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DOE OSTI2021

Renewable Thermal Energy Systems Designed for Industrial Process Solutions in Multiple Industries

The need for renewable heat in industry is vital for the next decade and beyond. Industrial decarbonization is a key area that must be accelerated, to foster the removal of fossil fuels from the provision of heat, especially at low temperatures. This paper looks at the development and results of case studies for understanding the economics and potential for renewable thermal energy systems (RTES), particularly in hybrid configurations to provide industrial process heat (IPH). For the case studies, these include non-concentrating e.g., heat pumps, and concentrating collectors e.g., parabolic trough collectors and direct steam generation (DSG)-linear Fresnel collectors (LFCs). The results show that a levelized cost of heat (LCOH) of $6-$8 per million British Thermal Units (MMBTU) is possible, depending on the direct normal irradiance (DNI) and the system sizing e.g., to increase the solar fractions. In Arizona for example, with a DNI of 7.36 kWh/m2/day, the base case for the DSG-LFC system with 6hrs of thermal energy storage could potentially meet a 1 MWth load 80% of the year.

concentrated solar thermal↗

DOE OSTI2019

SECARB Project Overview Book

In 2003, the United States Department of Energy (DOE) issued awards initiating seven Regional Carbon Sequestration Partnerships (RCSP) spanning the United States and portions of Canada. Managed by DOE’s National Energy Technology Laboratory (NETL), the RCSPs currently represent more than 400 state agencies, universities, and private companies, spanning 43 states, three Native American Organizations, and four Canadian provinces. The Southern States Energy Board (SSEB) received an award on October 1, 2003, which established the Board’s overall management and administration of the Southeast Regional Carbon Sequestration Partnership, or SECARB. The geographical region currently includes 13 states and a network of more than 100 stakeholders. The Nation’s leading scientists, university researchers, national laboratories, industrial representatives, environmental organizations, and many others have taken a proactive approach at identifying and characterizing the most promising options for technology deployment and carbon dioxide (CO2) utilization and storage (CCUS) for the Southeast. The results obtained during these injections will be important to the future commercialization of CCUS technologies and the continued use of fossil fuels as a significant energy source in a manner that is environmentally responsible. Each of the six SECARB project locations has been locally coordinated by its own field team. The field teams assume responsibility for the technical scope of work, local education and outreach, permitting, monitoring, verification, and accounting (MVA), and maintaining the validation test’s schedule and budget. Each team contributes new information to the continued characterization of the region. In addition, a task is dedicated to integrating field data and filling gaps in regional characterization data sets. Data and tools developed in the Continued Characterization task are incorporated into a relational database and geographic information system (GIS). All field tests, the continued characterization project, and the cross-cutting functions are designed to support the DOE roadmap by validating technologies and identifying locations throughout the region that could support full-scale CCUS deployment opportunities. Detailed fact sheets for the SECARB projects are available on the SECARB website at www.secarbon.org (see “Projects” tab).

RCSP↗

DOE OSTI2022

Wood combustion nanoparticles emitted by conventional and advanced technology cordwood boilers, and their interactions in vitro with human lung epithelial monolayers

Biomass-burning boilers and stoves are widely used in many parts of the world, producing combustion emissions linked with health risks. Here, combustion emission nanoparticles (NPs) were collected from four representative wood burning boilers using oak cordwood at specific times in the burn cycle. The morphology and composition of the NPs was characterized using transmission electron microscopy and energy dispersive X-ray analysis. To determine the degree of NP cytotoxicity with human lung tissue, the combustion NPs were introduced to incubated lung bronchial epithelial monolayers (NCI-H292) in vitro at doses of 0.1×10 -6 and 3.0×10 -6 kg/L for 2 and 4 h. Histochemical analysis showed that cell death increased by a factor of 3.5 for both doses after 4 h when compared to the control. Ultrapure NPs prepared by wet chemical methods were also introduced to the epithelial lung cells for similar doses and exposure times and the cultures exhibited significantly reduced mortality. Electron microscopy was used to study the mechanism of cell mortality for the synthesized and combustion-based NPs by examining how the NP byproducts interacted with individual cell organelles. It was found that cell survival was strongly correlated with the absence of contaminants (salts, heavy metals, poly aromatic hydrocarbons) associated with the NPs entering the cells. Synthesized NPs consisting of pure carbon were relatively well tolerated and could be excreted without damaging the cell ultrastructure. Thus, careful removal of extraneous contaminants by controlling the burn cycle with a catalyst is essential to minimize the health and environmental effects of wood biofuel combustion. In better words, optimized advanced technology wood-burning boilers and stoves can provide a CO 2 -neutral energy source and significantly contribute to a future where fossil fuels have a reduced role.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2015

