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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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At least 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Effectiveness of Residue and Tillage Management on Runoff Pollutant Reduction from Agricultural Areas

Highlights No-till and no-till residue systems were effective in reducing runoff particulate and total nutrients but increased dissolved nutrients. Maintaining >30% residue cover reduced most runoff constituents, irrespective of no-till or tillage. No-till-residue prevented runoff nutrient losses and benefitted farm revenue by avoiding tillage. Abstract. Reduced tillage management conservation practices (No-till and Reduced-till) are widely adopted in agriculture; however, understanding their overall effectiveness for water quality protection is challenging. A meta-analysis was conducted to understand and quantify the effectiveness of residue and tillage management on runoff, sediment, and nutrient losses from agricultural fields. Annual runoff and the associated sediment, and nutrient (nitrogen and phosphorus) loads were compiled from 60 peer reviewed research articles published across the United States and Canada. A total of 1575 site-years of data were categorized into tillage (<30% surface cover), no-tillage (<30% surface cover), tillage with residue (>30% surface cover), no-tillage with residue (>30% surface cover), and pasture management. No-tillage, no-tillage-residue, and tillage-residue managements were evaluated for their effectiveness in reducing runoff, nutrients, and sediment loads compared to tillage. Synthesized and surveyed corn yield data were used to evaluate the economic cost effectiveness of no-tillage-residue management with respect to tillage. Across the site years (1968-2019) studied, median runoff depth for no-tillage and no-tillage-residue were 84% and 70% greater than tillage and tillage-residue management, respectively. No-tillage-residue management had up to 86% less sediment losses than tillage systems, on average, for both >30% and <30% surface cover. No-tillage-residue management was most effective, with a positive performance effectiveness of 65% to 90% in controlling sediments, particulate, and total nutrient losses in runoff compared to tillage. Cost effectiveness analysis revealed the benefits of no-tillage-residue management in reducing nutrient loads and increasing net-farm revenue by avoiding tillage operational costs. Except for dissolved phosphorus, no-tillage-residue management cost effectiveness for sediments and nutrient loads ranged from negative $6 to negative $102 per every Mg or kg of load reduction, indicating it had both economic and environmental benefits compared to tillage management. Overall, these results indicate that over the long-term, no-tillage and tillage, combined with greater than 30% residue cover, can effectively reduce sediment and nutrient losses. This work highlights the importance of crop residues on the soil surface to reduce runoff losses, even in no-tillage systems. Keywords: Conservation tillage, No-tillage, Residue cover, Tillage, Water quality.

Agriculture↗
DOE OSTI2021

IDAES Enterprise: Generation Expansion Planning with Enhanced Requirements for Capacity Adequacy Under Renewable Intermittency

Achieving net zero carbon emissions likely requires future power systems to integrate new, flexible energy technologies to accommodate higher levels of capacity from variable renewable energy sources. To determine the optimal deployment of new electricity capacity and to study the likelihood of deployments of new energy technologies, an expansion planning model has been developed as part of the IDAES-Enterprise suite of grid models. The Generation Expansion Planning (GEP) model is a multi-period model in which investment decisions occur yearly, and a Unit Commitment (UC) problem is examined on an hourly timescale. To reduce computational complexity of the GEP model, the UC problem is solved for average “representative days” which leaves out extreme, but relatively common, scenarios in which low renewable generation occurs, leaving the system with inadequacy in capacity. The IDAES-Enterprise GEP model has been modified to include these extreme scenarios while keeping the model reasonably tractable. Specifically, a lazy constraint technique was implemented to check for capacity adequacy on an hourly basis over a large data set of aligned load-wind-solar profiles. As a vast majority of the capacity constraints will not be violated, the technique lowers computational expense by searching for violated capacity constraints over an “iterative manner,” adding those infeasible constraints back into the model. Results on a test case of the Southwest Power Pool shows that the lazy constraint technique significantly reduces retirements and increases installments of natural gas combined cycles and flexible natural gas units. It also reduces some retirements of coal units. These modifications provide a more reasonable estimation of required dispatchable power generation capacity to ensure feasibility during peak net load.

