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Electrification 2021 Annual Progress Report

During fiscal year 2021 (FY 2021), the U.S. Department of Energy (DOE) Vehicle Technologies Office (VTO) funded early-stage research, development, demonstration, & deployment (RDD&D) projects that address Batteries and Electrification of the U.S. transportation sector. The VTO Electrification Sub-Program is composed of Electric Drive Technologies, and Grid Integration activities. The Electric Drive Technologies group conducts R&D projects that advance electric motors and power electronics technologies. The Grid and Charging Infrastructure group conducts R&D projects that advance grid modernization and electric vehicle charging technologies. This document presents a brief overview of the Electrification Sub-Program and progress reports for its R&D projects. Each of the progress reports provide a project overview and highlights of the technical results that were accomplished in fiscal year (FY) 2021.

33 ADVANCED PROPULSION SYSTEMS↗

Machine Learning for Real-time Fusion Plasma Behavior Prediction and Manipulation (Final Report)

The goal of this project is to implement real-time analysis of 2D Beam Emission Spectroscopy (BES) data to predict and control transient and high-bandwidth events at DIII-D. In essence, we wish to bring high-bandwidth fluctuation diagnostics into the realm of real-time measurements and control. The BES ML models will necessarily be deep neural networks (DNN) with a “data flow” architecture for compatibility with high-throughput, low-latency evaluation on a field-programmable gate array (FPGA) or other emerging processor technologies. The real-time output will be fed to the plasma control system (PCS) for real-time control tasks, specifically for ELM control and avoidance and for QH-mode access and sustainment. We anticipate that the real-time analysis of fluctuation diagnostics will create new enabling technologies to predict and control transient events such as confinement mode transitions, edge-localized modes, Alfven eigenmode events, and disruptions. The proposed research is aligned with ITER research needs and DIII-D programmatic goals. For instance, the prediction and avoidance of ELM events is critical for ITER machine safety. Also, H-mode access with RMP ELM suppression in ITER is an active research area due to high separatrix density, narrow SOL width, and elevated LH transition power threshold.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Enhancing the Value of Wasted and Stranded Natural Gas Resources Through Conversion Into Aromatics Using Microwaves

Natural gas flaring results in the waste of significant amounts of valuable domestic energy resources while also producing undesirable environmental impacts. Transforming natural gas into value-added chemicals via direct nonoxidative reactions presents a compelling alternative to flaring. However, traditional thermal reactor systems face challenges due to thermodynamic limitations and poor catalyst stability. Microwave-assisted reactions offer a sustainable, on-demand approach for chemical production from natural gas, suitable for compact, flexible reactor systems at the well-site that can be powered by renewable energy. This method offers a novel, non-traditional approach in catalyst activation and product selectivity compared to a conventional thermal method, potentially leading to faster rates, higher selectivities, and higher conversion efficiencies. Despite these advantages, challenges exist, such as the low microwave-sensitivity of the state-of-the-art zeolite catalyst that is highly active for the methane dehydroaromatization reaction. This presentation will discuss recent research from the National Energy Technology Laboratory concerning microwave-assisted natural gas conversion directly into aromatics. It will address the difficulties with microwave heating of traditional thermochemical catalysts, and the application of Multiphysics modeling to understand temperature and field strength in the reactor, to enhance chemical conversion. The presentation will also cover how heating aids can mitigate heating challenges and transform microwave catalysis into a quasi-thermal kinetic problem. Additionally, catalyst activation and deactivation under microwave conditions will be examined, along with the future outlook and needs for microwave enhanced catalysis applications.

catalysis↗

Capability Building Progression of an Insider Threat Mitigation Program at an International Nuclear Power Plant (Rev. 1)

With threats to nuclear facilities continuously evolving, the development and implementation of insider threat mitigation programs (ITMPs) are increasingly important. The Office of International Nuclear Security (INS) within the U.S. Department of Energy’s National Nuclear Security Administration (DOE/NNSA’s) developed Capability Building Progression of an Insider Threat Mitigation Program at an International Nuclear Power Plant to assist newcomers and existing nuclear power plant (NPP) operators in addressing insider threats and establishing effective response measures for insider activities.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗

PID-Regulated Heating System for PIP-II Reference Line

The Proton Improvement Plan 2 (PIP-II) centers on building a new superconducting linear particle accelerator (Linac) at Fermilab. At the heart of the accelerator is the reference line. It is a critical system that defines the ideal path for the beam as it passes through magnets, RF cavities, and other beamline elements. Temperature stability is crucial for the reliable operation of RF components, such as mixers and filters. Fluctuations affect key performance parameters like conversion loss, isolation, and linearity. To mitigate any drift caused by ambient temperature changes, a heating plate assembly is utilized to maintain key components at a controlled temperature of 40 C. Utilizing an actively regulated heating system, a metal-oxide-semiconductor field-effect transistor (MOSFET) based power control circuit which provides input to a controller; forming a closed-loop system that maintains the desired setpoints with high precision.