Ecological objectives can be achieved with wood-derived bioenergy

Renewable, biomass-based energy options can reduce the climate impacts of fossil fuels. However, calculating the effects of wood-derived bioenergy on greenhouse gases (GHGs), and thus on climate, is complicated (Miner et al. 2015). To clarify concerns and options about bioenergy, in November 2014, the US Environmental Protection Agency (EPA) produced a second draft of its Framework for Assessing Biogenic CO 2 Emissions fromStationary Sources (http://1.usa.gov/1dikgHq), which considers the latest scientific information and input from stakeholders. Furthermore, the EPA is expected to make decisions soon about the use of woody biomass under the Clean Power Plan, which sets targets for carbon pollution from power plants.

09 BIOMASS FUELS↗

DOE OSTI2022

liionpack: A Python package for simulating packs of batteries with PyBaMM

Electrification of transport and other energy intensive activities is of growing importance as it provides an underpinning method to reduce carbon emissions. With an increase in reliance on renewable sources of energy and a reduction in the use of more predictable fossil fuels in both stationary and mobile applications, energy storage will play a pivotal role and batteries are currently the most widely adopted and versatile form. Therefore, understanding how batteries work, how they degrade, and how to optimize and manage their operation at large scales is critical to achieving emission reduction targets. The electric vehicle (EV) industry requires a considerable number of batteries even for a single vehicle, sometimes numbering in the thousands if smaller cells are used, and the dynamics and degradation of these systems, as well as large stationary power systems, is not that well understood. As increases in the efficiency of a single battery become diminishing for standard commercially available chemistries, gains made at the system level become more important and can potentially be realised more quickly compared with developing new chemistries. Mathematical models and simulations provide a way to address these challenging questions and can aid the engineer and designers of batteries and battery management systems to provide longer lasting and more efficient energy storage systems.

25 ENERGY STORAGE↗

DOE OSTI2023

DPFEHM: a differentiable subsurface physics simulator

The Earth’s subsurface is a key resource that provides energy via fossil fuels and geothermal sources, stores drinking water, and is used in the fight against climate change via carbon sequestration. Simulating the physical processes that occur in the Earth’s subsurface with computers enables better use of this resource. DPFEHM is a Julia package that includes computer models with a focus on the Earth’s subsurface, especially fluid flow, which is critical for the aforementioned applications. DPFEHM is able to solve the groundwater flow equations (single phase flow), Richards equation (air/water), the advection-dispersion equation, and the 2d wave equation. One of the key features of DPFEHM is that it supports automatic differentiation, so it can be integrated into machine learning workflows using frameworks such as Flux or PyTorch. The automatic differentiation capabilities give it the same performance as adjoint methods.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2024

EchemFEM: A Firedrake-based Python package for electrochemical transport

The transition from fossil fuels to renewable energy has brought about a rapid increase in the availability of clean electricity. However, electricity generated from sources such as wind and solar are limited to intermittent operation due to daily and seasonal variation. One solution is to utilize electrochemical devices in energy storage and electrochemical manufacturing applications, where they can harness surplus energy and decarbonize chemical industries traditionally reliant on petrochemical feedstocks. Managing the growing prevalence of renewable energy underscores the importance of developing and scaling up these technologies, which can in turn facilitate the achievement of carbon emission reduction commitments of companies and developed economies. Likewise, the electrification of transport creates an increasing need for energy-dense electrochemical energy storage devices such as batteries and supercapacitors. Naturally, simulation tools are required to assist in the design of efficient and industrial-scale electrochemical devices.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2021

Modeling Contact Angle vs. Temperature for the Quartz-Water-Decane System

Innovative approaches are needed to improve the efficiency of oil recovery technologies to meet the growing demands of fossil-fuel based energy consumption. Enhanced oil recovery (EOR) methods such as low-salinity waterflooding and chemically tuned waterflooding aim to optimize the reservoir’s wetting properties, detaching oil globules from rock surfaces and allowing easier oil flow through pore throats. This wetting behavior is commonly quantified by contact angle measurements of the rock-oil-brine interface, which have been thoroughly investigated and theorized for many systems at ambient temperatures and pressures. However, few studies exist for extending contact angle theories away from ambient conditions. In this paper, we model the contact angles of a quartz-water-decane system at elevated temperatures using the surface tension component (STC) approach. Temperature-dependent van der Waals [Lifshitz-van der Waals (LW)] interactions and hydrogen-bonding (acid-base) interactions were calculated and are incorporated into the model for the quartz-water-decane interface. Additionally, the Hough and White procedure was used to create temperature-dependent dielectric functions of quartz, water, and normal decane for calculations of Hamaker coefficients. Hamaker coefficients calculated this way are highly linear with temperature and agree well with Israelachvili’s approximation. The acid-base interactions likely contribute the most to system wettability changes. Resulting contact angles of the quartz-water-decane system shift from water-wet (16°) to slightly water-wet (57.4°) as temperature increases. The model was also successfully verified for the quartz-air-water system. Our results can be used in future studies to determine optimal injected water compositions for specific rock-oil-brine and other systems with consideration of reservoir temperature.

