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DOE OSTI2024

Electrochemically Regenerated Solvent for Direct Air Capture with Co-generation of Hydrogen at Bench-scale

The goal of this final project report is to summarize the work conducted on project DE-FE0032125. In accordance with the Statement of Project Objectives (SOPO), the University of Kentucky Institute for Decarbonization and Energy Advancement (UK IDEA) (Recipient) developed an intensified process to capture CO 2 from ambient conditions (415 ppm CO 2 ). The process combines low-temperature solvent-aided membrane capture with electrochemically-mediated solvent regeneration to simultaneously capture ambient CO 2 while regenerating the solvent. The technology employs only two primary units, a regenerator and an absorber/contactor, while generating high purity hydrogen as a co-product that can be sold, used for energy storage, or cost-saving depolarization of the direct air capture (DAC) system during the grid peak demand, allowing for flexible operation. Since the technology is powered directly by DC electricity, it can seamlessly tie in with power sources like solar cells without the need for AC/DC converters, therefore allowing for a remote operation to further mitigate greenhouse gas generation toward deploying a negative carbon emissions technology that is completely decoupled from the carbon emissions from the power source for the DAC unit. The completion of the project results in significant progress toward the Department of Energy’s (DOE’s) goal of advancing lab and bench-scale DAC systems to a sufficient maturity level that can justify their continued scale-up through the verification testing of the electrochemically regenerated solvent system for DAC with co-generation of hydrogen at bench-scale. The technology addressed the complexities of incumbent DAC systems by demonstrating at ambient conditions (1) low gas-side pressure-drop facile CO 2 capture via an intensified membrane absorber with in-situ regenerated hydroxide as capture solvent, (2) multi-functional electrochemical regenerator for hydroxide regeneration, CO 2 concentration and hydrogen production at less than 3 V, and (3) stable DAC performance including >90% capture with air influent at the CFM scale. The data from this project enables the completion of Techno-Economic Analysis (TEA) and Life Cycle Assessment (LCA). TEA and LCA demonstrate the potential of the proposed electrochemical solvent-based process to be a viable DAC option. The analysis did not identify any obvious concern for the bench-scale operation and no apparent barriers to implementing UK IDEA carbon capture and solvent regeneration system at a larger scale.

08 HYDROGEN↗

DOE OSTI2024

Engineering-Scale Testing of the Biphasic Solvent Based CO 2 Absorption Capture Technology at a Covanta Waste-to-Energy Facility

The original goals of this project were to advance the development and demonstration of the Biphasic CO 2 Absorption Process (BiCAP) technology for CO 2 capture from waste-to-energy (WTE) generation at a 2.5 tonne per day (TPD) engineering scale. This project has primarily focused on the basic design of the 2.5 TPD pilot system within the inside battery limits pertaining to CO 2 capture. The project also conducted a preliminary techno-economic analysis (TEA) for BiCAP at a scale of 100,000 tonne per year (TPY) of CO 2 capture and a preliminary life cycle analysis (LCA) with a primary focus on the environmental impacts related to global warming potential.

09 BIOMASS FUELS↗

DOE OSTI2024

A Highly Efficient and Affordable Hybrid System for Hydrogen and Electricity Production (Final Project)

The pursuit of clean, secure, and sustainable energy has sparked significant interest in fuel cells for power generation and electrolyzer cells for hydrogen production. Among all types of fuel and electrolyzer cells, solid oxide cells (SOCs) have emerged as promising candidates due to their high efficiency and versatility. However, conventional oxygen-ion conductive SOCs face several challenges related to their performance and durability associated with their high-temperature operation (≥ 800 ºC). This has led to a growing interest in intermediate-temperature (≤ 650 ºC) proton-conducting solid oxide cells (p-SOCs) as potential alternatives. In collaboration between Phillips 66 and Georgia Tech, this project aims to achieve a 1 kW p-SOCs system to demonstrate the commercial viability of efficient SOC systems. This report addresses four primary areas and key challenges we overcame: (1) development of efficient and durable proton-conducting electrolyte (e.g., BaHf 0.1 Ce 0.7 Yb 0.2 O 3-δ ) and electrode/catalyst materials, (2) large area cell fabrication (10 x 10 cm 2 ), (3) scalable stack design and building (250 W and 1 kW), and (4) demonstration of a 1 kW prototype system. Notably, significant challenges faced during the large area cell fabrication process were addressed by achieving cell flatness, improving fabrication yield, and ensuring electrode/electrolyte interfacial adhesion. Stack designs were also developed, focusing on reducing contact resistance and optimizing stack components (e.g., sealants). These efforts resulted in the achievement of high performance and durability with promising outputs of 250 W and 1 kW. Furthermore, the integration of these stacks into a fuel-powered system was explored, with refinements made to heat management, as well as to pressure and heating conditions. The results demonstrated the potential applicability of our p-SOC technology in commercial energy storage and power generation systems. Additionally, the report discusses techno-economic analysis and a market transformation plan, aiming to evaluate and advance the commercial feasibility of this technology.

