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DOE OSTI2025

Enhanced Power Grid Maintenance Planning and Quantum-Inspired Combinatorial Prospects

Efficient and reliable scheduling of maintenance for power generation and transmission infrastructure is essential for minimizing operational costs and ensuring grid stability. This paper introduces an integrated optimization framework for coordinated maintenance scheduling of generators and transmission lines under resource and reliability constraints. The model minimizes a composite cost function including maintenance and generation costs, as well as penalties for delayed maintenance, while satisfying N−1 security constraints, operational limits, and crew availability. Case studies on the IEEE 300-bus test system demonstrate the effectiveness of the proposed approach in producing feasible and cost-effective maintenance schedules. To address scalability and combinatorial complexity, the model is mapped into a Quadratic Unconstrained Binary Optimization (QUBO) problem, enabling exploration of solution approaches based on Quantum Imaginary Time Evolution (QITE). While the QUBO reformulation provides a foundation for future quantum-inspired optimization, this study focuses primarily on the development and demonstration of the classical optimization framework and illustrates the potential applicability of QITE in large-scale maintenance scheduling.

Chen, Yang [ORNL] (ORCID:0000000271693874)↗

DOE OSTI2021

Electrification Futures Study: Operational Analysis of U.S. Power Systems with Increased Electrification and Demand-Side Flexibility

This report provides a high-resolution U.S. national-scale power systems assessment of scenarios with widespread electrification using detailed grid simulations. We find that high electrification scenarios envisioned in the Electrification Futures Study can be operated at the hourly level to meet future increased levels of electrified demand and, under the most aggressive cases, with up to 66% of generation from wind and solar technologies. The analysis also examines the value of flexibility from demand by supporting system operability under high electrification and high renewable systems. Demand-side flexibility—especially flexibility from newly electrified loads—is found to enhance the operational efficiency by reducing VRE curtailment and increasing utilization of generators with lower operating costs. It can also enhance the ability of electrification to decarbonize the energy sector.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

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 OSTI2020

A comprehensive review of solar only and hybrid solar driven multigeneration systems: Classifications, benefits, design and prospective

Depending on the application and demands, different products can be generated utilizing multigeneration systems. To drive such systems, solar energy can be used as a primary energy source or in hybridization with other renewable or nonrenewable energy sources. Solar driven multigeneration systems are appealing due to the broad availability of solar energy and related technologies. Here, the objective of this study is to review, categorize and discuss different configurations, benefits, potentials, challenges, future research directions and market perspectives of solar energy-driven multigeneration systems, comprehensively. This study also reviews how solar energy systems can be used to hybridize systems for multigeneration purposes. Regardless of using fossil fuel backup sources, these systems are classified as (1) solar only-driven and (2) hybrid solar-driven, in which solar energy is used together with other renewable sources. Reviewing the literature demonstrates numerous ways to build solar energy-driven multigeneration systems by coupling a variety of different cycles and devices. Such systems offer multiple benefits such as enhancing the efficiency, reducing capital and operating costs and carbon dioxide emission. Hybridizing solar with other renewable energies enables continuous operation and dispatchability management. This review shows that for configuration selection and design, different thermodynamics, economic and environmental aspects should be considered. To advance the solar driven multigeneration systems development, further multidisciplinary research on different aspects of such systems is necessary. Particularly, investigations should focus on building different prototypes and on conducting experimental assessments. Also, new incentives and long-term purchase agreements for the products must be established.

14 SOLAR ENERGY↗

DOE OSTI2023

Isotherm modeling and techno-economic analysis of a TSA moving bed process using a tetraamine-appended MOF for NGCC applications

Tetraamine-appended metal-organic frameworks (MOF) are a new family of amine-functionalized MOF materials that show potential for CO 2 capture from flue gas conditions relevant to natural gas combined cycle (NGCC) power plants. This work presents isotherm modeling of the tetraamine-appended MOF Mg 2 (dobpdc)(3-4-3)(dobpdc 4- =4,4'-dioxidobiphenyl-3,3'dicarboxylate;3-4-3=N,N'bis(3-aminopropyl)-1,4-diaminobutane), process modeling, scale up, and a techno-economic optimization of a moving bed Temperature Swing Adsorption (TSA) process for carbon capture using this sorbent. This MOF exhibits a unique two-step CO 2 adsorption profile in three different pressure ranges. Thus, arctangent-based logistic functions and, quadratic and Langmuir models were employed to represent such isotherm behavior. The results of the isotherm model show good fitting vs the experimental data with an RMSE of 0.41. Here, to model the carbon capture process, the isotherm model was embedded into a moving bed contactor model, and this was used to simulate a TSA CO 2 capture cycle and evaluate cost-optimal designs considering flue gas from a -650 MWe NGCC power plant. The capital cost model consists of CAPEX correlations for reactors, compressors, ducting, etc., while the operating costs include steam, water, chemicals, and electricity (following NETL's quality guidelines for energy systems studies). A techno-economic optimization of the capture system was performed by using NETL's Framework for the Optimization and Quantification of Uncertainty and Surrogates tool (FOQUS). Results suggest that a moving bed carbon capture system with tetraamine-appended MOF can be competitive compared to conventional MEA solvent-based capture processes for NGCC plants, when a heat recovery efficiency of at least 40% is achieved, and MOF materials can be produced at a cost below -$9/kg.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2026