Liu, Peng↗
DOE OSTI2022

Integrating Concentrating Solar Power Technologies into the Hybrid Optimization and Performance Platform (HOPP)

As the world increases renewable energy deployment, there is an increasing interest in hybridizing various generation and storage technologies to maximize net benefit to the developer and/or off-taker. A particularly interesting combination of renewable technologies is concentrating solar power (CSP) with thermal energy storage (TES), photovoltaics (PV), and electrochemical battery energy storage (BESS). Due to the system complexity of CSP technology, it is difficult to evaluate the technological and financial performance of a CSP-PV hybrid system without detailed modeling of annual operations. To address this challenge, we have developed a modeling framework for evaluating the performance and financial viability of CSP systems hybridized with PV and battery technologies. This modeling effort incorporates CSP tower and trough systems into an existing modeling tool recently developed by NREL referred to as the Hybrid Optimization and Performance Platform (HOPP). This report outlines the modeling methodology as well as preliminary results from example case studies conducted using the model. The methodology describes: (i) the integration of CSP tower and troughs into HOPP using python interfaces to access System Advisor Model (SAM) underlining technology models, (ii) the mathematical formulation of the mixed integer linear program dispatch optimization model which optimizes operations of storage asset to either maximize system revenue or minimize operating cost while load following, (iii) the design analysis methods implemented within HOPP, and (iv) simulation clustering for the purposes of reducing computational expense. We exercise the model using a case study of a future scenario where we assume (i) CSP and PV technologies achieve the 2030 cost targets provided by the Solar Energy Technologies Office (SETO), (ii) battery costs reduce to the 2030 mid cost projection presented by NREL. Lastly, (iii) electricity prices for southern California in 2030 are provided by NREL's Cambium database, and (iv) a capacity payment of $150/kW-yr based on the system capacity factor during the to 100 net-load hours.

14 SOLAR ENERGY↗
DOE OSTI2026

LAF-Net: A Deep Residual and Cross-Attention Framework for Day-Ahead Load Forecasting: Preprint

Accurate day-ahead load forecasting is essential for reliable power system operations and market efficiency. System operators such as the Midcontinent Independent System Operator (MISO) rely on forecasts from multiple vendors, yet combining them effectively remains a persistent challenge due to vendor-specific biases. This paper presents a novel LSTM-Attention Fusion Network with Error Representation (LAF-Net) that enhances day-ahead hourly load forecasting through deep residual learning and multi-modal cross-attention. The proposed model builds a historical error memory from past vendor performance and dynamically queries it with future hour context to generate adaptive, hour-specific trust weights for each vendor. A bounded residual correction further refines forecasts by mitigating systematic and temporally localized errors. Tested on real MISO LBA data with multi-vendor forecasts, LAF-Net consistently outperforms the best vendor baseline across all 38 LBAs, achieving more than a 40% reduction in system-level mean absolute error (MAE) during peak load hours relative to the best vendor baseline.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2022

The Role of Regional Connections in Planning for Future Power System Operations Under Climate Extremes

Identifying the sensitivity of future power systems to climate extremes must consider the concurrent effects of changing climate and evolving power systems. We investigated the sensitivity of a Western U.S. power system to isolated and combined heat and drought when it has low (5%) and moderate (31%) variable renewable energy shares, representing historic and future systems. We used an electricity operational model combined with a model of historically extreme drought (for hydropower and freshwater-reliant thermoelectric generators) over the Western U.S. and a synthetic, regionally extreme heat event in Southern California (for thermoelectric generators and electricity load). We found that the drought has the highest impact on summertime production cost (+10% to +12%), while temperature-based deratings have minimal effect (at most +1%). The Southern California heat wave scenario impacting load increases summertime regional net imports to Southern California by 10-14%, while the drought decreases them by 6-12%. Combined heat and drought conditions have a moderate effect on imports to Southern California (-2%) in the historic system and a stronger effect (+8%) in the future system. Southern California dependence on other regions decreases in the summertime with the moderate increase in variable renewable energy (-34% imports), but hourly peak regional imports are maintained under those infrastructure changes. By combining synthetic and historically driven conditions to test two infrastructures, we consolidate the importance of considering compounded heat wave and drought in planning studies and suggest that region-to-region energy transfers during peak periods are key to optimal operations under climate extremes.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2023

Ducted Fuel Injection Provides Consistently Lower Soot Emissions in Sweep to Full-Load Conditions

Earlier studies have proven how ducted fuel injection (DFI) substantially reduces soot for low- and mid-load conditions in heavy-duty engines, without significant adverse effects on other emissions. Nevertheless, no comprehensive DFI study exists showing soot reductions at high- and full-load conditions. This study investigated DFI in a single-cylinder, 1.7-L, optical engine from low- to full-load conditions with a low-net-carbon fuel consisting of 80% renewable diesel and 20% biodiesel. Over the tested load range, DFI reduced engine-out soot by 38.1–63.1% compared to conventional diesel combustion (CDC). This soot reduction occurred without significant detrimental effects on other emission types. Thus, DFI reduced the severity of the soot–NO x tradeoff at all tested conditions. While DFI delivered considerable soot reductions in thepresent study, previous DFI studies at low- and mid-load conditions delivered larger soot reductions (>90%) compared to CDC operation at the same conditions. Therefore, the DFI configuration used here has been deemed nonoptimal (in terms of parameters such as the injector-spray and piston geometries), and several improvements are recommended for future studies with high-load DFI. Further, these improvements include employing better spray-duct alignment, a deeper piston bowl with a smaller injector umbrella angle, and a fuel injector that opens and closes faster. The study also suggests future research to make DFI ready for commercialization, such as metal-engine tests to ensure desirable DFI performance over an engine’s complete speed/load map. Overall, this study supports the continued development and commercialization of DFI to meet upcoming emissions regulations for heavy-duty vehicles. Specifically, multicylinder engine experiments and CFD simulations should be utilized to optimize the performance and clarify the full potential of DFI.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

