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All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Kansas City, Missouri, Streetlight Electric Vehicle Charging: Strategies and challenges for site selection of streetlight electric vehicle infrastructure in Kansas City, Missouri (Final Report)

Public streetlight charging, whether on streets in central business districts or residential areas, provides easy charging access for apartment residents and homeowners alike. While most electric vehicle (EV) drivers charge at home, they do so in garages or on driveways they own. For renters and residents of multifamily housing (MFH), however, this may not be an option. EVs have a lower cost of ownership compared to conventional vehicles, and a used EV may be an affordable option for a lower-income household. But without easy access to charging, even a low-cost used EV may not be an option for a prospective buyer. An affordable curbside charging network has the potential to expand EV adoption into neighborhoods that have to date seen minimal interest and uptake of the technology and associated charging infrastructure. Streetlight charging networks can provide an economical, scalable, and effective approach to providing equitable and convenient charging. Metropolitan Energy Center (MEC) is dedicated to the mission of creating resource efficiency, environmental health, and economic vitality in the Kansas City region and beyond. Since 1983, MEC has provided resources, outreach, and training to make alternative fuels and energy efficiency commonplace. MEC led a streetlight charging pilot project that installed limited EV charging infrastructure on the streetlight system in Kansas City, Missouri, to demonstrate and test the benefits of curbside charging for EVs at existing on-street parking locations. The project aimed to cost-effectively expand the charging network in Kansas City to support residential charging and provide infrastructure in one or more charging deserts throughout the city. This pilot evaluates the impact and overall success of streetlight charging based on community feedback, utilization of charging infrastructure, technical feasibility, and cost. The project has pursued a data- and community-driven site selection process designed to identify sites with high demand and high opportunity for EV charging. This project was funded by the U.S. Department of Energy (DOE) and awarded to MEC through a competitive proposal process. The novelty and complexity of this project required an organization that could facilitate collaboration across levels of government, community members, and industry partners. For the past 25 years, through Kansas City Regional Clean Cities, MEC has worked with numerous public and private fleets on a variety of projects to improve the environmental performance and efficiency of the regional vehicle fleet. To advance affordable, efficient, and clean transportation efforts, DOE Clean Cities and Communities coalitions create local networks of public and private sector stakeholders and engage communities. Rooted within their local communities, the coalitions serve as experts and ambassadors, bringing to bear the collective knowledge, experience, and practical know-how of the entire network from within DOE, its national laboratories, and diverse stakeholders in the field. MEC and its project partners made in-kind contributions to leverage federal dollars for the benefit of the Kansas City community. Findings from this project will help determine the best applications for streetlight charging technologies to maximize funding impact and serve community needs. The team evaluated locations based on expected charging demand, technical feasibility, safety considerations, and enhanced charging network siting needs. Throughout the project, the team gathered feedback and evaluated ways to make public charging for EVs available to all community members. The insights will help Kansas City and other communities streamline future efforts to support EV drivers through public charging in the city right-of-way. Furthermore, this project will inform citywide guidance for future installations. MEC is committed to a transparent and publicly accessible approach that encourages the collaborative evaluation of streetlight charging. The project has engaged the community to proactively identify and evaluate the benefits and impacts of streetlight charging. It was a priority for the project to ensure the benefits of this pilot are distributed equitably to all members of the Kansas City community and that new charging opportunities and associated resources are available in diverse neighborhoods across the city. The charging infrastructure supports an affordable curbside charging network that will enable more drivers to choose EVs and provide easy charging access for all community members interested in driving an EV. The community feedback received through this project informed future resources and opportunities to make EVs more accessible to all members of the Kansas City community. MEC worked with several community partners on this project, including Missouri University of Science and Technology (MST), Pennsylvania State University (Penn State), the National Renewable Energy Laboratory (NREL); the city of Kansas City, Missouri; Evergy; Black and McDonald (B&M); LilyPad EV; EVNoire; and Westside Housing Organization (WHO). Project partners contributed to the cost match required for DOE grants through capital expenditures, personnel, and other in-kind contributions. Detailed descriptions of project team organizations can be found in Appendix A. Project Partners. Analysts at NREL and MST/PennState developed site maps based on demand and equity considerations. MEC conducted outreach to community members to garner input on project design and site selection, and received approval from the Missouri Public Service Commission (PSC) for Evergy’s EV charging station ownership. MEC worked with all partners to gather additional siting criteria and developed a site selection evaluation checklist, and partners conducted site visits to proposed installation sites. Next, B&M, Evergy, and the city executed all site agreements, conducted site-specific engineering design, acquired associated permits, and issued notices to proceed site by site or in small batches. Finally, from January to April 2023, the project team installed 23 EV charging stations built on Kansas City’s streetlight system in six council districts. Evergy will own, operate, and monitor the stations for 10 years, sharing charging data with MEC for at least 1 year.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Enhancing Cloud Cybersecurity: Prescriptive Controls for Operational Technology