02 PETROLEUM↗

DOE OSTI2015

Integrated PEV Charging Solutions and Reduced Energy for Occupant Comfort [Brochure]

Brochure on Vehicle Testing and Integration Facility, featuring the Vehicle Modification Facility, Vehicle Test Pad and ReCharge Integrated Demonstration System. Plug-in electric vehicles (PEVs) offer the opportunity to shift transportation energy demands from petroleum to electricity, but broad adoption will require integration with other systems. While automotive experts work to reduce the cost of PEVs, fossil fueled cars and trucks continue to burn hundreds of billions of gallons of petroleum each year - not only to get from point A to point B, but also to keep passengers comfortable with air conditioning and heat. At the National Renewable Energy Laboratory (NREL), three installations form a research laboratory known as the Vehicle Testing and Integration Facility (VTIF). At the VTIF, engineers are developing strategies to address two separate but equally crucial areas of research: meeting the demands of electric vehicle-grid integration and minimizing fuel consumption related to vehicle climate control. Part of NREL's Center for Transportation Technologies and Systems (CTTS), the VTIF is dedicated to renewable and energy efficient solutions. This facility showcases technology and systems designed to increase the viability of sustainably powered vehicles. NREL researchers instrument every class of on-road vehicle, conduct hardware and software validation for electric vehicle (EV) components and accessories, and develop analysis tools and technology for the Department of Energy, other government agencies and industry partners. Research conducted at the VTIF examines the interaction of building energy systems, utility grids, renewable energy sources and PEVs, integrating energy management solutions, and maximizing potential greenhouse gas (GHG) reduction, while smoothing the transition and reducing costs for EV owners. NREL's collaboration with automakers, charging station manufacturers, utilities and fleet operators to assess technologies using VTIF resources is designed to enable PEV communication with the smart grid and create opportunities for vehicles to play an active role in building and grid management. Ultimately, this creates value for the vehicle owner and will help renewables be deployed faster and more economically, making the U.S. transportation sector more flexible and sustainable.

02 PETROLEUM↗

DOE OSTI2011

A Greenhouse-Gas Information System: Monitoring and Validating Emissions Reporting and Mitigation

Current GHG-mitigating regimes, whether internationally agreed or self-imposed, rely on the aggregation of self-reported data, with limited checks for consistency and accuracy, for monitoring. As nations commit to more stringent GHG emissions-mitigation actions and as economic rewards or penalties are attached to emission levels, self-reported data will require independent confirmation that they are accurate and reliable, if they are to provide the basis for critical choices and actions that may be required. Supporting emissions-mitigation efforts and agreements, as well as monitoring energy- and fossil-fuel intensive national and global activities would be best achieved by a process of: (1) monitoring of emissions and emission-mitigation actions, based, in part, on, (2) (self-) reporting of pertinent bottom-up inventory data, (3) verification that reported data derive from and are consistent with agreed-upon processes and procedures, and (4) validation that reported emissions and emissions-mitigation action data are correct, based on independent measurements (top-down) derived from a suite of sensors in space, air, land, and, possibly, sea, used to deduce and attribute anthropogenic emissions. These data would be assessed and used to deduce and attribute measured GHG concentrations to anthropogenic emissions, attributed geographically and, to the extent possible, by economic sector. The validation element is needed to provide independent assurance that emissions are in accord with reported values, and should be considered as an important addition to the accepted MRV process, leading to a MRV&V process. This study and report focus on attributes of a greenhouse-gas information system (GHGIS) needed to support MRV&V needs. These needs set the function of such a system apart from scientific/research monitoring of GHGs and carbon-cycle systems, and include (not exclusively): the need for a GHGIS that is operational, as required for decision-support; the need for a system that meets specifications derived from imposed requirements; the need for rigorous calibration, verification, and validation (CV&V) standards, processes, and records for all measurement and modeling/data-inversion data; the need to develop and adopt an uncertainty-quantification (UQ) regimen for all measurement and modeling data; and the requirement that GHGIS products can be subjected to third-party questioning and scientific scrutiny. This report examines and assesses presently available capabilities that could contribute to a future GHGIS. These capabilities include sensors and measurement technologies; data analysis and data uncertainty quantification (UQ) practices and methods; and model-based data-inversion practices, methods, and their associated UQ. The report further examines the need for traceable calibration, verification, and validation processes and attached metadata; differences between present science-/research-oriented needs and those that would be required for an operational GHGIS; the development, operation, and maintenance of a GHGIS missions-operations center (GMOC); and the complex systems engineering and integration that would be required to develop, operate, and evolve a future GHGIS. Present monitoring systems would be heavily relied on in any GHGIS implementation at the outset and would likely continue to provide valuable future contributions to GHGIS. However, present monitoring systems were developed to serve science/research purposes. This study concludes that no component or capability presently available is at the level of technological maturity and readiness required for implementation in an operational GHGIS today. However, purpose-designed and -built components could be developed and implemented in support of a future GHGIS. The study concludes that it is possible to develop and provide a capability-driven prototype GHGIS, as part of a Phase-1 effort, within three years from project-funding start, that would make use of and integrate existing sensing and system capabilities. As part of a Phase-2 effort, a requirements-driven, operational GHGIS could be developed, within ten years from project funding start. That schedule is driven by the development and long lead-times for some system components. The two efforts would be focused on different deliverables but could commence concurrently, to save time, if that was deemed desirable. We note that, developing and supporting an operational GHGIS will require a new approach and management, sustained funding and other support, as well as technical advances and development of purpose-built components that meet the requisite specifications. A functioning GHGIS will provide the basis for reasoned choices on how best to respond to rising GHG levels, especially when proposed U.S. actions are compared with or conditioned on the actions of other nations.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2012