Infinitely rugged intra-cage potential energy landscape in metallic glasses caused by many-body interaction

The absence of translational symmetry in glassy materials poses a significant challenge in establishing effective structure-property relationships in real space. Consequently, the potential energy landscape (PEL) in phase space is widely utilized to comprehend the complex phenomena in glasses. The classical PEL features a two-scale profile comprising mega-basins and sub-basins, corresponding to α-relaxations (e.g. glass transition) and β-relaxations (e.g. local cage-breaking atomic rearrangements), respectively. Recent studies, however, reveal that sub-basins are not smooth and contain finer structures, the origins of which remain elusive. Here we probe the smoothness of sub-basin bottoms in glasses' PEL by introducing small intra-cage cyclic loading and then measuring the net changes in atomic-level stresses. Compared to glasses with pair interaction, glasses with many-body interaction exhibit orders-of-magnitude larger and loading-dependent stress changes even before the first cage-breaking event takes place, which reflect much more feature-rich sub-basins. We further demonstrate this stark contrast stems from the spatial distribution of individual atom's constraining force field. Specifically, at vanishing perturbations, many-body interactions disrupt the positive-definite synchrony in energy variations of the perturbed atom and the whole system, causing inherently less confined atomic responses and infinitely rugged sub-basins. The implications of these findings for the selective addition or removal of fine structures in the PEL and the subsequent tuning of glassy materials' responses to external stimuli are also explored.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Heat Loss Characteristics and Energy Use of Piperazine with the Advanced Stripper (PZAS) at the UT-SRP Pilot Plant

Heat duty and heat loss were measured at the pilot plant at UT Austin. Heat loss was measured with energy balances using water. Heat loss was studied using surface temperature measurements over 68 different locations at the pilot plant. Surface temperature measurements indicated that bare metal surfaces were the primary source of heat loss from the pilot plant. Heat loss from bare metal surfaces was at least 50% controlled by natural convection and in many cases was as high as 75% natural convection controlled. Measured heat loss at the pilot plant was 20100 BTU/hr and overall heat loss did not show any dependence on the heat rate of the plant. Compared to PZAS™ at the National Carbon Capture Center, heat loss relative to heat rate was higher at 38%. The relative heat loss at the pilot plants was found to decrease by 20% per MW of added capacity. Measured net heat duty was found to be dependent on measured lean loading and cold rich bypass flow rate. Measured net heat duty was between 2.2 and 2.4 GJ/tonne at an optimum lean loading of 0.2–0.21 mol/mol. Data reconciliation by Aspen Plus® Data Fit™ underpredicted CO2 flow rate by 20% due to an overprediction of lean loading by 19%, indicating a necessary change in thermodynamic parameters in the model. This resulted in an over prediction of heat duty by 33% on average.

Amine scrubbing, stripper, energy requirement, hea↗
DOE OSTI2024

Pathways to commercial building plug and process load efficiency and control

Abstract To accomplish net-zero carbon emissions in the built environment by 2050, we must equitably decarbonize commercial buildings, including reducing plug and process loads (PPLs). PPLs are plug-in or hardwired electric and gas loads that are not associated with major building end uses like lighting and HVAC. Research shows PPL energy reduction strategies and control technologies have the potential to save energy. But even when implemented, these savings have rarely been achieved and there has not been widespread uptake in U.S. commercial buildings. We investigate why these technologies and strategies have not seen widespread adoption and identify behavior and technology pathways to increase PPL reduction in U.S. commercial buildings. We examined behaviors of commercial building stakeholders through 44 interviews and cross-referenced qualitative analysis findings with in-depth technical knowledge of existing PPL control technologies and reduction strategies. PPL control implementation must be paired with management strategies, such as occupant engagement and training, to achieve optimal savings, and best practices should be disseminated across the industry. We found that increasing access to cost and energy savings data will promote uptake of PPL control technologies and allow designers to better incorporate PPLs into building design. Improving access to funding for PPL energy efficiency projects and addressing the split-incentive problem will increase adoption of PPL efficiency and control. Code bodies should continue to include PPL monitoring and reduction measures in energy codes. Key building stakeholders, including cybersecurity and information technology teams, should be involved in PPL monitoring and reduction strategy processes for successful implementation.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

Ducted fuel injection with Low-Net-Carbon fuels as a solution for meeting future emissions regulations