Mosher, Alexander [U. Illinois, Chicago]↗

Mechanical Solution for Existing Conductors

The rapid growth in energy demand, driven by advancements in AI technology, renewable energy integration, and increased industrial activity, highlights the need for innovative solutions to improve the resiliency and efficiency of the power grid. This report details the fire testing of GridWrap’s Composite WiRe Wrap, to evaluate the wrap's ability to enhance conductor performance under wildfire-simulated conditions. Conductors were prepared and tested in a controlled environment at 400°C for 18 minutes, during which sag and temperature data were recorded. The results demonstrated that the unwrapped conductor sagged 3/16ths of an inch, while the WiRe Wrapped conductor sagged only 1/16th of an inch under identical conditions, indicating a significant improvement in mechanical performance. This project, conducted as part of a collaborative effort between BEA (Idaho National Laboratory’s managing contractor) and GridWrap, Inc., demonstrates the potential of grid-enhancing technologies like WiRe Wrap to reduce sag, increase grid resiliency, and support the future energy landscape. By validating the performance of such technologies in real-world scenarios, this work provides critical insights for industry adoption, benefiting both grid operators and U.S. taxpayers through improved reliability, reduced emissions, and enhanced energy delivery.

24 - POWER TRANSMISSION AND DISTRIBUTION↗

2026 Annual Molten Salt Reactor Campaign Review

This report documents the 2026 Annual Molten Salt Reactor (MSR) Campaign Review held in Albuquerque, New Mexico, from April 21–24, 2026. The review was organized by Dr. Patricia Paviet, National Technical Director of the Advanced Reactor Technology (ART) MSR program for the U.S. Department of Energy Office of Nuclear Energy (DOE-NE), and included participation from principal investigators, federal managers, developers, regulators, and members of the broader MSR community. The 2026 review expanded beyond the ART-MSR campaign to include related DOE-NE programs supporting molten salt reactor advancement, including the Nuclear Energy Advanced Modeling and Simulation (NEAMS) program, the Advanced Materials and Manufacturing Technologies (AMMT) program, Advanced Reactor Safeguards and Security (ARSS), Material Protection, Accounting and Control Technologies (MPACT), and relevant advanced fuels activities. Three days were dedicated to technical presentations and panel discussions covering thermal properties, off-gas management, modeling and simulation, safety and licensing, safeguards and security, materials and corrosion, and irradiation activities. A fourth day was dedicated to technical tours of Sandia National Laboratories and Kairos Power facilities. Attendance was strong and comparable to the prior annual review, with approximately 75 in-person participants per day, 75–80 virtual attendees per day, and approximately 30 participants in the tour day. The review fostered significant technical exchange across national laboratories, universities, industry, regulators, and international participants. This report summarizes the review structure, technical themes, participation, tours, feedback, and conclusions relevant to future planning for the MSR campaign.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Modeling the effects of active wake mixing on wake behavior through large-scale coherent structures

The use of active wake mixing (AWM) to mitigate downstream turbine wakes has created new opportunities for reducing power losses in wind farms. However, many current analytical or semi-empirical wake models do not capture the flow instabilities that are excited through the blade pitch actuation. In this work, we develop a framework, which accounts for the impacts of the large-scale coherent structures and turbulence on the mean flow, for modeling AWM. The framework uses a triple-decomposition approach for the unsteady flow field and models the mean flow and fine-scale turbulence with a parabolized Reynolds-averaged Navier–Stokes (RANS) system. The wave components are modeled using a simplified spatial linear stability formulation that captures the growth and evolution of the coherent structures. Comparisons with high-fidelity large eddy simulations (LESs) of the turbine wakes showed that this framework was able to capture the additional wake mixing and faster wake recovery in the far-wake regions for both the pulse and helix AWM strategies with minimal computational expense. In the near-wake region, some differences are observed in both the RANS velocity profiles and initial growth of the large-scale structures, which may be due to some simplifying assumptions used in the model.