Laboratory Experiments on the Effects of Blade Strike from Hydrokinetic Energy Technologies on Larval and Juvenile Freshwater Fishes

There is considerable interest in the development of marine and hydrokinetic energy projects in rivers, estuaries, and coastal ocean waters of the United States. Hydrokinetic (HK) technologies convert the energy of moving water in river or tidal currents into electricity, without the impacts of dams and impoundments associated with conventional hydropower or the extraction and combustion of fossil fuels. The Federal Energy Regulatory Commission (FERC) maintains a database that displays the geographical distribution of proposed HK projects in inland and tidal waters (FERC 2012). As of March 2012, 77 preliminary permits had been issued to private developers to study HK projects in inland waters, the development of which would total over 8,000 MW. Most of these projects are proposed for the lower Mississippi River. In addition, the issuance of another 27 preliminary permits for HK projects in inland waters, and 3 preliminary permits for HK tidal projects (totaling over 3,100 MW) were under consideration by FERC. Although numerous HK designs are under development (see DOE 2009 for a description of the technologies and their potential environmental effects), the most commonly proposed current-based projects entail arrays of rotating devices, much like submerged wind turbines, that are positioned in the high-velocity (high energy) river channels. The many diverse HK designs imply a diversity of environmental impacts, but a potential impact common to most is the risk for blade strike to aquatic organisms. In conventional hydropower generation, research on fish passage through reaction turbines at low-head dams suggested that strike and mortality for small fish could be low. As a consequence of the large surface area to mass ratio of small fish, the drag forces in the boundary layer flow at the surface of a rotor blade may pull small fish around the leading edge of a rotor blade without making physical contact (Turnpenny 1998, Turnpenny et al. 2000). Although there is concern that small, fragile fish early life stages may be unable to avoid being struck by the blades of hydrokinetic turbines, we found no empirical data in the published literature that document survival of earliest life-stage fish in passage by rotor blades. In addition to blade strike, research on passage of fish through conventional hydropower turbines suggested that fish mortalities from passage through the rotor swept area could also occur due to shear stresses and pressure chances in the water column (Čada et al. 1997, Turnpenny 1998). However, for most of the proposed HK turbine designs the rotors are projected to operate a lower RPM (revolutions per minute) than observed from conventional reaction turbines; the associated shear stress and pressure changes are expected to be lower and pose a smaller threat to fish survival (DOE 2009). Only a limited number of studies have been conducted to examine the risk of blade strike from hydrokinetic technologies to fish (Turnpenny et al. 1992, Normandeau et al. 2009, Seitz et al. 2011, EPRI 2011); the survival of drifting or weakly swimming fish (especially early life stages) that encounter rotor blades from hydrokinetic (HK) devices is currently unknown. Our study addressed this knowledge gap by testing how fish larvae and juveniles encountered different blade profiles of hydrokinetic devices and how such encounters influenced survivorship. We carried out a laboratory study designed to improve our understanding of how fish larvae and juvenile fish may be affected by encounters with rotor blades from HK turbines in the water column of river and ocean currents. (For convenience, these early life stages will be referred to as young of the year, YOY). The experiments developed information needed to quantify the risk (both probability and consequences) of rotor-blade strike to YOY fish. In particular, this study attempted to determine whether YOY drifting in a high-velocity flow directly in the path of the blade leading edge will make contact with the rotor blade or will bypass the blade while entrained in the boundary layer of water flowing over the blade surface. The study quantified both immediate and delayed mortalities (observed immediately, 3 hours, and 24 hours after encountering the blade) among freshwater YOY fish resulting from contact with the blade or turbulent flows in the wake of the blade.

