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2020 Hydrogen and Fuel Cell Technologies Market Report

This report features summaries of relevant hydrogen and fuel cell activity in 2020, consistent with prior annual reports across applications and sectors. However, 2020 was no ordinary year. Despite pandemic hardships, the hydrogen and fuel cell industry not only stepped up to assist with humanitarian and healthcare efforts but saw continued momentum in several growing market sectors with numerous partnerships, initiatives, and investments. Using hydrogen and fuel cell technologies to provide an environmental and economic pathway to clean, reliable power was a key feature of world economic recovery and energy infrastructure plans. Today, hydrogen energy and fuel cell systems are being developed and deployed in a range of stationary power, portable power, and transportation applications around the world. Throughout 2020, there were significant achievements in each sector, building on years of research and development (R&D), field testing, large-scale demonstration projects, and real-world customer experience. The heavy-duty truck market in particular continued to make substantial gains, with new players entering the space and a coalition of companies pledging to produce and deploy more than 100,000 fuel cell trucks in the next two decades. To provide hydrogen for trucks and other end users, larger and larger electrolyzer projects were announced throughout the year. Collectively, there were more than 430 megawatts (MW) of electrolyzer systems either deployed, ordered, or proposed around the world. This 2020 report also provides special “Spotlights” on the collective industry response to the COVID-19 pandemic as well as international commitments and hydrogen strategies, providing overviews of significant activity during and after the initial onset of COVID-19 around the world.

08 HYDROGEN↗

Consensus International Solar Resource Standards and Best Practices Development: Preprint

Standardization and best practices of data sets and models enable the industry to develop widely accepted protocols for various stages of solar project development and operations. In collaboration with the International Energy Agency Photovoltaic Power Systems Programme Task 16, the National Renewable Energy Laboratory (NREL) developed and regularly updates the Best Practices Handbook for the Collection and Use of Solar Resource Data for Solar Energy Applications. In collaboration with ASTM members on the radiometry subcommittee, NREL assists in and leads the development of radiometric standards that contribute to increased accuracy in the measurement of solar resources available to conversion systems and to the development and improvement of models. These models can then provide long-term geographic distribution of solar resources for areas where measured solar data are not available. Further, these standards play a preeminent role in all aspects of solar energy projects, including standard conditions, methods and instrumentation, accelerated testing, and service lifetime of materials.

41 EE - Solar Energy Technologies Office (EE-4S)↗

Deep Cyber-Physical Situational Awareness for Energy Systems: A Secure Foundation for Next-Generation Energy Management

This document provides the final report for the CYPRES project. The purpose is (1) to highlight and summarize its major accomplishments and (2) to provide guidance on how its outcomes have informed and can inform important additional research and technology transfer. The goal of CYPRES was the research, development, and demonstration of a security-oriented next generation cyber-physical EMS for electric power systems that detects malicious and abnormal events through the fusion of cyber and physical data. To achieve this, the CYPRES project team researched, developed, and built a prototype of the solution, referred to as the CYPRES EMS. The CYPRES EMS is a proof-of-concept cyber-physical platform that demonstrates the management of the energy system, communications, security, and cyber-physical grid modeling and analytics. As part of the capabilities of the CYPRES EMS, the team designed and developed a suite of power system applications for monitoring, risk analyses, detection, and control that are inherently cyberaware. At its core, the project aimed to research, develop, and demonstrate a security-oriented next-generation cyber-physical Energy Management System (EMS) capable of detecting malicious and abnormal events through the innovative fusion of cyber and physical data. This approach represents a fundamental shift from traditional EMS, reimagining how critical infrastructure can be protected through unified cyber-aware and physics-aware secure data flow pipelines. The project’s cornerstone deliverable, the CYPRES EMS, serves as a proof-of-concept cyber-physical platform that revolutionizes the management of energy systems, communications, security, and cyber-physical grid modeling and analytics. This prototype implements a comprehensive suite of power system applications for monitoring, risk analyses, detection, and control, all designed with inherent cyber awareness. The system’s architecture extends from end-devices in the field through to control center applications, establishing a secure and resilient control framework that addresses the challenges posed by diverse devices of unknown trustworthiness connecting to modern power systems. Through this innovative approach to deep cyber-physical situational awareness, the CYPRES project not only advances the state-of-the-art in energy infrastructure protection but also establishes a new paradigm for how EMS can be designed, deployed, and operated in an increasingly complex threat landscape. The findings and developments from this project provide crucial insights for stakeholders across the energy sector, offering a blueprint for enhancing the reliability and resilience of our nation’s critical energy infrastructure in the face of evolving cyber threats.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Proactive Posturing of Large Power Grid for Mitigating Hurricane Impacts

