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DOE OSTI2021

Traveling wakefield tube: THz source powered by nonrelativistic electron beam

High peak power, tunable, narrowband terahertz emitters are becoming sought after given their portability, efficiency, and ability to be deployed in the field for industrial, medical, and military applications. The use of accelerator systems producing THz frequencies via Cherenkov radiation, generated by passing an electron beam through a slow-wave wakefield structure, is a promising method to meet future THz requirements. To date, efforts have been dedicated to analysis and design of sources utilizing laser seeded bunched electron beam drivers with relativistic energies beyond 5 MeV. Presented here is a wakefield THz generation scheme based on passing a long quasi-dc nonrelativistic beam (200 keV) through a dielectric loaded travelling wave structure. Reduced energy allows for compactness and portability of the accelerator as the size and weight of the dielectric slow wave structure is vanishingly small compared to the accelerator unit. The presented scheme can serve as a tunable high peak power THz source operated between 0.4-1.6 THz and produces power gain by a factor of five with an average efficiency of 6.8%

43 PARTICLE ACCELERATORS↗

DOE OSTI2026

Machine learning of factors for improving oyster hatchery production

Oyster aquaculture and restoration in the Chesapeake Bay are vital, yet hatcheries frequently struggle with inconsistent larval growth and sudden mass mortality events. Unpredictable disruptions in larval production cause large economic losses, represent a perceived risk to growers, and impede industry expansion. To better understand associations between production yield and its potential predictors, we applied machine learning (random forest, and neural network) and statistical (generalized additive model) models to a comprehensive dataset of environmental, water quality, and operational parameters from a Maryland oyster hatchery, aiming to identify key yield predictors and develop a robust forecasting tool. We used recursive Boruta algorithm for variable selection, pinpointing critical predictors, and employed cross-validation to fine-tune model settings. Shapley value analysis offered crucial insights into model interpretations, highlighting week number, Normalized Difference Vegetation Index, salinity, turbidity, and fecundity as primary drivers of yield variability. For low-yield cases, salinity-related variables were particularly important. Our findings provide an early warning system for potential production downturns, empowering hatchery operators to make data-driven decisions for optimizing water conditions, feeding schedules, and broodstock management. By boosting predictability and efficiency, this research directly supports economic stability of the oyster industry and ecological health of the Chesapeake Bay.

Vishwakarma, Srishti [Oak Ridge National Laborator↗

DOE OSTI2025

2024 Stor4Build Annual Meeting: Exploring Challenges and Opportunities in Thermal Energy Storage for Buildings

In late August 2024, Stor4Build brought nearly 80 stakeholders from the thermal energy storage industry to Oak Ridge National Laboratory (ORNL), including researchers, startups, electric utilities, nonprofits, implementers, state energy efficiency offices, and original equipment manufacturers. During the two-day Stor4Build Annual Meeting, participants engaged in vital discussions about the current challenges and opportunities for scaling thermal energy storage solutions in buildings. The event featured panel discussions led by leading technology experts and industry practitioners, as well as updates on Stor4Build–funded projects from national laboratories, highlighting advancements in the thermal energy storage field crucial to achieving the consortium’s mission.

25 ENERGY STORAGE↗

DOE OSTI2023

A review of artificial intelligence applications in manufacturing operations

Abstract Artificial intelligence (AI) and machine learning (ML) can improve manufacturing efficiency, productivity, and sustainability. However, using AI in manufacturing also presents several challenges, including issues with data acquisition and management, human resources, infrastructure, as well as security risks, trust, and implementation challenges. For example, getting the data needed to train AI models can be difficult for rare events or costly for large datasets that need labeling. AI models can also pose security risks when integrated into industrial control systems. In addition, some industry players may be hesitant to use AI due to a lack of trust or understanding of how it works. Despite these challenges, AI has the potential to be extremely helpful in manufacturing, particularly in applications such as predictive maintenance, quality assurance, and process optimization. It is important to consider the specific needs and capabilities of each manufacturing scenario when deciding whether and how to use AI in manufacturing. This review identifies current developments, challenges, and future directions in AI/ML relevant to manufacturing, with the goal of improving understanding of AI/ML technologies available for solving manufacturing problems, providing decision‐support for prioritizing and selecting appropriate AI/ML technologies, and identifying areas where further research can yield transformational returns for the industry. Early experience suggests that AI/ML can have significant cost and efficiency benefits in manufacturing, especially when combined with the ability to capture enormous amounts of data from manufacturing systems.

