BEEST Project: Sion Power is developing a lithium-sulfur (Li-S) battery, a potentially cost-effective alternative to the Li-Ion battery that could store 400% more energy per pound. All batteries have 3 key parts—a positive and negative electrode and an electrolyte—that exchange ions to store and release electricity. Using different materials for these components changes a battery’s chemistry and its ability to power a vehicle. Traditional Li-S batteries experience adverse reactions between the electrolyte and lithium-based negative electrode that ultimately limit the battery to less than 50 charge cycles. Sion Power will sandwich the lithium- and sulfur-based electrode films around a separator that protects the negative electrode and increases the number of charges the battery can complete in its lifetime. The design could eventually allow for a battery with 400% greater storage capacity per pound than Li-Ion batteries and the ability to complete more than 500 recharge cycles.

Broad Funding Opportunity Announcement Project: UIUC is experimenting with silicon-based materials to develop flexible thermoelectric devices—which convert heat into energy—that can be mass-produced at low cost. A thermoelectric device, which resembles a computer chip, creates electricity when a different temperature is applied to each of its sides. Existing commercial thermoelectric devices contain the element tellurium, which limits production levels because tellurium has become increasingly rare. UIUC is replacing this material with microscopic silicon wires that are considerably cheaper and could be equally effective. Improvements in thermoelectric device production could return enough wasted heat to add up to 23% to our current annual electricity production.

Electrofuels Project: MIT is using solar-derived hydrogen and common soil bacteria called Ralstonia eutropha to turn carbon dioxide (CO2) directly into biofuel. This bacteria already has the natural ability to use hydrogen and CO2 for growth. MIT is engineering the bacteria to use hydrogen to convert CO2 directly into liquid transportation fuels. Hydrogen is a flammable gas, so the MIT team is building an innovative reactor system that will safely house the bacteria and gas mixture during the fuel-creation process. The system will pump in precise mixtures of hydrogen, oxygen, and CO2, and the online fuel-recovery system will continuously capture and remove the biofuel product.

Electrofuels Project: MIT is using carbon dioxide (CO2) and hydrogen generated from electricity to produce natural oils that can be upgraded to hydrocarbon fuels. MIT has designed a 2-stage biofuel production system. In the first stage, hydrogen and CO2 are fed to a microorganism capable of converting these feedstocks to a 2-carbon compound called acetate. In the second stage, acetate is delivered to a different microorganism that can use the acetate to grow and produce oil. The oil can be removed from the reactor tank and chemically converted to various hydrocarbons. The electricity for the process could be supplied from novel means currently in development, or more proven methods such as the combustion of municipal waste, which would also generate the required CO2 and enhance the overall efficiency of MIT’s biofuel-production system.

GRIDS Project: Fluidic is developing a low-cost, rechargeable, high-power module for Zinc-air batteries that will be used to store renewable energy. Zinc-air batteries are traditionally found in small, non-rechargeable devices like hearing aids because they are well-suited to delivering low levels of power for long periods of time. Historically, Zinc-air batteries have not been as useful for applications which require periodic bursts of power, like on the electrical grid. Fluidic hopes to fill this need by combining the high energy, low cost, and long run-time of a Zinc-air battery with new chemistry providing high power, high efficiency, and fast response. The battery module could allow large grid-storage batteries to provide much more power on very short demand—the most costly kind of power for utilities—and with much more versatile performance.

Broad Funding Opportunity Announcement Project: GM is using shape memory alloys that require as little as a 10°C temperature difference to convert low-grade waste heat into mechanical energy. When a stretched wire made of shape memory alloy is heated, it shrinks back to its pre-stretched length. When the wire cools back down, it becomes more pliable and can revert to its original stretched shape. This expansion and contraction can be used directly as mechanical energy output or used to drive an electric generator. Shape memory alloy heat engines have been around for decades, but the few devices that engineers have built were too complex, required fluid baths, and had insufficient cycle life for practical use. GM is working to create a prototype that is practical for commercial applications and capable of operating with either air- or fluid-based heat sources. GM’s shape memory alloy based heat engine is also designed for use in a variety of non-vehicle applications. For example, it can be used to harvest non-vehicle heat sources, such as domestic and industrial waste heat and natural geothermal heat, and in HVAC systems and generators.

