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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 1,585 records · Page 88
All sourcesNASA NTRSDOE OSTI
DOE OSTI2012

High-Efficiency Low-Cost Thin-Film GaAs Photovoltaic Module Development Program: July 14, 2010 - January 13, 2012 (Final Technical Progress Report)

This is the final technical progress report of the High-Efficiency Low-Cost Thin-Film GaAs Photovoltaic Module Development Program. Alta Devices has successfully completed all milestones and deliverables established as part of the NREL PV incubator program. During the 18 months of this program, Alta has proven all key processes required to commercialize its solar module product. The incubatorfocus was on back end process steps directed at conversion of Alta's high quality solar film into high efficiency 1-sun PV modules. This report describes all program deliverables and the work behind each accomplishment.

14 SOLAR ENERGY↗
DOE OSTI2013

Life Cycle Analysis and Recycling of CdTe Solar Modules

Photovoltaic modules may contain small amounts of regulated materials, which vary from one type to another. The photovoltaic industry is investigating module recycling options as part of their pro- active long-term environmental strategy to preserve the environmental friendliness of solar cells. Previous studies at Brookhaven National Laboratory (BNL) and First Solar L.L.C. (FS) showed that recycling is technologically and economically feasible, but further research is needed to achieve complete separation and recovery of the metals. Brookhaven's PV EH&S Program and First Solar have collaborated in the past in the area of recycling research, with First Solar supplying samples of PV modules and samples of manufacturing waste that BNL needed for its research.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2013

Preliminary Thermal Modeling of Hi-Storm 100S-218 Version B Storage Modules at Hope Creek Nuclear Power Station ISFSI

This report fulfills the M3 milestone M3FT-13PN0810022, “Report on Inspection 1”, under Work Package FT-13PN081002. Thermal analysis is being undertaken at Pacific Northwest National Laboratory (PNNL) in support of inspections of selected storage modules at various locations around the United States, as part of the Used Fuel Disposition Campaign of the U.S. Department of Energy, Office of Nuclear Energy (DOE-NE) Fuel Cycle Research and Development. This report documents pre-inspection predictions of temperatures for four modules at the Hope Creek Nuclear Generating Station ISFSI that have been identified as candidates for inspection in late summer or early fall/winter of 2013. These are HI-STORM 100S-218 Version B modules storing BWR 8x8 fuel in MPC-68 canisters. The temperature predictions reported in this document were obtained with detailed COBRA-SFS models of these four storage systems, with the following boundary conditions and assumptions.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2012

Ultrafast Power Processor for Smart Grid: Power Module Development

This project’s goal was to increase the switching speed and decrease the losses of the power semiconductor devices and power switch modules necessary to enable Smart Grid energy flow and control equipment such as the Ultra-Fast Power Processor. The primary focus of this project involves exploiting the new silicon-based Super-GTO (SGTO) technology and build on prototype modules already being developed. The prototype super gate-turn-off thyristor (SGTO) has been tested fully under continuously conducting and double-pulse hard-switching conditions for conduction and switching characteristics evaluation. The conduction voltage drop measurement results indicate that SGTO has excellent conduction characteristics despite inconsistency among some prototype devices. Tests were conducted with two conditions: (1) fixed gate voltage and varying anode current condition, and (2) fixed anode current and varying gate voltage condition. The conduction voltage drop is relatively a constant under different gate voltage condition. In terms of voltage drop as a function of the load current, there is a fixed voltage drop about 0.5V under zero current condition, and then the voltage drop is linearly increased with the current. For a 5-kV voltage blocking device that may operate under 2.5-kV condition, the projected voltage drop is less than 2.5 V under 50-A condition, or 0.1%. If the device is adopted in a converter operating under soft-switching condition, then the converter can achieve an ultrahigh efficiency, typically above 99%. The two-pulse switching test results indicate that SGTO switching speed is very fast. The switching loss is relatively low as compared to that of the insulated-gate-bipolar-transistors (IGBTs). A special phenomenon needs to be noted is such a fast switching speed for the high-voltage switching tends to create an unexpected Cdv/dt current, which reduces the turn-on loss because the dv/dt is negative and increases the turn-off loss because the dv/dt is positive. As a result, the turn-on loss at low current is quite low, and the turn-off loss at low current is relatively high. The phenomenon was verified with junction capacitance measurement along with the dv/dt calculation. Under 2-kV test condition, the turn-on and turn-off losses at 25-A is about 3 and 9 mJ, respectively. As compared to a 4.5-kV, 60-A rated IGBT, which has turn-on and turn-off losses about 25 and 20 mJ under similar test condition, the SGTO shows significant switching loss reduction. The switching loss depends on the switching frequency, but under hard-switching condition, the SGTO is favored to the IGBT device. The only concern is during low current turn-on condition, there is a voltage bump that can translate to significant power loss and associated heat. The reason for such a current bump is not known from this study. It is necessary that the device manufacturer perform though test and provide the answer so the user can properly apply SGTO in pulse-width-modulated (PWM) converter and inverter applications.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2013