Plathottam, Siby Jose↗

DOE OSTI2023

Pilot Business Case Analysis for Digital Infrastructure

The Inflation Reduction Act Has Provided an Opening to Dramatically Change and Improve the Economics of Nuclear Power Until recently, the commercial nuclear sector has faced unprecedented financial challenges driven by low natural gas prices and subsidized renewables, in a marketplace that did not reward carbon-free baseload capacity. The industry is also plagued by labor shortages, increasingly obsolete labor-centric operating models and antiquated analog technology that threaten the viability of the long-term operations of domestic nuclear facilities. In this context, the economic survival of nuclear power plants requires an efficient and technology-centric operating model that harvests the native efficiencies of advanced technology. Such transformations have been made in many other industries – notably, oil and gas. The passage by Congress of the Inflation Reduction Act (IRA) in 2022 provides nuclear operators with unprecedented economic incentives to pursue these upgrades. To realize the benefits of these incentives and achieve the necessary transformations in the nuclear operating model, the nuclear industry must overcome both the continuing unease about licensing pathways and uncertainty related to implementation costs.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

NASA NTRS2018

Turbine Electrified Energy Management (TEEM) For Enabling More Efficient Engine Designs

NASA is investing in Electrified Aircraft Propulsion (EAP) research as part of an effort to assist industry in meeting the future needs of a global aviation market. The integration of electric machines into traditional turbine-based propulsion provides opportunities to change system architectures effecting radical improvements in propulsive efficiency. However, less consideration has been afforded to the utilization of these electrical machines to improve the thermal efficiency and performance of the gas turbine engine. Noting this deficit, a novel operability concept is proposed and is referred to as Turbine Electrified Energy Management (TEEM). The concept is a transient control technology that supplements the main fuel control for the suppression of the natural off-design dynamics associated with changes in engine operating state. Here the electric machines, used as engine actuators during the transient, add or extract torque from the engine shafts to maintain the speed-flow characteristics of steady-state design operation. This greatly reduces the need to maintain transient stall margin stack in the compressors, among other potential benefits. This paper demonstrates the feasibility of the concept in dynamic simulation using a Numerical Propulsion System Simulation (NPSS) engine model of a NASA hybrid electric propulsion concept known as the Parallel Hybrid Electric Turbofan (hFan).

Culley, Dennis E.↗

DOE OSTI2023

A Case Study of Luminaire-Level Lighting Control: Lighting the Northwest Energy Efficiency Alliance (NEEA) Office in Portland, OR

What happens when advanced lighting and control systems are installed in the real world? Are the advantages and energy savings realized? By observing the design, installation, commissioning, and ongoing use of connected lighting systems in real-world settings, it is possible to identify the strengths, challenges, and points of human-technology interaction that may be new or unfamiliar to those responsible for implementing or maintaining the lighting system. Ultimately, understanding and experiencing each stakeholder’s interaction with the technology can allow the research team to synthesize feedback for manufacturers, improve industry understanding of the technology, and increase adoption. The Northwest Energy Efficiency Alliance (NEEA) office in Portland, OR, is a single-floor installation that puts tunable-white, interoperability, and luminaire-level advanced control capabilities to the test. Compared to simpler, “out-of-the-box” systems that minimize field-adjustable settings, the system utilized in this space allowed for granular field adjustments which required the system specifier, client, and programming agent to make additional decisions regarding system operation while the system was being programmed. This report communicates the observational findings from the installation, programming, and ongoing operation of an advanced office LLLC system.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2020

Critical Materials Supply Chain White Paper (April 2020)