In the past decade, natural disasters such as hurricanes have challenged the operation and control of U.S. power grid more. It is crucial to develop proactive strategies to assist grid operators for better emergency response and minimized electricity service interruptions. In this paper, we propose a proactive posturing methodology of power system elements, and formulated a Security-Constrained Optimal Power Flow (SCOPF) that informed by cross-domain hurricane modeling and its potential impacts on the grid elements. Simulation results based on real-world power grid and historical hurricane event validated the applicability of the proposed optimization formulation, and show potential to enable grid operators and planners with interactive cross-domain data analytics in mitigating hurricane impacts.

power system emergency response, security constrai↗

SO3/H2SO4 continuous real-time sensor demonstration at a power plant

We present results from field testing of a new, innovative sensor developed to measure SO3/H2SO4 continuously and in real time at a coal-fired power plant. The system utilizes the sensitivity, specificity, and real-time capabilities of mid-infrared (Mid-IR) laser-based sensor technology, along with a heated, close-coupled cell mounted directly to a power plant duct. Measurements were made by the laser sensor over a 2-day period and compared to results from the accepted method, EPA 8A, which requires a 30-minute collection, labor intensive processing, and off-site analysis at a lab. In contrast to the condensation method, the laser sensor continuously samples flue gas and reports measurements of the concentration of SO3/H2SO4, SO2 ever second with unattended operation. This initial demonstration proved the sensor concept and paves the way for its use for optimizing sorbent injection used to neutralize SO3/H2SO4. Optimized sorbent injection will enable significant cost savings associated with efforts to mitigate the presence and effects of SO3/H2SO4 such as “Blue Plume”, air heater fouling, and duct corrosion. In particular, the real-time, actionable information will enable better control of additive injection in flex conditions and variable fuels.

