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DOE OSTI2025

Low-cost buffer storage for solar industrial steam applications

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

14 SOLAR ENERGY↗

DOE OSTI2025

Phenylpropanoid methyl esterase unlocks catabolism of aromatic biological nitrification inhibitors

Microbial nitrification of fertilizers represents is a significant global source of greenhouse gas emissions. This process increases emissions, fosters toxic algal blooms, and raises crop production costs. Some plants naturally release biological nitrification inhibitors to suppress ammonium-oxidizing microbes and reduce nitrification. Engineering nitrification inhibitor production into food and bioenergy crops via synthetic biology offers a promising mitigation strategy, but its success depends on addressing gaps in our understanding of inhibitor degradation in soil. This study begins to fill this gap by identifying a previously unknown microbial pathway for degrading phenylpropanoid methyl esters, a key class of aromatic nitrification inhibitors. Using transcriptomics and high-throughput functional genomics, we discovered genes essential for phenylpropanoid methyl ester degradation. Genetic and biochemical analyses revealed two novel enzymes, including a newly identified phenylpropanoid methyl esterase, that direct phenylpropanoid methyl esters into known metabolic pathways. Importantly, transferring these genes into bacteria capable of metabolizing other phenylpropanoids enabled them to use the methyl esters as a carbon source. This work provides critical insights into microbial nitrification inhibitor degradation, a poorly understood element of the nitrification cycle.

Genetic Engineering↗

DOE OSTI2021

Techno‐economic feasibility analysis of engineered energycane‐based biorefinery co‐producing biodiesel and ethanol

Abstract High feedstock cost and low oil yields per unit of land from temperate oilseed crops limit the growth of commercial‐scale biodiesel production. Recently, highly productive crops, such as sugarcane and energycane, have been engineered to accumulate triacylglycerides (TAGs) that allow the production of far more industrial vegetable oil than previously possible. A proof‐of‐concept suggests that biodiesel production from engineered energycane will be possible. However, before making efforts for scale‐up, it is critical to understand the commercial feasibility and economic competitiveness of this process. This study performs techno‐economic analysis of a unique biorefinery processing energycane to co‐produce biodiesel and ethanol. Comprehensive process simulation models were developed for two scenarios: (i) biodiesel from TAGs and ethanol from fermentation of sugars in juice and (ii) biodiesel from TAGs and ethanol from fermentation of sugars in juice and hydrolysis of carbohydrates in bagasse. Based on the target levels, the analysis was performed for energycane containing 0%, 5%, and 7.7% TAGs (d.b.). The biodiesel from engineered energycane was found economically viable and competitive to soybean biodiesel. Although the capital investment is higher compared to the soybean biodiesel plant, the biodiesel production costs ($0.66–$0.9/L) were lower than soybean biodiesel ($0.91/L). Biorefinery‐scenario‐1 processing energycane containing 7.7% TAG produces biodiesel with profitability (IRR 7.84) slightly lower than soybean biodiesel (IRR 8.3), but yields five times of biodiesel per unit land and is self‐sustainable for energy requirements. The surplus electricity can displace fossil electricity and provide environmental benefits. Monte Carlo simulation indicated that biorefinery is profitable with a 29%–65% probability (NPV > 0) which is largely controlled by feedstock composition and biodiesel market price. It is important to note that energycane can be grown on the marginal rainfed lands in S.E. USA, where soybean would not be viable. Biodiesel from engineered energycane would therefore be complementary to soydiesel in the United States.

09 BIOMASS FUELS↗

NASA NTRS1981

Processing experiments on non-Czochralski silicon sheet

A program is described which supports and promotes the development of processing techniques which may be successfully and cost-effectively applied to low-cost sheets for solar cell fabrication. Results are reported in the areas of process technology, cell design, cell metallization, and production cost simulation.

Pryor, R. A.↗

DOE OSTI2020

Integrated Strategies to Enable Lower-Cost Biofuels

This report summarizes the findings of a qualitative analysis to identify integrated strategies needed for more affordable biofuels. It outlines five key strategies needed to achieve lower fuel production costs in an integrated biorefinery and provides high-level research needs across the biofuel supply chain.

