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DOE OSTI2020

A Data-driven Approach for Predicting Nepheline Crystallization in High-Level Waste Glasses

High-level waste (HLW) glasses with high aluminum content are prone to nepheline crystallization during the slow canister cooling that is experienced during large-scale production. Due to its detrimental effects on glass durability, nepheline precipitation must be avoided; however, developing robust, predictive models for nepheline crystallization behavior in HLW glasses is difficult due to their compositional complexity. Using overly conservative constraints to predict nepheline formation can limit the waste loading to lower than the achievable capacity. In this study, a robust data-driven model using five compositional features has been developed to predict nepheline formation. The analysis of the model and the data show that there is an overlap, instead of a distinct compositional boundary, between glasses that form and do not form nepheline. As a result, the model’s predictive accuracy is not the same throughout the feature space and instead is dependent on the location of the glass composition in the dimensionally reduced feature space.

Sargin, Irmak↗

DOE OSTI2026

Public Reference Data for Megawatt-Scale Hydrogen Electrolysis - NLR Historical Solar PV

The U.S. Department of Energy and National Laboratory of the Rockies (NLR) demonstrate hydrogen electrolysis from variable sources, hydrogen compression and storage, and hydrogen fuel cell power production using megawatt-scale equipment at NLR’s Flatirons Campus as part of the Advanced Research on Integrated Energy Systems (ARIES) research platform. This dataset represents part of that effort and is intended for academic, national laboratory, industrial, and other stakeholders to plan, design, and validate models of megawatt-scale hydrogen technologies and diverse energy infrastructure nationwide. These data provide a baseline for how existing hydrogen electrolysis technologies perform when coupled with various energy technologies. Future datasets will demonstrate how existing hydrogen fuel cell technologies can provide controllable, dispatchable, and variable power output for artificial intelligence data centers and other variable loads. This dataset entry describes the behavior of a 1.25-MW proton exchange membrane MC250 electrolyzer system, manufactured by Nel Hydrogen , [1] when fed historical data generated by the 430-kW, fixed-axis solar photovoltaic (PV) array located at NLR’s Flatirons Campus. (While the electrolyzer balance of plant supports up to 2.5 MW of electrolysis, NLR only has a single 1.25-MW electrolysis stack.) Solar PV power output data for the 2020 calendar year were categorized on a daily basis by total energy generation and standard deviation. Each day was then ranked by these metrics, and the 25th, 50th, and 100th percentiles were selected. The 75th percentile day did not exhibit sufficient variability to make for a valuable experiment. A similar process was used for the related historical wind dataset . [2] The historical days in 2020 that represented these percentiles are Dec. 19, March 29, and May 4, respectively. The entire solar day’s power profile was then fed through the MC250 electrolyzer. Due to its length, the 100th percentile day experiment was split into two parts, and the final 3 hours of the solar day were not captured. These final 3 hours contained no spikes or dips of interest and simply represented a slow decay of input solar power. Also, a single timestamp (13:13:47 on Jan. 14, 2026) was lost in the hydrogen system supervisory control and data acquisition. Finally, during the 25th percentile experiment (solar day Dec. 19, 2020) data recording was lost from 11:00:13 to 11:14:45. The roughly 15 minutes of the solar profile were rerun at the end of the experiment and spliced into this time slot during post-processing. The electrolysis system controls hydrogen production by varying direct current applied to the stack, from a maximum of 3,000 A to a minimum safe operation of 300 A, or 10%. Because the current–voltage characteristic changes as the stack ages and efficiency degrades, the actual minimum safe operating power changes over time. The historical solar profiles were translated from power (kilowatts) to current (amperes) using a curve fit with calibration data and sent to the electrolyzer power supply at 1-Hz frequency. For more details on the statistical analysis process, see the slide deck “Public Reference Data for Megawatt-Scale Hydrogen Electrolysis: NLR Historical Solar PV Analysis and Profile Generation” accessible with this data entry. These datasets report relevant hydrogen balance-of-plant and system data, all captured at 1 Hz, including hydrogen mass production measured with an Emerson Coriolis flow meter. Each .zip file represents a single solar PV electrolysis experiment and is formatted as: {technology}_{percentile}_{scaling factor} For instance, “solarPV-430kW_25_2x.zip” reports the experiment using the 25th percentile solar data from the historical 2020 solar PV dataset, scaled to 200%. Scaling factors were applied to the generated solar PV power output files to more closely match the 1.25-MW capacity of the electrolyzer. Each .zip folder contains the following files: A .csv file containing raw data. An .xlsx file explaining all the fields in the raw data. A .png plot showing the time series of hydrogen production, electrolysis power consumption, and solar power input. A PDF file detailing the historical solar data statistical analysis used to generate the solar profile. An experiment labeled “characterization_200.zip” demonstrates the MC250 electrolyzer steady-state response with 30-minute load steps for a total duration of 5 hours. Finally, a .csv file is provided with all experiments combined into one dataset labeled "combined_solarPV_experiments.csv". [1] nelhydrogen.com/product/mc-series-electrolyser . [2] data.nlr.gov/submissions/316 .