25 ENERGY STORAGE↗

DOE OSTI2023

Hydroelectric Power and Hydrogen Production Integration

Hydropower-based hydrogen production could introduce opportunities for new revenue streams for hydropower plants, including from energy storage and regeneration as well as from sale of the hydrogen product to external markets. Hydrogen-based energy storage and regeneration could also help support Idaho Power’s decarbonization goals by decreasing dependence on fossil-based peaking power plants. Additionally, integration of hydrogen production with hydropower generation could help address the issue of low dissolved oxygen river water conditions that commonly accompany hydropower plant operations by utilizing the oxygen byproduct from an electrolytic hydrogen production process as a resource for mitigation of low dissolved oxygen water conditions. Comprehensive techno-economic analysis of the hybrid hydroelectric and hydrogen energy storage system has revealed critical insights into the pathways and considerations for optimizing the economic value and environmental benefits of such systems. Among the three identified pathways of natural gas blending, regeneration, and direct sale of hydrogen, the direct sale of hydrogen emerges as the most profitable, particularly given the current pricing dynamics of hydrogen and electricity. However, as we anticipate a future grid characterized by higher renewable energy penetration, the landscape may evolve, featuring lower average electricity prices, heightened fluctuations, and more significant seasonal variations. Consequently, the attractiveness of electricity regeneration through hydrogen and the benefits of long-duration hydrogen storage are expected to increase substantially in such a dynamic energy scenario. The careful selection of component sizes within the hybrid system proves to be paramount for ensuring cost-effectiveness. Notably, the size of the hydrogen market has emerged as a critical determinant for the optimal size of the electrolyzer. Hydrogen storage should be sized to meet energy shifting requirements. The appropriate size of the fuel cell/microturbine generator hinges on the shape of electricity prices and the available revenue streams derived from participating in grid services. Striking the right balance among these components is essential for maximizing the overall efficiency and profitability of the hydrogen facility. Furthermore, the by-product of electrolysis, namely oxygen, introduces an additional dimension to the system's functionality. The oxygen generated can be effectively utilized for dissolved oxygen (DO) mitigation, particularly with larger electrolyzer sizes capable of satisfying the complete oxygen demand for this purpose. While the economic benefits derived from saved oxygen purchase costs may be relatively modest compared to other revenue streams, the environmental advantages of repurposing oxygen for DO mitigation could help Idaho Power meet their environmental obligations. In addition to the identified factors shaping the viability of hybrid hydrogen production and hydroelectric generation, it is noteworthy that the integration of hydrogen energy storage offers a unique advantage during unusually wet years. In such periods of increased water inflow, the hydrogen storage capacity serves as a valuable supplement to the reservoir. By utilizing hydrogen energy storage as a complementary reservoir, the system gains flexibility in reservoir management when dealing with fluctuations in water availability.

