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DOE OSTI2024

Materials scarcity during the clean energy transition: Myths, challenges, and opportunities

Abstract Efforts to reach net zero targets by the second half of the century will have profound materials supply implications. The anticipated scale and speed of the energy transition in both transportation and energy storage raises the question of whether we risk running out of the essential critical materials needed to enable this transition. Early projections suggest that disruptions are likely to occur in the short term for select critical materials, but at the same time these shortages provide a powerful incentive for the market to respond in a variety of ways before supply-level stress becomes dire. In April 2023, the MRS Focus on Sustainability subcommittee sponsored a panel discussion on the role of innovation in materials science and engineering in supporting supply chains for clean energy technologies. Drawing on examples from the panel discussion, this perspective examines the myth of materials scarcity, explains the compelling need for innovation in materials in helping supply chains dynamically adapt over time, and illustrates how the Materials Research Society is facilitating engagement with industry to support materials innovation, now and in the future. Graphical Abstract Highlights In this commentary, we examine the myth of materials scarcity, explain the compelling need for innovation in materials in helping supply chains dynamically adapt over time, and show how the materials research community can effectively engage with industry, policymakers, and funding agencies to drive the needed innovation in critical areas. Discussion Demand for certain materials used in clean energy technologies is forecasted to increase by multiples of current production over the next decades. This has drawn attention to supply chain risks and has created a myth that we will “run out” out of certain materials during the energy transition. The reality is that markets have multiple mechanisms to adapt over the long-term, and near-term shortages or expectations of shortages provide a powerful incentive for action. In this commentary, we highlight different ways materials innovation can help solve these issues in the near term and long term, and how the materials research community can effectively engage with industry and policymakers.

Ku, Anthony Y. (ORCID:0000000337622914)↗

DOE OSTI2021

A Circular Economy for Lithium-Ion Batteries Used in Mobile and Stationary Energy Storage: Drivers, Barriers, Enablers, and U.S. Policy Considerations

As large-format battery energy storage (BES) capacity increases in the United States, so will the volume of spent lithium-ion batteries (LiBs) (Bade 2019). Estimates based on a 10-year lifetime assumption found that the volume of LiBs that have reached the end of their utility for electric vehicle (EV) applications could total two million units (four million metric tons) annually by 2040 in the United States (Richa et al. 2014; Ai and Borucki 2018). Although there is currently no publicly available decommissioning or end-of-life (EoL) projection for stationary BES systems, the U.S. energy storage market is expected to grow from an annual deployment of 523 megawatts in 2013 to 7.3 gigawatts in 2025 (Wood MacKenzie and ESA 2020; Wesoff 2020). Despite potential secondary market opportunities and the potential benefits associated with the reuse/recovery of LiB material, anecdotal evidence suggests that in the United States most decommissioned LiBs from EVs are landfilled or otherwise disposed of (Steward et al. 2019; Salim et al. 2019; CPUC 2019; DTSC 2019d; NREL 2019b; Jacoby 2019; DOE 2019). The reuse of large-format LiBs is not at commercial scale and to date consists of only a handful of U.S.-led pilot projects. Similarly, less than 5% of LiBs from EVs are sent to recycling facilities in the United States (Steward et al. 2019; Jacoby 2019; America Made 2019; Patel 2017). As awareness of current practices grows, and the demand for critical LiB materials increases, U.S. industry stakeholders, regulators, and policymakers are starting to (1) consider solutions to drive and enable environmentally sustainable materials management decisions and behaviors and (2) identify barriers to a circular economy for LiBs (Figure 1). Circular economy principles (Figure 1) attempt to transition from a “take-make-consume-dispose” linear economic system to a circular system that allows for the long life, high performance, and the reuse/recovery of products and materials (Ellen MacArthur Foundation 2016). We begin this report by summarizing drivers, barriers, and enablers to a circular economy for LiBs used in mobile and stationary BES systems in the United States. We then report on our analysis of federal and state regulatory considerations that may impact the reuse/recovery and disposal of LiBs, and potential civil and criminal liabilities associated with noncompliance. We conclude by highlighting state policies and initiatives in the United States that expressly address reuse/recovery and disposal of large-format LiBs. Our results are based on legal and literature-based research and interviews with mobile and stationary BES industry stakeholders, regulators, and policymakers. While this report addresses stationary BES, as well as mobile BES, much of the information and experience with LiB decommissioning and EoL material management is derived from the increasing management of spent EV LiBs in the United States.

25 ENERGY STORAGE↗

DOE OSTI2024

DERiving Community Economic Development through Distributed Solar

This report explores how distributed solar stakeholders can plan and align economic development with existing community priorities while advancing new solar projects. Because the amount of local community influence drives community economic development, we note the need for investment in community ownership models, which are scarce today. This report seeks to outline the current barriers to community-led economic development through distributed solar, best practices for implementation, and recommendations for sector stakeholders.