13 HYDRO ENERGY↗

DOE OSTI2012

Foundation Heat Exchanger Final Report: Demonstration, Measured Performance, and Validated Model and Design Tool

Geothermal heat pumps, sometimes called ground-source heat pumps (GSHPs), have been proven capable of significantly reducing energy use and peak demand in buildings. Conventional equipment for controlling the temperature and humidity of a building, or supplying hot water and fresh outdoor air, must exchange energy (or heat) with the building's outdoor environment. Equipment using the ground as a heat source and heat sink consumes less non-renewable energy (electricity and fossil fuels) because the earth is cooler than outdoor air in summer and warmer in winter. The most important barrier to rapid growth of the GSHP industry is high first cost of GSHP systems to consumers. The most common GSHP system utilizes a closed-loop ground heat exchanger. This type of GSHP system can be used almost anywhere. There is reason to believe that reducing the cost of closed-loop systems is the strategy that would achieve the greatest energy savings with GSHP technology. The cost premium of closed-loop GSHP systems over conventional space conditioning and water heating systems is primarily associated with drilling boreholes or excavating trenches, installing vertical or horizontal ground heat exchangers, and backfilling the excavations. This project investigates reducing the cost of horizontal closed-loop ground heat exchangers by installing them in the construction excavations, augmented when necessary with additional trenches. This approach applies only to new construction of residential and light commercial buildings or additions to such buildings. In the business-as-usual scenario, construction excavations are not used for the horizontal ground heat exchanger (HGHX); instead the HGHX is installed entirely in trenches dug specifically for that purpose. The potential cost savings comes from using the construction excavations for the installation of ground heat exchangers, thereby minimizing the need and expense of digging additional trenches. The term foundation heat exchanger (FHX) has been coined to refer exclusively to ground heat exchangers installed in the overcut around the basement walls. The primary technical challenge undertaken by this project was the development and validation of energy performance models and design tools for FHX. In terms of performance modeling and design, ground heat exchangers in other construction excavations (e.g., utility trenches) are no different from conventional HGHX, and models and design tools for HGHX already exist. This project successfully developed and validated energy performance models and design tools so that FHX or hybrid FHX/HGHX systems can be engineered with confidence, enabling this technology to be applied in residential and light commercial buildings. The validated energy performance model also addresses and solves another problem, the longstanding inadequacy in the way ground-building thermal interaction is represented in building energy models, whether or not there is a ground heat exchanger nearby. Two side-by-side, three-level, unoccupied research houses with walkout basements, identical 3,700 ft{sup 2} floor plans, and hybrid FHX/HGHX systems were constructed to provide validation data sets for the energy performance model and design tool. The envelopes of both houses are very energy efficient and airtight, and the HERS ratings of the homes are 44 and 45 respectively. Both houses are mechanically ventilated with energy recovery ventilators, with space conditioning provided by water-to-air heat pumps with 2 ton nominal capacities. Separate water-to-water heat pumps with 1.5 ton nominal capacities were used for water heating. In these unoccupied research houses, human impact on energy use (hot water draw, etc.) is simulated to match the national average. At House 1 the hybrid FHX/HGHX system was installed in 300 linear feet of excavation, and 60% of that was construction excavation (needed to construct the home). At House 2 the hybrid FHX/HGHX system was installed in 360 feet of excavation, 50% of which was construction excavation. There are six pipes in all excavations (three parallel circuits - out and back), and the multiple instances of FHX and/or HGHX are all connected in series. The working fluid is 20% by weight propylene glycol in water. Model and design tool development was undertaken in parallel with constructing the houses, installing instrumentation, and monitoring performance for a year. Several detailed numerical models for FHX were developed as part of the project. Essentially the project team was searching for an energy performance model accurate enough to achieve project objectives while also having sufficient computational efficiency for practical use in EnergyPlus. A 3-dimensional, dual-coordinate-system, finite-volume model satisfied these criteria and was included in the October 2011 EnergyPlus Version 7 public release after being validated against measured data.

