Fiscal Year 2025 CLIMR Projects: Commercializing Energy Technologies

A Self-Guided Training Platform for MOOSE and MOOSE-Based Applications 

Lead Lab: Idaho National Laboratory 

Partnering Lab: Los Alamos National Laboratory 

This project aims to develop a self-guided training platform to support users who access INL’s Office of Nuclear Energy (NE) codes, primarily MOOSE and BISON. The interactive modules will comprise several hands-on exercises containing a problem setup, questions, and final answers for the user to attempt. The modular form provides users with a flexible, asynchronous, and accessible alternative to the current standard of in-person trainings and thus enhancing the impact of these codes by easing the learning curve of the software and increasing the number of users. 

Commercialization of Deliberate Motion Analytics (DMA) 

Lead Lab: Sandia National Laboratories 

The costs of physical security continue to escalate, yet nuclear power generation sites must guarantee nuclear materials are protected from malicious or terrorist attacks. Critical to physical security is a reliable intrusion detection system capable of detecting attackers with low nuisance alarm rates at lower costs than traditional security approaches. This project will commercialize a sensor fusion algorithm, capable of fusing new and emerging sensor technologies using an AI called Deliberate Motion Analytics (DMA). The DMA algorithm has been tested with sensors in nuclear power plant environments and has demonstrated its ability to provide reliable detection with low nuisance alarm rates; enabling new security architectures that can significantly reduce physical security costs. The proposed project is structured to commercialize DMA, resulting in a COTS technology that nuclear power plants and other critical energy sites can deploy. DMA also has potential for deployment at nuclear weapon sites and border environments. 

Commercializing Laser Technology for Atomic Vapor Laser Isotope Separation of Lithium-6 

Lead Lab: Lawrence Livermore National Laboratory 

This project will commercialize LLNL’s laser technology for lithium-6/lithium-7 isotope separation, leveraging $2B invested in AVLIS technology demonstrated for uranium in the 1970s–1990s but never realized. LLNL’s modernized AVLIS designs, combined with Hexium, Inc.’s need for high-power lasers, form the basis of this effort. LLNL will design and prototype two laser systems while Hexium procures and integrates laser hardware with a lithium separator. The goal is to prove the market viability of LLNL’s proprietary technology and unlock a domestic production route for critical isotopes such as lithium-6, lithium-7, and eventually HALEU. 

Component Manufacturing Technique Development for Novel Molten-Salt Resistant Alloys 

Lead Lab: Oak Ridge National Laboratory 

There is an increasing commercial interest is the development and deployment of liquid-fueled Molten Salt Reactors (MSRs). Hastelloy®N, the leading candidate MSR structural alloy, is not capable of operations at temperatures above 700°C, thus limiting the performance of these systems. This project will fabricate components using a new solid solution strengthened alloy in US Patent 9, 435, 011 B2 developed at Oak Ridge National Laboratory with improved creep resistance and test the component in an environment relevant to molten salt reactors to achieve TRL 6 for these alloys. The proposed project involves collaboration between ORNL, material supplier, a casting house and a reactor developer thereby accelerating commercialization of this technology. 

Development of a Liquid Metal-Cooled Fast Reactor Simulator 

Lead Lab: Argonne National Laboratory 

The objective of this project is to develop a liquid-metal-cooled fast reactor (LMFR) simulator by coupling Argonne National Laboratory’s SAS4A/SASSYS-1 (SAS) advanced LMFR safety analysis code with Curtiss-Wright’s commercial nuclear power plant simulator environment 3KEYMASTERTM. The creation and commercialization of an LMFR simulator serves a unique market need, since software models used within today’s commercial simulators are primarily intended for light water reactors and are known to contain certain limitations when it comes to modeling LMFRs. SAS is considered to be the most mature and comprehensive systems-level LMFR safety analysis tool available to domestic organizations, therefore its integration within an established commercial simulator will create a high-quality tool specifically applicable to LMFR designs. This project will create a modeling and simulation tool to accelerate development and deployment of advanced reactor concepts. 

