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DOE OSTI2022

Review of Electric Vehicle Charger Cybersecurity Vulnerabilities, Potential Impacts, and Defenses

Worldwide growth in electric vehicle use is prompting new installations of private and public electric vehicle supply equipment (EVSE). EVSE devices support the electrification of the transportation industry but also represent a linchpin for power systems and transportation infrastructures. Cybersecurity researchers have recently identified several vulnerabilities that exist in EVSE devices, communications to electric vehicles (EVs), and upstream services, such as EVSE vendor cloud services, third party systems, and grid operators. The potential impact of attacks on these systems stretches from localized, relatively minor effects to long-term national disruptions. Fortunately, there is a strong and expanding collection of information technology (IT) and operational technology (OT) cybersecurity best practices that may be applied to the EVSE environment to secure this equipment. In this paper, we survey publicly disclosed EVSE vulnerabilities, the impact of EV charger cyberattacks, and proposed security protections for EV charging technologies.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2023

Towards an Energy Future with Ubiquitous Electric Vehicles: Barriers and Opportunities

The electrification of personal transportation holds great potential for lowering greenhouse gas emissions and reducing climate change. The promise of electric vehicles (EVs) to serve these goals has resulted in a broad range of supporting policies aimed at encouraging widespread EV adoption at both the state and federal levels in the United States and around the world. While the EV revolution and prospects of a world with ubiquitous EVs are impacting various industries and many aspects of daily life, strategic interactions between the power grid and EVs are crucial for a successful energy transition. However, managing the interplay between EVs and the power grid remains a challenge. Motivated by that tension, this paper surveys a variety of solutions, policies, and incentives that are focused on effectively managing EV charging behaviors. The paper’s objective is to explore these tools to ensure that EV owners have ultimate control over their personal vehicles while simultaneously allowing the power grid to mitigate adverse network impacts. Furthermore, this paper examines the role of charging infrastructure technology and its strategic placement in facilitating the seamless integration of EVs into the grid. Additionally, the paper highlights financial mechanisms associated with EV integration and discusses the consequences of these mechanisms.

25 ENERGY STORAGE↗
DOE OSTI2023

A Review of Sensing Technologies for New, Low Global Warming Potential (GWP), Flammable Refrigerants

Commercial refrigeration systems currently utilize refrigerants with global warming potential (GWP) values ranging from 1250 to 4000. The advent of low GWP alternatives (GWP <150) is expected to significantly curtail direct emissions from this segment and greatly influence the ongoing electrification and decarbonization efforts. Most of the low GWP alternatives exhibit flammability risk and hence require robust sensing solutions for a reliable and safe operation of the equipment. This review article aims to provide an overview of different sensing mechanisms suitable for potential applications in systems employing flammable refrigerants, particularly those designated as A2L class. A summary of different A2L refrigerants and their properties is provided followed by a broad review of different classes of sensors, their working principle, transduction method, features, advantages, and limitations. Additionally, key performance characteristics of accuracy, selectivity, sensitivity, dynamic characteristic, and durability among other properties are discussed. Finally, areas of improvement and corresponding approaches are suggested for potential sensors in the successful adoption of A2L class refrigerants.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2020

0D-1D Hybrid Silicon Nanocomposite as Lithium-Ion Batteries Anodes

Lithium ion batteries (LIBs) are the enabling technology for many of the societal changes that are expected to happen in the following years. Among all the challenges for which LIBs are the key, vehicle electrification is one of the most crucial. Current battery materials cannot provide the required power densities for such applications and therefore, it makes necessary to develop new materials. Silicon is one of the proposed as next generation battery materials, but still there are challenges to overcome. Poor capacity retention is one of those drawbacks, and because it is tightly related with its high capacity, it is a problem rather difficult to address with common and scalable fabrication processes. Here we show that combining 0D and 1D silicon nanostructures, high capacity and stability can be achieved even using standard electrode fabrication processes. Capacities as high as 1200 mAh/g for more than 500 cycles at high current densities (2 A/g) were achieved with the produced hybrid 0D/1D electrodes. In this research, it was shown that while 0D nanostructures provide good strain relaxation capabilities, 1D nanomaterials contribute with enhanced cohesion and conductive matrix integrity.