The DOE Office of Energy Efficiency and Renewable Energy (EERE) Advanced Manufacturing Office (AMO) partners with industry, small business, universities, and other stakeholders to identify and invest in emerging technologies with the potential to create high-quality domestic manufacturing jobs and enhance the global competitiveness of the United States

Advanced Manufacturing Office↗

NASA NTRS2021

Air Pollution Trends Measured From Terra: CO and AOD Over Industrial, Fire-prone, and Background Regions

Following past studies to quantify decadal trends in global carbon monoxide (CO) using satellite observations, we update estimates and find a CO trend in column amounts of about −0.50 % per year between 2002 to 2018, which is a deceleration compared to analyses performed on shorter records that found −1 % per year. Aerosols are co-emitted with CO from both fires and anthropogenic sources but with a shorter lifetime than CO. A combined trend analysis of CO and aerosol optical depth (AOD) measurements from space helps to diagnose the drivers of regional differences in the CO trend. We use the long-term records of CO from the Measurements of Pollution in the Troposphere (MOPITT) and AOD from the Moderate Resolution Imaging Spectroradiometer (MODIS) instrument. Other satellite instruments measuring CO in the thermal infrared, AIRS, TES, IASI, and CrIS, show consistent hemispheric CO variability and corroborate results from the trend analysis performed with MOPITT CO. Trends are examined by hemisphere and in regions for 2002 to 2018, with uncertainties quantified. The CO and AOD records are split into two sub-periods (2002 to 2010 and 2010 to 2018) in order to assess trend changes over the 16 years. We focus on four major population centers: Northeast China, North India, Europe, and Eastern USA, as well as fire-prone regions in both hemispheres. In general, CO declines faster in the first half of the record compared to the second half, while AOD trends show more variability across regions. We find evidence of the atmospheric impact of air quality management policies. The large decline in CO found over Northeast China is initially associated with an improvement in combustion efficiency, with subsequent additional air quality improvements from 2010 onwards. Industrial regions with minimal emission control measures such as North India become more globally relevant as the global CO trend weakens. We also examine the CO trends in monthly percentile values to understand seasonal implications and find that local changes in biomass burning are sufficiently strong to counteract the global downward trend in atmospheric CO, particularly in late summer.

carbon monoxide↗

DOE OSTI2025

Enhancement of PyARC for Westinghouse Electric Company’s Lead Fast Reactor Design and Modeling (Final TCF Report)

Westinghouse Electric Company is a nuclear reactor vendor headquartered in the U.S. that is developing advanced reactor technology for the U.S. and global markets. Westinghouse has been relying on the neutronics Argonne Reactor Codes (ARC) executed through the NEAMS Workbench and its PyARC module that are developed under the DOE-NE Nuclear Energy Advanced Modeling and Simulation (NEAMS) and Advanced Reactor Technology (ART) – Fast Reactor programs. Through this user experience, Westinghouse identified several enhancements that would benefit the ARC codes’ usability by the US industry and therefore its commercialization potential. The enhancements were proposed to deliver both improvements in workflow and analysis capabilities to better support effective fast reactor core design and analysis to the nuclear industry. The PyARC workflow was extended in this project by integrating non-neutronic ARC codes DASSH and NUBOW-3D. The Ducted Assembly Steady-State Heat equation (DASSH) code is developed at ANL to perform steady-state thermal hydraulic sub-channel analysis in liquid metal fast reactor assemblies to determine optimized coolant flow and temperature distributions, which in this project was updated and validated for lead fast reactor (LFR) applications. The interface between REBUS and NUBOW-3D were improved in this project to assess the impact of the core restraint design and thermal induced expansion effects on the reactivity of the core, and to model the deformations of the fuel assemblies induced by temperature and irradiation. Finally, the ARC models that were extensively verified and validated through various SFR-based modeling benchmarks are extended in this project through code-to-code comparison on relevant LFR-specific neutronics benchmarks against Monte-Carlo neutronic solutions. Overall, this work enables verification of the capability of the ARC codes for a wide range of Generation-IV reactor designs. The outcome of this project is the release of a comprehensive modeling toolkit of validated, robust and efficient codes, as well as their user interface, that enables industry to perform a wide range of fast reactor analyses for design and licensing of their concepts.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2020

