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Economically Viable Intermediate to Long Duration Hydrogen Energy Storage Solutions for Fossil Fueled Assets

This report was prepared as an account of work sponsored by the Office of Fossil Energy and Carbon Management of U.S. Department of Energy under Funding Opportunity Announcement Number DE-FOA-0002332 “Energy Storage for Fossil Power Generation”. The work aimed to explore and advance an innovative hydrogen energy storage system – the synergistically integrated hydrogen energy storage system (SIHES) – that has the following characteristics: • Compatible with existing or new coal and gas fuel electricity generation units, • best suited for intermediate to long duration energy storage, from 12 hours to weeks even months, and • capable of storing energy at the utility scale – hundreds of MWh to GWh energy storage with power output level in tens to hundreds of MW. Preliminary front-end engineering design (Pre-FEED) studies was carried out to develop and refine a site-specific SIHES as peaking power generation units (so named as HyPeaker) as the first market entry point, to demonstrate both the technical feasibility and the economic viability to integrate the HyPeaker “within the fence” of a fossil power plant. This specific site was TVA’s Johnsonville Combustion Turbine Plant. The HyPeaker was designed and engineered to integrate with a 60MW aeroderivative gas turbine unit already available at TVA’s Johnsonville site. This site-specific HyPeaker consists of an alkaline electrolyzer to produce hydrogen from CO 2 free electricity sources, an innovative low-cost high-pressure hydrogen storage system (Big-Ton) and the aero gas turbine to generate electricity using blend of hydrogen and natural gas. A holistic system level technoeconomic analysis tool specific to HyPeaker was developed to optimize the engineering design of the Johnsonville site-specific HyPeaker for cost and performance. The optimal design and specification of the Johnsonville site-specific HyPeaker are the following: • Alkaline electrolyzer: 3MW • Big-Ton storage vessel: 11,000kg H 2 at 3000psi. • 4-stage diaphragm hydrogen compressor: 55kg-H 2 /hr from 150psi to 3000psi. The HyPeaker is designed to provide sufficient hydrogen for 90% continuous operation of the HyPeaker. All major components have design life of 30 years. The capex of HyPeaker is estimated at $\$$7.1M. This included $\$$1.5M for the electrolyzer, $\$$5.6M for the storage vessel and compressor. The cost of aero gas turbine was included as it is already available at the site. Key findings are: • HyPeaker can be designed, manufactured, installed and integrated with the fossil power plants, with sub-systems and components commercially available on the market today, even when it is scaled up to an order of magnitude larger than the one at the Johnsonville site. HyPeaker is a technologically viable solution to cover a wide range of energy storage duration needs, from daily peaking operation to seasonal shifting for fossil fueled assets. • The cost advantage of SCCV based Big-Ton H 2 storage vessel made it possible to “oversize” the H 2 storage subsystem to achieve overall system level cost optimization. The benefits are two-fold. First, it allows to significantly reduce the capacity and cost of electrolyzer by spreading H 2 production over a much longer period of time when the fuel cost for electricity production is low. Second, it allows to balance the hydrogen production and usage shift over weeks to months to meet the peak demands. As such, the capital cost of HyPeaker system using the Big-Ton was less than half of the cost of a system with today’s steel tube based H 2 storage system. The HyPeaker has even better cost advantage Li-ion battery based energy storage system. The estimated capital cost of Li-Ion battery system would be at $\$$38M, under the same projected 20-year electricity generation profile of the Johnsonville site. This is over 5 times more expensive than the HyPeaker system. • Since industry scale energy storage systems do not have 100% energy conversion and storage efficiency, energy storage systems using fossil fuel generated electricity would increase the CO 2 emission. This is particularly the case for HyPeaker due to its low round trip efficiency. Therefore, a more sensible solution would be to the excessive or curtailed electricity from CO 2 emission free sources such as solar farms, wind farms or nuclear power plants, to produce hydrogen, and integrate them with the HyPeaker. Electricity from TVA’s nuclear power plants was used for the Johnsonville HyPeaker. • The economic viability of HyPeaker is expected to be further improved when global supply chains are taken into consideration. For the same Johnsonville site specific HyPeaker, the capex would be reduced to ~$\$$3.6M from ~$\$$7.1M, and the added LCOE is reduced to ~$\$$85/MWh. With the bipartisan Infrastructure Investment and Jobs Act, the cost of domestically produced HyPeaker sub-systems would be at the level of today’s global suppliers. Since the peaking units generally operate at peak usage period, thereby demanding higher price, the projected $\$$85/MWh LCOE would be within the realm of financial viability for utility operators.

