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At least 793 records · Page 44

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DOE OSTI2020

Carbon Fiber Prepreg Recycling- Automated Perform Manufacturing Equipment (Final Technical Report)

Discontinuous fiber composites have a compelling business case as related to light metals such as aluminum and magnesium machined or die cast components. DFC’s have been in commercial production using carbon fiber/epoxy prepreg for both commercial aircraft and for military applications for a number of years and their usage is expanding into automotive and consumer goods components. Reasons for this include significantly lower cost as compared to continuous fiber composites easier design and understanding of the material by metal traditionalists, higher degree of part complexity with relatively simple and low cost molds when compared to high-pressure die casting, and potential for near zero waste. IACMI’s 10-year goals of reduction in carbon fiber reinforced plastics manufacturing cost by 25%, reduction in their embodied energy by 50%, and recyclability of 95% can all be advanced through robust recycling. With recycling We have shown that a 15% contribution in manufacturing cost reduction is feasible, that a significant reduction in embodied energy (over 90% for the recycled fraction) is achievable, and that when combined with primary pyrolysis recycling, the 95% target can be met. Large-scale application of advanced composites began with the aerospace industry, and CRTC’s location in Washington State provided access to a waste stream of nearly 900 tonnes/year that was going to landfill. As the aerospace industry has automated parts production, their material forms have become significantly easier to recycle, and some evidence of this exists for the future automotive and wind turbine components as well. CRTC decided to focus on re-purposing the carbon fiber/epoxy aerospace scrap streams through materials reformatting and reuse, and not on primary recycling (pyrolysis mainly) as this technology is commercially available. The main reasons for this were that it offers a route to effective use of the most widely available and consistent feedstock called edge-trim, as well as allows creation of complex and low-cost parts using rapid and cost-effective compression molding technologies. The reasons also include leading the way for potential automotive pre-preg recycling as the combination of roughly 85% virgin pre-preg and 15% recycled pre-preg directly supports IACMI’s goals and enables significant part cost reduction and a path to zero-waste composite manufacturing at the OEMs or Tier 1’s. The purpose of the project was to develop equipment and technology to transform continuous fiber pre-preg in roll forms into smaller chip-format DFC feedstock, and to determine impacts on moldability and performance based on lessons learned along the path. The availability of scrap from pre-preg manufacturers was a significant value to the program even though the aerospace pre-preg is designed to be autoclave molded thus has handling, tackiness, and processing factors that are not ideal for DFCs. The scope of the project was to develop a Phase 1 system that could identify and resolve some of the major hurdles, determine where to focus effort on building a commercial-scale Phase 2 system, and develop technology for handling a wide variety of incoming scrap materials to produce the most usable product. A chopping system was developed and reduced to practice via an experimental approach that enabled all forms of scrap coming from the pre-preg manufacturers and some forms of the scrap coming from OEM production lines to be very effectively re-purposed. The systems that were developed were not considered to be production robust but rather identified and resolved some of the major technical hurdles, and demonstrated the path towards effective full-scale commercialization.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Williston Basin Resource Study for Commercial-Scale Subsurface Hydrogen Storage