Transforming Reactor Design: Fast-Tracking Industrial Adoption of GPU-Powered OpenMC 

Lead Lab: Argonne National Laboratory 

The DOE has invested heavily in the development of the OpenMC Monte Carlo particle transport code via the recent Exascale Computing Project. Global Nuclear Fuels-Americas (GNF-A), the cost-share partner for this project, is seeking to apply OpenMC for reactor engineering design and analysis work in order to exploit OpenMC’s GPU-powered performance on modern GPU HPC resources. The significant speedups offered by OpenMC on GPU vs. CPU are expected to both 1) compress the costs and design timelines of existing engineering workflows for LWRs, and 2) empower advanced reactor design efforts. As proven by ExaSMR milestone results, OpenMC on GPU has already demonstrated a high technology readiness level, leaving relatively few barriers to commercial adoption by GNF-A. This proposal aims to address those few remaining barriers so as to bridge the final gap between DOE research and industrial adoption. 

Visualization for Predictive Maintenance Recommendation (VIPER) 

Lead Lab: Idaho National Laboratory 

Operation and maintenance costs (O&M) are one of the major non-capital costs contributing to the high overall operation costs of existing commercial nuclear power plants (NPPs). Compared to preventive and corrective maintenance strategies, predictive maintenance strategies are enabling approaches that maximize use and operation of equipment, optimize maintenance activities, minimize human errors, and reduce material and labor costs. The proposed effort would accelerate commercialization of the Idaho National Laboratory developed VIsualization for PrEdictive maintenance Recommendation (VIPER), a technology that takes advantage of advancements in sensors, data analytics, machine learning and artificial intelligence, and human factors. Commercializing VIPER will optimize maintenance programs for domestic NPPs, enabling cost- and time-effective O&M in the current competitive energy market. This would lay the foundation for leveraging VIPER to achieve predictive maintenance for advanced reactors, decreasing their O&M costs and accelerating their deployment. 

Software Updates for DER Operations in Real-Time (SUDO-RT) 

Lead Lab: Sandia National Laboratories 

Applying patches and updates to OT devices (without loss of availability) using software containers and orchestration technologies can prevent vulnerable software from exploitation. Currently, patches are only applied at regularly scheduled maintenance intervals to avoid downtime during the patching process. We have developed a live-patching/updating solution under a DOE CESER funded project named Containerized Application Security for Industrial Control Systems (CAPSec) where we have prototypes that have been tested and demonstrated at Duke Energy and at a microgrid at Fort Belvoir without loss of availability. We seek to partner with industry to commercialize this technology for broader energy sector adoption to better secure Operational Technology environments. Our technology will be demonstrated at an operational solar PV site of the local utility in Albuquerque, New Mexico. 

Diagnosis, Rational Design and Operation of Pouch Cells for Aqueous Zinc Ion Batteries 

Lead Lab: Oak Ridge National Laboratory 

ORNL will partner with zinc ion battery (ZIB) manufacturers and the university to improve the aqueous ZIB cycling performances at the pouch cell level based on ORNL’s developed aqueous electrolytes. The 1Ah multi-layer zinc ion pouch cells with different energy density levels will be assembled and tested with their failure mechanisms identified by developing non-destructive, real-time electrochemical analysis approaches, and their performances will be improved by optimizing pouch cell design (e.g. electrode porosity/mass loading, anode thickness, and electrolyte amount) and operation conditions (e.g. external pressures applied on the pouch cells and rational fixture designs). The knowledge that differs from conventional wisdom in traditional Li-ion batteries, will be gained, shedding light on diagnosis, design and operation of zinc ion pouch cells to guide the industries for commercializing aqueous ZIBs. 

Peak Load Prediction Platform for Resilient Grids under Extreme Temperatures 

Lead Lab: Lawrence Berkeley National Laboratory 

This project aims to enhance the peak load estimation under extreme temperature conditions to support the resilient planning and operation of grid systems, enabling riskinformed resilience investment decisions by electric utilities. By leveraging our previous work with Portland General Electric sponsored by DOE Office of Electricity, as well as our advanced urban scale building energy simulation expertise, we seek to build an automated data pipeline and apply advanced machine learning techniques powered by measurement data and simulation data to improve the accuracy of peak load estimation. Dedicated efforts will be made to automate and package the tools we developed in a flexible way to enhance the tool’s applicability and adaptability, which enables simple use or easy adoption in existing pipelines across the broader utilities community. 