Update of Emission Factors of Greenhouse Gases and Criteria Air Pollutants, and Generation Efficiencies of the U.S. Electricity Generation Sector

The last decade has seen a steady evolution of the electricity generation sector. Fuels used for electricity generation have shifted from coal to cleaner energy sources such as natural gas and renewables including solar, wind, and other renewable sources. The share of U.S. electricity generated from coal decreased from 45% in 2010 to 24% in 2019, and is expected to decrease further to 13% by 2050. The conversion efficiency of electricity generation has also increased gradually for fuels such as natural gas due as less-efficient old generators are retired and more-efficient generators replace them. These changes in the electricity generation industry are likely to cause changes in the emissions from power generation units. Emission factors of greenhouse gases (GHG) including CO 2 , CH 4 , and N 2 O, and criteria air pollutants (CAPs) including CO, NO x , PM 10 , PM 2.5 , and SO x , from power plants are important parameters for estimating life-cycle emissions associated with vehicle electrification, energy systems, and the production of materials and chemicals. The electricity generation technologies and associated emission factors in the Greenhouse Gases, Regulated Emissions, and Energy Use in Technologies (GREET) model need to be updated to reflect recent developments in the electricity generation sector. The most recent update of the electricity generation emission factors in GREET adopted a mixed method. The emission factors of CH 4 , N 2 O, NO x , and SOx were estimated using a “topdown” approach by dividing the total emissions by the total net electricity generation, because emission data of these pollutants are readily available in the Emissions & Generation Resource Integrated Database (eGRID). For other CAPs such as CO, VOC, PM 10 , and PM 2.5 , emission data were not reported in eGRID. A “bottom-up” method was used to estimate the emission factors for these pollutants by considering generic uncontrolled emission factors and the pollutant removal efficiencies of emission control technologies adopted in the electricity generation sector. However, the uncontrolled emission factors and the emission removal efficiencies of various emission control technologies considered in the 2012 study came from the legacy AP-42 emission factors, and may not reflect the actual emission performances of the electricity generation sector of today. To leverage new data that recently became available, especially emission data measured from continuous emission monitoring systems (CEMS), we developed a new “top-down” approach to estimate efficiencies and GHG and CAP emission factors for electricity generation from combustion of individual fuel types by individual combustion technologies on the basis of power-generation data from U.S. Energy Information Administration’s (EIA’s) form EIA-923, and plant emission data from Environmental Protection Agency’s (EPA’s) Clean Air Markets Division (CAMD) dataset and National Emissions Inventory (NEI) dataset. Detailed discussion of the method and data used in this study can be found in Section 2.1. With this topdown approach, we aim to improve the estimates of energy efficiencies and emission factors for power plants using a more consistent methodology, and to update the emission factors, generation efficiencies, and generation technologies mixes in GREET to reflect recent technology advancements in the electricity generation sector.

20 FOSSIL-FUELED POWER PLANTS↗

NASA NTRS1996

Performance Analysis of Two Early NACA High Speed Propellers with Application to Civil Tiltrotor Configurations

The helicopter industry is vigorously pursuing development of civil tiltrotors. One key to efficient high speed performance of this rotorcraft is prop-rotor performance. Of equal, if not greater, importance is assurance that the flight envelope is free of aeroelastic instabilities well beyond currently envisioned cuise speeds. This later condition requires study at helical tip Match numbers well in excess of 1.0. Two 1940's 'supersonic' propeller experiments conducted by NACA have provided an immensely valuable data bank with which to study prop-rotor behavior at transonic and supersonic helical tip Mach numbers. Very accurate 'blades alone' data were obtained by using nearly an infinite hub. Tabulated data were recreated from the many thrust and power figures and are included in two Appendices to this report. This data set is exceptionally well suited to re-evaluating classical blade element theories as well as evolving computational fluid dynamic (CFD) analyses. A limited comparison of one propeller's experimental results to a modem rotorcraft CFD code is made. This code, referred to as TURNS, gives very encouraging results. Detailed analysis of the performance data from both propellers is provided in Appendix A. This appendix quantifies the minimum power required to produce usable prop-rotor thrust. The dependence of minimum profile power on Reynolds number is quantified. First order compressibility power losses are quantified as well and a first approximation to design air-foil thickness ratio to avoid compressibility losses is provided. Appendix A's results are applied to study high speed civil tiltrotor cruise performance. Predicted tiltrotor performance is compared to two turboprop commercial transports. The comparison shows that there is no fundamental aerodynamic reason why the rotorcraft industry could not develop civil tiltrotor aircraft which have competitive cruise performance with today's regional, turboprop airlines. Recommendations for future study that will insure efficient prop-rotor performance to well beyond 400 knots are given.

