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DOE OSTI2023

Quality Guidelines for Energy System Studies: Performing a Techno-Economic Analysis for Carbon Conversion Technologies (Final Report)

This document provides DOE-FECM specific guidance for conducting techno-economic analysis (TEA) on carbon conversion technologies using NETL's established TEA methodology. The intent is to provide guidance to develop a consistent methodology for evaluating carbon conversion technologies within the DOE-FECM portfolio. The document provides guidance on the analysis methodology, evaluation metrics including performance, cost, emissions, and market considerations, and ample references to guide the end user in the development of consistent TEA of carbon conversion technologies.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2023

Representation of Fossil Power Generation Technologies in NREL’s Annual Technology Baseline

This presentation was delivered at the Energy Economics USAEE/IAEE North American Conference on November 7, 2023. The presentation highlights support provided by the National Energy Technology Laboratory (NETL) on the development of National Renewable Energy Laboratory's (NREL) Annual Technology Baseline (ATB). The ATB documents transparent, normalized technology cost and performance assumptions using public sources. NETL's role in the development was to provide NREL with performance and cost data for select fossil-based technology classes. The ATB was released in June 2023.

Hackett, Gregory↗

DOE OSTI2024

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

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

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2024

Advanced Compressors for CO2-Based Power Cycles and Energy

Pumped thermal energy storage (PTES) is a cost-effective method for grid-scale, long-duration electrical energy storage (LDES). PTES uses a heat pump cycle to transfer thermal energy from a low temperature reservoir (LTR) to a high temperature reservoir (HTR), later using a heat engine cycle to reverse the process. A key component of the PTES system, the heat pump compressor, represents a significant driver to the cost, performance and operating characteristics of the PTES system. For grid-scale charging (>100 MW), traditional compressor scaling charts indicate that the operating conditions needed would be best served by a multistage axial compressor. While frame gas turbine compressors at these power ratings exist and operate at higher pressure ratios than needed for the CO2 PTES system, the inlet pressure and fluid density of this application exceed experience values. A conceptual design of a large-scale CO2 axial compressor was completed, including mean-line estimates of the compressor performance at full power conditions. The results of the conceptual design were used to refine the PTES cycle design, and updated operating conditions provided for further aero design optimization. A roughly one third scale of the first three stages of the 100 MW compressor was designed, built, and tested at relevant PTES charging conditions. Results of this test program are compared against high-resolution computational fluid dynamics models.

Compressor Heat↗

DOE OSTI2024

Enhancing Header Shape Through Computational Fluid Dynamics for Improved Performance

Shape optimization in power plant design is crucial for maximizing efficiency and minimizing energy losses It impacts performance, cost effectiveness, and environmental sustainability Our project focuses on optimizing header pipe geometry using a method that considers temperature, flow, and pressure distributions, along with structural analysis This approach ensures structural integrity while minimizing material costs

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2023

Batteries 2022 Annual Progress Report

This document summarizes the progress of VTO battery R&D projects supported during the fiscal year 2022. Its R&D focus was on the development of high-energy batteries for PEVs. The electrochemical energy storage roadmap describes ongoing and planned efforts to develop electrochemical storage technologies for EVs. To advance battery technology, which can in turn improve market penetration of PEVs, the program investigates various battery chemistries to overcome specific technical barriers, e.g., battery cost, performance, life (both the calendar life and the cycle life), its tolerance to abusive conditions, and its recyclability/sustainability.

25 ENERGY STORAGE↗

DOE OSTI2024

Batteries (2023 Annual Progress Report)

This document summarizes the progress of VTO battery R&D projects supported during the fiscal year 2023. Its R&D focus was on the development of high-energy batteries for PEVs. The electrochemical energy storage roadmap describes ongoing and planned efforts to develop electrochemical storage technologies for EVs. To advance battery technology, which can in turn improve market penetration of PEVs, the program investigates various battery chemistries to overcome specific technical barriers, e.g., battery cost, performance, life (both the calendar life and the cycle life), its tolerance to abusive conditions, and its recyclability/sustainability.

25 ENERGY STORAGE↗

DOE OSTI2026

Coalition for Community-Supported Affordable Geothermal Energy Systems (C2SAGES)

