Power Conversion and Control Systems for a Modern Electric Grid
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Mueller, Jacob Andreas↗
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Cross-cutting strategies to lower electricity use of miscellaneous electric loads in the domestic sector
Miscellaneous Electric Loads (MELs) account for roughly one quarter of building electricity use in most developed countries. A product-specific approach to lowering MELs electricity use in this category takes too long and costs too much because there are so many MELs, each providing unique services. An alternative approach focusing on key functionalities was therefore explored. These functionalities include: (1) power management, (2) power scaling, and (3) power conversion. Cross-cutting efficiency improvements to these functionalities can be incorporated into broad categories of MELs, thus saving electricity and lowering costs. Even though the population of MELs is diverse and rapidly evolving, major technical opportunities exist to improve their efficiency in these functionalities. Research into energy-saving solutions within the cross-cutting technologies will probably have larger savings than focusing on single products.
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
Solution‐Phase Metathesis of Li 3 N and FeCl 3 to Synthesize Fe 2 N/Fe 3 N Nanoparticles
Soft magnetic materials play key roles in the flow of energy in electrically driven machines and power conversion electronics, and there is a great need for improvements in their magnetic properties to provide the right combination of high saturation magnetization, low coercivity, and high permeability. Most phases of iron nitride (Fe x N) are soft magnetic materials with these characteristics, but they exist as numerous phases which are not all stoichiometric compounds. While the production and magnetic properties of the different phases of bulk iron nitride are well known, accessing phase‐pure nanoscale iron nitride consistently remains a challenge. Most methods for the synthesis of iron nitride nanoparticles require complicated apparatus to achieve high‐temperature nitriding of nanoparticle precursors with gaseous nitrogen sources such as ammonia. The first solution‐phase metathesis reaction between FeCl 3 and Li 3 N in oleylamine is developed to directly synthesize Fe 2 N/Fe 3 N nanoparticles, requiring only a fume hood, glove box, standard chemistry laboratory glassware, and equipment. Finally, the ≈10–15 nm spheres display nearly soft magnetic behavior with a saturation magnetization ≈50–60 A m 2 kg −1 , coercivities between 40–50 kA m −1 , and susceptibility values from 0.0001–0.0006 m 3 kg −1 , well within the ranges reported with other published Fe x N nanoparticle synthesis methods.
iron nitride↗
High Power Density, Carbon Neutral Electrical Power Generation for Air Vehicles
The synergistic integration of a Solid Oxide Fuel Cell-Combustor (SOFC-C) with a turbogenerator (TG) will provide a very high fuel-to-electricity conversion efficiency while maintaining high power-to-weight ratio during high-altitude flight. The proposed SOFC-C-TG power generation technology exceeds the REEACH technical performance targets (TPT). This unique concept addresses many of the challenges faced in all electric propulsion-based aviation. The system has high part-load efficiency (more than 65% lower heating value (LHV)) during long cruise times, load following capability, high-power capacity at high altitudes adapting to low temperatures and pressures, rapid startup time of less than 30 minutes (proven with current SOFC technology), high power density (more than 3.2 kW/kg), efficient thermal management, and a foundation for a compact, efficient electrical storage and power generation system (ESPG). The SOFC-C concept achieves the technology targets by reducing the complexity of traditional fuel cell-gas turbine hybrid systems (FC-GT). The SOFC-C does not require heat exchangers and dramatically reduces the balance of plant increasing power density and performance in efficiency. The reduction in mass through elimination of heat exchangers, external reformer, and other components dramatically decreases the overall thermal dampening of the system which enables rapid startup and load following capability. Direct control of the cathode inlet temperature of the SOFC-C enables rapid warm-up of the SOFC tubes with the ability to reach operating temperature and full power in less than 30 minutes.