08 HYDROGEN↗

DOE OSTI2022

Flexible FlueCO2

Carbon dioxide (CO2) emission reductions remain a significant challenge on the path to clean energy. There are increasing legislative, social, and environmental factors motivating CO2 emissions reduction from power plants with carbon capture and storage (CCS). CCS in natural gas combined cycle (NGCC) power plants is critical to achieve a net-zero carbon electricity grid. Enhanced 45Q tax credits provide new incentives, but currently available technologies are unable to profitably operate in grids with deep variable renewable penetration which require flexible NGCC operation. Luna Labs has developed the FlueCO2 membrane to enable a profitable NGCC-CCS process. The FlueCO2 membrane couples steam transport across the membrane to CO2 transport in the opposite direction, enabling high capture efficiencies and low energy costs even at low CO2 concentrations. The dual-phase membrane can operate in the range of typical flue gas temperatures and pressures and does not require temperature or pressure cycling. Luna Labs’ FlueCO2 technology enables flexible and profitable operation of NGCC plants with lower capital investment and impact on electricity prices. In this Phase 1 project, Luna Labs utilized experimental testing, modeling, process simulation, and standardized costing methodologies to evaluate the techno-economic value of a 650 MW greenfield NGCC plant with FlueCO2 (NGCC-FlueCO2). Key design requirements for operation were established and plant performance under load-leveling conditions was validated through computational fluid dynamics and process modeling. Luna Labs developed a dynamic modeling tool which modeled plant operational modes across a variety of tax structures and electricity pricing scenarios to project the overall Net Present Value (NPV) of the NGCC-FlueCO2. FlueCO2 minimizes the impact of CCS integration on plant operation by integrating directly into the NGCC heat recovery steam generator (HRSG). By tapping into the plant’s low-pressure (LP) steam, operators can divert LP steam to the greenfield NGCC and/or CCS process in response to dynamic markets. Since FlueCO2 will not significantly affect HRSG (or NGCC) operation, CCS only turns off during peak power demand (>$250/MWh). Under baseload conditions, FlueCO2 lowers the capital (37%), energy (36%) and carbon capture (<$40/tonne) costs and can increase the overall plant lifetime NPV by approximately ~$1B in comparison with NGCC solvent-based capture reference cases (NETL Case 31B). Luna Labs has shared its costing tools with several interested partners and customers, which follows a generalizable approach to costing analysis.

Kelly, Jesse↗

DOE OSTI2023

Cooled Gas Turbine and Combined Cycle Analysis for H 2 -CH 4 Fuel Mixes (Up to 100% H 2 )

In this study, a cooled gas turbine analysis was conducted for varying levels of hydrogen (H 2 ) blends with the natural gas. The ultimate goal is to have a gas turbine design that can be used for all the fuel blends (including 100% H 2 ) without any changes to the system. The technological developments in the cooling system, gas turbine design and materials that will be required for H 2 combustion were identified and analyzed in this study to develop an advanced gas turbine design for H 2 fuels. The study includes a combined cycle performance analysis with the H 2 fuel blends using the advanced gas turbine design developed in this study. A techno-economic analysis was conducted for analyzing the impact of the H 2 fuels on the levelized cost of electricity and cost sensitivities to fuel price and capacity factor.

03 NATURAL GAS↗

DOE OSTI2023

Catalytic Upgrading of Carbohydrates in Waste Streams to Hydrocarbons: Paper Sludge to Fuel Project (PStF)

This research, funded by the Department of Energy Bioenergy Technologies Office (DOE BETO), aims to understand the barriers and assess opportunities for transforming carbohydrates in paper sludge, a solid lignocellulosic residue from the pulp and paper industry. The goal is to turn the paper sludge into a liquid hydrocarbon product that can be blended into jet fuel, both economically and sustainably. Research groups at North Carolina State University, National Renewable Energy Laboratory, and Yale University collaborated synergistically, leveraging their expertise in pulp and paper operations, biomass deconstruction, and catalytic upgrading to propose a pathway that efficiently captures the energy in paper sludge. Findings from this study could potentially contribute to advancing biomass conversion technologies, aligning with the efforts of the U.S. DOE BETO. This report documents the experimental and simulation results of a biochemical and catalytic pathway designed to transform paper sludge into a liquid hydrocarbon product. The process involves a sequence of seven steps, including ash removal, carbohydrate enzymatic hydrolysis, sugar dehydration, solvent recovery, aldol-condensation between furans and ketone, hydrogenation, and hydrodeoxygenation to obtain a hydrocarbon blend in the ~C10 range. The experimental efforts from the initiation of the project were guided by techno-economic analysis (TEA) and sensitivity analysis results including around seventy-eight operational parameters. This methodology facilitated the efficient use of resources over time. This study relies on detailed process simulations and TEA to determine the minimum fuel selling price (MFSP) for the hydrocarbon fuel product. Preliminary TEA results led to the evaluation of eight case studies considering alternative dehydration co-solvents, operational settings, and biorefinery layouts. Finally, the life cycle assessment of twenty-eight scenarios, comparing various dehydration co-solvents, fuel sources, chemical feedstock sources, side product utilization, and other process settings, was conducted. Landfilling scenarios with and without landfill gas recovery were also estimated, analyzed, and compared.

