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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 OSTI2023

Deep reinforcement learning assisted co-optimization of Volt-VAR grid service in distribution networks

With the increasing penetration of distributed energy resources in distribution networks, Volt-VAR control and optimization (VVC/VVO) have become very important to ensure an acceptable quality of service to all customers. System operators can rely on slow-responding utility devices, including capacitor banks and on-load tap changing transformers, along with fast-responding battery and photovoltaic (PV) inverters for the VVC/VVO implementation. Because of variations in response time of these two classes of devices, and different control actions (discrete versus continuous), coordinated and optimal scheduling and operation have become of utmost importance. Here, this paper develops a look-ahead deep reinforcement learning (DRL)-based multi-objective VVO technique to improve the voltage profile of active distribution networks, decrease network and inverter power loss, and save the operational cost of the grid. It proposes a deep deterministic policy gradient (DDPG)-based approach to schedule the optimal reactive and/or active power set-points of fast-responding inverters, and a deep Q-network (DQN)-based DRL agent to schedule the discrete decisions variables of slow-responding assets. The reactive power output of PV and battery smart inverters are scheduled at 30-minute intervals and the capacitors’ commitment status is scheduled with several hour intervals. The proposed framework is validated on the modified IEEE 34-bus and 123-bus test cases with embedded PV and PV-plus-storage. To validate the efficacy of the proposed VVO, it is compared with several scenarios, including the base case without VVO, localized droop control of DERs, DDPG-only, and twin delayed DDPG (TD3) agent-based DRL techniques. The results justify the superior performance of the proposed method to improve the voltage profile, reduce network power loss, and minimize the look-ahead grid operational cost while minimizing the undesirable power losses in inverters as a result of power factor adjustments.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2024

The role of hydrogen as long-duration energy storage and as an international energy carrier for electricity sector decarbonization

With countries and economies around the globe increasingly relying on non-dispatchable variable renewable energy (VRE), the need for effective energy storage and international carriers of low-carbon energy has intensified. This study delves into hydrogen's prospective, multifaceted contribution to decarbonizing the electricity sector, with emphasis on its utilization as a scalable technology for long-duration energy storage and as an international energy carrier. Using Japan as a case study, based on its ambitious national hydrogen strategy and plans to import liquefied hydrogen as a low-carbon fuel source, we employ advanced models encompassing capacity expansion and hourly dispatch. We explore diverse policy scenarios to unravel the timing, quantity, and operational intricacies of hydrogen deployment within a power system. Our findings highlight the essential role of hydrogen in providing a reliable power supply by balancing mismatches in VRE generation and load over several weeks and months and reducing the costs of achieving a zero-emission power system. The study recommends prioritizing domestically produced hydrogen, leveraging renewables for cost reduction, and strategically employing imported hydrogen as a risk hedge against potential spikes in battery storage and renewable energy costs. Furthermore, the strategic incorporation of hydrogen mitigates system costs and enhances energy self-sufficiency, informing policy design and investment strategies aligned with the dynamic global energy landscape.

08 HYDROGEN↗
DOE OSTI2025

Application of a temporal multiscale method for efficient simulation of degradation in PEM Water Electrolysis under dynamic operating conditions

Hydrogen is emerging as a vital energy carrier, driven by the need to reduce carbon emissions. Proton Electrolyte Membrane Water Electrolysis (PEMWE) enables hydrogen production under fluctuating renewable power conditions but requires improved understanding and stability of the anode catalyst layer under dynamic operating conditions, especially with low noble metal loadings. Long-term degradation experiments are both time-consuming and costly; therefore, a systematic, model-aided approach is essential. In the present work, a temporal multiscale method is applied to reduce the computational effort of simulating long-term degradation processes in PEMWE, with an exemplary focus on catalyst dissolution. A mechanistic model incorporating the oxygen evolution reaction, catalyst dissolution, and hydrogen permeation from the cathode to the anode was hypothesized and implemented. In this way, the local periodicity of transport and reaction processes in dynamic PEMWE operation, which influence the gradual degradation of the catalyst layer, is captured. The temporal multiscale method significantly reduces the computational effort of simulation, decreasing processing time from hours to mere minutes. This efficiency gain is attributed to the limited evolution of Slow-Scale variables during each period of time P of the Fast-Scale variables. Consequently, simulation is required only until local periodicity is achieved within each Slow-Scale time step. Hence, the fully resolved dynamic problem is decoupled into these two scales, employing a heterogeneous multiscale technique. The developed approach effectively accelerates parameter estimation and predictive simulations, supporting systematic modeling of PEMWE degradation under dynamic conditions.

