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

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All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Improving Coal-Fired Plant Performance Through Integrated Predictive and Condition-Based Monitoring Tools

The project demonstrated the ability to improve boiler performance and reliability through the integrated use of condition-based monitoring (CBM) and predictions of the impacts of coal quality on boiler operations at a full-scale coal-fired power plant. The advanced tool developed actively monitors and manages coal quality and overall boiler conditions that maximizes availability and maintains generating capacity while reducing cost. The tool is used to forecast and alert plant operators and engineers about poor boiler conditions which may occur as a result of incoming coal and/or current power plant operating conditions. The Combustion System Performance Indices (CSPI) and CoalTracker (CT) programs predicts fireside performance of the plant including slagging, fouling, erosion, slag flow, strength development (sintering/densification), and slag layer thickness based on the composition of delivered coal. CT program is tailored for each plant and is used to track the coal from the point of delivery to the burner. The most successful application of the CSPI-CT has been at plants where the coal composition is determined through the use of a full stream elemental analyzers based on prompt gamma neutron analysis (PGNAA). The CSPI-CT program information is used by coal procurement, coal mining and plant operations personnel to select and blend coal properties for the best plant performance.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2022

2020 Hydrogen and Fuel Cell Technologies Market Report

This report features summaries of relevant hydrogen and fuel cell activity in 2020, consistent with prior annual reports across applications and sectors. However, 2020 was no ordinary year. Despite pandemic hardships, the hydrogen and fuel cell industry not only stepped up to assist with humanitarian and healthcare efforts but saw continued momentum in several growing market sectors with numerous partnerships, initiatives, and investments. Using hydrogen and fuel cell technologies to provide an environmental and economic pathway to clean, reliable power was a key feature of world economic recovery and energy infrastructure plans. Today, hydrogen energy and fuel cell systems are being developed and deployed in a range of stationary power, portable power, and transportation applications around the world. Throughout 2020, there were significant achievements in each sector, building on years of research and development (R&D), field testing, large-scale demonstration projects, and real-world customer experience. The heavy-duty truck market in particular continued to make substantial gains, with new players entering the space and a coalition of companies pledging to produce and deploy more than 100,000 fuel cell trucks in the next two decades. To provide hydrogen for trucks and other end users, larger and larger electrolyzer projects were announced throughout the year. Collectively, there were more than 430 megawatts (MW) of electrolyzer systems either deployed, ordered, or proposed around the world. This 2020 report also provides special “Spotlights” on the collective industry response to the COVID-19 pandemic as well as international commitments and hydrogen strategies, providing overviews of significant activity during and after the initial onset of COVID-19 around the world.

08 HYDROGEN↗
DOE OSTI2022

Additively Manufactured Tamper Evident Container (TEC)

The protection of sensitive data, proprietary information, and physical assets from adversarial disclosure is a high priority in today’s environment of government and industrial espionage. Furthermore, knowledge of the security history and monitoring for potential acquisition or disclosure of the protected assets from oppositional sources is equally important. In 2016, as part of an LANL Institute for Materials Science (IMS) rapid response research initiative, the investigators of this technology demonstration project developed the concept of an additively manufactured tamper resistant container that possessed tamper evident features. Tamper evident seals and detection technologies have a long history in protecting consumers from product tampering, recording the installation and activation of mechanical safety panels and fasteners on dangerous electro-mechanical systems, and serving as a warranty void indicator on expensive electronic equipment. Examples of such tamper evident seals range from “no-tech” versions, e.g., the paper seals under medicine caps, to “high-tech” seals that are radio frequency-active and include encryption capabilities used by the International Atomic Energy Agency (IAEA) to monitor stored nuclear materials in support of safeguards missions. The tamper evident container (TEC) technology would have many uses.