17 WIND ENERGY↗

Snowmass2021 Cosmic Frontier CF6 White Paper: Multi-Experiment Probes for Dark Energy - Transients

This invited Snowmass 2021 White Paper highlights the power of joint-analysis of astronomical transients in advancing HEP Science and presents research activities that can realize the opportunities that come with current and upcoming projects. Transients of interest include gravitational wave events, neutrino events, strongly-lensed quasars and supernovae, and Type~Ia supernovae specifically. These transients can serve as probes of cosmological distances in the Universe and as cosmic laboratories of extreme strong-gravity, high-energy physics. Joint analysis refers to work that requires significant coordination from multiple experiments or facilities so encompasses Multi-Messenger Astronomy and optical transient discovery and distributed follow-up programs.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Analysis of Tasks in Autonomous Systems Using the EMRALD Dynamic Risk Assessment Tool

An autonomous system refers to the system that has the power and ability for self-governance in the performance of system functions. Autonomous systems have been actively pursued in a variety of domains such as automotive, aviation, maritime, medicine, and nuclear fields. As an unmanned concept employing the highest automation level, the autonomous system basically performs most of the work in normal operations or emergency situations. However, despite advances in technology, many researchers have noted these systems still require human actions. The nature of human actions on autonomous systems is different than the human actions that are considered in existing systems. Nevertheless, only a few studies have been conducted on 1) characterizing the different types of errors and risks associated with human actions interacting with autonomous systems and 2) how to evaluate human actions in the autonomous operations. As a starting point, this study aims to investigate differences of tasks in autonomous operation compared to those in existing nuclear power plant operation using the Event Modeling Risk Assessment Using Linked Diagram (EMRALD) software. In this paper, insights aspect of human error and time are derived out and discussed based on the output of the EMRALD models.

99 GENERAL AND MISCELLANEOUS↗

Active and Transfer Learning of High-Dimensional Neural Network Potentials for Transition Metals

Classical molecular dynamics (MD) simulations represent a very popular and powerful tool for materials modeling and design. The predictive power of MD hinges on the ability of the interatomic potential to capture the underlying physics and chemistry. There have been decades of seminal work on developing interatomic potentials, albeit with a focus predominantly on capturing the properties of bulk materials. Such physics-based models, while extensively deployed for predicting the dynamics and properties of nanoscale systems over the past two decades, tend to perform poorly in predicting nanoscale potential energy surfaces (PESs) when compared to high-fidelity first-principles calculations. These limitations stem from the lack of flexibility in such models, which rely on a predefined functional form. Machine learning (ML) models and approaches have emerged as a viable alternative to capture the diverse size-dependent cluster geometries, nanoscale dynamics, and the complex nanoscale PESs, without sacrificing the bulk properties. Here, in this study, we introduce an ML workflow that combines transfer and active learning strategies to develop high-dimensional neural networks (NNs) for capturing the cluster and bulk properties for several different transition metals with applications in catalysis, microelectronics, and energy storage, to name a few. Our NN first learns the bulk PES from the high-quality physics-based models in literature and subsequently augments this learning via retraining with a higher-fidelity first-principles training data set to concurrently capture both the nanoscale and bulk PES. Our workflow departs from status-quo in its ability to learn from a sparsely sampled data set that nonetheless covers a diverse range of cluster configurations from near-equilibrium to highly nonequilibrium as well as learning strategies that iteratively improve the fingerprinting depending on model fidelity. All the developed models are rigorously tested against an extensive first-principles data set of energies and forces of cluster configurations as well as several properties of bulk configurations for 10 different transition metals. Our approach is material agnostic and provides a methodology to transfer and build upon the learnings from decades of seminal work in molecular simulations on to a new generation of ML-trained potentials to accelerate materials discovery and design.

36 MATERIALS SCIENCE↗

COMSOL Results for the Nominal Steady-State Operation of the Proposed 95-MW LEU Silicide Core for HFIR Conversion

Engineering design studies are being performed to determine the feasibility of converting the High Flux Isotope Reactor (HFIR) from highly enriched uranium (HEU) to low-enriched uranium (LEU) fuel at Oak Ridge National Laboratory. This activity is sponsored by the Office of Reactor Conversion and Uranium Supply (ORCUS) under the auspices of the US Department of Energy National Nuclear Security Administration’s Office of Material Management and Minimization. HFIR is a very high flux, pressurized, light water–cooled and moderated, flux trap–type research reactor with a core made of involute shaped U 3 O 8 /Al cermet fuel plates and coolant channels. HFIR currently operates at a thermal power of 85 MW and supports key national and international missions in neutron scattering, isotope production, materials/fuels irradiation, neutron activation analysis, gamma irradiation, and neutrino research. Advanced multiphysics computational fluid dynamics models have been developed in the COMSOL Multiphysics software to simulate the steady-state operating conditions for the proposed low-and high-density LEU U 3 Si 2 -Al (uranium silicide dispersion) fuel designs. The COMSOL models for HFIR inner and outer fuel element models incorporate various essential inputs and physics such as spatially dependent nuclear heat deposition, multilayer heat conduction, conjugate heat transfer, turbulent flows (using Reynolds-averaged Navier Stokes turbulence models), structural mechanics (thermal–structural interactions and fuel swelling), and oxide layer build-up. This report presents the best-estimate thermal hydraulics results for the low- and high-density optimized silicide LEU core designs at 95 MW steady-state nominal operation.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Microscale thermophoresis as a powerful tool for screening glycosyltransferases involved in cell wall biosynthesis

