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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Energy Requirements for Integration of Nuclear Reactors with Iron and Steel Plants

This report identifies energy needs of heavy energy users within the domestic iron and steel industry and suggests solutions for integrating nuclear energy. The iron and steel industry, composed of several types of plants which perform different processes with varied energy demands and vectors, is a heavy consumer of electric power and fossil fuels including coke and natural gas. Almost all major process temperatures exceed the temperatures of direct heat available from advanced reactors, and so electricity and hydrogen were considered instead. Reference units were adopted and estimated energy demands computed for the blast furnace (BF), direct reduced iron (DRI) unit, electric arc furnace (EAF), and reheat furnaces. By utilizing production capacity data from industry reports, the ranges of power demands were estimated, including for hydrogen production by high temperature steam electrolysis (HTSE). For the EAF and DRI unit, more detailed integration studies with thermodynamic modeling were also conducted and determined a possible solution with a specific reactor design and number of modules. Furthermore, because many unit processes are co-located, entire plants were considered by adding the energy demands of the unit processes to form four hypothetical reference plants. The range of power needs for the reference plants is compatible with multi-unit banks of microreactors at the low end, and would create a need for multiple larger-capacity SMRs at the high end (1 GWe plus 0.14 GWt). Although the overall power need at the high end is well-matched with one present-day large reactor offering (1.1 GWe), redundancy considerations may require a minimum of two reactors, potentially eliminating the single large reactor from consideration. Auxiliary or house loads would increase the reference plant estimates. Finally, the report provides total estimated energy needs under integration of all U.S. units of each process (BF, DRI, EAF, and reheat furnaces), representing a national potential for nuclear energy in the industry. U.S. iron and steel plants may be candidates for integration with nuclear reactors via electricity and hydrogen, and many sites have energy requirements that correspond well to the capacities of several advanced nuclear power designs.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Low-cost buffer storage for solar industrial steam applications

Motivation and importance: Many industrial process heat consumers operate throughout the day, and deep decarbonization with solar energy requires thermal energy storage. Thermal energy storage provides an additional operational benefit of firm delivery of steam – essential to reducing the risk of costly production interruptions. The group of process heat consumers that use steam for biofuels production for the California transportation fuels market is incentivized through the Low Carbon Fuel Standard (LCFS) to reduce their carbon intensity through the use of solar steam. Examples include ethanol and dimethyl ether production. The production of these and other fuels involves distillation driven by steam reboilers with steam pressures in the range 100-280 psig. These pressures can be delivered from the type of thermal energy storage that has been the focus of this project – a steam accumulator Sunvapor, Inc. (SVI) calls a “Bullet Steam Accumulator” or “BSA TM ”. Our project adds to the understanding of the design and integration of steam accumulators charged by solar thermal energy in a biofuels production facility, and similar facilities that consume process steam. The fuel application requires a demanding level of Process Safety Management not found in other steam applications. The type of steam accumulator SVI engineered and built integrates steam generation and storage in one vessel to reduce cost. Achieving a first of a kind permit to operate such a first device has also added to the understanding of the industrial application of such systems. Goals: The overall goal of the project has been to demonstrate the advantages that a “Bullet Steam Accumulator” (BSA™) can provide to solar steam integration with a manufacturing process. The industrial host has already been convinced of the potential of the available solar steam to lower than carbon intensity score. They have been interviewed for a number of publications such as that tout the advantages SVI’s system brings to their operations. Accomplishments: At the end of 2023 Sunvapor placed in service the country’s first industrial solar boiler with thermal energy storage. At the same time, this placement in service represents the first pilot commercial system to decarbonize biofuels production through the use of solar thermal energy. While the full technical effectiveness will be shown as soon as the customer’s plant is able to consume the available steam, the economic feasibility was indicated early in the project when the combination of costs and steam pricing required to meet investor expectations was determined. The project represents a reference pilot from which a full-scale commercial system may be expanded. This pilot is a necessary first step in providing the full potential benefits to the public, including decarbonization of transportation fuels. The decarbonization of the separation steps in fuels production may be the most cost-effective and nearest term solar fuel. Co-benefits include a reduction of air pollutants such as NOx and particulate matter, and job creation for the construction, operation and maintenance of industrial solar facilities.