Harris, Franklin D.↗

DOE OSTI2025

Global Regulations for Sustainable Battery Recycling: Challenges and Opportunities

With the rapid expansion of transportation electrification worldwide, the demand for electric vehicles (EVs) has increased dramatically, creating new and sustainable growth opportunities for the global economy. However, as the most expensive component of EVs, lithium-ion batteries pose significant sustainability challenges due to raw material consumption and supply chain constrains, as well as the complexities of end-of-life battery disposal and recycling. To address these concerns, many countries are actively establishing regulations to promote sustainable pathways for battery reuse and recycling. Despite these efforts, existing battery recycling regulations remain often inefficient and vary significantly across different countries in legal enforcement, producer responsibility, waste classification, recycling targets, design standards, public engagement, and financial incentives, particularly given the complexities of the global supply chain and resource distribution within the battery industry. Understanding these regulatory differences and establishing a unified framework are therefore crucial to ensuring sustainable and efficient battery recycling. This review provides a comprehensive analysis of the necessity of establishing robust regulations for sustainable development of battery recycling industry. The evolution and refinement of battery recycling regulations are deeply reviewed to identifying persistent gaps and challenges in key countries. Furthermore, we discuss the challenges associated with regulatory enforcement and propose strategies for developing a more cohesive legislative framework to ensure the effective utilization of retired batteries.

25 ENERGY STORAGE↗

DOE OSTI2025

Multilayered Cu-Carbon Nanotube Composites for Advanced Conductors

Improving the efficiency of electrical components is critical in reducing energy consumption for various industrial and residential applications, ranging from rotating machinery to all electric devices and electric vehicle (EV) components to power grid systems. Substituting Cu wires with reduced resistance conductors that incorporate carbon nanotubes (CNTs) into Cu─ultraconductive Cu (UCC) composites─has recently been considered a promising strategy to improve energy efficiency, power density, and/or performance across various applications. Here, in this study, we created stable material formulations [CNT-containing polyvinylpyrrolidone (PVP) in dimethylformamide (DMF) solution] and utilized commercially viable fabrication approaches (electrospinning and magnetron sputtering) that produced high-performance multilayered tape-based UCC composite architectures. Increasing the CNT volume fraction by sequential layering of the structure with additional Cu-CNT layers showed a nearly stepwise improved performance in electrical and mechanical properties. This study also provides valuable insight into the effectiveness of nitrogen doping in modifying the conductivity of the CNT matrix. Fabricated prototypes demonstrated a >10% increase in current carrying capacity and >10% improvement in mechanical strength compared to those obtained on pure Cu. We believe that the properties demonstrated here, combined with the scalable manufacturing pathway of our approach, pave the way in designing future advanced conductors for diverse energy efficient and high-performance electrical systems and applications.

