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High-Temperature Heat Pump Model Documentation and Case Studies

High temperature heat pumps (HTHPs) have the potential to serve two valuable functions in the U.S. industry. First, by valorizing and elevating waste heat streams, HTHPs can improve industrial energy efficiency. Second, by electrifying process heat generation, HTHPs can replace combustion technologies with less carbon-intensive sources of energy and reduce industrial greenhouse gas emissions. In certain applications, the combination of increased efficiency, cost savings, and emissions reduction makes HTHPs a promising component of strategies for industrial electrification and clean energy transition. Researchers at NREL have developed a HTHP model. This model has both a physics-based performance estimation component and an economic evaluation component designed to demonstrate the potential economic competitiveness of HTHPs. This document has three main sections. First, an overview of HTHPs is provided as a literature review of relevant information to provide the reader with state-of-the-art information. Second, a description of the HTHP model is provided along with detailed instructions about how to use the model. Third, case studies are provided to showcase the deployment of the HTHP model.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Workshop Summary: Bridging the Gap Between Atmospheric Science and Grid Integration

The need for dedicated, accurate, expertly curated weather data is increasingly important as the share of variable renewable energy increases on the power system. Projections for futures with very high (50+% annual energy) shares of variable generation require ongoing assessment of data requirements from industry stakeholders in their power system operation and planning contexts. In March 2024, NREL organized a workshop entitled "Bridging the Gap Between Atmospheric Science and Grid Integration Workshop", which brought atmospheric scientists and power system experts together to refine the requirements of atmospheric datasets for grid integration, and to describe a holistic approach to creating new and regularly updated national scale wind datasets for power system planning and operations. The results of this workshop are being used to inform the near-term development and a longer-term strategy for DOE to produce relevant wind resource datasets and inform wider use of wind/solar/load data sets in power system planning. This presentation provides an overview of a preworkshop survey, an assessment of current state of the art of national-scale datasets for wind resource assessment and grid integration, insights on appropriate uses of the WTK-LED, power system perspectives on data needs, as well as recommended next steps as discussed in the workshop and how these steps support longer-term strategies.

17 WIND ENERGY↗

Data-Enabled Fusion Technology (Final Scientific/Technical Report)

Advancing Scientific Understanding in Fusion Energy and Machine Learning This research represented a significant step forward in machine learning (ML) applications for fusion energy experiments. The project integrated advanced data-driven modeling, optimization techniques, and artificial intelligence to enhance the predictive capabilities and operational efficiency of plasma-based fusion systems. Specifically, tasks focused on ML-enhanced diagnostics, operator guidance tools, and predictive modeling helped improve the ability to interpret complex fusion experiments. Key areas of advancement included: 1) data-driven plasma control, i.e., using ML algorithms to optimize experimental conditions and classify plasma behaviors based on historical data; 2) spectroscopy and diagnostics, i.e., applying AI models to extract previously inaccessible insights from experimental spectroscopy data; and 3) configuration mapping and operator guidance, i.e., developing a predictive framework to assist scientists in identifying the most effective experimental parameters, reducing reliance on manual adjustments. By refining these ML-driven techniques, the project contributed to the broader scientific community’s understanding of plasma dynamics and fusion energy viability. Technical Effectiveness and Economic Feasibility The methods investigated demonstrated high technical effectiveness, as reflected in milestones assessing the predictive accuracy, performance, and optimization of fusion configurations. The development of an Operator Guidance Tool (OGT), for example, led to more precise control of plasma conditions by learning from experimental data and offering real-time adjustments. From an economic standpoint, DeFT provided: 1) the ability to reduce trial-and-error experimentation, which lowered operational costs; 2) improved data interpretation methods, which enabled more efficient resource allocation in large-scale fusion research projects; and 3) the automation of key diagnostic tasks, which reduced manual labor and human error, increasing overall efficiency. 13 The final assessments of predictive models and optimization strategies demonstrated that these approaches were scalable and could be implemented across multiple fusion energy research programs. Public Benefit and Societal Impact This project contributed directly to the broader goal of achieving sustainable and commercially viable fusion energy, which had profound implications for clean energy production and climate change mitigation. The integration of AI-driven solutions into fusion research: 1) sped up scientific discovery, accelerating progress towards achieving energy breakthroughs; 2) reduced the cost of experimentation, making fusion research more accessible; and 3) provided a framework for future AI applications in high-energy physics, benefiting adjacent fields like space exploration, material science, and renewable energy. Additionally, by fostering collaborations between AI researchers and plasma physicists, this project promoted interdisciplinary innovation that could lead to broader applications beyond fusion research.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Grinding and Pelleting Characteristics of Municipal Solid Waste Fractions