36 MATERIALS SCIENCE↗
DOE OSTI2022

The Role of Innovation in the Electric Utility Sector

Innovation is essential for future power systems to be safe and secure, clean and sustainable, affordable and equitable, and reliable and resilient, according to a recent National Academies report. But state regulatory reforms are needed to encourage adoption of new technologies to support evolution of the nation’s power systems.1 Berkeley Lab's report, The Role of Innovation in the Electric Utility Sector, provides consumer, labor, utility, third-party provider, and clean technology consultant perspectives on this theme. To achieve state targets for clean energy and greenhouse gas emissions, some state regulatory utility commissions are exploring new approaches to spur innovation: -For utilities, regulatory and marketing flexibility, increased funding for demonstration projects, and performance-based ratemaking including multi-year rate plans -For third parties, ways to provide utility customers with innovative products and services directly Among the questions the report addresses: 1. How are consumer advocate views evolving with respect to innovative regulatory and ratemaking approaches? 2. How can utility decarbonization and grid modernization initiatives provide opportunities for local communities and workers to receive tangible benefits and facilitate community support for siting electricity infrastructure? 3. How are electric utilities partnering with technology companies to provide innovative energy management services and sustainable energy solutions for utility customers? 4. What regulatory innovations are public utility commissions exploring to enable third-party providers to participate in the transition to a modern electric system? 5. What regulatory changes are needed to enable innovative solutions from utilities and third parties at the necessary speed and scale to meet state decarbonization goals? The report is the 13th in the Future Electric Utility Regulation series, which taps leading thinkers to tackle complex regulatory issues for electricity. 1 National Academies of Sciences, Engineering, and Medicine. 2021. The Future of Electric Power in the United States. The National Academies Press.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2022

An Open-Source Framework for the Computational Analysis and Design of Autothermal Chemical Processes

The main project object was to develop software tools for simulating non-equilibrium autothermal processes, improving the prospects for identifying and designing such systems. The project demonstrates the use of these tools to simulate autothermal pyrolysis, a process recently developed at the pilot-plant scale at Iowa State University. In such process, instead of externally heating a reactor to pro-vide the enthalpy of pyrolysis, sufficient oxygen in the form of air is introduced into the reactor to support partial oxidation of reactants and products with the exothermic energy released supporting endothermic pyrolysis reactions. A fluidized bed is used to assure good mixing of biomass and oxidant and provide an isothermal reaction environment. The amount of oxygen required depends upon the kind of biomass being pyrolyzed and parasitic heat losses from the reactor. For example, for woody biomass pyrolyzed under conditions that simulate adiabatic operation, equivalence ratios can be as low as 0.06, compared to 0.20 or higher for autothermal gasifiers. By removing the heat transfer bottleneck of conventional pyrolysis, operation in autothermal mode allowed a significant increase in reactor throughput process, approaching five times the throughput of the conventionally operated pyrolyzer. Different simulation strategies were considered and developed: a zero-dimensional chemistry model was used to verify the applicability of kinetic schemes to predict biomass fast pyrolysis in autothermal conditions. Conventional chemical reactor models such as the plug flow reactor and the partially stirred reactor were used to investigate the role of mixing in the fluidized bed pyrolyzer and to establish the impact of mixing time on the gas-phase reactions. A comprehensive multiphase computational fluid dynamics (mCFD) framework, including polydisperse granular phase modeling and detailed chemical kinetics was formulated and used to model the experimental setup for autothermal biomass fast pyrolysis at ISU. Multiphase CFD was also used to investigate the role of biomass feed positioning on the mixing of biomass in the pyrolizer. Finally, a reduced order model (ROM), suitable to be implemented in process simulators was obtained. Both the mCFD and the ROM were validated against experiments.

09 BIOMASS FUELS↗
DOE OSTI2020

Validation of SAS4A/SASSYS-1 for Steady-State Single-Phase Natural Circulation

The development of numerical software for engineering applications requires the validation of the code against experimental benchmark datasets. To support the validation of SAS4A/SASSYS-1 in simulating the single-phase natural circulation within nuclear reactor systems, high-precision steady-state experiments are performed to capture single-phase natural circulation phenomena on an existing scaled facility with comprehensive instrumentation. Forced convection tests are designed precisely capturing the facility’s critical thermal-hydraulic parameters required for one-dimensional modeling, and a comprehensive single-phase natural circulation dataset is obtained with well-documented experimental uncertainty and facility description. Analysis and discussion based on the finalized dataset confirm the dataset’s ability in capturing dominant phenomena and address important physical interpretation of parameters. The dataset reported in this project provides a valuable benchmark resource for the validation of system analysis codes under single-phase natural circulation inside nuclear reactors. Validation of SAS4A/SASSYS-1 is then performed against the obtained benchmark dataset to confirm the capability of its physics model in simulating the steady-state single-phase natural circulation. The experimental facility is modeled in the candidate code. Solution verification is performed using Richardson-extrapolation-based estimators to quantify and restrict numerical errors from discretization. Numerical uncertainty originating from finite maximum pseudo-transient time is also quantified and restricted. Input uncertainty provided by the benchmark dataset is forward propagated through the candidate code, directly quantifying the simulation output in a Monte Carlo approach. The composition of the output uncertainty is further determined by the estimators of Sobol’ indices through a variance-based sensitivity analysis. With uncertainty quantified for each individual condition, detailed comparison between the simulation results and experimental data is performed covering the whole dataset, which shows consistent agreement for all important quantities. The validation activity reported in this project demonstrates that SAS4A/SASSYS-1 can predict the primary parameters with satisfactorily accuracy under steady-state single-phase natural circulation.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Update on the Investigation of Commercial Drying Cycles Using the Advanced Drying Cycle Simulator