08 HYDROGEN↗

DOE OSTI2025

Policy and Cost Allocation Considerations for Large Electric Load Interconnections: Emerging Policy Trends in Rate Structures, Interconnection, and Cost Impacts on Other System Users

Load growth in the United States is rapidly increasing: load from data centers alone has tripled over the past decade, and this growth is forecasted to continue accelerating. These and other large electric loads (LELs) promise economic benefits at the state and local level, but their deployment has also led to increasing concerns about grid impacts and potential cost shifts onto other ratepayers. Legislators, regulators, and other stakeholders are increasingly proposing and enacting policies in effort to balance these and other considerations. This white paper reviews state-level legislation, selected utility rate cases, and relevant federal orders in an effort to describe and categorize relevant trends in policies related to LEL cost allocation, interconnection, and deployment. Policy categories identified through this review include tax incentives, rate actions, and requirements related to interconnection, permitting, and reporting. By offering a taxonomy of policies, this white paper aims to offer a resource to policymakers and other stakeholders navigating this transformative moment for the grid.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2021

Energy flexibility of residential buildings: A systematic review of characterization and quantification methods and applications

With building electric demand becoming increasingly dynamic, and a growing percentage of intermittent renewable power generation from solar photovoltaics and wind turbines, the power grid is facing increasing challenge to manage the real time balance between the supply and demand. With advancements in smart sensing and metering, smart appliances, electric vehicles, and energy storage technologies, demand side management of residential buildings can help the grid to improve stability by optimizing flexible loads. This paper reviews recent studies on residential building demand side management, with a focus on characterization and quantification of energy flexibility covering various types of flexible loads, metrics, methods, and applications. The reviewed studies showed four levels of applications: building level (45%), district or community level (29%), system level (19%), and building sector level (7%). Shifting loads is the dominant flexibility type in 60% of applications, followed by shedding (19%), generation (16%), and modulating (6%). Depending on the technology and application scope, flexible operations have a wide range of performance, with peak power reductions of 1%~65%, energy savings up to 60%, operational cost reduction of 1%~48%, and greenhouse gas emission reductions of up to29%. More than half (51%) of the studies employed control strategies to achieve flexibility; among those 72% used optimal controls, while 28% used rule-based controls. About 58% of the studies used mathematical formulation to quantify energy flexibility. Most studies were based on simulation, while less than 15% of the studies had measurements from experiments or field tests. The review reveals research opportunities to address significant gaps in the existing literature: (1) establishing a common definition and performance metrics for energy flexibility of buildings that are technology and application agnostic, (2) developing an ontology to standardize representation of flexibility resources for interoperability, (3) integrating occupant impacts into the quantification and optimization of energy flexibility, and (4) developing requirements and credits of energy flexibility in building energy codes and standards. Findings from the review can inform future research and development of energy flexible buildings which are essential to a reliable and resilient power grid.