The efficient utilization of low-cost carbon feedstocks, such as municipal solid waste (MSW), in biorefineries has become increasingly important for reducing GHG emissions and meeting the growing demand for renewable energy sources. However, MSW as a feedstock presents several challenges, including high moisture content, compositional variability, particle size and shape, density, and ash content. To address these challenges, the potential of mechanical dewatering and high-moisture pelleting processes for densifying MSW fractions, such as paper, cardboard, thin plastic, and thick plastic, into low-cost carbon feedstocks with improved handling and conversion properties were investigated. The effect of these preprocessing technologies on the critical quality attributes (CQAs) of the resulting pellets, including bulk density, durability, and size uniformity, were evaluated. The results showed that with these preprocessing technologies, the paper and cardboard fractions could be pelleted at moisture contents over 40% (w.b.) while achieving >99% durability and >300 kg/m3, while the high moisture plastic fractions were not suitable for pelleting. The thick plastic fraction processed in a screw press was shown to remove up to 30% of the moisture content in a single pass. These findings suggest that these mechanical preprocessing technologies can improve the physical properties of low-cost municipal solid waste fractions for biofuels production.

09 BIOMASS FUELS↗

Weatherization Updates From the National Renewable Energy Laboratory

The National Renewable Energy Laboratory (NREL) provides technical assistance and research to support high-quality work and highly qualified workers in the weatherization and home performance industry. NREL staff will provide updates on their work on the Standard Work Specifications, Home Energy Professional Certifications, Continuous Improvement Workshops, workforce training and research, and other topics.

continuous improvement↗

Cyber-Resilient Distributed Autonomous Energy Grid

The aim of Cyber-Resilient Distributed Autonomous Grid research initiative is to advance fundamental science and engineering approaches for cyber-resilient design, control, and operation of a distributed, highly interconnected, and autonomous energy grid of the future. From increasing penetration of DERs, smart homes and building with highly controllable loads at the distribution layer, to the interconnection of bulk renewables at the transmission layer the fundamental nature of the energy grid is changing, and these changes are enabled by rapid increase in dependence on the communication infrastructure and independent third parties for control and operation of the grid. NREL's Integrated Energy Pathways critical objective correctly identifies that there are fundamental cyber-resilience challenges inherent in the grid's evolution, and this effort is establishing strong and novel integrated cyber-resilience framework and approaches to address these new and fundamental challenges.

controls↗

Process for purification of malonic acid from fermentation broth

A process for the preparation of bio-based malonic acid and crystalline calcium malonate is provided. The calcium malonate is highly pure and provides a source of malonic acid made from a renewable carbon source rather than existing processes which rely on the use of petroleum-based products. The calcium malonate provides an improved source of malonic acid, which is important to many industrial processes.

09 BIOMASS FUELS↗

Extraction of Oil From Camelina Seeds Using Liquefied Dimethyl Ether

With a changing climate and a push for net-zero carbon emissions, sustainable aviation fuel (SAF) is gaining interest worldwide. Due to its compatibility with current infrastructure and potential to reduce emissions by up to 94%, SAF has been identified as the best near-term opportunity to decrease carbon emissions in the aviation industry. SAF can be produced from various renewable feedstocks, with Camelina sativa (L.) seeds standing out due to their high oil content. Conventionally, the oil is extracted using hydrothermal liquefaction (HTL), which involves the pressurized heating of water and biomass up to 400°C, making it incredibly energy-intensive. Conversely, liquefied dimethyl ether (DME) extraction operates at room temperature and is capable of near 100% solvent recycling. In this work, we propose the use of DME extraction as a substitute for HTL, hypothesizing that it can overcome the challenges of current oil extraction methods while maintaining the same oil yields.

09 - BIOMASS FUELS↗

Modeling Tool Development and Validation for Solar Industry Process Heat Using Particle Thermal Energy Storage