09 BIOMASS FUELS↗

DOE OSTI2024

Bioblendstocks to Optimize Mixing Controlled Compression Ignition (MCCI) Engines

In this project, a team of researchers from the University of Massachusetts Lowell, the University of Maine, and Mainstream Engineering developed an integrated process for the product of bioblendstocks to optimize mixing controlled compression ignition (MCCI) engines. The objective was to improve the energy density, sooting propensity, and cetane number of base diesel fuel while maintaining cold weather behavior. The process converts woody biomass (e.g. sawmill residues) into bio-oil through selective fast pyrolysis; the bio-oil is then selectively upgraded to form selectively oxygenated, minimally-branched hydrocarbons using non-noble metal catalysts in combination with metal-catalyzed hydrogenation. Advanced predictive models, in conjunction with existing property databases, and experimental testing are used to evaluate overall bioblendstock properties and their impact on base diesel fuel. An iterative, targeted upgrading approach was implemented to optimize the proposed bioblendstock’s properties. Assessment methodologies included techno-economic analysis, life-cycle assessment, property testing, and engine testing. Ultimately, the project team successfully produced a viable bioblendstock while identifying critical process points related to scale-up efforts. It was found that producing pyrolysis oils at 500 degrees C and with pine particle sizes of 1-2 mm led to bio-oil with a higher yield (of approximately 45 wt%) and rich amounts of aromatic alcohols. The resultant pyrolysis oil was then upgraded using a sequence of mild hydrotreating, followed by catalytic etherification and esterification, followed by another final mild hydrotreating to produce a blendstock containing saturated species with a limited, but non-zero, amount of oxygen. The aromatic alcohols produced by pyrolysis were especially helpful in this regard, as the resulting bicycloethers and derivatives exhibited high cetane numbers. While most bulk properties of the bioblendstock met or exceeded targeted thresholds, viscosity and cloud point notably fell outside the expected range; this could be addressed by blending limits and/or through the use of additives that are commonplace in current refinding practices. Identification of a bioblendstock that can be produced economically at scale while improving the performance and emissions characteristics of internal combustion engines positively affects the economy by boosting domestic fuel production and the environment by decreasing harmful emissions and increasing efficiency.

09 BIOMASS FUELS↗

DOE OSTI2024

Abstract for CRADA between National Energy Technology Laboratory and Carbon To Stone, Inc.

The National Energy Technology Laboratory (NETL) and Carbon To Stone (CTS), Inc. (Participant) will collaborate on a techno-economic assessment (TEA) and life cycle assessment (LCA) of CTS’s carbon dioxide removal (CDR) technology under an awarded project from the Department of Energy’s Direct Air Capture Pre-Commercialization Technology Prize. CTS has developed a technological platform that captures carbon dioxide (CO2) from air and mineralizes it into durable carbonates using alkaline industrial residues such as steel slag and mine tailings. In addition, CTS’s technology uses electrochemistry to recover value-added energy critical metals (ECMs) from these residues. NETL has expertise in CDR TEA and LCA development. The collaboration between CTS and NETL aims to quantify the performance, cost and lifecycle impacts of CTS’s technology and produce LCA and TEA models that can accelerate development and deployment of this technology.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2024

Remanufacturable "Net-Zero Pb" Perovskite Solar Modules

Our introduced a low-cost recycling method for perovskite PV cells which utilize KI salt-based solvents, a more sustainable chemical compared to commonly used chemicals such as DMF, chlorobenzene etc. All steps of the recycling method were demonstrated in detail in publications and presentations of the team. In addition, the techno-economic team demonstrated that the KI-based method is a more promising option compared to other methods investigated in the literature.

