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FY2019 Technology Integration Annual Progress Report

The 2019 Technology Integration Annual Progress Report covers 30 multi-year projects funded by the Vehicle Technologies Office. The report includes information on 23 competitively awarded projects, ranging from safety training and design for maintenance facilities housing gaseous fuel vehicles, to electric vehicle community partner programs, to truck platooning with advanced driver assistance systems. It also includes seven projects conducted by several of VTO’s National Laboratory partners, Argonne National Laboratory, Oak Ridge National Laboratory and the National Renewable Energy Laboratory. These projects range from a Technical Assistance project for business, industry, government and individuals, to the EcoCar Advanced Vehicle Technology Competition, and the Fuel Economy Information Project.

33 ADVANCED PROPULSION SYSTEMS↗

Helium recovery system at IB3A

The growing demand for sustainable cryogenic operations at Fermilab has underscored the need to improve helium management, particularly at the Industrial Building 3A (IB3A) test facility. IB3A characterizes and tests superconductors, cables, and coils for projects such as the HL-LHC AUP and Mu2e, yet currently relies on 500 L Dewars whose boil-off is vented to atmosphere, wasting a critical, non-renewable resource and increasing the cost of testing. A project is therefore under way to link IB3A to an existing purification and liquefaction station in a neighboring building through a dedicated pipeline. Captured helium will be transferred, purified, reliquefied, and returned for reuse, cutting losses and operating costs. This paper details the first two project phases: "Design and Engineering" and "Procurement and Installation." The design phase finalizes pipeline specifications, establishes flow-control requirements, and resolves integration challenges with existing cryogenic infrastructure. The procurement and installation phase covers material sourcing, pipeline construction, and deployment of control and monitoring systems to assure reliable, efficient operation. Key technical hurdles-route optimization, pressure drop mitigation, and interface compatibility-are discussed alongside implemented solutions. Implementing the pipeline and upgrading IB3A will dramatically reduce helium consumption and therefore testing cost, strengthening Fermilab's capacity to support frontier science far into the future.

Porwisiak, D. [Fermilab; Wroclaw Tech. U.]↗

Geospatial Data Platform for All

Spatiotemporal data has evolved in scale due to augmented use in cross-domain applications. Simultaneously, there is substantial growth in the availability of Geographic Information Systems (GIS) data provided by the United States Geological Survey (USGS) along with other federal, state, county, or local agencies through open-data portals and public access APIs. However, data availability does not equate with accessibility. Large-scale analyses and applications require robust, performant data management with co-location of data storage and computing. The insufficiency of data management infrastructure compels researchers to adopt ad hoc project- specific GIS data storage solutions (e.g., copying data to High-Performance computer file systems). As an ad hoc storage strategy does not scale, it hampers cross-domain analyses causing difficulty in data reuse and utilizing existing code bases. Furthermore, GIS data is complex and requires expertise to analyze and manipulate due to its intricate data structures and data-specific projection transformations. Despite the challenges, we recognize that derived GIS data products, e.g., satellite or LIDAR-based images, can be used in downstream applications such as AI by domain, but non-GIS experts. To address the data needs and overcome the challenges, we are working towards a GIS Data Platform focused on efficient data storage, data discovery and access, and an API to enable common workflows. We propose a knowledge-graph (KG) approach for data discovery, whereby datasets are semantically linked to higher- level constructs such as projects and research areas. The semantic data links enable researchers to explore datasets in a top-down approach by specifying relevant and meaningful terms (assists in finding hidden data). An advantage is that the nodes and edges in a knowledge graph create built-in semantic documentation. Deeper spatiotemporal connections between data sources can be encoded via Graph Neural Networks (GNN) (Zhang et al., 2021). The KG approach can be extended to integrate the data itself in a Virtual KG (VKG). Our work will derive inspiration from large-scale VKG efforts that have been undertaken or are currently underway as part of the OpenStreetMap project (Ding et al., 2021). For DOE Data Days, we share the proposed geospatial data platform hybrid (cloud/on-prem) architecture, our work-to-date on storing, retrieving, and transforming LiDAR and raster data relevant to two important NREL use-cases, including the Renewable Energy Potential (reV) Model, and present our proposal for a KG based data discovery engine.