U.S. industry sectors used 26.2 quadrillion Btu and accounted for 33% of total energy consumption in 2021 according to the Energy Information Agency. Industrial process heat accounts for 70% of industrial energy use with application temperatures ranging from 60 degrees -1100 degrees C. Industry processes, heavily relying on fossil fuels of cheap coal or natural gas, differ widely in operating conditions and load requirements which makes them difficult to standardize and imposes great challenges in decarbonization. Industry processes require reliable energy supply and vary widely in temperature ranges. Storing energy from renewable sources is necessary to improve reliability and to mitigate renewable intermittency when replacing carbon fuel-based heat supplies to achieve energy savings and reduce emissions. To this end, we have developed a particle-based thermal energy storage (TES) technology using low-cost and highly stable silica sand as a storage medium. The economic and performance-based analysis is key for renewable energy sources to reliably supply industry process heat and ultimately displace fossil fuels for decarbonization. The diversified industrial processes need case-by-case analysis and design. Therefore, an adaptive modeling tool is key for renewable power with energy storage to meet industry demands. Thus, a modeling tool to simulate a solar industry process heat system using the particle TES has been developed using the object-oriented equation-based language Modelica and the commercial platform of Modelon Impact. The Modelica-based software tool provides a general simulation environment for the design of reliable solar energy sources integrated with TES for various industrial process applications at different temperatures for economic competence with fossil fuels such as coal and natural gases. It uses both customized and standard component modeling modules in Modelon libraries for the flexibility to be adapted to a specific energy demand application. The particle TES system establishes a uniform energy supply platform with an efficient heat exchanger and particle thermal energy reservoir integrated with renewable powers. The particle TES system can provide a wide temperature range and can have a large storage temperature difference that increases storage energy density; therefore, it can be an adaptable energy storage system integrated with renewable power to supply 24/7 heat for industry decarbonization.

concentrated solar thermal↗

Impact of High Penetration Distributed Energy Resources on the Bulk Electric System

The growth of distributed energy resources (DERs), mostly generation using intermittent renewable energy sources, along with the retirement of central generation (mostly conventional power plants using fossil-fuel-based resources) has implications for the steady-state and dynamic performance of the bulk electric system (BES). Among the DERs connected to the distribution system, photovoltaic (PV) systems are the most prevalent and have been installed at an increasing rate. Until recently, the penetration levels of DERs have not been high enough to create significant impacts on the reliability and security of power system operation. However, in recent years, the penetration levels of DERs have risen to a level that their impacts on the bulk electric system should be considered in a detailed fashion in planning and operations.

24 POWER TRANSMISSION AND DISTRIBUTION↗

North American energy system responses to natural gas price shocks

As of 2020, North American natural gas extraction and use in the electricity sector have both reached all-time highs. The combination of North America's increased reliance on natural gas with a potential disruption to the natural gas market has several energy security implications. Additionally, policymakers interested in economic resiliency will find this study's results useful for informing the implications of the energy sectors' long-term planning and investment decisions. This paper evaluates how both the electricity and natural gas sectors could respond to hypothetical gas price shocks under different system configurations. We impose unforeseen natural gas price shocks under reference and alternative configurations resulting from a renewable generation mandate or variations to renewable capacity costs. Results from several different models are presented for the electricity and natural gas sectors separately for Canada, Mexico, and the United States. Generally, the US becomes more (less) reliant on electricity imports from Canada given a high (low) gas price shock but increases (decreases) exports to Mexico. The renewable mandate is shown to buffer electricity price increases under high price shocks but price reductions under the low price shocks are dampened given less flexibility to take advantage of the low-priced natural gas. The United States is demonstrated to reduce natural gas production and net exports with high natural gas price shocks given a reduction in demand.

03 NATURAL GAS↗

Reports from the Frontier: Understanding Voltage Losses in Anion Exchange Membrane Water Electrolyzers

With the growth of renewable energy sources, hydrogen is attracting significant attention worldwide as an effective medium for energy storage. “Green hydrogen” is currently produced primarily by water electrolysis in which water is split into hydrogen and oxygen using power from low-carbon energy sources such as wind, solar, and nuclear. Among the low temperature water electrolysis technologies, anion exchange membrane water electrolyzers (AEMWEs) have recently emerged as a promising competitor to traditional alkaline water electrolyzers (AWEs) and proton exchange membrane electrolyzers (PEMELs) due to their potential stack cost reduction in various cell components. In conclusion, favorable aspects of AEMWEs include the use of PGM-free electrocatalysts as well as low-cost membranes, bipolar plates (BPs), and porous transport layers while offering high voltage efficiency and durability.