14 SOLAR ENERGY↗

DOE OSTI2024

Assessment of Amine-Based CO2BOLs for Direct Air Capture

Direct air capture (DAC) technologies extract CO 2 from the atmosphere for CO 2 storage, or utilization. Capturing CO 2 from the air is the most expensive application of carbon capture because CO 2 in the atmosphere is very dilute. There are limited number of CO 2 capture technologies for DAC application. This project aims at developing an energy efficient technology for DAC, leveraging two PNNL’s chemistries (solid and liquid CO 2 capture). Three CO 2 capture sorbents consisting of amine based CO 2 BOLs immobilized in mesoporous silica were designed, synthesized, and tested. These sorbents had ~ 19-23 wt.% amine loadings which is lower than typical amine-based silica sorbents. The surface area and pore volumes of these solid supported CO 2 BOLs are lower compared to those of the pristine silica support. The CO 2 capture performance of these materials was significantly lower than the typical silica supported amines due to low amine loading and higher molecular weight with low amine density. These results show that immobilize CO 2 BOLs in silica are not viable materials for removing CO 2 from ambient air. This project also designed, synthesized at tested liquid solvents for DAC application. Solvent properties that is vapor pressure, CO 2 uptake capacity, kinetics, and viscosity for three novel solvents were evaluated. The CO 2 uptake capacity for one of the most promising amine-based solvent BEPBEGDA was the highest at 13.2 wt% corresponding to 97 mol%. The vapor pressure of the BEPBEGDA solvents were very low at 80 °C compared to other solvents making them suitable for DAC application. The effect of humidity on the CO 2 capture performance of these solvents was evaluated which shows that presence of moisture doesn’t have a negative effect on the CO 2 uptake performance but makes it slightly better. The performances of these solvents were slightly below that of the 0.1M NaOH solution tested under similar conditions. Despite of the slightly lower CO 2 uptake, it is expected that these liquid solvents will have lower regeneration temperature and minimum evaporative losses due their low vapor pressure. Future work will focus on optimization of the liquid solvents for DAC application to improve both CO 2 capture efficiency and capacity without viscosity and vapor pressure increase. Testing of these solvents under DAC conditions using a gas liquid contactor that mimic industrial applications is needed. Solvent cost projection, techno-economic analysis and life cycle analysis are required to evaluate economic viability of this technology.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2024

The HyRIGHT Project: 700 bar Hydrogen Refueling Interface for Gaseous Heavy-Duty Trucks

Heavy duty truck fueling places additional constraints on the station. The HyRIGHT project was developed to evaluate a subset of key areas around precooling, communications, and safety risks that aims to:  Utilize a dynamic model that includes the relevant station components and vehicle to develop an optimized precooling strategy based on initial precooling status, real time communications that can support fueling protocol development.  Perform a techno economic cost assessment (TEA) related to effects of precooling including station storage and efficiency effects.  Develop a Cyber Vulnerability assessment and framework for refueling of HD vehicles with station communications.  Disseminate the results in support of the HD fueling protocol development to the relevant standards development organizations.

JAMES, Charles W.↗

DOE OSTI2024

Technical and Economic Screening for Potential of Distributed Energy Resource Integration at Chervonohrad Water Utility in Ukraine

In this report, the authors present a preliminary techno-economic screening for distributed renewable energy for Chervonohrad Vodokanal, the water utility in Chervonohrad, Ukraine. The screening estimates the technical potential and economics of integrating solar photovoltaics (PV) and battery energy storage systems (BESS) at Chervonohrad Vodokanal water pumping stations, Pravda, Bendiuha, and Mezhyrichchya. For the Ukrainian version of this report, see NREL/TP-7A40-90360 (https://www.nrel.gov/docs/fy24osti/90360.pdf).