This whitepaper provides strategic insights and recommendations into security cloud-based solutions for electric utilities, encompassing operational technology (OT), virtual power plants (VPP), distributed energy resources (DERs), applications, networks, and data storage as they transition to and leverage cloud infrastructure through managed service providers (MSPs) and cloud service providers (CSPs). Principles derived from established frameworks serve as a foundation for best practices across cybersecurity projects and remove the constraints of settling on a single framework. For organizations that prefer not to integrate a specific framework altogether, elements of the proposed approach could be adopted or tailored to best fit defined requirements and expected functionalities. The Cirrus assessment, a utility cloud feasibility tool, and the roadmap it provides serve as a precursor to this paper, which seeks to be a valuable resource for defining next steps following cloud technology integration feasibility appraisal. With its comprehensive approach to adoption, the Cirrus framework offers strategic guidance on responsibly preparing for or deploying a utility cloud solution. The previously published whitepaper, “Use Case-Informed Framework for Utility Cloud Migration,” details the guiding strategy, research, and deployment of cloud solutions within electric and interconnected grid systems. Before implementing the controls suggested in this document, it is recommended that stakeholders complete Cirrus's cloud integration assessment and pair the results with their unique cybersecurity controls to form a comprehensive cloud-based utility cybersecurity plan. The Cirrus outcome will consider a series of future architectures for the grid before and after the energy transition and evaluate the arguments for and against cloud applications for each electric and interconnected grid layer. This document is a companion to the original whitepaper, "Use Case-Informed Framework for Utility Cloud Migration" to further identify and recommend security controls based on Cirrus’s cloud integration assessment output. The following whitepaper outlines the cybersecurity controls that secure cloud-service models pertinent to the electric sector using the predefined categories identify, protect, detect, and respond and recover. The objective is to outline prescriptive security controls based on the type of architecture and data stored in the cloud. The focus includes dissecting the shared responsibility model and elucidating what on-premises Infrastructure as a Service (IaaS), Platform as a Service (PaaS), and Software as a Service (SaaS) entail. A pivotal consideration in this context is allocating responsibility for foundational cybersecurity aspects—having used Cirrus for the cloud integration assessment. The ensuing controls detailed herein also represent a checklist of controls necessary for a secure cloud transition, equipping utilities with the knowledge to navigate this digital transformation with confidence and strategic foresight in a safe and responsible manner.

42 ENGINEERING↗
DOE OSTI2023

Scoping Study for Fast Flux Testing in the Advanced Test Reactor

The value of fast spectrum reactors remains prominent in the nuclear technology portfolio. The performance of these reactors can be maximized with advancements in nuclear fuel technologies, but development of these technologies is currently held back by lack of fast spectrum test reactors available to the United States. Spectral modification of experiment positions in the thermal spectrum Advanced Test Reactor (ATR) has long been used to support fast reactor fuel development, but these methods have not been progressed to their full potential. This study investigated the use of concentric rings of aluminum-clad fuel plates in ATR flux traps and thermal neutron absorbing filters to increase fast neutron flux on test specimens. This concept was termed the Boosted Energy Advanced Spectrum Test (BEAST). This approach will enable irradiation of advanced fuel designs in prototypic-length fuel pins and representative flux environment to support post irradiation exams, enable transient testing, and produce the type of data that will permit lead test assembly irradiations in true Sodium Fast Reactors (SFRs) when they become available. Neutronic predictions were performed to investigate BEAST design options and thermal hydraulic models were produced to ensure feasibility of BEAST. Two versions were considered based on the geometric limitations of ATR’s small and large flux traps. The small version was found to be preferable due to slightly higher fast flux and fast-to-thermal neutron ratio. Perhaps more influentially, the small flux trap option was also preferred to avoid conflict with ongoing very high temperature reactor fuel irradiation programs in ATR’s large northeast flux trap. The small flux trap option provided less than half the test volume of the large version, but still had adequate volume for seven SFR pins in cross section which could be stacked two-high in ATR’s 1.2m long core to accommodate up to 14 EBR-II size pins. The preference for the small flux trap configuration should be revisited if additional collaborative test programs emerge with the need to irradiate a significant volume of additional specimens. Calculations were performed regarding a lithium deuteride ring to convert thermal neutrons into 14 MeV fusion neutrons. At the time this report was written these calculations were partially complete and it remains to be seen whether the concept would be worth including in BEAST. Given the preference for the small flux trap option, which does not afford enough room for the 14 MeV ring, it was concluded to defer future work on the lithium deuteride ring. This decision could be revisited if fusion material research programs emerge for collaborative testing in BEAST. A cadmium-lined specimen holder design was found to be adequate in filtering thermal neutrons and preferred over other neutron absorbers based on past experience with cadmium baskets. It was acknowledged that cadmium-bearing hardware would become depleted and need to be replaced occasionally, which appeared feasible from a mechanical design perspective. Neutronic studies investigated different enrichment levels in the booster fuel using uranium-molybdenum alloy dispersion fuel which has performed well in past ATR irradiations. Both options were able to drive fuel pins to SFR-like fission heating rates. The high enriched booster fuel option outperformed the low enriched option by ~20% on key metrics including fast flux and fast-to-thermal ratio, but the low enriched option was favored in order to broaden options for potential fuel suppliers. The preferred BEAST design options including cadmium filter with low enriched booster fuel in the small flux trap configuration was predicted to achieve 6.2E14 n/cm2sec fast flux (>0.1 MeV) with a fast-to-thermal ratio of 44.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Proteomics Analysis of Human Contaminant Proteins

