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DOE OSTI2024

Developing Platinum-Group-Metal-Free Catalysts for Oxygen Reduction Reaction in Acid: Beyond the Single Metal Site

This project is to develop M (x) -N-C catalysts with dense multiple metal center (MMC) sites to meet the DOE 2025 activity target of 0.044 mA/cm 2 at 0.9 V IR-free ., as well as other goals such as durability. We have made important contributions to both catalyst development and fundamental understandings of the active sites in M-N-C catalysts in this project. We successfully made M (x) -N-C catalysts with some multiple metal center (MMC) sites by combining ionothermal carbonization with chemical vapor deposition (CVD). These catalysts, however, are not as active as the most active single-atom Fe-N-C catalysts made by the similar CVD process, owing likely to the low site density and the presence of inorganic Fe species such as iron carbides and nanoparticles. The most significant accomplishments we achieved in this project are: (1) we unraveled the formation pathway of Fe-N 4 sites during pyrolysis step-by-step and identified the trans-metalation mechanism, in collaboration with Deborah Myers and her colleagues at Argonne National Laboratory (ANL); (2) inspired by this finding, we pioneered the CVD synthesis of M-N-C catalysts (M = Mn, Fe, and Co), in which the Fe-N-C catalyst by CVD demonstrated an ORR activity of 33 mA/cm 2 at 0.9 V in H 2 -O 2 proton exchange membrane fuel cells (PEMFCs), very close to the ultimate goal of 35 mA/cm 2 of our project. This catalyst is the first Fe-N-C catalyst that contains only D1 sites without the D2 sites; whereas D1 and D2 sites have been always identified by Mossbauer in previous Fe-N-C catalysts. This finding helps to understand what the D1 and D2 sites are and their roles in catalyzing the ORR. (3) by improving the mass transport of the carbon matrix prior to the CVD process, the revised Fe-N-C catalyst made by CVD delivered a maximum power density of 0.53 W/cm 2 in H 2 -air PEMFCs. The improvement strategy was partly inspired by the computational modeling work by Adam Weber from LBNL, the Co-PI of this project, by developing, coding, and exercising a continuum level model of transport phenomena within a PGM-free catalyst layer. The model demonstrated that local resistances combined with limited site density of the PGM-free catalyst can result in limiting currents and poor polarization performance. The model also gave design guidance for impact of ECSA and overall catalyst-layer thickness. However, both Fe-N-C and Co-N-C catalysts developed by CVD showed poor durability in PEMFCS, in comparison with the traditional M-N-C catalysts synthesized via regular pyrolysis process. Consequently, we did not achieve the proposed durability targets. Despite so, we believe the FeNC-CVD catalysts with the poor durability and D1 sites only provides an excellent platform to understand the degradation mechanism of Fe-N-C in PEMFCs, the most important challenge in the development of M-N-C catalysts.

08 HYDROGEN↗

DOE OSTI2024

Puerto Rico Grid Resilience and Transitions to 100% Renewable Energy Study (PR100) (Summary Report)

The Puerto Rico Grid Resilience and Transitions to 100% Renewable Energy Study (PR100) is a comprehensive analysis based on extensive stakeholder input of possible pathways for Puerto Rico to achieve its goal of 100% renewable energy by 2050. In this summary report of the PR100 Final Report, we describe the background and motivation behind the study, provide an overview, summarize results, highlight key findings, and outline implementation actions for stakeholders to take in the immediate-, near-, mid-, and long-term to achieve Puerto Rico’s energy system goals.