Accelerating the Optimization of Direct Methanol Synthesis from Stranded Methane through Advanced Manufacturing Design and AI/ML Guidance 

Lead Lab: Oak Ridge National Laboratory 

Partnering Lab: Brookhaven National Laboratory 

Oak Ridge National Laboratory (ORNL) in collaboration with Brookhaven National Laboratory (BNL), Georgia Institute of Technology (GT) and Pioneer Energy, aim to advance and validate a costeffective, environmentally friendly, catalytic technology to enable the direct production of methanol from stranded methane streams to rival multi-step and energy intensive solutions. The new technology integrates two innovations recently developed at ORNL and BNL with a highly selective and scalable sulfur tolerant catalyst, that yields high purity methanol. Artificial intelligence and machine learning will be used to predict and optimize conditions for accelerating scaled, commercially viable performance that transforms complex methane feeds and delivers a high purity product. The technology will be validated on a customized fixed bed reactor for a continuous scaled process intensification pathway. Co-design will enable the technology demonstration of the process, supported through technoeconomic and life cycle analysis (TEA/LCA) performed by PE and GT to guide market deployment. 

Achieving American Energy Dominance by Unleashing Produced Water Innovation 

Lead Lab: Los Alamos National Laboratory 

Disposal of vast volumes of produced water from oil and gas production is constraining domestic production and presents huge economic costs and environmental risks. Simultaneously, numerous locations across U.S. lack adequate cleaner water supply for industrial use. Therefore, low-cost technology for treating produced water for industrial use would have enormous economic value. The Los Alamos National Laboratory (LANL) has developed technologies to use the organics in the produced water for generating clean industrial water supply with near-zero external energy consumption. LANL will coordinate and utilize the capabilities of University of Oklahoma (OU) and Libertad Power to identify and resolve technical challenges associated with upscaling of a LANL-developed desalination technology for generation of deionized water from produced water. Successful project completion will demonstrate a pilot scale desalination system at a flowrate 15 gal/hour for hydrogen production at TRL 6-7, with a potential reduction in external energy consumption by 80%. 

Transforming Underutilized/Stranded Natural Gas into Liquid Products by Advancing Plasma Reactors and Catalytic Conversion Technologies 

Lead Lab: Oak Ridge National Laboratory 

Partnering Lab: Argonne National Laboratory 

A team of researchers and engineers from Oak Ridge National Laboratory (ONRL), Argonne National Laboratory (ANL), Pendulum Power, and RedShift Energy, Inc. (RSE) proposes the development of a technology for transforming underutilized/stranded natural gas (UNG/SNG) into liquid products by advancing catalytic plasma reactor technologies. This will transform UNG waste streams into easily transportable liquid hydrocarbons and thus eliminate natural gas flaring. Led by ORNL, in partnership with Pendulum Power, RSE (small businesses providing cost share) and ANL, the project will utilize ORNL's intellectual property (IP). The National Lab team will employ advanced reactors and nano-catalysts to generate liquid chemicals. 

In-Situ Fabrication of Non-Rare Earth Magnets Within Motors During Assembly 

Lead Lab: Ames National Laboratory 

This project seeks to develop an injection molding (IM)-based technology for the in-situ fabrication of non-rare earth MnBi bonded magnets during the motor assembly process. Fine MnBi powder, with a particle size of less than 10 μm, is first converted into anisotropic granules with a particle size of 300±100 μm, making them suitable for handling in air. These MnBi granules are then combined with binders and processed into composite pellets with a higher loading fraction through extrusion. Finally, the pellets are integrated into motor parts and magnetized during assembly using injection molding. This approach aims to enable the costeffective, large-scale production of high-performance rare-earth free industrial motors. 

Manufacture High Performance ODS Copper Parts via ShAPE 

Lead Lab: Pacific Northwest National Laboratory

This project develops a process to manufacture high-performance oxide-dispersion-strengthened (ODS) copper alloy parts using Shear Assisted Processing and Extrusion (ShAPE) for heat exchangers. ODS copper is crucial for applications in the energy and chemical sectors due to its strength, thermal stability, and high thermal and electrical conductivity. Proof-of-concept ODS copper samples have been fabricated by ShAPE in a previous work. Results have demonstrated ShAPE addresses these issues by enabling refined grain-structure, uniform oxide-dispersion, and enhancing energy efficiency. The project aims to facilitate commercialization by scaling up heat exchanger prototype piping by PNNL and demonstrate performance in a pilot plant of Dimensional Energy. Technical goals are to obtain 12.7 mm diameter, >1 m long ODS copper tubes with advanced features, and yield strength >300MPa. This manufacturing method promises to improve material performance, reduce costs, and strengthen domestic supply chains, aligning with the DOE’s goals of advancing innovative technologies and strengthening energy reliability. 

