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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Securing Grid-interactive Efficient Buildings (GEB) through Cyber Defense and Resilient System (CYDRES)

The DOE CYDRES project is driven by the urgent need to address critical research gaps in the domain of cyber-physical security of smart buildings, including Grid-interactive Efficient Buildings (GEBs). CYDRES, a real-time advanced building resilient platform, aims to enhance the cyber-attack-immune capabilities of buildings through multi-layered prevention, detection, and adaptation mechanisms. CYDRES consists of five key modules: a multi-layer network analyzer, an Automatic Fault Detection, Diagnosis, and Prognosis (AFDDP) framework, an intelligent mode selector, a cyber-resilient control framework, and a situation awareness platform. The Network Analyzer employs a data-driven framework that includes a protocol state learning tool and a CRF (Conditional Random Field) command validator. In Hardware-In-the-Loop (HIL) testbeds, it achieved 100% detection accuracy with a false alarm rate of 3%, validating its efficacy in identifying selected cyber-attacks. The AFDDP framework leverages pattern matching, PCA (Principal Component Analysis)-based strategies, and a DBN (Dynamic Bayesian Network)-based fault diagnosis approach to pinpoint the causes of physical system abnormalities using Building Automation System (BAS) data. In HIL experiments, the AFDDP module attained a detection accuracy of over 95% with a false alarm rate below 7%. Additionally, the fault detector utilized machine learning (Random Forest) and deep learning (Multi-Layer Perceptron) methods with acoustic sensor data to achieve a 100% fault detection accuracy in Heating, Ventilation, and Air-Conditioning (HVAC) equipment. The Mode Selector offered real-time impact analysis, allowing immediate actions to protect BASs in the face of emerging threats. The cyber-resilient control framework included an adaptive Model Predictive Control (MPC) and a measurement compensator, reducing temperature violations by up to 94% and improving the total demand flexibility by up to 70% in HIL experiments. Such HIL experiments covered a cyber-attack case and a physical fault case, showcasing CYDRES’ efficiency in maintaining operational continuity during threats. The situation awareness platform in Grafana enhanced real-time threat detection and response visualization, augmenting the operational awareness for building operators. CYDRES demonstrated high technical effectiveness in various test scenarios, particularly in HIL environments. The project's phased development approach ensured efficient use of resources, highlighting its practical feasibility and readiness for commercialization. By enhancing the security and resilience of building operations, CYDRES represents a significant advance in mitigating risks associated with cyber-physical systems, thereby enhancing public confidence in the safety of modern building infrastructure. Future directions for the project include expanding testing protocols, refining AFDDP methodologies, exploring more comprehensive resilient control strategies, and testing in real commercial buildings.

42 ENGINEERING↗
DOE OSTI2023

NETL’s Perspective on Storage Efficiency and CO2-SCREEN

Carbon capture and storage (CCS) is a process that captures carbon dioxide (CO2) by separating it from anthropogenic emissions sources before atmospheric release and storing that CO2 in deep geologic reservoirs. CCS is a powerful method for reducing anthropogenic CO2 which can ultimately diminish the effects of climate change. Prospective CO2 storage resource is the amount of carbon dioxide that can be stored in a given geologic formation typically given as a mass (e.g., metric tons). Obtaining accurate estimates of CO2 storage resources is necessary for governments and industries to make energy-related policy decisions. Researchers at the National Energy Technology Laboratory (NETL) under the Department of Energy (DOE) developed a methods and a tool [CO2-SCREEN (Storage prospeCtive Resource Estimation Excel aNalysis) to estimate prospective carbon storage resources for saline formations, unconventional shale formations, and residual oil zones. The methods and tool provide CO2 storage and efficiency outputs in the form of probability estimates (i.e. P10 and P90) as well as partitioning storage and efficiency estimates based on storage mechanism (total, free phase, sorbed phase, and dissolution phase). This presentation will focus on how storage efficiency is calculated based on numerical modeling efforts, how it’s applied in the storage methods and tool, and then highlighting needs for future development.