Complete characterization of unknowns via proteomics remains challenging. There exist regions of mass spectrometry-based proteomics data where empirical measurements are not attributed to peptides, and/or sequenced peptides from mass spectra are not attributed to any source. These uncharacterized regions are known as the “dark” proteome. Many proteomics tools rely on some a priori knowledge of sample composition; few tools allow for investigation of unknowns without relying on composition assumptions. Further, the potential low abundance of minor traces in these uncharacterized regions can make elucidation of the “dark” proteome challenging. Herein, we describe the development and evaluation of approaches to study the “dark” proteome and move towards an untargeted approach for more complete characterization, namely by studying minor human protein traces in non-human samples and combining that approach with non-human source organism identification without relying on assumptions. Human protein markers, in the form of genetically variant peptides, have been extensively examined in a variety of human matrices, including blood, plasma, and hair, but have yet to be investigated in non-human samples, such as cell cultures, as human contaminant traces. Genetically variant peptides are those that are found in proteins carrying single nucleotide polymorphisms. In this work, we aimed to (1) investigate the feasibility of detecting human contaminant genetically variant peptides (GVPs) in a diverse set of non-human organisms using public proteomics data and a computational pipeline, as well as to (2) develop a combined capability for untargeted source organism characterization and GVP detection. To our knowledge, this is the first report of applying these approaches towards a more complete proteomic characterization of unknowns. We successfully demonstrate the feasibility of broad human contaminant GVP detection in proteomics data, develop a better understanding of GVP detectability, characterize the sample-to-sample variability in GVP detection, and identify a core set of GVPs that can potentially be used as markers indicative of the human contaminant traces portion of the “dark” proteome. Further, we developed and evaluated a combined pipeline, MARLOWE-GVP, that enables both untargeted source organism characterization and GVP detection. We show high accuracy of correct source organism characterization and high degree of similarity of human contaminant GVP detection compared to the conventional approach. Success on both these efforts have allowed us to advance our understanding and characterization of the “dark” proteome.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2023

Preliminary Characterization and Evaluation on FFF Manufactured 316H and ODS Steels

The Advanced Materials and Manufacturing Technology (AMMT) program develops cross-cutting technologies in support of a broad range of nuclear reactor technologies and maintains U.S. leadership in materials and manufacturing technologies for nuclear energy applications. The overarching vision of AMMT is to accelerate the development, qualification, demonstration, and deployment of advanced materials and manufacturing technologies to enable reliable and economical nuclear energy. Solid-state advanced manufacturing techniques can overcome some of the challenges in liquid-based additive manufacturing (AM) processes and should therefore be considered in material design and manufacturing as well. The work presented in this report forms part of a study on solid-state AM techniques of 316 stainless steels (SS) and oxide dispersion strengthened (ODS) steel components and supports the vision and goals of the AMMT program relevant to accelerate the development and deployment of advanced manufacturing processes. Achieving this can provide a safety improvement through larger safety margins, economic benefit for higher efficiency during operation, and a cost reduction through more effective manufacturing processes and less waste. This study provides preliminary information on development of the fused-filament fabrication (FFF) process using different powder types to demonstrate the sensitivity, and therefore the characterization of these sample components. The full solid-state manufacturing feasibility study will be completed and reported in a final feasibility evaluation during 2025. The study investigation used two 14YWT ODS powder batches, which provided information and the effect of different powder morphologies on manufacturability. The two 316SS powders demonstrated the effect of powder size on the manufacturability using FFF. Two product forms, namely a honeycomb structure and flat samples, were manufactured to demonstrate the flexibility of product form.