Broad Funding Opportunity Announcement Project: FastCAP is improving the performance of an ultracapacitor—a battery-like electronic device that can complement, and possibly even replace, an HEV or EV battery pack. Ultracapacitors have many advantages over conventional batteries, including long lifespans (over 1 million cycles, as compared to 10,000 for conventional batteries) and better durability. Ultracapacitors also charge more quickly than conventional batteries, and they release energy more quickly. However, ultracapacitors have fallen short of batteries in one key metric: energy density—high energy density means more energy storage. FastCAP is redesigning the ultracapacitor’s internal structure to increase its energy density. Ultracapacitors traditionally use electrodes made of irregularly shaped, porous carbon. FastCAP’s ultracapacitors are made of tiny, aligned carbon nanotubes. The nanotubes provide a regular path for ions moving in and out of the ultracapacitor’s electrode, increasing the overall efficiency and energy density of the device.

This report documents the results of Cooperative Agreement DE-FC26-05NT42613 between Siemens Energy and the U.S. Department of Energy for the period October 1, 2008 through September 30, 2010. The Phase I POCD8R0 stack test was successfully completed as it operated for approximately 5,300 hrs and achieved all test objectives. The stack test article contained twenty-four 75 cm active length Delta8 scandia-stabilized zirconia cells. Maximum power was approximately 10 kWe and the SOFC generator demonstrated an availability factor of 85% at 50% power or greater. The Phase II POCD8R1 stack test operated for approximately 410 hrs before being aborted due to a sudden decrease in voltage accompanied by a rapid increase in temperature. The POCD8R1 test article contained forty-eight 100 cm active length Delta8 scandia-stabilized zirconia cells arranged in an array of six bundles, with each bundle containing eight cells. Cell development activities resulted in an approximate 100% improvement in cell power at 900°C. Cell manufacturing process improvements led to manufacturing yields of greater than 40% for the Delta8 cells. Delta8 cells with an active length of 100 cm were successfully manufactured as were cells with a seamless closed end. A pressurized cell test article was assembled, installed into the pressurized …

GRIDS Project: Proton Energy Systems is developing an energy storage device that converts water to hydrogen fuel when excess electricity is available, and then uses hydrogen to generate electricity when energy is needed. The system includes an electrolyzer, which generates and separates hydrogen and oxygen for storage, and a fuel cell which converts the hydrogen and oxygen back to electricity. Traditional systems use acidic membranes, and require expensive materials including platinum and titanium for key parts of the system. In contrast, Proton Energy Systems’ new system will use an inexpensive alkaline membrane and will contain only inexpensive metals such as nickel and stainless steel. If successful, Proton Energy Systems’ system will have similar performance to today’s regenerative fuel cell systems at a fraction of the cost, and can be used to store electricity on the electric grid.

Electrofuels Project: UCLA is utilizing renewable electricity to power direct liquid fuel production in genetically engineered Ralstonia eutropha bacteria. UCLA is using renewable electricity to convert carbon dioxide into formic acid, a liquid soluble compound that delivers both carbon and energy to the bacteria. The bacteria are genetically engineered to convert the formic acid into liquid fuel—in this case alcohols such as butanol. The electricity required for the process can be generated from sunlight, wind, or other renewable energy sources. In fact, UCLA’s electricity-to-fuel system could be a more efficient way to utilize these renewable energy sources considering the energy density of liquid fuel is much higher than the energy density of other renewable energy storage options, such as batteries.

An analysis of improving the power output of small wind turbines by adding a venturi housing was done. Including the effects of back pressure developed at the input to the housing lowers the efficiency gain from a factor of 5 to a factor of 2 for a turbine blade radius of 24 inches. The gain is small enough that only large systems could profit from the application.