20 FOSSIL-FUELED POWER PLANTS↗

Advancement of hybrid fluid-kinetic modeling for HEDP and ICF science

We report on the development progress of a hybrid fluid-kinetic code for simulating fluids and plasmas in a wide range of environments, such as laser–matter interactions, inertial confinement fusion, magnetic confinement fusion, and pulsed power. The suite of numerical tools under development utilizes heterogeneous computer architectures and leverages the benefits of particle–based simulation techniques. By working to combine the kinetic particle-in-cell (PIC) model with a particle-based fluid simulation technique, such as smoothed particle hydrodynamics, we are developing a flexible framework capable of accurately modeling complex flows within and between kinetic and fluid regimes. The TriForce code is under development as a C++ framework for parallel, 3D, particle-based, hybrid fluid-kinetic plasma simulations. The fluid half of TriForce will be based upon the meshless smoothed-particle-hydrodynamics (SPH) approach, well-suited for shear, mixing, and turbulence, whereas the kinetic half resembles a traditional particle-in-cell (PIC) code; other particle-based approaches to fluid modeling that do use a mesh are also possible to use and are under investigation. Maxwell’s electromagnetic field equations are solved either via explicit or implicit algorithms or approximated via resistive magnetohydrodynamics (MHD) using an Ohm’s law and resulting induction equation (extended MHD is under development). A primary goal of enabling direct comparisons, from the same code, between results from the variants of MHD and implicit electromagnetic solutions is to improve our fundamental understanding of systems with magnetic fields. The code is under development to recover results from both radiation-MHD and fully kinetic codes in those limits, and is continuing to be developed from other follow-on grants to operate in between where both descriptions may co-exist and interact. For certain applications, it is desired for a simulation to contain fluid ions and electrons as well as kinetic ions and electrons. Typically, it is too computationally intensive to model a full-scale ICF or HEDP experiment fully kinetically since many cycles are expended with very small time steps on modeling the fluid part of a material that is well treated by the fluid approximation. In this case, many traditional PIC particles can be replaced with a single fluid particle representing the thermal part of the distribution function, and there are fewer needed kinetic particles, which describe the non-thermal part and can be sub-cycled relative to the fluid particle advance. Furthermore, a pure fluid code may, depending on the problem, simply lack many physically important details that are beyond the scope of its reduced approximations and assumptions. In this report, we summarize the objectives achieved in the development of the collisional and kinetic half of the code, and the physics problems to which the code has been applied in the areas of advanced and innovative fusion concepts, pulsed power, and magneto-inertial fusion.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Methods and system for siting advanced nuclear reactors and evaluating energy policy concerns

There is a growing sociopolitical desire to develop cleaner energy sources in the United States and maintain energy security. Regardless of politics, many coal-fired electric plants have already been shut down and many utilities are vowing to retire their current coal-fired assets within the next two decades. Replacement power assets require consideration of appropriate siting. A geographic information system (GIS)-based multicriteria decision analysis approach is useful to assist utility and energy companies, as well as policymakers, to evaluate potential areas for siting new plants in the contiguous United States. A GIS-based framework is simply a database of location information that allows for mapping, querying, modeling, and analyzing data based on location. The spatial output can be structured to be visual, allowing for easier analysis of location data. The need to site additional power assets, including renewable resources and clean power sources, such as nuclear, led to the development of the Oak Ridge Siting Analysis for power Generation Expansion (OR-SAGE) tool discussed in this paper. The tool takes inputs such as population growth, water availability, environmental indicators, and tectonic and geological hazards to provide an in-depth visual analysis for siting options. Energy companies and other stakeholders can use OR-SAGE to procure feedback quickly and effectively on land suitability based on technology specific inputs. Policymakers can use OR-SAGE to analyze the impacts of future energy technology decisions, while balancing competing resource use. Overall, this paper discusses the recent use of OR-SAGE for these purposes and plans for future development.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Feasibility of using nuclear microreactor process heat for bioconversion and agricultural processes

Introduction There is a global goal to reduce greenhouse gas emissions by 43% by 2023. Nuclear microreactors, a subset of small modular reactors, offer a potential solution due to their compact size, transportability, and carbon-neutral power generation capabilities. Methods This study explores the feasibility of using heat from nuclear microreactors for bioconversion and agricultural processes, including transforming biomass into energy carriers and products such as syngas, bio-oil, and pasteurized milk. Operating requirements for gasification, pyrolysis, hydrothermal carbonization, hydrothermal liquefaction, hydrothermal gasification, ethanol production, anaerobic digestion, and pasteurization were obtained through a literature review. A Brayton cycle model based on the eVinci TM microreactor was developed to assess the feasibility of powering these processes using nuclear microreactor heat. Results and Discussion Exergetic efficiency values for high-temperature processes ranged from 72% to 100%, whereas lower-temperature processes ranged from 2% to 53%. These efficiencies depend on the available source temperature for each microreactor design. There were trade-offs between producing net power and using process heat, particularly for high-temperature processes. Three heat exchanger locations were considered: before the turbine (600 ℃ ), between the turbine and regenerator (370 ℃ ), and after the regenerator (192 ℃ ). High-temperature processes like gasification require temperatures too high for feasibility. Middle temperature processes are better suited to a heat exchanger between the turbine and regenerator, while also operable before the turbine. Lower-temperature processes like pasteurization and anaerobic digestion can use waste heat after the regenerator and do not impact power production. These findings are valuable for optimizing nuclear microreactor heat use and aligning with global climate initiatives.