0D↗
DOE OSTI2021

Drop Size Distribution Variability in Central Argentina during RELAMPAGO-CACTI

The Remote sensing of Electrification, Lightning, And Meso-scale/micro-scale Processes with Adaptive Ground Observations (RELAMPAGO) and the Cloud, Aerosol, and Complex Terrain Interactions Experiment Proposal (CACTI) field campaigns provided an unprecedented thirteen-disdrometer dataset in Central Argentina during the Intensive (IOP, 15 November to 15 December 2018) and Extended (EOP, 15 October 2018 to 30 April 2019) Observational Periods. The drop size distribution (DSD) parameters and their variability were analyzed across the region of interest, which was divided into three subregions characterized by the differing proximity to the Sierras de Córdoba (SDC), in order to assess the impact of complex terrain on the DSD parameters. A rigorous quality control of the data was first performed. The frequency distributions of DSD-derived parameters were analyzed, including the normalized intercept parameter (logN w ), the mean volume diameter (D 0 ), the mean mass diameter (D m ), the shape parameter (μ), the liquid water content (LWC), and the rain rate (R). The region closest to the SDC presented higher values of logN w , lower D 0 , and higher μ, while the opposite occurred in the farthest region, i.e., the concentration of small drops decreased while the concentration of bigger drops increased with the distance to the east of the SDC. Furthermore, the region closest to the SDC showed a bimodal distribution of D 0 : the lower values of D 0 were associated with higher values of logN w and were found more frequently during the afternoon, while the higher D 0 were associated with lower logN w and occurred more frequently during the night. The data were analyzed in comparison to the statistical analysis of Dolan et al. 2018 and sorted according to the classification proposed in the cited study. The logN w -D 0 and LWC-D 0 two-dimensional distributions allowed further discussion around the applicability of other mid-latitude and global precipitation classification schemes (startiform/convection) in the region of interest. Finally, three precipitation case studies were analyzed with supporting polarimetric radar data in order to relate the DSD characteristics to the precipitation type and the microphysical processes involved in each case.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Towards Energy-Positive Buildings through a Quality-Matched Energy Flow Strategy

Current strategies for net-zero buildings favor envelopes with minimized aperture ratios and limiting of solar gains through reduced glazing transmittance and emissivity. This load-reduction approach precludes strategies that maximize on-site collection of solar energy, which could increase opportunities for net-zero electricity projects. To better leverage solar resources, a whole-building strategy is proposed, referred to as “Quality-Matched Energy Flows” (or Q-MEF): capturing, transforming, buffering, and transferring irradiance on a building’s envelope—and energy derived from it—into distributed end-uses. A mid-scale commercial building was modeled in three climates with a novel Building-Integrated, Transparent, Concentrating Photovoltaic and Thermal fenestration technology (BITCoPT), thermal storage and circulation at three temperature ranges, adsorption chillers, and auxiliary heat pumps. BITCoPT generated electricity and collected thermal energy at high efficiencies while transmitting diffuse light and mitigating excess gains and illuminance. The balance of systems satisfied cooling and heating demands. Relative to baselines with similar glazing ratios, net electricity use decreased 71% in a continental climate and 100% or more in hot-arid and subtropical-moderate climates. Total EUI decreased 35%, 83%, and 52%, and peak purchased electrical demands decreased up to 6%, 32%, and 20%, respectively (with no provisions for on-site electrical storage). Decreases in utility services costs were also noted. These results suggest that with further development of electrification the Q-MEF strategy could contribute to energy-positive behavior for projects with similar typology and climate profiles.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Towards Net Zero: Modeling Approach to the Right-Sized Facilities