36 MATERIALS SCIENCE↗
DOE OSTI2024

2023 Business Case Study: Hydrothermal Liquefaction of Algal Bloom Biomass

A business case study was developed for the fiscal year (FY) 2023 to explore the technical and economic feasibility of converting lake-harvested algal bloom biomass (ABB) into biofuel via hydrothermal liquefaction (HTL). The case study includes reporting on the experimental demonstration of converting the algal feedstock to HTL biocrude. Using the experimental data, a preliminary techno-economic assessment (TEA) of a commercial-scale facility was completed to determine the economic feasibility of the process.

09 BIOMASS FUELS↗
DOE OSTI2024

Simple and Scalable Process for Nanocellulose Production from Residues and Waste (CRADA Final Report)

This project successfully developed an innovative, cost-effective, and scalable method for converting low-cost agricultural waste feedstocks into nanocellulose—a sustainable material with wide-ranging industrial applications. It addressed the critical challenges of high production costs and limited global supply, which have hindered the widespread adoption of nanocellulose in industry. Through this work, significant advancements were made in optimizing resource use, improving process efficiency, and reducing costs. Notable achievements included a 50% reduction in water usage, 30% lower chemical consumption, and 20% energy savings, all while maintaining high-quality product standards. The technical feasibility of the process was further validated at a 10L scale in collaboration with the Advanced Biofuels and Bioproducts Development Unit (ABPDU), demonstrating scalability and replicability. Key challenges in reducing nanocellulose production costs were addressed by utilizing low-cost biomass feedstocks and implementing low-temperature conversion reactions, leading to lower capital and operating expenses. The project also mitigated financial risk by generating critical data on the feasibility, adaptability, and scalability of the conversion technology, paving the way for its commercial implementation. Public benefits include advancing the circular bioeconomy, reducing environmental impact, fostering job creation, and enabling a shift toward biobased materials as sustainable alternatives to fossil-based products. These outcomes align closely with national goals to reduce greenhouse gas emissions and promote sustainable technological innovation.

09 BIOMASS FUELS↗
DOE OSTI2024

Enhancing Fluid Flow Pressure and Saturation Prediction Accuracy and Reducing Uncertainty with Committee Machine – Illinois Basin Decatur Project (IBDP) as a Case Study

Presentation at the 17th International Conference on Greenhouse Gas Control Technologies GHGT-17 held in Calgary, Canada, October 20-24, 2024. Carbon capture and storage (CCS) is a way to play a critical role in the global transition to a low-emission economy. Current progress is hampered by a number of factors, among which the lack of risk-informed design tools and decision support frameworks is seen as a major roadblock. Significant interest exists in using artificial intelligence to accelerate CCS site feasibility studies, as well as to facilitate the permit application process. Existing works commonly train a single deep learning model. This work investigates the feasibility of using a conventional ensemble learning (committee machine) technique to further improve prediction accuracy. Ensemble-based algorithms generally improve over individual base learners in terms of robustness and accuracy. Deep ensembles, however, are time-consuming to create and train. A pragmatic question is whether small-sized ensembles may lead to prediction improvement. Here we evaluated the efficacy of an ensemble learning technique using the latent spectral model (LSM), an efficient deep neural operator algorithm, as base learners. Preliminary results, obtained using the Illinois Basin-Decatur Project (IBDP) carbon sequestration data/model, show that small-sized ensembles can improve prediction over the base learners, achieving prediction accuracy of ~1.6 psi root mean square error (RMSE) on pressure (relative the average reservoir pressure of 3150 psi), and less than 1.3% for saturation.

Sun, Alexander↗
DOE OSTI2024

Evaluation of Rooftop Solar Potential in Chernihiv and Lviv, Ukraine, and Efficacy of High-Resolution 3D Data Digital Twins [Slides]

NREL evaluated rooftop solar photovoltaic (PV) siting opportunities in the cities of Chernihiv and Lviv, Ukraine, leveraging very-high-resolution 3D elevation data to calculate technical potential. The study assessed total rooftop solar capacity and annual energy production. In Chernihiv and Lviv, 116,503 buildings were analyzed for their rooftop solar potential. The buildings in the study areas include a mixture of residential, commercial, and industrial buildings, characterized by diverse roof shapes and sizes. The total estimated rooftop solar capacity is 332 MWDC in Chernihiv and 873 MWDC in Lviv with annual energy production up to 376.2 GWhDC in Chernihiv and 995.5 GWhDC in Lviv. This accounting provides a clear estimate of the potential rooftop solar installations that could be realized under optimal conditions, considering both technical constraints and the geographic distribution of available rooftop space. Related to Russia's invasion of Ukraine, NREL estimates loss from buildings damaged or destroyed of 2,754 buildings, 20.15 MWDC of capacity, and 22,869 MWhDC of annual energy production in Chernihiv as well as a loss of 1,316 buildings, 34.49 MWDC of capacity, and 39,369 MWhDC of annual energy production in Lviv. The study also assessed the feasibility of adapting this methodology on a national scale using either simulated digital surface models (DSMs) or a digital twin approach. While the very-high-resolution DSM provided more precise results, the simulated DSM demonstrated reasonable accuracy for broader applications in modeling aggregated distributed solar supply. The feasibility of using a digital twin for Ukraine's national rooftop solar potential is considered promising, with certain limitations in areas with highly variable building stock and heavy war damage.

