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DOE OSTI2024

Enhancing Header Shape Through Computational Fluid Dynamics for Improved Performance

Shape optimization in power plant design is crucial for maximizing efficiency and minimizing energy losses It impacts performance, cost effectiveness, and environmental sustainability Our project focuses on optimizing header pipe geometry using a method that considers temperature, flow, and pressure distributions, along with structural analysis This approach ensures structural integrity while minimizing material costs

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2025

Rheo–Electric Foundations and Engineering of Carbon Slurry Flow Electrodes

Flowable carbon slurry electrodes promise continuous, scalable electrochemical desalination and energy storage when their rheology (flow and stability) and electronic connectivity are jointly optimized. This report integrates six complementary thrusts that we executed under the Laboratory Directed Research and Development (LDRD) project: (i) a fast, ex situ, centrifuge-compatible method to quantify pellet (packed slurry) electronic conductivity, with a validated cell constant (“shape factor”) and quantitative structure–property insights for carbon mixtures; (ii) a controlled circulation study showing that peristaltic pumping can irreversibly alter particle size and morphology over laboratory-relevant durations; (iii) development of a miniature jet pump that preserves particle integrity while achieving entrainment ratios of 2–4 at practical flow rates; (iv) a comprehensive mapping of how a representative non-ionic surfactant (Tween 20) collapses the carbon gel network, separating network-percolation losses from intrinsic particle contact resistance; (v) in-situ visualization revealing how gravitational settling and flow-driven mixing compete to control charge transport, with dynamic bed layers preventing saturation while achieving 30-fold local concentration enhancement; and (vi) a simple, widely adoptable fabrication route to structured, gas-nitrided titanium nitride (TiN) titanium current collectors that dramatically lower interfacial losses and enable geometry-driven performance gains. Together, these results provide a coherent toolchain and design rules to accelerate formulation screening, de-risk device prototyping, and standardize characterization for carbon slurry electrodes in flow-electrode capacitive deionization (FCDI), electrochemical flow capacitor (EFC), and related systems.

25 ENERGY STORAGE↗

DOE OSTI2022

Quality Analysis of Baseline Time-Lapse CSEM Data CarbonSAFE Project, North Dakota

Conference presentation at International Meeting for Applied Geoscience & Energy (IMAGE), Houston, TX, August 28 – September 2, 2022. When a series of time-lapse CSEM surveys are designed to measure the often-small variations in signal seen in CCUS projects, the primary concern must be collecting the highest-quality data and reducing as much noise as possible. This includes optimization during planning and feasibility, careful and consistent quality checks in the field, and transparent and repeatable postprocessing steps. We apply this practice to a baseline (prior to CO 2 injection) CSEM data set collected for a time-lapse survey in Center, North Dakota, as a part of the North Dakota CarbonSAFE project, and describe the rigorous quality control and assessment methods used, including noise removal and data validation with 1D and 3D inversion to tie results to borehole logs. The final result is an accurate and representative CSEM data set and information that stakeholders can use to inform future time-lapse survey costs and designs.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2025

Newberry SHR Demonstration Project – Bipartisan Infrastructure Law Enhanced Geothermal (EGS) Pilot Demonstration (Abstract)

This project will create an Engineered Geothermal System (EGS) comprising two or more wells drilled to a depth of 4.25 km into superhot rock (SHR) with a temperature of 425 °C at Newberry Volcano in Central Oregon. An EGS is a manufactured heat exchanger in which water is injected in a deep injection well, or injector, to extract heat from the hot rock at depth and steam is returned to the surface in a production well, or producer, to generate electricity. In this project, the SHR EGS will be made using new methods and technologies to stimulate and connect hydraulic and natural fractures to enable multiple flow pathways between wells, allowing for optimal heat mining from the reservoir rock. The new technologies are designed to operate at rock temperatures much higher than those encountered in traditional geothermal. Following EGS completion, water will be injected into the injector well and steam extracted from the producer well in a long-term connectivity flow test demonstrating SHR reservoir evolution with time and use. Success will be measured by demonstrating the efficacy of new technologies and by producing economic quantities of steam (>40 MWth).