The Energy & Environmental Research Center (EERC), in partnership with the U.S. Department of Energy (DOE) National Energy Technology Laboratory (NETL), the EERC’s State Energy Research Center (SERC), MPLX Operations LLC, and TC Energy Development Holdings Inc. (a subsidiary of TC Energy Corporation), studied the potential for subsurface hydrogen storage and recovery in the Williston Basin of western North Dakota. The project’s goal was to evaluate the feasibility of large-scale, secure geologic H 2 storage to support future hydrogen generation, storage, and use. This work included laboratory testing, H 2 –rock–fluid exposure experiments, literature reviews on H 2 embrittlement, and reservoir modeling and simulations. The study included an assessment of storage potential across three types of storage reservoirs using both reservoir simulation and DOE’s web-based tool SHASTA-HELP (Subsurface Hydrogen Assessment, Storage, and Technology Acceleration – Hydrogen Estimator for Logistical Planning), as well as investigation of potential H 2 production and markets for commercial-scale deployment. Building on prior EERC gas storage research, three storage options were selected for detailed evaluation: the Broom Creek Formation (a clastic saline reservoir), the Dickinson Lodgepole Mounds (DLM) complex (carbonate mud mound structures) of the Lodgepole Formation (an active oil and gas producing reservoir), and the Dunham Salt Interval of the Piper Formation (to be used for engineered salt cavern development). These targets were prioritized based on prior EERC research using datasets related to seal capacity, reservoir quality, mechanical integrity, and injectivity. Exposure tests on Broom Creek and DLM samples showed mineral dissolution and precipitation that increased brine salinity and altered reservoir rock surfaces. Although these results provide useful insight, they are limited by small sample sizes and short-term (30-day) exposure, requiring further study to assess long-term storage integrity. Salt formations were not tested because of their known nonreactivity and established mechanical stability. Results of reservoir simulations performed for a single site demonstrated that the Broom Creek Formation may be capable of receiving up to 42,000 tonnes of injected H 2 over 7 months via one well. H 2 recovery took place over 5 months, resulting in approximately 26,000 tonnes (~62% without cushion gas [CG]). This work suggests water production may be important and subsequent cycles of injection and production may perform more efficiently; however, significant site-specific work in the future is needed to assess actual reservoir performance of injection and withdrawal of H 2 storage. For oil reservoir potential, a multiple-well model was used to simulate injection of approximately 32,000 tonnes of H 2 into a single wellbore while simultaneously producing in place reservoir fluids from four offset wells to maintain reservoir pressure. The simulation results suggested a high recovery (~98%); in addition, cost advantages through existing infrastructure could be realized. Challenges in this reservoir include vi managing gas purity and leakage risks. In both scenarios, production of H 2 takes place in a single-well scenario with 10 cycles (7 months of injection and 5 months of production) over 10 years. Finally, the use of engineered caverns in the Dunhan Salt was evaluated, and the results suggest that while they have a smaller capacity (<1000 tonnes per cavern), they exhibit nearly complete gas recovery (>99%), fast response times, and low purity risk. While caverns in North Dakota may be smaller in capacity, fields can be developed in galleries to accommodate the volumetric needs and rapid turnaround times necessary to meet market demands. Geographic limitations and thin salt intervals in North Dakota may represent less total storage potential than salt domes elsewhere, but significant opportunities exist to expand this market for gas storage in North Dakota. A basinwide assessment was performed to estimate a first-of-its-kind value for H 2 storage on a large scale. DOE’s SHASTA-HELP, combined with EERC simulation work, was used to perform the assessment. Estimated H 2 storage potential varied widely for each formation type. The Broom Creek saline formation was estimated to have a storage potential of approximately 1.7–90.5 million tonnes (MMt). The DLM oil reservoirs were estimated to have 0.07–0.19 MMt of capacity. Notably, each of these estimates relies on significant assumptions regarding reservoir thickness, porosity, permeability, and CG needed for operation. Much research is needed to understand the true site-specific storage resource potential of each formation. Using the Dunham Salt Interval for cavern development may result in as much as 4.79 MMt (up to 2.87 MMt working gas) of H 2 storage potential. An important note for consideration is that the values presented here need significantly more geological characterization and engineering assessments prior to gaining confidence in performance. This will be a focal point for future research and development needs. The basinwide evaluation also indicated that North Dakota has significant H 2 generation potential, with estimates up to a possible 13 MMt annually, suggesting a substantial opportunity for H 2 market development and thus the need for commercial-scale H 2 storage to facilitate growth and resilience. Key Recommendations 1. Conduct detailed site characterization (3D seismic, well logs, core sampling) to reduce geologic uncertainty. 2. Perform techno-economic analyses incorporating market, regulatory, and incentive frameworks. 3. Investigate long-term interactions among H 2 , CGs, well materials, and formations to assess risks. 4. Develop pilot- and field-scale demonstrations to validate models and establish best practices.

03 NATURAL GAS↗

DOE OSTI2023

Field validation of isotropic analytical models for simulating fabric shades

Fabric roller shades are common shading materials used in commercial and residential buildings. Accurately characterizing and modeling shades helps practitioners select the appropriate product and its control strategy based on climate and occupants' priorities, such as visual comfort and view to outdoors. Previous studies established a generalized method for modeling complex fenestration systems using data-driven tabulated bidirectional scattering distribution functions. However, deploying such a method at scale to all fabric shading products on the market is too costly and time-consuming. Analytical models that are based on a limited set of measurements (e.g., normal-normal and normal-hemispherical visible transmittance and reflectance, and directional cut-off angles) can be used to model the wide variety of shading products on the market. This study evaluates the performance of two isotropic analytical models, Roos-Wienold and Modified-Kotey, for modeling fabric roller shades, with a focus on the model's ability to predict occupant visual comfort. The performance evaluation was conducted through laboratory and field measurements and simulations. The results showed that both models are sufficient for predicting vertical illuminance at seated eye-level. Roos-Wienold model was able to predict binary visual comfort classification (glare/no-glare) under a wide range of luminance conditions, while Modified-Kotey model did not perform as well under high-contrast low-adaptation conditions. Both models are insufficient in predicting visual comfort at a four-point scale (e.g., imperceptible, perceptible, disturbing, intolerable). The two isotropic models become less accurate when the fabric exhibits high anisotropy.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2026