14 SOLAR ENERGY↗
DOE OSTI2025

ROTA-CAP™: An Intensified Carbon Capture System Using Rotating Packed Beds (Final Scientific/Technical Report)

GTI Energy and Carbon Clean Solutions Limited successfully designed, constructed, and operated an integrated ROTA-CAP carbon capture skid. ROTA-CAP™ is a process intensification technology, applied for post-combustion carbon capture, which utilizes the centrifugal forces generated from rotation of rotating packed beds as well as advanced solvents to achieve increased mass transfer rates 1-2 orders of magnitude higher than conventional columns while substantially decreasing footprint. The test skid, which consisted of a dual stage RPB absorber with external interstage cooling and a single stage RPB regenerator, was operated at capacities up to 0.5 tonne/day of CO 2 capture with flue gas concentrations ranging from 4% to 22% CO 2 by vol. CO 2 removal rates greater than 95% were achieved, with CO 2 product purity also exceeding 95% by vol. Over 1,600 hours of operation were accumulated throughout the project, including over 1,000 hours of operation of the with real flue gas containing at least 9.8% CO 2 by vol. The skid was operated continuously for 24 hours per day and 7 days per week over the course of 7 long-term test campaigns, with the campaigns ranging from approximately 2-4 weeks per campaign. A techno-economic analysis was performed, and a cost of capture of $\$$41.18/tonne CO 2 was calculated for the ROTA-CAP process, compared to $\$$45.75/tonne for a Cansolv-based process. These results show a cost reduction of approximately 10% compared to the Cansolv-based process. Although this still exceeds the target cost of capture of $\$$30/tonne specified for this project, GTI expects that the cost of capture can be further reduced through further optimization of the design and technology. GTI also performed an engineering design review to determine the scale-up potential of the technology, with the results of the preliminary assessment indicating that it appears to be feasible to scale up the RPB technology to 4,000 TPD. It was also determined that both horizontal and vertical rotor orientations are feasible, though there are mechanical advantages to the vertical orientation.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2025

University of Hawai‘i, Shallow Geothermal Resources: Energy Technology Innovation Partnership Project (Final Report)

Scientists at Lawrence Berkeley National Laboratory (Berkeley Lab) have teamed up with the University of Hawai‘i at Manoa (UH Manoa) through the U.S. Department of Energy’s Energy Technology Innovation Partnership Project to evaluate the technological and market feasibility of shallow geothermal heat exchanger (GHE) technology. UH requested this analysis to evaluate opportunities in building cooling, energy efficiency, and emissions reduction applications in Hawai‘i. UH has an abundance of geologic and geothermal data and is looking to the national labs’ expertise to execute this analysis. UH is also interested in investigating policy, regulatory, and business conditions advantageous for implementation of a pilot project and more broad deployment of this technology in Hawai‘i. In many locations around the world, the demands for heating and cooling are roughly balanced over the course of the year, so GHEs do not cause significant long-term changes in subsurface temperature. This is not the case in Hawai’i, where the demand for heating is very small, meaning that, over time, GHEs will add heat to the subsurface. If temperatures increase significantly, GHE systems will not work as designed. Regional groundwater flow has the potential to sweep heated water away from boreholes, thereby maintaining the functionality of the GHE system. Significant regional groundwater flow requires two things: a sufficiently large driving hydraulic head gradient (usually closely related to surface topography), and sufficient porosity and permeability to enable groundwater to flow in large enough quantities to enable near-borehole temperatures to be maintained at ambient values. Hawai‘i’s volcanic terrain offers ample surface topographic variation. The lava itself shows an extremely large range of porosity and permeability, so sites with large enough values of these properties must be selected. Numerical modeling of coupled groundwater and heat flow can be used to determine how large is large enough. Primarily, closed-loop systems have been investigated. Other options considered are open-loop systems and using cool seawater as the chilling source. Project work investigated the feasibility of GHE technology at two scales. At the island scale, GIS layers of various attributes relevant for GHE were combined to develop an overall favorability map for employing GHE in Hawai‘i. At the local scale, a hydrogeologic model for the subsurface component of a closed-loop system was developed for the Stan Sheriff Center at the UH Manoa campus. This site is considered promising because the rock below and immediately downgradient of the borefield is highly permeable, consisting of a subsurface karst system (limestone containing high-permeability open channels), which is underlain by a thick, high-permeability fractured basalt. Moreover, the site is near the base of the Ko‘olau Range, providing a large hydraulic head gradient. Thus, groundwater flow through the site is expected to be large, enabling efficient removal of heated groundwater. A full-GHE-system model of the site was also developed, with a simplified representation of the subsurface, in which groundwater flow is not considered and heat transfer is purely by conduction. Using the building cooling load data provided by UH, simulation results show that with groundwater flow present, a GHE can operate successfully for at least 10 years, but with no groundwater flow, the subsurface begins to heat up after only one year of operation, making the GHE unviable within 2-6 years. The team also developed a techno-economic model for this site to compare the cost of cooling using a GHE system with the costs of operating the current air-conditioning system. The GHE system is advantageous economically if favorable tax incentives and interest rates can be obtained.