As the concentration of greenhouse gases (GHGs) in the atmosphere increases, the concerns about carbon emissions are growing. Several net-zero initiatives are taking place around the globe to achieve a balance between the GHGs put into the atmosphere and those taken out. While most efforts present a sectorized approach, this paper describes the importance of integrating information across different sectors for effective modeling of carbon emissions and holistic reduction opportunity analysis. Using the Idaho National Laboratory (INL) campus as a test case, this work provides a web-based tool for INL stakeholders to use when engaging in strategic planning to achieve carbon emissions reduction. This net-zero engineering support tool (NEST) uses historical data as foundational information for applying the modeling framework. Prediction of CO 2 emissions throughout project completion integrates various approaches and schedules aimed at energy conservation, fleet decarbonization, and other GHG reduction activities. Using NEST, stakeholders can visualize carbon emissions, electricity consumption, and costs for decision making when planning the pathway for reaching carbon net zero. The INL’s initiative to transition into an EV fleet was used to demonstrate the developed framework and the advantages of using NEST. It was shown that electrifying different fossil-fueled campus vehicles before 2030 with aggressive replacement schedules require high annual capital expenditure (CAPEX), which may not be available. The tool allows decision makers to test different replacement schedules and prioritize those that yield CAPEX below a certain threshold while meeting target milestones. While the demonstration focused on vehicle electrification, the developed framework lays the foundation for further quantitative analysis of other GHG reduction activities.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2025

Global Regulations for Sustainable Battery Recycling: Challenges and Opportunities

With the rapid expansion of transportation electrification worldwide, the demand for electric vehicles (EVs) has increased dramatically, creating new and sustainable growth opportunities for the global economy. However, as the most expensive component of EVs, lithium-ion batteries pose significant sustainability challenges due to raw material consumption and supply chain constrains, as well as the complexities of end-of-life battery disposal and recycling. To address these concerns, many countries are actively establishing regulations to promote sustainable pathways for battery reuse and recycling. Despite these efforts, existing battery recycling regulations remain often inefficient and vary significantly across different countries in legal enforcement, producer responsibility, waste classification, recycling targets, design standards, public engagement, and financial incentives, particularly given the complexities of the global supply chain and resource distribution within the battery industry. Understanding these regulatory differences and establishing a unified framework are therefore crucial to ensuring sustainable and efficient battery recycling. This review provides a comprehensive analysis of the necessity of establishing robust regulations for sustainable development of battery recycling industry. The evolution and refinement of battery recycling regulations are deeply reviewed to identifying persistent gaps and challenges in key countries. Furthermore, we discuss the challenges associated with regulatory enforcement and propose strategies for developing a more cohesive legislative framework to ensure the effective utilization of retired batteries.

25 ENERGY STORAGE↗
DOE OSTI2025

Impact of Regional and Seasonal Characteristics on Battery Electric Vehicle Operational Costs in the U.S.

This study investigates the operational cost competitiveness of battery electric vehicles (BEVs) in the United States, considering regional climates, energy prices, and driving patterns. By comparing BEVs with plug-in hybrid electric vehicles (PHEVs), hybrid electric vehicles (HEVs), and the alternative use of BEVs and conventional vehicles (Convs), the analysis incorporates thermal dynamometer tests, real-world vehicle miles traveled (VMT), and state-specific energy prices. Using detailed simulations, the study evaluates energy consumption across varying temperatures and driving distances. The findings reveal that, while BEVs remain cost-effective for short trips in moderate climates, PHEVs are more economical for long-range trips and cold environments, due to the excessive cost of using external direct current fast chargers (DCFCs) and reduced BEV efficiency at low temperatures. HEVs are identified as the most cost-efficient option in regions like New England, characterized by high residential electricity prices. These insights are critical for shaping vehicle electrification strategies, particularly under diverse regional and seasonal conditions, and for advancing policies on alternative energy and fuels.