15 GEOTHERMAL ENERGY↗

DOE OSTI2012

Tidal Energy System for On-Shore Power Generation (Final Technical Report)

Addressing the urgent need to develop LCOE competitive renewable energy solutions for US energy security and to replace fossil-fuel generation with the associated benefits to environment impacts including a reduction in CO2 emissions, this Project focused on the advantages of using hydraulic energy transfer (HET) in large-scale Marine Hydrokinetic (MHK) systems for harvesting off-shore tidal energy in US waters. A recent DOE resource assessment, identifies water power resources have a potential to meet 15% of the US electric supply by 2030, with MHK technologies being a major component. The work covered a TRL-4 laboratory proof-in-concept demonstration plus modeling of a 15MW full scale system based on an approach patented by NASA-JPL, in which submerged high-ratio gearboxes and electrical generators in conventional MHK turbine systems are replaced by a submerged hydraulic radial pump coupled to on-shore hydraulic motors driving a generator. The advantages are; first, the mean-time-between-failure (MTBF), or maintenance, can be extended from approximately 1 to 5 years and second, the range of tidal flow speeds which can be efficiently harvested can be extended beyond that of a conventional submerged generator. The approach uses scalable, commercial-off-the-shelf (COTS) components, facilitating scale-up and commercialization. All the objectives of the Project have been successfully met (1) A TRL4 system was designed, constructed and tested. It simulates a tidal energy turbine, with a 2-m diameter blade in up to a 2.9 m/sec flow. The system consists of a drive motor assembly providing appropriate torque and RPM, attached to a radial piston pump. The pump circulates pressurized, environmentally-friendly, HEES hydraulic fluid in a closed loop to an axial piston motor which drives an electrical generator, with a resistive load. The performance of the components, subsystems and system were evaluated during simulated tidal cycles. The pump is contained in a tank for immersion testing. The COTS pump and motor were selected to scale to MW size and were oversized for the TRL-4 demonstration, operating at only 1-6% of rated values. Nevertheless, in for 2-18 kW drive power, in agreement with manufacturer performance data, we measured efficiencies of 85-90% and 75-80% for the pump and motor, respectively. These efficiencies being 95-96% at higher operating powers. (2) Two follow-on paths were identified. In both cases conventional turbine systems can be modified, replacing existing gear box and generator with a hydraulic pump and on-shore components. On a conventional path, a TRL5/6 15kW turbine system can be engineered and tested on a barge at an existing site in Maine. Alternatively, on an accelerated path, a TRL-8 100kW system can be engineered and tested by modifying a team member's existing MHK turbines, with barge and grid-connected test sites in-place. On both paths the work can be expedited and cost effective by reusing TRL-4 components, modifying existing turbines and using established test sites. (3) Sizing, performance modeling and costing of a scaled 15MW system, suitable for operation in Maine's Western Passage, was performed. COTS components are identified and the performance projections are favorable. The estimated LCOE is comparable to wind generation with peak production at high demand times. (4) We determined that a similar HET approach can be extended to on-shore and off-shore wind turbine systems. These are very large energy resources which can be addressed in parallel for even great National benefit. (5) Preliminary results on this project were presented at two International Conferences on renewable energy in 2012, providing a timely dissemination of information. We have thus demonstrated a proof-in-concept of a novel, tidal HET system that eliminates all submerged gears and electronics to improve reliability. Hydraulic pump efficiencies of 90% have been confirmed in simulated tidal flows between 1 and 3 m/s, and at only 1-6% of rated power. Total system efficiencies have also been modeled, up to MW-scale, for tidal, and wind, systems. Projected efficiencies are between 81% (full rated flow) and 86% (1/3 rated flow). This high efficiency in a wide operating range compares favorably with conventional systems having a performance range of 87% (full rated flow) to 0% (1/3 rated flow) efficiency. An accelerated path to commercialization is identified, leveraging conventional MHK system technology and COTS components to meet the urgent need for renewable energy generation.