15 GEOTHERMAL ENERGY↗

DOE OSTI2026

Blueprint: Open Worldwide Application Security Project Top 10 Common Weakness Enumerations for Electric Vehicle Supply Equipment

This report categorizes the top 10 security weaknesses in electric vehicle supply equipment (EVSE) using a similar approach by the Open Worldwide Application Security Project (OWASP) Top 10, and it describes example exploitations, methods for prevention, and related common weakness enumerations (CWEs) for each category. The weaknesses listed in this report could lead to security issues or vulnerabilities in EVSE if they are exploited by an attacker to compromise the confidentiality, integrity, or availability of a system. This report also recommends EVSE industry best practices and remediations for the identified weaknesses to use as guidelines for their secure products and systems.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2026

A large-scale benchmarking of deterministic and stochastic derivative-free optimization algorithms

This presentation summarizes our work in the PrOMMiS project on benchmarking of data-driven optimization algorithms and their applications in self-driving laboratories. This work supports the broader project goal of accelerating the identification of promising separation methods and operating conditions for critical minerals separation processes. We present a systematic benchmarking study of 42 data-driven optimization algorithms on a broad collection of 502 test problems. The results identify BAM, GLCCLUSTER, and MULTIMIN as the most effective optimization solvers, with BAM showing the highest overall performance and solving more than 80% of the benchmark problems. The study also shows that no single solver consistently outperforms the others across all problem types, indicating that our future laboratory applications may benefit from using a small set of strong solvers rather than relying on a single method. The presentation also illustrates an in-silico chemical reactor case study showing that data-driven optimization methods can guide autonomous experimentation in a self-driving laboratory and identify optimal operating conditions within a small number of experiments. Overall, the results provide a basis for selecting efficient optimization methods and demonstrate the practical use of data-driven optimization in self-driving laboratory workflows.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Algorithm-guided experimentation for autonomous AI systems in self-driving laboratories

36 MATERIALS SCIENCE↗

DOE OSTI2025

Marine Hydrogen Demonstration

This report summarizes Phase 1 of a project involving the design of a Floating Hydrogen Production and Dispensing Barge destined for the Port of San Francisco (SF). The H 2 Barge is designed to produce renewable H 2 at the rate of ~ 530 kg/day, storing 512 kg of hydrogen at 517-bar, allowing fast refueling of hydrogen fuel cell vessels and land-side hydrogen delivery trailers for distribution into the nascent SF hydrogen ecosystem. The broader considerations that impacted the H2 Barge design are also described. An account is given of a new review process formulated by the United States Coast Guard (USCG) to review this first-of-its-kind maritime implementation of hydrogen technology. The immediate goals of the H 2 Barge Project are to 1) demonstrate the feasibility, viability and methods of hydrogen production, storage and fueling in a maritime context, 2) help shape (where needed) and navigate the required local, state and federal regulatory gauntlet and 3) catalyze a “green hydrogen ecosystem” (both marine and landside) with locally produced renewable hydrogen at the San Francisco waterfront. A summary is also given of the modeling and experimental activity of Phase 1 directed to the development of science-based refueling protocols for large marine Type IV 250-bar hydrogen tanks. Combined modeling and experimental studies are reported of the filling of large (28 kg) 250-bar Type IV hydrogen tanks of the type being deployed on early hydrogen ferries, such as the MV Sea Change. The primary question was to determine how such tanks can be successfully filled (state of charge greater than 97%) within 45 minutes without exceeding the 82 °C temperature limit historically set for such tanks. The studies show that a gas injector is needed avoid thermal stratification during filling which can result in potential hot spots. Pre-cooling of the hydrogen was found to be essential in most cases, as ambient conditions greatly affect the need for a pre-cooling to achieve the 45-minute fill time. Pre-cooling cannot be supplied by nearby water, such as that found in nature (bays, lakes, rivers, etc.) because pre-cooling cooling below 0 °C was found to be necessary to avoid excessive compression heating. The experimental results afforded a calibration of the engineering model (SOFIL) for these large 250-bar tanks, which now enables using SOFIL to predict volume-averaged hydrogen filling temperatures to an accuracy of +/- 2.7°C for these tanks. The model can therefore be used to evaluate potential scenarios for development of a standardized fueling methodology for ferries utilizing large Type-IV tanks of the type examined here.

