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DOE OSTI2026

There and Back Again: Reimagining Cryogenic Cooling for Scalable Arrays of Dilution Refrigerators for future Quantum Datacenters

While pulse tube cryocoolers enabled the rapid expansion of dilution refrigerator technology over the past two decades, the transition to large-scale quantum systems is now driving a reassessment of the DR’s higher-temperature-stage cooling strategies and how these systems can be effectively scaled in a modular way. Quasi-wet architectures based on centralized cryoplants and forced-flow helium distribution offer compelling advantages in energy efficiency, operational cost, and scalability. With appropriate redundancy, standardized interfaces, and optimized distribution system designs, these architectures will provide a practical and robust path forward for the next generation of quantum computing infrastructure.

Hansen, B. [Fermilab]↗

DOE OSTI2025

Flexible Operation of Microgrids Through Operator-Configurable Microgrid Controllers

Microgrids are becoming critical assets in power distribution systems. This is partly due to the resiliency and reliability challenges faced by power distribution systems in the last decade and partly due to the increased integration of distributed energy resource assets, such as solar photovoltaic. This increased need for microgrids has created a multitude of needs for microgrid controllers. Most microgrid controllers in the past decade have been uniquely programmed or custom programmed to meet the needs of a specific microgrid. Currently, IEEE standards aim to integrate the needs and capabilities of microgrid controllers under a unified umbrella. But the standards do not recommend necessary or appropriate software development practices for microgrid controllers. In addition, the programmable nature and maintenance of controllers are also key characteristics that fall outside the coverage of the standards. In this paper, we present the best software practices that utility engineers and microgrid operators should consider in the microgrid software platform. This paper can be used as an information document for developing documentation of controller requirements and assessing microgrid controller requirements.

Banshee microgrid↗

DOE OSTI2025

Techno-economic assessment of distributed wellhead RO water treatment for nitrate removal and salinity reduction: A field study in small disadvantaged communities

Techno-economic analysis of distributed wellhead water treatment and desalination (DWTD) systems was carried out based on a three-year field study in three small, disadvantaged communities (DACs) to evaluate the reliability and affordability of upgrading their impaired well water. The local water supplies of the three study DACs, located in Salinas Valley, California, were contaminated with nitrate at levels (~ 12–87 mg/L NO$^{-}_{3}$ - N) ) above the California maximum contaminant level (MCL) of 10 mg/L NO$^{-}_{3}$ - N , and had elevated water salinity (~600–1,600 mg/L total dissolved solids(TDS)) above its secondary MCL (SMCL) of 500 mg/L TDS. Well water nitrate removal and salinity reduction were accomplished via reverse osmosis (RO) based DWTD systems that operated autonomously, supported by remote monitoring and supervisory cyberinfrastructure. Reliable DWTD operation provided treated water quality, with respect to nitrate and salinity, in the range of 0.5–6.3 mg/L NO$^{-}_{3}$ - N and 57–161 mg/L TDS, respectively, which were well below the respective MCL and SMCL. The levelized cost of water treatment was in the range of ~$$2/m 3 - $$2.9/m 3 which aligns with typical residential water costs in California and in the study region, and monthly residential water costs (39 dollars-74 dollars/residential unit/month) were also within the range in California. The study showcased the DWTD approach as a viable and potentially scalable solution for upgrading impaired local potable water supply of communities lacking centralized water delivery infrastructure. However, streamlined permitting processes and standardized regulatory frameworks are critical to promoting wider adoption and maximizing the socio-economic benefits of the DWT approach. Moreover, DACs are likely to require government subsidies in order to cover the CapEx of DWTD systems in addition to upgrade of site infrastructure.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2025

PowderJet: Spherical metal powder production via multi-orifice droplet-on-demand metal jetting

Leading metal additive manufacturing techniques, such as laser powder bed fusion and directed energy deposition, rely on high-quality spherical metal powders. However, traditional powder production methods like gas atomization face limitations, including low in-spec yield, asphericity, and internal porosity. We introduce PowderJet, a powder production platform that uses electromagnetic pulses to eject liquid metal droplets from a multi-orifice nozzle. Unlike stochastic methods, PowderJet tightly controls powder size, distribution, and purity through a droplet-on-demand approach. We detail the system’s design, operation, and performance using a combined experimental and computational fluid dynamics (CFD) framework. Initial results with Al4008 and Cu110 alloys demonstrate successful production, yielding unsieved aluminum powder batches with a mean diameter of 200 µm and a narrow size distribution (15 µm standard deviation). The produced powders are highly spherical, achieving a roundness > 0.95. PowderJet operates with a small melt volume (3 mL) and supports continuous refilling, enabling production rates between 30 and 140 cm³/hr depending on jetting frequency, number of orifices and particle size. CFD simulations show that future systems could achieve rates exceeding 1000 cm³/hr for particle sizes as small as 40 µm. PowderJet’s high yield of in-spec powder makes it ideal for producing precious or hazardous materials that are inefficient to manufacture using conventional methods. This platform offers a scalable, precise, and efficient solution for producing high-quality powders tailored for advanced manufacturing applications.