03 NATURAL GAS↗
TCF Base Technology-Specific Final Report: Negative Cracked Film Lithography for PERC CdTe
NLR worked with the world's leading thin-film photovoltaic manufacturer - First Solar, an American company - to develop electrical contacting methods that improve the power conversion efficiency of First Solar's cells by 0.5% absolute. We met this milestone but contrary to our hypothesis, these performance gains are not passivation (PERC)-based. Instead, we identified another mechanism by which our micropatterned Al 2 O 3 contacts improve efficiency. Using the results of this project, we will adapt NLR's cracked film lithography intellectual property (IP) toward the application we identified, which is a new route to commercialization.
14 SOLAR ENERGY↗
A fresh perspective on the role of band bending, and related contributors, in light-driven production of electricity and chemicals
It is widely known that semiconductor-based solar energy conversion could power our planet. This is in part because high-quality semiconductor structures are unrivalled in their ability to separate photogenerated electrons and holes. One effective approach to achieving this photoinduced charge separation relies on a phenomenon known as “band bending”. But details to justify why band bending results in photoinduced charge separation are more complex than often appreciated. This underappreciation is an impediment to the rational, hypothesis-driven design of next-generation approaches to solar energy conversion. Herein we show, by means of derivations rooted in physical chemistry, that several phenomena – not just band bending – can facilitate photoinduced charge separation, and that each is influenced by nonequilibrium species concentration and a parameter, such as diffusion coefficient or rate coefficient, that introduces dynamics. To help visualize the impact of each phenomenon, we introduce plots that depict their contributions as free energy, force, flux, force constant, and rate. We reveal that spatial dopant distributions that define band bending are predictors of initial photogenerated species transport rates. But charge separation alone does not guarantee high-efficiency operation. A photogenerated change in energy that is freely available to do useful work is also essential, and is strongly dependent on semiconductor optical properties and reaction kinetics. Notably, this information reveals that specificity of interfacial chemical reactions – even when they are not preceded by charge separation elsewhere – can result in efficient solar energy conversion. We expect that this tutorial will guide researchers in their pursuit to uncover new mechanisms for light to perform useful work.
14 SOLAR ENERGY↗
Electric Drive Technologies Consortium (EDTC)/ Cost competitive, high-Performance, highly Reliable (CPR) Power Devices on 4H-SiC (Final Report)
4H-Silicon carbide (4H-SiC) is a wide bandgap semiconductor that offers superior material properties over silicon, including higher critical electric field, thermal conductivity, and electron saturation velocity. These advantages make 4H-SiC highly attractive for high-voltage, high-efficiency power electronics. However, realizing the full potential of SiC requires device technologies that are not only high-performing but also manufacturable and reliable under real-world operating conditions. This report summarizes the outcomes of a five-year R&D effort funded by the U.S. Department of Energy (DOE) under the Electric Drive Technologies Consortium (EDTC), focused on developing cost-competitive, high-performance, and highly reliable (CPR) power devices on 4H-SiC substrates. The program targeted scalable and manufacturable 1.2 kV-class SiC MOSFETs optimized for next-generation electric vehicles, renewable energy systems, and industrial power conversion. The project delivered transformative advancements in SiC power device performance and ruggedness. Particularly, Specific on-resistance (R on,sp ) was reduced by up to 37%, from ~4.0 m$\Omega \cdot$cm 2 in earlier designs to an industry-leading 2.40 m$\Omega \cdot$cm 2 , driven by optimized doping, refined JFET widths, and layout engineering. Breakdown voltages (BV) exceeded 1600 V, marking improvement over legacy baselines, and demonstrating the robustness of newly implemented junction profiles and edge terminations. Short-circuit withstand time (SCWT) saw a remarkable 4$\times$ increase, from ~2 $\mu$s to over 8 $\mu$s, achieved through the successful deployment of deep P-well structures (~1.8–2.0 $\mu$m) via channeling implantation. This innovative process breakthrough enabled precise junction formation without MeV-class implantation tools, reduced leakage under high field stress, and allowed even the shortest-channel devices (down to 0.3 $\mu$m) to achieve both high BV and excellent ruggedness—breaking the traditional trade-off between conduction efficiency and blocking capability. Several novel architectures pushed the performance envelope further. JBSFETs—featuring embedded Schottky portions—eliminated bipolar