Hanson, Angela Goodman↗
DOE OSTI2024

A Highly Efficient and Affordable Hybrid System for Hydrogen and Electricity Production (Final Project)

The pursuit of clean, secure, and sustainable energy has sparked significant interest in fuel cells for power generation and electrolyzer cells for hydrogen production. Among all types of fuel and electrolyzer cells, solid oxide cells (SOCs) have emerged as promising candidates due to their high efficiency and versatility. However, conventional oxygen-ion conductive SOCs face several challenges related to their performance and durability associated with their high-temperature operation (≥ 800 ºC). This has led to a growing interest in intermediate-temperature (≤ 650 ºC) proton-conducting solid oxide cells (p-SOCs) as potential alternatives. In collaboration between Phillips 66 and Georgia Tech, this project aims to achieve a 1 kW p-SOCs system to demonstrate the commercial viability of efficient SOC systems. This report addresses four primary areas and key challenges we overcame: (1) development of efficient and durable proton-conducting electrolyte (e.g., BaHf 0.1 Ce 0.7 Yb 0.2 O 3-δ ) and electrode/catalyst materials, (2) large area cell fabrication (10 x 10 cm 2 ), (3) scalable stack design and building (250 W and 1 kW), and (4) demonstration of a 1 kW prototype system. Notably, significant challenges faced during the large area cell fabrication process were addressed by achieving cell flatness, improving fabrication yield, and ensuring electrode/electrolyte interfacial adhesion. Stack designs were also developed, focusing on reducing contact resistance and optimizing stack components (e.g., sealants). These efforts resulted in the achievement of high performance and durability with promising outputs of 250 W and 1 kW. Furthermore, the integration of these stacks into a fuel-powered system was explored, with refinements made to heat management, as well as to pressure and heating conditions. The results demonstrated the potential applicability of our p-SOC technology in commercial energy storage and power generation systems. Additionally, the report discusses techno-economic analysis and a market transformation plan, aiming to evaluate and advance the commercial feasibility of this technology.

25 ENERGY STORAGE↗
DOE OSTI2024

High-Efficiency Thermoelectric Clothes Dryer (CRADA Final Report)

A typical clothes dryer in the US accounts for 7% of the average residential customer’s electric bill. Nationwide, consumers pay about $\$$9 billion annually for clothes drying. While energy efficiency for most household appliances has improved by a factor of 2 or more in recent decades, today’s clothes dryers perform similarly to units from the 1970s. Dryer efficiency is measured by the combined energy factor (CEF), with today’s units typically drying 3.73 lb of cloth per kWh consumed. An ENERGY STAR qualified unit must achieve 3.93 lb/kWh (for standard size electric units) and dry in less than 80 minutes. ORNL and CRADA partner Samsung Electronics America have developed an efficient prototype clothes dryer that uses thermoelectric heat pumps instead of electric resistance to dry the clothes. The prototype fabricated at ORNL successfully demonstrated in the laboratory a CEF of 6.89 lb/kWh at standard conditions of 75°F and 50% Relative Humidity (RH), exceeding the original project target of 6.0 lb/kWh. Additional trials on the same prototype achieved faster dry time with slightly lower CEF, meeting all requirements for ENERGY STAR product qualification. Deploying dryers with energy factor of 6 nationwide represents a technical potential of 234 TBtu/yr primary energy savings. The modeling and prototype development activities for the thermoelectric clothes dryer under this CRADA are summarized in this final report.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Simulating the Phonon Collection Efficiency in KIPMDs

Kinetic inductance phonon-mediated (KIPM) detectors are superconducting microcalorimeters that use microwave kinetic inductance detectors (MKIDs) to read out phonon signals in the device substrate. In order to improve the design of these detectors, we need to understand the effect of various detector design elements on the physical processes that take place within the detector through simulation efforts. One figure of merit for KIPM detectors is the phonon collection efficiency, $\eta_{ph]$, defined as the ratio of phonon energy detected by the sensitive element in the detector and the energy deposited by incident phonons in the substrate. Comparing the phonon collection efficiency obtained in simulation and in experiment for the same detector geometry provides insight to physical processes in the detector, such as phonon absorption at substrate-sensor interfaces and phonon loss to non-sensitive detector elements. This work models the phonon collection efficiency in two KIPM detectors with different geometries, one located at the Fermi National Accelerator Laboraory, the other located at the SLAC National Accelerator Laboratory.