Atomization↗

DOE OSTI2026

Artificial Intelligence-Driven Management of Sustainable Energy Resources: Visibility, Operation, and Control

The rapid global transition toward sustainable energy resources (SERs) is reshaping how modern power systems are observed, optimized, and controlled. While SERs have significantly advanced decarbonization, their weather dependence, variability, and inverter-dominated characteristics challenge traditional, centralized, and deterministic grid operation. At the same time, the proliferation of high-resolution data from inverters, smart meters, and sensors offers unprecedented visibility into system dynamics. Yet, it also exceeds the analytical capability of conventional model-based approaches. Artificial intelligence (AI) provides a new foundation for addressing these challenges by bridging physical laws with data-driven learning, enabling accurate state awareness, adaptive operation, and coordinated control across distributed assets. This article examines how AI transforms the management of SER-rich power systems along three critical dimensions: 1) enhancing visibility by inferring behind-the-meter (BTM) activities, assessing SER flexibility, and reconstructing system states from sparse or noisy measurements; 2) improving operation through AI-enhanced SER service provision, volt/var control (VVC), and dynamic operating envelopes (DOE) for efficiency and security; and 3) advancing control by embedding learning-based intelligence into inverter coordination, voltage and frequency regulation, and long-term dispatch. Together, these developments reveal how AI can convert the variability of SERs from an operational challenge into a source of flexibility, resilience, and intelligence, paving the way toward sustainable, adaptive, and self-optimizing power systems.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2025

Master Services Agreement - Flexible Feeder/Distribution System Support: Cooperative Research and Development (Final Report)

PGE will engage NREL on a broad range of projects related to the integration of distributed energy resources (DERs) into the utility's operations. This portfolio of work could include projects focused on DER adoption models, advanced distribution management system (ADMS) and distributed energy management system (DERMS) design, DER dispatch strategy development, and DER valuation framework development. Additional topics could include long-term energy planning, renewable energy, energy efficiency and demand-side management. As well as technology evaluations and design guidance for building retrofits and new construction projects, energy and energy infrastructure planning, policies, and markets (and their analysis), energy storage, energy security and resilience (including energy system-related cybersecurity), transportation and mobility, technology integration analysis. Additionally, other assistance as requested by PGE consistent with NREL’s expertise.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2026

Online task-space motion control for positioner-coordinated multi-robot manufacturing systems

Incorporating multiple robotic manipulators into large-scale manufacturing systems enhances production efficiency and expands manufacturing capabilities beyond those of single-robot systems. Workpiece positioners in robotic manufacturing have demonstrated significant benefits for process optimization, but coordination strategies for multi-robot systems with shared positioners have received limited attention. This work presents a task-space coordinated trajectory-tracking control framework for multi-robot manufacturing systems, in which robots coordinate their motions within a shared, dynamic workpiece positioning frame. A workpiece positioner actively adjusts the pose of the manufactured component to enable greater operational concurrency and improve overall production efficiency. The proposed motion-coordination scheme employs a distributed and scalable architecture, supporting coordination across heterogeneous multi-robot systems. Two optimization methodologies are introduced to manage kinematic redundancies and maintain continuous, near-optimal operation throughout the manufacturing process. The first strategy exploits a task-space dimensionality reduction to achieve locally optimal configurations by leveraging symmetry-axis rotations of the tool. The second strategy utilizes the workpiece positioner to drive the coordinated robots toward stable and kinematically favorable configurations. For both optimization strategies, multiple objectives are defined to improve key performance metrics, including manipulability, configuration consistency, proximity to mechanical limits, and motion efficiency. Addressing a key limitation of existing coordination approaches, the framework is designed around online setpoint modification, allowing coordinated robots to respond effectively to in-situ process feedback. The proposed control framework is validated using the Robot Operating System (ROS) middleware on a combination of physical and simulated multi-robot system hardware.