15 GEOTHERMAL ENERGY↗
DOE OSTI2025

Advanced System Thermal Fluids Solver Development for SAM

This work summarizes a feasibility study on testing numerical algorithms that are suitable and efficient for advanced system analysis code development under the mutli-physics framework, MOOSE. The key is the implementation of a high-order one-dimensional staggered-grid finite volume method (SG-FVM), and its direct interaction with the linear/nonlinear solver, PETSc. Leveraging the existing capabilities of the SAM code, significant code coverages were established in the finite volume method code. This in turn allows for a suite of test problems with different problem sizes and levels of complexity to be used to quantify the performance improvement of the finite volume method code. As evidently shown in this study, the implemented SG-FVM demonstrated superior performance improvement against a direct finite element method implementation through MOOSE for the wide range of selected problems. On two computer systems, the speedup was observed to be significant, with at least one order of magnitude of solving time reduction. In addition, for a complex reactor model, transient simulation was performed using the finite volume method code, the results of which agree very well with the reference results from the finite element method code. Overall, this study demonstrates a successful feasibility study on the proposed numerical algorithms and software structure to support advanced system analysis tool development. In this work, short-term priority development and testing items were identified, and long-term code adoption and integration plans were made for the eventual deployment of the finite volume method in the SAM code.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2024

Co-synthesis of Hydrogen and High-Value Carbon Products from Methane Pyrolysis

The ARPA-E Methane Pyrolysis Project successfully developed a scalable technology for hydrogen production with low-CO x emission through methane pyrolysis, co-producing high-value carbon nanotubes (CNTs). The project focused on optimizing reactor design, enhancing catalyst performance, and assessing techno-economic feasibility to create a commercially viable and environmentally sustainable process. The fluidized bed reactor achieved over 90% methane (CH 4 ) conversion by using a 5% CO 2 co-feed, which stabilizes carbon yields and minimizes catalyst deactivation. This setup allowed for continuous operation across ten cycles, each consisting of a 14-minute pyrolysis phase followed by a 10-minute dislodging phase to remove a fraction of the accumulated carbon, resulting in stable performance and high-quality CNT production. In parallel, monolith reactors coated with Fe demonstrated a sustained methane conversion of 73% while producing CNTs with high crystallinity. Although promising for continuous operation, monolith reactors face challenges in coating durability and scalability, highlighting areas for further optimization in commercial applications. Catalyst formulation played a key role in enhancing process efficiency. The core catalyst used was 5%Fe/Al 2 O 3 (wt%), optimized through wet impregnation, which improved CNT morphology, yielding longer and more uniform CNTs. The catalyst's performance was further enhanced by adding promoters: 2.5 wt% Ni increased methane conversion close to the thermodynamic limit, while 2.5 wt% Mn improved CNT alignment and crystallinity, and 1.5 wt% NaCl boosted CNT morphology but slightly lowered methane conversion. These adjustments allowed the reactor to maintain high methane conversion while producing high-quality CNTs, enabling stable performance over multiple cycles. To address carbon buildup and ensure uninterrupted operation, a pneumatic conveying tube was implemented for effective carbon dislodging in the fluidized bed configuration. CO 2 and H 2 O co-feeds were also introduced to enhance carbon removal, with CO 2 boosting CNT yield by approximately 15%. This setup enabled stable reactor operation across multiple cycles, preventing clogging and minimizing catalyst wear, making the process suitable for industrial scaling. Techno-economic analysis (TEA) projected hydrogen production costs between $\$$1.00 and $\$$1.64 per kilogram, with CNT values assumed at $\$$375/ton and $\$$100/ton. The life cycle assessment showed that CO 2 emissions could be as low as 0.64 kg CO 2 e/kg H 2 at 95% methane conversion assuming an electricity input of 50 kg CO 2 e/MWh. Even at 50% methane conversion, emissions remained below 1 kg CO 2 e/kg H 2 , demonstrating the process's low-emission potential and making it a viable alternative to traditional steam methane reforming. Overall, the results from this project demonstrate the feasibility of a pyrolysis process where carbon is continuously removed from the catalyst surface and hydrogen is continuously produced until a catalyst regeneration step is required to fully clean the catalyst surface and renew catalyst performance. Major open challenges are related to avoiding the loss of catalyst material in the dislodged carbon during fluidized bed conditions, since our best result demonstrated a carbon purity of ~70 wt. % (rest being iron and alumina). A monolith reactor was used to favor dislodgement of carbon compared to fluidized bed conditions but our results do not demonstrate an advantage of the monolith configuration. Catalyst performance was similar to fluidized bed conditions with slower deactivation rates overall, but we could not observe carbon dislodging in any of the tens of experiments that were run at Stanford. Our results show that the most relevant areas of improvement are related to the fundamental understanding of the iron-carbon interface for dislodging, and the development of catalyst that can produce CNTs via a base-growth mechanism such that catalyst is not lost in the dislodgement steps. The final report documents all findings and methodologies in detail, providing a valuable resource for the scientific community. By building on these results, researchers can further advance methane pyrolysis technology, moving toward a more sustainable, scalable pathway for hydrogen production. This work lays the foundation for future research and commercial efforts to reduce emissions in hydrogen production while generating valuable carbon products.