16 TIDAL AND WAVE POWER↗

DOE OSTI2012

Functional Multi-Layer Solution Processable Polymer Solar Cells (Final Closeout Report)

The original objectives were: (1) Develop a method to deposit multiple conjugated polymer film layers and avoid the problem of dissolution from mutually solubility; (2) Use this deposition method to develop multi-layer polymer based solar cells with layers that are function specific; (3) characterize these layers and devices; (4) develop electrical and optical models that describe and predict the properties of the multi-layers; and (5) Ultimate efficiency goals are ≈6.75% with J sc = 12 mA/cm 2 , FF = 0.75, and V oc = 0.75. The question of whether photovoltaic (PV) cells will ever be able to replace fossil fuels as the main provider of electrical power is not just a question of device efficiency; it is a question of how much power can be provided for what price. It has been well documented that PV devices at 10% power efficiency can provide for all of the world's power needs without covering too much of the earth's surface. Assuming desert like cloud coverage, an area equivalent to the land area of Texas would have to be covered. However, it has also been shown that using the current state-of-the-art silicon devices, the price-per-Watt will never be low enough to be economically feasible for large-scale development. Solution-processable PV devices based on polymers are a very attractive alternative to traditional Silicon PV because this technology is much lower in materials cost and in environmentally toxic waste production. Solution-based polymers can be rapidly deposited using printing technologies and are compatible with light-weight flexible substrates that can increase the range of available PV applications. In the past ten years, the efficiency of polymer based PV devices has increased from ≈1% to over 10%. The highest efficiency organic solar cells are based upon a single layer than consists of a mixture of donor and acceptor moieties. This one layer has multiple optical and electrical functions, so the design of a single heterojunction layer is based upon the idea of balancing good and bad properties within a single film. This proposal addresses the idea that the use of multiple layers that have differing electrical and optical functions could lead to greater efficiency because fewer materials compromises must be made. This idea is not new, multiple functional layer have been successfully used in cross-linked OLED's and organic small molecule evaporated PV devices. The main reason that multiple layers of polymers are not commonly deposited is that most conjugated polymers are mutually soluble in the same solvents. The work outlined in the proposal was intended to develop a new deposition strategy that would allow multiple organic layers to be deposited from solution using spin coating. The deposition method that we proposed was successful, sometimes, but ultimately not reliable. Instead we focused on more reliable methods to implement doping along the interface between layers. This work has been very successful. We found that using PEDOT:PSS, the PSS would form a surface layer of ≈2-3 nm thickness that would mix with and electrochemically react with P3HT upon heating. This mechanism is also a crosslinking reaction in that H 2 is released and permanent new bonds are formed. Using the Plextronics Inc. replacement to PEDOT:PSS, for which there are no mobile dopants, we were able to show that a second and different mechanism can be used to p-type dope organic materials. We are currently working with Plextronics to develop a new product. Finally we produced n-type doping of a thin fullerene layer near the cathode also using a self-assembly method. Low work function metals will diffuse into the BHJ layer and dope the fullerene upon heating. This doping also affects the vertical segregation of BHJ materials in a predictable way. We accomplished all of the scientific goals that we set out in the proposal written in May 2007. Some of the methods we proposed were not fully successful, but we did come up with better methods to achieve the same goal. We did not achieve the efficiency goal for this proposal. We did increase V oc and explain why, but the same effect did not affect FF or J sc as we had proposed.

14 SOLAR ENERGY↗

DOE OSTI2012

Immediate Deployment of Waste Energy Recovery Technologies at Multi Sites

Verso Paper Corp. implemented a portfolio of 13 commercially available proven industrial technologies each exceeding 30% minimum threshold efficiency and at least 25% efficiency increase. These sub-projects are a direct result of a grant received from the Department of Energy (DOE) through its FOA 0000044 (Deployment of Combined Heat and Power (CHP) Systems, District Energy Systems, Waste Energy Recovery Systems, and Efficient Industrial Equipment), which was funded by the American Recovery Act. These were installed at 3 sites in 2 states and are helping to reduce Verso costs, making the facilities more competitive. This created approximately 100 construction jobs (FTE's) and reduced impacted Verso facilities' expense budgets. These sub-projects were deployed at Verso paper mills located in Jay, Maine, Bucksport, Maine, and Sartell, Minnesota. The paper mills are the economic engines of the rural communities in which these mills are located. Reinvestment in waste energy recovery capital improvements is providing a stimulus to help maintain domestic jobs and to competitively position the US pulp and paper industry with rising energy costs. Energy efficiency improvements are also providing a positive environmental impact by reducing greenhouse gas emissions, the quantity of wastewater treated and discharged, and fossil fuel demand. As a result of these projects, when fully operating, Verso realized a total of approximately 1.5 TBtu/Year reduction in overall energy consumption, which is 119% of the project objectives. Note that three paper machines have since been permanently curtailed. However even with these shutdowns, the company still met its energy objectives. Note also that the Sartell mill's paper machine is down due to a recent fire which damaged the mill's electrical infrastructure (the company has not decided on the mill's future).