Arbogast, Alex [ORNL] (ORCID:0000000154740723)↗

DOE OSTI2024

Testbed Demonstration of a Microgrid Building Block Prototype

With the adoption of ambitious climate action goals, the penetration level of distributed energy resources (DERs) is rapidly increasing. Microgrids are an efficient way to integrate these DERs, facilitating their operation and control. Additionally, microgrids enhance the overall resilience of the distribution system by serving critical loads both within and outside their boundaries. However, the need for substantial customized engineering leads to a high cost of development, installation and maintenance of microgrids. To address this challenge, Microgrid Building Blocks (MBB) are proposed to reduce the deployment cost of microgrids through modular, standardized design and implementation. This work presents a testbed demonstrating the integrated power conversion, control, and communication functionalities of an MBB. The testbed is formed by a real-time electromagnetic transient (EMT) simulation combined with a hardware and software prototype of MBB. The use cases supported by the MBB testbed are enumerated. The islanded operation, voltage regulation, and optimal dispatch capabilities of an MBB-based microgrid controller are validated through a case study.

Somda, Baza [Virginia Tech]↗

DOE OSTI2025

Dynamic Boundary Microgrids Under Privatization Considerations

Microgrids have physical, electrical, and logical (data, network, and ownership) boundaries. To power unserved customer loads during an outage, microgrids can extend the traditional operational boundaries. This can become complex when considering microgrid-to-microgrid (M2M) interactions where sensitive information such as competitive microgrid operational data is not shared. This work proposes an optimization method coordinated between microgrid controllers and distribution management systems that limits data sharing. The method involves a competitive bidding strategy that maximizes unserved load coverage while minimizing resource utilization and sensitive operational data sharing among entities. The work is validated on a two-microgrid system with photovoltaic and energy storage systems and curves of load derived from real world residential buildings datasets. Results show that the proposed method, when applied for three distinct use cases of energy storage sufficiency to cover the predefined boundary and/or the expanded boundary, can successfully select and bid the available load coverage.

Starke, Michael [ORNL] (ORCID:0000000221211195)↗

DOE OSTI2024

Flexible dynamic boundary microgrid operation considering network and load unbalances

Flexible microgrids with dynamic boundaries have recently been introduced in the literature. With the ability to reconfigure the topology of the microgrids dynamically through remotely controlled switches, flexible microgrids with dynamic boundaries can further improve the resiliency and energy efficiency of microgrids with distributed energy resources (DERs). This paper focuses on the optimal operation considering one of the predominant characteristics of microgrids and distribution systems – unbalanced networks and loads. In existing literature, balanced modeling of microgrids is more common due to its attractive simplicity. The three-phase power unbalance has not been considered as a constraint on the generation units in a microgrid. Further, negative sequence constraints have also been neglected. In this article, we propose a set of constraints that is specifically related to the capabilities of inverter interfaced resources to supply unbalanced current/power when the microgrid is islanded from the main distribution grid. We incorporate the new set of constraints into two optimization formulations leveraging two convex relaxations of the three-phase power flow equations: mixed-integer linear programming (MILP) and mixed-integer semidefinite programming (MISDP) that optimize the dispatch of controllable switches and DERs in the microgrid. The algorithms are then extended to networked microgrids with grid-forming sources. We test the algorithms on a realistic community microgrid model in Puerto Rico as well as standardized IEEE distribution test feeders. The testing results demonstrate the performance of the proposed algorithms. The MILP is fast and scalable, and the MISDP enforces the negative sequence voltage constraints.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2025

Dual-season thermal energy storage-integrated heat pump system for load shifting: experiments, modeling and nationwide analysis

Here, this paper proposes and validates a dual-season thermal energy storage-integrated heat pump (TES-HP) system that shifts building electric load in both cooling and heating modes using a single phase-change TES. The design uses the TES as a heat sink for the condenser in summer and a heat source for the evaporator in winter, thereby reducing on-peak electric demand while ensuring compatible with existing air-distribution systems. A 14-kW TES-HP prototype with six operating modes and novel refrigerant charge management strategies was experimentally tested under varied conditions. Subsequently, data-driven polynomial performance curves were developed and validated against experiments, then coupled with a phase change material (PCM) model and a calibrated building model within a rule-based controller. Single-day case studies demonstrated effective on-peak demand reduction while maintaining thermal comfort. During cooling, hourly power was lowered by up to 1.5 kW; in heating, average hourly power decreased from over 3.5 kW to 1.8 kW, compared to an HP-only system, achieving 64.5 % load shifting, and the need for resistance heating was eliminated. Seasonal simulations showed typical on-peak electricity savings of 25–35 % in cooling and 40–65 % in heating, with the largest benefits on the hottest and coldest days. Extended response-surface analysis and nationwide mapping quantified load shifting as functions of ambient and TES temperatures, revealing a seasonal trade-off in TES phase-change temperature. These results demonstrate the TES-HP system as a practical and scalable solution for grid-interactive buildings that reduces on-peak demand and electricity use while maintaining thermal comfort and enhancing grid flexibility and reliability.