14 SOLAR ENERGY↗

DOE OSTI2024

DERiving Community Economic Development through Distributed Solar

14 SOLAR ENERGY↗

NASA NTRS1971

Ion-acoustic instability of a two-temperature, collisional, fully-ionized plasma.

From a perturbation analysis of the fluid equations for a homogeneous unmagnetized plasma, it is shown that long wavelength ion waves are unstable when the electron temperature exceeds the ion temperature. Thus, the temperature difference can drive a resistive-type ion wave instability in a plasma which on a collisionless basis is stable. The additional destabilizing effect of a current is also investigated.

Rognlien, T. D.↗

NASA NTRS1982

Verification testing of the PKI collector at Sandia National Laboratories, Albuquerque, New Mexico

Verification testing of a solar collector was undertaken prior to its operation as part of an industrial process heat plant at Capitol Concrete Products in Topeka, Kansas. Testing was performed at a control plant installed at Sandia National Laboratory, Albuquerque, New Mexico (SNLA). Early results show that plant performance is even better than anticipated and far in excess of test criteria. Overall plant efficiencies of 65 to 80 percent were typical during hours of good insolation. A number of flaws and imperfections were detected during operability testing, the most important being a problem in elevation drive alignment due to a manufacturing error. All problems were corrected as they occurred and the plant, with over 40 hours of operation, is currently continuing operability testing in a wholly-automatic mode.

Hauger, J. S.↗

NASA NTRS1983

Monolithic short wave infrared (SWIR) detector array

A monolithic self-scanned linear detector array was developed for remote sensing in the 1.1- 2.4-micron spectral region. A high-density IRCCD test chip was fabricated to verify new design approaches required for the detector array. The driving factors in the Schottky barrier IRCCD (Pdsub2Si) process development are the attainment of detector yield, uniformity, adequate quantum efficiency, and lowest possible dark current consistent with radiometric accuracy. A dual-band module was designed that consists of two linear detector arrays. The sensor architecture places the floating diffusion output structure in the middle of the chip, away from the butt edges. A focal plane package was conceptualized and includes a polycrystalline silicon substrate carrying a two-layer, thick-film interconnecting conductor pattern and five epoxy-mounted modules. A polycrystalline silicon cover encloses the modules and bond wires, and serves as a radiation and EMI shield, thermal conductor, and contamination seal.

Source record↗

NASA NTRS1986

A double layer model for solar X-ray and microwave pulsations

The wide range of wavelengths over which quasi-periodic pulsations have been observed suggests that the mechanism causing them acts upon the supply of high energy electrons driving the emission processes. A model is described which is based upon the radial shrinkage of a magnetic flux tube. The concentration of the current, along with the reduction in the number of available charge carriers, can rise to a condition where the current demand exceeds the capacity of the thermal electrons. Driven by the large inductance of the external current circuit, an instability takes place in the tube throat, resulting in the formation of a potential double layer, which then accelerates electrons and ions to MeV energies. The double layer can be unstable, collapsing and reforming repeatedly. The resulting pulsed particle beams give rise to pulsating emission which are observed at radio and X-ray wavelengths.

Tapping, K. F.↗

NASA NTRS1987

Double layers and plasma-wave resistivity in extragalactic jets - Cavity formation and radio-wave emission

Current driven electrostatic-wave- and electromagnetic-wave-produced resistivities do not occur in extragalactic jets for estimated values of the carried currents. Strong plasma double layers, however, may exist within self-maintained density cavities. The relativistic double-layer-emitted electron and ion beams drive plasma-wave resistivities in the low- and high-potential plasma adjacent to the double layers. The double-layer-emitted electron beams may also emit polarized radio waves via a collective bremsstrahlung process mediated by electrostatic two-stream instabilities.

Borovsky, Joseph E.↗

NASA NTRS1987

Development of a semi-autonomous service robot with telerobotic capabilities

The importance to the United States of semi-autonomous systems for application to a large number of manufacturing and service processes is very clear. Two principal reasons emerge as the primary driving forces for development of such systems: enhanced national productivity and operation in environments whch are hazardous to humans. Completely autonomous systems may not currently be economically feasible. However, autonomous systems that operate in a limited operation domain or that are supervised by humans are within the technology capability of this decade and will likely provide reasonable return on investment. The two research and development efforts of autonomy and telerobotics are distinctly different, yet interconnected. The first addresses the communication of an intelligent electronic system with a robot while the second requires human communication and ergonomic consideration. Discussed here are work in robotic control, human/robot team implementation, expert system robot operation, and sensor development by the American Welding Institute, MTS Systems Corporation, and the Colorado School of Mines--Center for Welding Research.