Design of a Marx-Topology Shaped-Pulse Modulator for FNAL

Fermi National Accelerator Laboratory is undergoing an effort to upgrade the 201 MHz Proton Source system. One subset of this upgrade is addressing the triode modulator reliability and performance issues. SLAC National Accelerator Laboratory proposes a Marxtopology modulator to replace the existing system. This paper presents the system design of this modulator, the SLAC F1 Marx.

Kemp, M. A.↗
DOE OSTI2014

GREET Pretreatment Module

A wide range of biofuels and biochemicals can be produced from cellulosic biomass via different pretreatment technologies that yield sugars. Process simulations of dilute acid and ammonia fiber expansion pretreatment processes and subsequent hydrolysis were developed in Aspen Plus for four lignocellulosic feedstocks (corn stover, miscanthus, switchgrass, and poplar). This processing yields sugars that can be subsequently converted to biofuels or biochemical. Material and energy consumption data from Aspen Plus were then compiled in a new Greenhouses Gases, Regulated Emissions, and Energy Use in Transportation (GREET TM ) pretreatment module. The module estimates the cradle-to-gate fossil energy consumption (FEC) and greenhouse gas (GHG) emissions associated with producing fermentable sugars. This report documents the data and methodology used to develop this module and the cradle-to-gate FEC and GHG emissions that result from producing fermentable sugars.

09 BIOMASS FUELS↗
DOE OSTI2015

Update on ORNL TRANSFORM Tool: Simulating Multi-Module Advanced Reactor with End-to-End I&C

The Small Modular Reactor (SMR) Dynamic System Modeling Tool project is in the fourth year of development. The project is designed to support collaborative modeling and study of various advanced SMR (non-light water cooled reactor) concepts, including the use of multiple coupled reactors at a single site. The focus of this report is the development of a steam generator and drum system model that includes the complex dynamics of typical steam drum systems, the development of instrumentation and controls for the steam generator with drum system model, and the development of multi-reactor module models that reflect the full power reactor innovative small module design concept. The objective of the project is to provide a common simulation environment and baseline modeling resources to facilitate rapid development of dynamic advanced reactor models; ensure consistency among research products within the Instrumentation, Controls, and Human-Machine Interface technical area; and leverage cross-cutting capabilities while minimizing duplication of effort. The combined simulation environment and suite of models are identified as the TRANSFORM tool. The critical elements of this effort include (1) defining a standardized, common simulation environment that can be applied throughout the Advanced Reactors Technology program; (2) developing a library of baseline component modules that can be assembled into full plant models using available geometry, design, and thermal-hydraulic data; (3) defining modeling conventions for interconnecting component models; and (4) establishing user interfaces and support tools to facilitate simulation development (i.e., configuration and parameterization), execution, and results display and capture.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2015

Module Embedded Micro-inverter Smart Grid Ready Residential Solar Electric System

The “Module Embedded Micro-inverter Smart Grid Ready Residential Solar Electric System” program is focused on developing innovative concepts for residential photovoltaic (PV) systems with the following objectives: to create an Innovative micro-inverter topology that reduces the cost from the best in class micro-inverter and provides high efficiency (>96% CEC - California Energy Commission), and 25+ year warranty, as well as reactive power support; integrate micro-inverter and PV module to reduce system price by at least $0.25/W through a) accentuating dual use of the module metal frame as a large area heat spreader reducing operating temperature, and b) eliminating redundant wiring and connectors; and create micro-inverter controller handles smart grid and safety functions to simplify implementation and reduce cost.