08 HYDROGEN↗

Distribution System Model Calibration for GMLC 3.3.3 "Incipient Failure Identification for Common Grid Asset Classes" - Project Summary

Distribution system model calibration is a key enabling task for incipient failure identification within the distribution system. This report summarizes the work and publications by Sandia National Laboratories on the GMLC project titled “Incipient Failure Identification for Common Grid Asset Classes”. This project was a joint effort between Sandia National Laboratories, Lawrence Livermore National Laboratory, National Energy Technology Laboratory, and Oak Ridge National Laboratory. The included work covers distribution system topology identification, transformer groupings, phase identification, regulator and tap position estimation, and the open-source release and implementation of the developed algorithms.

24 POWER TRANSMISSION AND DISTRIBUTION↗

CORE-CM in The Greater Green River and Wind River Basins: Transforming and Advancing a National Coal Asset (Final Report)

The following document summarizes project results from “CORE-CM in the Greater Green River and Wind River Basins: Transforming and Advancing a National Coal Asset”. This project is part of the U.S. Department of Energy’s (“DOE”) National Energy Technology Laboratory’s (“NETL”) Carbon Ore, Rare Earth Elements, and Critical Minerals (CORE-CM) Initiative. This report concludes that the Greater Green River and Wind River Basins (GGRB-WRB) Area-of-Interest (AOI 9) is the ideal region for continued research and development in progressing the broader CORE-CM goals outlined by the DOE. Based upon the extensive analyses of technical, social, and community criteria, this report illustrates that the GGRB-WRB hosts numerous potential CORE-CM feedstocks (both coal- and non-coal based), diverse opportunities for utilizing existing industrial waste streams, ample infrastructure and industry to support new CORE-CM-focused technologies, and a highly motivated, well educated, and adaptable workforce to further develop the regional and national CORE-CM supply chain. Additionally, some potential solutions for technological gaps suggest that the GGRB-WRB's diverse resources can play a significant role in achieving the national goal of critical materials independence. With full community participation, meaningful involvement of regional Tribal Nations, and building upon the stakeholder engagement demonstrated here, the GGRB-WRB region presents a unique opportunity for advancing the CORE-CM Initiative. This project was designed to bring together coal-based communities and stakeholders from across the GGRB-WRB to advance new industries for CORE-CM resources. The University of Wyoming (UWyo) School of Energy Resources (SER) led a project team of experts from the Colorado Geological Survey (CGS), Colorado School of Mines (CSM), Los Alamos National Lab (LANL), and local community colleges. Input from basinal, regional, and national experts bolstered the coalition in order to advance the mission of DOE’s CORE-CM initiative and develop the domestic CORE-CM supply chain. Phase I of this project was designed to address the goal of developing and catalyzing economic growth, job creation, and technology innovation in the GGRB-WRB of Wyoming and Colorado, by increasing the supply of CORE-CM to manufacturers of non-fuel Carbon Based Products (CBP) and products reliant upon CM. The GGRB-WRB CORE-CM project worked toward providing benefit through several avenues of performance and research. • Develop a coalition team to achieve project objectives • Complete detailed assessments, including State-of-the-Art (SOTA) Data acquisition of potential CORE-CM materials across the AOI, and meaningfully contributes to DOE’s CORE-CM goals nationally. • Strategic planning for regional economic growth, job creation, and associated technology innovation around coal materials, including plans to maximize the development of potential CORE-CM resources and technology by creating regional public-private partnerships. • Define regional economic growth potential around existing strengths, energy infrastructure, business and industry, including planning for the leveraging of highly trained workforces, existing and novel coal technologies, and energy infrastructure in development of CORE-CM supply chains. • Develop a preliminary strategic plan for increasing the supply of CORE-CM materials to manufacturers of non-fuel Carbon Based Products (CBP) and products reliant upon CM, focusing on regional strengths that result in an emerging diversified CORE-CM economy. • Assemble a committed network of stakeholders and communities that learn about, accept, and grow new energy technologies within coal regions. Additionally, the project team significantly contributed to the CORE-CM Initiative’s national goals, through cross-regional scoping, collaborating with CORE-CM projects in other AOIs, and including parallel regional project experts. In addition to active inclusion and meaningful engagement and contribution to DOE-led working groups, the project team focused on engaging with regional communities including Tribal Nations, economic development groups, and regional government organizations. The project’s CORE-CM development and commercialization plan identified diverse CORECM feedstocks, potential routes towards integration with existing industries, methods for supply-chain development that leverage existing infrastructure and businesses considering the regional economy, identified entry barriers for incorporating traditional and new technologies in those supply chains, recognized opportunities for public-private partnerships to develop technology innovation centers, identified diverse workforces, and conducted stakeholder outreach and education to build a community of understanding on CORE-CM potential in the GGRB-WRB region. Detailed task descriptions can be found in each chapter.