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2012

Effect of Component Failures on Economics of Distributed Photovoltaic Systems

This report describes an applied research program to assess the realistic costs of grid connected photovoltaic (PV) installations. A Board of Advisors was assembled that included management from the regional electric power utilities, as well as other participants from companies that work in the electric power industry. Although the program started with the intention of addressing effective load carrying capacity (ELCC) for utility-owned photovoltaic installations, results from the literature study and recommendations from the Board of Advisors led investigators to the conclusion that obtaining effective data for this analysis would be difficult, if not impossible. The effort was then re-focused on assessing the realistic costs and economic valuations of grid-connected PV installations. The 17 kW PV installation on the University of Hartford's Lincoln Theater was used as one source of actual data. The change in objective required a more technically oriented group. The re-organized working group (changes made due to the need for more technically oriented participants) made site visits to medium-sized PV installations in Connecticut with the objective of developing sources of operating histories. An extensive literature review helped to focus efforts in several technical and economic subjects. The objective of determining the consequences of component failures on both generation and economic returns required three analyses. The first was a Monte-Carlo-based simulation model for failure occurrences and the resulting downtime. Published failure data, though limited, was used to verify the results. A second model was developed to predict the reduction in or loss of electrical generation related to the downtime due to these failures. Finally, a comprehensive economic analysis, including these failures, was developed to determine realistic net present values of installed PV arrays. Two types of societal benefits were explored, with quantitative valuations developed for both. Some societal benefits associated with financial benefits to the utility of having a distributed generation capacity that is not fossil-fuel based have been included into the economic models. Also included and quantified in the models are several benefits to society more generally: job creation and some estimates of benefits from avoiding greenhouse emissions. PV system failures result in a lowering of the economic values of a grid-connected system, but this turned out to be a surprisingly small effect on the overall economics. The most significant benefit noted resulted from including the societal benefits accrued to the utility. This provided a marked increase in the valuations of the array and made the overall value proposition a financially attractive one, in that net present values exceeded installation costs. These results indicate that the Department of Energy and state regulatory bodies should consider focusing on societal benefits that create economic value for the utility, confirm these quantitative values, and work to have them accepted by the utilities and reflected in the rate structures for power obtained from grid-connected arrays. Understanding and applying the economic benefits evident in this work can significantly improve the business case for grid-connected PV installations. This work also indicates that the societal benefits to the population are real and defensible, but not nearly as easy to justify in a business case as are the benefits that accrue directly to the utility.

14 SOLAR ENERGY↗

DOE OSTI2012

Fort Carson Wind Resource Assessment

The U.S. Army has long been interested in reducing its dependence on fossil fuels for energy, increasing its energy security, and reducing its energy intensity. Increasing the use of renewable energy at Army bases serves all of these goals. As part of these efforts, the Army has been collaborating with the U.S. Department of Energy’s (DOE’s) National Renewable Energy Laboratory (NREL) to evaluate renewable energy options at Fort Carson, Colorado. This report focuses on the wind resource assessment, the estimated energy production of wind turbines, and economic potential of a wind turbine project on a ridge in the southeastern portion of the Fort Carson Army base. Wind data was collected from a 50-meter (m) meteorological (met) tower on a small ridge in the southeastern part of the Fort Carson base. A mini sonic detection and ranging (miniSODAR) unit was also deployed at this site to measure wind speeds at elevations 30 to 140 m (98 to 459 ft) above the ground. The data collected provided an effective dataset for comparative analysis of wind speed, turbulence intensity, and energy production of several wind turbines suitable for the wind conditions at the site.

17 WIND ENERGY↗

DOE OSTI2012

Modeling thermal abuse in transportation batteries

Transition from fossil-fueled to electrified vehicles depends on developing economical, reliable batteries with high energy densities and long life. Safety, preventing premature or catastrophic failure, is of paramount importance in battery design. The largest gaps in our technical understanding of the safe operation of electrical energy storage devices involve the fundamental mechanisms, energetics, and inefficiencies of complex processes that occur during battery operation that can lead to thermal runaway: charge transfer, charge carrier and ion transport, both in the bulk and at various interfaces, and morphological and phase transitions associated with Li ion transport between cathode and anode. We have developed a suite of modeling tools to consider phenomena related to battery safety, thermal management, and the onset of thermal runaway in transportation-based secondary Li-ion batteries, rooted in a first-principles description of the governing atomistic processes at the electrode-electrolyte interface, propagating chemical information through multiple scales to a continuum-scale description of thermal transport and failure capable of addressing a variety of operational and thermal excursion conditions. These tools enable the identification of potential safety and stability issues of new battery designs prior to experimental realization.

Muller, Richard Partain↗