Several studies have proven how ducted fuel injection (DFI) reduces soot emissions for compression-ignition engines. Nevertheless, no comprehensive study has investigated how DFI performs over a load range in combination with low-net-carbon fuels. In this study, optical-engine experiments were performed with four different fuels—conventional diesel and three low-net-carbon fuels—at low and moderate load, to measure emissions levels and performance. The 1.7-liter single-cylinder optical engine was equipped with a high-speed camera to capture natural luminosity images of the combustion event. Conventional diesel and DFI combustion were investigated at four different dilution levels (to simulate exhaust-gas recirculation effects), from 14 to 21 mol% oxygen in the intake. At a given dilution level, with commercial diesel fuel, DFI reduced soot by 82% at medium load, and 75% at low load without increasing NO x . The results further show how DFI with dilution reduces soot and NO x without compromising engine performance or other emission types, especially when combined with low-net-carbon fuels. DFI with the oxygenated low-net-carbon blend HEA67 simultaneously reduced soot and NO x by as much as 93 % and 82 %, respectively, relative to conventional diesel combustion with commercial diesel fuel. These soot and NO x reductions occurred while lifecycle CO 2 was reduced by at least 70 % when using low-net-carbon fuels instead of conventional diesel. All emissions changes were compared with future emissions regulations for different vehicle sectors to investigate how DFI can be used to facilitate achievement of the regulations. Finally, the results show how the DFI cases fall below several future emissions regulation levels, rendering less need for aftertreatment systems and giving a possible lower cost of ownership.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2021

Extreme Miller cycle with high intake boost for improved efficiency and emissions in heavy-duty diesel engines

This study experimentally investigates the impact of extreme Miller cycle strategies paired with high intake manifold pressures on the combustion process, emissions, and thermal efficiency of heavy-duty diesel engines. Well-controlled experiments isolating the effect of Miller cycle strategies on the combustion process were conducted at constant engine speed and load (1160 rpm, 1.76 MPa net IMEP) on a single cylinder research engine equipped with a fully-flexible hydraulic valve train system. Late intake valve closing (LIVC) timing strategies were compared to a conventional intake valve profile under either constant cylinder composition, constant engine-out NO x emission, or constant overall turbocharger efficiency (η TC ) to investigate the operating constraints that favor Miller cycle operation over the baseline strategy. Furthermore, utilizing high boost with conventional intake valve closing timing resulted in improved fuel consumption at the expense of sharp increases in peak cylinder pressures, engine-out NO x emissions, and reduced exhaust temperatures. Miller cycle without EGR at constant λ demonstrated LIVC strategies effectively reduce engine-out NO x emissions by up to 35%. However, Miller cycle associated with very aggressive LIVC timings led to fuel consumption penalties due to increased pumping work and exhaust enthalpy. LIVC strategies allowed for increased charge dilution at the baseline NO x constraint of 3.2 g/kWh, resulting in significant fuel consumption benefits over the baseline case without compromising exhaust temperatures or peak cylinder pressures. As Miller cycle implementation was shown to affect the boundary conditions dictating η TC , the LIVC and conventional IVC cases were studied at an equivalent η TC point representative of high boost operation. With high boost, LIVC yielded reduced NO x emissions, reduced peak cylinder pressures, and elevated exhaust temperatures compared to the conventional IVC case without compromising fuel consumption.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

Case Study: Hybridizing Nuclear Energy Systems in the U.S.

This case study was presented at the ICTP-IAEA VIRTUAL Course on Nuclear-Renewable Integrated Energy Systems: Phenomenology, Research and Development. It provides preliminary results on an analysis of hybridizing the two nuclear power plants owned by Xcel Energy and located in Minnesota. The analysis extends previous analyses that provided only price-taker results. Those assume adjusting the generation sold to the grid does not impact locational marginal electricity prices nor do they estimate impacts on the total net cost to serve the load. This presentation summarizes the new technique that was developed to both optimize the size and operations of the hybridized system and the resulting impacts on the grid when it is operated optimally.

ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2021

True Load Balancing for Matricized Tensor Times Khatri-Rao Product

MTTKRP is the bottleneck operation in algorithms used to compute the CP tensor decomposition. For sparse tensors, utilizing the compressed sparse fibers (CSF) storage format and the CSF-oriented MTTKRP algorithms is important for both memory and computational efficiency on distributed-memory architectures. Existing intelligent tensor partitioning models assume the computational cost of MTTKRP to be proportional to the total number of nonzeros in the tensor. However, this is not the case for the CSF-oriented MTTKRP on distributed-memory architectures. We outline two deficiencies of nonzero-based intelligent partitioning models when CSF-oriented MTTKRP operations are performed locally: failure to encode processors' computational loads and increase in total computation due to fiber fragmentation. We focus on existing fine-grain hypergraph model and propose a novel vertex weighting scheme that enables this model encode correct computational loads of processors. We also propose to augment the fine-grain model by fiber nets for reducing the increase in total computational load via minimizing fiber fragmentation. In this way, the proposed model encodes minimizing the load of the bottleneck processor. In conclusion, parallel experiments with real-world sparse tensors on up to 1024 processors prove the validity of the outlined deficiencies and demonstrate the merit of our proposed improvements in terms of parallel runtimes.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2023