The purpose of this report is to document updates on the apparatus to simulate commercial vacuum drying procedures at the Nuclear Energy Work Complex at Sandia National Laboratories. Validation of the extent of water removal in a dry spent nuclear fuel storage system based on drying procedures used at nuclear power plants is needed to close existing technical gaps. Operational conditions leading to incomplete drying may have potential impacts on the fuel, cladding, and other components in the system during subsequent storage and disposal. A general lack of data suitable for model validation of commercial nuclear canister drying processes necessitates well-designed investigations of drying process efficacy and water retention. Scaled tests that incorporate relevant physics and well-controlled boundary conditions are essential to provide insight and guidance to the simulation of prototypic systems undergoing drying processes. This report documents a new test apparatus, the Advanced Drying Cycle Simulator (ADCS). This apparatus was built to simulate commercial drying procedures and quantify the amount of residual water remaining in a pressurized water reactor (PWR) fuel assembly after drying. The ADCS was constructed with a prototypic 17×17 PWR fuel skeleton and waterproof heater rods to simulate decay heat. These waterproof heaters are the next generation design to heater rods developed and tested at Sandia National Laboratories in FY20. This report describes the ADCS vessel build that was completed late in FY22, including the receipt of the prototypic length waterproof heater rods and construction of the fuel basket and the pressure vessel components. In addition, installations of thermocouples, emissivity coupons, pressure and vacuum lines, pressure transducers, and electrical connections were completed. Preliminary power functionality testing was conducted to demonstrate the capabilities of the ADCS. In FY23, a test plan for the ADCS will be developed to implement a drying procedure based on measurements from the process used for the High Burnup Demonstration Project. While applying power to the simulated fuel rods, this procedure is expected to consist of filling the ADCS vessel with water, draining the water with applied pressure and multiple helium blowdowns, evacuating additional water with a vacuum drying sequence at successively lower pressures, and backfilling the vessel with helium. Additional investigations are expected to feature failed fuel rod simulators with engineered cladding defects and guide tubes with obstructed dashpots to challenge the drying system with multiple water retention sites.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

LCOE reduction through proactively optimized monitoring of PV Systems (Final Technical Report)

The project demonstrates the value proposition for a high-resolution monitoring system (HRMS) with diagnostic-prognostic capability and determine its impact on LCOE. The HRMS differs from conventional monitoring systems in a number of ways. First it will include the capability to automatically measure IV curves at the string and module levels. This provides a much richer view into the DC performance of the PV system and allows classification of many typical failure and degradation modes. Second, it will incorporate software capable of quantifying power and energy losses in the field as well as define the location and mechanism of the power and energy loss. Moreover, we aimed to deliver a prognostic system that is capable of predicting certain failures before they occur and giving system operators the opportunity to more efficiently plan operations and maintenance (O&M) activity in order to lower costs and increase yield over the life of the system. The research identifies cost targets required for different monitoring stages, including at the string combiner, at the individual string, and at the module level, to lower the levelized cost of energy (LCOE). Finally, a comprehensive guide determines the value PV monitoring brings to PV field operations. The guide assists plant operators in maximizing value from existing plants and identify the trade-offs of different monitoring solutions for future plants depending on the size, location, and expected system lifetime.