14 SOLAR ENERGY↗

DOE OSTI2024

Fluidized-Bed Gasification of Coal-Biomass-Plastics for Hydrogen Production

Coal is one of the most abundant fossil energy resources in the United States and in the world. The recoverable reserves in the United States are estimated to be about 252 billion tons – more than 350 years of supply at current rates of usage. However, the share of coal in total primary energy consumption in the US has been declining over the years. The decline of coal is mainly attributed to cheap natural gas and precipitous declines in the cost of electricity production from renewable technologies such as wind and solar. Coal can potentially be used if it is coupled with carbon-neutral feedstock such as biomass-agricultural residues, forest biomass, and forest residues. Co-gasification of coal and biomass can become a negative carbon emission technology if the carbon dioxide (CO 2 ) is captured and sequestered. Although the biomass gasification process has a lot of similarities to coal gasification, the large-scale adaptation of power production sourced from biomass has not come to fruition. The main reason is that the power production from biomass is still expensive when compared with natural gas or coal power technologies. To address the feedstock cost, one approach is to use low-cost feedstocks, such as municipal solid wastes (MSW) or plastics, for gasification. Gasification involves the partial oxidation of coal and/or biomass feedstocks to produce a combustible fuel called synthesis gas (syngas) which is composed of carbon monoxide (CO), hydrogen (H 2 ), CO 2 , methane (CH 4 ), nitrogen (N 2 ), water (H 2 O), and other compounds that might be considered as contaminants. Raw syngas from gasification must go through multiple steps to produce high-purity hydrogen. The specific steps depend upon the quality (gas composition, contaminants, and their concentration) and condition (pressure and temperature) of syngas. The long-term goal of the project was to utilize coal and plastics together with biomass to produce energy and fuels using a gasification platform while reducing greenhouse gas emissions. The main objective of this research was to examine gasification performance in a laboratory-scale fluidized-bed gasifier for hydrogen production. The specific objectives of the research were to: (i) study coal-plastic-biomass mixture flowability for consistent feeding in the gasifier; (ii) understand the gasification behavior of the mixture in steam and oxygen environments; (iii) perform thermal property characterization of ash and slag from the mixture feedstock and refractory-ash interface of the mixture under gasification conditions; and (iv) develop process models to determine the technology needed for syngas cleanup and contaminants. The study found that there was no apparent segregation when biomass, coal, and waste plastics were mixed together during feeding. Although there were differences in hydrogen production when individual feedstock were fed, the hydrogen concentration remained almost constant with various blends. Therefore, blending waste plastics with biomass and coal, which are all abundant, is a better approach for energy production. Results of the techno-economic analysis suggested that integration of advanced gasification (GTI’s R-GAS™) and syngas cleanup and conditioning technologies (RTI’s WDP and AFWGS) for clean hydrogen production resulted in substantial benefits, including significant capital cost and operating cost reductions. Advanced technologies resulted in 16% reduction in the hydrogen production cost (COH) from 2.94 $\$$/kg to 2.47 $\$$/g, with further scope for optimization and cost reduction. These advanced technologies also result in lower emissions, and improved energy efficiency.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2021

Pilot Unit Testing at NCCC of Sorbent based CO2 Capture

TDA Research, Inc. is developing a new CO2 sorbent (alkalized alumina) technology for post-combustion CO2 capture. In this DOE sponsored project (DE-FE0012870), TDA constructed a pilot-scale skid, which was installed and tested at National Carbon Capture Center (NCCC). It was designed to process coal derived flue gas equivalent to 0.5 MWe of power generation. The pilot test data shows that TDA’s process can achieve 90% capture rate and 95% CO2 purity (the performance target) for both coal and natural gas (NG) flue gases. The techno-economic analysis (TEA) for a 550-MWe supercritical coal fired power plant with CO2 capture shows that the capture cost for TDA’s process is $34.9/tonne CO2 captured, which meets DOE’s goal of $40/tonne and is 17.1% less than the DOE baseline Case 12 (an amine solvent technology).

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2024

Vouchers to Enable Laboratory and Organizational Collaboration for Innovation and Technology Improvements (VELOCITI) Round 6 (Abstract)

For the past several years, the National Renewable Energy Laboratory (NREL), Sandia National Laboratories (SNL), and Pacific Northwest National Laboratory (PNNL) have provided technical assistance to the recipients of Department of Energy (DOE)-funded voucher programs, namely American-Made Challenges (AMC), the Incubator Program, and the Small Business Vouchers Program. Drawing on lessons learned and from first-hand experiences, NREL is leading a new holistic and streamlined voucher program aimed at strengthening ties between American innovators and the national labs. This new program, “Vouchers to Enable Laboratory and Organizational Collaboration for Innovation and Technology Improvements,” or VELOCITI, will leverage the successful elements of past programs, create administrative efficiencies, and enable the buildout of a national program to drive strong relationships between entrepreneurs and the national labs to accelerate the roll-out of new technologies in the US solar sector. This work will develop a comprehensive techno-economic assessment to understand the potential of repurposed batteries to achieve the DOE’s target of 5 cents per kWh Levelized Cost of Storage (LCOS), thereby facilitating the more affordable and widespread adoption of solar energy.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2022