Electrofuels Project: LBNL is improving the natural ability of a common soil bacteria called Ralstonia eutropha to use hydrogen and carbon dioxide for biofuel production. First, LBNL is genetically modifying the bacteria to produce biofuel at higher concentrations. Then, LBNL is using renewable electricity obtained from solar, wind, or wave power to produce high amounts of hydrogen in the presence of the bacteria—increasing the organism’s access to its energy source and improving the efficiency of the biofuel-creation process. Finally, LBNL is tethering electrocatalysts to the bacteria’s surface which will further accelerate the rate at which the organism creates biofuel. LBNL is also developing a chemical method to transform the biofuel that the bacteria produce into ready-to-use jet fuel.

ADEPT Project: Currently, charging the battery of an electric vehicle (EV) is a time-consuming process because chargers can only draw about as much power from the grid as a hair dryer. APEI is developing an EV charger that can draw as much power as a clothes dryer, which would drastically speed up charging time. APEI's charger uses silicon carbide (SiC)-based power transistors. These transistors control the electrical energy flowing through the charger's circuits more effectively and efficiently than traditional transistors made of straight silicon. The SiC-based transistors also require less cooling, enabling APEI to create EV chargers that are 10 times smaller than existing chargers.

ADEPT Project: Transphorm is developing transistors with gallium nitride (GaN) semiconductors that could be used to make cost-effective, high-performance power converters for a variety of applications, including electric motor drives which transmit power to a motor. A transistor acts like a switch, controlling the electrical energy that flows around an electrical circuit. Most transistors today use low-cost silicon semiconductors to conduct electrical energy, but silicon transistors don’t operate efficiently at high speeds and voltage levels. Transphorm is using GaN as a semiconductor material in its transistors because GaN performs better at higher voltages and frequencies, and it is more energy efficient than straight silicon. However, Transphorm is using inexpensive silicon as a base to help keep costs low. The company is also packaging its transistors with other electrical components that can operate quickly and efficiently at high power levels—increasing the overall efficiency of both the transistor and the entire motor drive.

BEEST Project: PolyPlus is developing the world’s first commercially available rechargeable lithium-air (Li-Air) battery. Li-Air batteries are better than the Li-Ion batteries used in most EVs today because they breathe in air from the atmosphere for use as an active material in the battery, which greatly decreases its weight. Li-Air batteries also store nearly 700% as much energy as traditional Li-Ion batteries. A lighter battery would improve the range of EVs dramatically. Polyplus is on track to making a critical breakthrough: the first manufacturable protective membrane between its lithium–based negative electrode and the reaction chamber where it reacts with oxygen from the air. This gives the battery the unique ability to recharge by moving lithium in and out of the battery’s reaction chamber for storage until the battery needs to discharge once again. Until now, engineers had been unable to create the complex packaging and air-breathing components required to turn Li-Air batteries into rechargeable systems.

ADEPT Project: The CUNY Energy Institute is developing less expensive, more efficient, smaller, and longer-lasting power converters for energy-efficient LED lights. LEDs produce light more efficiently than incandescent lights and last significantly longer than compact fluorescent bulbs, but they require more sophisticated power converter technology, which increases their cost. LEDs need more sophisticated converters because they require a different type of power (low voltage direct current, or DC) than what's generally supplied by power outlets. The CUNY Energy Institute is developing sophisticated power converters for LEDs that contain capacitors made from new, nanoscale materials. Capacitors are electrical components that are used to store energy. CUNY's unique capacitors are configured with advanced power circuits to more efficiently control and convert power to the LED lighting source. They also eliminate the need for large magnetic components, instead relying on networks of capacitors that can be easily printed on plastic substrate. CUNY's prototype LED power converter already meets DOE's 2020 projections for the energy efficiency of LED power converters.

BEEST Project: Applied Materials is developing new tools for manufacturing Li-Ion batteries that could dramatically increase their performance. Traditionally, the positive and negative terminals of Li-Ion batteries are mixed with glue-like materials called binders, pressed onto electrodes, and then physically kept apart by winding a polymer mesh material between them called a separator. With the Applied Materials system, many of these manually intensive processes will be replaced by next generation coating technology to apply each component. This process will improve product reliability and performance of the cells at a fraction of the current cost. These novel manufacturing techniques will also increase the energy density of the battery and reduce the size of several of the battery’s components to free up more space within the cell for storage.