100% renewable energy target↗

DOE OSTI2024

Estudio de Resiliencia de la Red Electrica de Puerto Rico y Transiciones a Energia 100% Renovable (PR100): Informe resumido [Spanish Translation of Puerto Rico Grid Resilience and Transitions to 100% Renewable Energy Study (PR100) (Summary Report)]

100% renewable energy target↗

DOE OSTI2023

Roads to Removal: Options for Carbon Dioxide Removal in the United States

Our analysis shows it is feasible for the United States to remove a staggering amount of CO 2 from the air—this will be critical to becoming carbon neutral by 2050. Our comprehensive, first-of-its-kind, county-resolution analysis indicates that our country can accomplish this goal by relying on demonstrated technology, natural resources, and workforces we already have. Additionally, ongoing technology development can lower costs, shorten timelines, and deliver new solutions. Our analysis evaluated how we can use forests, cropland soils, and waste biomass, along with purpose-built machines, to get us to net-zero. Further, we considered community impacts and identified locations where certain solutions could be uniquely beneficial or potentially counterproductive. Our findings enable decisionmakers to weigh both opportunities and constraints and to decide what roads to use to meet our national climate goal for net-zero CO 2 emissions.

03 NATURAL GAS↗

DOE OSTI2023

ES4SE Technical Assistance Program Evaluation

Technical assistance (TA) programs can provide organizations and communities with the information, tools, and resources needed to support their development and resilience goals. The Energy Storage for Social Equity (ES4SE) TA program sought to empower undeserved communities through co-development of energy storage pathways and solutions to address community-defined challenges and needs. Evaluating the design, implementation, and outcomes of TA programs like ES4SE is critical to understanding whether program and participant goals were accomplished and how to adjust the TA approach to better meet participant needs. This evaluation explores the experiences and perceptions of community participants in the ES4SE TA program.

25 ENERGY STORAGE↗

DOE OSTI2023

Durable and Low-Cost Fractal Structured Multifunctional Coatings for Next-Generation CSP

Fractal coatings on various low-cost and high-temperature metallic substrates such as SS316, SS347, In800H, In740H, In625, Haynes 230, etc. were fabricated employing our patented novel electrodeposition process at various deposition potentials and deposition times, as well as chemical etching. The best combination of the materials and processing conditions were co-optimized for the reliable and repeatable fabrication of the multifunctional coatings. Surface morphologies were examined using SEM and AFM, and fractal characterization was done using a 3D optical surface profiler. Fractal dimension was used to identify successful fabrication and material parameters. The mechanical durability of the coatings was evaluated using several standardized tests, such as sand abrasion (ASTM D968) and adhesion (ASTM D3359), to fully characterize and demonstrate the mechanical durability of the fabricated surfaces. HTF immersion tests on the fractal multifunctional coatings were conducted based on a modification of the ASTM D870, which is established for static water immersion testing. To calculate the corrosion rates and descaled weight loss of the samples subjected to thermal exposure for different time durations (100 h, 300 h, 500 h, and optionally 750 h) to estimate the corrosion rate. While protecting the substrates from corrosion is an important goal, an allied goals is also to examine the post-corrosion temperature stability and properties of the molten salts themselves due to the dissolution of the constituents of the alloys and the corrosion products from the coatings that cause “fouling” of the molten salts. Fouling characteristics of the different molten salt HTFs exposed to coated and uncoated substrates were investigated. Finally, considering a prototype molten salt/sCO2 heat exchanger, cost/performance model is developed to demonstrate that the coatings on low-cost alloys such as stainless steel provide lower levelized cost of heat exchanger compared to high nickel content Ha230.

14 SOLAR ENERGY↗

DOE OSTI2023

South Africa: Energy Efficiency Demand Side Management Experience (2004-2022)

In July 2022, President Cyril Ramaphosa announced an emergency response plan to address the growing electricity crisis in South Africa, which included the necessity for customers of Eskom, South Africa’s primary electricity supplier, to implement demand-side energy efficiency measures. This report is the first of two reports that provides the foundation for a strategic Demand-Side Management (DSM) approach to reduce load shedding and maximize energy savings in South Africa, through inter-governmental collaboration and increased coordination of energy efficiency activities. This first report focuses on the experience of Eskom’s rate-funded Integrated Demand Management (IDM) programme, from its beginning in 2004 to today, highlighting the factors that led to failed support for the programme, and emphasizing the measures that will need to be addressed to meet the government’s energy efficiency (EE) goals, as well as other socio-economic and environmental priorities, such as job creation, affordability and greenhouse gas (GHG) emission reduction goals.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2024