The C2SAGES project evaluated the feasibility of a community geothermal system for the planned Windy Ridge affordable housing development in Hinesburg, Vermont. Led by GTI Energy with Vermont Gas Systems, LN Consulting, NREL, and Frontier Energy, the work assessed technical design, energy performance, costs, business models, community engagement, maintenance, workforce development, and permitting. The proposed system was designed to serve 100% of the development’s heating, cooling, and domestic hot water loads. Compared with a baseline using air-source heat pumps and natural gas water heating, the geothermal system was estimated to reduce HVAC and domestic hot water energy use by about 45% to 48%, lower operating and maintenance costs, and reduce 30-year life-cycle costs by 37% for Phase 1 and 10% for Phase 2. Technical testing and modeling indicated that the Windy Ridge site is suitable for a community-scale geothermal system. The project also developed borehole field layouts, piping concepts, pump house designs, controls, maintenance plans, and supporting engineering drawings. The business model analysis found that first cost, ownership structure, and customer affordability remain major deployment challenges. Utility-led maintenance and operation were viewed favorably, but traditional utility cost-recovery models may require subsidy or revised financing structures to be practical for affordable housing. Community engagement highlighted the need for clear public education, transparent financing, reliable long-term maintenance, trained technicians, and the potential to pair geothermal systems with weatherization. Overall, the report concludes that community geothermal is technically feasible and offers meaningful energy, emissions, and life-cycle cost benefits, but broader deployment will depend on workable financing models and workforce readiness.

15 GEOTHERMAL ENERGY↗

DOE OSTI2022

Role of On-Site Generation in Carbon Emissions and Utility Bill Savings under Different Electric Grid Scenarios

Energy-efficient and sustainable technologies are necessary to lower energy and carbon footprints. Many technologies are being pursued to meet the increasing energy demand in buildings. An attractive option is efficient utilization of available energy resources, including renewables, to support current and future building energy needs while targeting grid resiliency, energy, and environmental security at an affordable cost via on-site cogeneration-based approaches. This must include energy-efficient technologies with lower greenhouse gas emissions and optimized cost, performance, and reliability. This paper presents the economic and environmental benefits associated with power technologies such as thermionics and solid oxide fuel cells. Hybrid configurations consisting of heat pumps, power systems, and renewable photovoltaics in cogeneration and trigeneration modes of operation are presented. The role of such technologies in lowering CO2 emissions while improving energy resiliency and serving the needs of underprivileged communities is discussed. The key barriers of affordability and potential solutions for large-scale implementation of these promising technologies are reviewed. Case studies demonstrating the influence of power rating, electrical efficiency, design configuration, carbon dioxide intensity of the grid, and fuel on annual greenhouse gas emissions are presented for residential and commercial buildings.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2021

A Circularity Assessment for Silicon Solar Panels Based on Dynamic Material Flow Analysis

Solar photovoltaics (PV) are the fastest growing renewable energy technology for clean, inexpensive, and sustainable electricity generation. Along with numerous technical roadmaps to improve system cost, performance and reliability, the PV industry should also plan to handle large volumes of silicon panel waste, which is initially estimated to be ~13 million metric tons (MT) by 2050 in the U.S. alone. Understanding the magnitude of material needs and how material flows throughout the PV panel life cycle could respond to design, operational and different end-of-life (EOL) circular pathways will help transition into a circular, resource-conserving economy. Herein, we introduce a dynamic material flow analysis (DMFA) framework based on electricity generation to quantify time-series stocks and flows of bulk PV materials (e.g., solar glass and aluminum frames) throughout the life cycles of utility-scale silicon PV systems in the U.S. in the period 2000-2100. We apply the model to a range of scenarios to understand how material demands depend on selected PV-related parameters, different material circularity strategies, and recent module design trends (e.g., bifacial, frameless). We found that float glass and aluminum in PV installations would likely reach 100 million MT and 12 million MT by 2100, respectively, in the baseline scenario. The most influential parameters for PV installation and subsequent waste reduction are found to be module lifetime, module efficiency, annual degradation, and material reduction. Module recycling and component remanufacturing were found to be the most effective material circularity strategies for waste minimization. Panel reuse has negligible savings on waste under current module efficiencies compared to replacements with newer generations with higher efficiency. Ongoing trends to produce larger power frameless modules could save 10 million MT of glass and ~9 million MT of aluminum. Our results enable advanced planning for future materials needs and provide insight into potential opportunities to minimize waste.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2021

A Circularity Assessment for Silicon Solar Panels Based on Dynamic Material Flow Analysis: Preprint

circular economy↗

DOE OSTI2024

Pathways to a Sustainable Aviation Ecosystem: Aviation Energy Research and Operation Simulator (AEROSim)

The National Renewable Energy Laboratory (NREL) has developed highly accessible tools for ground vehicle modeling, making it easy to quickly compare powertrains and estimate the impact of technology improvements on fuel/energy consumption, performance, cost, and battery life. With AEROSim, NREL advanced aircraft, enabling the same level of ease and versatility in comparing aircraft designs across a range of scenarios and conditions.

advanced air mobility↗

DOE OSTI2020

High-performance and cost-effective membrane electrode assemblies for advanced proton exchange membrane water electrolyzers: Long-term durability assessment