degradation and drastically reduced third-quadrant leakage, while Ladder MOSFETs introduced a clever orthogonal conduction path that achieved a 15.4% reduction in R on,sp over standard linear designs. Switching performance reached new benchmarks: short-channel devices showed a 31% reduction in total switching energy compared to 0.5 $\mu$m counterparts, while maintaining manageable gate drive requirements. Layout-optimized structures not only improved transconductance but also accelerated switching transitions, pointing to real-world benefits in converter-level efficiency. The devices also passed rigorous reliability validation. Stress-tested across TDDB, HTGB, HTRB, HVP, and burn-in, the devices screened under 30 V/10 hr and 43 V/1 s protocols consistently exhibited tighter lifetime distributions and long-term oxide robustness. These screening techniques proved effective in identifying latent defects and ensuring deployment-grade reliability. Meanwhile, advanced 3D TCAD simulations revealed and resolved electric field hotspots—particularly in HEXFET corners—where fields exceeding 4.8 MV/cm were mitigated through geometry-aware layout corrections. Overall, the results of this project demonstrate a manufacturable and scalable SiC power device platform that addresses key DOE performance targets for efficient, robust, and reliable 1.2kV 4H-SiC Power Devices. The developed technologies represent a meaningful step forward in the commercial readiness of high-voltage SiC solutions and provide a strong foundation for continued advancement in wide bandgap power electronics.
42 ENGINEERING↗
Upgrading Biogas through in situ Conversion of Carbon Dioxide to Biomethane in Anaerobic Digesters
Organic waste streams generated by wastewater treatment plants, agricultural operations, and food processing industries represent an important yet underutilized opportunity for renewable energy production in the United States. Through anaerobic digestion, these waste streams can produce biogas, a mixture primarily composed of methane (CH4) and carbon dioxide (CO2), that can be upgraded to pipeline-quality natural gas. However, most existing upgrading technologies remove CO2 from biogas rather than utilizing it, leaving a significant portion of the potential energy unused. This project investigates a novel biological upgrading approach that converts CO2 into additional CH4 by supplying hydrogen (H2) to specialized microorganisms capable of performing hydrogenotrophic methanation. The main challenges associated with biological biogas upgrading are related to hydrogen supply, gas-liquid mass transfer, and process stability. First, due to the high cost of hydrogen gas, it is preferable that H2 be produced on-site using renewable energy sources such as wind or solar power. Second, hydrogen has low solubility in liquids, which limits its availability to microorganisms and requires strategies to improve gas dissolution and transfer within the reactor. Third, process inhibition may occur as a result of increased pH caused by CO2 consumption or elevated H2 partial pressure, both of which can negatively affect methanogenic activity. Although research in these areas has advanced during the course of this project, these challenges have not yet been fully resolved. To date, the biological systems that have achieved the highest methane concentrations are typically ex-situ reactors, where operational conditions can be more easily controlled. For this reason, the findings of the present project remain highly relevant. The project goal was to develop an innovative system that can accomplish biogas upgrading via biological conversion of CO2 to CH4, in a novel hybrid approach that combines the advantages of both in-situ and ex-situ systems. The proposed system employs a three-phase upflow anaerobic bioreactor with H2 delivery through a gas-permeable membrane, enabling efficient hydrogen transfer and microbial conversion. Under optimized operating conditions, the system achieved 99% H2 consumption and 90% CO2 conversion. A subsequent gas cleaning stage was implemented to further improve gas quality and meet target purity standards. The upgraded gas composition reached 97.7% CH4, 2.2% CO2, and 0.97% O2, while H2S concentrations remained below detection limits. In addition, a flue gas-driven inorganic thermoelectric generator (TEG) system was designed and experimentally validated as a potential source of electricity for H2 production. The system consisted of six TEG modules connected in series and achieved an open-circuit voltage of 4.5 V and a maximum power output of 224 mW at a temperature difference of approximately 53.5 °C, demonstrating effective conversion of waste heat into electrical power under simulated flue gas conditions. Finally, a comprehensive techno-economic analysis was completed to evaluate the capital and operating costs associated with the proposed system. The results provide important insights to guide future scale-up, optimization, and potential deployment of integrated biological biogas upgrading technologies.