14 SOLAR ENERGY↗
DOE OSTI2026

Design and performance assessment of a dual-mode latent thermal storage integrated heat pump across multiple climate zones

The electrification of space cooling and heating systems risks overloading the existing electrical grid during peak hours. Heat pumps integrated with thermal energy storage (HP-TES) offer a promising solution by shifting peak loads to off-peak hours, reducing grid strains. This work presents the design and assessment of a dual-mode HP-TES that uses a single 22°C phase-change material (PCM) as a heat source or sink in heating and cooling modes, respectively. Performance assessment was conducted using Modelica-based transient models, and full-year simulations were conducted across eight US climate zones using typical weather data. Two HP-TES performance metrics: peak energy reduction and recharge energy increases, were defined by comparing HP-TES energy consumption with base HP peak consumptions. Annual heating demand reductions (40–65%) exceeded cooling demand reductions (15–20%) due to the elimination of peak-hour backup heating. Cooling mode recharge energy requirements (0–10%) were reduced in locations with lower summer nighttime temperatures, while heating recharge requirements were lower than the high base-peak energy demand from backup heating. Simplified rapid methods that were 10 7 times faster than annual simulations were developed to predict seasonal cooling and heating energy reductions, and recharge energy requirements, with maximum deviations of ±2.5% and ±3.5% points. These methods enabled rapid parametric studies that identified optimal location-specific PCM temperatures between 22°C and 27°C, highlighting the need to consider both discharge and recharge energy requirements to achieve sustainable, energy-efficient peak load shifting across various climate zones.

25 ENERGY STORAGE↗
DOE OSTI2025

Ocean Wave Energy Harvester with Oak Ridge Converter

Oceans can provide great potential for the American energy dominance. There is significant potential to utilize marine energy resources. In the United States, the total amount of marine energy available is equivalent to about 57% of the country's total power generation in 2019. Even if a fraction of this technical potential is harnessed, marine energy technologies could play a crucial role in fulfilling the nation's energy requirements. Marine energy resources are spread out geographically, and because more than 50% of the United States' population resides within 50 miles of the coastline, they are well-positioned to power local communities. These resources are also very dependable, making them a viable option for contributing to a consistent, trustworthy energy grid. Due to their predictable daily and seasonal patterns, marine energy resources can be integrated into our energy generation portfolio. On the other hand, ocean environment presents many challenges for cost-effective renewable energy conversion, including optimal control of ocean wave energy. This report presents a novel cost-effective energy conversion technique for ocean wave energy harvesters. The proposed system is simulated by using the Oak Ridge Converter to directly interface ocean wave energy source with the utility grid. The system description and simulation results are presented in detail. The results show that the proposed system is a cost effective and promising technology to reduce the infrastructure cost for ocean wave energy harvesters.

Sutton, Elizabeth [ORNL] (ORCID:0009000078885935)↗
DOE OSTI2026

Techno-Economic Comparison of Molten-Salt Electrolysis and Carbothermic Reduction for the Production of Metallurgical-Grade Silicon

Metallurgical-grade silicon (MG-Si) is an important source material for many industrial applications, including the manufacture of alloys, solar photovoltaics, and electronics. The process to refine raw materials into MG-Si is energy-intensive, with the predominant method of submerged-arc furnaces requiring energy consumption of approximately 11–13 kWh/kg Si. Recent research has discussed promising methods for reducing the energy required for the silicon production process, including the use of molten-salt electrolysis (MSE), a technique that offers potential savings in energy consumption without requiring carbon inputs for the process. This paper presents a techno-economic study of a potential industrial-scale MSE plant for MG-Si production to evaluate the trade-offs between capital and operating costs of the system. Capital costs are sourced from recent MG-Si plants and an existing cost model developed for MSE processes that includes the size of the plant and the operating temperature among its inputs. The results show that MSE technology has the potential to be an economically cost-competitive option for MG-Si production if the technology successfully scales to industrial production and matures enough to allow for financing costs similar to that of a comparably sized submerged-arc furnace plant.