09 BIOMASS FUELS↗

A modeling pipeline to relate municipal wastewater surveillance and regional public health data

As COVID-19 becomes endemic, public health departments require improved passive indicators, which are independent of voluntary testing data, to estimate the prevalence of COVID-19 in local communities. Quantification of SARS-CoV-2 RNA from wastewater has the potential to be a powerful passive indicator. However, connecting measured SARS-CoV-2 RNA to community prevalence is challenging. We have developed a generalized methodology to improve the predictive power of wastewater measurements and applied it to data collected from treatment plants in the Chicago area. We built and compared a set of multi-linear regression models, which incorporate pepper mild mottle virus (PMMoV) as a population biomarker, Bovine coronavirus (BCoV) as a recovery control, and wastewater system flow rate into a corrected estimate for SARS-CoV-2 RNA concentration. For our data, models with BCoV performed better than those with PMMoV, but all model estimates of prevalence significantly improved correlation compared to doing no correction. We also investigate the utility of RNA measurements in wastewater as a leading indicator of COVID-19 trends. We do this in a rolling manner for corrected wastewater data and for other prevalence indicators, and statistically compare the temporal relationship between new increases in the wastewater data and those in other prevalence indicators. We find that wastewater trends often lead other COVID-19 indicators in predicting new surges.

60 APPLIED LIFE SCIENCES↗

A Persistence Meter for Nimble Alarming Using Ambient Synchrophasor Data

Persistent oscillations in the power grid are often indicative of fragility, and may be harbingers of systemic or cascading failures. Modernization of the grid, including increased penetration of intermittent renewables and integration of new power electronics, is making the oscillatory swing dynamics of the network both more complex and variable. In this project researchers from the University of Wisconsin-Madison (Bernard Lesieutre, lead), Washington State University (Sandip Roy, lead), and the Electric Power Group (Neeraj Nayak, lead) have developed technologies that monitor persistent oscillations in the grid and provide operators with alarms and analytics when concerning oscillations are detected. Some of the algorithms have already been implemented in EPG’s PGDA software and integrated into their RTDMS system for use in control rooms.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Deployment of Advanced Electroanalytical Sensors in the Kairos Power Engineering Test Unit (ETU) (Final CRADA Report)

This document serves as a summary report for the work conducted under CRADA 2022-22119 between Argonne National Laboratory and Kairos Power LLC. As part of this project, Argonne and Kairos worked to develop an advanced electrochemical system and testing protocol for the Kairos Power Enineering Test Unit (ETU), an industrial scale 14 ton molten FLiBe salt system. The main goals were (1) measurements of fundamental properties for key salt species, (2) the deployment and operations of sensors in the ETU, and (3) the development of automated approaches to analyze the measurements.

42 ENGINEERING↗

2020 Component Innovation Awardee: Windurance LLC

Currently, there is no wind system power-conversion component available to wind turbine OEMs that is certified to applicable standards for use in the U.S. distributed wind energy market. Off-the-shelf industrial drives have features that are not needed by distributed wind OEMs and lack other features that would be valuable for the operation and control of wind turbine generating systems. In addition to adding costs for OEMs, these industrial drives increase uncertainty and risk for project developers and prospective owners. All of this presents barriers and increases costs for the development of distributed wind in the United States. With funding from CIP, Windurance plans to develop an industry-specific power-conversion component that will offer application-specific features at lower cost for distributed wind OEMs.