Polymerization of Textile-Derived Monomers and Characterization of Polymer and Fiber Products 

Lead Lab: National Renewable Energy Laboratory 

Partnering with Tereform, Inc., a textile recycling startup, this project will support the commercialization of an NREL developed technology (acidolysis of mixed textiles) by demonstrating a minimum viable product (MVP). The acidolysis textile recycling process depolymerizes polyester, nylons, and spandex fabrics, in the presence of other contaminants, into recoverable and processable building blocks that can be reused to generate virgin quality fabrics again. Tereform is licensing this technology and needs to demonstrate an MVP in the form of recycled polyester and nylon fibers to secure investment and partnerships with apparel brands to build a 10-ton-per-year pilot plant in Colorado. This project will focus on developing an MVP polyester and nylon product from the waste molecules produced in the acidolysis process at Tereform, optimizing the remanufacturing conditions, and producing well-characterized spools of recycled fiber. 

Prototype Photonic Solid Electrolyte Manufacturing System 

Lead Lab: Argonne National Laboratory 

Argonne National Laboratory and PulseForge are collaborating to commercialize a novel rapid and energy-efficient photonic processing technology for ceramic lithium battery electrolyte material manufacturing. This technology has demonstrated significant energy and cost advantages over the conventional ceramic sintering technologies, including a tenfold reduction in energy consumption and a 200-fold increase in manufacturing speed. The team will further increase technology readiness level (TRL) and adoption readiness level (ARL) through intensive customer engagement and prototype manufacturing equipment construction during the project. 

Using Domestically Sourced Materials in the Development of Lower-Cost, Lower-Energy Platform Materials for the Thermoplastic Composite Manufacturing Industry 

Lead Lab: Oak Ridge National Laboratory 

This project will leverage patented technology available at Oak Ridge National Laboratory to enable a new industrial pathway for creating novel, lower energy and cost feedstock composite materials for a wide range of industrial applications. We will manufacture new composites made by incorporating a domestically sourced carbon fiber sourced from existing waste material streams with >75% reduced embodied energy and cost. This recycled carbon fiber (rCF) – recovered from automotive, aerospace, and energy generation scrap – will be used as a lower-cost, lower-energy filler for newly developed thermoplastic composites to overcome fiber length degradation caused by conventional re-manufacturing. We will also optimize fiber length in the resulting manufactured parts leveraging predictive computational analysis. At the end of this project, we will perform an industrial demonstration proving that the newly produced feedstock materials meet all mechanical and thermomechanical performance of virgin materials while reducing the overall cost and embodied energy. 

Advancing the Commercialization Potential of a High Specific-Energy Density SAF Blendstock from Bio-Derived Methanol 

Lead Lab: National Renewable Energy Laboratory 

This project will investigate the production of a high specific-energy density synthetic aviation fuel (SAF) from bio-methanol using a patented catalyst developed at the National Renewable Energy Laboratory (NREL). The project features catalyst manufacture and testing at NREL (M 1-6) followed by optimization of process conditions for SAF production using authentic biomass-derived methanol at Frontline Bioenergy’s 0.5 ton per day pilot plant in Nevada, Iowa (M 3–12). Finally, the liquid product will be distilled to isolate the SAF-range portion and fuel property analysis will be performed. The fuel property data will be combined with techno-economic analysis and adoption readiness level analysis to inform the commercialization potential (M 13-18). 

Commercialization of Oleo-Furan Surfactants: Innovative Manufacturing Process for Advancing Surfactants Industry 

Lead Lab: Los Alamos National Laboratory 

This project aims to commercialize LANL-developed technology for affordable alkanoyl furan productionand facilitate the market introduction of 100% bio-based Sironix Renewables' Oleo-FuranSulfonate (OFS) surfactants through a commercialization plan. The project focuses on reducing energy, costs, while enhancing performance, security, andmarket potential, all while eliminating harmful chemical releases—marking a significant advancement in surfactant technology. An in-depth Class 3 Techno-economic analysis will bea key delivery, evaluating commercial viability using experimental data and physical propertymeasurements from LANL and manufacturing sites. The outcomes will de-risk manufacturing methods and facilitate scalability. Building on this progress, investment in an OFS productionline will foster industry adoption through strategic partnerships with consumer goods and chemical manufacturers. This effort will address growing manufacturer interest and position new bioproduct technology in the market, contributing to the $44 billion global anionic surfactants market and strengthening the U.S. domestic supply and economy. 