Ten questions concerning low-cost indoor air quality sensors: Perspectives from research and practice

Low-cost indoor air quality (IAQ) sensors are increasingly being used in homes and commercial and public buildings, driven by growing concerns about the impact of air on health, cognitive performance, and occupant wellbeing. These sensors offer a potentially transformative opportunity to increase spatial and temporal coverage of IAQ monitoring at a fraction of the cost of conventional reference instruments. However, their widespread use raises questions around accuracy, calibration, placement, data handling and interpretation, and integration into existing standards and workflows. This paper presents ten critical questions concerning the use of low-cost IAQ sensors in buildings, drawing on the latest empirical research, field deployments, and emerging practice. It discusses potential frameworks for deployment and evaluation, examines current sensor capabilities for measuring common pollutants, identifies methodological gaps in validation and uncertainty quantification, and outlines the extent to which existing IAQ standards can accommodate sensor-based evidence. The paper also explores how monitoring needs and deployment models vary by building type, the potential of real-time IAQ data to support building operations, and the ethical and legal implications of widespread sensor use. While significant challenges remain in ensuring data quality and building stakeholder trust, new applications are emerging through open data initiatives and advances in analytics and visualization. As the technology, science, and standards co-evolve, low-cost IAQ sensors are poised to become integral to routine building operation, building science, and environmental health research.

Parkinson, Thomas↗

DOE OSTI2025

Single-Ion Conducting Polymer Electrolyte Enabled via Aza-Michael Addition

Single-ion conducting polymer electrolytes present a possible route for achieving high energy density next-generation batteries due to their flexible nature and high cation transport number. The trifluoromethanesulfonimide (TFSI) functional group represents one of the most efficient tethered anions for Li-ion conductivity. However, the covalent attachment of TFSI groups into polymer electrolytes has been challenging and costly due to its synthetic difficulty and limited commercial availability of building blocks. Here, we present a new polymer electrolyte synthesized by the Michael addition reaction between poly(allylamine) (PAA) and a vinyl TFSI anion under mild reaction conditions. The resulting PAATFSI exhibits a lower glass transition temperature and several orders of magnitude higher Li-ion conductivity than similar TFSI-based single-ion conducting homopolymers in the dry state. Moreover, PAATFSI exhibits excellent Li-ion conductivity (2.7 × 10 –4 S/cm at 30 °C) with the addition of a plasticizer (60 wt % of carbonate solvent), which enables stable lithium–metal battery performance. In conclusion, this study demonstrates a facile route for the synthesis of new single-ion conducting polymer electrolytes that opens a library of possibilities to enable the realization of polymer-based batteries.

25 ENERGY STORAGE↗

DOE OSTI2024

Geographic Information System Mapping Tool for Rainwater Harvesting in the United States

The Rainwater Harvesting Tool is a publicly available web-based geographic information system tool developed using geospatial analysis in combination with historic ZIP Code level monthly average precipitation and evapotranspiration data across the United States to help select potential locations for harvesting rainwater. Rainwater harvesting can provide a key source of alternative water for a variety of uses including landscape irrigation, vehicle wash, cooling tower makeup, dust suppression, and toilet flushing. Rainwater harvesting can help support institutional, commercial, and residential buildings in diversifying water sources and offset the use of freshwater. This tool aims to help organizations strategically target locations to implement rainwater harvesting systems. The metric used in the tool is called the rainwater harvesting potential, which is a normalized metric, measured in inches per year. The rainwater harvesting potential describes the amount of rainwater that can be reasonably collected and stored at a specific location. This metric was used to rank areas delineated by ZIP Codes across the US, from lowest to highest to show the relative availability of rainwater for harvesting. Two mapping layers are included in the tool that show the general rainwater harvesting potential for all applications and a layer that specifically shows the potential for harvesting rainwater to supply irrigation The Rainwater Harvesting Tool allows users to view overall trends across the United States, while also allowing the user to zoom in to a scale where ZIP Code boundaries are clearly delineated. The tool can be used to help organizations with buildings located in multiple regions to strategically identify where to install rainwater harvesting systems and prioritize locations that may be optimal for rainwater harvesting.