Li, H↗

DOE OSTI2026

Tokamak level performance in the optimized stellarator Wendelstein 7-X with stable peaked density profiles

Progress towards achieving net gain from nuclear fusion is typically characterized by the triple product 𝑛⁢𝑇⁢𝜏. Although stellarators have several benefits for a reactor, such as the inherent steady-state capability and the lack of disruptions, the maximum achieved triple product has historically lagged behind that of tokamaks. In the large optimized stellarator Wendelstein 7-X, a triple product of (1.10 ± 0.15) × 10 20 m −3 ⁢ keVs has recently been achieved and held stable for 1.9 s. This marks an important step in stellarator core plasma performance and puts it in line with 𝐻-mode performance in similar sized tokamaks. The progress in Wendelstein 7-X performance is due to the suppression of ion-temperature-gradient turbulence by strong density gradients. In the record case, these are maintained by a fine balance of the core particle transport and central fueling using neutral beam injection. The duration of the scenario was limited in time only by technical restrictions of the neutral beam injectors and control of the divertor heat loads. This paper presents the result in the context of the leading magnetic confinement devices along with details of the scenario.

Bannmann, Sebastian [Max Planck Institute for Plas↗

DOE OSTI2025

Defining a Platform Approach and Market Participation: Data Driven Business Models for Solid State Transformer-Based Synthetic Inertia and Voltage Stability Controls (CRADA Final Report, Project 1, Mod 1)

The primary objective of this project is to determine the incremental value created with the medium voltage solid-state transformer (MV SST) technology to different stakeholders in view of the updated DER grid regulations. This includes studying the benefits of the MV SST technology in a range of use cases for EV and DER penetration including (1) “corridor charging” for EVs and (2) solar plus storage (FERC 2222). The potential customers of this technology include utilities for EV charging, DER installers who must meet utility interconnection requirements, balancing authorities, and DER aggregators. The traditional transformers on the grid could be a limiting factor for the EV-grid integration as the distribution transformers were not designed to handle the dynamic and fluctuating EV charging loads. Thus, the issues such as voltage fluctuations, increased losses and reduced efficiency [1] can negatively impact the grid operation. To address these challenges, transformers with flexibility and adaptability become imperative to meet the evolving energy demands. In this regard, the concept of Medium Voltage Solid-State Transformers.

14 SOLAR ENERGY↗

NASA NTRS1972

Application of polyimide actuator rod seals

Development of polyimide two-stage hydraulic actuator rod seals for application in high-performance aircraft was accomplished. The significant portion of the effort was concentrated on optimization of the chevron and K-section second-stage seal geometries to satisfy the requirements for operation at 450 K (350 F) with dynamic pressure loads varying between 200 psig steady-state and 1500 psig impulse cycling. Particular significance was placed on reducing seal gland dimension by efficiently utilizing the fatigue allowables of polyimide materials. Other objectives included investigation of pressure balancing techniques for first-stage polyimide rod seals for 4000 psig 450 K(350 F) environment and fabrication of a modular retainer for the two-stage combination. Seals were fabricated in 0.0254 m (1.0in.) and 0.0635 m (2.5in.) sizes and tested for structural integrity, frictional resistance, and endurance life. Test results showed that carefully designed second stages using polyimides could be made to satisfy the dynamic return pressure requirements of applications in high-performance aircraft. High wear under full system pressure indicated that further research is necessary to obtain an acceptable first-stage design. The modular retainer was successfully tested and showed potential for new actuator applications.