Process Integration for Conversion of Distillers' Grains to Synthetic Aviation Fuel 

Lead Lab: Lawrence Berkeley National Laboratory 

Partnering Lab: Sandia National Laboratories 

The team employs a cost-effective technology that uses distiller’s grains with solubles (DGS), an abundant, low-cost byproduct of ethanol production, to simultaneously process its carbohydrate and protein fractions. This process converts DGS into mixed C2-C8 alcohols through an integrated pretreatment, hydrolysis and fermentation process. The mixed alcohols are then reprocessed through multiple catalytic conversion steps to produce synthetic aviation fuel. Economic viability of the process will be evaluated based on the integrated process. 

Easier & More Accurate Manual J Technology 

Lead Lab: National Renewable Energy Laboratory 

Partnering Lab: Pacific Northwest National Laboratory 

NREL and PNNL, in partnership with ACCA, PSD, and Zero Homes propose to develop a more accurate and simplified Manual J calculation tool and web API that facilitates greater adoption by energy & HVAC software companies and reduces overall industry costs. The project will A)identify opportunities to reduce data collection of onerous inputs through rigorous sensitivity analysis, B) incorporate modern building science into the ACCA Manual J standard, and C) showcase that 50% time and cost savings can be accrued through private-sector demonstrations on real homes. The project leverages existing DOE national laboratory products and expertise, including OpenStudio-HPXML, EnergyPlus, Home Energy Score, and ResStock. 

Self-Healing Microgrids for Threat-Agnostic Resilience 

Lead Lab: Idaho National Laboratory  

Partnering Lab: Sandia National Laboratories 

The proposed project would fund a collaboration between Idaho National Laboratory and Sandia National Laboratories to perform a detailed design of the system and experiments necessary to perform at-scale demonstration of the Self-Healing Power Systems Toolbox (SHePS Toolbox), a set of tools for creating self-healing microgrids that provide threatagnostic robust resilience and do not require high-speed communications. The SHePS Toolbox has been extensively tested in simulation. This demonstration will move the SHePS Toolbox from TRL 3-4 to TRL 7-8, and position it for commercialization. 

Stereo-Vision Thermal Imaging System for Tracking Flying Animals in Wind Farm Areas 

Lead Lab: Pacific Northwest National Laboratory 

Partnering Lab: National Renewable Energy Laboratory 

ThermalTracker-3D is a stereo vision thermal imaging system that provides 3D flight information on detected birds, bats, and other targets. The system was initially developed at PNNL for use in the siting and monitoring of offshore wind projects but can be applied to all wind energy projects as well as national security monitoring. Sightir, Inc. has licensed the technology for commercial development and lessons learned from NREL’s development of WEBAT will be incorporated into system optimization. The proposed work will advance commercialization readiness by streamlining calibration methods; introducing edge computing to reduce cost, footprint, and real-time data transfer needs and broaden geographic applications by implementing and refining a machine learning model for taxonomic identification of targets. The prototype system will then be deployed in the vicinity of a wind turbine for demonstration. This work will advance the TRL from 7 to 8 and advance the ARL from 4 to 8. 

Added Value Geothermal Energy Battery: Combining Surplus Renewables and Dispatchable Output (AVGEB) 

Lead Lab: Los Alamos National Laboratory 

Geothermal energy offers an opportunity for value-added energy storage. For instance, a well can store 30 MWh of hydraulic energy by pressurizing water in fractures using surplus energy. Next, the Earth adds 60 MWh of heat energy to the fluid while it is underground. Completing a diurnal cycle, this energy is recovered to produce 90 MWh. We estimate our technology’s cost to be $80/MWh, which is less than the $200/MWh of lithium batteries, but we require more lab and field data along with techno-economic analysis to verify our concept’s market readiness. Los Alamos National Laboratory will lead the laboratory experimental effort and the economic analysis using its lab-developed method for rock fracture control (patent) and software for economic performance forecasting (copyright). 