Background: Identification and characterization of key enzymes associated with cell wall biosynthesis and modification is fundamental to gain insights into cell wall dynamics. However, it is a challenge that activity assays of glycosyltransferases are very low throughput and acceptor substrates are generally not available. Results: We optimized and validated microscale thermophoresis (MST) to achieve high throughput screening for glycosyltransferase substrates. MST is a powerful method for the quantitative analysis of protein-ligand interactions with low sample consumption. The technique is based on the motion of molecules along local temperature gradients, measured by fluorescence changes. We expressed glycosyltransferases as YFP-fusion proteins in tobacco and optimized the MST method to allow the determination of substrate binding affinity without purification of the target protein from the cell lysate. The application of this MST method to the β-1,4-galactosyltransferase AtGALS1 validated the capability to screen both nucleotide-sugar donor substrates and acceptor substrates. We also expanded the application to members of glycosyltransferase family GT61 in sorghum for substrate screening and function prediction. Conclusions: This method is rapid and sensitive to allow determination of both donor and acceptor substrates of glycosyltransferases. MST enables high throughput screening of glycosyltransferases for likely substrates, which will narrow down their in vivo function and help to select candidates for further studies. Additionally, this method gives insight into biochemical mechanism of glycosyltransferase function.

59 BASIC BIOLOGICAL SCIENCES↗

Modular Coaxial Power Converter for High-Density Integration into Medium-Voltage Cables

This work proposes to combine the functionality benefits of power electronics with the power density benefits of medium-voltage cables to create a streamlined, high-density power electronics solution that seamlessly integrates with medium-voltage cables. Located at the ends of a medium- or high-voltage line, the proposed converter uses a cascade of coaxial power conversion cells to gradually step down the voltage, and excels in high step-down applications. By mimicking the coaxial geometry of medium-voltage cables, the converter preserves the axisymmetric electric field of the cable which, when combined with a solid insulating dielectric, provides a voltage scaling advantage over conventional planar and PCB-based converter solutions. Similar to medium voltage cables, the converter is fully passively cooled. A passive cooling strategy allows for combined installation with existing medium voltage cable systems without the added cost, maintenance needs, infrastructure, and reliability concerns associated with active cooling systems. The scalability of the modular structure in combination with the integration benefits provide a flexible power electronics system that can adapt to the evolving demands of the grid.

coaxial power conversion cells↗

5G Securely Energized and Resilient: (5G-SER) (Final Report)

NREL's work on 5G integration with physical power systems (versus simulated systems demonstrated in task 3) under 5G-Securely Energized and Resilient (5G-SER) achieved a major milestone in with the completion of Task 4 activities. After many months (6+) of planning and development along with scaling challenges along the way, a full 5G end-to-end network with physical hardware components (physical inverter, physical power panel, physical battery, etc.) was deployed in a containerized environment. In parallel, a distributed controls architecture for a microgrid powering 5G resources was also successfully modified from its previous instantiation for a simulated environment to work with these physical components. These accomplishments set the stage to use newly setup 5G technology with physical microgrid components to test the feasibility of 5G wireless with physical systems to enable resilient communications between controls and distributed solar and storage resources while exploring ways to configure 5G components to survive power disturbances. The results detailed in the report below show that even utilizing physical components, 5G wireless systems were able to provide resilient results that were similar to the results from the simulated environment Task 3).

