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DOE OSTI2021

Pushing the efficiency limit of low-cost, industrially relevant Si solar cells to > 22.5% by advancing cell structures and technology innovations (Final Report)

The overall objective of this program is to achieve ~23% bifacial n-type cell efficiencies by developing and implementing optimized homogeneous or selective boron (B) emitter on front and tunnel oxide passivated contact (TOPCon) on rear side, in combination with advanced fine-line screen-printing metallization with floating busbars. During this research project, first we developed a technology roadmap to drive the 21% n-PERT cell efficiency from 21% to 23% by transforming the cell design to n-TOPCon and establishing the requirements for each layer, including B emitter, rear n-TOPCon, n-base Si and screen-printed contacts. Next, consistent with our roadmap, we developed advanced homogeneous implanted B emitter (150-180 Ω/⌫) passivated with ALD Al 2 O 3 layer capped with PECVD SiN x /SiO x double-layer antireflection coating This gave a very low recombination current density of 10-15 fA/cm 2 prior to metallization. In addition, we demonstrated metallized recombination current density of ~31 fA/cm 2 for this advanced homogeneous B emitter with industrial screen-printed, fire-through contacts with 40 μm wide grid lines, floating busbars and implementation of an advanced Ag-Al paste which resulted in local or reduced area metal-Si contact under the grid lines with virtually no emitter surface etching. This paste reduced the full area metallized J oe,metal from >1100 fA/cm 2 to ~700 fA/cm 2 . We also developed novel processes for the formation of p + /p ++ selective B emitter by a) single B diffusion with selective etch back and b) two-steps diffusion with implanted B in field region and APCVD B diffusion under the metal grid. We achieved very low un-metallized recombination current density (J 0 ) of ~18 fA/cm 2 for the selective p ++ p + emitters (30/150 Ω/⌫) and metallized J 0 of ~28 fA/cm 2 with ~3% screen-printed metal contact to p ++ regions. Next, we developed the technology for n-TOPCon by growing phosphorus-doped LPCVD and PECVD poly-Si on top of ~ 15Å chemically grown (NAO) tunnel oxide. After an optimized anneal at 875 °C for 30 min, passivated n-TOPCon have unmetallized J 0 of ~ 5 fA/cm 2 which went down further to ~ 1 fA/cm 2 after a 700 Å SiN x capping layer and simulated contact firing cycle at 770 °C. After screen-printed fire-through metallization on this n-TOPCon with ~13% metal coverage, metallized J 0 value increased to only ~5 fA/cm 2 which is among the lowest reported value to the best of our knowledge for screen-printed metallization. Finally, we integrated all the above technology innovations and enhancements and demonstrated low-cost manufacturable screen-printed n-TOPCon bifacial Si solar cell with ~23% efficiencies. Based on the experimental and theoretical understanding developed in this project, we have developed a new technology roadmap that shows that implementation of busbarless contacts, 10-20 ms bulk lifetime Si, and selective B emitter or selective TOPCon on the front can drive ~23% efficient cells achieved in this research to ~25% at low-cost.

14 SOLAR ENERGY↗

DOE OSTI2021

A Circularity Assessment for Silicon Solar Panels Based on Dynamic Material Flow Analysis: Preprint

Solar photovoltaics (PV) are the fastest growing renewable energy technology for clean, inexpensive, and sustainable electricity generation. Along with numerous technical roadmaps to improve system cost, performance and reliability, the PV industry should also plan to handle large volumes of silicon panel waste, which is initially estimated to be ~13 million metric tons (MT) by 2050 in the U.S. alone. Understanding the magnitude of material needs and how material flows throughout the PV panel life cycle could respond to design, operational and different end-of-life (EOL) circular pathways will help transition into a circular, resource-conserving economy. Herein, we introduce a dynamic material flow analysis (DMFA) framework based on electricity generation to quantify time-series stocks and flows of bulk PV materials (e.g., solar glass and aluminum frames) throughout the life cycles of utility-scale silicon PV systems in the U.S. in the period 2000-2100. We apply the model to a range of scenarios to understand how material demands depend on selected PV-related parameters, different material circularity strategies, and recent module design trends (e.g., bifacial, frameless). We found that float glass and aluminum in PV installations would likely reach 100 million MT and 12 million MT by 2100, respectively, in the baseline scenario. The most influential parameters for PV installation and subsequent waste reduction are found to be module lifetime, module efficiency, annual degradation, and material reduction. Module recycling and component remanufacturing were found to be the most effective material circularity strategies for waste minimization. Panel reuse has negligible savings on waste under current module efficiencies compared to replacements with newer generations with higher efficiency. Ongoing trends to produce larger power frameless modules could save 10 million MT of glass and ~9 million MT of aluminum. Our results enable advanced planning for future materials needs and provide insight into potential opportunities to minimize waste.