Grid-interactive buildings↗

DOE OSTI2024

Multi-Timescale Optimal Operation Framework for Integrated Economic and Reliability Analysis of Hybrid Power Plants

This paper introduces a hierarchical modeling framework for hybrid power plants (HPP) to facilitate the operation of HPP in power systems similar to conventional generators (Congens) in the integrated multi-timescale optimal operation framework. To consider the uncertainties of HPP renewable power in the day-ahead scheduling, distributionally robust optimization (DRO) is used. To ensure that the state-of-charge (SOC) of energy storage systems in HPPs aligns closely with the planned value for long-term reliability, real-time SOC management is incorporated. In addition, an adjustable real-time control is designed for the robust delivery of HPP real-time services. Case studies performed on a revised IEEE 39-bus system demonstrate the effectiveness of the proposed framework for HPP operation. Simulation results highlight that the proposed framework not only can help operators schedule HPP similar to Congens in varying weather conditions but can also maintain the frequency reliability of the system.

frequency stability↗

DOE OSTI2025

Black-Starting Microgrids Using Inverter-Based Distributed Energy Resources

Recent trends in power systems show increasing deployment of inverter-based distributed energy resources (DERs) at the distribution level. Efforts have also been made to use inverter-based DERs for system restoration of critical sections of distribution feeders. In the past few years, there has been active consideration of using local grid-forming (GFM) DERs, which can form their own voltage and frequency, to black-start microgrids instead of waiting for the bulk system for supply restoration. However, using current-limited inverter-based DERs for black-start operations with high inrush currents can pose some technical challenges. This paper presents detailed electromagnetic transient studies on a digital real-time simulator to assess the operational feasibility of using local inverter-based GFM DERs for microgrid black-start operations as a bottom-up approach instead of a top-down approach where the substation is used to restore critical sections of the feeder. The paper presents key modeling details for distribution system components for studying GFM DER-based microgrid black-start operations. The paper presents simulation results comparing different black-start approaches using GFM DERs for two test systems: i) a simple test microgrid and ii) a real-world utility microgrid currently being designed and deployed by Holy Cross Energy in Colorado.

black start↗

DOE OSTI2025

Hydrogen Transportation and Distributed Energy Systems Seismic Risk Assessment for Cascadia Subduction Zone Airport Facilities

08 HYDROGEN↗

DOE OSTI2025

Hydrogen Transportation and Distributed Energy Systems Seismic Risk Assessment for Cascadia Subduction Zone Airport Facilities

Portland International Airport in Oregon is exploring operating a fleet of 28 fuel cell electric buses to support airport operations and possibly provide backup power during outages. In this report, we evaluate the risk of hydrogen deployment at an airport considering the potential for seismic activity. We present a seismic risk assessment for pressurized piping for a generic hydrogen refueling station at the airport. Only pressurized piping was considered in the risk analysis because of its vulnerability and availability of fragility information unlike the other components. Seismic capacity of other components should be included as more information becomes available. To characterize the seismic hazard, we considered the initiating event frequency of a Cascadia Subduction Zone earthquake event based on data from the literature. Seismic stressors that translate to the site from an earthquake event are expressed as peak ground acceleration. Site disturbance is characterized as a function of soil conditions, represented by different shear wave velocity values, which affect how seismic waves propagate and impact structures. Pipe fragility curves as a function of seismic capacity were used to correlate ground acceleration and failure probability. These fragility characteristics were combined with site-specific soil conditions to calculate the probability of pipe rupture during a seismic event. It should be noted that multiple simultaneous failures due to an earthquake event as a common cause are not considered. Some epistemic uncertainties such as self-exciting shocks, aftershocks, and the time variant nature of the ground motion are not considered either.