Multi-Source Machine Learning and Thermoplastics Enhanced Aerostructure Manufacturing (mTEAM)

RTX Technology Research Center (RTRC), together with Collins Aerospace (Collins) and Oak Ridge National Laboratory (ORNL) has developed an Artificial Intelligence (AI) / Machine Learning (ML) guided solution to advance the manufacturing and assembly of high performance and lightweight thermoplastic composite (TPC) aerospace products. The solution aims to lower risk, cost and lead time for induction heating based welding and consolidation processes for TPC structure. The cost and lead time of part and material specific process development for induction welding (IW) and induction consolidation will be reduced by replacing traditional empirical methods with optimization methods that merge AI/ML and physics-based process simulations and process experiments with sensing and controls. TPC-IW process development is empirical in nature, and uncertainties in material & process behavior exist near & far from the induction coil. Physics-based simulations can be leveraged directly for process optimization but can be too computationally expensive to run in high fidelity and real time to do robust process optimization. The key impact of successful TPC induction consolidation and welding is cost & lead time reduction for part & material specific consolidation and welding recipes. This is an enabler for more rapid deployment of TPC structures via joining assembly, which can reduce energy & cost intensive usage of autoclaves & ovens. The solution aimed to advance the U.S. Department of Energy’s interests in using thermoplastics and automation in composite manufacturing for improvement of products for existing markets via increased production speeds, reduced costs, and lowered use of energy. Welded TPC structures can offer significant weight & energy savings for high-value commercial aerospace & industrial applications compared to metal & thermoset composite structures assembled by mechanical fastening and/or adhesive bonding. The project was organized into two Budget Periods. Budget Period 1 (BP1) was 15 months and its goal was to perform ML process optimization framework development & deployment on lab-coupon aerostructure components. A Go/No-Go Review was performed at the end of BP1 to verify fulfilment of key tasks & milestones to justify a Go Decision to move into the next Budget Period. Budget Period 2 (BP2) was 12 months and its goal was the deployment of the ML framework for ML process optimization of pilot industrial scale aerostructure components. The overall project aim was to develop & demonstrate ML-enhanced modeling framework that learns process-property mapping from multiple data sources at different fidelities. During BP1, the team accomplished key tasks & milestones to demonstrate the concept of multi-source ML for TPC aerostructure consolidation and assembly. First, the team completed documentation of induction based TPC heating requirements including baseline metrics to compare measured results against. Next the team completed demonstration of data generation from physics-based simulations for ML surrogate model generation and demonstrated the integration of physics-based simulation data into multi-source AI/ML algorithms. In parallel, the team established the lab-coupon scale induction welding system and completed a process to label and reduce generated data from physics-based simulation and experiments for ML surrogate models to enable multi-source ML model training & testing. To complete BP1, the team integrated physics-based simulation data and experimental data into multi-source ML algorithms. This was based on the team completing ML deployment of the induction welding on a lab system at RTRC and AI/ML deployment on existing induction welding line at Collins. ORNL visited both Collins and RTRC sites to witness the TPC induction welding process. Then, ORNL designed and constructed a new version of their vision-based sensing system better adapted to acquire process signals of the TPC induction welding process for process anomaly and defect detection. In BP2, the team accomplished key tasks & milestones to scale up multi-source ML for TPC aerostructure consolidation and assembly from the lab-coupon scale to the pilot-industrial scale. In BP2, the team demonstrated real time anomaly & defect detection via experiments performed by ORNL & RTRC. The team completed ML-optimization heating trials for TPC induction consolidation at Collins, and the team confirmed pilot industrial scale experimental data from Collins was compatible with the developed ML pipeline from RTRC. The team completed sub-element scale ML process optimization demonstration at RTRC, where the team leveraged RTRC’s robotic TPC welding setup to de-risk the ML process optimization by performing ML analysis of recorded temperatures to account for complex part features. Then, the team applied its ML-derived control strategies and ML process optimization framework at Collins to the pilot-industrial scale on a demo skin-stiffener part representative of a nacelle aerostructure fan cowl section. The key innovation is the AI/ML framework enabling effective process development of high performance, lightweight, energy efficient TPCs for composite aircraft structures.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Multi-Probe FY25 Omega EP Shot Request [Slides]