01 COAL, LIGNITE, AND PEAT↗

Vulcan Test Platform: Demonstrating the Data Center as a Flexible Grid Asset

Explosive data center demand is outpacing grid infrastructure development. AI workloads and hyperscale cloud growth are creating unprecedented power requirements, while traditional grid expansion faces multi-year development timelines, regulatory hurdles, and decarbonization challenges. Sidewalk Infrastructure Partners recognized this impending crisis years ago and founded Verrus to develop an innovative solution: data centers that function as grid assets rather than passive loads. The Verrus approach integrates proprietary grid-aware controls with battery energy storage systems (BESS) in a medium-voltage architecture that delivers three critical capabilities: Fast-responding demand flexibility that can service requests from the utility within 10 seconds, Uninterrupted transition to islanded operation during grid disturbances, Continuous uptime assurance while maintaining all customer service level commitments Through Verrus' strategic partnership with the National Renewable Energy Laboratory (NREL), we validated these capabilities on Vulcan, a 70 MW utility-scale test platform powered by NREL's ARIES Virtual Emulation Environment. This deployment-ready technology has successfully demonstrated that Verrus data centers can deliver meaningful grid services while maintaining mission-critical reliability. This technical report outlines the design, methodology, and results of this emulated deployment, demonstrating that data centers can play a pivotal role in enhancing grid flexibility and reliability, without sacrificing service level guarantees.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Tracking and Protecting High-Value/High-Visibility Assets

Pacific Northwest National Laboratory’s (PNNL’s) Independent Oversight (IO) office led an assessment to evaluate PNNL’s approach to tracking and protecting high-value/high-visibility assets. The approach used by the assessment team included a review of requirements (including records), staff interviews, on-site and virtual walkthroughs of lab spaces, review of data, and the development of three separate workflows to capture PNNL’s current practices in the areas of controlled substances, select toxins, and precious metals. Summary results are provided within the report, including all findings and opportunities for improvement (OFIs).

99 GENERAL AND MISCELLANEOUS↗

Watching for light: An enterprise roadmap for trustworthy laser threat warning (LTW) to protect national assets

Comprehensive space force protection must include effective and trustworthy laser threat warning (LTW). Effective LTW will detect and characterize threats to space assets and thus enhance space deterrence. LTW must be trustworthy: able to categorize threats and non-threats by being both sensitive to true events and resistant to false alarms. Outside of the laboratory, the statistics and even the roles of lasers become unclear. In the chain of events leading to an attack, the laser may be the last link to be understood. Human situational awareness and informal reasoning must blend statistics with circumstantial evidence to visualize these chains before they are clear. This paper sets out an industrial model for an enterprise that will routinely produce trustworthy LTW. By incorporating psychology and economics, this enterprise can overcome the difficulties and perils of cooperation in networked defense and intelligence. This roadmap suggests how the enterprise can incentivize distracted actors with different goals to share what they know and coordinate what they do.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗

Existing Hydropower Assets (EHA) Puerto Rico Plant Database Extension

This dataset is an extension and subset of the Existing Hydropower Assets (EHA) Plant Database, 2025, released by Oak Ridge National Laboratory through HydroSource covering hydropower plants in Puerto Rico. The extension enhanced EHA to support modeling performed under the Department of Energy Hydropower Office's SECURE Water Act Section 9505 Fourth Assessment (9505). Included is a spatial dataset containing the location of the powerhouse and plant characteristics and a spatial dataset containing the location of the point-of-diversion and plant characteristics. Enhancements made in this dataset from EHA include updating plant’s spatial locations to explicitly represent the location of the powerhouse; identifying a plant’s point-of-diversion (source of water) spatial location; adding additional plants not included in the 2025 EHA, and revising attributes with updated information.

Broman, Daniel P [Pacific Northwest National Labor↗

Existing Hydropower Assets (EHA) Hawaii Plant Database Extension

This dataset is an extension and subset of the Existing Hydropower Assets (EHA) Plant Database, 2025, released by Oak Ridge National Laboratory through HydroSource covering hydropower plants in Hawaii. The extension enhanced EHA to support modeling performed under the Department of Energy Hydropower Office's SECURE Water Act Section 9505 Fourth Assessment (9505). Included is a spatial dataset containing the location of the powerhouse and plant characteristics and a spatial dataset containing the location of the point-of-diversion and plant characteristics. Enhancements made in this dataset from EHA include updating plant’s spatial locations to explicitly represent the location of the powerhouse; identifying a plant’s point-of-diversion (source of water) spatial location; adding Intertie Region as and attributes, and revising the County, Pt_Own, OwType, and Dam_Own attributes with updated information.

Broman, Daniel P [Pacific Northwest National Labor↗

Existing Hydropower Assets (EHA) Alaska Plant Database Extension

This dataset is an extension and subset of the Existing Hydropower Assets (EHA) Plant Database, 2025, released by Oak Ridge National Laboratory through HydroSource covering hydropower plants in Alaska. The extension enhanced EHA to support modeling performed under the Department of Energy Hydropower Office's SECURE Water Act Section 9505 Fourth Assessment (9505). Included is a spatial dataset containing the location of the powerhouse and plant characteristics and a spatial dataset containing the location of the point-of-diversion and plant characteristics. Enhancements made in this dataset from EHA include updating plant’s spatial locations to explicitly represent the location of the powerhouse; identifying a plant’s point-of-diversion (source of water) spatial location; adding State of Alaska Plant ID, Intertie Region, and Alaska Energy Region as attributes, and revising the County, Pt_Own, OwType, and Dam_Own attributes with updated information.

Broman, Daniel P [Pacific Northwest National Labor↗

Transforming Windows from Energy Liabilities to Zero-Energy Assets: Next-Generation Solutions for Buildings

Windows have traditionally contributed to a building's HVAC load, but they can also become a source of net energy gain or even operate as zero-energy components. For heating applications, highly insulating windows can harness more solar heat than the energy lost through them, transforming windows from energy liabilities to assets. Dynamic glazings provide further benefits by regulating solar heat gain, reducing cooling loads in summer and heating demands in winter. This simulation study focuses on developing the next generation of zero-energy windows (ZEW) for residential new construction. Through annual energy simulations across climate zones 1-8, ZEW performance benchmarks were established based on current code-level buildings, and we've identified the regions where meeting ZEW standards are most achievable. This work evaluates both static and dynamic window technologies, assessing their effects on annual energy use and cost. Key findings demonstrate that ZEW performance is achievable across diverse climate zones, with specific regional requirements. Most climate zones from 3-8 can achieve ZEW with specific configurations, while some warm climates (1-2) appear challenging for ZEW implementation. Climate zones 4-6 consistently allow for zero energy window implementation, offering multiple pathways through either static or dynamic window technologies. Colder climate zones (7-8) ZEW products allow for higher SHGC values while requiring low U-values.