CIP↗

Techno-Economic Analysis of Natural Gas Fuel Cell Plant Configurations

The United States (U.S.) Department of Energy (DOE) Office of Fossil Energy and Carbon Management (FECM) and the National Energy Technology Laboratory (NETL) have been pursuing the development of solid oxide fuel cell (SOFC) technology to enable future power generation systems that are consistent with the cornerstones of the DOE mission—to ensure America’s security and prosperity by addressing its energy and environmental challenges through transformative science and technology solutions. The U.S. DOE FECM SOFC Program is currently focused on the development of low-cost, highly efficient, and reliable SOFC power systems. NETL’s SOFC technology development roadmap is aligned with near-term market opportunities in the distributed generation sector to validate and advance the technology while paving the way for utility-scale (> 50 MW) natural gas and coal-derived synthesis gas-fueled applications via progressively larger system demonstrations. The present study represents a part of a series of system evaluations being developed at NETL to aid in prioritizing technological advances along research pathways to the realization of utility-scale SOFC systems, a transformational goal of the fuel cell program. In particular, the system performance of utility-scale natural gas fuel cell (NGFC) systems with and without carbon dioxide (CO 2 ) capture is presented. The objective of the study is to provide targeted research and development (R&D) guidance to the FECM SOFC Program and SOFC commercial developers to accelerate technology deployment.

03 NATURAL GAS↗

High operating temperature heat transfer fluids for solar thermal power generation. Final report

This is the final technical report for the DOE MURI project on developing high-operating temperature heat transfer fluids for solar thermal power generation. This project aimed to evaluate liquid metals as a heat-transport fluid and potential energy storage medium for concentrated solar powered (CSP) systems. The project consisted of five phases, starting with fluid selection and screen and ending with potential CSP integration. The initial fluid selection arrived at heavy liquid metals as candidate fluids such as lead bismuth eutectic (LBE) as the prime liquid-alloy candidate to be studied, given the conditions above. Fifty-seven liquid compositions were initially identified with liquidus temperatures lower than 200°C, composed of elements that provide no driving force to the reduction of Cr 2 O 3 or Al 2 O 3 passivation layers in pipe material which is required for corrosion prevention. LBE was identified as the primary candidate fluid after these compositions were compared against computational thermodynamic modeling to screen all of the selected systems that would be compatible with our design objectives. Twenty-eight of these compositions were also investigated with the rapid characterization methods; the accuracies of the liquidus temperature and the specific heats predicted by the computations were better than 3 percent and 9 percent, respectively. We conducted numerus corrosion tests of various Fe-Cr-Al based steels in LBE and its variants at temperate as high as 800°C. It was found that minor additions to the liquid did not provide sufficient corrosion protection to warrant their use in real applications. Furthermore, we investigated the detailed mechanism of corrosion between heavy liquid metal and the pipe material at these very high temperatures. A liquid metal loop was constructed to operate at these high temperatures. The loop construction and operation lead to valuable lessons learned that will be needed for industrial scale loops. Furthermore, we learned that electromagnetic pumps at these extreme temperatures will have to be reengineered and redesigned to be used for CSP applications.

14 SOLAR ENERGY↗

Vascular Carbon/Carbon composites for concentrated solar power

Due to their exceptional mechanical and thermal properties under high temperature conditions, for the first time, a novel vascular (embedded channels) Carbon/Carbon (C/C) composite was developed for use as a modular concentrated solar power (CSP) gas receiver. The fabrication process involves the combination of the vaporization of sacrificial component (VaSC) technique with conventional methods to produce C/C composites with well preserved channels. Different heat treatments were evaluated together with X-ray diffraction (XRD) analysis to determine optimal fabrication conditions that maintains the material and channel’s integrity. Mechanical testing confirms that structural integrity is maintained, with statistical analyses indicating no compromise in flexural strength or modulus. Furthermore, this research introduces an innovative pathway for efficient CSP gas receivers, which can bridge the gap towards improved energy generation efficiency in next-gen CSP plants through higher operating temperatures with the use of C/C composites.