24 POWER TRANSMISSION AND DISTRIBUTION↗

A Hot‐Swappable, Fault‐Tolerant, Modular Power Converter System for Solar Photovoltaic Plants

The performance metrics of the state-of-the-art commercial solar inverters, such as system cost, operation and maintenance (O&M) cost, service life, reliability, maintainability, and power density are much lower than the target metrics needed to achieve SunShot’s 2030 levelized cost of energy (LCOE) goals. To overcome the shortcomings of the existing solar inverters, this project proposed a novel Hot-Swappable, Fault-Tolerant, Modular Power Converter (HSFT-MPC) concept for solar photovoltaic (PV) plants and proved the concept through the design, fabrication, and laboratory test validation of a single-phase HSFT-MPC prototype. The HSFT-MPC has the following distinct advantages over the state-of-the-art: 1) elimination of harmonic/ electromagnetic interference (EMI) filter in the inverter stage due to the novel topology, 2) lower system cost and higher power density due to the modular design, elimination of harmonic/EMI filter, and lower cooling requirement, 3) higher efficiency due to lower switching frequencies, 4) higher reliability and longer (50 years) service life due to simpler cooling and fault tolerance capability, 5) easier installation, lower O&M cost, and improved maintainability due to the modular design and hot-swappable power electronic building blocks (PEBBs), and 6) improved manufacturability due to the modular design. This project developed a single-phase HSFT-MPC prototype with 25kW nominal output power, 2.4kV, 60Hz nominal AC output, lower than 5% AC output voltage total harmonic distortion, over 5 kW/L inverter power density, and 99.4% inverter peak efficiency, being tolerant to failure of single and multiple PEBBs, and capable of hot swapping of the failed PEBB(s). The HSFT-MPC enables uninterruptable operation of the solar PV plant when failure of single or multiple PEBBs or PV modules occurs. Compared with the existing solar inverters in the market, the HSFT-MPC is expected to reduce the inverter failure-caused downtime and energy losses of solar PV plants by more than 60% and 50%, respectively. Project findings have been presented at major conferences in the field and published in peer-reviewed papers, which added new knowledge to the field of power electronics for solar PV systems. A minicourse on Solar PV Systems was developed for outreach activities. The minicourse will help attract young individuals to the renewable energy profession which has a significant talent shortage. The HSFT-MPC is expected to overcome all of the shortcomings of the state-of-the-art solar inverters in terms of cost, efficiency, service life, reliability, maintainability, and manufacturability targets needed to achieve SunShot’s 2030 LCOE goals. Therefore, the proposed HSFT-MPC concept has the great potential to disrupt the current solar inverter market. This project created a pathway towards industry adoption of the HSFT-MPC to help achieve 50-year service life solar PV systems. Since the solar PV plants using the HSFT-MPC will feature with higher reliability, longer service life, and easier maintenance, they are particularly useful for the rural areas with underserved populations that demand reliable and affordable clean electricity. The outcomes of the project have the strong potential to address national needs in the field of renewable energy to reduce CO 2 emissions from the electricity sector, reduce imports of energy from foreign sources, and improve energy security, efficiency, and sustainability. Since electricity is used in almost all of society’s sectors, the outcomes of the project will benefit various sectors of society and economy.

14 SOLAR ENERGY↗

An Integrated Paradigm for the Management of Delivery Risk in Electricity Markets: From Batteries to Insurance and Beyond

If power systems transition to integrate higher amounts of variable renewable energy sources, storage technologies, and distributed energy resources (DERs), new risk management frameworks are necessary to ensure cost-effective and reliable power system operations. Projects funded by the Advanced Research Projects Agency-Energy (ARPA-E) Performance-based Energy Resource Feedback, Optimization, and Risk Management (PERFORM) program aim to contribute new risk management frameworks by developing methods to quantify and manage risk at grid asset and system levels. The National Renewable Energy Laboratory (NREL) led a PERFORM project in collaboration with the Johns Hopkins University, the Electric Power Research Institute (EPRI), kWh Analytics, Packetized Energy, and Imperial Consultants (ICON). The project addressed two challenges related to risk management in electricity markets: managing net load imbalances and flexibility from DERs. This final technical report presents a list of project accomplishments, activities, and outputs.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Evaluating the Impact of Power Outages on Occupancy Patterns During the 2021 Texas Power Crisis

Large-scale power outages, such as those caused by extreme weather events, have a big impact on human behavior. A short power outage is merely a nuisance for most, and may not change people's locations. An outage that lasts for a few hours can result in spoiled food and medical supplies, and people will have to restock spoiled items. Long outages result in temperatures outside tolerable levels in homes, and may prompt people to acquire supplies, such as generators and gas, or change location. The long outages during Winter Storm Uri in Texas resulted in millions of dollars in property damage due to freezing pipes. This level of damage is expected to result in a sharp increase in supply runs and contractor activity. In this paper, we present a tool to explore differences in visiting patterns before, during, and after power outages. It allows to compare different points of interest like medical facilities, grocery stores, hardware stores, and other types of businesses.

big data↗