08 HYDROGEN↗

DOE OSTI2021

Hot Stars with Kepler Planets Have High Obliquities

It has been known for a decade that hot stars with hot Jupiters tend to have high obliquities. Less is known about the degree of spin–orbit alignment for hot stars with other kinds of planets. Here, we reassess the obliquities of hot Kepler stars with transiting planets smaller than Neptune, based on spectroscopic measurements of their projected rotation velocities (vsin i). The basis of the method is that a lower obliquity—all other things being equal—causes sin i to be closer to unity and increases the value of vsin i. We sought evidence for this effect using a sample of 150 Kepler stars with effective temperatures between 5950 and 6550 K and a control sample of 101 stars with matching spectroscopic properties and random orientations. The planet hosts have systematically higher values of vsin i than the control stars, but not by enough to be compatible with perfect spin–orbit alignment. The mean value of sin i is 0.856 ± 0.036, which is 4σ away from unity (perfect alignment), and 2σ away from π/4 (random orientations). There is also evidence that the hottest stars have a broader obliquity distribution: when modeled separately, the stars cooler than 6250 K have 〈sin i〉=0.928±0.042 while the hotter stars are consistent with random orientations. This is similar to the pattern previously noted for stars with hot Jupiters. Based on these results, obliquity excitation for early-G and late-F stars appears to be a general outcome of star and planet formation, rather than being exclusively linked to hot Jupiter formation.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2025

The NGC 3109 Satellite System: The First Systematic Resolved Search for Dwarf Galaxies Around an SMC-mass Host

We report the results of the deepest search to date for dwarf galaxies around NGC 3109, a barred spiral galaxy with a mass similar to that of the Small Magellanic Cloud (SMC), using a semiautomated search method. Using the Dark Energy Camera, we survey a region covering a projected distance of ∼70 kpc of NGC 3109 (D = 1.3 Mpc, R vir ∼ 90 kpc, M ∼ 10 8 M*) as part of the MADCASH and DELVE-DEEP programs. We introduce a newly developed semiresolved search method, used alongside a resolved search, to identify crowded dwarf galaxies around NGC 3109. Using both approaches, we successfully recover the known satellites Antlia and Antlia B. We identified a promising candidate, which was later confirmed to be a background dwarf through deep follow-up observations. Our detection limits are well defined, with the sample ∼80% complete down to M V ∼ −8.0, and include detections of dwarf galaxies as faint as M V ∼ −6.0. This is the first comprehensive study of a satellite system through resolved stars around an SMC mass host. Our results show that NGC 3109 has more bright (M V ∼ −9.0) satellites than the mean predictions from cold dark matter models, but well within the host-to-host scatter. A larger sample of LMC/SMC-mass hosts is needed to test whether or not the observations are consistent with current model expectations.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2026