The goal of the Multi-Probe experimental campaign is to assess the feasibility of using multiple probe types (x ray, proton, neutron, and electron) in future LANL radiographic facilities. X-ray and proton platforms have been demonstrated. The first attempts at simultaneous radiography were hampered by cross talk, which was the subject of FY23 & FY24 experiments. The major goal for FY25 is to demonstrate simultaneous radiography of both static and dynamic objects.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Next Gen High Efficiency Boosted Engine Development

This work represents an advanced engineering research project partially funded by the U.S. Department of Energy (DOE). Ford Motor Company, FEV North America, and Oak Ridge National Laboratory collaborated to develop a next generation boosted spark ignited engine concept. The project goals, specified by the DOE, were 23% improved fuel economy and 15% reduced weight relative to a 2015 or newer light-duty vehicle. The fuel economy goal was achieved by designing an engine incorporating high geometric compression ratio, high dilution tolerance, low pumping work, and low friction. The increased tendency for knock with high compression ratio was addressed using early intake valve closing (EIVC), cooled exhaust gas recirculation (EGR), an active pre-chamber ignition system, and careful management of the fresh charge temperature. Engine weight reduction measures were implemented throughout the engine system making use of composite materials, advanced manufacturing techniques, and architectural choices. This report outlines the analytical, design, fabrication, and test work conducted for the duration of the project. The combustion system stability, EGR tolerance, and knock resistance were validated on a single cylinder engine. An inline six-cylinder engine was then designed targeting application in the Ford F150. Multi-cylinder engines were produced and tested achieving the target vehicle fuel economy improvement of 23% assessed using measured engine fuel consumption combined with a vehicle drive cycle simulation. Actions were identified and designs were demonstrated to achieve the 15% weight reduction target. This project included items covering a range of technology readiness levels. Some of the technologies explored are production ready, while others were investigated to understand the limitations for what can be achieved in a stoichiometric, gasoline-fueled, spark-ignited internal combustion engine.

42 ENGINEERING↗

DOE OSTI2024

Establishing a clostridia foundry for biosystems design by integrating computational modeling, systems-level analyses, and cell-free engineering technologies (Final Report)

Rapid population growth, a rise in global living standards, and economic competitiveness have intensified the need for sustainable, low-cost biofuels and bioproducts production. Industrial biotechnology using microbial cell factories – and waste and/or renewable feedstocks – is one of the most attractive approaches for addressing this need, particularly when large-scale chemical synthesis is untenable. Unfortunately, designing, building, and optimizing biosynthetic pathways in cells remains a complex challenge. With support from the Department of Energy, we worked to address this challenge in a new interdisciplinary venture that established the world’s first clostridial Foundry for Biosystems Design (cBioFAB). Working both in vitro (cell-free) and in vivo, the goal of this project was to interweave and advance state-of-the-art computational modeling, genome editing, omics measurements, systems-biology analyses, and cell-free technologies to expand the set of platform organisms that meet DOE bioenergy goals. Specifically, we manufactured fuel and chemical intermediates via existing and de novo pathways. This report covers the outcomes of our research project.