47 OTHER INSTRUMENTATION↗

DOE OSTI2025

Multi-Agent Hierarchical Deep Reinforcement Learning for HVAC Control With Flexible DERs

As electricity consumption in commercial and residential buildings continues to rise, reducing energy costs presents an increasing challenge. Heating, ventilating, and air-conditioning (HVAC) systems, which typically account for 40%-50% of a building's energy use, are prime targets for energy savings. Intelligent control of HVAC temperature through the exploitation of HVAC load flexibility brings significant potential to reduce energy consumption and electricity expenses. The nonlinear models of HVAC systems challenge traditional control methods, while the uncertainty introduced by HVAC load flexibility complicates distributed energy resource (DER) management using conventional optimal dispatch techniques. In response to these challenges, we propose a hierarchical multi-agent deep reinforcement learning (DRL) approach. The lower-level agents focus on balancing comfort and energy conservation, while the upper-level DRL agents optimize the use of DERs to reduce peak demand based on the control outcomes of the HVAC by the lower-level agents. Here, in the upper-level agents, we incorporate a multi-agent structure based on ensemble learning, which acts based on historical and current data without relying on precise load forecasting to address the delayed rewarding issue in DRL. This allows for the effective reduction of energy costs. The proposed method is tested using a real-world microgrid comprising 413 buildings in Southern California, and the results demonstrate that our approach can significantly reduce overall electricity bills while ensuring the comfort of consumers and residents.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2026

A Central Plant Retrofit Assessment Guide for Owners

This document offers support to owners considering optimization upgrades, retrofits, or complete replacement of a central plant, with a particular focus on improving energy efficiency and reliability of the central plant, ultimately leading to reduced energy costs. It outlines recommended steps to prepare for and facilitate a thorough central plant assessment, empowering owners to move forward with the appropriate next steps. While the primary focus is on central plants serving commercial and institutional buildings, the principles and recommendations presented can also be adapted for use in other building types, such as industrial or manufacturing facilities.

42 ENGINEERING↗

DOE OSTI2021

Advancing insulation retrofits from flexible inexpensive lucid materials (AIR FILMs) for single-pane windows

This project focused on Advancing Insulation Retrofits from Flexible Inexpensive Lucid Materials (AIR FILMs) for Single-Pane Windows. The team developed innovative porous materials that can improve the energy efficiency of existing single-pane windows in commercial and residential buildings in two technical product categories: (1) retrofits that can be applied onto existing windowpanes and (2) manufactured windowpanes that can be installed into the existing window sash.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2022

MFVI Energy Efficiency Audit Training - Module 1.1: Introduction to Efficient Lighting [Slides]

This guide is designed to help trained energy efficiency professionals conduct an energy efficiency audit for commercial and industrial buildings, particularly for micro-, small-, and medium-sized businesses in Mexico. This guide is focused on auditing lighting systems. As such, it will assist its user in determining the optimal lighting for a given space and then identifying the most efficient means of delivering that lighting.

21CPP↗

DOE OSTI2022

MFVI Energy Efficiency Audit Training - Module 1.2: Lighting Analysis [Slides]

21CPP↗

DOE OSTI2022

MFVI Energy Efficiency Audit Training Module 2.2: Plug Loads Analysis [Slides]

This guide is designed to help trained energy efficiency professionals conduct an energy efficiency audit for commercial and industrial buildings, particularly for micro-, small-, and medium-sized businesses in Mexico. This guide is focused on auditing plug load systems. As such, it will assist its user in documenting the plug loads in the space and then identifying the most efficient means of delivering those plug loads.

21CPP↗

DOE OSTI2022

MFVI Energy Efficiency Audit Training Module 2.1: Plug Loads [Slides]

This guide is designed to help trained energy efficiency professionals conduct an energy efficiency audit for commercial and industrial buildings, particularly for micro-, small-, and medium-sized businesses in Mexico. This guide is focused on auditing plug load systems. As such, it will assist its user in documenting the plug loads in the space and then identifying the most efficient means of delivering those plug loads.

21CPP↗

DOE OSTI2022

MFVI Energy Efficiency Audit Training Module 3.1: Cooling Systems [Slides]

This slide deck is designed to help trained energy efficiency professionals conduct an energy efficiency audit for commercial and industrial buildings, particularly for micro-, small-, and medium-sized businesses in Mexico. This training module is focused on cooling systems. As such, it will assist its user in determining the optimal cooling system for a given space and then identifying the most efficient means of delivering that system.