14 SOLAR ENERGY↗
DOE OSTI2024

Uncertainty in determining carbon dioxide removal potential of biochar

A quantitative and systematic assessment of uncertainty in life-cycle assessment is critical to informing sustainable development of carbon dioxide removal (CDR) technologies. Biochar is the most commonly sold form of CDR to date and it can be used in applications ranging from concrete to agricultural soil amendments. Previous analyses of biochar rely on modeled or estimated life-cycle data and suggest a cradle-to-gate range of 0.20–1.3 kg CO 2 net removal per kg of biomass feedstock, with the range reported driven by differences in energy consumption, pyrolysis temperature, and feedstock sourcing. Herein, we quantify the distribution of CDR possible for biochar production with a compositional life-cycle inventory model paired with scenario-aware Monte Carlo simulation in a 'best practice' (incorporating lower transportation distances, high pyrolysis temperatures, high energy efficiency, recapture of energy for drying and pyrolysis energy requirements, and co-generation of heat and electricity) and 'poor practice' (higher transportation distances, lower pyrolysis temperatures, low energy efficiency, natural gas for energy requirements, and no energy recovery) scenarios. In the best-practice scenario, cradle-to-gate CDR (which is representative of the upper limit of removal across the entire life cycle) is highly certain, with a median removal of 1.4 kg of CO 2 e/kg biomass and results in net removal across the entire distribution. In contrast, the poor-practice scenario results in median net emissions of 0.090 kg CO 2 e/kg biomass. Whether this scenario emits (66% likelihood) or removes (34% likelihood) carbon dioxide is highly uncertain. The emission intensity of energy inputs to the pyrolysis process and whether the bio-oil co-product is used as a chemical feedstock or combusted are critical factors impacting the net carbon dioxide emissions of biochar production, together responsible for 98% of the difference between the best- and poor-practice scenarios.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

High Energy Physics Network Requirements Review: Final Report, July 2024–December 2024

The world-class research infrastructure at the US Department of Energy (DOE) Office of Science (SC) provides the research community with premier observational, experimental, computational, and network capabilities. Each user facility is designed to provide unique capabilities to advance the core DOE mission in science and technology for its SC program to stimulate rich scientific discoveries and enhance its innovation ecosystem. Research communities gather and flourish around each user facility, bringing together new and enhanced perspectives. The continual reinvention of the practice of science — as users and staff forge novel approaches expressed in research workflows — unlocks new discoveries and propels scientific progress. Within this research ecosystem, the high-performance computing (HPC) and networking user facilities stewarded by the SC’s Advanced Scientific Computing Research (ASCR) program play a dynamic cross-cutting role, enabling complex workflows demanding high-performance data, networking, and computing solutions. The ASCR facilities enterprise seeks to understand and meet the needs and requirements across SC and DOE domain science programs and priority efforts, highlighted by the formal requirements review methodology. Between July and December 2024, the Energy Sciences Network (ESnet) and the Office of High Energy Physics (HEP) of the DOE-SC organized an ESnet requirements review of HEP-supported program activities. Preparation for these events included identification of key stakeholders: program and facility management, research groups, and technology providers. Each stakeholder group was asked to prepare formal case study documents about its relationship to the HEP program to build a complete understanding of the current, near-term, and long-term status, expectations, and processes that will support the science going forward.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2025

Stress evolution and creep deformation in solid-oxide electrolysis cell systems – Dynamic modeling and multi-objective optimization to maximize stack life and efficiency