Sage Geosystems will provide access to upscaled field tests to validate our concepts. 

Solutions Engineering will provide an expert review of the marketability of our technologies. 

Geological Thermal Energy Storage for Industrial Heating: The RATE GEOTES Software Tool to Build Customer Confidence 

Lead Lab: National Renewable Energy Laboratory 

We will develop the RATE GEOTES software tool that will build customer confidence in Geological Thermal Energy Storage (GeoTES), thus accelerating the uptake of this technology. GeoTES systems provide daily and seasonal energy storage and can be used to deliver industrial process heating or cooling. GeoTES costs are predicted to be very low – once the wells have been drilled, additional energy capacity is effectively “free”. The RATE GEOTES software tool will help GeoTES developers to build customer confidence in these systems. The RATE GEOTES software tool will demonstrate the benefits and costs of GeoTES to the customer’s specific end-use and will be based on previously-developed techno-economic models. The tool will enable industrial organizations to assess the commerciality of their GeoTES projects, validate their own models and system concepts, and evaluate the impact of regulations and incentives on project timelines, finance, and acceptance. 

Thermal Shock Resistant Thermally Insulating Cement Blends for Reservoir Thermal Energy Storage Wells 

Lead Lab: Brookhaven National Laboratory 

Partnering Lab: Los Alamos National Laboratory  

The project focuses on commercialization of cementing and predictive modeling solutions for the high temperature reservoir thermal energy storage (HT RTES) wells, as well as any other subterranean reservoir. Techno-economic analyses of HT RTES wells demonstrated that relatively shallow reservoirs (250-1000 m) are of interest for both daily and seasonal energy storage. Such wells require cementing formulations solidifying at low temperatures of 25-50C but withstanding repeated thermal shocks from pumping in heated fluid of ~200C. Hydrophobic thermally insulating cements (thermal conductivity more than 3 times below that of regular cements) developed for HT RTES at Brookhaven National Laboratory (BNL) and tested by Los Alamos National Laboratory (LANL) can provide up to 60% energy savings for daily energy storage. This project is a collaborative effort between BNL, LANL, CUDD Energy Services aiming at increasing technology commercialization maturity level, decreasing its cost, designing user friendly cement performance modeling tool, and conducting field tests of the new cementing technology. 

FueL Additives for Solid Hydrogen Carriers for Electric Aviation of Drones - FLASH 2.0 

Lead Lab: National Renewable Energy Laboratory 

Partner Lab: SLAC National Accelerator Laboratory 

Honeywell is advancing hydrogen (H2) fuel systems for unmanned aerial vehicles (UAVs) by developing solid-state hydrogen carrier cartridges, offering extended flight times and safe H2 storage in chemical bonds, at ambient conditions. The FLASH carriers enable innovative metal-borohydride cartridges with thermal actuation, overcoming prior limitations. Building on previous successes from a TCF-funded project, FLASH 2.0 targets commercialization in the billion-dollar drone market by addressing remaining critical challenges in fuel chemistry. Key goals include validating the technology as a safe, low-cost, drop-in replacement for Honeywell’s fuel carrier cartridge. To meet this goal, NREL's focus in FLASH 2.0 will be enhancing FLASH storage density to 7 wt%, optimizing material engineering for prolonged shelf-life, while finding safer alternatives to the hazardous hydrazinium salts. 

High Performance Electrolysis for Methanol Production 

Lead Lab: Lawrence Livermore National Laboratory 

This project aims to advance the technology readiness level and adoption readiness level of Lawrence Livermore National Laboratory’s (LLNL’s) CO2 electrolyzer. LLNL has developed a CO2 electrolyzer capable of operating with a deionized water anolyte feed at industrially relevant current densities. LLNL will incorporate Oxylus Energy’s selective CO2 to methanol catalyst into their electrolyzer to develop a highly energy efficient CO2 to methanol reactor capable of mitigating salt precipitation and flooding. This reactor will serve as a demonstration for a viable CO2 to X reactor that is capable of decreasing energy consumption and improving durability for various chemicals and fuels based on choice of catalyst. 