21CPP↗

DOE OSTI2023

Assessing Methodologies for Detecting Water Intrusion in Wall Systems: Phase 2

Studies by the University of Florida, the Environmental Protection Agency (EPA) and the U.S. Department of Housing (HUD) have revealed that there is a substantial fraction of commercial and residential buildings that have been exposed to moisture resulting in damage or durability problems. Water intrusion into building envelope components leads to a variety of undesirable conditions such as mold, wood rot, corrosion, and aesthetic damage. Tests methods that are presently used to evaluate the amount of water intrusion into a building envelope component are usually qualitative in nature. For example, ASTM E 331, Standard Test Method for Water Penetration of Exterior Windows, Curtain Walls, and Doors by Uniform Static Air Pressure Difference requires that you “observe and record points of water leakage, if any.” This test was originally developed to assess the performance of fenestration products but is commonly adapted to evaluate other enclosure assemblies. However, when it is typically used for walls, this procedure is limited to recognizing if the moisture is visually observable from the backside side of the sheathing. It does not address moisture that is absorbed in the layers of the building envelope component, which could impact the durability of the assembly. Clearly a quantitative means of determining water penetration would improve the quality of this type of test and assist with better understanding the resultant impact on enclosure assemblies. In 2018-20, Oak Ridge National Laboratory, in conjunction with the Air Barrier Association of America, initiated a research project to address this issue. The purpose of that study was to evaluate nine different methods of detecting moisture intrusion through a wall assembly. air and water barrier. The wall assemblies included metal frame construction faced with gypsum sheathing and both self-adhered and fluid applied air and water barriers (AWB) were evaluated for this exercise. This project did not test the efficacy of the different AWBs, rather, fasteners were purposely installed in various ways to foster water penetration and activate the different methods of detection. Each detection method was evaluated for five features that included simplicity of use, cost of implementation, whether the method was quantitative or subjective, accuracy, and applicability. A scale of green/yellow/red was used to assess each feature where green was acceptable, yellow was borderline, and red was not to be pursued at this time. This report covers additional research that has been undertaken to extend the activities initiated in this earlier project with refinements for specific detection methods and considerations for expansion related to field versus laboratory testing standards.

42 ENGINEERING↗

DOE OSTI2021

Low-Cost Electrochemical Compressor (ECC) Utilizing Green Refrigerants for HVAC Applications [Slides]

HVAC systems account for approximately 14 Quads or primary energy annually, or nearly 30% of all energy used in the U.S. commercial and residential buildings. Electrochemical compression (ECC) is a transformative solid-state technology and ECC based HVAC systems could result in 40% less energy use. The goal of the project was to develop the most efficient, noiseless, and most environmentally friendly cooling system based on integrating 2 (two) technologies: a) electrochemical compressors (ECC) to replace mechanical compressors for use in building heating, ventilation, and air conditioning (HVAC) applications and b) Ionic Liquid Desiccant Systems. The overall objective was to develop and build a scalable ILD/ECC-based air conditioning system operating with a COP of 4.5, with a price premium of $70 installed per kBTU/hr.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2020

Simulation-Based Design and Optimization of Waste Heat Recovery Systems

This fact sheet features an R&D project that will develop a modeling platform that can quantify the value of a district energy system and its potential for waste heat recovery. The new software analysis platform will evaluate and optimize district energy systems to better utilize low-temperature waste heat from nearby commercial and industrial buildings. The platform will help project developers and engineers easily quantify the potential value and cost savings of community energy systems for both producers and consumers of waste heat.

Combined heat and power, CHP, District energy, Was↗

DOE OSTI2022

From fault-detection to automated fault correction: A field study

A fault detection and diagnostics (FDD) tool, as addressed by this study, is a tool that continuously identifies the presence of faults and efficiency improvement opportunities through a one-way interface to the building automation system and the application of automated analytics. Although FDD tools can inform operators of building operational faults, currently an action is always required to correct the faults to generate energy savings. Fault auto-correction integrating with commercial FDD technology offerings can close the loop between the passive diagnostics and active control, increase the savings generated by FDD tools, and reduce the reliance on human intervention. This paper presents the field study of seven fault auto-correction algorithms implemented in commercial FDD platforms. Implementation includes software changes in the FDD tools and additional controls hardware or software changes in the BAS that were required to enable the execution of different types of auto-correction algorithms in real buildings. The routines successfully and automatically correct faults and improve the operation of large built-up Heating, Ventilation, and Air Conditioning (HVAC) systems, common in most commercial buildings. The auto-correction algorithms are tested across four buildings and three different building automation systems, following a rigorous procedure to make sure they work properly and do not negatively impact the system and building occupants. Finally, technology benefits, market drivers, and scalability changes are drawn from the implementation effort and test results, to drive future research and industry engagement.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