Kim, Kyung-Ho (ORCID:0009000450851732)↗
DOE OSTI2025

Staying Competitive in Clean Manufacturing: Insights on Barriers from Industry Interviews

While industrial emissions research has historically focused on energy-intensive sectors like steel, cement, and chemicals, this study addresses a critical gap by examining barriers across all the manufacturing industry in the U.S. Sectors like food processing, retail, plastics, and transportation face unique challenges distinct from heavy industry, operating on thin margins with limited bargaining power while experiencing heightened consumer and stakeholder pressure for improved environmental responsibility. Through structured interview data collection process and using quantitative ratings and qualitative analysis, this research identifies and categorizes emission reduction barriers across four key themes: financial, technical, organizational, and regulatory. Unlike energy-intensive industries that may pursue hydrogen or carbon capture technologies, discrete manufacturing industry like automotive, electrical and electronics, and machine manufacturers typically focus on energy efficiency, electrification of thermal processes, and alternate fuel switching, solutions better aligned with their lower-temperature processes and distributed facility profiles. The study’s primary contribution lies in documenting specific barrier manifestations within organizations and identifying proven mitigation strategies that companies have successfully implemented or observed among peers.

business competitiveness↗
DOE OSTI2021

Evaluating China’s Passenger Vehicle Market under the Vehicle Policies of 2021–2023

China is well known for its determination on large-scale vehicle electrification, which currently is mainly driven by fuel economy and electric vehicle policies mixed with the extensive charging infrastructure support and monetary incentives from the government. This study adopted the New Energy and Oil Consumption Credits (NEOCC) model 2020 version, a vehicle policy analysis tool developed by the Oak Ridge National Laboratory, in order to systematically quantify the potential impacts of the “Passenger Cars Corporate Average Fuel Consumption and New Energy Vehicle Credit Regulation”, which is a revised version released in June 2020 for the timeframe 2021–2023, the so-called dual credit policy (2021–2023). It was found that, under the dual credit policy (2021–2023), the sales of hybrid electric vehicles could reach 0.91 million by the end of 2023, which would increase much faster than they did in 2018–2020. The annual sales share of plug-in electric vehicles (PEVs) could reach 11.7%, and the PEV stocks could achieve 11.70 million by the end of 2023 if it keeps the expansion to the level of how it was in 2017. In addition, the BEVs with long electric range (such as 400 km) and the plug-in hybrid electric SUVs could be the most popular PEV types.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

Depot Charging Schedule Optimization for Medium- and Heavy-Duty Battery-Electric Trucks

Charge management, which lowers charging costs for fleets and prevents straining the electrical grid, is critical to the successful deployment of medium- and heavy-duty battery-electric trucks (MHD BETs). This study introduces an energy demand and cost management framework that optimizes depot charging for MHD BETs by combining an energy consumption machine learning model and a linear program optimization model. The framework considers key factors impacting real-world MHD BET operations, including vehicle and charger configurations, duty cycles, use cases, geographic and climate conditions, operation schedules, and utilities’ time-of-use (TOU) rates and demand charges. The framework was applied to a hypothetical fleet of 100 MHD BETs in California under three different utilities for 365 days, with results compared to unmanaged charging. The optimized charging solution avoided more than 90% of on-peak charging, reduced fleet charging peak load by 64–75%, and lowered fleet energy variable costs by 54–64%. This study concluded that the proposed charge management framework significantly reduces energy costs and peak loads for MHD BET fleets while making recommendations for fleet electrification infrastructure planning and the design of utility TOU rates and demand charges.

Song, Shuhan↗
DOE OSTI2022

Results of Application Demonstration of Autonomous Offshore Power System Supporting Multiple Mobile and Static Assets

Over the last decade, several technology trends have dominated the innovation cycle within the terrestrial economy. Electrification, cloud computing, decarbonization, digitization, and autonomy are representative examples of macro trends that have had a rapid and fundamental impact; an impact felt not only in user-facing technologies, such as electric vehicles and software-as-a-service, but also in the infrastructure required to deliver those technologies. However, the scale of the impact and rollout has not been felt equally between the terrestrial and ocean economies. Here, the innovation cycle in the ocean economy is significantly slower. What accounts for the difference and are there solutions to this issue?