14 SOLAR ENERGY↗
DOE OSTI2017

Innovative manufacturing technologies for low-cost, high efficiency PERC-based PV modules

The goal this project was to accelerate the deployment of innovative solar cell and module technologies that reduce the cost of PERC-based modules to best-in-class. New module integration technology was to be used to reduce the cost and reliance on conventional silver bus bar pastes and enhance cell efficiency. On the cell manufacturing front, the cost of PERC solar cells was to be reduced by introducing advanced metallization approaches to increase cell efficiency. These advancements will be combined with process optimization to target cell efficiencies in the range of 21 to 21.5%. This project will also explore the viability of a bifacial PERC solar cell design to enable cost savings through the use of thin silicon wafers. This project was terminated on 4/30/17 after four months of activity due financial challenges facing the recipient.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2017

Final Technical Report for Automated Manufacturing of Innovative CPV/PV Modules

Cogenra’s Dense Cell Interconnect system was designed to use traditional front-contact cells and string them together into high efficiency and high reliability “supercells”. This novel stringer allows one to take advantage of the ~100 GW/year of existing cell production capacity and create a solar product for the customer that will produce more power and last longer than traditional PV products. The goal for this program was for Cogenra Solar to design and develop a first-of-kind automated solar manufacturing line that produces strings of overlapping cells or “supercells” based on Cogenra’s Dense Cell Interconnect (DCI) technology for their Low Concentration Photovoltaic (LCPV) systems. This will enable the commercialization of DCI technology to improve the efficiency, reliability and economics for their Low Concentration Photovoltaic systems. In this program, Cogenra Solar very successfully designed, developed, built, installed, and started up the ground-breaking manufacturing tools required to assemble supercells. Cogenra then successfully demonstrated operation of the integrated line at high yield and throughput far exceeding expectations. The development of a supercell production line represents a critical step toward a high volume and low cost Low Concentration Photovoltaic Module with Dense Cell Interconnect technology and has enabled the evaluation of the technology for reliability and yield. Unfortunately, performance and cost headwinds on Low Concentration Photovoltaics systems including lack of diffuse capture (10-15% hit) and more expensive tracker requirements resulted in a move away from LCPV technology. Fortunately, the versatility of Dense Cell Interconnect technology allows for application to flat plate module technology as well and Cogenra has worked with the DOE to utilize the learning from this grant to commercialize DCI technology for the solar market through the on-going grant: Catalyzing PV Manufacturing in the US With Cogenra Solar’s Next-Generation Dense Cell Interconnect PV Module Manufacturing Technology. This program is now very successfully building off of this work and commercializing the technology to enable increased solar adoption.

14 SOLAR ENERGY↗
DOE OSTI2018

High-Efficiency Solid State Heat Pump Module

The baseline heat pumping technology today is dominated by vapor compression refrigeration cycle that involves use of global warming potential fluids (e.g. hydrofluorocarbons HFC). Current regulations (e.g. 2016 Kigali agreement) and market needs are driving HVAC&R related building, automotive and aerospace industries to safe, compact and cost-effective systems with low global warming potential (GWP) footprint (i.e. direct GWP impact) and higher efficiencies (i.e. indirect GWP impact) and low life cycle cost. Among the solid-state technology options, electrocaloric heat pumping (ECHP) technology has potential to be more efficient, quiet and compact than vapor compression systems. However, electrocaloric technology is still at low maturity, as expressed by standard technology readiness level (TRL) assessments and hence was the focus of the current effort. During the current research effort, UTRC proved feasibility (TRL2/3) of the direct-air ECHP concept by demonstrating cooling of ambient air by 8.4°C (under no load conditions) in a laboratory environment. To the team’s knowledge this is the largest direct air cooling demonstration using electrocaloric technology. The technology was matured from lab-scale dime-sized materials to module-scale dimensions and further demonstrated the feasibility of integrating these electrocaloric materials into modules for providing direct-air cooling. The use of inexpensive polymer-based materials validates the economic feasibility of the proposed technology. Future effort is required to further mature this promising technology to TRL 4/5 demonstrating module and system performance at full capacity and efficiency. Maturity to beyond TRL4/5 could be done with limited potential field trials. Successful field trials can pave the way for commercialization. At full commercialization, electrocaloric based heating and cooling technologies have the potential to enable annual energy savings upwards of a quadrillion BTUs and reduction of 10s of million metric tons/yr of Green-House Gas (GHG) emissions in the US, leapfrogging emerging technologies and disrupting traditional cooling and heating systems in residential and commercial HVAC applications and enabling new applications. This would result in reduction of energy imports, greenhouse gas (GHG) emissions and help create US jobs in this new technical area.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2018