Ecosystem-Level Biomimicry for the Built Environment: Adopting Systems Ecology Principles for the Control of Heterogeneous Energy Systems

This paper presents, to our knowledge, the first system-level engineering study to bio-mimic the cybernetics and flow dynamics of energy resources in natural ecosystems for the control of heterogeneous energy infrastructures in the built environment. To this end, we introduce a novel Biomimetic Pulsing State (BPS) control that functionally mimics mature ecosystems. A preliminary Modelica-based case study features a single-family residential building with electrical and HVAC subsystems. The BPS control objective is to minimize the energy exchange between the building and the grid for the purposes of future self-supporting buildings and grid stability. The building contains PV, a wind turbine, a battery storage system, and a fan coil/heat pump HVAC system served by an ambient district energy network. Evaluating the control performance (BPS vs. constant setpoint) over several renewable energy scenarios (net importer, net zero, net exporter), simulation results show how the building's HVAC system can dynamically adjust its electrical load and temperatures to the electrical system's net energy status in real-time with BPS control. As a net importer, the heat pump consumed 29% less energy and its peak power reduced by 15% with BPS control compared to the constant setpoint case, with the zone air temperature 1 degree C lower on average. As a net exporter, the heat pump effectively consumed the same energy, but the peak power increased by 34% with BPS control, while the zone air temperature was 1 degree C higher when renewable energy was abundant, preheating the home. BPS and constant setpoint control produced comparable results under a net zero scenario. While further evaluation is essential, BPS control may help communities meet their sustainability and resiliency targets as they transition towards fully distributed and renewable energy grids.

biomimicry↗
DOE OSTI2025

Field Validation of Thermoelectric Generation System at Holcim Cement Plant in Alpena, Michigan