Watermann, A. W.↗

DOE OSTI2025

Dual-Fuel Ammonia Equivalence Ratio Sweep Data

Ammonia (NH3) has garnered significant interest as an alternative fuel for meeting international emissions reduction mandates in sectors with high weight and distance requirements, such as shipping. Technical barriers and unanswered questions remain on the combustion strategies that can maximize ammonia utilization and minimize emissions. Prior research studies at the US Department of Energy’s Oak Ridge National Laboratory have shown strong performance with NH3 under dual-fuel mode using conventional diesel combustion (CDC) manifold air pressure settings. Diesel airflow was initially used to simplify retrofitting (no turbocharger modification), which resulted in air-fuel equivalence ratios (λ) greater than 1.5. To characterize potential improvements in dual-fuel NH3 combustion performance at richer in-cylinder conditions, a global λ sweep compared the use of early (E-pilot) and late (L-pilot) single diesel injections. The experiments were conducted at 1200 RPM and 12.8 ± 0.2 bar (75 % load), and λ was varied by decreasing the commanded air flow to the engine at greater than 90 % ammonia energy substitution level. A diesel injection timing sweep was conducted for both the injection strategies at fixed λ, and the timing with the lowest engine-out N2O emissions was identified. The results indicated an optimal balance between CO2,eq and thermal efficiency benefits both E-pilot and L-pilot injection strategy cases compared with CDC at a λ of 1.4. The indicated nitrogen-based emissions exhibited a strong correlation to the ratio of CA5–50 and ignition delay for L-pilot, but no apparent trend emerged for the E-pilot injection strategy at the tested boundary conditions. This dataset includes the raw experimental data and documentation of the experiment conditions and methods.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2020

Energy considerations regarding pulsed arc production of nanomaterials

Atmospheric arc discharge volumes have been estimated from the light distribution emitted during evaporation of graphite and molybdenum disulphide (MoS 2 ) anodes. These data have been correlated to the peak power in the case of pulsed arc discharge held at different frequencies (1, 2 and 5 Hz). The measured power density values and the corresponding specific energies per particle have been compared to DC values, and showed that pulsed arc discharges deliver electrical power more efficiently than DC arc discharges do with yet lower thermal loads. In particular, the power density of ≈1 kW/cm 3 characteristic of pulsed arcs (10-20 kW/cm 3 in DC) suffices to provide 15 eV/particle to the arc plasma (≈10 eV/particle or less in DC). Such an energy balance resulted in high ionization rates of the ablated material and production yields of carbon nanotubes around 10 11 cm -2 kWh -1 . Lastly, in situ probe experiments showed that pulsed arcs enhance the transport to substrate of the generated nanoparticles, such as graphene and MoS 2 monolayers. Pulsed anodic arcs open the possibility to generate further nanomaterials thanks to a more rational power investment and a better control of the discharge region.

42 ENGINEERING↗

DOE OSTI2025

Coupled momentum balance and phase-field solver with fenicsx module

Code solves momentum balance and phase-field equations simultaneously. The differential equations are solved on a discretized domain with appropriate boundary and initial conditions using finite element method. Primary purpose of the code is to simulate brittle fracture under dynamic loading. Constitutive equations are that of linear elasticity with degradation of stress due to fracture. Small strain formulation is used.

Zecevic, Milovan↗

NASA NTRS1983

Weight trends for a fully reusable advanced single-stage shuttle

The rate at which subsystem weights grow with vehicle gross weight is assessed and is shown to be critical to the efficiency of large Earth to orbit transports. The overall trend, however, is a reduction in the inerts as a percentage of gross weight as the vehicle size is increased. For this reason, the larger the vehicle, the greater the payload weight delivered per pound of vehicle manufactured. Other critical issues addressed include the effects of wing loading and wing size on wing weight, the effect of entry planform loading on thermal protection system weight, the impact of power demand on cooling system and prime power weight, and tank fineness ratio on insulation weight. The effects of body shape and various internal packaging arrangements on weight and balance are also discussed. The greatest impact on overall vehicle weight is body shape and internal packaging, and could account for weight savings of up to 30 percent in body structure. Other subsystems are important, but the savings are much smaller in relation to overall vehicle weight--individually less than one percent.