Advanced QPSK Optical Modulators Using Lithium Niobate Thin Films (Final Scientific Report)

Lithium niobate thin film based optical modulator devices have been produced using this SBIR award. A bonding apparatus was developed that was used to bond lithium niobate to silicon at room temperature. The bonding apparatus was designed, assembled and qualified for production of thin film substrates. The optical properties of ion sliced thin films produced using this bonding apparatus was optimized to achieve low loss optical waveguides. Optical grating coupler and other component of the proposed optical modulator were designed. Preliminary results show the proposed method for making optical modulator meets the required customer specifications. All the required process steps for manufacturing of the devices were developed and optimized. Further funding is required to make a final prototype device that can be provided to customers.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Module OT PNM Field Demonstration Test Procedure

This document will detail a field demonstration test procedure for the Module OT device developed for the joint NREL-SNL DOE CEDS project titled "Modular Security Apparatus for Managing Distributed Cryptography for Command & Control Messages on Operational Technology (OT) Networks." The aim of this document is to create the testing and evaluation procedure for field demonstration of the device; this includes primarily functional testing and implementation testing at Public Service Company of New Mexico's (PNM's) Prosperity solar site environment. Specifically, the Module OT devices will be integrated into the Prosperity solar site system; traffic will be encrypted between several points of interest at the site (e.g., inverter micrologger and switch). The tests described in this document will be performed to assess the impact and effectiveness of the encryption capabilities provided by the Module OT device.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2020

Improved Performance of Cu(InGa)(SeS) 2 PV Modules Using the Reaction of Metal Precursors. Final Report

This project “Improved Performance of Cu(InGa)(SeS) 2 PV Modules using the Reaction of Metal Precursors” was a partnership led by the Institute of Energy Conversion (IEC) at the University of Delaware with Columbia University and the Molecular Foundry at the Lawrence Berkeley National Laboratory. The aim was to develop pathways to improve Cu(InGa)(SeS) 2 (CIGSS) thin film photovoltaic modules using processes compatible with low manufacturing cost. The CIGSS approach investigated was a two-step process including deposition of metal precursor films following by reaction in hydride gases utilizing IEC’s novel reactor. The process was similar to that under commercial development by the project’s industry partner Stion. When Stion went out of business mid-project the focus changed to a rapid thermal process considered more commercially viable. Approaches to improve the performance of solar cells using the reacted films focused on two material innovations. First, the overall Ga content was increased to increase the operating voltage, which is desirable for scale-up to commercial modules. Second, the processing and performance advantages arising from Ag alloying were investigated. Advanced characterization guided process and material development including control of relative composition gradients. Research on the formation of Cu-Ga-In metal precursors utilized sputtering deposition which is normally used in commercial applications. The work resulted in processes for deposition of precursor stacks with increased relative Ga content and effects of deposition parameters on morphology and phase composition were established. It was shown that the metal precursor films have comparable phase composition and morphology so subsequent reaction follows from the same starting point. The addition of Ag to the metal precursors gave more uniform morphology and improved adhesion of reacted films which enable higher reaction temperature for faster processing. A novel outcome was the discovery of a previously undocumented material phase in sputter-deposited and evaporated Ag-Cu-In-Ga thin films. Hydride gas reaction processes including time-temperature-concentration profiles were developed for different precursor compositions. This enables control of composition profiles to engineer through-film gradients for solar cell optimization with characterization and simulations used to correlate measured film composition profiles to measurements of devices. In particular, the gradient of sulfur at the front of the CIGSS film was found to be critical. The simulations guided process development leading to improved reproducibility of devices improved performance with higher Ga content and higher voltage. With Ag-alloyed precursors, the reaction pathways leading were determined. A significant finding was that Ag-alloying increases the reaction rate to completely convert precursor films to the final chalcopyrite which could enable reduced reaction time to benefit manufacturability. To maintain potential commercial viability, the process under investigation was refocused to a rapid thermal process that could potentially be incorporated into an in-line process for manufacturing. Precursors with different composition were capped with an extra selenium layer and reacted in hydrogen sulfide 5-15 minutes, compared to typically 2 hours in the previous multi-step batch process. Critical RTP parameters were identified to control the reaction. Further optimization would be needed for high efficiency solar cells but pathways to high quality devices with further optimization and improved heating uniformity were developed. The project also developed new optoelectronic characterization approaches with a focus on development and application of spatial- and time-resolved photoluminescence and a custom mapping photoluminescence microscope built. It was shown how critical electronic transport properties strongly depend on the chemical composition of the material and that a wide range of samples show inhomogeneity on a length scale larger than the grains in the films. Additionally, two-photon excitation capability was developed to distinguish bulk vs surface losses. The project advances the state-of-the -art for precursor reaction processes in several ways that could impact manufacturing. This includes validation of approaches to increase voltage and establishment of model-guided control to form optimal composition profiles. The application of process control approaches with knowledge of phase formation and reaction pathways can be critically valuable in designing a large-scale process.