GRIDS Project: Beacon Power is developing a flywheel energy storage system that costs substantially less than existing flywheel technologies. Flywheels store the energy created by turning an internal rotor at high speeds—slowing the rotor releases the energy back to the grid when needed. Beacon Power is redesigning the heart of the flywheel, eliminating the cumbersome hub and shaft typically found at its center. The improved design resembles a flying ring that relies on new magnetic bearings to levitate, freeing it to rotate faster and deliver 400% as much energy as today’s flywheels. Beacon Power’s flywheels can be linked together to provide storage capacity for balancing the approximately 10% of U.S. electricity that comes from renewable sources each year.

Electrofuels Project: NC State is working with the University of Georgia to create Electrofuels from primitive organisms called extremophiles that evolved before photosynthetic organisms and live in extreme, hot water environments with temperatures ranging from 167-212 degrees Fahrenheit The team is genetically engineering these microorganisms so they can use hydrogen to turn carbon dioxide directly into alcohol-based fuels. High temperatures are required to distill the biofuels from the water where the organisms live, but the heat-tolerant organisms will continue to thrive even as the biofuels are being distilled—making the fuel-production process more efficient. The microorganisms don’t require light, so they can be grown anywhere—inside a dark reactor or even in an underground facility.

Broad Funding Opportunity Announcement Project: GE is using nanomaterials technology to develop advanced magnets that contain fewer rare earth materials than their predecessors. Nanomaterials technology involves manipulating matter at the atomic or molecular scale, which can represent a stumbling block for magnets because it is difficult to create a finely grained magnet at that scale. GE is developing bulk magnets with finely tuned structures using iron-based mixtures that contain 80% less rare earth materials than traditional magnets, which will reduce their overall cost. These magnets will enable further commercialization of HEVs, EVs, and wind turbine generators while enhancing U.S. competitiveness in industries that heavily utilize these alternatives to rare earth minerals.

ADEPT Project: Cree is developing silicon carbide (SiC) power transistors that are 50% more energy efficient than traditional transistors. Transistors act like a switch, controlling the electrical energy that flows through an electrical circuit. Most power transistors today use silicon semiconductors to conduct electricity. However, transistors with SiC semiconductors operate at much higher temperatures, as well as higher voltage and power levels than their silicon counterparts. SiC-based transistors are also smaller and require less cooling than those made with traditional silicon power technology. Cree's SiC transistors will enable electrical circuits to handle higher power levels more efficiently, and they will result in much smaller and lighter electrical devices and power converters. Cree, an established leader in SiC technology, has already released a commercially available SiC transistor that can operate at up to 1,200 volts. The company has also demonstrated a utility-scale SiC transistor that operates at up to 15,000 volts.

Advanced Research Projects Agency-Energy project sheet summarizing general information about the Batteries for Electrical Energy Storage in Transportation (BEEST) program including critical needs, innovation and advantages, impacts, and contact information. This sheet discusses a new lithium-air battery for electric vehicles as part of the "High Performance Cathodes for Lithium-Air Batteries" project.

Broad Funding Opportunity Announcement Project: FloDesign Wind Turbine’s innovative wind turbine, inspired by the design of jet engines, could deliver 300% more power than existing wind turbines of the same rotor diameter by extracting more energy over a larger area. FloDesign Wind Turbine’s unique shrouded design expands the wind capture area, and the mixing vortex downstream allows more energy to flow through the rotor without stalling the turbine. The unique rotor and shrouded design also provide significant opportunity for mass production and simplified assembly, enabling mid-scale turbines (approximately 100 kW) to produce power at a cost that is comparable to larger-scale conventional turbines.

BEEST Project: Scientists at 24M are crossing a Li-Ion battery with a fuel cell to develop a semi-solid flow battery. This system relies on some of the same basic chemistry as a standard Li-Ion battery, but in a flow battery the energy storage material is held in external tanks, so storage capacity is not limited by the size of the battery itself. The design makes it easier to add storage capacity by simply increasing the size of the tanks and adding more paste. In addition, 24M's design also is able to extract more energy from the semi-solid paste than conventional Li-Ion batteries. This creates a cost-effective, energy-dense battery that can improve the driving range of EVs or be used to store energy on the electric grid.