14 SOLAR ENERGY↗
DOE OSTI2022

The SMART Cables Initiative for Ocean and Geophysical Observing [Slides]

SMART Cables are becoming a reality, and have the potential to revolutionize submarine oceanographic and geophysical sensing. Pilot / demonstration projects are underway to test the technology and explore the feasibility of incorporating both in-repeater standardized sensor packets but also ancillary sensor types on external, branching nodes. The projects currently in planning will set the standard and influence the norms for the future of SMART systems. The interest of all potential stakeholders and users, and input as to needs and concerns, is welcomed as testing proceeds.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2023

Accelerated Materials Design for Molten Salt Technologies Using Innovative High-Throughput Methods

The focus of the project is on building an innovative accelerated materials design platform for molten salt technologies using novel high-throughput methods coupled to data analytics. The main objectives is to predict a FeCrMnNi alloy compositional space with better corrosion resistance than stainless steel 316 and identify new molten salt corrosion mechanisms. The project demonstrates the feasibility to use high-throughput methods coupled to data analytics to accelerate alloy design for extreme environments applications. Using a trained and tested machine learning (ML) model, 2000 FeCrMnNi alloy corrosion rate in molten chloride salts were predicted and a compositional field with corrosion rate lower than 316 stainless steel was identified. The ML model interpretability unveiled multiple features of importance in the model prediction. Some features were expected to be of relative significance, such as work function, surface energy and alloy electronegativity, and the ML model interpretability analysis confirmed those. On the other hand, the most important feature is the diffusion coefficient of Ni in the bulk alloy which indicates that a surface diffusion mechanism plays an important role in the overall corrosion mechanism in molten salts.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Multi-Timescale Integrated Dynamics and Scheduling for Solar (MIDAS-Solar) (Final Technical Report)

Solar photovoltaic (PV) installations have experienced unprecedented growth in the United States. PV will become not only an energy producer but also a necessary provider of ancillary services at multiple timescales. Conventional methods to simulate power systems operations - such as long-term production simulation (which typically considers schedules from hours to minutes by using an optimization framework) and short-term transient studies (which simulate dynamics from seconds to sub-seconds using state variables and differential equations) - are not sufficient for studying the multiple-timescale variation of solar generation and its impact on system reliability. Long-term system economics and short-term system dynamics are highly coupled, particularly when the penetration level of renewable generation is extremely high, because the uncertainty and variability of solar generation will impact both power system steady-state and dynamic performance. This project helps meet and exceed the U.S. Department of Energy Office of Energy Efficiency and Renewable Energy Solar Energy Technologies Office goal of systems integration by directly addressing this stability and reliability challenge for power grid planning and operation. We have developed a temporally comprehensive, closed-loop simulation model, named Multi-timescale Integrated Dynamics and Scheduling (MIDAS), that seamlessly simulates power system operations from economic scheduling (day-ahead to hours) to dynamic response analysis (seconds to sub-seconds). For schedules with very high levels of inverter-based resources (IBRs), up to and including 100%, the stability of grid controls has been evaluated through electromagnetic transient (EMT) simulations and power-hardware-in-the-loop (PHIL) simulations of key transient events at key schedule points. Specifically, MIDAS provides: 1) a closed-loop simulation framework for simulating timescales from economic scheduling to dynamic stability analysis; 2) machine learning-based stability assessment; 3) EMT modeling and analysis for large-scale power systems; 4) MIDAS PHIL test bed. We worked with Hawaii Electric Companies to apply the MIDAS study framework to a Maui grid study. The entire island's transmission system was modeled in detail - from a yearly scheduling model, to a second-level frequency dynamic model, down to a sub-second-scale EMT model to address critical stability issues. The project demonstrated how MIDAS can help system planners and operators assess system reliability and stability while the power grid is marching toward a high-renewable, high-IBR future. In this Maui grid study, we found that 100% instantaneous IBR operation is achievable in EMT simulation and PHIL testing, and grid planners and operators might need new analysis/simulation tools to assess grid reliability and stability in the scheduling stage. MIDAS will bring Maui and other systems closer to 100% clean and stable energy futures. (In this study, we examined transient stability. Other topics necessary for 100% IBR operation, such as protection and resource adequacy, were not examined.)

100% Renewables↗
DOE OSTI2023

Social Acceptance of a Reduced-Footprint Synthetic Mooring System for Floating Offshore Wind Turbines in the Gulf of Maine

Engineers are looking to reduce the size of floating offshore wind mooring footprints to minimize conflict with other ocean users. To this end, the University of Maine (UMaine) received funding from the United States Department of Energy (DOE) to design, demonstrate, and validate a novel reduced-footprint synthetic mooring system for floating offshore wind turbines (FOWTs) that reduces impacts to fisheries and the levelized cost of energy. UMaine designed two mooring systems for the New England Aqua Ventus (NEAV) I demonstration project to quantify the technical, economic, and social impacts of a reduced-footprint hybrid mooring system. Specifically, a traditional catenary chain mooring system and a novel polyester rope-chain hybrid system were designed to the front-end engineering design level for this assessment. The National Renewable Energy Laboratory (NREL) was funded by DOE to help independently quantify the social and techno-economic impacts of the rope-chain hybrid mooring system designed by UMaine. This report focuses on NREL's assessment of the social acceptance of the reduced-footprint rope-chain hybrid mooring system and the conventional all-chain mooring system by competing users in the Gulf of Maine.