Numerical Modeling of a Two-Stage Ocean Current Turbine

The Equinox Ocean Turbines (EQOT) current energy converter has a unique design with power generation in two small-diameter turbines attached to the tips of a large-diameter passive rotor. This configuration offers some key advantages for capturing ocean currents. With no centrally placed generator, almost no reaction torque is required at the nacelle of the main large-diameter rotor, and the small-diameter tip turbine generators operate at a higher speed and lower torque. The physics that determine the performance and loads on the turbine are also unique. The interactions of the flow field between the two stages and the general architecture of the system cannot be captured with traditional mid-fidelity modeling tools. For design iterations and large sets of load cases, it is important to have mid-fidelity models that can capture the important phenomenon with enough accuracy to identify global trends. This work uses a limited set of high-fidelity computational fluid dynamics (CFD) simulations to help inform the selection of and construction of a custom mid-fidelity model. Mid-fidelity modeling approaches were verified by comparing key turbine performance quantities to those found with the CFD model. Hydrodynamic interactions of the two-stage rotor were identified through high-fidelity CFD modeling. This highlighted the impact of the main rotor tip vortex and wake on the secondary rotor apparent inflow. This results in a relative flow rotation and sharp deficit, that change the optimal secondary rotor rotation speed and adds unsteadiness to the blade loading respectively. Multiple mid-fidelity approaches were evaluated for their ability to capture these effects. A simple approximation of the combined-stage performance based on single-stage BEM provides a reasonable rough prediction, especially near the peak TSR values, with some larger discrepancy at higher TSRs. Predicting the combined-stage performance based on single-stage CFD data improves this prediction across the TSR range. Although the combined-stage modeling in OLAF was not successful in this stage of the project, it showed promise as a mid-fidelity method, assuming the parameters can be tuned to account for the significant differences in time and length scales between the main and secondary rotors. This may be addressed through code changes in future work. A significant finding from the OLAF work was the agreement between the vortex core radius values found independently via a parameter space search and via CFD. The technique of using single-stage secondary rotor BEM, with a custom inflow taken from single-stage main rotor CFD or OLAF, provides an efficient method to capture one-way coupled flow interactions. This method provided generally good predictions of the impact of the flow rotation on the secondary rotor but struggled to accurately predict the peaks of the unsteady load progression. Future work could include some superposition of a tuned main rotor trailing edge viscous wake into the custom inflow to better predict this interaction.

16 TIDAL AND WAVE POWER↗

DOE OSTI2020

Electric Motor Thermal Management

Thermal management enables more efficient and cost-effective motors. This Annual Merit Review presentation describes the technical accomplishments and progress in electric motor thermal management R&D over the last year. This project supports a broad industry demand for data, analysis methods, and experimental techniques to improve and better understand motor thermal management.

47 OTHER INSTRUMENTATION↗

DOE OSTI2022

Electric Motor Thermal Management

ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2023

Electric Motor Thermal Management

ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2025

Safe Physics-Informed Machine Learning for Dynamics and Control

This tutorial paper focuses on safe physics-informed machine learning in the context of dynamics and control, providing a comprehensive overview of how to integrate physical models and safety guarantees. As machine learning techniques enhance the modeling and control of complex dynamical systems, ensuring safety and stability remains a critical challenge, especially in safety-critical applications like autonomous vehicles, robotics, medical decision-making, and energy systems. We explore various approaches for embedding and ensuring safety constraints, including structural priors, Lyapunov and Control Barrier Functions, predictive control, projections, and robust optimization techniques. Additionally, we delve into methods for uncertainty quantification and safety verification, including reachability analysis and neural network verification tools, which help validate that control policies remain within safe operating bounds even in uncertain environments. The paper includes illustrative examples demonstrating the implementation aspects of safe learning frameworks that combine the strengths of data-driven approaches with the rigor of physical principles, offering a path toward the safe control of complex dynamical systems.