09 BIOMASS FUELS↗
Comparative life cycle assessment of woody biomass processing: air classification, drying, and size reduction powered by bioelectricity versus grid electricity
Sulfur accumulation during biofuel production is pollutive and toxic to conversion catalysts and causes the premature breakdown of processing equipment. Air classification is an effective preprocessing technology for ash and sulfur reduction from biomass feedstocks. Here, a life cycle assessment (LCA) sought to understand the environmental impact of implementing air classification as a sulfur-mitigation technique to improve feedstock quality for pine residues using a grid electricity scenario (GES) versus a bioelectricity scenario (BES). Global warming potential (GWP) for preprocessing was simulated using inventory databases embedded in SimaPro and the Argonne National Laboratory’s GREET model, specifically focusing on comparing the GWP of a GES versus a BES. Overall, the GES had a GWP impact over seven times that of the BES (136 versus 18 kg CO 2 equivalent per tonne of usable feedstock), with steam generation during rotary drying accounting for 57% of the GES’s GWP. Air classification represents 0.4% and 1.6% of the total GWP impact for the GES and BES, respectively. Therefore, air classification can facilitate a 30% reduction in feedstock sulfur content to improve feedstock quality for biofuel conversion and lessen corrosion of equipment while contributing minimal GWP impact during preprocessing.
Air classification↗
Integration Methods for High-Density Integrated Electric Drives (Final Technical Report)
The project goal was to research, design and fabricate high-power-density, high-performance SiC power electronic modules for motor drive inverters in electric vehicles (EVs) to enable the subsequent motor drive to achieve a power density of 100 kW/l. EVs use electric motors instead of internal combustion engines as the prime mover, and their core components are semiconductor-based power electronic modules. Efficient power electronic modules play a vital role in power conversion systems. The performance of power modules directly affects the energy efficiency and overall performance of electric vehicles. Therefore, it is particularly important to develop power modules with high power density and high electrical performance that will perform reliably under EV environmental conditions. To achieve these goals, advanced electronic packaging technologies are required. This report describes a 5-year effort to integrate key aspects surrounding the basic power devices into the module itself to increase power density. These include sensing and sensing readout circuits, gate driver circuits, and two-sided cooling solutions.
33 ADVANCED PROPULSION SYSTEMS↗
Tutorial - Electric Motor and Integrated Traction Drive Thermal Management
The share of vehicles with fully electric propulsion systems is constantly increasing, and so is their traction drive power. The continuous push to increase power of electric vehicle (EV) traction drives necessitates their efficient cooling to prevent damage to temperature sensitive components of the drive system and achieving higher power outputs in a smaller footprint. With increasing power and power density of electric traction drives, their thermal management is becoming increasingly challenging. This tutorial will provide an overview of thermal management approaches for electric motors and power electronics in EV applications. It will review examples of current industry solutions for power-dense electric motor cooling, power electronics (inverter) cooling, their integration concepts and thermal management system solutions. We'll look at the advantages and challenges of power electronics integration into a single traction drive unit and respective thermal management system concepts. We'll talk about barriers to implementation of a unified thermal management system. The tutorial will also review key aspects of thermal management system design: modeling and simulation using FEA and CFD tools, experimental characterization, and general workflow for thermal management system evaluation.