ENGINEERING,WIND ENERGY↗
DOE OSTI2021

Domestic Extremism: Countering the Threat Posed to Critical Assets

Domestic extremism has been a growing concern in the United States in recent months, as illustrated in multiple bulletins from the Department of Homeland Security (DHS) warning law enforcement partners of the heightened threat. As concerns about these actors grows, it is important that facilities in the U.S. and internationally that protect critical assets, such as sensitive information, hazardous materials, or critical infrastructure, have effective methods in place to secure those assets. DE has challenged security systems through the threat of insider attack and violence, creating a new threat to be countered in the Office of Radiological Security’s radiological source security mission. In this effort, we used a literature review and focus group discussions with experts in critical asset security and extremism to understand the nature of the domestic extremist threat, to identify best practices in securing assets, recognize potential gaps in security measures to be corrected, and recommend actions and next steps. Twenty-two subject matter experts participated in a series of five focus group sessions. Questions focused on definitions of domestic extremism, potential changes in the threat, best practices in securing facilities, assets, and personnel, and any perceived gaps. Upon completion of the focus groups, notes were analyzed thematically to identify any recurring patterns in the results. In addition, a review of academic, industry, and government literature was conducted to understand the threat, describe the process of radicalization to extremism, and to identify empirically informed practices in prevention and response. Results of this project demonstrated that further work is needed to define domestic extremism in law, regulation, and policy, to help the U.S. develop a consistent response to the threat within organizations. This is especially important, as SMEs emphasized the need for early intervention in prevention efforts, noting that organizations need clear guidance on when and how to intervene. In addition, the need for social media monitoring was discussed, although challenges remain to do so with appropriate respect for privacy and civil liberties concerns.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗
DOE OSTI2022

Efficient Multi-Scale, Thermo-Hydro-Mechanical Numerical Model for Simulation of Long-Term Stability of Rooms for Nuclear Waste Disposal

This project demonstrated the feasibility of developing a numerical modeling tool that provides an efficient and unique approach to analyze the geomechanical performance of a deep geological repository (DGR) for high-level nuclear waste. The numerical modeling tool is physics-based and models the thermo-hydro-mechanical (THM) processes during the required time (up to one million years) for a DGR. The unique capability of the developed code is explicit representation of fracturing and a discrete fracture network (DFN) in the model that includes the entire repository layout for simulated time of one million years. Therefore, it can potentially address one of the challenges of analysis of a DGR, which is efficient numerical simulation of a multi-scale, physics-based models.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2023

The Impacts of Developing a Port Network for Floating Offshore Wind Energy on the West Coast of the United States

Floating offshore wind is a pre-commercial industry with the potential for significant market growth on the U.S. West Coast in the near future; however, significant investment in port infrastructure will be required to enable the industry to progress from demonstration projects to efficient and cost effective commercial deployment. Developing a system of ports that can enable commercial-scale floating wind development on the West Coast of the United States will require significant levels of funding and coordination between governments, industry, ports, and local communities. A critical first step to strategically planning these resources is understanding the number of ports (and associated investment) that would be required to support different phases of offshore wind projects, including manufacturing, installation, and operation. But simply tallying up these costs is not sufficient to understand how a robust network of ports could impact local communities, the environment, workforce development, the offshore wind industry, and the West Coast region as a whole. In this report, the authors present analyses and perspectives related to port development in California, Oregon, and Washington. We describe the requirements for floating offshore wind ports that conduct manufacturing, installation, and/or service activities, and estimate the investment and time frames required to construct these ports at suitable locations in West Coast states. We develop indicators for the vulnerability and workforce accessibility of coastal communities and consider the potential risks and benefits associated with port development in these locations. We model how the proximity of an offshore wind project to installation and operations ports can impact the levelized cost of energy of the project, and then consider how these costs could be affected by local or foreign supply chains. We build upon these analyses to develop scenarios with increasing levels of offshore wind deployment and port assets on the West Coast and show how these ports could enable deployment goals to be achieved. Finally, we draw upon outreach with key floating wind stakeholders to summarize five key challenges that will need to be overcome to develop a comprehensive port network, and present potential approaches that could help to address these obstacles.