Dang, Stella Q.↗
DOE OSTI2024

Driving Uptake for Energy Efficiency Financing Programs: Marketing and Outreach, Partnership Networks, and Program Design Considerations

Many energy efficiency financing programs could achieve greater uptake and impact by more effectively recruiting participants. This report examines some of the primary factors that have contributed to high participant uptake among successful financing programs. We review best practices in partnerships (Chapter 2), direct marketing (Chapter 3), and program design (Chapter 4) that facilitate robust participation. This report is primarily designed for state and local governments that have established energy efficiency financing programs or are considering doing so and are seeking insight into how they can ramp up program participation. In disseminating lessons learned from well-established programs that have experienced success in their target markets, the objective is to help scale up the large number of energy efficiency financing programs that seek to replicate these successes. This report can inform states, local governments, and other entities that will establish or expand clean energy financing programs with funding made available under the Infrastructure Investment and Jobs Act and the Inflation Reduction Act.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2024

Impact of Source Geometry on Detector Response Matrix Efficiency: Simulations of the PFUNS-MUSiC Experiments

This work looks at two different bare highly enriched uranium (HEU) systems, configuration one from Measurements of Uranium Subcritical and Critical (MUSiC) and Prompt Fission Uranium Neutron Spectrum (PFUNS) to see the effect geometry has on detector efficiency and the response matrix. The distance from the multiplying source, the medium between the source and detector, and the geometry of the source all play a part in the efficiency of the detector. These factors are especially important when performing spectrum unfolding. Spectrum unfolding is a process used to reconstruct a true spectrum from measured detector response data. It involves interpreting a set of measured values, such as a light signal from a scintillator, to recover the original neutron energy spectrum. This leads to the question, how much will the efficiency of a detector change when you measure a point source compared to an extended source? The distance and solid angle from the source to the detector may be different. It may only be a minuscule change, but in the spectrum unfolding process it can have a considerable effect on the unfolded spectrum

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2024

Improving Efficiency of Off-Road Vehicles by Novel Integration of Electric Machines and Advanced Combustion Engines

Modern off-road equipment will increasingly rely on electrified implements that will deliver precision control with a smaller footprint than hydraulics. The primary energy converter, however, will be an onboard reciprocating internal combustion engine because of the power density of hydrocarbon fuels in comparison to electrical energy storage and the remote locations where much of this equipment is deployed. Adding energy storage and electric machines creates opportunities to improve efficiency while reducing emissions. This program investigated approaches to take advantage of the extra flexibility that an enhanced electrical system to enable high-efficiency, low-emissions combustion technologies. The current program evaluated hybridization of both the torque application and air-handling systems to maximize efficiency while minimizing cost. This program designed, analyzed and tested a hybrid off-road vehicle consisting of a series electric powertrain with energy storage, an electrified air system, and a 33% downsized diesel engine. Detailed comparisons were made between the base powertrain and the developed powertrain using powertrain simulations, engine testing, and vehicle testing. The key results of the study are: • The resulting vehicle reduces fuel consumption by 5% to 15% at equal productivity. The primary improvements were due to recovery of regenerative braking losses for cycles where large transients are encountered. • The electrified air system was an enabler to allow engine downsizing. This was most important for duty-cycles where the engine primarily operated at moderate loads and had few low speed high torque conditions. • Engine level improvements showed re-optimization of the powertrain is possible when electrified air handing is available. Increased exhaust gas recirculation and advanced injection timing allowed up to a 15% reduction in brake specific fuel consumption at equal NOx and transient response. Compared to the larger engine, the downsized engine achieves up to an 18% reduction in brake specific fuel consumption over the non-road transient cycle. • The life cycle analysis and total cost of ownership study showed that the hybrid powertrain has the potential to reduce 5-year CO2 and total cost of ownership by ~6% over the baseline vehicle. The results also indicated that a pure battery electric vehicle is not feasible in this application and is likely to increase the CO2 emissions due to the CO2 from battery production. A hybrid powertrain with low carbon fuels shows the potential to substantially reduce CO2 and total cost of ownership.