circular economy↗

DOE OSTI2020

Tandem particle-slurry batch reactors for solar water splitting (Final Scientific/Technical Report)

Economically, particle slurry reactors are projected to be one of the most promising technologies for solar photoelectrochemical hydrogen production, according to a 2009 techno-economic analysis commissioned by the US DOE and performed by Directed Technologies, Inc. The Fuel Cell Technologies Office’s Multi-Year Research, Development and Demonstration (MYRD&D) goals and targets are to reduce the cost of H 2 produced from renewable sources at the plant gate (i.e. not including delivery, dispensing, or storage) to < $2.00/gge, equivalent to ~$2.00/kg H 2 . Research results from our techno-economic modeling research suggest that this target could be met using particle slurry reactors assuming STH efficiencies in the range of 5 – 10%, materials lifetimes of < 1 year, and nanoparticles that cost up to 20 times more than projected costs of TiO 2 -coated Fe 2 O 3 nanoparticles. Although most large worldwide research efforts directed at solar photoelectrochemical hydrogen production focus on wafer-based designs, the projected lower cost for a particle slurry reactor at these disparate projected STH efficiencies clearly suggests that particle slurry reactors could be a scalable and deployable technology, assuming several challenges are overcome. These major technological challenges include the demonstration of a vertically-stacked-vessel architecture that is capable of operating sustainably while mostly relying on diffusion and natural convection to mix the redox shuttles between the vessels, and the demonstration that photocatalyst particles can operate at an overall 1% STH efficiency or larger when incorporated into this two-vessel design. Our research adds to the understanding of photocatalytic reactors for solar water splitting through numerical modeling results and experimental results. Numerical models were developed to simulate relevant device physics including particle and reactor dimensions which affect optical, transport, and rheological properties, electrocatalytic and photovoltaic properties of particles at various temperatures, and properties of redox shuttles and separators. Moreover, theoretical maximum solar-to-hydrogen efficiencies for ensembles of particles like in photocatalyst reactors were modeled and simulated and shown to equal or exceed those of photoelectrochemical designs under most scenarios. These results help determine constraints on the reactor that will enable more optimal designs for future prototypes. In parallel, experiments were performed to identify the most effective redox shuttles and to empirically validate the numerical models and simulations. Toward the latter, state-of-the-art light-absorbing particles and electrocatalysts were synthesized and characterized physically and photoelectrochemically for water electrolysis and redox chemistry with redox shuttles in the form factor of mesoporous electrodes and free-floating particles. The most promising materials candidates were used in a suspension reactor to evaluate performance toward photocatalytic H 2 production and results from the two measurements were compared. Predominantly, state-of-the-art cocatalyst-modified Rh-doped SrTiO 3 and BiVO 4 particles were further characterized to assess for their ability to perform visible-light-driven H 2 and O 2 evolution, respectively, and results were similar to those reported for the state-of-the-art in the peer-reviewed literature. Outcomes from this work inform the public of the effectiveness and promise of solar photocatalytic water splitting for clean and renewable hydrogen production. This work may also help increase research interest and funding for photocatalysis projects, which will accelerate development of a technology that will benefit the public by generating fuel while emitting few greenhouse gases and pollutants.

08 HYDROGEN↗

DOE OSTI2021

Influence of the Bulk Resistivity on Silicon Heterojunction Solar Cells and Module Reliability

Recent developments in industry on surface passivation open the possibility of using less doped substrates in silicon solar cells. In this report we investigate how the bulk resistivity affects the performance of silicon cells and the reliability of modules. Herein, n- and p-type silicon heterojunction cells with bulk resistivities between 3 and 15 000 Ωcm are studied. We measure the current–voltage characteristics of n-type cells across the resistivity range, and we find comparable responses to illumination intensities between 0.1 and 1 suns. The cells with bulk resistivities over 1000 Ωcm show breakdown voltages larger than -1000 V, almost two orders of magnitude higher than in typical commercial cells. Although modules have bypass-diodes to prevent cells from going into breakdown, higher breakdown voltages can improve the reliability of modules in case of bypass-diode failure and reduce the module cost by easing the number of bypass-diodes required. Finally, the cells have been submitted to light soaking. The float-zone p-type cells with bulk resistivities over 10 000 Ωcm are less sensitive to light-induced degradation than cells with bulk resistivities below 10 Ωcm. The former show to recover few hours after light soaking, while the latter recover only after dark annealing.