08 HYDROGEN↗
DOE OSTI2024

Rapid Design and Manufacturing of High-Performance Materials for Turbine Blades

This research demonstrated the concept of carbide precipitation-strengthened refractory high entropy alloys (RHEA). The advantage of a precipitation strengthened alloy is all phases are in thermodynamic equilibrium promoting microstructural stability, and consequently retention of properties at elevated temperatures. Additionally, as with any precipitation strengthened – or age hardened - alloy, components can be heat-treated after manufacturing to manipulate the microstructure and optimize properties for performance. This is an advantage of the precipitation strengthened alloys over composites and ceramics materials, where the microstructure and properties are essentially fixed upon the initial materials manufacturing stage. High throughput (HT), multi-scale computer modeling was used to identifying novel RHEA compositions with desired characteristics needed for precipitation strengthening. Designs were validated by producing small ingots via are melting. The results showed that carbides precipitated and consequently, the strength of the alloys (measured in compression) increased after heat-treatment, which is the desired effect. The project also demonstrated the feasibility of producing articles from RHEA by additive manufacturing (AM). Electron beam melting (EBM) and laser direct energy deposition (L-DED) additive manufacturing methods, were explored with various processing parameters were interrogated for both methods. Sound (crack-free and dense) precipitation strengthened RHEA samples were produced via EDM AM, demonstrating the feasibility of the concept.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Developing multi-gene CRISPRa/i programs to accelerate DBTL cycles in ABF hosts engineered for chemical production

This project developed and implemented a modular CRISPR activation and interference (CRISPRa/i) platform to accelerate strain optimization and pathway development for industrially relevant microbial hosts. By integrating multiplexed transcriptional perturbation tools with data-driven Design–Build–Test–Learn (DBTL) workflows, the team achieved reductions in cycle time and enhanced production of industrial aromatics, particularly 4-aminocinnamic acid (4-ACA), in Pseudomonas putida. Key accomplishments included: ● Development of a robust, tunable CRISPRa/i system in P. putida that enabled efficient multi-target gene regulation via guide RNA (gRNA) programs ● Completion of two full DBTL cycles, guided by machine learning (ML) models trained on transcriptomic and performance data, reducing engineering time by over 30% ● Optimization of multi-gene regulatory programs to balance expression of host and pathway modules, improve 4-ACA titers, and resolve metabolic bottlenecks ● Demonstration of system portability through a limited proof-of-concept extension in Acinetobacter baylyi, underscoring the generalizability of the approach ● Evaluation of strain performance on lignocellulosic biomass-derived substrates, demonstrating the feasibility of converting renewable carbon into aromatic building blocks These results illustrate the feasibility of applying ML-guided CRISPRa/i perturbation strategies to accelerate strain development in complex microbial systems. The resulting tools and datasets contribute to DOE objectives by improving platform predictability, reducing development costs, and enabling broader access to sustainable, economically viable bioproduction technologies.