data platform↗

HERO WEC V1: Design and Experimental Data Collection Efforts

The Hydraulic and Electric Reverse Osmosis Wave Energy Converter (HERO WEC) is a research platform aimed at developing a modular, small-scale wave-powered desalination system for remote and disaster-response applications. Funded by the Department of Energy (DOE)'s Water Power Technologies Office (WPTO), the project aims to advance wave-powered desalination by developing and testing a small-scale, modular wave energy converter (WEC). The insights gained from this project will help guide the design and development of larger-scale wave energy devices as well as the integration of marine energy and reverse osmosis (RO) desalination. The HERO WEC was initially developed to derisk the Waves to Water prize, enabling the staff to practice WEC deployment and recovery, while optimizing installation protocols ologies, aiming to advance the broader fields of marine energy and water treatment.

13 HYDRO ENERGY↗

The reservoir network: A new network topology for district heating and cooling

Thermal district networks are effective solutions to substitute fossil fuels with renewable energy sources for heating and cooling. Moreover, thermal networking of buildings allows energy efficiency to be further increased. The waste heat from cooling can be reused for heating in thermal district systems. Because of bidirectional energy flows between prosumers, thermal networks require new hydraulic concepts. In this work, we present a novel network topology for simultaneous heating and cooling: the reservoir network. The reservoir network is robust in operation due to hydraulic decoupling of transfer stations, integrates heat sources and heat sinks at various temperature levels and is flexible in terms of network expansion. Furthermore, we used Modelica simulations to compare the new single-pipe reservoir network to a basecase double-pipe network, taking yearly demand profiles of different building types for heating and cooling. The electric energy consumed by the heat pumps and circulations pumps differs between the reservoir and base case networks by less than 1%. However, if the reservoir network is operated with constant instead of variable mass flow rate, the total electrical consumption can increase by 48% compared to the base case. As with any other network topology, the design and control of such networks is crucial to achieving energy efficient operation. Investment costs for piping and trenching depend on the district layout and dimensioning of the network. If a ring layout is applied in a district, the reservoir network with its single-pipe configuration is more economical than other topologies. For a linear layout, the piping costs are slightly higher for the reservoir network than for the base case because of larger pipe diameters.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Electrical Energy Storage Data Submission Guidelines, Version 2

Energy storage technologies are positioned to play a substantial role in power delivery systems. They have the potential to serve as an effective new resource to maintain reliability and allow for increased penetration of renewable energy. However, because of their relative infancy, there is a lack of knowledge about how these resources truly operate over time. A data analysis can help ascertain the operational and performance characteristics of these emerging technologies. Rigorous testing and a data analysis are important for all stakeholders to ensure a safe, reliable system that performs predictably on a macro level. Standardizing testing and analysis approaches to verify the performance of energy storage devices, equipment, and systems when integrating them into the grid will improve the understanding and benefit of energy storage over time from technical and economic vantage points. Demonstrating the life-cycle value and capabilities of energy storage systems begins with the data that the provider supplies for the analysis. After a review of energy storage data received from several providers, some of these data have clearly shown to be inconsistent and incomplete, raising the question of their efficacy for a robust analysis. This report reviews and proposes general guidelines, such as sampling rates and data points, that providers must supply for a robust data analysis to take place. Consistent guidelines are the basis of a proper protocol and ensuing standards to (1) reduce the time that it takes for data to reach those who are providing the analysis; (2) allow them to better understand the energy storage installations; and (3) enable them to provide a high-quality analysis of the installations. The report is intended to serve as a starting point for what data points should be provided when monitoring. Readers are encouraged to use the guidance in the report to develop specifications for new systems, as well as enhance current efforts to ensure optimal storage performance. As battery technologies continue to advance and the industry expands, the report will be updated to remain current.