09 BIOMASS FUELS↗

DOE OSTI2024

Final Report for Center for Tokamak Transient Simulations at USU

Providing plasma fluid codes like NIMROD with continuum drift kinetic (CDK) physics that is quantitatively valid and computationally feasible throughout the spatial domain is difficult. Work at Utah State University (USU), in collaboration with the Center for Tokamak Transient Simulations (CTTS), focused on applying CDK closures in disruption-related calculations. Three examples where kinetic physics is paramount are (1) the electron stress tensor closure in Ohms law for accurately describing neoclassical tearing mode (NTM) evolution, (2) runaway electron (RE) density (nRE) and current (jRE) moments in NIMROD’s extended MHD model for self-consistent evolution of RE populations during disruptions and, (3) energetic ion effects on a myriad of MHD instabilities. While NTM simulations and continuum and PIC approaches to energetic ions in NIMROD have been a major goals of USU’s closure work for several years, the development of self-consistent CDK RE capability in NIMROD was started and extended considerably during the CTTS effort. Some goals of CDK RE in NIMROD are to explore the effects of the 2D relativistic phase space in 4D simulations and compare with NIMROD’s fluid RE model. Four publications and two PhD theses came out of the USU CTTS effort.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2024

Delivering Clean Air in Denver: Propane Trucks and Infrastructure in Mail Delivery Application

In 2021, Drive Clean Colorado, a Denver-based Clean Cities coalition, initiated the deployment of five Class 6 medium-duty propane autogas delivery trucks into a United States Postal Service (USPS) mail delivery contractor fleet with the goal of providing a proof-of-concept demonstration for mail delivery fleets nationwide. Funded by the U.S. Department of Energy's Office of Energy Efficiency & Renewable Energy, the project, titled "Delivering Clean Air in Denver: Propane Trucks and Infrastructure in Mail Delivery Application," enabled the purchase and deployment of the propane-powered trucks, refueling infrastructure, and supporting analysis by the National Renewable Energy Laboratory (NREL). Key objectives of the analysis included calculating the propane vehicles' emissions reductions, analyzing the costs and operational performance of the propane fleet compared to conventional diesel-powered vehicles, and evaluating the viability of propane as a clean and cost-effective alternative to conventional diesel trucks (AFDC 2023b, 2023c). The primary goal of the project was to demonstrate alternative fuel vehicles in a mail transport application and evaluate the viability of propane as a clean and cost-effective alternative to conventional diesel trucks. This proof-of-concept demonstration is expected to lead to improved understanding of the performance attributes, costs, and operational issues to inform technology adoption decisions, helping to spur market transformation toward lower-emission truck fleets. By reducing the risk of first adoption, potential exists to transform the U.S. Postal Service (USPS) mail delivery system into a lower-carbon national fleet. This technical report details the vehicle duty cycle characterization and fleet cost and performance comparison performed by the National Renewable Energy Laboratory, in addition to estimated emissions reductions for delivery operations.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2024

Orbital-Free Quantum Simulation Methods for Application to Warm Dense Matter (Final Technical Report)

Predictive simulations for prediction of condensed system behavior in state conditions far from ambient is increasingly crucial to DOE priorities. Warm dense matter (WDM) is the paradigm: temperature T > 1-15 eV, pressures P to 1 Mbar or greater. Experiments under such state conditions are difficult and costly. We summarize work driven by the need and opportunity to make free-energy density functional theory (DFT) as powerful a tool for ab initio simulation of matter under such extreme conditions as ground state DFT is for ordinary matter Advancing orbital-free DFT (OF-DFT) to eliminate the Kohn-Sham (KS) scaling bottleneck in such simulations is the other priority. The concurrent challenge for both goals is the intrinsic complexity of WDM. We summarize 15 years of successes and major progress on (1) free energy exchange-correlation functionals; (2) non-interacting free energy functionals (counterpart to T=0 Kohn-Sham kinetic energy density functionals); (3) rigorous results and constraints for free-energy DFT; (4) software for free energy DFT calculations in both conventional Kohn-Sham and OF-DFT form; (5) de-orbitalization of advanced orbital-dependent ground state functionals for use in OF-DFT; (6) demonstration calculations; (7) ancillary achievements (e.g. major review articles, secondary explorations motivated by primary goals).