Macconochie, I. O.↗

NASA NTRS1983

Weight trends for a fully reusable advanced single-stage Shuttle

The rate at which subsystem weights grow with vehicle gross weight is assessed and is shown to be critical to the efficiency of large earth-to-orbit transports. Some subsystems grow as the square of vehicle size, others grow as the cube of vehicle size, and still others remain nearly constant irrespective of vehicle size. The overall trend, however, is a reduction in the inerts as a percentage of gross as the vehicle size is increased. For this reason, the larger the vehicle, the greater the payload weight delivered per pound of vehicle manufactured. Other critical issues addressed include the effects of wing loading and wing size on wing weight, the effect of entry planform loading on thermal protection system weight, the impact of power demand on cooling system and prime power weight, and tank fineness ratio on insulation weight. The effects of body shape and various internal packaging arrangements on weight and balance are also discussed. Of greatest impact on overall vehicle weight is body shape and internal packaging and could account for weight savings of up to 30 percent in body structure. Other subsystems are important but the savings are much smaller in relation to overall vehicle weight - individually less than one percent.

Macconochie, I. O.↗

DOE OSTI2020

Joint Planning of EV Fast Charging Stations and Power Distribution Systems With Balanced Traffic Flow Assignment

To tackle the challenges introduced by the fast-growing charging demand of electric vehicles (EVs), the power distribution systems (PDSs) and fast charging stations (FCSs) of EVs should be planned and operated in a more coordinated fashion. However, existing planning approaches generally aim to minimize investment costs in PDSs while ignoring the risk of worsening traffic conditions. To overcome this research gap, this article integrates the interests of traffic networks into PDS and FCS joint planning model to mitigate negative impacts on traffic conditions caused by installing FCSs. First, a novel microscopic method that is different from traditional assignment methods is proposed to simulate the influences of FCSs on traffic flows and EV charging loads. Then, a multiobjective joint planning model is developed to minimize both the planning costs and unbalanced traffic flows. A new bilayer Benders decomposition algorithm is designed to solve the proposed joint planning model. Numerical results on two practical systems in China validate the feasibility of our microscopic method by comparing the simulated results with real data. Compared with existing approaches, it is also demonstrated that the proposed joint planning approach helps to balance traffic flow assignments and relieve traffic congestion.

bilayer expanded Benders decomposition↗

DOE OSTI2024

Super Resolving Unrolled Neural Networks for Remote Sensing

In remote sensing systems, the capabilities of the system are constrained by the complex interactions between size, weight, and power (SWAP) of potential designs. In electro-optical (EO) systems, examples of these critical parameters include the system’s sensitivity and resolution. Those parameters can be increased by ever larger optical apertures and focal planes but at the cost of more SWAP. Multi-image super resolution (MISR) techniques allow resolution to be enhanced via computation rather than more sophisticated optical hardware. These algorithms combine multiple images together into a single, higher resolution image, trading temporal resolution and computation for spatial resolution. Fielded MISR techniques, such as Drizzle, can require several hundred images to create a single super resolved image, implying reduced temporal resolution, increased data acquisition load, and limiting mission applications. Iterative techniques, such as model-based image reconstruction and compressive sensing, have been shown to create super resolved images using fewer images than Drizzle. They do this by posing an optimization problem that balances accuracy between a highly accurate physical model and an image model. In the case of super resolution, the physical model is defined by the relation between low resolution input images and the desired high resolution output image. The image model encodes some assumptions about the super resolved image. These assumptions are meant to suppress reconstruction artifacts that arise due to deterministic physical model error, stochastic measurement noise, and potential undersampling. In practice, the performance of iterative methods are limited by imaging models compatible with optimization. Deep learning-based methods can effectively learn image models of arbitrary complexity, but lack the theoretical explainability and robustness of iterative techniques. Consensus equilibrium (CE) generalizes the iterative techniques beyond optimization, enabling blackbox algorithms such as traditional and neural image denoisers to be used as the image model. CE-based approaches retain much of the explainability and robustness of iterative techniques while allowing the expressiveness of machine learning image models to be used. Additionally, by unrolling iterations of CE with an embedded image denoiser, the image denoiser can be further trained and specialized to the specific application with potentially higher quality reconstructions. Under this project, we demonstrated the feasibility of training an unrolled neural network based upon CE. While we didn’t train one, we showed that the CE process is differentiable and its gradient can be tractably computed. We also explored the usage of a variants of CE akin to generative neural works. Most importantly, we applied the CE framework to a number of problems including non-blind deconvolution, upsampling, single-image super resolution, MISR, event-based sensing, and saturated deconvolution. Our MISR prototype creates high quality reconstructions with an order of magnitude fewer images than previous approaches and, critically, produces these reconstructions fast enough for practical usage.