08 HYDROGEN↗
DOE OSTI2024

Development of Property Composition Models For RPP-WTP LAW Glasses (Final Report)

This report describes the development of property-composition models for low-activity waste (LAW) glasses for the River Protection Project Waste Treatment Plant (RPP-WTP) at the Hanford site. The RPP-WTP will separate Hanford tank wastes into LAW and high-level waste (HLW) streams and each stream will be vitrified separately. The development of LAW and HLW glass formulations for the RPP-WTP has been reported previously and is an ongoing activity. Acceptable formulations must meet a variety of processability, product quality, and waste loading requirements that are dictated either by the RPP-WTP contract or by the characteristics of the particular treatment processes that have been selected. These requirements amount to constraints on the acceptable ranges of certain glass properties. These properties are determined first and foremost by the composition of the glass or glass melt. Thus, while there is no direct way of controlling the glass properties of interest during production, there are simple and extremely effective methods of achieving the same result by instead controlling the glass composition. This basic principle is no different from that used to produce enormous volumes of commercial glass to meet exacting product specifications. An essential difference in waste vitrification, however, is that one of the raw materials (the waste itself) can be subject to considerable compositional uncertainty and variability. Thus, waste vitrification facilities and associated process control systems (of which, the operating envelope in glass formulation space is a key part) must, of course, be designed to be robust with respect to such variations. The determination of quantitative relationships between the glass properties that must be controlled and the glass composition can play an important role in the development of such facilities.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

Development of Scalable Coastal and Offshore Macroalgal Farming

The US DOE/ARPA-E MARINER program funded a four-year project to determine an optimal way to grow kelps in large, nearshore and offshore arrays for the eventual purpose of biofuel production with the goal of keeping the cost below $\$$80 USD per dry metric ton of kelp. This project specifically looked at how Saccharina latissima can be grown in the Gulf of Alaska to reach that goal. There were three major aspects of the research: 1) optimizing nursery production and seeding lines for outplanting, 2) designing an economical, modular outplanting structure and 3) developing methods to efficiently harvest the product. Farm designs were based on catenary structures and the use of spreader bars with variable spacing of grow lines and line types. The spacing of the grow lines makes a difference in the yield. Grow line spacing of ≥1.5m showed about a 50% increase in kg/m. There was no statistical difference in the growth of Saccharina latissima whether in the middle or the outside of the array, but the line type and perhaps line thickness can make a difference in yield. Sagging caused by the weight of the mature fronds resulted in lower growth at depth. Various harvesting approaches for mature kelps were tested by collaborating farmers. One promising innovation is the use of large bags for holding the freshly harvested fronds. Although the weight of the fronds on the growlines causes the lines to sink, the bags packed with the harvested fronds float, allowing for easy loading to the transfer vessel. Another advance in harvesting is a specially built harvest vessel, the Harvest Buddy, allowing a more mechanized and faster way to harvest. A significant aspect of this project was the TTO/T2M. Several different outreach activities were performed by the Alaska Fisheries Development Foundation and GreenWave. A techno-economic assessment (TEA) using our data has pointed to solutions to reach the $\$$80 goal. A second phase of this project involved the co-culture of two different species of kelps. Interest in farming kelps has grown beyond using kelp for food, feed or biofuels. There is considerable interest in generating biomass from seaweed for use in bioplastics and other products that would substitute for petroleum-derived products. For these uses to be viable, large amounts of biomass are needed. Very large kelp farms can be expensive to build and maintain, leading to the need to optimize the biomass per unit area. Although close spacing of growlines can lead to poor growth, a viable approach may be to grow two species of kelps together: one that hangs down and one that is buoyant, growing up. This system would increase the spacing in three dimensions. In Alaska, Saccharina latissima is commonly grown hanging down from longlines. One of the buoyant Alaskan kelps is Nereocystis luetkeana. Because there are commercial uses for wild-harvested Nereocystis in Alaska, we undertook a preliminary trial in Kodiak, Alaska that grew both Saccharina and Nereocystis in the same longline array. Closely spaced lines were seeded the first week of February 2023 and set at 3m below the surface. The arrays were harvested in late June 2023. Despite having 45% fewer grow-lines, the total yield of the Nereocystis on the combined arrays was statistically similar to the Nereocystis only arrays. Total yields were greatest on the combined arrays, followed by the Nereocystis only and Saccharina only arrays. These results may have significance for large scale macroalgal production.

09 BIOMASS FUELS↗
DOE OSTI2022

Colorado Residential Retrofit Energy District (CoRRED) Phase I: Final Modeling Results

Electrification of buildings and transportation coupled with increased deployment of distributed energy resources (DERs) has been identified as a key step toward meeting emissions reduction goals across the U.S. Examples of pilot projects that feature innovative, 'smart' electric neighborhoods are largely focused on new construction projects, but there is a need to address the millions of existing homes so that they too may accommodate cleaner yet variable energy production in ways that benefit both the utility grid and the homes' residents. The Colorado Residential Retrofit Energy District (CoRRED) project used building and grid co-simulation tools to model an advanced energy district demonstration in an existing residential neighborhood in Denver, Colorado, and explored how existing building and utility infrastructures can be enhanced with combinations of traditional energy-efficiency retrofit measures and integration of solar panels and other DER technologies to provide better affordability and reliability. We analyzed which packages of DERs most reliably enable demand flexibility in response to a time-of-use (TOU) rate. Our results clearly indicate that incorporating DERs into efficient electrification produces much bigger utility bill savings on an annual basis than efficient electrification without DERs. While electrifying a neighborhood will increase the maximum load, batteries and solar panels can reduce load during peak hours so that the community can be a net producer during peak periods. A remaining challenge is to overcome first cost barriers to implementing energy-efficiency and DER technologies, as modest utility bill savings require long payback periods that are not practical for most homeowners.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2026

