approaches for each LIB-alternative may never allow for at-scale deployment. In order for RFBs to meaningfully compete with LIBs in the realm of LDES, a new disruptive approach based on cross-industry learning and coordination is needed - and this is exactly what our Ad-Mat concept aims to tackle. In this re-envisioned manufacturing landscape, tools and processes from mature industries can be adapted and deployed across the range of alternative energy storage technologies. Adapting tools, equipment, processes, and industrial learning from mature industries to meet the technological requirements of RFBs would open new markets for existing OEMs in adjacent industries, would prevent unnecessary duplication and re-development, would improve efficiency across the manufacturing chain, and would ultimately support reduced costs and accelerated deployment of RFBs at scale.

adaptive manufacturing↗

DOE OSTI2024

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

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

composite manufacturing↗