14 SOLAR ENERGY↗

DOE OSTI2022

A Search for Predicted Astrometric Microlensing Events by Nearby Brown Dwarfs*

Gravitational microlensing has the potential to provide direct gravitational masses of single, free-floating brown dwarfs, independent of evolutionary and atmospheric models. The proper motions and parallaxes of nearby brown dwarfs can be used to predict close future alignments with distant background stars that cause a microlensing event. Targeted astrometric follow up of the predicted microlensing events permits the brown dwarf’s mass to be measured. Predicted microlensing events are typically found via searching for a peak threshold signal using an estimate of the lens mass. We develop a novel method that finds predicted events that instead will lead to a target lens-mass precision. The main advantage of our method is that it does not require a lens-mass estimate. We use this method to search for predicted astrometric microlensing events occurring between 2014 and 2032 using a catalog of 1225 low-mass star and brown-dwarf lenses in the Solar Neighborhood of spectral type M6 or later and a background source catalog from DECaLS Data Release 9. The background source catalog extends to g = 23.95, providing a more dense catalog compared to Gaia. Our search did not reveal any upcoming microlensing events. We estimate the rate of astrometric microlensing event for brown dwarfs in the Legacy Survey and find it to be low ~10 -5 yr -1 . We recommend carrying out targeted searches for brown dwarfs in front of the Galactic Bulge and Plane to find astrometric microlensing events that will allow the masses of single, free-floating brown dwarfs to be measured.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2020

A giant planet candidate transiting a white dwarf

Astronomers have discovered thousands of planets outside the Solar System1, most of which orbit stars that will eventually evolve into red giants and then into white dwarfs. During the red giant phase, any close-orbiting planets will be engulfed by the star2, but more distant planets can survive this phase and remain in orbit around the white dwarf3,4. Some white dwarfs show evidence for rocky material floating in their atmospheres5, in warm debris disks6,7,8,9 or orbiting very closely10,11,12, which has been interpreted as the debris of rocky planets that were scattered inwards and tidally disrupted13. Recently, the discovery of a gaseous debris disk with a composition similar to that of ice giant planets14 demonstrated that massive planets might also find their way into tight orbits around white dwarfs, but it is unclear whether these planets can survive the journey. So far, no intact planets have been detected in close orbits around white dwarfs. Here we report the observation of a giant planet candidate transiting the white dwarf WD 1856+534 (TIC 267574918) every 1.4 days. We observed and modelled the periodic dimming of the white dwarf caused by the planet candidate passing in front of the star in its orbit. The planet candidate is roughly the same size as Jupiter and is no more than 14 times as massive (with 95 per cent confidence). Other cases of white dwarfs with close brown dwarf or stellar companions are explained as the consequence of common-envelope evolution, wherein the original orbit is enveloped during the red giant phase and shrinks owing to friction. In this case, however, the long orbital period (compared with other white dwarfs with close brown dwarf or stellar companions) and low mass of the planet candidate make common-envelope evolution less likely. Instead, our findings for the WD 1856+534 system indicate that giant planets can be scattered into tight orbits without being tidally disrupted, motivating the search for smaller transiting planets around white dwarfs.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2021

A Circularity Assessment for Silicon Solar Panels Based on Dynamic Material Flow Analysis

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2023

Demand for off-grid desalination technology in small-island communities — Can interfacial solar vapor generation be the answer?