02 PETROLEUM↗
DOE OSTI2025

Brochure on the 2024 ASCR Workshop on Energy-Efficient Computing for Science

Large-scale computing has enabled numerous scientific discoveries, including ground-breaking achievements facilitated by the US Department of Energy (DOE) supercomputers and advances in applied mathematics and computer science. While important advances were made in energy efficiency to enable exascale computing, continued efforts are needed to dramatically improve the energy efficiency of the next generation of high-performance computing (HPC) systems and, more broadly, AI data centers. Without substantial improvements in energy efficiency, the energy consumption associated with computing could become a limiting factor for future scientific discovery, national security, and technological advancement.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Carbonate Management to Enable Energy- and Carbon-Efficient CO 2 Electrolysis (Final Technical Report)

The rapid growth and plummeting cost of solar energy have created great interest in using CO 2 electrolysis to produce chemical feedstocks and fuels such as carbon monoxide, ethylene, ethanol, and propanol. While research in CO 2 electrolysis has yielded substantial progress in both fundamental understanding of the requisite electrocatalytic reactions and design of prototype devices, the energy efficiency (electrical energy to-product) and carbon efficiency (CO 2 -to-product) of CO 2 electrolysis remain far too low for large-scale deployment. A preponderance of evidence indicates that the principal reason for these low efficiencies is the rapid and thermodynamically favorable reaction of CO 2 with hydroxide (OH–) to form carbonate , which forces CO 2 electrolysis cells to operate under conditions that result in large voltage and CO 2 losses. This “CO 3 2 – problem” presents a fundamental scientific barrier to creating a viable electrochemical option for converting solar energy into chemicals and fuels.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Design, Fabrication, and testing of Direct Air Capture Sorbent modules to increase understanding of trade-offs in pressure drop and capture efficiency

Conference presentation for the work entitled “Design, Fabrication, and testing of Direct Air Capture Sorbent modules to increase understanding of trade-offs in pressure drop and capture efficiency”. In recent years, there has been a growing interest in Direct Air Capture (DAC) of CO2. This technology is gaining attention as a method to enhance the reduction of atmospheric greenhouse gases (GHGs), particularly when used alongside other decarbonization strategies. The route for efficient and net carbon negative DAC is challenging because CO2 in the atmosphere is highly diluted (~400ppm). This work, utilizing 3D printing capabilities for rapid prototyping, presents application-based findings on the design, fabrication, and testing of DAC module form factors that house solid sorbents. The work leverages an experimental rig that can achieve air throughput and velocities approaching that which are anticipated for commercial scales. The tradeoffs of pressure drop, footprint and capture efficiency are discussed for different orientations of a NETL patented sorbent material.

Riley, Jarrett↗
DOE OSTI2025

Novel Electrowinning Reactor for the Energy-Efficient, Low- Cost Production of Rare Earth Metals

This project developed a novel neodymium (Nd) electrowinning reactor for energy-efficient electrowinning of Nd metal. Throughout this project we have developed an alternative chloride based molten salt electrolysis process. Our process lowers the specific electrical energy consumption compared to the state of the art, while producing reusable chlorine gas and eliminating direct CO2 and PFC emissions. Facilities required for implementing the project were setup and designs were finalized, and a standard operating procedure for safe operation of high temperature electrolysis cells was written. The electrowinning reactor was designed and constructed. Electrolysis experiments confirmed the ability to reproducibly electrowin Nd metal on a Mo cathode. The current efficiency for Nd electrowinning was measured as a function of applied current density in the presence of the separator. Successful electrowinning of Nd sponge at high current densities (200 mA/cm2 and above) at a current efficiency >80% was demonstrated using multiple techniques. Stable Nd electrowinning up to 10h at 250 mA/cm2 was demonstrated. All of these design advancements were used to develop a techno-economic and life cycle assessment model that demonstrated that our process could be operated at cost of less than $0.20/kg-Nd (~30% lower compared to state of the art when comparing electrolysis energy cost) with a >20% total reduction in global warming potential compared to the state of the art while generating no direct CO2 or perfluorocarbon emissions.