25 ENERGY STORAGE↗

Recyclable Design for Retaining High Solar Absorptivity of the Media in CSP

Efficient thermal energy storage is pivotal to lowering the levelized cost of electricity (LCOE) for Concentrating Solar Power (CSP) plants. In solid-particle systems, however, prolonged high-temperature service degrades particle solar absorptivity, eroding overall efficiency. This project demonstrates a hydrogen-assisted recovery process that reliably restores absorptivity to >90 %, offering a practical route to sustain long-term CSP performance. Bench-scale investigations mapped the reduction kinetics of optically faded particles across hydrogen concentrations, temperatures, and residence times. Coupling mass-spectrometric monitoring with machine-learning optimization minimized energy demand while maximizing absorptivity gain. The resulting process window—moderate hydrogen partial pressures, 15–30 min dwell times, and temperatures well below initial calcination levels—cuts energy consumption well below that of incumbent re-blackening methods. A prototype recovery reactor processed multiple 2 kg batches with repeatable outcomes, confirming scalability and operational robustness. Integrated techno-economic analysis indicates material and operating cost reductions exceeding 15 % relative to conventional particle replacement or chemical re-coating, translating directly into lower LCOE for next-generation CSP facilities. By uniting fundamental reaction-kinetics insight with pragmatic engineering, this work advances the solid-particle pathway, delivering a cost-effective, field-deployable solution to one of CSP’s key durability challenges and strengthening the commercial outlook for high-temperature renewable power.

14 SOLAR ENERGY↗

Advances in polycrystalline thin-film photovoltaics for space applications

Polycrystalline, thin-film photovoltaics represent one of the few (if not the only) renewable power sources which has the potential to satisfy the demanding technical requirements for future space applications. The demand in space is for deployable, flexible arrays with high power-to-weight ratios and long-term stability (15-20 years). In addition, there is also the demand that these arrays be produced by scalable, low-cost, high yield, processes. An approach to significantly reduce costs and increase reliability is to interconnect individual cells series via monolithic integration. Both CIS and CdTe semiconductor films are optimum absorber materials for thin-film n-p heterojunction solar cells, having band gaps between 0.9-1.5 ev and demonstrated small area efficiencies, with cadmium sulfide window layers, above 16.5 percent. Both CIS and CdTe polycrystalline thin-film cells have been produced on a laboratory scale by a variety of physical and chemical deposition methods, including evaporation, sputtering, and electrodeposition. Translating laboratory processes which yield these high efficiency, small area cells into the design of a manufacturing process capable of producing 1-sq ft modules, however, requires a quantitative understanding of each individual step in the process and its (each step) effect on overall module performance. With a proper quantification and understanding of material transport and reactivity for each individual step, manufacturing process can be designed that is not 'reactor-specific' and can be controlled intelligently with the design parameters of the process. The objective of this paper is to present an overview of the current efforts at MMC to develop large-scale manufacturing processes for both CIS and CdTe thin-film polycrystalline modules. CIS cells/modules are fabricated in a 'substrate configuration' by physical vapor deposition techniques and CdTe cells/modules are fabricated in a 'superstrate configuration' by wet chemical methods. Both laser and mechanical scribing operations are used to monolithically integrate (series interconnect) the individual cells into modules. Results will be presented at the cell and module development levels with a brief description of the test methods used to qualify these devices for space applications. The approach and development efforts are directed towards large-scale manufacturability of established thin-film, polycrystalline processing methods for large area modules with less emphasis on maximizing small area efficiencies.