In this work, improved activity and durability performance of a two-cell (86 cm 2 ) proton exchange membrane water electrolyzer (PEMWE) stack is reported for the first time. Both membrane electrode assemblies (MEAs) contain one order of magnitude lower platinum group metal (PGM) loadings compared to the state-of-the-art PEMWEs and incorporate novel Pt recombination layers. The high-performance and cost-effective MEAs are fabricated by the unique reactive spray deposition technology (RSDT). This advanced methodology allows for one-step fabrication of MEAs and ensures precise control and distribution of the catalyst composition and loading. The RSDT-fabricated MEAs contain only 0.2 and 0.3 mg PGM cm –2 loading in the cathode and anode electrodes, respectively, and demonstrate excellent activity and durability for over 3000 h of operation at industrially-relevant operating conditions without showing significant loss in performance. This novel work shows that a significant cost reduction for PEMWEs is achieved while maintaining excellent durability, high catalysts activities, and low hydrogen cross-over.

Proton exchange membrane water electrolyzer↗

DOE OSTI2025

Initial assessment of alternative carbon fiber geometries for design of cost-effective compressive performance: Size effect studies

Carbon fiber provides opportunity to reduce weight in structural composites, including wind turbine blades, due to the material's superior specific stiffness and specific strength compared to alternatives. Despite these advantages, cost and compressive performance are considered weaknesses for carbon fiber products available today. Studies to produce low-cost carbon fiber alternatives, including the use of textile-derived precursor systems, have shown progress and merit through the DOE/ORNL low-cost carbon fiber initiatives. Here, this work focuses on enabling increases in compressive strength through design of the carbon fiber geometry, applicable to both textile and conventional precursor systems, while also providing opportunities to reduce carbon fiber processing costs. Fiber-resin interface and fiber alignment are among the most frequently cited factors controlling composite compressive performance. However, it is believed that there is opportunity in traditionally unexplored routes to increasing compressive strength through alteration of the carbon fiber geometry by increasing the fiber area moment of inertia and/or the fiber perimeter and interfacial area. This paper presents initial results from manufacturing carbon fiber materials to assess the impacts of carbon fiber size on tested composite compressive performance with projected neutral or even beneficial impact on fiber and composite manufacturing economics. Carbon fiber systems with increasing size illustrate a favorable correlation for compressive performance greater than predicted from a micromechanical failure model. The manufacturing and mechanical test results support the hypothesis of this work that alterations to fiber geometry can be used to produce improvements of the compressive strength of carbon fiber reinforced polymers and provide incentive for related work in designing alternative shapes to further enhance compressive performance.

42 ENGINEERING↗

DOE OSTI2022

Predicted Impacts of Pt and Ionomer Distributions on Low-Pt-Loaded PEMFC Performance

Low-cost, high performance proton exchange membrane fuel cells (PEMFCs) have been difficult to develop due to limited understanding of coupled processes in the cathode catalyst layer (CCL). Low-Pt-loaded PEMFCs suffer losses beyond those predicted solely due to reduced catalyst area. Although consensus links these losses to thin ionomer films in the CCL, a precise mechanistic explanation remains elusive. In this publication, we present a physically based PEMFC model with novel structure-property relationships for thin-film Nafion, validated against PEMFC data with low Pt loading. Results suggest that flooding exacerbates kinetic limitations in low-loaded PEMFCs, shifting the Faradaic current distribution. As current density increases, protons travel further into the CCL, resulting in higher Ohmic overpotentials. We also present a parametric study of CCL design parameters. We find that graded Pt and ionomer loadings reduce Ohmic losses and flooding, but individually do not provide significant improvements. However, a dual-graded CCL (i.e., graded Pt and ionomer) is predicted to significantly improve the maximum power density and limiting current compared to uniformly loaded CCLs. This work highlights the importance of accurate transport parameters for thin-film Nafion and provides a pathway to low-cost PEMFCs via precise control of CCL microstructures.

08 HYDROGEN↗

DOE OSTI2022

Powertrain Performance and Total Cost of Ownership Analysis for Class 8 Yard Tractors and Refuse Trucks