42 ENGINEERING↗
DOE OSTI2025

Enhancing the Energy Efficiency of Room Air Conditioners in Malaysia: Opportunities and Impact Analysis

The global room air conditioner (AC) market is rapidly transitioning toward variable-speed units, offering significant opportunities for energy-efficient designs and the adoption of low-global warming potential (GWP) refrigerants. Emerging economies, particularly in regions such as Malaysia, are expected to drive consumer demand for ACs. This report reviews key trends in the Malaysian AC market, including the availability of high-efficient ACs. Currently, variable-speed units account for 30–65% of the market, achieving cooling seasonal performance factor (CSPF) levels of between 5.0 and 6.0. Cost comparisons show that CSPF 5–6-rated, inverter-driven room ACs are competitively priced against lower-efficiency, fixed-speed units.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

Nanosecond Laser Drying in Wafer Foundries for Significant Energy Efficiency Improvement

Surface drying is a critical process in microelectronics wafer fabrication. In order to reduce and eliminate watermarks, many surface drying processes have been studied and used. Most of the wafer foundries currently use drying processes based on Isopropyl Alcohol (IPA), which causes serious safety (fire), health, environmental, and energy efficiency issues. The long-term goal of this project is to develop a fast, effective, chemical-free, and extremely energy efficient wafer drying technology that employs nanosecond laser-induced sub-surface evaporation and explosion. The objectives of this project are to 1) experimentally develop and verify the laser surface drying method, explore and identify how and to what extent various physical parameters influence the drying efficiency and effectiveness; and 2) understand and optimize the underlying thermodynamics in the proposed laser surface drying, including micro/nanoscale sub-surface superheating, evaporation, explosion, and photo/thermochemical bond breaking via atomistic modeling and experimental characterization. Toward these objectives, five tasks have been accomplished successfully, including 1) develop in-lab laser surface drying setup and study the effect of varied laser parameters, 2) use multiscale hybrid-modeling to study and understand the physics of water behavior during drying toward process optimization, 3) investigate the effect of drying conditions on the drying effectiveness, 4) develop a large-scale laser drying scanning system with automatic scanning, and 5) conduct large-scale simulation to study the effect of dopant level and develop strategies for system development toward industry deployment.

42 ENGINEERING↗
DOE OSTI2024

Evaluation of flame propagation of retrofit energy efficient wall assemblies

Leveraging safety science experience and industry relationships, UL Solutions and the International Association of Fire Fighters (IAFF) initiated a joint project in 2022 under an agreement with the US Department of Energy to evaluate the flame propagation of retrofit energy efficient wall assemblies. A draft of the protocol from the ASTM work was used to test and comparatively study various retrofit energy efficient designs to gain a better understanding of their fire behavior. The goals of this study were as follows: Develop an understanding of fire propagation across new, cost effective, and energy efficient exterior retrofit wall assemblies. Refine the flame propagation draft test method for exterior wall assemblies based on ASTM E2707. Identify conditions that create fire propagation hazards in exterior wall assemblies and educate the fire service on the findings.