Multipoint Aerostructural Optimization of Wind Turbine Rotors Using a Coupled Blade‐Resolved Aerostructural Solver

Physics‐based design optimization workflows thread the needle between computational cost limitations and simulation complexity, often compromising between modeling detail and the range of operating design conditions. Multipoint aerostructural optimization of wind turbine rotors has so far been confined to low‐fidelity analyses or to high‐fidelity studies with simplified structural models, leaving the most complex design trade‐offs unexplored. We close this gap by performing the first tightly coupled gradient‐based multipoint aerostructural rotor optimization using 3D aerodynamic and structural solvers with discrete coupled adjoints. The optimizer simultaneously varies blade planform, airfoil shapes, and structural thickness through more than 270 design variables, minimizing a weighted combination of rotor mass and power across multiple wind speeds. Applied to a modified DTU 10‐MW benchmark under conservative structural and aerodynamic constraints, our multipoint optimization reduces rotor mass by up to 36% and increases power by 12%–15% across the main operating conditions; biasing the objective toward power yields power gains up to 18% and a 17% mass reduction. For a nominal wind distribution, 3‐point rotor designs accounting for low RPM and high thrust conditions capture dominant trade‐offs and outperform single‐point designs. Adding two off‐design points changes individual‐condition power by less than 3% but leaves the weighted average within 0.5%, and the mass‐power bias has a stronger effect on the final design than the operating‐point weighting itself. Our framework extends naturally to richer load cases and site‐specific wind distributions, providing a basis for high‐fidelity multipoint design earlier in industrial workflows.

17 WIND ENERGY↗
DOE OSTI2023

Solution and sensitivity analysis of nonlinear equations using a hypercomplex-variable Newton-Raphson method

Here, the classical Newton-Raphson (NR) method for solving nonlinear equations is enhanced in two ways through the use of hypercomplex variables and algebra. In particular, i) the Jacobian is computed in a highly accurate and automated way, and ii) the derivative of the solution to the nonlinear equations is computed with respect to any parameter contained within the system of equations. These advances provide two significant enhancements in that it is straightforward to provide an accurate Jacobian and to construct a reduced order model (ROM) of arbitrary order with respect to any parameter of the system. The ROM can then be used to approximate the solution for other parameter values without requiring additional solutions of the nonlinear equations. Several case studies are presented including 1D and 2D academic examples with fully functioning Python code provided. Additionally, a case of study of the catenary of an elastic cable subject to its own weight and a vertical point load. Derivatives up to 10th order were computed with respect to material, loading, and geometrical parameters. The derivatives were used to generate reduced order models of the cable deformation and reaction forces at its ends with respect to multiple input parameters. Results show that from a single hypercomplex evaluation of the cable under a single vertical point load, it is possible to generate an accurate reduced order model capable of predicting the cable deformation with 1.5 times the load in the opposite direction and with 3.5 times the load in the same direction without resolving the system of equations.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2026

Inundation and Sediment Supply Predict Annual but Not Centennial Carbon Accumulation in Tidal Wetlands Across Land‐Use Types

Despite growing interest in the contributions of tidal wetlands to natural climate solutions, data remain scarce on how land use affects their carbon accumulation rates (CAR). Additionally, environmental factors driving the large observed variability in CAR among sites are poorly understood. To address these knowledge gaps, we measured short-term (∼1 year) and long-term (∼100 years) CAR using feldspar marker horizons, 210 Pb profiles, and surface elevation tables from 39 sites in seven estuaries in Oregon and Washington, USA. Sites varied in wetland type (tidal marsh, tidal swamp, nontidal pasture), land-use history (reference, restored, and disturbed), and salinity (fresh to polyhaline). Across both timescales, CAR was lowest in disturbed pastures and highest in restored marshes, reflecting patterns in sediment accretion rates. Short-term CAR exceeded long-term CAR by approximately 50% on average and was only weakly correlated with long-term CAR, with differences among hydrogeomorphic setting. Short-term CAR was well predicted by summer inundation frequency and relative sediment load, together explaining 60% of variance, whereas long-term CAR was poorly predicted by contemporary environmental conditions. These findings highlight the importance of aligning predictor and response timescales when modeling blue carbon dynamics, and reinforce the climate mitigation potential of tidal wetland restoration.

land use and land cover change↗
DOE OSTI2025

Clarifying the trophic state concept to advance macroscale freshwater science and management