17 WIND ENERGY↗
DOE OSTI2023

Stable Cadmium-Free Quantum Dot Optical Down-Converters for Solid State Lighting

Quantum dots (QDs) have been used in commercial solid-state lighting (SSL) applications to improve the energy efficiency of light generation at warm color temperatures. By increasing the amount of QDs used in each product, further energy savings are possible; however, traditional QDs contain cadmium, which has regulatory limits on its concentration in consumer products. As described within this final technical report, we have established that heavy-metal free QDs made from indium phosphide (InP) exhibit highly efficient emission at the temperatures and fluxes relevant to SSL. However, the maintenance of this emission is compromised during long term operation due to QD oxidation. We have identified multiple methods to slow the oxidation rate, which has improved the operational stability of these materials more than 200 times longer than at the project start. Beyond these improvements, heavy-metal free QDs require a further hundred-fold increase in stability to enable use in mid-power SSL and a ten-fold increase in stability to enable use in diffuse SSL applications. The outcomes of this project demonstrate feasibility for the use of heavy-metal free QDs in commercial SSL applications with potential use in diffuse SSL applications in the near term (1-2 years) pending market need.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

Grid Resilient, Self-Powered, Fuel Flexible, High Efficiency Heating System (Final Report)

The Grid Independent High Efficiency System (GIHES) delivers a heating system that operates free from the power grid and provides ultra-low emissions and high efficiency heating for residential and commercial buildings. The project demonstrated two weeks of continuous grid independent operation of a storage water heater equipped with a powered damper. The Thermoelectric Generator (TEG) integrated GIHES technology revolutionizes heating systems to provide grid resilient hot water production, while delivering significant value to the end user by eliminating impacts of power interruption and enhancing comfort, convenience and productivity. The system maximizes the thermal-to-electric conversion efficiency by optimizing location and orientation of the TEGs and durability while lowering system costs. The TEGs generate enough power to charge a battery and run the storage water heater unit with a powered damper uninterrupted by providing the required parasitic electrical power for start-up, shutdown and during idling. Several TEGs were analytically and experimentally evaluated based on the size, surface area and the power being generated before designing and fabricating a complete multi-TEG assembly for integration with the water heater. The GIHES technology can be extended to boilers, furnaces and tankless water heaters and integrated with heat pump to further increase the overall equipment efficiency. The technology has the potential to reduce the amount of dispatch power and peak power plant operation. An advanced burner was designed, developed and 3D printed for fuel flexible operation. The burner was designed to enable tighter integration with TEGs for potentially higher TEG output, should this be necessary. A bench-scale test rig to perform testing of a 200,000 Btu/h burner and capable of handling up to 10% H2 (by volume) was setup at GTI’s laboratory with appropriate safety and controls to ensure smooth and safe operation. Testing of the 3D burner showed < 5 ppm NOx emissions can be achieved for the entire firing range and with different levels of hydrogen blends with natural gas. The burner will enable a more integrated TEG-burner module design for improved system performance, should this be required in the future. Techno-economic analysis (TEA) of the TEG integrated with the water heaters was performed. The testing data and the power output were used to develop the TEA. The analysis for the storage unit with damper showed that the TEG integrated system costs $95. This is much lower than a one-time charge needed to wire and install dedicated power. Discussions with TEG manufacturers and OEM’s will provide more detailed information and methods to further lower these costs.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Developing Materials for High-Energy-Density Solid State Li-S Batteries

Solid-state lithium-sulfur batteries are considered to be the next-generation power source for vehicle applications due to their high energy density (up to 3 times more than current Li-ion) and low cost of sulfur (100 times less than conventional cobalt oxide). However, issues with solid-state electrolyte stability, conduction pathways in the sulfur cathode, and the interface between solid-state electrolyte and sulfur cathode must be solved in order to allow commercialization. This project demonstrates the creation of new, advanced materials which overcome these inherent issues. Current approaches based on polymer or liquid electrolyte with additives have been able to improve stability at the cost of efficiency. In contrast, by creating new hybrid materials it is possible to achieve both stability and efficiency. We developed a novel sulfide-based solid electrolyte, a sulfur-carbon composite cathode, and explored various additives to stabilize the interface of solid electrolyte and cathode. After the desired properties were achieved, these materials were integrated into a high-performance solid-state battery, bringing low-cost high-energy solid-state lithium-sulfur batteries one step closer to reality.

25 ENERGY STORAGE↗