14 SOLAR ENERGY↗
DOE OSTI2021

Generalizable Mechanistic Understanding of Module-Level Light-Moisture and Thermal-Induced Instabilities in CIGS Photovoltaics (Final Report)

The objectives of this project are to identify the root causes of light, heat and humdity induced instabilities in the operation and accelerated testing of commercial Cu(In,Ga)Se 2 [CIGS] photovoltaic modules produced by major module manufacturers (e.g.: Solibro and MiaSolé), correlate them with module degradation/failure modes, and produce accurate service lifetime prediction models.

14 SOLAR ENERGY↗
DOE OSTI2021

Reliability and Power Degradation Rates of PERC Modules Using Differentiated Packaging Strategies and Characterization Tools

The reliability, durability and lifetime performance of passivated emitter, rear cell (PERC) modules used in real-world PV power plants is a critical challenge underlying the rapid adoption and bankability of these PERC cells, whose high efficiency help reduce the levelized cost of electricity (LCOE). We propose a degradation-science study of PERC module degradation pathways, benchmarking them relative to known degradation mechanisms and pathways of the incumbent aluminum back surface field (Al-BSF) modules exposed to real-world and accelerated exposure conditions.

14 SOLAR ENERGY↗
DOE OSTI2021

PV Module Design for Recycling Guidelines

The global growth of clean energy technology deployment will be inexorably followed by a parallel growth of end-of-life (EOL) products that bring both challenges and opportunities. Cumulatively, by 2050, estimates project 78 million tonnes of raw materials embodied in the mass of EOL photovoltaic (PV) modules. Owing partly to concern that the projected growth of clean energy technologies could become constrained by availability of raw materials, despite ongoing dematerialization efforts, significant attention under the umbrella of circular economy has been brought to recycling these technologies at EOL. Yet PV has not been designed with recycling at EOL in mind, and it presents challenges to returning embodied raw materials back to use in new products through recycling. This study aims to inform future designs to improve recyclability through synthesis of prior published works augmented by novel recommendations that result in a set of general design for recycling (DfR) guidelines, with a subset specific to PV modules. We further discuss how established trends in design of PV modules could affect recyclability. If adopted today, application of these DfR guidelines could help to mitigate tomorrow's resource scarcity, lower the barriers and cost for PV recycling, and enable a circular economy during the energy transition.

14 SOLAR ENERGY↗
DOE OSTI2023

Advanced Module Architecture for Reduced Costs, High Durability and Significantly Improved Manufacturability (Final Report)

This project demonstrated a new module architecture (referred to herein as Glass/Glass) using silicone edge seals and an interlayer polymer that reduces manufacturing costs, significantly streamlines manufacturing processes, and reduces cap-ex costs while improving module reliability. A prototype manufacturing process to fabricate this new module architecture was demonstrated with a significantly improved process cycle time for the lamination step from the current industry standard of 13.5 minutes to approximately 30 seconds for each of the individual edge seal and internal polymer application steps. Samples are fabricated, strenuously stressed, and characterized to quantify the cost benefits, hardware capacities and accelerated stress performance of the new architecture. These results are being compared to a standard, laminated baseline architecture using a Glass/EVA/Glass or Glass/Thermoplastic/Glass design that traditionally has high moisture vapor transmission rates (MVTR).

14 SOLAR ENERGY↗