For over a century, ecologists have used the concept of trophic state (TS) to characterize an aquatic ecosystem's biological productivity. However, multiple TS classification schemes, each relying on a variety of measurable parameters as proxies for productivity, have emerged to meet use‐specific needs. Frequently, chlorophyll a, phosphorus, and Secchi depth are used to classify TS based on autotrophic production, whereas phosphorus, dissolved organic carbon, and true color are used to classify TS based on both autotrophic and heterotrophic production. Both classification approaches aim to characterize an ecosystem's function broadly, but with varying degrees of autotrophic and heterotrophic processes considered in those characterizations. Moreover, differing classification schemes can create inconsistent interpretations of ecosystem integrity. For example, the US Clean Water Act focuses exclusively on algal threats to water quality, framed in terms of eutrophication in response to nutrient loading. This usage lacks information about non‐algal threats to water quality, such as dystrophication in response to dissolved organic carbon loading. Consequently, the TS classification schemes used to identify eutrophication and dystrophication may refer to ecosystems similarly (e.g., oligotrophic and eutrophic), yet these categories are derived from different proxies. These inconsistencies in TS classification schemes may be compounded when interdisciplinary projects employ varied TS frameworks. Even with these shortcomings, TS can still be used to distill information on complex aquatic ecosystem function into a set of generalizable expectations. The usefulness of distilling complex information into a TS index is substantial such that usage inconsistencies should be explicitly addressed and resolved. To emphasize the consequences of diverging TS classification schemes, we present three case studies for which an improved understanding of the TS concept advances freshwater research, management efforts, and interdisciplinary collaboration. To increase clarity in TS, the aquatic sciences could benefit from including information about the proxy variables, ecosystem type, as well as the spatiotemporal domains used to classify TS. As the field of aquatic sciences expands and climatic irregularity increases, we highlight the importance of re‐evaluating fundamental concepts, such as TS, to ensure their compatibility with evolving science.

classification↗
DOE OSTI2021

Performance Considerations for Ground Source Heat Pumps in Cold Climates: Preprint

Remote, cold climates present challenges to finding safe and affordable options to heat homes. In Alaska, residential ground source heat pumps (GSHPs) have been gaining in popularity to fill this gap. However, there is little research on their long-term performance or effect on soil temperatures. The extended heating season and cold soils of Alaska provide a harsh testing ground for GSHPs, even those designed and marketed for colder climates. The large and unbalanced heating load of cold climates creates a challenging environment for GSHPs. In 2013 the Cold Climate Housing Research Center (CCHRC) installed a GSHP at its Research and Testing Facility (RTF) in Fairbanks, Alaska. The heat pump replaced an oil-fired condensing boiler heating a 464 m2 office space via an in-floor hydronic radiant heating system. The ground heat exchanger (GHE) was installed in moisture-rich silty soils underlain with permafrost near 0°C. The intent of the installation was to observe and monitor the system over a 10-year period in order to develop a better understanding of the performance of GSHPs in sites with permafrost and to help inform future design. As of this writing, the heat pump system has been running for seven heating seasons. The efficiency in those seven heating seasons has been variable with ups and downs that have been difficult to explain. This paper seeks to understand the variability in performance as well as make recommendations for GSHP use in other cold climates.

cold climate↗
DOE OSTI2022

Optimal management of electric hotel loads in mild hybrid heavy duty truck

Here, the problem of engine idling for heavy-duty trucks has been under study for decades with Auxiliary Power Units (APUs) and Truck Stop Electrification (TSE) as the most compelling solutions. With the electrification of trucks approaching feasibility in terms of cost-effective technology, hybridization offers another “degree of freedom” to tackle the problem. Here, this work aims at exploiting a battery pack of a 48 V mild-hybrid heavy-duty truck to store sufficient onboard energy for powering the auxiliary loads during the hoteling. This problem is not trivial, as the battery packs typically cannot recover the entire energy required through regeneration alone; hence an optimal energy management strategy needs to be employed to charge the battery through the engine during drive operation. This strategy optimizes powertrain performances among the four modes: (i) Engine of Coasting (EOC), (ii) Regeneration by braking, (iii) Regeneration by engine, and (iv) engine idling. This paper presents the development of a Dynamic Programming (DP) framework that employs a multi-objective cost function to minimize the fuel consumption and maximize the regeneration using the above-mentioned four modes. A typical heavy-duty truck drive cycle is used to represent the drive phase, with mandatory hoteling stops as per regulations. A comprehensive powertrain model is developed using validated components’ model. The DP employs two state variables: battery State-of-Charge (SOC) and engine mode, and three control inputs: (i) the engine ON–OFF state, (ii) clutch engagement state, and (iii) power request at the Electric Machine (EM) for calculating optimal SOC trajectory. The framework also tackles rapid engine ON–OFF scenarios to avoid the challenges associated with DP and the compromises in fuel cost with those approaches. Finally, the effectiveness of the proposed framework is tested for potential fuel savings on two different battery packs by performing the full cycle simulations. The results show 6.47% of fuel consumption reduction as compared to traditional APU-based heavy-duty truck.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2022

Meshfree Methods for Modeling Chemo-Mechanical Cathode Cracking in Li-Ion Batteries