16 TIDAL AND WAVE POWER↗
DOE OSTI2019

Mixing-limited Combustion of Alcohol Fuels in a Diesel Engine

Diesel-fueled, heavy-duty engines are critical to global economies, but unfortunately they are currently coupled to the rising price and challenging emissions of Diesel fuel. Public awareness and increasingly stringent emissions standards have made Diesel OEMs consider possible alternatives to Diesel, including electrification, fuel cells, and spark ignition. While these technologies will likely find success in certain market segments, there are still many applications that will continue to require the performance and liquid-fueled simplicity of Diesel-style engines. Three-way catalysis represents a possible low-cost and highly-effective pathway to reducing Diesel emissions, but that aftertreatment system has typically been incompatible with Diesel operation due to the prohibitively high levels of soot formation at the required stoichiometric fuel-air ratios. This paper explores a possible method of integrating three-way catalysis with Diesel-style engine operation. The proposed concept utilizes a high-temperature combustion system-enabled by a combination of thermal insulation, reduced turbocharger aftercooling, and exhaust gas retention-to combust low-cetane “sootless” fuels like ethanol, methanol, and natural gas in a traditional Diesel-style combustion mode (i.e. mixing-limited diffusive combustion, rather than HCCI-like strategies). The proposed concept has demonstrated the ability to meet EPA 2010 soot emissions limits without a particulate filter, while also maintaining a stoichiometric exhaust composition that is compatible with three-way catalysis. Further, the proposed concept can meet, and even exceed, baseline Diesel engine efficiency by combining the high compression ratio Diesel engine design with reduced heat transfer losses. Finally, use of mixing-limited, Diesel-style combustion drastically simplifies combustion phasing, and limits rate of rise. These early results motivate additional work on this concept, further optimizing components for high-temperature operation on alcohol fuels, and integrating the results into a commercial multi-cylinder engine demonstration.

Blumreiter, Julie↗
DOE OSTI2020

Understanding the Charging Flexibility of Shared Automated Electric Vehicle Fleets

The combined anticipated trends of vehicle sharing (ride-hailing), automated control, and powertrain electrification are poised to disrupt the current paradigm of predominately owner-driven gasoline vehicles with low levels of utilization. Shared, automated, electric vehicle (SAEV) fleets offer the potential for lower cost and emissions and have garnered significant interest among the research community. While promising, unmanaged operation of these fleets may lead to unintended negative consequences. One potentially unintended consequence is a high quantity of SAEVs charging during peak demand hours on the electric grid, potentially increasing the required generation capacity. This research explores the flexibility associated with charging loads demanded by SAEV fleets in response to servicing personal mobility travel demands. Travel demand is synthesized in four major United States metropolitan areas: Detroit, MI; Austin, TX; Washington, DC; and Miami, FL. In each of these four cities, SAEV simulations are performed using local projected electricity prices from the Regional Energy Deployment System (ReEDS) for a handful of supply side scenarios. A coordinated charging model is introduced that seeks to reduce fleet charging costs in response to time-varying electricity prices and increasing shares of personal trip demand served (between 1% and 25% of all metro trips served by the SAEV fleet). Simulation results are presented across various scenarios assuming fleetwide coordination to minimize charging energy costs while constrained by offering adequate mobility service to fleet customers. The results indicate that the SAEV charging load is highly flexible; energy costs were shown to reduce between 13% and 46% across a wide range of simulated scenarios. In addition, these savings were realized without detrimentally impacting the fleet’s ability to service trips.

autonomous vehicle↗
DOE OSTI2020

Dyno-in-the-Loop: An Innovative Hardware-in-the-Loop Development and Testing Platform for Emerging Mobility Technologies