ADVANCED PROPULSION SYSTEMS,DIRECT ENERGY CONVERSI↗
Microwave-photonic control of optically accessible spin defects in diamond
A growing variety of optically accessible spin qubits have emerged in recent years as key components for quantum sensors, computers, and memories. However, the scalability of conventional spin-based quantum architectures remains limited by direct microwave delivery, which introduces thermal noise, electromagnetic crosstalk, and design constraints for cryogenic, high-field, and distributed systems. In this work, we present a unified framework for RF-over-fiber (RFoF) control of spins accessible through optically detected magnetic resonance (ODMR) spectroscopy of nitrogen-vacancy (NV) centers in diamond. The RFoF platform relies on an intensity-modulated 1310 nm laser carrying microwave signals over fiber and a high-speed photodiode for optical-to-electrical conversion to drive NV spin transitions. We report an RFoF power-conversion efficiency of 3.42% for an RF output PRF,out=-5.5 dBm at 2.87 GHz, enabling clear resolution of Zeeman splitting in
Rahman, M Reefaz [ORNL] (ORCID:0000000323541611)↗
Pilot-Scale Algal Oil Production
The main objective of the project is complete: development of a preliminary planning and design for a pilot-scale algal oil cultivation and processing facility, FEL-3 design with -5% / +15% cost estimate accuracy, and conversion of the algal oil to biofuel in an off-site existing bio-oil refinery. The design basis includes 10 tons per day of dried algae cultivated with CO 2 supplied by direct air capture, electricity supplied solar power, well water supply, zero liquid discharge, off-site extraction, and off-site conversion of oil to biofuel. The design and permitting package is an important milestone in the path to commercialization of algal biofuels and bioproducts as it provides the preliminary design, permitting path, long-term land lease, planning documents, and team needed for success in future engineering, construction, start-up and operations of a pilot-scale farm at a site in Paso Robles, CA. Outcomes of the business assessment include (i) identification of a product spectrum for economical algal biofuels using co-products with markets that are commensurate with production of 6-7 billion gallons per year of sustainable aviation fuel (SAF), renewable diesel, and renewable gasoline, (ii) a path toward near-term contribution of algae oil to SAF, and (iii) an approach for long-term operation of a pilot-scale farm.
09 BIOMASS FUELS↗
MCP-eGridGPT (MCP-Enabled Chatbot with Electrical Power System Analysis and Interactive Visualization Tool) [SWR-25-126]
This software is an advanced chatbot system that integrates the Model Context Protocol (MCP) to provide intelligent electrical power system analysis and automated visualization generation. The system enables users to interact with complex electrical engineering tools through natural language, automatically analyzes power system data for voltage violations and grid health assessment, and generates professional interactive HTML dashboards and reports. Key features include dynamic tool discovery from MCP servers, multi-LLM provider support, intelligent data interpretation using large language models, automated chart generation, and a web-based interface for real-time analysis. The software bridges sophisticated electrical engineering analysis with user-friendly interfaces, making power system diagnostics accessible through conversational AI.
Choi, Seong [National Laboratory of the Rockies (N↗
Enabling Ultra-Compact, Lightweight, Efficient, and Reliable 6.6 kW On-Board Bi-Directional Electric Vehicle Charger with Advanced Topology and Control
The research explored new topologies, control methods, mechanical integration, and thermal management methods for electric vehicle (EV) on-board chargers. The team investigated capacitor-based power conversion, leveraging the high energy densities inherent to capacitive energy storage compared to inductive methods. The proposed topologies simultaneously enabled high power density and high efficiency of the design. The proposed architecture was demonstrated in a 6.6 kW bi-directional charger prototype. The research pursued several directions to improve system performance. Innovative topologies were studied for both the main power conversion stage as well as the single-phase twice-line-frequency energy buffer. To ensure robust and efficient operation, new control methods were developed to integrate these two subsystems. To achieve high power density in the full system solution, the mechanical structure of the charger is highly optimized to maximally fill the converter box volume. In parallel with the mechanical design effort, the converter was packaged with high-performance cooling methods which removed heat from key areas of power dissipation in the converter. The thermal management system was optimized to minimize its weight and volume, ultimately motivating the design of a custom additively manufactured cold-plate. The full system achieves a peak power of 7 kW with less than 0.3% total harmonic distortion (THD) and greater than 0.994 power factor in power factor correction (PFC) operation, corresponding to a total box-volume power density of 47.9 kW/L and gravimetric power density of 24.6 W/g. The system achieves a peak efficiency of 98.9%, with 97.9% efficiency at maximum power.