Technoeconomic and Life Cycle Analysis of an Integrated Fermentation and Microbial Electrochemical Process for Volatile Fatty Acid Production from Food Waste

Techno-economic analysis (TEA) and life cycle assessment (LCA) were conducted for an integrated system designed for the production of volatile fatty acid (VFA) from food waste. The TEA estimated a production cost of $\$$3.12/kg VFA, and the LCA predicted negative greenhouse gas (GHG) emissions of -0.4 kg CO 2 e/kg VFA, driven primarily by diverting organic waste from landfills and avoiding methane emissions while producing valuable chemical products. Hotspot analysis showed arrested methanogenesis (AM) fermentation as the largest contributor to costs (37%) and environmental burden (47%), driven by high sodium hydroxide (NaOH) consumption. Distillation and microbial electrosynthesis (MES) units were the next-largest environmental contributors (28% and 18%). Major cost drivers also included residuals management (biosolids and wastewater) and the equipment and operating costs for AM, MES, and sonication pretreatment units. Although the new integrated system is environmentally benign, its costs and environmental impacts can be further reduced by integrating alternative energy sources, minimizing chemical and energy inputs through process optimization, and improving efficiency. In conclusion, this work highlighted the viability of waste-derived VFA production and provided a clear, data-driven strategy to accelerate the commercialization of waste valorization technology.

Carboxylic Acid Production↗

DOE OSTI2021

Stochastic Techno Economic Model

The Stochastic Techno-Economic Model or STEM is an analytical tool that estimates the logistics cost of different biomass feedstocks by incorporating uncertainty into the modeling framework. The scope of the model covers multiple stages of the biomass life cycle spanning feedstock harvest, collection, transportation and handling, preprocessing, and storage. The model determines the total logistics cost per dry metric ton ($/DM ton) for biomass and breaks down the costs for important cost categories including ownership related costs such as interest and depreciation, insurance, housing, and taxes as well as operating costs like repairs and maintenance, labor costs, and fuel and lube costs.

Burli, PralhadH↗

DOE OSTI2024

State of the art in low-temperature and high-temperature electrolysis

Water electrolysis is gaining traction in large-scale applications, with production of multiple technologies scaling to hundreds and thousands of megawatts of new electrolyzer capacity annually. Low-temperature electrolysis has dominated the electrolyzer market for decades, but still only represents a small amount of the overall hydrogen market, due to the higher production costs versus hydrogen derived from fossil fuels. Advances are needed in capital cost and efficiency to close the cost gap, especially for energy applications. Similarly, while high-temperature electrolyzers can operate more efficiently, reducing the operating cost, they still need further scale-up and cost reduction to compete in these markets. Understanding the recent advances in each and the priority research directions is important to focus and accelerate innovation, and will be discussed in this article. The different advantages and disadvantages of each of these technologies will also be reviewed; there will likely be applications for each in the overall deployment of renewable hydrogen.

36 MATERIALS SCIENCE↗

DOE OSTI2023

A Technology Roadmap for Advanced Geothermal Well Construction

Recent analysis has shown that by 2050, geothermal energy can supply up to 90 GW of power to the U.S. electrical grid. Reducing the lifecycle cost of geothermal wells is critical to achieving this level of adoption. While time-related costs of drilling remain an important issue, there is also a need to focus on the costs associated with casing and cementing of geothermal wells. This report provides a roadmap of R&D activities needed to reduce the life cycle cost of casing and cementing while improving life-of-well performance. The purpose of the roadmap is to develop priorities for R&D in the areas of (1) high-performance and cost-effective materials for target geothermal well conditions, (2) well construction methods and techniques to reduce construction costs, and (3) methods and techniques to decrease to decrease long-term operating costs. The roadmap sets targets for the next 10-year period and purposely excludes R&D efforts into improved rock reduction. The roadmap was developed by a joint working group of experts from Oak Ridge National Laboratory, Brookhaven National Laboratory, and Sandia National Laboratories as well as 35 experts from industry and academia. Input from a series of information gathering sessions was used to inform and guide the development of the roadmap.