Ducted Fuel Injection with Domestically Produced Fuels for Difficult-to-Electrify Heavy-Duty Applications 

Lead Lab: Sandia National Laboratories 

The proposed project will advance energy addition and unleash American energy innovation by focusing on activities to facilitate the successful commercial deployment of ducted fuel injection (DFI) with domestically sourced fuels in heavy-duty applications that are difficult to electrify or convert to carbon-free fuels. DFI is a small, mechanical, retrofittable engine technology that is both compatible with current diesel fuels and synergistic with emerging domestically produced alternative diesel fuels. The approach has the potential to reduce harmful emissions rapidly and dramatically at a fraction of the cost of competing technologies, because it uses existing manufacturing capacity and supply chains. It also provides valuable, effective diversification in America’s portfolio of technology options for meeting economic goals now and into the future. 

Manufacturing of Nano-Sized, High-Conductivity Sulfide Solid-State Electrolytes 

Lead Lab: Pacific Northwest National Laboratory 

This project will advance the domestic manufacturing readiness for advanced sulfide solid electrolytes, which are essential for the development of high performance and safe all-solid-state batteries. The objective is to scale up an innovative steric stabilization synthesis technology for the direct production of nanosized sulfide solid state electrolytes. The successful commercialization of the proposed technology could address material supply chain challenges and significantly accelerate all-solid-state-battery research and technology integration in the United States. 

Pathways Toolkit for Economically Viable Freight Depot Operations 

Lead Lab: Argonne National Laboratory 

The “Pathways Toolkit for Economically Viable Freight Depot Operations” will accelerate the adoption of advanced vehicle technologies, including electrified, natural gas and hydrogen-powered trucks, within freight depots. Fleet operators currently cannot holistically assess the impact of new technologies on their operations and business models, leading to uncertainty in investment decisions and operational planning. By integrating multiple Argonne’s state-of-the-art capabilities into a coherent framework, fleet operators will be able to optimize vehicle selection, route planning, charging and refueling infrastructure, and operational adaptability across metrics (e.g., cost, infrastructure, energy consumption, depot space planning, regulatory compliance). By offering a comprehensive, user-friendly solution, the toolkit will also bring together all stakeholders, allowing truck OEMs to closely partner with their customers to understand their requirements and enhance technology deployment strategies. The toolkit will be commercialized through easy-to-use platforms (e.g., desktop and web-based) to ensure widespread adoption. The project will accelerate the adoption of low-emission mobility solutions by lowering investment risks to optimize freight depot operations and reduce shipping costs nationwide while improving U.S. economic competitiveness. 

Qualification of an Advanced High Temperature Steel to Enable High Efficiency Engines for Off-Road Vehicles, Rail, and Hybrid Electric Freight Systems 

Lead Lab: Oak Ridge National Laboratory 

This project will address specific commercialization barriers and broader critical gaps in technical understanding related to the impacts of hydrogen (H2) fuels and high intensity diesel combustion on the ductility, strength, oxidation resistance, and fatigue resistance of an advanced high temperature steel very recently developed by Oak Ridge National Laboratory, in collaboration with Cummins, Inc. This new state-of-the-art high temperature steel, designated Nano eXtreme Temperature (Nano-XT) steel, due to its highly stable nano scale precipitates and high temperature strength, was designed with a unique but relatively low alloy composition, as an affordable and manufacturable steel for pistons, with properties and performance targeted to enable higher efficiency diesel internal combustion engines (ICEs) for freight, hybrid-electric, off-road, rail and defense systems. The goal of this proposed new effort is to address the commercialization potential of Nano-XT steel to enable pistons, and possibly fuel injectors, for advanced H2 and diesel fueled ICEs. 

FlexiSLIC: Addressing Manufacturing Challenges of a Flexible Antifouling Coating 

Lead Lab: Pacific Northwest National Laboratory 

Commercialization of a non-toxic antifouling coating for flexible surfaces will be de-risked by overcoming barriers to integration into commercial manufacturing processes. Biofouling is a challenge for innovative marine and hydro energy technologies and commercial coatings have not evolved to meet the unique needs of flexible surfaces such as nets and membranes. FlexiSLIC – a flexible superhydrophobic lubricant-infused composite – was developed at PNNL for scalable, non-toxic prevention of biofouling on a variety of surfaces. FlexiSLIC is currently in field testing to validate real world performance. However, flexible antifouling coatings have never been introduced to the rope/netting production process. PNNL will work with industry partners to apply FlexiSLIC to rope and netting using a commercially relevant process to find potential problems, address manufacturability concerns, and validate coating performance. Mitigating manufacturing concerns will encourage netting and rope manufacturers to adopt the FlexiSLIC technology, thereby increasing the speed at which it can enter the market. 