33 ADVANCED PROPULSION SYSTEMS↗
ARC-SAFE: Accelerated Response semiconducting Contactors and Surge Attenuation For DC Electrical systems (Final Scientific/Technical Report)
The landscape of power transmission and distribution is quickly evolving as more power conversion is done through power electronics and transmitted or distributed at medium voltage direct current (MVDC). As power electronics tend to store less energy and be less resilient to faults than conventional power transformers, a reliable and fast protection against faults is critical to protect power electronics (PE) based infrastructure, especially for medium- and high-voltage applications. This motivates the development of PE based protection circuits to replace slower contemporary electromechanical breakers. In this project a novel PE based MVDC circuit breaker is developed; the new design is comprised of 1) a normally-on leg made of commercially-available, cascaded SiC junction field effect transistors (JFETs) with a passive balancing network, and 2) a normally-off leg based on an optically-triggered gallium nitride (GaN) photoconductive semiconductor switch (PCSS). The normally-off leg was designed to be quickly turned on, to divert current to an auxiliary dissipative circuit, as the normally-on leg is turned off. This approach, using solid-state devices, was selected for a high-performance, fast-switching operation for the DC circuit breaker as compared to approaches that use slower mechanical switches. To be practical, the circuit breaker must have low conduction loss (low Ron) in the normally-on leg and fast coordinated triggering of the normally-off leg to avoid damage from inductive flyback, which could be considerable for long lengths of cable.
24 POWER TRANSMISSION AND DISTRIBUTION↗
Efficient on-chip terahertz generation and detection with GaN photoconductive emitters
Photoconductive emitters for terahertz generation hold promise for highly efficient down-conversion of optical photons because it is not constrained by the Manley-Rowe relation. Existing terahertz photoconductive devices, however, faces limits in efficiency due to the semiconductor properties of commonly used GaAs materials. Here, we demonstrate that large bandgap semiconductor GaN, characterized by its high breakdown electric field, facilitates the highly efficient generation of terahertz waves in a coplanar stripline waveguide. Towards this goal, we investigated the excitonic contribution to the electro-optic response of GaN under static electric field both through experiments and first-principles calculations, revealing a robust excitonic Stark shift. Using this electro-optic effect, we developed a novel ultraviolet pump-probe spectroscopy for in-situ characterization of the terahertz electric field strength generated by the GaN photoconductive emitter. Our findings show that terahertz power scales quadratically with optical excitation power and applied electric field over a broad parameter range. We achieved an optical-to-terahertz conversion efficiency approaching 100% within the 0.03–1 THz bandwidth at the highest bias field (116 kV/cm) in our experiment. Further optimization of GaN-based terahertz generation devices could achieve even greater optical-to-terahertz conversion efficiencies.
Uzundal, Can B↗
Sustainable Valorization of CO2 through Nuclear Power-to-X Pathways
Some of the issues concerning energy security and climate change can be addressed by employing nuclear power (NP) to supply the energy required for the conversion of carbon dioxide (CO2) into chemicals, products, and materials. Nuclear energy represents a neutral carbon source that can be generated sustainably, reliably, and consistently. Nuclear power plants (NPPs) could supply energy in the form of heat, electricity, and ionizing radiation to drive CO2 chemical reactions underpinning NP-to-X type of pathways. CO2 conversion processes are either commercially available or emerging technologies at different developmental maturity stages. This work reviews the published literature (articles and patents) that reports R&D results and the understanding and development of chemical reactions and processes, as well as the efforts in integrating NPPs and chemical processes (CPs). As will be made evident, a new industrial era for the manufacturing of decarbonized chemicals, products, and materials will be possible by developing and implementing new (more energy- and carbon-efficient) processes responding to the NP-to-X pathways. This new decarbonizing platform not only contributes to achieving net zero goals but also broadens the NPP product beyond electricity.
08 HYDROGEN↗