The demand for an off-grid desalination technology and the feasibility of using interfacial solar vapor generation (ISVG) to address the problem were evaluated within the context of Bungin Island. Bungin Island is a small-island community in Indonesia facing water scarcity. By conducting interviews with households there, we found that households located on the exterior portion of the island faced the greatest challenges to water access. For example, only 17% of exterior households had piped water access, whereas 67% central households had piped water access. Similar inequities for exterior households were also found with respect to the cost of getting additional water. Thus, we determined that an off-grid desalination technology is best suited for solving the water access problems for the most vulnerable communities in small islands. Further, ISVG technologies that draw on the radiative energy in sunlight to achieve desalination are promising in increasing water access by offering a floating off-grid devices on water near exterior households, passive operation, low capital investment, and simple maintenance. These findings stress the importance of understanding how contextual factors shape barriers to water access and provide a road map on how to begin incorporating these factors into the development of a more sustainable desalination technology.

42 ENGINEERING↗

DOE OSTI2024

A Tutorial on the Control of Floating Offshore Wind Turbines: Stability Challenges and Opportunities for Power Capture

Climate change is a serious threat facing humanity. The United States (U.S.) and many other countries are increasing the amount of electrical power generated from renewable energy sources in an effort to combat climate change and ensure energy independence. The U.S. has set goals to achieve a 100% decarbonized electric grid by 2035 and a net-zero emissions economy by no later than 2050. Renewable energy currently accounts for about 20% of the U.S. power grid. According to the U.S. Department of Energy and the National Renewable Energy Laboratory (NREL), in the U.S. in 2021, wind and solar photovoltaic generation supplied 9.1% and 4% of total electricity generation, respectively, and the latest publicly available data show that hydropower represented 6.6% of all electricity generated in the U.S. in 2019. As wind farms have been built in many of the best wind resource areas on land, the U.S. and many other countries are turning to offshore wind for further growth of wind power capacity. Further, the U.S. has committed to deploy 30 GW of offshore wind by 2030, a significant increase from the 0.04 GW of installed offshore wind in the country as of the end of 2023. Many other countries have also established ambitious goals or plans to increase the amount of installed offshore wind power.

17 WIND ENERGY↗

DOE OSTI2025

Development of ~25% Efficient Double Side Screen Printed Poly-Si/SiO x Passivated Contact Solar Cells

This program aims to overcome these challenges and develop high-efficiency (24-25%) double-side (DS) TOPCon solar cells by maximizing passivation on both sides while mitigating light absorption losses. To achieve this, the program will implement either thin (≤ 20 nm) homogeneous n-TOPCon on the entire front surface or selective area thick (≥ 100 nm) n-TOPCon only underneath the front metal contact with ~90% field region composed of dielectric passivated textured n-Si in between the poly-Si/metal grid. The rear side will feature ~250 nm-thick full-area planar p-TOPCon, which functions as the rear junction. Recombination and parasitic absorption losses in the front and rear TOPCon layers will be minimized by tailoring their doping profiles and thickness. Additionally, the device performance will be further enhanced through the optimization of bulk parameters, including the carrier lifetime, resistivity, and thickness of the n-type Si absorber. Finally, advanced metallization techniques, such as fine-line printing, and floating busbar or busbar-less designs, will be employed to reduce recombination, resistive, and optical losses. The program started with the development of a technology roadmap for DS-TOPCon cells to achieve target efficiency.

14 SOLAR ENERGY↗

DOE OSTI2021

Structural organization of space polymers

Extraterrestrial polymers of glycine with iron have been characterized by mass spectrometry to have a core mass of 1494 Da with dominant rod-like variants at mass to charge ratios of 1567 and 1639 [McGeoch et al., “Meteoritic proteins with glycine, iron and lithium,” arXiv:2102.10700 (2021)]. Several principal macro-structural morphologies are observed in solvent extracts from a chondritic Vigarano class alteration type 3 meteoritic material. The first is an extended sheet of linked (three-legged) triskelia containing the 1494 Da core entity that encloses gas bubbles in the solvent. A second is of fiber-like crystals found here, via x-ray diffraction, to be multiple-walled nanotubes made from a square lattice of the 1494 Da polymer. A third is a dispersion of floating phantom-like short tubes of up to 100 μm length with characteristic angled bends that suggest the influence of a specific underlying protein structure. Here, it is proposed that the angled tubes are the observable result of a space-filling superpolymerization of 1638 Da polymer subunits guided by the tetragonal symmetry of linking silicon bonds. Distorted hexagonal sheets are linked by perpendicular subunits in a three-dimensional hexagonal diamond structure to fill the largest possible volume. This extended very low-density structure is conjectured to have dominated in a process of chemical selection because it captured a maximum amount of molecular raw material in the ultra-low density of molecular clouds or of the proto-solar nebula. This could have led ultimately to the accretion of the earliest planetary bodies.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2025