15 GEOTHERMAL ENERGY↗

DOE OSTI2020

Fluorine Limits and Impacts in High-Level Waste Glass Compositions

The impact of elevated fluorine (F) content on Hanford high-level waste (HLW) glasses has not previously been studied in detail. This effort represents the first systematic study to determine what F concentration limits should be used for the design of alkali-borosilicate-based Hanford Waste Treatment and Immobilization Plant (WTP) HLW glasses, and to document the technical basis for that limit. If alkali borosilicate glass made from Hanford HLW can accommodate a large amount of F, the large capital costs for complex sludge washing facilities may be avoided, as would much of the operational costs and negative schedule impacts associated with handling the large volumes of water required to dissolve these salts. In order to determine a limit for F in likely HLW glass compositions, an evaluation was conducted on glasses with F ≤ 0.90 mass% from previous nuclear waste glass studies. The collected dataset contains 239 glasses (232 HLW glasses and 7 LAW glasses) including 109 glasses with 0.9 ≤ F mass% ≤ 2.5, 116 with 2.5 < F mass% ≤ 8.0, and 14 with F mass% ≥ 8 (max. F mass% = 17.42). The collected composition and property data were analyzed to determine the basis for the F tolerance, i.e. the maximum F concentration that can be processed without potential issues. Fluorine volatility, product consistency test (PCT) response, liquidus temperature (T L ), glass melt viscosity, and crystallinity have been investigated. No limits for F concentration can be made based on F volatility, T L , or glass melt viscosity, because the data show that high F in glasses do not indicate, with high probability, being restricted by those property constrains. However, crystallinity and PCT response were used to estimate the F tolerance. The results show that glasses with high F (≥ 0.90 mass%) are more likely to form large fractions of F-containing crystal phases which may increase PCT responses, i.e. decrease the glass durability. Based on the results of crystallinity and PCT data, the F tolerance of 4.5 mass% is estimated. There is no evidence of other glass components, such as calcium oxides and alkali metal oxides have combined impacts with F on the glass properties. Overall, the available high-F glass data is limited, especially in the designed HLW glass composition regions. Future work on formulation and testing of HLW glasses with F ≥ 0.9 mass% will close the data gaps and expand operational flexibility with respect to the fluoride tolerances. Volatility of F from melters and corrosion of materials in contact with glass melts are important for processing of high-F wastes; yet no test data are currently available. It is recommended tests be conducted to address these two potential issues.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2020

Joint Design of Multimodal Transit Networks and Shared Autonomous Mobility Fleets

Providing quality transit service to travelers in low-density areas, particularly travelers without personal vehicles, is a constant challenge for transit agencies. The advent of fully-autonomous vehicles (AVs) and their inclusion in mobility service fleets may allow transit agencies to offer better service and/or reduce their own capital and operational costs. This study focuses on the problem of allocating resources between transit patterns and operating (or subsidizing) shared-use AV mobility services (SAMSs) in a large metropolitan area. To address this question, a joint transit network redesign and SAMS fleet size determination problem (JTNR-SFSDP) is introduced, and a bi-level mathematical programming formulation and solution approach are presented. The upper-level problem modifies a transit network frequency setting problem (TNFSP) formulation via incorporating SAMS fleet size as a decision variable and allowing the removal of bus routes. The lower-level problem consists of a dynamic combined mode choice-traveler assignment problem (DCMC-TAP) formulation. The heuristic solution procedure involves solving the upper-level problem using a nonlinear programming solver and solving the lower-level problem using an iterative agent-based assignment-simulation approach. To illustrate the effectiveness of the modeling framework, this study uses traveler demand from Chicago along with the regions existing multimodal transit network. The computational results indicate significant traveler benefits, in terms of improved average traveler wait times, associated with optimizing the joint design of multimodal transit networks and SAMS fleets compared with the initial transit network design.

bi-level programming↗

DOE OSTI2024

Optimal Managed Fast-Charging Model for Electric Vehicle Fleets with High Utilization and Multiple Charge-Acceptance Curves

A predictive control/scheduling optimization model is proposed for managed charging of an electric vehicle (EV) fleet - under time-of-use energy and demand prices, high vehicle utilization frequency (short dwell times), multiple charge- acceptance curves (configurable charging rates), and flexible vehicle demand. This context is particularly relevant for flight schools (small electric aircraft) or other commercial facilities where an EV fleet performs multiple operating and fast-charging sessions on the same day. The proposed model performs both the operational and charging scheduling of the vehicles, which is not typically done for residential managed charging and significantly increases problem complexity. The problem is formulated as a MILP model and a case study of a small fast-charging station is presented. Results demonstrate a significant reduction in operating cost, mainly from peak shaving during high demand price periods, achieved by coordinating the operation of different vehicles, chargers and charging rates.