Low-Cost, Easy-To-Integrate and Reliable Grid Energy Storage System with 2 nd Life Lithium Batteries

Batteries retired from electric vehicles have the potential to extend their service as low-cost stationary energy storage systems. However, disperse battery state of health (SOH) and nonuniform battery characters often lead to compromised battery performance and reliability, which greatly hinder their adoption. A Heterogenous Unifying Battery (HUB) system is proposed to stage 2 nd life battery bricks for a period, and enable them to attain improved SOH uniformity, performance, and reliability before being sold for 2 nd life applications, while simultaneously providing grid services. It may offer a technically and economically advantageous solution for the broad utilization of 2 nd use batteries. The goal of this project was to develop the hardware and software that enables the key functions of the HUB system. The first achievement of the project was the development of a 1kW scale proof-of-concept (POC) system, which comprises (i) a modular plug-n-play DC-DC power converter matrix with isolated series output connections to achieve fully independent control of energy flow to each of the connected battery units at low voltage; (ii) enhanced model based control that drives each batteries’ SOH towards uniformity while collectively providing grid energy storage services; and (iii) comprehensive procedures to perform battery diagnostics and prognostics. The second achievement was the development of a 100kW scale HUB system and demonstrated its performance of re-establishing battery SOH uniformity through a period of battery cycling operation. The final HUB system incorporates six DC-DC power converter matrices paired with six battery bricks. Hot swapping of a single battery brick while maintaining consistent system power was demonstrated and system operation was validated to be capable of implementing the approved grid duty cycle and of balancing and conditioning the battery bricks. Through the course of the project, the team optimized the building-block design, form-factors, and adjusted life balancing control. An up-sized 250kW Scale was developed and deployed in October 2022 with pack-level battery form factors, see photo in Figure 1 The third achievement of the project was to perform a techno-economic analysis in order to better understand the cost and revenue potentials in this new “recondition-then-resell" value proposition. The final TEA quantified the economics of new Li-ion batteries as well as second-life batteries processed via reconditioning and traditional binning. Results showed the reconditioned second-life batteries in this project to be economically favorable and viable in grid energy storage markets. The TEA results were published in the Applied Energy journal. The fourth achievement of the project was to deliver a tech-to-market plan for the HUB system that includes funding, IP, and manufacturing strategies. The final T2M plan outlines a business strategy in which the HUB provides a B2B service to EV companies as an alternative to battery recycling that can prepare batteries for 2nd life applications. A company named Smartville Inc. was founded to carry on the commercialization, funding, and technical IP licensing activities of the OPEN project.

25 ENERGY STORAGE↗

DOE OSTI2024

ТЕХНІКО-ЕКОНОМІЧНИЙ АНАЛІЗ ПОТЕНЦІАЛУ ІНТЕГРАЦІЇ РОЗПОДІЛЕНИХ ЕНЕРГЕТИЧНИХ РЕСУРСІВ ДЛЯ ВОДОКАНАЛУ М.ЧЕРВОНОГРАД В УКРАЇНІ [Technical and Economic Screening for Potential of Distributed Energy Resource Integration at Chervonohrad Water Utility in Ukraine] (Ukrainian Translation)

In this report, the authors present a preliminary techno-economic screening for distributed renewable energy for Chervonohrad Vodokanal, the water utility in Chervonohrad, Ukraine. The screening estimates the technical potential and economics of integrating solar photovoltaics (PV) and battery energy storage systems (BESS) at Chervonohrad Vodokanal water pumping stations, Pravda, Bendiuha, and Mezhyrichchya. For the English version of this report, see NREL/TP-7A40-89599 (https://www.nrel.gov/docs/fy24osti/89599.pdf).

14 SOLAR ENERGY↗