Carbon nanotubes↗

DOE OSTI2022

Scalable Gas Diffusion Electrode Fabrication for Electrochemical CO 2 Reduction Using Physical Vapor Deposition Methods

Electrochemical CO 2 reduction (ECR) promises the replacement of fossil fuels as the source of feedstock chemicals and seasonal storage of renewable energy. While much progress has been made in catalyst development and electrochemical reactor design, few studies have addressed the effect of catalyst integration on device performance. Using a microfluidic gas diffusion electrolyzer, we systematically studied the effect of thickness and the morphology of electron beam (EB) and magnetron-sputtered (MS) Cu catalyst coatings on ECR performance. We observed that EB-Cu outperforms MS-Cu in current density, selectivity, and energy efficiency, with 400 nm thick catalyst coatings performing the best. Additionally, the superior performance of EB-Cu catalysts is assigned to their faceted surface morphology and sharper Cu/gas diffusion layer interface, which increases their hydrophobicity. Tests in a large-scale zero-gap electrolyzer yielded similar product selectivity distributions with an ethylene Faradaic efficiency of 39% at 200 mA/cm 2 , demonstrating the scalability for industrial ECR applications.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Phonon-mediated quantum efficiency measurement in semiconductors

Accurate quantum efficiency measurement not only provides crucial information for the photovoltaic cell industry but also supports experiments aimed at directly detecting dark matter and elastic neutrino interactions. The dark matter direct searches paradigm has recently expanded to include particles with masses below 1,MeV/c2, where the expected signal in an electron–recoil interaction is approximately in the eV range, just above the energy gap for silicon and germanium. A robust calibration method for ionization signals in this lower energy region is essential. This paper presents a method for measuring quantum efficiency and yield (q/E) in semiconductors using phonon-mediated calorimetry. The Neganov–Trofimov–Luke phonon amplification method in low-temperature semiconductor crystals has been employed to indirectly measure ionization down to single-electron accuracy. Specifically, at zero bias, the phonon readout directly quantifies the total energy deposited within the detector, independent of the ionization yield. This eliminates a significant source of systematic uncertainty in quantum efficiency estimates associated with total energy uncertainty. The paper includes results from an updated ionization efficiency measurement in a germanium detector.

Physics↗

DOE OSTI2026

Impact of anion-exchange membrane degradation on long-term CO 2 electrolysis to ethylene

Electrochemical CO 2 reduction (eCO2R) to ethylene offers a unique opportunity to diversify domestic supply chains for chemical manufacturing. Large-scale deployment of eCO2R to ethylene reactors is currently limited by low energy efficiencies and poor durability. Herein, we demonstrate >100 h of continuous electrolysis at an industrially relevant current density of 200 mA cm −2 in a 25 cm 2 geometric area zero-gap reactor with a full-cell voltage <3.1 V and ethylene Faradaic efficiency >30%. Incorporating expanded polytetrafluoroethylene (PTFE)-supported electrodes into zero-gap reactors allows for durable electrode catalysts that are resistant to flooding, and this enables wider ranges of operating parameters not typically accessible in CO 2 electrolysis. Finally, we identify membrane degradation, evidenced by a loss of membrane ion-exchange capacity, as the leading cause of performance loss over 144 h of electrolysis.

Energy - Conversion↗

DOE OSTI2025

Revealing the potential of nickel zinc ferrite: Facile synthesis and cost-effective anode for lithium-ion batteries

The increasing demand for lithium-ion batteries (LIBs) underscores the need for cost-effective alternative anode materials to ensure efficient Li-ion storage, given their pivotal role in various industries. This research focuses on the facile synthesis of nickel zinc ferrite (NZFO: Ni 0.65 Zn 0.35 Fe 2 O 4 ) and conducts comprehensive electrochemical analyses to evaluate its potential as a high-capacity alternative anode material for LIBs. The NZFO-CMR [sodium carboxymethyl cellulose (2%) and styrene-butadiene rubber (1%)] exhibited an initial delithiated capacity of ∼1232 mA h g −1 and maintained a stable capacity of around 358 mA h g −1 , along with an average Coulombic efficiency of 99.6% over 200 cycles. Cyclic voltammetry analysis revealed that Li-ion insertion was predominantly governed by ion diffusion, and the consistent correlation observed in electrochemical impedance spectroscopy spectra indicated stable electrochemical behavior throughout cycling. The facile synthesis approach and reasonable electrochemical performance of NZFO suggest its potential as an alternative anode material for advancing LIB's technology.

25 ENERGY STORAGE↗