Here, this study develops a thermal stress model of solid-oxide electrolysis cells (SOECs) including a model for creep strain and failure probability that is integrated with a dynamic plant-wide model of a hydrogen production process. Uncertainties in key material properties of the cell are quantified to assess their impact on stress profile variability. The oxygen electrode is found to have about 10 times higher failure probability compared to the fuel electrode. The study shows that if the stack operation is not optimized, cycling operation would lead to stress build-up eventually leading to catastrophic failure. A dynamic optimization problem is set up for obtaining the optimal operational profile considering a variable hydrogen production rate. Due to the tradeoff between the efficiency and stress build-up, the dynamic optimization problem is multi-objective. It is observed that the optimizer can considerably reduce the stress build-up (i.e., can increase the stack life) albeit at the cost of a lower efficiency thus exhibiting strong tradeoffs between capital and operating costs. For example, if the stack would be replaced in 0.5 yr, specific energy requirement would be 48.5 kWh/kg H 2 while for a stack replacement time of about 6 yr, the specific energy requirement rises by about 4.2 %.

SOEC↗
DOE OSTI2024

Seawater alkalization via an energy-efficient electrochemical process for CO 2 capture

Electrochemical pH-swing strategies offer a promising avenue for cost-effective and energy-efficient carbon dioxide (CO 2 ) capture, surpassing the traditional thermally activated processes and humidity-sensitive techniques. The concept of elevating seawater’s alkalinity for scalable CO 2 capture without introducing additional chemical as reactant is particularly intriguing due to its minimal environmental impact. However, current commercial plants like chlor-alkali process or water electrolysis demand high thermodynamic voltages of 2.2 V and 1.23 V, respectively, for the production of sodium hydroxide (NaOH) from seawater. These high voltages are attributed to the asymmetric electrochemical reactions, where two completely different reactions take place at the anode and cathode. Here, we developed a symmetric electrochemical system for seawater alkalization based on a highly reversible and identical reaction taking place at the anode and cathode. We utilize hydrogen evolution reaction at the cathode, where the generated hydrogen is looped to the anode for hydrogen oxidation reaction. Theoretical calculations indicate an impressively low energy requirement ranging from 0.07 to 0.53 kWh/kg NaOH for established pH differences of 1.7 to 13.4. Experimentally, we achieved the alkalization with an energy consumption of 0.63 kWh/kg NaOH, which is only 38% of the theoretical energy requirements of the chlor-alkali process (1.64 kWh/kg NaOH). Further tests demonstrated the system’s potential of enduring high current densities (~20 mA/cm 2 ) and operating stability over an extended period (>110 h), showing its potential for future applications. Notably, the CO 2 adsorption tests performed with alkalized seawater exhibited remarkably improved CO 2 capture dictated by the production of hydroxide compared to the pristine seawater.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Sub-Ambient Performance of Potassium Sarcosinate for Direct Air Capture Applications: CO 2 Flux and Viscosity Measurements

Absorption based direct air capture (DAC) technologies have garnered significant interest in recent years due to their scalability, competitive regeneration energy requirements, and low susceptibility to degradation. One of the key advantages of DAC lies in its flexible siting options and the potential to utilize low-value land. However, most of the research in this field has been focused on ambient climate zones (T > 20 °C), overlooking sub-ambient (–30 °C < T < 20 °C) regions, which comprise approximately 70 % of the Earth’s surface. To fully realize the potential of DAC, it is essential to understand how DAC solvents perform in these sub-ambient conditions before any large-scale deployment can be considered. Among DAC solvents of interest, potassium sarcosinate (K-SAR) has emerged as a promising candidate due to its high CO 2 capacity, fast uptake kinetics, compatibility with contactor packing materials, low volatility, good thermal and oxidative stability, and competitive regeneration energy requirements compared to current industry standards. This paper characterizes the CO 2 flux and viscosity of K-SAR at sub-ambient conditions and explores the potential of using ethylene glycol and triethylene glycol as additives to prevent solvent freezing in DAC applications. For 1 M K-SAR, the CO 2 flux ranges between 1.3 × 10 -5 and 8.0 × 10 -5 mol m –2 s –1 across a temperature range of –5 °C to 45 °C. Ethylene glycol is shown to effectively suppress the freezing point of K-SAR below –30 °C with volumetric loadings of the additive as low as 0.1. Here, a reaction model was developed to predict the CO 2 flux for 1 M K-SAR at different temperatures, demonstrating good agreement between experimental and theoretical fluxes.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Beyond conventional batteries: a review on semi-solid and redox targeting flow batteries-LiFePO{sub 4} as a case study.