ADVANCED PROPULSION SYSTEMS,ENERGY PLANNING, POLIC↗

DOE OSTI2022

Advanced CO 2 Capture Solvent Systems for Dynamic Power Generation

RTI International, in collaboration with Pacific Northwest National Laboratory (PNNL), Carbon Capture Simulation for Industry Impact (CCSI 2 ), Electricity Power Research Institute (EPRI), and West Virginia University (WVU), successfully completed a joint research effort in developing a cost-effective, resilient, load-following advanced CO 2 capture technology for natural gas power plants. The project’s objective was to develop a CO 2 capture process that maximizes the net present value (NPV) of the electricity sale by minimizing the levelized cost of electricity (LCOE) under dynamic plant loads and high renewable penetration environments. The two key innovations developed in this project were the use of (i) advanced water-lean solvents (WLSs) and (ii) process intensification equipment, such as a rotating packed bed (RPB) absorber and dual-stage flash regeneration. The process’s low CO 2 capture cost is realized through WLSs’ low energy required for solvent regeneration, which lowers the operating cost while RPBs intensify the absorption process and reduces the power plant capital cost. A suite of advanced computational and simulation packages was implemented to guide the process design, validate the dynamic response of the capture plant, evaluate system-wide performance, and maximize the power plant’s profit. The project also engaged with power producers and other stakeholders to ensure its technical relevance and techno-economic viability. The development of this highly disruptive CO 2 capture technology could accelerate the industry adoption and thereby lower the greenhouse gas emissions of the U.S. power sector. Deployment of this technology can increase the reliability and decrease the cost of electricity generation in the U.S. by enabling the use of low-carbon fossil fuels to balance fluctuations of renewable energy availability.

03 NATURAL GAS↗

DOE OSTI2024

Potential reductions in fine particulate matter and premature mortality following implementation of air pollution controls on coal-fired power plants in India

Coal-fired power plants (CFPPs) account for > 70% of electricity generation in India, but < 5% of facilities have installed technologies for sulfur dioxide (SO 2 ) and nitrogen oxide (NO X ) removal. Emissions of these pollutants lead to the formation of fine particulate matter (PM 2.5 ) and an increased risk of premature mortality for exposed populations. Here, we use a nested version of the GEOS-Chem global chemical transport model (0.5° × 0.625° resolution) for India to estimate reductions in PM 2.5 concentrations that could have been achieved by implementing existing emission control technologies like flue-gas desulfurization (FGD) and/or selective catalytic reduction (SCR). We quantify the associated burden of disease using the integrated exposure response (IER) and global exposure mortality model (GEMM) functions and compare the costs of premature mortality to those for FGD installation. Model simulations for 2010 suggest installation of FGD would have reduced mean annual PM 2.5 concentrations across India by 8%, compared to 3% with SCR installation, and 11% with both FGD and SCR. A 7–28% reduction in PM 2.5 was simulated for local communities closest to CFPPs (same model grid cell), leading to up to 17% reduction in annual premature mortality. Overall, more than 0.21–0.48 million premature deaths would have been avoided over a 10-year period if FGD had been implemented on all CFPPs, compared to 0.09–0.21 million with SCR and 0.22–0.72 million with both FGD and SCR. Benefits associated with such actions are approximately $\$18.1$–$\$604$ billion USD per year, which is equivalent to ~ 0.44 to 10% of India’s GDP. These results suggest that monetary benefits from avoided premature mortality far outweigh the capital and operational costs of FGD and/or SCR installation of $\$19.5$ billion and/or $\$32.8$ billion per year, respectively. This information is essential because the high costs of installation and operation are often given as reasons for delaying installation and commissioning. Finally, we conclude that policy actions to control air pollution from CFPPs are economically justifiable.