Through repeated charging and discharging, the electrodes of a Li-ion battery experience cyclic loading causing swelling and contraction due to the movement of lithium, also known as intercalation. This research focuses specifically on the chemo-mechanical cracking in the cathode. Because cathode particles are comprised of many randomly-oriented grains, which have highly anisotropic material properties, the expansion and contraction is very non-uniform. As a result, stress concentrations tend to form between grains, which necessitates the modeling of crack propagation largely along grain boundaries. Chemo-mechanical models are simulated mainly by two methods: the cohesive zone model (CZM) and the continuous damage model (CDM). The CZM is more accurate at capturing the sharp discontinuities of a crack but is very computationally expensive and intractable for large-scale models as a result. Conversely, the CDM is easily computed but not well-suited to easily allow for discontinuous field variables, which are inherent across a crack. This study aims to improve the CDM's ability to capture discontinuous cracks. Current versions of the CDM use the finite element method (FEM), which is one of the most widely used approaches for spatial discretization. This research investigates the use of the Reproducing Kernel Particle Method (RKPM), a meshfree method, for spatial discretization and aims to achieve a chemo-mechanical crack propagation model that achieves both intermediate accuracy and computational time between a CDM and CZM. To gain a better understanding of how the meshfree model compares to the current FEM model in capturing cathode crack propagation, further investigation is needed.

cathode cracking↗
DOE OSTI2020

Characteristics of locational uncertainty marginal price for correlated uncertainties of variable renewable generation and demands

With the rapid increase of variable renewable energy sources in power systems, how to manage and price the uncertainty of renewable resources’ power outputs is becoming an urgent issue. Current market designs considering the uncertainties are mainly based on the probabilistic scenario set of demand and renewable energy resources power outputs. This consideration makes market designs vulnerable to three significant challenges when put into practice. First, the accurate probability distribution of renewable generation is hard to obtain in real-time. Second, it is challenging to clear the market timely with many scenarios to guarantee accuracy. Third, generation cost recovery cannot be guaranteed for some scenarios. To overcome these challenges, this paper proposes a locational uncertainty marginal price model to price the uncertainty explicitly based on a scenario-free stochastic market-clearing model. Instead of using the probabilistic scenario set, the uncertainty of renewable energy sources and loads is modeled with distributionally-robust chance constraints. The correlation of uncertainties can be endogenously modeled in both the market-clearing and the locational uncertainty marginal price formation. Furthermore, this paper proves that generation cost recovery, revenue adequacy, and partial market equilibrium can be achieved using the locational uncertainty marginal price model. Numerical results from both the small and large systems simulations validate that the generation cost recovery is maintained no matter the generation participates in uncertainty mitigation or not. The transmission congestion surplus is also allocated appropriately among loads, renewable energy sources, and financial transmission right owners.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2023

Understanding the Shift of Drivers of Soil Erosion and Sedimentation Based on Regional Process-Based Modeling in the Mississippi River Basin During the Past Century

Soil erosion and sedimentation problems remain a major water quality concern for making watershed management policies in the Mississippi River Basin (MRB). It is unclear whether the observed decreasing trend of stream suspended sediment loading to the mouth of the MRB over the last eight decades truly reflects a decline in upland soil erosion in this large basin. Here, for this work, we improved a distributed regional land surface model, the Dynamic Land Ecosystem Model, to evaluate how climate and land use changes have impacted soil erosion and sediment yield over the entire MRB during the past century. Model results indicate that total sediment yield significantly increased during 1980–2018, despite no significant increase in annual precipitation and runoff. The increased soil erosion and sediment yield are mainly driven by intensified extreme precipitation (EP). Spatially, we found notable intensified EP events in the cropland-dominated Midwest region, resulting in a substantial increase in soil erosion and sediment yield. Land use change played a critical role in determining sediment yield from the 1910s to the 1930s, thereafter, climate variability increasingly became the dominant driver of soil erosion, which peaked in the 2010s. This study highlights the increasing influences of extreme climate in affecting soil erosion and sedimentation, thus, water quality. Therefore, existing forest and cropland Best Management Practices should be revisited to confront the impacts of climate change on water quality in the MRB.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

A Time-Dependent Directional Damage Theory for Brittle Rocks Considering the Kinetics of Microcrack Growth

In this work, a novel microcrack damage theory for describing the time-dependent behavior of brittle rocks is proposed. Instead of using scalar or tensorial variables to approximate the effect of microcracks, the concept of directional damage is introduced by upscaling the directional distribution density of microcracks through the noninteracting homogenization scheme. The contribution of an individual crack on global strain is first derived from the crack-opening displacements including sliding, closure, and dilation. The model is then cast in the free energy form, and the range of parameters ensuring compliance with the second law of thermodynamics is derived rigorously. Considering that the subcritical propagation of microcracks is the dominant mechanism behind the time-dependent deformation and failure of brittle rocks, the driving force for directional damage is defined as the corresponding energy release rate, and the effect of time is introduced through a damage evolution law inspired from the kinetics of subcritical crack growth. The model is applied to simulate the behavior of basalt rock under various loading conditions. In addition to predicting the stress–strain–time response, the model offers enhanced resolution in representing the anisotropic characteristics of microcrack-induced damage in brittle rocks and their time-dependent evolutions.