09 BIOMASS FUELS↗
DOE OSTI2025

Considerations for a Medium-Voltage DC Electrolysis Testbed

Here we present the results of a study focused on the feasibility of using Medium Voltage DC (MVDC) power distribution from wind power generation to electrolyzers for hydrogen production. This approach, using hybrid energy generation in a MVDC microgrid, offers many advantages. These include possible improvements in efficiency, reliability and installation cost compared to a more typical state-of-the-art AC distribution configuration. It also eliminates the need for transformers, which have recently been subject to price volatility and availability concerns. This study highlights the practical feasibility of MVDC distribution networks for integrating various energy sources, offering improved efficiency and reduced system complexity compared to conventional AC-based solutions. Future work will focus on enhancing fault protection strategies, scaling the system to larger renewable installations, and conducting hardware implementation at the National Renewable Energy Laboratory's (NREL) Flatirons Campus (FC). In the sections that follow we show that a DC Collection and Distribution System (DC CDS) reduces the losses associated with the electrical conversion / distribution process relative to a state-of-the-art AC approach, improving overall efficiency by 5%. On the qualitative side, reducing the number of conversion stages is likely to improve reliability, reduce capital investment cost, and enable simpler control algorithms to be used, and reduced risk of instabilities and malfunctions.

08 HYDROGEN↗
DOE OSTI2025

Scoping Study of Integrated Geothermal CO 2 Heat Pump and Water Well System in Cold Climate Region

This study evaluates the feasibility of using ground-source heat pumps (GSHPs) integrated with water wells for residential heating demands in cold regions of the United States. Four different heat pump systems were evaluated and compared: a CO 2 air-source heat pump (ASHP), a R-410A ASHP, a CO 2 GSHP integrated with well water, and a R-410A GSHP integrated with well water. Simulations were conducted at both equipment and building integration levels, followed by a nationwide analysis across 10 selected cities. Results indicate that integrating GSHP technology with existing water wells (e.g., artesian, bedrock, drilled, and collector wells) is a feasible heating solution because of their high flow rates, good water quality, stable temperatures, and low environmental impact. Although R-410A systems demonstrate higher efficiency, CO 2 systems are more suitable for heating from contamination-free and energy security perspective. The CO 2 GSHPs maintain better performance in colder climates compared with that of ASHPs, providing higher coefficient of performance and environmental benefits because CO 2 refrigerant leakage would not contaminate well water. A national analysis confirms that CO 2 GSHPs outperform furnaces, especially in cold climates, making them a promising solution for residential heating.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2025

Illinois Storage Corridor CarbonSAFE Phase III: Stakeholder Engagement and Outreach Plan

The Stakeholder Engagement and Outreach Plan provides a comprehensive framework for engaging stakeholders of the Illinois Storage Corridor (ISC) project. The ISC project is a CarbonSAFE Phase III project designed to facilitate commercial deployment of carbon capture, utilization, and storage (CCUS) in Illinois. The project aims to establish a multi-industry carbon storage corridor through development of storage sites near the One Earth Energy (OEE) ethanol production facility in north-central Illinois and the Prairie State Generating Company (PSGC) coal-fired power plant in south-central Illinois, with combined annual CO 2 capture ultimately exceeding 8.6 million tons per year. Stakeholder engagement is recognized as a critical component for successful CCUS deployment, alongside technical and economic considerations. As an emerging technology, CCUS may not be well understood by the general population, and lack of public awareness can lead to opposition that poses significant barriers to project development. This plan addresses this challenge through systematic stakeholder identification, analysis, planning, and implementation of engagement actions. The plan is structured around four main sections: Communication, Stakeholder Analysis, Stakeholder Engagement, and Environmental Justice. Activities will be conducted under Tasks 1 and 4 of the project's Statement of Project Objectives, with two key subtasks: (1) developing a stakeholder analysis and engagement plan through face-to-face meetings, facilitated discussions, and surveys; and (2) implementing stakeholder engagement and public outreach activities including meetings, open houses, and permit hearings. The Illinois State Geological Survey (ISGS) will manage engagement activities following DOE-NETL best practices, focusing on providing objective, fact-based information about CCUS and the ISC project. A comprehensive Communication Plan establishes protocols for media contacts, site visits, and crisis communications. The stakeholder analysis follows a structured workflow process divided into Pre-feasibility and Feasibility phases, incorporating contextual understanding, assessment, data collection, and analysis. Key stakeholder groups include government bodies, educational organizations, conservation and environmental groups, agricultural communities, and religious organizations. The plan addresses common stakeholder questions regarding project risks, benefits, safety, property values, liability, and environmental impacts. Recommendations emphasize developing clear messaging, creating informational materials, and preparing to address both project-specific and broader environmental concerns to ensure transparent communication and build stakeholder support throughout project implementation.

25 ENERGY STORAGE↗