14 SOLAR ENERGY↗

Variable Renewable Energy Grid Integration Studies: A Guidebook for Practitioners

This guidebook provides power system planners with a brief but comprehensive summary of the strategies, best practices, and terminology associated with conducting a high-impact grid integration study. The objective is to provide practical guidance to teams that are in the initial stages of designing a grid integration study effort. Though this guidance is broadly applicable to most power systems, it emphasizes considerations relevant to developing economies, drawing on experiences from efforts by the United States Agency for International Development (USAID) to support this type of analysis with its partner countries.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Restoration Hydro: A Watershed Approach to Standard Modular New Hydropower

The objectives of FOA DE- FOA-0001836- “Standard Modular Hydropower” included designing a standardized, modular, and environmentally compatible hydropower schematic for implementation in greenfield sites that generate up to 10 MW of capacity. Utilizing funds competitively awarded under DOE’s Water Power Technologies Office, the Natel Energy team developed a concept for modular new stream reach (NSR) hydropower that incorporates multi species upstream and downstream fish passage, improved river channel connectivity, and recreational modules. The in-stream design of the collective modules minimized site specific design and maximized the opportunities for modularity. Financial data was also presented using actual costs from regional suppliers, with figures provided in 2022 dollars. While the project team did not address potential permitting process improvements, the site selection criteria did consider established barriers to hydropower development such as tribal and preserved lands, interconnection proximity, and endangered species to exclude or deprioritize. The project’s design schematic met the objectives of the FOA, and presented a unique solution that targets alluvial pockets as natural features for sustainable development. Natel’s concept also incorporated the company's fish-safe Restoration Hydro Turbine for safe downstream passage, while featuring a rock arch that integrates fish passage, water, recreation, and grade control modules (including sediment). Alignment with the Department of Energy Office of Energy Efficiency and Renewable Energy (EERE) “Innovative Design Concepts for Standard Modular Hydropower and Pumped-Storage Hydropower” Program: According to the Hydropower Vision (DOE, 2016), approximately 16 GW of hydropower growth is possible with the development of technology solutions that balance efficiency, economics, and environmental sustainability. The desired outcome of the SMH program is transformational innovation specifically in the site identification, conceptual, and detailed design phases of technology development lifecycles (DOE, 2018). In developing the SMH design schematic, the team aimed to address the opportunities outlined in the Vision through an inverted design philosophy; rather than singularly prioritizing efficiency and power production, the team focused on integrating hydropower with restoration of degraded streams to optimal ecosystem function and provision of exceptional recreation value as design criteria. To achieve this, Restoration Hydro incorporates the principles of nature-based engineering (WWAP, 2018) and biomimicry (Biomimicry NL.) to strategically deploy complementary combinations of permanent, semi-permanent, and ephemeral low-head structures - such as natural and engineered log jams - that harness geomorphological and hydrological processes at the landscape-scale. Primary applications of Restoration Hydro include: 1) restoration of degraded watersheds’ natural ecological function and enhancement of hydrological connectivity; and 2) creation of associated co-benefits to hydro production, including increased groundwater recharge, improved sediment transport and management, improved water security and water quality. Restoration Hydro projects build upon proven watershed restoration engineering techniques by integrating hydropower turbines into low-head structures using innovative and evolving civil works concepts that facilitate fish and sediment passage, and in some cases create additional revenue-generating recreational opportunities. Powering low-head structures creates a directly monetizable layer of economic value in the form of flexible, reliable, renewable energy on top of the already high-value water, environmental and recreational benefits of watershed and river restoration. The approach aims to create a virtuous, self-reinforcing cycle whereby Restoration Hydro projects support the scaling of ecosystem restoration activities, creating a water-energy-carbon multiplier effect that, through the principles of adaptive change management: 1) improves the resilience of landscapes and downstream population centers for changing hydrological cycles; 2) creates a reliable energy resource that facilitates the integration of intermittent renewable power sources into grids; and 3) supports climate change mitigation through grid decarbonization and enhanced ecosystem carbon capture and retention.

13 HYDRO ENERGY↗