36 MATERIALS SCIENCE↗

DOE OSTI2024

Building efficiency, electrification, and distributed solar PV bill savings under time-based retail rate designs

Building energy technologies and distributed generation, including energy efficiency (EE), distributed solar PV (DPV), and building electrification, are critical to meeting decarbonization goals. Rate design may play an important role in determining the customer economics of adopting these technologies, but it is unclear whether – and to what extent – current rate design trends support or impede progress toward these goals. In this study, we answer these questions by quantifying the range of residential customer bill impacts of EE, DPV, and building electrification investments under current and emerging time-based retail electricity rate designs (i.e., time-of-use, event-based pricing, coincident demand charges, and real time pricing). We also compare these customer bill savings to power system and societal benefits and assess how well the investments are compensated relative to the societal value they provide.

14 SOLAR ENERGY↗

DOE OSTI2024

Prefeasibility Analysis of Behind-the-Meter Distributed Energy Resources in Highland Park, MI: Highland Park Pathways to Power [Slides]

Through the Communities LEAP (Local Energy Action Program) Pilot, the National Renewable Energy Laboratory (NREL) engaged the Highland Park Stakeholder Coalition to scope four technical assistance work areas to address their energy needs and goals. This slide deck addresses the highlighted tasks under work area "B" related to policy analysis, due diligence, and case studies for removing barriers and providing best practices for local clean energy development. NREL used the REopt platform to evaluate the techno-economic potential of adding solar PV, electric storage, and/or diesel generators at several locations in Highland Park, Michigan: a typical residential and commercial building in Highland Park, the Earnest T. Ford Recreation Center, and the Parker Village Microgrid. The analysis goals focused on the ability of solar PV, electric storage, and/or diesel generators to reduce electricity costs and improve site resilience.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2024

Household Energy Burden in Lawrence, Massachusetts [Slides]

The City of Lawrence consists of 18 census tracts, of those, 9 census tracts have an average energy burden (the percent of income spent on energy bills) of 6% or greater. The Lawrence Stakeholders Coalition's (LSC) main goal is to "Reduce energy burden and create well-paying local jobs and businesses by increasing the distribution and use of sustainable technologies such as heat pumps, community and rooftop solar, and weatherization." As part of that goal, the LSC is interested in understanding Lawrence's pathway to electrification, specifically through the building sector. This technical assistance aims to assist the LSC's electrification and energy burden reduction planning by: 1) Identifying the most energy-burdened households by owner-occupied and renter-occupied housing status; 2) Identifying and quantifying the characteristics of the most energy-burdened housing units by housing type, age, and heating fuel type; 3) Identifying the tenure and housing types of the most energy-burdened and prevalent households for subsequent ResStock analysis of cost-effective efficiency upgrades.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2024

Production of Astatine-211 for Translational Science in Radiotherapy (Research Performance Progress Report)

In this proposal we outline the methods to improve the isotope production of astatine-211 at the University of Pennsylvania Cyclotron Facility. Astatine-211 is an isotope that emits alpha- radiation and has high potential for treating otherwise untreatable cancers. The goal of this proposal is two fold, 1) Optimize current production of astatine-211 and maintain routine production and 2) develop new isotope production target systems and chemical isolation systems. By completing this proposal we will ensure that the University of Pennsylvania Cyclotron Facility continues to build it’s isotope program in an effort that unites under DOE isotope network supply initiatives with the overall goal of increasing the national supply of isotopes. The University of Pennsylvania is uniquely located in the northeast corridor of the United States of America and has access to dozens of institutions that could use astatine-211 in their research. With the support of the DOE we have the opportunity to provide additional momentum to this growing field of research and will be able to provide the foundation for economical development of astatine-211 research and application in medicine.

62 RADIOLOGY AND NUCLEAR MEDICINE↗