Yu, Lili↗

Integrated tracking of components by engineering and logistics utilizing logistics asset tracking system

The Logistics Asset Tracking System (LATS) devised by NASA contains data on Space Shuttle LRUs that are daily updated to reflect such LRU status changes as repair due to failure or modification due to changing engineering requirements. The implementation of LATS has substantially increased personnel responsiveness, preventing costly delays in Space Shuttle processing and obviating hardware cannibalization. An evaluation is presented of LATS achievements in the direction of an integrated logistical support posture.

Renfroe, Michael B.↗

Future Assets, Student Talent (FAST)

Future Assets, Student Talent (FAST) motivates and prepares talented students with disabilities to further their education and achieve High Tech and professional employment. The FAST program is managed by local professionals, business, and industry leaders; it is modeled after High School High Tech project TAKE CHARGE started in Los Angeles in 1983. Through cooperative efforts of Alabama Department of Education, Vocational Rehabilitation, Adult and Children Services, and the President's Committee on Employment of People with Disabilities, north central Alabama was chosen as the second site for a High School High Tech project. In 1986 local business, industry, education, government agencies, and rehabilitation representatives started FAST. The program objectives and goals, results and accomplishments, and survey results are included.

Source record↗

Technology for national asset storage systems

An industry-led collaborative project, called the National Storage Laboratory, was organized to investigate technology for storage systems that will be the future repositories for our national information assets. Industry participants are IBM Federal Systems Company, Ampex Recording Systems Corporation, General Atomics DISCOS Division, IBM ADSTAR, Maximum Strategy Corporation, Network Systems Corporation, and Zitel Corporation. Industry members of the collaborative project are funding their own participation. Lawrence Livermore National Laboratory through its National Energy Research Supercomputer Center (NERSC) will participate in the project as the operational site and the provider of applications. The expected result is an evaluation of a high performance storage architecture assembled from commercially available hardware and software, with some software enhancements to meet the project's goals. It is anticipated that the integrated testbed system will represent a significant advance in the technology for distributed storage systems capable of handling gigabyte class files at gigabit-per-second data rates. The National Storage Laboratory was officially launched on 27 May 1992.

Coyne, Robert A.↗

Secure, Network-Centric Operations of a Space-Based Asset: Cisco Router in Low Earth Orbit (CLEO) and Virtual Mission Operations Center (VMOC)

This report documents the design of network infrastructure to support operations demonstrating the concept of network-centric operations and command and control of space-based assets. These demonstrations showcase major elements of the Transformal Communication Architecture (TCA), using Internet Protocol (IP) technology. These demonstrations also rely on IP technology to perform the functions outlined in the Consultative Committee for Space Data Systems (CCSDS) Space Link Extension (SLE) document. A key element of these demonstrations was the ability to securely use networks and infrastructure owned and/or controlled by various parties. This is a sanitized technical report for public release. There is a companion report available to a limited audience. The companion report contains detailed networking addresses and other sensitive material and is available directly from William Ivancic at Glenn Research Center.

Ivancic, William↗

ISS Asset Tracking Using SAW RFID Technology

A team at the NASA Johnson Space Center (JSC) is undergoing final preparations to test Surface Acoustic Wave (SAW) Radio Frequency Identification (RFID) technology to track assets aboard the International Space Station (ISS). Currently, almost 10,000 U.S. items onboard the ISS are tracked within a database maintained by both the JSC ground teams and crew onboard the ISS. This barcode-based inventory management system has successfully tracked the location of 97% of the items onboard, but its accuracy is dependant on the crew to report hardware movements, taking valuable time away from science and other activities. With the addition of future modules, the volume of inventory to be tracked is expected to increase significantly. The first test of RFID technology on ISS, which will be conducted by the Expedition 16 crew later this year, will evaluate the ability of RFID technology to track consumable items. These consumables, which include office supplies and clothing, are regularly supplied to ISS and can be tagged on the ground. Automation will eliminate line-of-sight auditing requirements, directly saving crew time. This first step in automating an inventory tracking system will pave the way for future uses of RFID for inventory tracking in space. Not only are there immediate benefits for ISS applications, it is a crucial step to ensure efficient logistics support for future vehicles and exploration missions where resupplies are not readily available. Following a successful initial test, the team plans to execute additional tests for new technology, expanded operations concepts, and increased automation.