Clean and sustainable energy is becoming increasingly crucial to tackle the current energy crisis. However, the intermittent nature of renewable energy sources presents a challenge for their effective implementation. Redox flow batteries (RFBs) have emerged as a promising solution to this problem, as they can help enhance the stability of grid networks and promote the use of renewable energy sources. RFBs are highly modular and scalable systems that can be customized to meet the power and energy requirements of different renewable energy plants. Moreover, they offer several advantages over conventional battery technologies, including cost and safety concerns. However, conventional RFBs have limited energy densities due to the low solubility of their active species in electrolyte. To overcome this limitation, semi-solid (SSRFBs) and redox targeting (RTFBs) flow batteries have been proposed. These systems feature high concentrations of active species and impressive energy densities, making them highly attractive for renewable energy applications. LiFePO4 (LFP) is a highly promising active material for semi-solid and targeting flow batteries. One of the key advantages of LFP is its low raw materials cost, as it is composed of Earth-abundant elements such as iron and phosphorus. This makes it an attractive option for large-scale battery production. The recent developments in SSRFBs and RTFBs using LFP as catholyte hold great promise for the future of sustainable energy storage. The combination of LFP's low cost, safety, durability, and high energy density with the modularity and scalability of flow battery systems make for a compelling solution to the challenges of intermittent renewable energy sources. Ongoing research and development in this area will likely yield even further improvements in the performance and efficiency of LFP-based flow batteries, opening exciting new possibilities for sustainable energy storage.

El Halya, Nabil↗
DOE OSTI2024

Transforming nanoscale VO 2 (B) into a scalable sodium-ion electrode

The intermittent nature of renewable energies requires highly reliable grid-level energy storage approaches. A critical consideration in developing this technology is the areal capacity which determines battery performance and influences the cost of battery technology. Of related importance is finding new ways of developing scalable electrodes. In recent years, three-dimensional (3D) printing of conductive scaffolds has emerged as an alternative to overcome the scalability limitations of commercial tape cast electrodes. The research carried out in the current study demonstrates a successful scalability pathway for nanoscale VO 2 (B), a desirable cathode for sodium-ion batteries which has a nano-flower morphology with a crystallite size < 20 nm. By electrodepositing VO 2 (B) onto a graphene aerogel scaffold, we were able to achieve mass loading of over 100 mg·cm −2 and still possess an areal capacity of 10 mAh·cm −2 at a current density of 5 mA·cm −2 . Moreover, after 1000 cycles, these electrodes retained 75% to 80% of their initial capacity. Even at high loading levels, the electrodeposited VO 2 (B) exhibits pseudocapacitive material signatures such as a box-like voltammetry response, linear galvanostatic response, and no phase change upon lithiation. The scalability of the VO 2 (B) electrode is demonstrated in a series of experiments which show the areal capacity to scale upon increase in both mass loading and electrode thickness, with only small changes in specific capacity. Furthermore, this study establishes that nanoscale materials can be scaled up to achieve thick electrodes without compromising their electrochemical properties.

additive manufacturing↗
DOE OSTI2025

Drying of strawberries with airborne ultrasound and other integrated dehydration mechanisms