42 ENGINEERING↗
DOE OSTI2024

Scalable and Highly-Efficient Microbial Electrochemical Reactor for Hydrogen Generation from Wastes

The overall goal of this project was to develop a scalable and highly efficient hybrid microbial electrochemical reactor for hydrogen recovery from waste streams at a cost of less than $\$$2/kg H₂. The specific objectives were: (1) to design and fabricate a scalable and highly efficient microbial electrochemical cell (MEC) reactor, and (2) to determine the techno-economic feasibility of the system for H₂ generation from organic-rich waste streams. We achieved the first objective by (a) developing low-cost electrode materials, (b) synthesizing a highly efficient cathode catalyst in a scalable manner, (c) evaluating and validating the developed electrode material and catalyst in MEC reactors, and (d) designing and fabricating a larger reactor that incorporates (a) to (c). We met the second objective by (a) identifying the impacts of wastewater composition and operational conditions on H₂ production, and (b) developing a cost-performance model that identified critical parameters affecting the system's performance and cost, providing a pathway for further improvement.

08 HYDROGEN↗
DOE OSTI2025

Multiplexing Focusing Analyzer for Efficient Stress-Strain Measurements

Statement of the problem or situation that is being addressed. Although thermal and cold neutron scattering is widely used and is critical for success in many areas of materials science and engineering, relatively low neutron fluxes severely limit applications of not only laboratory neutrons generators, but also large national neutron facilities. State-of-the-art thermal and cold neutron sources are large expensive national facilities, which serve diverse community of scientific and industrial users. The constant need to improve the instruments performance, stems from the fact that neutron methods are gaining in popularity, and becoming more and more powerful, while new neutron sources are not being constructed to keep pace with the developments and needs of the scientific community. Small research reactors at universities and National Labs, and laboratory-based neutron generators, are necessary not only for education and training, but also when samples cannot be transported to other facilities. However, the standard neutron techniques, which were developed for high-flux facilities, require much higher efficiencies to be used effectively with the low fluxes of small sources. Thus, the efficient use of neutron sources, such as with our proposed analyzer, is important for the progress and broader use of these neutron techniques. General statement of how this problem is being addressed. We propose to design and demonstrate novel diffractive optical device, which will enable very efficient residual stress neutron diffractometers. The proposed device will be a multi-foil analyzer, where each foil is constructed of focusing bent single crystals of Si. Such device will enable polychromatic residual stress neutron diffraction. At large national facilities, such as at Oak Ridge National Laboratory, these analyzers would enable very fast measurements for determining residual stress tensors, raster large samples or screen multiple samples. Commercial Applications and Other Benefits The outcome of this project would be the demonstration of commercial devices, novel neutron optical components, which could be utilized to improve the performance of existing instruments or build novel neutron scattering instruments at DOE neutron facilities and commercial laboratory neutron sources. These new devices will widen the scope of research conducted using neutrons and enable measurements not feasible at present. Summary for Members of Congress Thermal and cold neutron beams are a powerful materials science probe, which provide unique information about the structure of matter. The proposed innovations expand the reach of neutron-based investigations to new materials and industries by enabling new instrumentation capabilities, thereby greatly enhancing and expanding the role of small, laboratory-based neutron instrumentation, and improving education and training of neutron users.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2025

Integrated Radio Frequency and Ultrasonics with Conventional Processes for Efficient Water Removal in Pulp and Paper and Other Biomaterial Applications

Conventional drying processes used in the pulp and paper industry primarily involve lengthy, surface based, multi-cylinder conductive and convective drying with low thermal efficiencies and often use some fossil-based energy. Integration of cross cutting, electrically-powered, volumetric drying process intensification technologies based on Radio Frequency (RF) and acoustics (Ultrasonics) (US) will directly impart energy into the biomaterials resulting in improved energy efficiency and throughput. Integration of RFUS-based drying technology is expected to enable U.S. manufacturing industry to reduce capital and operating costs, energy consumption, and carbon emissions while increasing energy efficiency and throughput, improving product quality and sustainability, and helping preserve U.S. manufacturing jobs. The hybrid drying approach incorporates directed radio frequency (RF) and ultrasonic (US) energy with conventional conduction, diffusion and convective heat and mass transfer overcoming the limitations of the conventional drying processes and that meets/exceeds the minimum goals. We have shown the effective removal of free and bound water in the biomaterials by leveraging the synergies of RF and US technologies integrated with conventional manufacturing processes.

42 ENGINEERING↗