Executive Summary Project Background The Industrial Technology Validation (ITV) program aims to identify and demonstrate the performance of new, emerging, and underutilized energy-saving technologies in the industrial sector to help inform decisions to help accelerate their commercialization and deployment, as well as to help make industries more competitive. This ITV demonstration evaluated a thermoelectric generation (TEG) technology at a cement plant, aiming to reduce energy demand in the cement industry. A median cement plant consumes 5.73 million British thermal units per ton of clinker production (resulting in 0.838 metric tons of carbon dioxide [CO₂] emissions per ton of clinker) (Boyd and Zhang 2011, EPA 2021), equivalent to approximately 6.9 trillion British thermal units (TBtu) per year in energy consumption at a cement plant producing 3,300 tons of clinker per day.¹ Collaborating with Holcim, Advanced Thermovoltaic Systems (ATS) developed and deployed a pilot-scale thermoelectric power system to efficiently capture and convert waste heat to electricity. The system leverages the Seebeck effect to convert temperature differences on two sides of semiconductor cartridges into electrical power (ScienceDirect, n.d.). This generation is realized with minimal moving parts compared to existing waste-heat-to-generation solutions and allows capture from heat sources with temperatures as low as 150°C. This project aimed to validate a scalable solution applicable for capturing medium-temperature waste heat, including ambient losses from other high-temperature processes, and high-temperature sources less suitable for other waste-heat-to-power solutions. By recovering this otherwise wasted heat, this project intends to validate improvements to overall process efficiency through reduction in purchased electricity, thereby reducing operational costs while enhancing resiliency and competitiveness. Description and Scope This study evaluated the performance of a TEG system from ATS as a solution to convert waste heat into useful power at a Holcim cement plant in Alpena, Michigan. This plant is a fully integrated cement plant that has been operating since 1907. The facility operates continuously (24/7/365) with approximately 250 employees and five long dry kilns, yielding a total production capacity of 7,852 tons of cement per day (EPA 2023). Currently, the Alpena plant uses waste heat boilers to convert waste heat from the exhaust of each kiln into steam, which drives steam turbine generators. The ATS TEG is being evaluated for its potential to supplement the steam turbines by capturing the remaining lower grade heat. This technology is also being considered for other Holcim plants where steam turbines are not a viable option. ATS installed a pilot-scale TEG unit with an array of 582 individual thermoelectric semiconductor cartridges, of which 573 were operational. The cartridges are sandwiched between 48 hot plates and 49 cold plates. Each cartridge is designed to generate 20 watts (W) of gross power at a hot-side temperature of 240°C and cold-side temperature of 20°C. As such, the total gross generation capacity of the installed system is 11.5 kilowatts (kW) at design conditions. The system configuration for the evaluation was designed to prioritize convenience of installation and minimize disruption to production at the site, while ensuring that the heat required can be obtained for evaluating the TEG system at various operational conditions. To accomplish this, a portion of the steam supplied to Alpena’s steam turbine generation system was diverted to be used as the heat source for the TEG system, while water was supplied to the cold side of the system from nearby Lake Huron. This configuration was designed for the evaluation of the pilot-scale system to assess the performance at different conditions. A commercial-scale system will likely vary from the pilot system depending on typical configurations, including both scale and application. Future commercial applications of the ATS system would involve integrating the system into the exhaust from kiln preheaters, clinker coolers, or radiant heat capture from kiln shells for the heat source. For the cold source, a range of cooling solutions can be considered, including a mechanical cooling system, depending on the location and the application. To increase the generation capacity for commercial applications, the technology provider is working toward developing a commercial-scale TEG system, which would combine multiple TEG units (each similar in design to the pilot system) together. The scope of this evaluation includes the pilot-scale TEG system and all impacted equipment including pumps, controllers, and power handling equipment. Study Objectives The evaluation's goal was to assess the potential of the ATS TEG system to generate useful electrical power by capturing waste heat from cement production kilns. The objectives of this study are to evaluate and verify the following claims made by ATS regarding the pilot-scale system installed at the Holcim Alpena plant. The following design parameters and claims are also outlined in Table ES- 1 and Table ES- 2: • Gross Power: The thermoelectric system converts heat into power to create gross power, the total measured power generated by the system. The 573 active cartridge pilot-scale system is expected to generate 11.5 kW of gross power at the designed hot-side temperature of 240°C and cold-side temperature of 20°C. Power production is dependent on the temperature difference between the heat source (ultimately from the waste heat) and cold temperature supply source. • Net Power: The net power is the total usable power provided to the site by the TEG system after deducting parasitic power loads from the gross generated power. Supplementary equipment is required to operate the TEG system including pumps, controllers, and, in certain anticipated applications, mechanical cooling, which introduce parasitic loads to system operation. After deducting the parasitic loads from the gross power generation, ATS anticipates achieving a net power generation of 7.5 kW from the pilot-scale system. • Thermal Efficiency: The thermal efficiency is the percent of the total heat transferred to the TEG system that is converted to gross power. Historically, TEGs have a thermal efficiency of 2%–5% (DOE 2008). Prior industrial-scale TEG systems, such as the E1 TEG offered by Alphabet Energy, operated at an efficiency of 2.5% (Lamonica, 2014). ATS anticipates achieving an average efficiency of 4.8% or higher in converting heat energy to usable electricity. • Cartridge Performance: The TEG system comprises 573 active individual semiconductor cartridges, each of which generates a portion of the total power. Cartridge optimization and selection is an important design consideration for potential future TEG system design performance. Therefore, understanding the distribution of gross power and efficiency within the pilot system is vital to understanding what is achievable. At a design hot-side temperature of 240°C and cold-side temperature of 20°C, ATS anticipates a cartridge performance of 20 W of gross power per cartridge at an efficiency of 4.8% per cartridge. In addition to evaluating the claimed performance of the TEG pilot-scale unit, the study estimated the potential annual impacts of a scaled-up commercial system used to capture kiln waste heat over annual operations. The evaluation estimated the gross and net annual electric generation achievable by capturing heat from the two proposed tap-in points: the kiln exhaust and the clinker cooler exhaust; see Section 2.1 for details. Two use cases were examined: • Holcim Alpena: The Holcim Alpena site consists of long dry kilns with superheater boilers, which differs from the rest of Holcim’s cement plant