Advanced powertrain technologies, specifically fuel cell electric powertrains, have gained attention as viable alternatives for medium- and heavy-duty (M/HD) vehicles. However, it is unclear how these alternative powertrain vehicles stack up against their diesel counterparts in terms of performance and total cost of ownership (TCO). Furthermore, there are vehicle segments within the M/HD sector that have remained unstudied for fuel cell electric applications. This analysis aims to provide a comparative scoping-level TCO and performance analysis for two heavy-duty vocation vehicles (Class 8 U.S. port-side yard tractor and Class 8 U.S.-based refuse truck) for both conventional diesel and heavy-duty fuel cell electric (HDFC) powertrains. The refuse truck analysis also considered compressed natural gas powertrains (CNG) for comparison. The analysis includes seven timeframes (2020, 2025, 2030, 2035, 2040, 2045, and 2050) for comparison. This simplified TCO analysis includes only direct costs (fuel price, glider purchase price, and operating & maintenance costs) and excludes any associated indirect cost (e.g., dwell time costs and other opportunity based costs). Representative drive cycles for each vehicle were based on on-board GPS logged data and chosen by the analysis team to represent average, non-extreme driving conditions. At the time the analysis was performed, the Inflation Reduction Act was not in effect and therefore any potential subsidies and future cost reductions enacted under the Inflation Reduction Act were not included. Based on the operational setpoints used in this analysis, HDFC powertrains for both yard tractors and refuse trucks have the potential to achieve TCO advantages over conventional diesel powertrains (and CNG for refuse truck applications) in the near- to mid-term future while meeting the necessary duty cycle performance requirements. Yard tractors and refuse trucks spend a significant amount of time operating at low speeds, with long durations of idling, and experience numerous start/stop occurrences. These operational characteristics favor fuel cell performance as fuel cells operate with higher efficiencies at lower percentages of total power output. Conversely, conventional diesel and CNG engines are most efficient at higher percentages of total power output. This helps HDFC powered yard tractors and refuse trucks realize improved fuel economy when compared to their diesel counterparts, which helps reduce total fuel costs and therefore, total TCO. The analysis demonstrates that fuel prices play a significant role in determining TCO for each vehicle and should remain an R&D focus area. Overall, under the analysis' specified conditions, HDFC yard tractors have the potential to achieve cost parity with diesel yard tractors as early as 2025. For refuse trucks, HDFC refuse trucks have the potential to achieve cost parity with diesel and CNG refuse trucks in 2030 and 2040, respectively.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2021

The Co-Optimization of Sustainable Aviation Fuel: Cost, Emissions, and Performance

The combustion of petroleum-based fuels contributes to increases in atmospheric CO2, contributing to climate change. As other sectors electrify, current battery technology makes this impractical for the aviation industry. The fastest pathway to reducing the carbon contributions of aviation is to create low or no net carbon-emitting drop-in petroleum alternatives. This research explores 3 potential sorghum derived jet fuel molecules from 4 different production routes, hydro-processed esters and fatty acids (HEFA), and Jet A, to identify how blends including these fuels could offer improved performance (MJ/kg, MJ/L) and improved emissions (gCO2/MJ) while minimizing costs. Different applications will value each target metric differently. This research utilizes the Jet Fuel Blend Optimizer (JudO) to create a 4-dimensional Pareto front across potential solutions. The molecules considered will not offer reduced cost compared to conventional jet fuel (Jet A), but they can be utilized to create blends with higher specific energy, greater energy density, and reduced greenhouse gas emissions. Considerations including carbon credits, the sale of byproducts, and the valuation of improved performance will make the proposed molecules more commercially viable. At the lowest region of GHG solutions, coupled with equivalent LCFS approximations, JudO determined blends that could achieve as high as 69% overall carbon reductions at a premium of $0.34/L.

Feldhausen, John J.↗

DOE OSTI2022

Performance and Total Cost of Ownership of a Fuel Cell Hybrid Mining Truck

The main objective of this work was to investigate the potential of hydrogen and fuel cells replacing diesel and internal combustion engines in the ultraclass haul trucks deployed in the mining sector. Performance, range, durability, and cost are the main criteria considered for comparing the two fuels and engine options. Fuel cell system (FCS) performance is characterized in terms of heat rejection, efficiency, and fuel consumption for a hybrid platform equivalent to a 3500 hp diesel engine operating on a representative open pit mining duty cycle. A hybrid platform was chosen because the heat rejection, with a constrained radiator frontal area, limits the maximum fuel cell-rated power by about 50% compared to that of the diesel truck. The hybrid powertrain was 81–88% more efficient than the diesel powertrain on the truck duty cycle. A liquid hydrogen storage system is required for an equal range or time between refilling, but the packaging remains a challenge. Fuel cell and battery durability were evaluated for their performance degradation and lifetime. Achieving a fuel cell lifetime comparable to the time between major overhauls for diesel trucks necessitates the oversizing of the membrane-active area, catalyst overloading, and voltage clipping. For an equal lifetime, the battery must be oversized to control its depth of discharge and charge/discharge rates. A total cost of ownership (TCO) analysis considering the initial capital expenditures, as well as the lifetime cost of fuel, operation, and maintenance, indicates that fuel cells and hydrogen can compete with diesel. A breakeven fuel cost for TCO parity is obtained if H2 is available at USD 5.79–6.85/kg vs. diesel at USD 3.25/gal and the FCS-specific cost is USD 323/kW e relative to USD 250/kW for a diesel genset. Volume manufacturing is required for FCS cost reduction. High volume is possible through the standardization, modularity, and proliferation of class 8 long-haul truck systems across different heavy-duty applications.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