08 HYDROGEN↗

Children Of the Sun Solar Initiative (COSSI) (Final)

The Children Of the Sun Solar Initiative (COSSI) project is a pivotal step towards energy independence for the Spokane Tribe and the Spokane Indian Housing Authority (SIHA). It involves evaluating the solar potential of 32 SIHA and Tribal buildings, with a goal of achieving energy autonomy through renewable sources. By installing 652.5 kW of solar photovoltaic (PV) systems, the project significantly reduces carbon emissions, lowers energy costs, and enhances sustainability. Key Points: (1) COSSI's mission is to empower the Spokane Tribe and SIHA with clean energy solutions, aligning with their Long-Term Energy Vision. (2) The project includes solar installations on 32 buildings, generating approximately 700,000 kWh annually. (3) It also involves collaboration with SIHA's Weatherization Program and offers training opportunities for tribal members. (4) The installations aid energy efficiency and cost reduction for high-energy-use structures. (5) The initiative advances the Tribe's economic infrastructure, fostering renewable resources and sustainable practices. (6) COSSI serves as a model for leveraging federal funding and tax credits to establish clean energy projects, while generating training and job prospects. (7) The project contributes to energy independence through the adoption of evolving solar technologies. Overall, COSSI is a forward-looking effort to usher in clean energy, enhance infrastructure, and inspire similar projects across tribal and housing authorities.

14 SOLAR ENERGY↗

Thermophotovoltaic efficiency of 40%

Thermophotovoltaics (TPVs) convert predominantly infrared wavelength light to electricity via the photovoltaic effect, and can enable approaches to energy storage and conversion that use higher temperature heat sources than the turbines that are ubiquitous in electricity production today. Since the first demonstration of 29% efficient TPVs (Fig. 1a) using an integrated back surface reflector and a tungsten emitter at 2,000°C (ref. 10), TPV fabrication and performance have improved. However, despite predictions that TPV efficiencies can exceed 50%, the demonstrated efficiencies are still only as high as 32%, albeit at much lower temperatures below 1,300 C (refs. 13,14,15). Here we report the fabrication and measurement of TPV cells with efficiencies of more than 40% and experimentally demonstrate the efficiency of high-bandgap tandem TPV cells. The TPV cells are two-junction devices comprising III–V materials with bandgaps between 1.0 and 1.4 eV that are optimized for emitter temperatures of 1,900–2,400°C. The cells exploit the concept of band-edge spectral filtering to obtain high efficiency, using highly reflective back surface reflectors to reject unusable sub-bandgap radiation back to the emitter. A 1.4/1.2 eV device reached a maximum efficiency of (41.1 ± 1)% operating at a power density of 2.39 W cm –2 and an emitter temperature of 2,400°C. A 1.2/1.0 eV device reached a maximum efficiency of (39.3 ± 1)% operating at a power density of 1.8 W cm–2 and an emitter temperature of 2,127°C. These cells can be integrated into a TPV system for thermal energy grid storage to enable dispatchable renewable energy. This creates a pathway for thermal energy grid storage to reach sufficiently high efficiency and sufficiently low cost to enable decarbonization of the electricity grid.

14 SOLAR ENERGY↗

Optimal design and integration of decentralized electrochemical energy storage with renewables and fossil plants

Increasing renewable energy requires improving the electricity grid flexibility. Existing measures include power plant cycling and grid-level energy storage, but they incur high operational and investment costs. Using a systems modeling and optimization framework, we study the integration of electrochemical energy storage with individual power plants at various renewable penetration levels. Furthermore, our techno-economic analysis includes both Li-ion and NaS batteries to encompass different technology maturity levels. A California case-study indicates localized integration to be cost-effective for greater grid flexibility. Li-ion batteries can mitigate the residual demand fluctuations of small to medium-sized plants, while NaS batteries would be best-suited for larger storage with higher renewable penetration. Overall, the battery-enabled renewable integration could reduce the unmet grid demand by 75%, the renewable curtailment by 58%, and the CO 2 emission intensity by 16% while including the life cycle emissions of the battery and the renewable farm. Our scenario-based analysis also indicates that rather than replacing all fossil power plants, it is more economical to combine batteries and renewables with individual fossil plants to achieve a clean energy grid.