47 OTHER INSTRUMENTATION↗

NASA NTRS1971

Dynamic testing of a single-degree-of-freedom strapdown gyroscope

Test methods and results are presented for the equivalent average input rate of a single-degree-of-freedom gyroscope operated both open loop and with a ternary-logic pulse-torque-to-balance loop during multiaxis angular oscillation. For the open-loop tests, good agreement was obtained with theoretical results. Two-axis testing was performed for oscillations about the Input-Output axes, the Input-Spin axes, and the Spin-Output axes. These tests run in the torque-to-balance mode revealed significant departures from open-loop results in the induced drift rate. An analysis is developed explaining much of the closed-loop data presented. Test data for the gryoscope in a ternary torque-to-balance loop with constant input rates is presented. The tests demonstrate that the instrument rate linearity does not change with interrogation frequency from 3,600 to 14,400 Hz if the torque coil is tuned to offer a resistive load to the current switch. Analysis cited shows that gyroscope lag compensation eliminates multiple pulsing and other equivalent forms of degraded resolution in a wide variety of quantizing loops. This result is test verified for the ternary delta-modulator loop.

Lory, C. B.↗

NASA NTRS1981

High-power baseline and motoring test results for the GPU-3 Stirling engine

Test results are given for the full power range of the engine with both helium and hydrogen working fluids. Comparisons are made to previous testing using an alternator and resistance load bank to absorb the engine output. Indicated power results are presented as determined by several methods. Motoring tests were run to aid in determining engine mechanical losses. Comparisons are made between the results of motoring and energy-balance methods for finding mechanical losses.

Thieme, L. G.↗

NASA NTRSDate not supplied

Effects of Defects Analysis and Sizing Framework for Efficient Design of Composite Structures

Design of large composite structures requires striking a balance between permitted flaw size,strength margins, weight, and production rate. Stringent requirements manufacturing flaws can result in a lightweight structure because the strength properties are assumed to be closer to pristine. However, these stringent requirements can lead to production delays due to increased inspection and rework needed during the layup and rejection of parts after cure. Conversely, permitting larger flaws can reduce production delays, but will likely result in a heavier structure due to increased conservatism needed to maintain acceptable structural margins. The tradeoff between these criteria can vary between different structures and material systems, so the balance between manufacturing and design requirements is always a moving target. Assessment of this tradeoff requires having the ability to quickly evaluate the impact of flaw size on strength margin across an entire structure for a large number of load cases. The approach taken in this work is to implement an effects of defects analysis and sizing framework within HyperX. HyperX performs optimization of composite structures; this capability has been enhanced to include structural flaw data in the margin of safety calculations performed during optimization. Both the flaw import process and analysis of flaws have been generalized such that any flaw type from any source can be considered. The resulting tool enables rapid assessment of the impact of defects both at a vehicle and part level.

Effects of defects↗

NASA NTRSDate not supplied

Effects of Defects Analysis and Sizing Framework for Efficient Design of Composite Structures

Effects of defects↗