portfolio and results in lower waste heat temperatures. The study estimates gross and net annual generation using the superheater boiler exhaust and clinker cooler exhaust, based on 2023 operational data. • Typical Installation: Common cement plants have preheater kilns with higher exhaust temperatures than Holcim Alpena across a range of production rates. The study estimates gross and net annual generation using the preheater exhaust and clinker cooler exhaust, with a sensitivity analysis to account for the typical range of preheater exhaust temperatures, clinker cooler exhaust temperatures, and clinker production rates. Methodology The evaluation methodology followed a measurement and verification (M&V) strategy based on the International Performance Measurement and Verification Protocol Option B through comprehensive measurements and analyses of the affected systems. Evaluation data was collected from March 9 to March 11, 2024, the test period of the pilot TEG system. During the test period, in coordination with the ITV team, the ATS team adjusted system operations to capture the range of variability expected for each of the variables pertinent to performance of the system. The methodology consisted of two parts: evaluating the performance of the pilot unit's TEG system and estimating the annual TEG impact in terms of gross and net power based on a given waste heat profile. First, the evaluation of the thermoelectric generation performance of the pilot unit relative to the claims was performed by analyzing the collected test data. Gross power of the pilot TEG system was directly measured. Net power was determined by deducting the measured parasitic power from the gross power. The gross power generation was compared to heat transferred to the system by the working fluid (which was heated by steam generated from the kiln waste heat) to calculate the thermal efficiency achieved by the system. Performance of individual semiconductor cartridges within the pilot array was also assessed in terms of measured gross cartridge power and calculated cartridge thermal efficiency. The second part of the evaluation estimated the annual TEG impacts in terms of gross power and net power (calculated from the difference between gross power and parasitic power). This analysis comprised development of mathematical regression models for gross power and parasitic power, with assessment of each model’s goodness-of-fit characteristics to ensure satisfaction of statistical requirements. The models predicted the gross power generation, the parasitic load based on the temperature difference between the hot working fluid and the cold-side fluid (cold water from Lake Huron) entering the system, the volumetric flow rate of the cold-side fluid at the inlet, and the volumetric flow rate of the hot working fluid at the inlet. The annual impact analysis considered a theoretical commercial-scale system sized to capture the available waste heat at a cement plant, consisting of linked pilot-scale units that receive heat from a theoretical gas-to-working-fluid heat exchanger. To estimate annual impacts at the Alpena plant, the gross power and parasitic power regression models were applied to the arrays in the theoretical commercial-scale system. The heat supplied to the unit was calculated based on the kiln run time, annual production, kiln exhaust waste heat, and clinker cooler waste heat derived from 2023 Holcim Alpena kiln operational data. Net power impacts were calculated by deducting the resulting parasitic power from the estimated gross power. Inputs for the model were generated from a combination of hourly data, assumed design considerations for TEG system scale-up from the pilot-scale unit, and assumptions regarding TEG system operations. This analysis was then used as the basis for estimating annual impacts of typical TEG installation at cement plants, by applying sensitivity analyses to key kiln operational characteristics including kiln preheater exhaust temperatures, cooler clinker exhaust temperatures, and plant daily production rates across a range of expected values. Project Results/Findings Table ES- 2 and Table ES- 2 provide a summary of the operating conditions and evaluation results compared to the stated claims from the technology provider. Key takeaways include: • Gross Power: The peak gross power achieved during the testing period was 10.0 kW, compared to the 11.5 kW expected for 573 active cartridges. The claimed gross power was associated with a target hot side of 240°C; however, the system only received a maximum hot-side mean plate temperature of 212°C during the testing period. • Net Power: The pilot-scale unit exceeded the claims for net power, achieving a peak of 7.7 kW net compared to a claim of 7.5 kW. One factor contributing to the higher achieved net power is the relatively high water pressure available through Lake Huron. The pilot TEG system did not require cold-side pumps during the test, whereas most installations would. This reduced the parasitic loads on the system, ultimately contributing to higher net power relative to the gross power. • Thermal Efficiency: The pilot-scale unit outperformed the claimed efficiency, achieving a peak system efficiency of 5.0% thermal efficiency compared to the stated 4.8%. • Cartridge Performance: To compare cartridge performance against claims, the study focused on the third day of testing, which aimed for conditions closest to the design specifications, with a hot side of 240°C and cold-side exit temperature of 6.4°–30°C. On this day, the mean gross power observed in the cartridges within the TEG array was 18.1 W/cartridge, and the peak performance was 34.7 W/cartridge. The estimated mean cartridge efficiency was 5.2%, and the estimated efficiency at peak gross cartridge power was 10%. The regression models developed for gross power generation and parasitic loads were used to estimate the generation impact for given heat input to the TEG from the working fluid (captured from the waste heat) and from the cold loop (Lake Huron) on an hourly basis for a year of operation. Based on this analysis, installation of a commercial-scale TEG system at the Holcim cement plant in Alpena, Michigan, with a waste heat exchanger of 0.85 effectiveness, would generate up to 391 kW of net power, translating to between 920,000 and 1,800,000 kilowatt-hours (kWh) in net electricity per year. Based on typical grid emissions for Alpena, this would avoid estimated net emissions by 752 metric tons of CO₂ annually.² The sensitivity analysis estimated that typical TEG system installations at cement plants could generate an average of 56–1,040 kW of net power, or between 488,000 and 9,110,000 kWh of net energy. This generation potential is most significantly affected by plant production rates and also influenced by preheater and clinker cooler exhaust temperatures. Applying the national average emission rate, typical commercial-scale installations at Holcim plants are projected to avoid between 182 and 3,401 metric tons of CO₂ annually per site. Table ES- 3 shows a summary of the estimated annual impacts.³ While parasitic loads are significant and vary by application, this analysis assumed the use of heating loop pumps and access to Lake Huron as a cold sink. This setup assumed no need for cooling loop pumps due to the available water pressure at the test site. Applications that require cooling towers or additional equipment are likely to experience higher parasitic loads. Therefore, the study’s estimates are most applicable to scenarios with similar parasitic load configurations—namely, access to a high-pressure cold sink. Applicability to other locations may be limited, as differing conditions could necessitate additional pumps and cooling systems, potentially impacting performance significantly.