Today’s transportation is quickly transforming with the nascent advent of connectivity, automation, shared-mobility, and electrification. These technologies will not only affect our safety and mobility, but also our energy consumption, and environment. As a result, it is of unprecedented importance to understand the overall system impacts due to the introduction of these emerging technologies and concepts. Existing modeling tools are not able to effectively capture the implications of these technologies, not to mention accurately and reliably evaluating their effectiveness with a reasonable scope. To address these gaps, a dynamometer-in-the-loop (DiL) development and testing approach is proposed which integrates test vehicle(s), chassis dynamometer, and high fidelity traffic simulation tools, in order to achieve a balance between the model accuracy and scalability of environmental analysis for the next generation of transportation systems. With this DiL platform, a connected eco-operation system for the plug-in hybrid electric bus (PHEB) has been developed and tested, which can optimize the vehicle dynamics (and potentially powertrain control via smart energy management) to reduce the operational energy consumption as well as tailpipe emissions of the target PHEB. The system performance has been evaluated on the DiL platform with respect to a variety of traffic congestion levels. The results have shown that the developed system can save fuel by more than 13% while reducing the electricity consumption by 2% in the test scenarios.

Wu, Guoyuan↗
DOE OSTI2021

Impact of Materials Properties on Higher-Temperature Engine Operation

Here, we examine the effects on materials temperatures and engine efficiency via simulations of engines operating at temperatures which exceed the thermal limits of today’s materials. Potential focus areas include high-speed, high-load operation (in the fuel-enrichment zone) as well as conditions of selective cooling at lower speeds and loads. We focus on a light-duty DISI and a heavy-duty CI engine using GT-Power. Temperature distributions within the head, block, piston, and valves were obtained from 3D FEA simulations coupled with 1D GT-Power representations of the engine’s gas flow and combustion regions. We use experimentally measured thermal properties of current commercial alloys for specific engine components, as well as candidate developmental alloys with improved temperature tolerance, to gauge the effects of materials properties on engine performance, particularly focusing on operating areas where materials which can withstand higher temperatures can enable intensified combustion conditions and increased specific output. The outcome of this work is guidance on materials selection targets and benefits as OEMs meet engine-performance needs in the coming decades, to include Class 8 line-haul freight vehicles with reduced emissions, as well as design of future near net zero-carbon light-duty range extenders for more rapid electrification of medium- and heavy-duty vehicles.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Quantifying System Level Impact of Connected and Automated Vehicles in an Urban Corridor

Numerous studies have demonstrated significant energy reduction for an ego vehicle by up to 20% leveraging Vehicle-to-Everything (V2X) technologies [1-4]. Some studies have also analyzed the impact of such vehicles on the energy consumption of other vehicles in a suburban or a highway corridor [5, 6], but the impact in an urban setting has not been studied yet. Southwest Research Institute (SwRI), in collaboration with Continental and Hyundai, is currently working on a Department of Energy funded project that is focused on quantifying the impact of multiple ego vehicles (smart vehicles) on the total energy consumption of the corridor under various traffic conditions, vehicle electrification level, vehicle-to-vehicle (V2V) technology penetration, and the number of smart (ego) vehicles in an urban setting. A six-kilometer-long urban corridor from Columbus, Ohio was modeled and calibrated with real-world data in PTV Vissim traffic microsimulation software. Five forward-looking powertrain models, consisting of two battery electric vehicles (BEVs), a hybrid electric vehicle (HEV), and two internal combustion engine (ICE) powered vehicles, were developed to estimate the energy consumption of vehicles on the corridor. A comprehensive full factorial simulation study was performed. The simulation results indicate that for a traffic mix based on projected new vehicles sales in 2025, a 15% corridor-level energy consumption reduction can be achieved. The paper details the development and validation of the simulation framework, design of experiments conducted, a discussion of challenges faced, and results under various test conditions.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