63 RADIATION, THERMAL, AND OTHER ENVIRON. POLLUTAN↗

DOE OSTI2026

Estimating value of information for heliostat washing operations at solar thermal plants

Concentrating solar power (CSP) plants depend on thousands of heliostats whose reflectance declines as dust accumulates. Operators routinely measure reflectance to estimate soiling and, in turn, inform cleaning schedules, but the value of collecting more frequent or more accurate data has not been formally quantified. This study introduces a Monte Carlo discrete event simulation framework that integrates stochastic models of soiling, weather, and measurement error with a dynamic cleaning dispatch policy to estimate annual energy production and operations costs. Applied to two representative central-receiver field configurations, the results show that both the frequency and accuracy of reflectance measurements can meaningfully impact plant performance. In both case studies, reducing measurement intervals yields significant returns, with the energy gains greatly exceeding the cost of more frequent data collection. The simulation framework serves as a decision-support tool for CSP operators, allowing them to input site-specific soiling conditions, measurement accuracy, and survey frequency to evaluate the tradeoffs between data collection cost and energy recovery, and to identify measurement strategies that maximize plant profit.

14 SOLAR ENERGY↗

DOE OSTI2026

Understanding Advanced Vehicle Technology Adoption Potential in Commercial Fleets Across Major Trucking Sectors

Adopting advanced vehicle technologies, such as battery-electric, hybrid, and hydrogen fuel cell vehicles, can be an effective strategy for reducing fleet owners' operating costs. However, different trucking sectors, such as private and for-hire carriers and short- or long-haul operations, may face unique challenges in adopting those vehicle technologies due to their own operational needs and budget constraints. Current studies on fleet-wide vehicle technology projections frequently overlook such sectoral differences and fail to capture variation in adoption potential across sectors. This study addresses this gap by analyzing the disparities in the total cost of ownership (TCO) and payback period (PBP) among a large and heterogeneous sample of fleet owners. It aims to understand the sectoral differences in the long-term potential for adopting advanced vehicle technologies. Utilizing the 2021 US Vehicle Inventory and Use Survey (US VIUS), which offers data on various commercial vehicle sectors, their operational patterns, and current vehicle assets, this research estimates the TCO and PBP for individual trucks over multiple future years. The results reveal variation in the cost-effectiveness of different vehicle technologies across trucking sectors, as well as the potential technology landscape in both the short and long term. The findings from this study can inform policymakers and practitioners on how to prioritize sectors with lower barriers for advanced vehicle technology adoption and support industries that face challenges in switching to advanced vehicles.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2022

Optimization of key energy and performance metrics for drug product manufacturing

During the development of pharmaceutical manufacturing processes, detailed systems-based analysis and optimization are required to control and regulate critical quality attributes within specific ranges, to maintain product performance. As discussions on carbon footprint, sustainability, and energy efficiency are gaining prominence, the development and utilization of these concepts in pharmaceutical manufacturing are seldom reported, which limits the potential of pharmaceutical industry in maximizing key energy and performance metrics. Based on an integrated modeling and techno-economic analysis framework previously developed by the authors, this study presents the development of a combined sensitivity analysis and optimization approach to minimize energy consumption while maintaining product quality and meeting operational constraints in a pharmaceutical process. The optimal input process conditions identified were validated against experiments and good agreement resulted between simulated and experimental data. Here, the results also allowed for a comparison of the capital and operational costs for batch and continuous manufacturing schemes under nominal and optimized conditions. Using the nominal batch operations as a basis, the optimized batch operation results in a 71.7% reduction of energy consumption, whereas the optimized continuous case results in an energy saving of 83.3%.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2020

High-Performance Integrated Window and Façade Solutions for California

The researchers developed a new generation of high-performance façade systems and supporting design and management tools to support industry in meeting California’s greenhouse gas reduction targets, reduce energy consumption, and enable an adaptable response to minimize real-time demands on the electricity grid. The project resulted in five outcomes: (1) The research team developed an R-5, 1-inch thick, triplepane, insulating glass unit with a novel low-conductance aluminum frame. This technology can help significantly reduce residential cooling and heating loads, particularly during the evening. (2) The team developed a prototype of a windowintegrated local ventilation and energy recovery device that provides clean, dry fresh air through the façade with minimal energy requirements. (3) A daylight-redirecting louver system was prototyped to redirect sunlight 15–40 feet from the window. Simulations estimated that lighting energy use could be reduced by 35–54 percent without glare. (4) A control system incorporating physics-based equations and a mathematical solver was prototyped and field tested to demonstrate feasibility. Simulations estimated that total electricity costs could be reduced by 9-28 percent on sunny summer days through adaptive control of operable shading and daylighting components and the thermostat compared to state-of-the-art automatic façade controls in commercial building perimeter zones. (5) Supporting models and tools needed by industry for technology R&D and market transformation activities were validated. Attaining California’s clean energy goals require making a fundamental shift from today’s ad-hoc assemblages of static components to turnkey, intelligent, responsive, integrated building façade systems. These systems offered significant reductions in energy use, peak demand, and operating cost in California.

24 POWER TRANSMISSION AND DISTRIBUTION↗