Drgona, Jan↗

DOE OSTI2022

WBS 2.2.1.402 - Wave-SPARC: Systematic Process & Analysis for Reaching Commercialization

Wave-SPARC is empowering the marine energy community with the tools necessary to achieve a significant improvement in techno-economic performance of wave generated grid power. A detailed systems engineering approach simultaneously balances around 100 cost and performance drivers (functional requirements and capabilities) of wave energy converters (WECs). Publicly accessible technology innovation and assessment methods and tools (new to the wave energy sector) have been delivered. They guide technology development trajectories to successful outcomes in less time, at less overall cost, and with less encountered risk. Through the use of these methods and tools along with proven structured inventive techniques the project continues to deliver high potential novel wave energy technology concepts for validation and subsequent development by industry. The intended outcomes are: (1) Invention, assessment, identification, verification and validation of novel and high techno-economic-potential WEC technology concepts to deliver high-confidence "seeds" for subsequent industrial development to full commercial application and economic viability (2) Development and delivery of WEC technology innovation and assessment methodologies and tools and provision of these as services and for free use by industry and the entire sector (3) International collaboration for global best practice alignment of assessment and innovation methods.

innovation↗

DOE OSTI2025

Efficiently resolving the terrestrial-aquatic interface in E3SM with sub-grid methods to improve coastal simulations (Final Technical Report)

The broad goal of this project was to extend the capabilities of MPAS‐Ocean, the ocean component of DOE’s Energy Exascale Earth System Model (E3SM), to better resolve the hydrodynamics of the terrestrial‐aquatic interface without significantly increasing computing resource requirements. Specifically, our goal was to better resolve the small-scale features across the terrestrial‐aquatic interface which includes the low lying coastal floodplain and a dendritic network of hydraulically efficient channels connected to estuarine systems and back bays, barrier islands and high energy inlets. The processes driving flow across the terrestrial‐aquatic interface include upland and floodplain hydrology, tides, wind and atmospheric pressure (including coastally generated storm surge across continental shelves and within estuaries and bays), wind waves and water temperature and salinity gradients.

58 GEOSCIENCES↗

DOE OSTI2024

IMAGINE BioSecurity: Mesocosm-Based Methods to Evaluate Biocontainment Strategies and Impact of Industrial Microbes Upon Native Ecosystems

Project Goals: The Integrative Modeling and Genome-scale Engineering for Biosystems Security (IMAGINE BioSecurity) SFA project seeks to establish an understanding of the behavior of engineered microbes in controlled versus environmental conditions to predictively devise new strategies for responding to biological escape. To this end, the IMAGINE Team has established a plant-soil mesocosm platform to track and quantify the fate of industrial microbes in environmental systems and assess the efficacy of biocontainment constraints upon genetically engineered microbe escape frequency and the impact of industrial microbes upon native ecological microbiomes. Abstract Text: Genetically modified industrial production microbes and their associated bioproducts have emerged as an integral component of a sustainable bioeconomy. However, the rapid development of these innovative technologies raises biosecurity concerns, namely, the risk of environmental escape. Thus, the realization of a bioeconomy hinges not only on the development and deployment of microbial production hosts, but also on the development of secure biosystems and biocontainment designs. Current laboratory-based biocontainment testing systems do not accurately reflect complexities found in natural environments, necessitating an environmentally relevant analysis pipeline that allows for the detection of rare escapees, the effect of associated bio-products, and the impact on native ecologies. To this end, we have developed an approach that utilizes soil mesocosms and integrated systems analyses to evaluate the efficacy of novel biocontainment strategies and to assess the impact of production systems upon terrestrial microbiome dynamics. We demonstrate the utility of this approach by modeling a contamination with industrial microbial chasses versus their biocontained counterparts. Here we demonstrate the broad utility of this system by highlighting findings from both strains of Saccharomyces cerevisiae that are contained with an inducible toxin anti-toxin system, and stains of Escherichia coli that are contained via genomic recoding. The resultant data demonstrate that this system has broad utility across diverse microbial chassis and biocontainment strategies, enables us to track the fate of our contaminating microbe with high sensitivity in the soil, as well as monitor broader impacts of the perturbation on the underlying soil system. The findings presented here support the use of this mesocosm-based approach to assess the environmental impact of industrial microbes and to validate biocontainment strategies.

BASIC BIOLOGICAL SCIENCES,INORGANIC, ORGANIC, PHYS↗