Jones, J. E.↗

NASA NTRS1991

Nonlinear baroclinic adjustment

The concept of baroclinic adjustment is reexamined in the context of a fully nonlinear two-layer model on a beta-plane. Based on the results, a single, conceptually very simple mechanism of the nonlinear equilibration of waves and the mean flow is proposed, which is termed 'nonlinear baroclinic adjustment'. The new concept appears applicable to cases that currently require different explanations, varying from case to case, to account for the equilibration of the mean temperature gradient in the presence of external driving.

Cehelsky, Priscilla↗

NASA NTRS1994

Modification of the Ames 40- by 80-foot wind tunnel for component acoustic testing for the second generation supersonic transport

The development of a large-scale anechoic test facility where large models of engine/airframe/high-lift systems can be tested for both improved noise reduction and minimum performance degradation is described. The facility development is part of the effort to investigate economically viable methods of reducing second generation high speed civil transport noise during takeoff and climb-out that is now under way in the United States. This new capability will be achieved through acoustic modifications of NASA's second largest subsonic wind tunnel: the 40-by 80-Foot Wind Tunnel at the NASA Ames Research Center. Three major items are addressed in the design of this large anechoic and quiet wind tunnel: a new deep (42 inch (107 cm)) test section liner, expansion of the wind tunnel drive operating envelope at low rpm to reduce background noise, and other promising methods of improving signal-to-noise levels of inflow microphones. Current testing plans supporting the U.S. high speed civil transport program are also outlined.

Schmitz, F. H.↗

NASA NTRS2003

Phenomenological Model of Current Sheet Canting in Pulsed Electromagnetic Accelerators

The phenomenon of current sheet canting in pulsed electromagnetic accelerators is the departure of the plasma sheet (that carries the current) from a plane that is perpendicular to the electrodes to one that is skewed, or tipped. Review of pulsed electromagnetic accelerator literature reveals that current sheet canting is a ubiquitous phenomenon - occurring in all of the standard accelerator geometries. Developing an understanding of current sheet canting is important because it can detract from the propellant sweeping capabilities of current sheets and, hence, negatively impact the overall efficiency of pulsed electromagnetic accelerators. In the present study, it is postulated that depletion of plasma near the anode, which results from axial density gradient induced diamagnetic drift, occurs during the early stages of the discharge, creating a density gradient normal to the anode, with a characteristic length on the order of the ion skin depth. Rapid penetration of the magnetic field through this region ensues, due to the Hall effect, leading to a canted current front ahead of the initial current conduction channel. In this model, once the current sheet reaches appreciable speeds, entrainment of stationary propellant replenishes plasma in the anode region, inhibiting further Hall-convective transport of the magnetic field; however, the previously established tilted current sheet remains at a fairly constant canting angle for the remainder of the discharge cycle, exerting a transverse J x B force which drives plasma toward the cathode and accumulates it there. This proposed sequence of events has been incorporated into a phenomenological model. The model predicts that canting can be reduced by using low atomic mass propellants with high propellant loading number density; the model results are shown to give qualitative agreement with experimentally measured canting angle mass dependence trends.

Markusic, Thomas↗

NASA NTRS2003

1400-1900 GHz local oscillators for the Herschel Space Observatory

JPL continues to develop robust planar, all solid-state sources to cover the 1414 to 1908 GHz band. These sources will be used as local oscillators to drive hot electron bolometer (HEB) heterodyne mixers on the Herschel Space Observatory to observe high resolution spectra in the interstellar medium. We report our current progress and present recent results.

Schottky diode frequency multiplier THz local osci↗

NASA NTRS1995

AC motor controller with 180 degree conductive switches

An ac motor controller is operated by a modified time-switching scheme where the switches of the inverter are on for electrical-phase-and-rotation intervals of 180.degree. as opposed to the conventional 120.degree.. The motor is provided with three-phase drive windings, a power inverter for power supplied from a dc power source consisting of six switches, and a motor controller which controls the current controlled switches in voltage-fed mode. During full power, each switch is gated continuously for three successive intervals of 60.degree. and modulated for only one of said intervals. Thus, during each 60.degree. interval, the two switches with like signs are on continuously and the switch with the opposite sign is modulated.