25 ENERGY STORAGE↗

Mesoscale Modeling to Characterize Eagle Soaring Habitat

Uncovering drivers of risk is crucial to understanding interactions between wildlife and wind turbines, and identifying options for impact minimization. These drivers tie to co-variates linked to behavior and movement patterns that allow us to estimate locations and periods of risk. For volant species, atmospheric flow can have significant influence on flight patterns. For obligate soaring birds, like golden eagles, updraft velocities can inform where eagles are likely to travel, at what altitude, and where conditions are not likely sufficient to sustain soaring flight. This has been an active area of study in recent years, using relatively coarse atmospheric data generally at the 20km x 20km scale or larger. Leveraging a 20-year dataset from the Weather Research and Forecasting Model (WRF) (https://www.mmm.ucar.edu/weather-research-and-forecasting-model), we are quantifying vertical velocities across the continental United States at a 2km x 2km resolution. Wind resource data sets originally were static maps showing the mean annual wind speed over an area. However, for these data sets to be optimally used for various applications they must be high-resolution time series, seamlessly span large geographic contexts, and account for uncertainty in wind speed. The National Renewable Energy Laboratory is producing public available datasets that meet these criteria and will be bias corrected to yield the most accurate wind resource data. This effort is an augment to the current WIND Toolkit which houses a high resolution data set. In the new iteration of the WIND Toolkit, a 20-year dataset will be used to improve the accuracy and estimate uncertainty using ensemble and machine-learning techniques. The resulting product will be the most accurate dataset of its size and at a 2km x 2km spatial and 5-minute temporal resolution. Through this work, a mesoscale vertical velocity layer will be produced by calculating the likelihood of orographic updraft and thermal updraft conditions across the continental United States. Specifically, we will use WRF model output combined with digital elevation maps to predict updrafts and then determine if vertical velocities are sufficient to support Golden Eagle soaring and gliding. Ultimately this data layer will be made available as a GIS layer in the Wind Prospector (maps.nrel.gov/wind-prospector/) tool or a similar framework. Data that will be incorporated include wind speed, direction temperature, relative humidity, barometric pressure, air density, precipitation rate, solar radiation, atmospheric stability, skin temperature, and upward heat flux. These products will advance research on interactions between volant species and wind energy by providing open access to highly resolved data with uncertainty quantification not previously available at this scale.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Reversible redox chemistry in azobenzene-based organic molecules for high-capacity and long-life nonaqueous redox flow batteries

Redox flow batteries (RFBs), often categorized as aqueous and nonaqueous systems, represent a type of large-scale energy storage technology for renewable energy resources. Redox-active organic molecules have recently drawn extensive interests in RFBs as promising active materials due to their elemental abundance, structural diversity and high tunability of properties, but employing organic molecules in nonaqueous systems is far limited in terms of useable capacity and cycling stability. Here we introduce a class of azobenzene-based organic compounds with the azo group as redox-active center in the p-conjugated structure as new active materials to realize high-performance nonaqueous RFBs with long cycling life and high capacity. By screening suitable organic solvents with high solubility and conductivity, the azobenzene organic molecule was capable to achieve a stable long cycling with a low capacity decay of 0.014% per cycle and 0.16% per day over 1000 cycles. And the stable cycling of electrolytes under a high concentration of 1 M was also realized, delivering a high reversible capacity of ~46 Ah L -1 . The unique lithium-coupled redox chemistry accompanied with a voltage increase was observed and revealed by experimental characterization and theoretical simulation. With the reversible two-electron redox activity of azo group in p-conjugated structures, azobenzene as an azo-aromatic molecule represents a class of promising redox-active organics for potential grid-scale energy storage systems.

25 ENERGY STORAGE↗

Strikingly high amount of tricin-lignin observed from vanilla (Vanilla planifolia) aerial roots

Lignin has attracted tremendous interest as a renewable resource for biofuels, biomaterials, and chemicals especially in the era of bio-based refineries. The structural studies of lignin play an essential role in both understanding the nature and biosynthesis of these polymers and optimizing their valorization values. In this study, we have investigated the structures of lignin from different tissues—aerial roots, nodes, internodes, and seeds, from vanilla (Vanilla planifolia) by using gel permeation chromatography (GPC), heteronuclear single-quantum coherence (HSQC) nuclear magnetic resonance (NMR), and 31P NMR. An unusual tricin-lignin was observed in the aerial roots of vanilla with an strikingly high level of tricin unit, whereas the lignin from the nodes and internodes displayed traditional S/G type lignin with only 4–10% tricin abundance. The aerial roots lignin is primarily composed of β-O-4' alkyl-aryl ether substructures (96% of linkages) in comparison to 65 and 73% in the nodes and internodes lignin, respectively. Additionally, thioacidolysis quantification results showed that lignin from aerial roots has 29.1 mg g -1 tricin, about 3- to 5-fold higher than the lignins isolated from nodes (10.1 mg g -1 ) and internodes (6.9 mg g -1 ). This communication of a particularly high level of tricin-lignin in vanilla plant has important impacts including: (1) the presence of the high amount of tricin as part of lignin from aerial roots could play a vital role for the valorization of lignin, even tricin itself, as a feedstock for value-added chemicals and commodities; and (2) it could open new ways to scientists to design and engineer the structure of tricin-lignin, or lignin in general, to confer plants with new or improved properties due to the plasticity of lignification.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