Ionic Liquid-Enhanced Environmentally Acceptable Lubricants (IL-EALs) for Waterpower and Beyond 

Lead Lab: Oak Ridge National Laboratory 

The need for Environmentally Acceptable Lubricants (EALs) is increasingly being recognized with a rapid market growth of 12.5% annually. For water power turbomachinery, inevitable lubricant leaks/spills contaminate water resources directly, posing a serious threat to the ecosystem. ORNL recently invented a new class of ionic liquids (ILs) as EAL additives that possess superior lubricating performance, significantly lower aquatic toxicity, and enhanced biodegradability compared with commercial baselines. In this project, ORNL collaborates with Valvoline and Syensqo to develop fullyformulated IL-enhanced EALs specifically for hydroelectric turbine lubrication. The goals are to address critical technical barriers and establish a business model to pave the way to manufacturing, scale-up, and commercialization. The IL-enhanced EAL technology is expected to positively influence water power and broader fields including hydraulics, water transport, agricultural machinery, etc. with enhanced durability and reliability, improved mechanical efficiency, and reduced environmental impact. 

Optimization and Commercialization of the Shad Acoustic Transmitter 

Lead Lab: Pacific Northwest National Laboratory 

PNNL has developed a revolutionary acoustic transmitter, the Shad Tag, to study the behavior and survival of sensitive species, such as juvenile American shad. Measuring 8.0 mm in length, 2.0 mm in diameter, and weighing 50 mg (one-fifth the mass of commercially available technology), the Shad Tag has a service life of 30 days when transmitting every five seconds. The technology enables detailed tracking of fish movements and life stages, offering valuable information on migration timing, behaviors, habitat use, fishway utilization and performance, and survival rates at hydropower facilities. These capabilities facilitate more informed management decisions that increase power generation and minimize environmental impacts. 

We propose expanding the Shad Tag's applications to other species while further optimizing and commercializing the technology. Additionally, the microbattery essential to the Shad Tag’s operation will be optimized for separate commercialization due to its broad applicability in other microsensor technologies. 

New Low-Voltage Network Protection for Increasing DER Penetration in Downtown Areas 

Lead Lab: Sandia National Laboratories 

This project will decrease the barriers to adopting and commercializing next-generation low-voltage network protector (NP) relay technologies that will allow for interconnections of distributed energy resources (DERs) and microgrids in downtown networks while maintaining high levels of reliability to customers. Most downtown areas and critical customers are connected through low-voltage networks that strictly limit DERs and batteries for resilience due to the limitations of the NP relays. Working with Eversource, we will study, install, and test the previously developed new NP relays into their system to demonstrate the ability for energy storage to be interconnected into the low-voltage network. This successful prototype demonstration will provide utilities with new options for upgrading their low-voltage networks to increase energy abundance in major cities and to provide the possibility of DER backup power for microgrids at critical customer locations. 

Industry-Requested and Guided Validation and Enhancement of Lab-Owned OpenOA Software to Improve Wind Plant Operational Performance Assessment 

Lead Lab: National Renewable Energy Laboratory 

Partner Lab: Sandia National Laboratories 

Preconstruction wind plant energy yield assessments (EYAs) tend to overpredict actual energy production. As reported by U.S. industry partners, this can harm wind plant owner/operators’ (O/Os’) finances and require additional costly electricity generators. To characterize the accuracy of EYAs, the National Renewable Energy Laboratory (NREL) developed the Open Operational Assessment (OpenOA) software, which performs post-construction yield assessments (PCYAs) to estimate long-term wind plant energy yield using operational data. OpenOA also estimates individual performance categories to understand sources of prediction error. However, industry feedback suggests a need to validate these methods, expand the performance categories, and improve usability. Therefore, NREL and Sandia National Laboratories are partnering with the energy utility Xcel Energy to validate OpenOA’s PCYA method using Xcel’s wind plant data, implement an individual wind turbine performance feature, and enhance the ease of use. This will increase industry adoption of OpenOA and help O/Os better predict energy yield moving forward.