58 GEOSCIENCES↗
DOE OSTI2022

Flexible FlueCO2

Carbon dioxide (CO2) emission reductions remain a significant challenge on the path to clean energy. There are increasing legislative, social, and environmental factors motivating CO2 emissions reduction from power plants with carbon capture and storage (CCS). CCS in natural gas combined cycle (NGCC) power plants is critical to achieve a net-zero carbon electricity grid. Enhanced 45Q tax credits provide new incentives, but currently available technologies are unable to profitably operate in grids with deep variable renewable penetration which require flexible NGCC operation. Luna Labs has developed the FlueCO2 membrane to enable a profitable NGCC-CCS process. The FlueCO2 membrane couples steam transport across the membrane to CO2 transport in the opposite direction, enabling high capture efficiencies and low energy costs even at low CO2 concentrations. The dual-phase membrane can operate in the range of typical flue gas temperatures and pressures and does not require temperature or pressure cycling. Luna Labs’ FlueCO2 technology enables flexible and profitable operation of NGCC plants with lower capital investment and impact on electricity prices. In this Phase 1 project, Luna Labs utilized experimental testing, modeling, process simulation, and standardized costing methodologies to evaluate the techno-economic value of a 650 MW greenfield NGCC plant with FlueCO2 (NGCC-FlueCO2). Key design requirements for operation were established and plant performance under load-leveling conditions was validated through computational fluid dynamics and process modeling. Luna Labs developed a dynamic modeling tool which modeled plant operational modes across a variety of tax structures and electricity pricing scenarios to project the overall Net Present Value (NPV) of the NGCC-FlueCO2. FlueCO2 minimizes the impact of CCS integration on plant operation by integrating directly into the NGCC heat recovery steam generator (HRSG). By tapping into the plant’s low-pressure (LP) steam, operators can divert LP steam to the greenfield NGCC and/or CCS process in response to dynamic markets. Since FlueCO2 will not significantly affect HRSG (or NGCC) operation, CCS only turns off during peak power demand (>$250/MWh). Under baseload conditions, FlueCO2 lowers the capital (37%), energy (36%) and carbon capture (<$40/tonne) costs and can increase the overall plant lifetime NPV by approximately ~$1B in comparison with NGCC solvent-based capture reference cases (NETL Case 31B). Luna Labs has shared its costing tools with several interested partners and customers, which follows a generalizable approach to costing analysis.

Kelly, Jesse↗
DOE OSTI2025

Field Validation of Thermoelectric Generation System at Holcim Cement Plant in Alpena, Michigan