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DOE OSTI2024

Paths Forward: Approaches to Achieve Plug and Process Load Efficiency and Control in Commercial Buildings: Preprint

To accomplish net-zero carbon in the built environment by 2050, we must equitably decarbonize commercial buildings, which includes reducing plug and process loads (PPLs). PPLs are plug-in or hardwired electric and gas loads that are not directly associated with major building end uses like lighting and heating, ventilating, and air conditioning. PPLs account for a growing portion of U.S. commercial building energy consumption. Although commercial building PPL strategies and technologies are available today, they have not been adopted at a level sufficient to achieve significant savings and load flexibility across the building stock. In our "Pathways to Plug and Process Load Efficiency and Control" study, we investigated why these technologies and strategies have not seen widespread adoption and identified five behavior and technology pathways to increase PPL reduction in commercial buildings. In this paper, we expand beyond identifying the pathways and discuss approaches for achieving them. We discuss the importance of collecting and sharing data and case studies on PPL energy consumption and savings from control technology implementation, including code-required measures, for increasing adoption. Centralizing case studies and data, engaging industry organizations, and promoting awareness of PPL efficiency benefits to relevant groups are also key approaches. Additionally, funding, incentives, and rebate programs play important roles in driving PPL efficiency and control adoption. Finally, we discuss integrating PPL efficiency into broader company goals, such as environmental, social and governance (ESG) strategies and green building certifications, to further drive adoption.

adoption pathways↗
DOE OSTI2025

Factors influencing recent trends in retail electricity prices in the United States

This study analyzes the primary drivers of recent state-level trends in U.S. retail electricity prices. We summarize pricing trends, explore descriptive relationships, and employ regression models to quantify the influence of various factors. Although the recent national rise in retail prices has largely tracked inflation, state-level trends vary widely. We identify a number of factors that explain trends in subsets of states. States with the greatest price increases typically exhibited shrinking customer loads—partially linked to growth in net metered behind-the-meter solar—and had renewables portfolio standards (RPS) in concert with relatively costly incremental renewable energy supplies. By contrast, recent utility-scale wind and solar deployment that occurred outside RPS programs (but that benefited from tax incentives) had no discernible impact on increased retail prices. Hurricanes, storms and wildfires also contributed to sizable price increases in some states, most notably in California, where wildfire risk mitigation and liability insurance were major cost drivers. Fluctuations in natural gas prices—particularly following the onset of the Ukraine-Russia war—further contributed to sharp price increases through 2022–2023 in many states, with moderation in 2024. The relative influence of these factors varies across states and over time, and relationships may change in the future. Nonetheless, the findings underscore the diverse set of price determinants and highlight the need for continued research to inform effective policy and ensure customer affordability.

Customer load↗
DOE OSTI2021

Open Building Control

Best practice control sequences are often not implemented correctly, or are not implemented at all, in large commercial buildings. This typically leads to 10-30 percent energy waste, along with reduced occupant productivity and unnecessary equipment wear. The current process of designing and implementing such control sequences is a manual process that starts with designers who often don’t have adequate training, then requires controls programmers to interpret and program a verbose written sequence. This process has been shown to fail to deliver high performance control sequences at scale. The Open Building Control project digitizes the current control delivery process. The project is developing tools for system designers to select control sequences, assess their energy performance and load flexibility potential using whole building simulation, specify the sequence for implementation using machine-to-machine translation by a control provider and formally testing the as-installed sequences by a commissioning agent. The project developed tools for each stage of this delivery process. The key innovation of the project is the development of the Control Description Language, a language that allows such a digitized control delivery process with end-to-end verification. Libraries of control sequences have been implemented using the Control Description Language, and their performance has been demonstrated using whole building energy simulation. An automated translation of such sequences to a commercial control product line has been conducted using a prototype translator. Tools for formal verification of as-installed control sequences relative to their specification have been developed and demonstrated. The American Society of Heating, Refrigerating and Air-Conditioning Engineers (ASHRAE) started the process of forming a committee to make this language an ASHRAE/ANSI Standard. This new standard will complement existing and emerging ASHRAE standards for building communication and semantic modeling by providing a standard for expressing the control logic - the actual brain of the building. We expect this language and the process it enables to be an important contribution to the deployment of high performance building control sequences at scale because it allows taming the complexity of the control delivery process, which is continually increasing due to the need for higher performance and increased load flexibility to meet goals for net zero energy and increased renewable integration.

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