08 HYDROGEN↗

DOE OSTI2025

Machine Learning-Assisted Distribution System Network Reconfiguration Problem

High penetration from volatile renewable energy resources in the grid and the varying nature of loads raise the need for frequent line switching to ensure the efficient operation of electrical distribution networks. Operators must ensure maximum load delivery, reduced losses, and the operation between voltage limits. However, computations to decide the optimal feeder configuration are often computationally expensive and intractable, making it unfavorable for real-time operations. This is mainly due to the existence of binary variables in the network reconfiguration optimization problem. To tackle this issue, we have devised an approach that leverages machine learning techniques to reshape distribution networks featuring multiple substations. This involves predicting the substation responsible for serving each part of the network. Hence, it leaves simple and more tractable Optimal Power Flow problems to be solved. This method can produce accurate results in a significantly faster time, as demonstrated using the IEEE 37-bus distribution feeder. Compared to the traditional optimization-based approaches, a feasible solution is achieved approximately ten times faster for all the tested scenarios.

deep neural networks↗

DOE OSTI2024

Optimization-Based Deconfliction of Distribution System Applications

Power distribution systems are transitioning towards a future with large numbers of controllable grid-edge devices and distributed generation, as well as more complex operational objectives. This evolution requires a new distribution management approach, and modular applications can play a significant role. Thus, new strategies to coordinate independent applications with diverging operational goals are necessary. In this paper, we propose a novel optimization-based deconflictor to facilitate coordination in future advanced distribution management systems.

application deconfliction, power system optimizati↗

DOE OSTI2024

Leveraging Existing Assets for Long Duration Energy Storage

Increased renewables penetration to electrical grid is necessary to reduce overall emissions from the electrical power generation sector. Nonetheless, its integration creates challenges to grid operators who must match the power being generated by intermittent renewables and other traditional energy sources with the demand from consumers, while ensuring the reliability and power quality for the entire system. Energy storage has been proposed as an alternative to natural gas peaking plants and a form to deliver excess renewable energy generation at times of peak demand. For energy storage to provide benefits to end customers (energy consumers), it must be reliable, efficient, and cost effective. The Illinois Sustainable Technology Center (ISTC), one of the surveys that integrate the Prairie Research Institute (PRI), aims to develop a Center for Energy Storage at Existing Assets (CESEA) at UIUC with the participation of Waste Pressure Corp and Ecotek Engineering USA LLC. CESEA will focus on LDES systems that can integrate to existing infrastructure in a manner that reduces the initial capital expenditure and demonstrates the ability to repurpose fossil assets that would otherwise become stranded, to serve the energy transition. CESEA aims to leverage UIUC’s unique facilities to validate LDES systems performance at a relevant operating environment. UIUC’s facilities include a 85-MW combined heat and power (CHP) power plant, two (2) solar PV plants totaling over 18 MWdc of installed capacity, an electrical grid along with a substation at transmission and distribution voltages, a 22-mile gas pipeline network operating at two pressure levels, along with steam and chilled water distribution networks. The new LDES systems will connect to the existing UIUC grid through a new test electrical station, which will have the capacity to accommodate additional connections to test new devices and technologies as part of future CESEA R&D activities. The test electrical station will contain meters, instrumentation, and controls to accurately capture data and allow optimization of control algorithms. CESEA will initially focus on technologies that: i) utilize existing equipment or facilities to perform at least one of the process steps in LDES (charging, storage, or discharging), ii) leverage mature or commercially available components or controls, iii) show potential for cost-leadership in 10+ hour storage at a commercial scale. Initial technologies that were identified to meet these criteria include Compressed Gas Energy Storage (CGES), and TES. CGES stores electricity by raising the pressure of a compressible gas inside a control volume and converting the stored energy to electricity via expansion-generation. CGES is a generalization of CAES that covers any working gas (not just air). A successful CGES demo will help to circumvent many challenges faced by CAES (long development times due to site prospecting, high cost of compression and storage, heat recovery management, etc.) by: 1) utilizing existing infrastructure (compressors, pipelines, underground storage or pressure vessels) used in the transportation and storage of industrial gases for LDES charging and storage; 2) deploying over sites already-developed for industrial applications with minor additional work; 3) leveraging the price structure of commercial industrial gas to cover the costs of electricity used during charging. A previous DOE-sponsored conceptual study (DE-FE-0032018) estimated the levelized cost of energy of a 1.1 MW / 17 MWh CGES system at $0.08/kWh, with a commercial 10x scale system cost estimated at <$0.04/kWh (Giardinella, 2022). The pilot-sized system was estimated to avoid up to 2693 tons of CO2/year.

25 ENERGY STORAGE↗