Schellhase, Amy↗

The Real Time Mission Monitor: A Situational Awareness Tool For Managing Experiment Assets

The NASA Real Time Mission Monitor (RTMM) is a situational awareness tool that integrates satellite, airborne and surface data sets; weather information; model and forecast outputs; and vehicle state data (e.g., aircraft navigation, satellite tracks and instrument field-of-views) for field experiment management RTMM optimizes science and logistic decision-making during field experiments by presenting timely data and graphics to the users to improve real time situational awareness of the experiment's assets. The RTMM is proven in the field as it supported program managers, scientists, and aircraft personnel during the NASA African Monsoon Multidisciplinary Analyses experiment during summer 2006 in Cape Verde, Africa. The integration and delivery of this information is made possible through data acquisition systems, network communication links and network server resources built and managed by collaborators at NASA Dryden Flight Research Center (DFRC) and Marshall Space Flight Center (MSFC). RTMM is evolving towards a more flexible and dynamic combination of sensor ingest, network computing, and decision-making activities through the use of a service oriented architecture based on community standards and protocols.

Blakeslee, Richard↗

IPv6 and IPsec Tests of a Space-Based Asset, the Cisco Router in Low Earth Orbit (CLEO)

This report documents the design of network infrastructure to support testing and demonstrating network-centric operations and command and control of space-based assets, using IPv6 and IPsec. These tests were performed using the Cisco router in Low Earth Orbit (CLEO), an experimental payload onboard the United Kingdom – Disaster Monitoring Constellation (UKDMC) satellite built and operated by Surrey Satellite Technology Ltd (SSTL). On Thursday, 29 March 2007, NASA Glenn Research Center, Cisco Systems and SSTL performed the first configuration and demonstration of IPsec and IPv6 onboard a satellite in low Earth orbit. IPv6 is the next generation of the Internet Protocol (IP), designed to improve on the popular IPv4 that built the Internet, while IPsec is the protocol used to secure communication across IP networks. This demonstration was made possible in part by NASA’s Earth Science Technology Office (ESTO) and shows that new commercial technologies such as mobile networking, IPv6 and IPsec can be used for commercial, military and government space applications. This has direct application to NASA’s Vision for Space Exploration. The success of CLEO has paved the way for new space-based Internet technologies, such as the planned Internet Routing In Space (IRIS) payload at geostationary orbit, which will be a U.S. Department of Defense Joint Capability Technology Demonstration. This is a sanitized report for public distribution. All real addressing has been change to psueco addressing.

Communication↗

Ares V: A National Launch Asset for the 21st Century

NASA is designing the Ares V as the cargo launch vehicle to carry NASA's exploration plans into the 21st century. The Ares V is the heavy-lift component of NASA's dual-launch architecture that will replace the current space shuttle fleet, complete the International Space Station, and establish a permanent human presence on the Moon as a stepping stone to destinations beyond. During extensive independent and internal architecture and vehicle trade studies as part of the Exploration Systems Architecture Study, NASA selected the Ares I crew launch vehicle and the Ares V to support future exploration. The smaller Ares I will launch the Orion crew exploration vehicle with four to six astronauts into orbit. The Ares V is designed to carry the Altair lunar lander into orbit, rendezvous with Orion, and send the mated spacecraft toward lunar orbit. The Ares V will be the largest and most powerful launch vehicle in history, providing unprecedented payload mass and volume to establish a permanent lunar outpost and explore significantly more of the lunar surface than was done during the Apollo missions. The Ares V also represents a national asset offering opportunities for new science, national security, and commercial missions of unmatched size and scope. Using the dual-launch Earth Orbit Rendezvous approach, the Ares I and Ares V together will be able to inject roughly 57percent more mass to the Moon than the Apollo-era Saturn V. Ares V alone will be able to send nearly 414,000 pounds into low Earth orbit (LEO) or more than 138,000 pounds directly to the Moon, compared with 262,000 pounds and 99,000 pounds, respectively for the Saturn V. Significant progress has been made on the Ares V to support a planned fiscal 2011 authority-to-proceed (ATP) milestone. This paper discusses recent progress on the Ares V and planned future activities.

Sumrall, Phil↗