Executive Summary Project Background The Industrial Technology Validation (ITV) program aims to identify and demonstrate the performance of new, emerging, and underutilized energy-saving technologies in the industrial sector to help inform decisions to help accelerate their commercialization and deployment, as well as to help make industries more competitive. This ITV demonstration evaluated a thermoelectric generation (TEG) technology at a cement plant, aiming to reduce energy demand in the cement industry. A median cement plant consumes 5.73 million British thermal units per ton of clinker production (resulting in 0.838 metric tons of carbon dioxide [CO₂] emissions per ton of clinker) (Boyd and Zhang 2011, EPA 2021), equivalent to approximately 6.9 trillion British thermal units (TBtu) per year in energy consumption at a cement plant producing 3,300 tons of clinker per day.¹ Collaborating with Holcim, Advanced Thermovoltaic Systems (ATS) developed and deployed a pilot-scale thermoelectric power system to efficiently capture and convert waste heat to electricity. The system leverages the Seebeck effect to convert temperature differences on two sides of semiconductor cartridges into electrical power (ScienceDirect, n.d.). This generation is realized with minimal moving parts compared to existing waste-heat-to-generation solutions and allows capture from heat sources with temperatures as low as 150°C. This project aimed to validate a scalable solution applicable for capturing medium-temperature waste heat, including ambient losses from other high-temperature processes, and high-temperature sources less suitable for other waste-heat-to-power solutions. By recovering this otherwise wasted heat, this project intends to validate improvements to overall process efficiency through reduction in purchased electricity, thereby reducing operational costs while enhancing resiliency and competitiveness. Description and Scope This study evaluated the performance of a TEG system from ATS as a solution to convert waste heat into useful power at a Holcim cement plant in Alpena, Michigan. This plant is a fully integrated cement plant that has been operating since 1907. The facility operates continuously (24/7/365) with approximately 250 employees and five long dry kilns, yielding a total production capacity of 7,852 tons of cement per day (EPA 2023). Currently, the Alpena plant uses waste heat boilers to convert waste heat from the exhaust of each kiln into steam, which drives steam turbine generators. The ATS TEG is being evaluated for its potential to supplement the steam turbines by capturing the remaining lower grade heat. This technology is also being considered for other Holcim plants where steam turbines are not a viable option. ATS installed a pilot-scale TEG unit with an array of 582 individual thermoelectric semiconductor cartridges, of which 573 were operational. The cartridges are sandwiched between 48 hot plates and 49 cold plates. Each cartridge is designed to generate 20 watts (W) of gross power at a hot-side temperature of 240°C and cold-side temperature of 20°C. As such, the total gross generation capacity of the installed system is 11.5 kilowatts (kW) at design conditions. The system configuration for the evaluation was designed to prioritize convenience of installation and minimize disruption to production at the site, while ensuring that the heat required can be obtained for evaluating the TEG system at various operational conditions. To accomplish this, a portion of the steam supplied to Alpena’s steam turbine generation system was diverted to be used as the heat source for the TEG system, while water was supplied to the cold side of the system from nearby Lake Huron. This configuration was designed for the evaluation of the pilot-scale system to assess the performance at different conditions. A commercial-scale system will likely vary from the pilot system depending on typical configurations, including both scale and application. Future commercial applications of the ATS system would involve integrating the system into the exhaust from kiln preheaters, clinker coolers, or radiant heat capture from kiln shells for the heat source. For the cold source, a range of cooling solutions can be considered, including a mechanical cooling system, depending on the location and the application. To increase the generation capacity for commercial applications, the technology provider is working toward developing a commercial-scale TEG system, which would combine multiple TEG units (each similar in design to the pilot system) together. The scope of this evaluation includes the pilot-scale TEG system and all impacted equipment including pumps, controllers, and power handling equipment. Study Objectives The evaluation's goal was to assess the potential of the ATS TEG system to generate useful electrical power by capturing waste heat from cement production kilns. The objectives of this study are to evaluate and verify the following claims made by ATS regarding the pilot-scale system installed at the Holcim Alpena plant. The following design parameters and claims are also outlined in Table ES- 1 and Table ES- 2: • Gross Power: The thermoelectric system converts heat into power to create gross power, the total measured power generated by the system. The 573 active cartridge pilot-scale system is expected to generate 11.5 kW of gross power at the designed hot-side temperature of 240°C and cold-side temperature of 20°C. Power production is dependent on the temperature difference between the heat source (ultimately from the waste heat) and cold temperature supply source. • Net Power: The net power is the total usable power provided to the site by the TEG system after deducting parasitic power loads from the gross generated power. Supplementary equipment is required to operate the TEG system including pumps, controllers, and, in certain anticipated applications, mechanical cooling, which introduce parasitic loads to system operation. After deducting the parasitic loads from the gross power generation, ATS anticipates achieving a net power generation of 7.5 kW from the pilot-scale system. • Thermal Efficiency: The thermal efficiency is the percent of the total heat transferred to the TEG system that is converted to gross power. Historically, TEGs have a thermal efficiency of 2%–5% (DOE 2008). Prior industrial-scale TEG systems, such as the E1 TEG offered by Alphabet Energy, operated at an efficiency of 2.5% (Lamonica, 2014). ATS anticipates achieving an average efficiency of 4.8% or higher in converting heat energy to usable electricity. • Cartridge Performance: The TEG system comprises 573 active individual semiconductor cartridges, each of which generates a portion of the total power. Cartridge optimization and selection is an important design consideration for potential future TEG system design performance. Therefore, understanding the distribution of gross power and efficiency within the pilot system is vital to understanding what is achievable. At a design hot-side temperature of 240°C and cold-side temperature of 20°C, ATS anticipates a cartridge performance of 20 W of gross power per cartridge at an efficiency of 4.8% per cartridge. In addition to evaluating the claimed performance of the TEG pilot-scale unit, the study estimated the potential annual impacts of a scaled-up commercial system used to capture kiln waste heat over annual operations. The evaluation estimated the gross and net annual electric generation achievable by capturing heat from the two proposed tap-in points: the kiln exhaust and the clinker cooler exhaust; see Section 2.1 for details. Two use cases were examined: • Holcim Alpena: The Holcim Alpena site consists of long dry kilns with superheater boilers, which differs from the rest of Holcim’s cement plant portfolio and results in