Lanning, Bruce R.↗

Space Solar Power Demonstrations: Challenges and Progress

The prospects of using electrical power beamed from space are coming closer to reality with the continued pursuit and improvements in the supporting space solar research and technology. Space Solar Power (SSP) has been explored off and on for approximately three decades as a viable alternative and clean energy source. Results produced through the more recent Space Solar Power Exploratory Research and Technology (SERT) program involving extensive participation by industry, universities, and government has provided a sound technical basis for believing that technology can be improved to the extent that SSP systems can be built, economically feasible, and successfully deployed in space. Considerable advancements have been made in conceptual designs and supporting technologies including solar power generation, wireless power transmission, power management distribution, thermal management and materials, and the integrated systems engineering assessments. Basic technologies have progressed to the point were the next logical step is to formulate and conduct sophisticated demonstrations involving prototype hardware as final proof of concepts and identify high end technology readiness levels in preparation for full scale SSP systems designs. In addition to continued technical development issues, environmental and safety issues must be addressed and appropriate actions taken to reassure the public and prepare them for the future use of this alternative renewable energy resource. Accomplishing these objectives will allow informed future decisions regarding further SSP and related R&D investments by both NASA management and prospective external partners. In particular, accomplishing these objectives will also guide further definition of SSP and related technology roadmaps including performance objectives, resources and schedules; including 'multi-purpose' applications (terrestrial markets, science, commercial development of space, and other government missions).

Howell, Joe T.↗

An Update to the National Renewable Energy Laboratory Baseline Wind Turbine Controller

The National Renewable Energy Laboratory's 5-MW wind turbine model is well established as an industry standard and is often used as a comparison model, or a model on which to build upon. Though effective, the legacy controller for the 5-MW wind turbine uses a simple algorithm that is not up to date with many industry standards. Additionally, as the research community has advanced into fast-paced development cycles, as systems engineering tools such as Wind-Plant Integrated System Design & Engineering Model (WISDEM ®) [1] are employed, and as a greater focus on controls co-design practices is encouraged, demand for a generic wind turbine controller has arisen. This work presents updates for the NREL 5-MW controller to a more modern control architecture, and establishes a generic tuning framework that can be easily adapted to various wind turbines. Based on initial results, the updated generic controller eases the automatic tuning process while maintaining or improving the performance of the legacy NREL 5-MW controller.

17 WIND ENERGY↗

Prefabricated Zero Energy Retrofit Technologies: A Market Assessment

The U.S. Department of Energy (DOE) Office of Energy Efficiency and Renewable Energy’s (EERE’s) mission is to “create and sustain American leadership in the transition to a global clean energy economy.” EERE’s vision is a strong and prosperous America powered by clean, affordable, and secure energy. In support of this vision, one of EERE’s strategic pillars is to stimulate the growth of a thriving domestic clean energy manufacturing industry. This report seeks to identify products in the European and U.S. markets that can enable a more integrated and standardized approach to conducting zero energy retrofits, leveraging off-site construction and manufacturing. Greater integration of energy conservation measures into prefabricated building components will further enable efficiency adoption, while reducing project complexity, risks, and costs.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Development of a hardware-in-the-loop testbed for laboratory performance verification of flexible building equipment in typical commercial buildings

The goals of reducing energy costs, shifting electricity peaks, increasing the use of renewable energy, and enhancing the stability of the electric grid can be met in part by fully exploiting the energy flexibility potential of buildings and building equipment. The development of strategies that exploit these flexibilities could be facilitated by publicly available high-resolution datasets illustrating how control of HVAC systems in commercial buildings can be used in different climate zones to shape the energy use profile of a building for grid needs. This article presents the development and integration of a Hardware-In-the-Loop Flexible load Testbed (HILFT) that integrates physical HVAC systems with a simulated building model and simulated occupants with the goal of generating datasets to verify load flexibility of typical commercial buildings. Compared to simulation-only experiments, the hardware-in-the-loop approach captures the dynamics of the physical systems while also allowing efficient testing of various boundary conditions. The HILFT integration in this article is achieved through the co-simulation among various software environments including LabVIEW, MATLAB, and EnergyPlus. Although theoretically viable, such integration has encountered many real-world challenges, such as: 1) how to design the overall data infrastructure to ensure effective, robust, and efficient integration; 2) how to avoid closed-loop hunting between simulated and emulated variables; 3) how to quantify system response times and minimize system delays; and 4) how to assess the overall integration quality. Lessons-learned using the examples of an AHU-VAV system, an air-source heat pump system, and a water-source heat pump system are presented.