Oximberg, Carol A.↗

NASA NTRS2004

Improved Electromagnetic Brake

A proposed design for an electromagnetic brake would increase the reliability while reducing the number of parts and the weight, relative to a prior commercially available electromagnetic brake. The reductions of weight and the number of parts could also lead to a reduction of cost. A description of the commercial brake is prerequisite to a description of the proposed electromagnetic brake. The commercial brake (see upper part of figure) includes (1) a permanent magnet and an electromagnet coil on a stator and (2) a rotor that includes a steel contact plate mounted, with tension spring loading, on an aluminum hub. The stator is mounted securely on a stationary object, which would ordinarily be the housing of a gear drive or a motor. The rotor is mounted on the shaft of the gear drive or motor. The commercial brake nominally operates in a fail-safe (in the sense of normally braking) mode: In the absence of current in the electromagnet coil, the permanent magnet pulls the contact plate, against the spring tension, into contact with the stator. To release the brake, one excites the electromagnet with a current of the magnitude and polarity chosen to cancel the magnetic flux of the permanent magnet, thereby enabling the spring tension to pull the contact plate out of contact with the stator. The fail-safe operation of the commercial brake depends on careful mounting of the rotor in relation to the stator. The rotor/stator gap must be set with a tolerance between 10 and 15 mils (between about 0.25 and about 0.38 mm). If the gap or the contact pad is thicker than the maximum allowable value, then the permanent magnetic field will not be strong enough to pull the steel plate across the gap. (For this reason, any contact pad between the contact plate and the stator must also be correspondingly thin.) If the gap exceeds the maximum allowable value because of shaft end play, it becomes impossible to set the brake by turning off the electromagnet current. Although it may still be possible to set the brake by applying an electromagnet current to aid the permanent magnetic field instead of canceling it, this action can mask an out-of-tolerance condition in the brake and it does not restore the fail-safe function of setting the brake when current is lost.

Martin, Toby B.↗

NASA NTRS2017

Impacts of Launch Vehicle Fairing Size on Human Exploration Architectures

Human missions to Mars, particularly to the Martian surface, are grand endeavors that place extensive demands on ground infrastructure, launch capabilities, and mission systems. The interplay of capabilities and limitations among these areas can have significant impacts on the costs and ability to conduct Mars missions and campaigns. From a mission and campaign perspective, decisions that affect element designs, including those based on launch vehicle and ground considerations, can create effects that ripple through all phases of the mission and have significant impact on the overall campaign. These effects result in impacts to element designs and performance, launch and surface manifesting, and mission operations. In current Evolvable Mars Campaign concepts, the NASA Space Launch System (SLS) is the primary launch vehicle for delivering crew and payloads to cis-lunar space. SLS is currently developing an 8.4m diameter cargo fairing, with a planned upgrade to a 10m diameter fairing in the future. Fairing diameter is a driving factor that impacts many aspects of system design, vehicle performance, and operational concepts. It creates a ripple effect that influences all aspects of a Mars mission, including: element designs, grounds operations, launch vehicle design, payload packaging on the lander, launch vehicle adapter design to meet structural launch requirements, control and thermal protection during entry and descent at Mars, landing stability, and surface operations. Analyses have been performed in each of these areas to assess and, where possible, quantify the impacts of fairing diameter selection on all aspects of a Mars mission. Several potential impacts of launch fairing diameter selection are identified in each of these areas, along with changes to system designs that result. Solutions for addressing these impacts generally result in increased systems mass and propellant needs, which can further exacerbate packaging and flight challenges. This paper presents the results of the analyses performed, the potential changes to mission architectures and campaigns that result, and the general trends that are more broadly applicable to any element design or mission planning for human exploration.

Jefferies, Sharon↗

NASA NTRS2019

Modeling of the Influence of a Damaged Thermally Grown Oxide (TGO) Layer in an Environmental Barrier Coating System

Environmental barrier coatings (EBC) are an enabling technology for the successful application of ceramic matrix composites (CMCs) in air-breathing gas turbine engines. EBCs are susceptible to a number of failure modes including oxidation/delamination, recessions, chemical attack and dissolution, thermomechanical degradation, erosion, and foreign object impact damage in a combustion environment. Spallation of environmental barrier coating (EBC), induced by a thermally grown oxide (TGO) layer, is a key EBC failure mode. The TGO layer, resulting from steam oxidation, grows either from a silicon bond coat layer (if present) or from a silicon carbide (SiC) based substrate itself. The TGO layer evolves (i.e., thickness increases with time) as water vapor and oxygen gradually diffuse through the EBC, and the EBC spalls off once the TGO layer reaches some critical thickness. The critical thickness of the TGO layer for failure is in the range of 20-30 microns, but it can vary due to exposure temperature, microstructure etc. Current work at NASA Glenn Research Center, under the Revolutionary Tools and Methods (RTM) subproject is aimed at addressing associated failure modes in EBC systems and developing robust analysis tools to aid in the design/analysis of these systems. The objective of the current work is to conduct a sensitivity study to examine the influence of uniformly and non-uniformly grown oxide layers on the associated driving forces leading to spallation of the EBC when subjected to isothermal loading. The effect of damage in the TGO layer on the resulting stress states is also assessed both in uniform and non-uniform TGO layers.

Mital, Subodh K.↗