lower waste heat temperatures. The study estimates gross and net annual generation using the superheater boiler exhaust and clinker cooler exhaust, based on 2023 operational data. • Typical Installation: Common cement plants have preheater kilns with higher exhaust temperatures than Holcim Alpena across a range of production rates. The study estimates gross and net annual generation using the preheater exhaust and clinker cooler exhaust, with a sensitivity analysis to account for the typical range of preheater exhaust temperatures, clinker cooler exhaust temperatures, and clinker production rates. Methodology The evaluation methodology followed a measurement and verification (M&V) strategy based on the International Performance Measurement and Verification Protocol Option B through comprehensive measurements and analyses of the affected systems. Evaluation data was collected from March 9 to March 11, 2024, the test period of the pilot TEG system. During the test period, in coordination with the ITV team, the ATS team adjusted system operations to capture the range of variability expected for each of the variables pertinent to performance of the system. The methodology consisted of two parts: evaluating the performance of the pilot unit's TEG system and estimating the annual TEG impact in terms of gross and net power based on a given waste heat profile. First, the evaluation of the thermoelectric generation performance of the pilot unit relative to the claims was performed by analyzing the collected test data. Gross power of the pilot TEG system was directly measured. Net power was determined by deducting the measured parasitic power from the gross power. The gross power generation was compared to heat transferred to the system by the working fluid (which was heated by steam generated from the kiln waste heat) to calculate the thermal efficiency achieved by the system. Performance of individual semiconductor cartridges within the pilot array was also assessed in terms of measured gross cartridge power and calculated cartridge thermal efficiency. The second part of the evaluation estimated the annual TEG impacts in terms of gross power and net power (calculated from the difference between gross power and parasitic power). This analysis comprised development of mathematical regression models for gross power and parasitic power, with assessment of each model’s goodness-of-fit characteristics to ensure satisfaction of statistical requirements. The models predicted the gross power generation, the parasitic load based on the temperature difference between the hot working fluid and the cold-side fluid (cold water from Lake Huron) entering the system, the volumetric flow rate of the cold-side fluid at the inlet, and the volumetric flow rate of the hot working fluid at the inlet. The annual impact analysis considered a theoretical commercial-scale system sized to capture the available waste heat at a cement plant, consisting of linked pilot-scale units that receive heat from a theoretical gas-to-working-fluid heat exchanger. To estimate annual impacts at the Alpena plant, the gross power and parasitic power regression models were applied to the arrays in the theoretical commercial-scale system. The heat supplied to the unit was calculated based on the kiln run time, annual production, kiln exhaust waste heat, and clinker cooler waste heat derived from 2023 Holcim Alpena kiln operational data. Net power impacts were calculated by deducting the resulting parasitic power from the estimated gross power. Inputs for the model were generated from a combination of hourly data, assumed design considerations for TEG system scale-up from the pilot-scale unit, and assumptions regarding TEG system operations. This analysis was then used as the basis for estimating annual impacts of typical TEG installation at cement plants, by applying sensitivity analyses to key kiln operational characteristics including kiln preheater exhaust temperatures, cooler clinker exhaust temperatures, and plant daily production rates across a range of expected values. Project Results/Findings Table ES- 2 and Table ES- 2 provide a summary of the operating conditions and evaluation results compared to the stated claims from the technology provider. Key takeaways include: • Gross Power: The peak gross power achieved during the testing period was 10.0 kW, compared to the 11.5 kW expected for 573 active cartridges. The claimed gross power was associated with a target hot side of 240°C; however, the system only received a maximum hot-side mean plate temperature of 212°C during the testing period. • Net Power: The pilot-scale unit exceeded the claims for net power, achieving a peak of 7.7 kW net compared to a claim of 7.5 kW. One factor contributing to the higher achieved net power is the relatively high water pressure available through Lake Huron. The pilot TEG system did not require cold-side pumps during the test, whereas most installations would. This reduced the parasitic loads on the system, ultimately contributing to higher net power relative to the gross power. • Thermal Efficiency: The pilot-scale unit outperformed the claimed efficiency, achieving a peak system efficiency of 5.0% thermal efficiency compared to the stated 4.8%. • Cartridge Performance: To compare cartridge performance against claims, the study focused on the third day of testing, which aimed for conditions closest to the design specifications, with a hot side of 240°C and cold-side exit temperature of 6.4°–30°C. On this day, the mean gross power observed in the cartridges within the TEG array was 18.1 W/cartridge, and the peak performance was 34.7 W/cartridge. The estimated mean cartridge efficiency was 5.2%, and the estimated efficiency at peak gross cartridge power was 10%. The regression models developed for gross power generation and parasitic loads were used to estimate the generation impact for given heat input to the TEG from the working fluid (captured from the waste heat) and from the cold loop (Lake Huron) on an hourly basis for a year of operation. Based on this analysis, installation of a commercial-scale TEG system at the Holcim cement plant in Alpena, Michigan, with a waste heat exchanger of 0.85 effectiveness, would generate up to 391 kW of net power, translating to between 920,000 and 1,800,000 kilowatt-hours (kWh) in net electricity per year. Based on typical grid emissions for Alpena, this would avoid estimated net emissions by 752 metric tons of CO₂ annually.² The sensitivity analysis estimated that typical TEG system installations at cement plants could generate an average of 56–1,040 kW of net power, or between 488,000 and 9,110,000 kWh of net energy. This generation potential is most significantly affected by plant production rates and also influenced by preheater and clinker cooler exhaust temperatures. Applying the national average emission rate, typical commercial-scale installations at Holcim plants are projected to avoid between 182 and 3,401 metric tons of CO₂ annually per site. Table ES- 3 shows a summary of the estimated annual impacts.³ While parasitic loads are significant and vary by application, this analysis assumed the use of heating loop pumps and access to Lake Huron as a cold sink. This setup assumed no need for cooling loop pumps due to the available water pressure at the test site. Applications that require cooling towers or additional equipment are likely to experience higher parasitic loads. Therefore, the study’s estimates are most applicable to scenarios with similar parasitic load configurations—namely, access to a high-pressure cold sink. Applicability to other locations may be limited, as differing conditions could necessitate additional pumps and cooling systems, potentially impacting performance significantly.

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