Chen, zhelun↗

Toward the Analytic Bootstrap of Energy Correlators

In this paper, we present a framework for the analytic bootstrap of three-point energy correlators, a crucial observable in N = 4 N=4 super Yang-Mills theory and quantum chromodynamics (QCD). Our approach combines spherical contour techniques, general physical constraints such as pole cancellations, and power correction data in the singular limits to determine its analytic expression. In contrast to previous bootstrap studies restricted to scattering amplitudes for supersymmetric theories, our framework makes use of the properties of Feynman integrals, marking a significant step toward bootstrapping realistic QCD observables. Using this method, we derive analytic expressions for leading-order three-point energy correlators with equal and unequal energy weights, where the latter are crucial ingredients for projected N N-point energy correlators. We also apply the recently developed technique of analytic regression with lattice reduction as a way to bypass needing explicit expressions for the singular limits. Bridging theoretical advances in scattering amplitudes with the renewed interest in weighted cross-sections, our work opens the door to precision tests of QCD dynamics through analytic event-shape predictions.

Gong, Jianyu [State Key Laboratory]↗

Environmental Impact Specification for Direct Space Weathering of Kuiper Belt and Oort Cloud Objects

The Direct Space Weathering Project of NASA's Outer Planets Research Program addresses specification of the plasma and energetic particle environments for irradiation and surface chemical processing of icy bodies in the outer solar system and the local interstellar medium. Knowledge of the radiation environments is being expanded by ongoing penetration of the twin Voyager spacecraft into the heliosheath boundary region of the outer heliosphere and expected emergence within the next decade into the very local interstellar medium. The Voyager measurements are being supplemented by remote sensing from Earth orbit of energetic neutral atom emission from this boundary region by NASA's Interstellar Boundary Explorer (IBEX). Although the Voyagers long ago passed the region of the Classical Kuiper Belt, the New Horizons spacecraft will encounter Pluto in 2015 and thereafter explore one or more KBOs, meanwhile providing updated measurements of the heliospheric radiation environment in this region. Modeling of ion transport within the heliosphere allows specification of time-integrated irradiation effects while the combination of Voyager and IBEX data supports projection of the in-situ measurements into interstellar space beyond the heliosheath. Transformation of model ion flux distributions into surface sputtering and volume ionization profiles provides a multi-layer perspective for space weathering impact on the affected icy bodies and may account for some aspects of color and compositional diversity. Other important related factors may include surface erosion and gardening by meteoritic impacts and surface renewal by cryovolcanism. Chemical products of space weathering may contribute to energy resources for the latter.

Cooper, John F.↗

Lessons Learned from AskGDR: Usage and Impact Analysis of the Geothermal Data Repository's AI Research Assistant: Preprint

In October of 2024, the Department of Energy's (DOE) Geothermal Data Repository (GDR) team officially launched AskGDR, an AI research assistant resulting from the integration of a Large Language Model (LLM) with the metadata and supporting documents associated with GDR datasets. AskGDR allows GDR users to ask deeper questions about the origin of datasets, the methods used to collect them, and the findings they help support. Using Retrieval Augmented Generation (RAG), AskGDR can be used to summarize findings spread across dozens of papers and technical reports or to extract relevant information describing a single data field. However, generative AI is experimental. The National Renewable Energy Laboratory (NREL) has been collecting metrics on AskGDR and documenting lessons learned during its deployment. This paper will outline the efficacy and impact of AskGDR through analysis of its use, operating costs, number and types of questions asked, and the quality of answers provided.