This article presents a comprehensive investigation into the drying of strawberries using multiple dehydration methods with an emphasis on energy efficiency and sustainability. Initially, an airborne ultrasonic transducer with a frequency of 21 kHz was employed in batch operations to examine the effects of controlling parameters, including applied power, distance from the transducer plate, sample thickness, and sample holder type. The Energy Ratio, defined as the ratio of thermal energy required to evaporate moisture to ultrasonic energy, was observed to reach up to 2.2, particularly during the initial stages of drying. Subsequently, the Smart Dryer integrated airborne ultrasound (US) dehydration, slot jet reattachment (SJR) nozzle convective drying, infrared (IR) drying, and their combinations, enabling a systematic exploration of various drying conditions on the drying time and quality of strawberries. The integration of airborne US with SJR nozzles and IR drying demonstrates a promising approach for optimizing drying processes. This method not only preserves the quality of dried strawberries but also improves the energy factor to 0.88, reducing drying time by 89% compared with other conditions. Key quality attributes of the dried strawberries, such as color and water activity, were evaluated to understand the influence of each drying method. The findings highlight the potential of these integrated drying techniques as sustainable solutions for efficient and high-quality strawberry dehydration.

42 ENGINEERING↗
DOE OSTI2024

System and Component Development of Particle-Based Pumped Thermal Energy Storage

Reliable power supply from variable renewable resources requires energy storage at various scales to overcome resource intermittency. Long-duration energy storage (LDES, 10-100 hours) can improve dispatchability and grid reliability with increasing levels of renewable power supply. Thermal energy storage (TES) has siting flexibility and the ability to store a large capacity of energy, and thus has the potential to meet the LDES need and provide charging and discharging durations beyond the economic capacity of conventional batteries. TES technology has evolved from concentrating solar thermal power (CSP) generation and is recognized as an economic large-scale energy storage method. A standalone electric-thermal energy storage system supporting renewable integration of wind and solar power without CSP solar field can firm renewable generation and boost overall grid resilience and security.

concentrating solar thermal power↗
DOE OSTI2024

Gaseous contaminant transfer in membrane-based air-to-air energy exchangers

Membrane-based air-to-air energy exchangers (M–AAEEs) transfer heat and moisture between building exhaust air and fresh ventilation air streams through a membrane, thereby reducing the energy required for conditioning the fresh ventilation air. Energy exchangers are typically used in buildings with relatively clean building exhaust air, such as office buildings and schools. Recently interest in using energy exchangers in a wider range of buildings has grown, to reduce the energy consumption associated with the heating, ventilating, and air-conditioning (HVAC) systems in these buildings. However, if the building exhaust air is not clean, as would be the case for laboratories or factories, new risks are encountered when using energy exchangers. It is possible that gaseous contaminants in the exhaust air may also transfer along with the moisture through the membranes, contaminating the incoming fresh ventilation air. Current test standards provide a test procedure to determine the contamination of the fresh ventilation air by measuring the transfer of an inert tracer gas in an energy exchanger. However, the tracer gas test may not represent the transfer of common indoor air contaminants due to differences in their transport properties. Therefore, in this study, an experimental facility is developed to determine the transfer of seven different contaminants through two membranes (porous and dense) at different flow rates. Contaminant transfer is quantified using a parameter called the exhaust contaminant transfer ratio (ECTR), which gives the fraction of the contaminants transferred from the exhaust air to the fresh ventilation air. A theoretical model based on the effectiveness-number of transfer units (ε-NTU) correlation and moisture transfer resistance of the membrane is presented to determine transfer through porous membranes and validated with experimental results. The major contribution of this paper is that it presents a simple method to predict the transfer of different contaminants through a porous membrane based on the moisture transfer resistance of the membrane at different operating conditions. It is found that as contaminant diffusivity decreases, ECTR generally also decreases, and as the flow rate increases, ECTR decreases, which is consistent with the predictions from the correlation.

42 ENGINEERING↗