Assessing the levelized cost of energy in South Korea

This study evaluates the levelized cost of energy (LCOE) for various energy technologies in the Republic of Korea (Korea) from 2023 to 2050, highlighting cost trajectories and potential crossovers among competing technologies. The analysis projects that, based on our set of assumptions, utility-scale photovoltaic systems achieve lower LCOEs than nuclear by 2030, while fixed offshore wind is expected to become cost-competitive with coal-fired generation around the same time. Floating offshore wind is projected to reach cost parity with coal in the late 2030s. Co-firing with natural gas and green hydrogen is identified as the highest-cost generation option due to high natural gas and green fuel costs and declining capacity utilization. This study further examines the potential for hybrid systems that integrate renewable energy with energy storage to serve as flexible, cost-effective, zero-emission alternatives to green hydrogen-based generation. Spatial LCOE assessments indicate that near-shore offshore wind sites may achieve lower costs despite modest capacity factors, contingent on site-specific factors such as grid integration and social acceptance. The findings indicate that renewable energy technologies are expected to experience continued cost declines, with solar photovoltaic becoming the most competitive energy source in Korea by 2030–2035. Incorporating social costs accelerates this shift from conventional alternatives.

Green hydrogen↗

DOE OSTI2023

Five grand challenges of offshore wind financing in the United States

Offshore wind energy has the potential to play a critical role in fostering a renewable energy transformation in the United States. This owes to its massive technical potential, strategic location near densely populated coastlines, and - relative to onshore wind and solar - high capacity factors and consistent production. The Biden Administration's target to build 30 GW of offshore wind capacity by 2030 (from 0.04 GW today) requires the creation and swift development of a new industry that interlinks the wind and power industries with the maritime sector. Critical to its success is financing. While financial capital is abundant, deploying it for offshore wind faces major challenges. We identify and describe five grand challenges affecting offshore wind finance in the U.S. Failing to address these challenges may put deployment targets at risk. The challenges include (1) Early years financing: navigating the complexities, timing mismatches, and high costs of projects in the development phase; (2) Policy support for project financial solvency: addressing the uncertainty and systematic transfers of tax credits away from offshore wind, characteristic of the U.S. Investment Tax Credit; (3) Workforce development: building a skilled workforce for an emerging market; (4) Transmission and integration barriers: upgrading the power grid to reliably support large scale offshore wind integration; and (5) Floating wind development: financing the development and scale-up of floating offshore wind technologies. The second challenge has already been solved to a large extent by the Inflation Reduction Act.

17 WIND ENERGY↗

DOE OSTI2025

The Imprint of Southern Ocean Storms on Modeled Surface Chlorophyll, Their Drivers and Satellite Biases

Southern Ocean (SO) phytoplankton chlorophyll is highly variable on sub-seasonal time scales. Although the SO is the windiest ocean basin globally, it is not conclusively understood how storms impact SO phytoplankton dynamics. Much of our existing knowledge stems from satellites, but biases due to data gaps from cloud cover and low solar angles remain unquantified. Here, we use ocean–sea-ice simulations with the Community Earth System Model to quantify the climatological 1997–2018 imprint of storms on chlorophyll and phytoplankton dynamics in the ice-free SO. Additionally, by comparing the full-field model output to synthetic satellite observations, we quantify sampling biases in satellite-derived estimates. We find that both the sign and the magnitude of the average surface chlorophyll imprint vary substantially across storms but last for at least 4 days after the storm passing. Based on our analysis, more than one third of the storms explain the majority of local non-seasonal chlorophyll variability, but satellite-derived storm imprints are often too large in magnitude. On the day of the storm passing, changes in vertical mixing predominantly cause surface chlorophyll anomalies, and reduced light availability due to enhanced cloud cover outweighs the enhanced nutrient availability due to entrainment. Interestingly, storms imprint differently on total net primary production than on surface chlorophyll, demonstrating the difficulty to derive carbon-cycle impacts from a surface-chlorophyll assessment. With SO future storm activity projected to increase, complementing satellite observations with other observing technologies, for example, profiling floats, is necessary to better constrain how storms impact biological carbon cycling in the SO.

Nissen, Cara [University of Colorado, Boulder, CO ↗