15 GEOTHERMAL ENERGY↗

Analysis of pumped thermal energy storage using particle media integrated with concentrating solar power

Pumped Thermal Energy Storage (PTES) is an electricity storage system that converts electricity into thermal energy which is stored and later transformed back into electricity. Previous work has illustrated that particles have low capital costs and can be operated over a wide range of temperatures. PTES with particle storage achieves higher round-trip efficiency and specific power output than when molten salt thermal energy storage is used. This article explores hybrid systems that combine PTES with Concentrating Solar Power (CSP). Hybrid systems share the majority of components thereby reducing costs compared to two stand-alone devices. In addition, hybrid systems can provide multiple services (such as renewable power generation and electricity storage services). Using particle thermal storage in these hybrid concepts provides freedom in choosing the design conditions, since a wide range of operating temperatures is allowable, therefore making it possible to identify hybrid system designs that have good performance. In this article, two concepts for hybrid PTES-CSP are introduced. Thermodynamic models are developed and these are used to evaluate the performance of two hybrid systems. These models account for turbomachinery efficiency, and approach temperature and pressure loss in heat exchangers, as well as other sources of inefficiency, such as motor-generator losses, and air fan power. The “Solar Top-Up” Concept uses CSP to increase the temperature delivered by the charging heat pump. The discharging system uses a topping gas cycle and a bottoming steam cycle to fully exploit the available energy. Using solar heat to increase the maximum temperature from 750 K to 1100 K increases the round-trip efficiency from 41 % to 62 % and the specific work output from 88 kJ/kg to 301 kJ/kg. The second concept is a “Dual-Mode” device which provides both electricity storage and solar electricity generation with the same set of components. The PTES-mode and CSP-mode performance are optimized at different design values but careful parameter selection leads to good performance of both modes: one design produces PTES round-trip efficiency > 60 %, CSP heat engine efficiency > 40 %, and specific work outputs > 150 kJ/kg (for both cycles), when the particle receiver temperature is > 1200 K and maximum heat pump temperature is 1100 K.

14 SOLAR ENERGY↗

Grazer-induced changes in molecular signatures of cyanobacteria

Algal biomass production is an emerging renewable source of fuels, nutrients, manufacturing materials, and pharmaceuticals. Industrial-scale production is predominantly performed in open raceway ponds that are inexpensive to build, operate, and maintain compared to closed bioreactors. However, these open pond systems suffer from increased opportunities for biological contamination from predators, pathogens, and competitors, which result in reduced biomass quality and yields and often the complete destruction of the crop over a short period of time. Early detection of contaminants is a necessary step of integrated pest management for triggering and informing interventions to prevent crop losses. To develop a sensitive method of detection utilizing mass spectrometry (MS), we used three methods – imaging mass spectrometry (imaging MS), liquid chromatography MS/MS (LC-MS/MS) combined with molecular networking, and gas chromatography MS/MS (GC–MS/MS) – to observe and identify molecular signatures from a model predator-prey system of the heterolobosean amoeba HGG1 preying on the filamentous cyanobacterium Anabaena sp. PCC 7120. Imaging MS enabled the association of molecules with the crop, the predator, or the activity of protozoan grazing, while LC-MS/MS-based molecular networking identified a subset of the grazing-specific signals as the chlorophyll breakdown products pyropheophytin, pheophorbide A, and pyropheophorbide. Application of MS techniques to other amoebacyanobacterial predator-prey pairs allowed categorization of grazing signatures as universal or specific to the species of prey, predator, or the prey-predator pairing, indicating that MS-based techniques can distinguish crops from competitors and potentially identify predators. Finally, GCMS/MS was shown to be capable of monitoring novel volatile organic compounds (VOCs), including those predicted to be released through chlorophyll breakdown, in the headspace over algal cultures under predation. Furthermore, these results demonstrate that the combination of multiple MS technologies creates a predictive framework to identify and catalog relevant molecular signatures for informing crop protection strategies.

09 BIOMASS FUELS↗