09 BIOMASS FUELS↗

DOE OSTI2021

Cooperative Research and Development Agreement between National Energy Technology Laboratory and Nuionic Technologies (Canada) Inc. [Abstract]

The National Energy Technology Laboratory (NETL) and NuIonic will collaborate in the development and commercial scaling of low-temperature and pressure ammonia synthesis using microwaves. Ammonia is one of the largest used chemicals in the world and is currently manufactured with a high temperature and pressure Haber-Bosch process. The current economical production scale of ammonia using Haber-Bosch (HB) synthesis is too large for the deployable scale of renewables (from 1 to 150 MW). Scaling down a HB process to 170,000 ton/year would increase production costs by a factor of 2-3. This collaboration will facilitate the deployment of a non-HB process for ammonia production that can directly interface and provide storage for intermittent renewable energy.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2022

Transmission Alternatives for California North Coast Offshore Wind, Volume 4: Cost-Benefit Analysis Report

The purpose of this report is to compare the costs and benefits of installing offshore wind power plants with capacities up to 500 megawatts (MW) in the Humboldt Wind Energy Area offshore California, focusing on identifying the costs related to transmission upgrades and possible alternatives such as energy storage. We identify several options that result in lower costs than upgrading transmission to provide full deliverability. Our estimates of the levelized cost of energy (LCOE) assuming full deliverability range from $80/MWh for a 144-MW plant to $73/MWh for a 480-MW plant with a 2030 commercial operation date; however, the additional cost of transmission upgrades increases these values to between $86/MWh and $98/MWh. Based on curtailment and revenue estimates developed using a production cost model, the LCOEs for plant capacities of 144 MW and 168 MW with Energy Only deliverability are lower than the combined cost of energy and transmission upgrades for full deliverability. The addition of a 4-hour, 15-MW battery energy storage system increases revenue for both plant sizes, with the 144 MW + storage scenario producing the most revenue relative to LCOE.

17 WIND ENERGY↗

DOE OSTI2020

Preservation of Microalgae, Lignocellulosic Biomass Blends by Ensiling to Enable Consistent Year-Round Feedstock Supply for Thermochemical Conversion to Biofuels

Seasonal variation in microalgae productivity is a significant barrier to economical production of algae biofuels and chemicals. Summer production can be 3–5 times higher than in the winter resulting in uneven feedstock supplies at algae biorefineries. A portion of the summer production must be preserved for conversion in the winter in order to maintain a biorefinery running at capacity. Ensiling, a preservation process that utilizes lactic acid fermentation to limit microbial degradation, has been demonstrated to successfully stabilize algae biomass (20% solids) and algae-lignocellulosic blends (40% algae-60% lignocellulosic biomass, dry basis) for over 6 months, resulting in fuel production cost savings with fewer emissions. Preservation of algae as blends could be beneficial to biorefineries that utilize thermochemical approaches to fuel production as co-processing of algae and lignocellulosic biomass has been observed to enhance biocrude yield and improve oil quality. This study conducts a resource assessment of biomass residues in the southern United States to identify materials available during peak algae productivity and in sufficient quantity to meet the algae storage needs of an algae biofuel industry. Eight feedstocks met the quantity threshold but only three, distillers grains, haylage, and yard waste, were also available in season. Storage experiments utilizing both freshwater and marine strains of microalgae – Scenedesmus acutus, Chlorella vulgaris, Chlorella zofingiensis, Nannochloropsis gaditana, and Porphyridium purpureum – and yard waste were conducted for 30 days. Storage losses were less than 10% in all but one case, and the pH of all but one blend was reduced to less than 4.7, indicating that yard waste is a suitable feedstock for blending with algae prior to storage. To better understand whether the benefits to conversion realized by processing blends might be affected by storage, elemental analysis and bomb calorimetry of pre- and post-storage algae-yard waste blends were conducted to characterize changes occurring during storage. Storing algae biomass as blends with lignocellulosic biomass could be an effective method of mitigating seasonal variability in algae biomass production while retaining the synergistic effect of co-processing algae blends in thermochemical conversion.

09 BIOMASS FUELS↗

NASA NTRS1985

Current and future engine applications of Gr/PI composites

The application of organic matrix composites to gas turbine engine components has been the subject of numerous government and company funded programs since the 1960's. The possibility of significant weight reductions, performance improvements and lower component costs have made the organic matrix composites extremely attractive to aircraft engine designers. Very little of this potential was incorporated into production engines over the years even though a significant number of components were designed, fabricated and tested. Some of the reasons behind the slow rate of incorporation include the following: (1) criticality; (2) engine operating temperature; (3) small component size; (4) small production volume; (5) high production cost; and (6) interfacing with metal parts.

Cavano, P. J.↗

NASA NTRS2005

Family System of Advanced Charring Ablators for Planetary Exploration Missions

Advanced Ablators Program Objectives: 1) Flight-ready(TRL-6) ablative heat shields for deep-space missions; 2) Diversity of selection from family-system approach; 3) Minimum weight systems with high reliability; 4) Optimized formulations and processing; 5) Fully characterized properties; and 6) Low-cost manufacturing. Definition and integration of candidate lightweight structures. Test and analysis database to support flight-vehicle engineering. Results from production scale-up studies and production-cost analyses.

Congdon, William M.↗

DOE OSTI2023

Dispatch Informed Hydrogen Production

The cost of hydrogen production is projected to decline over the next several decades alongside the widespread deployment of energy constrained generating resources and electrification. While today’s system can utilize fast responding thermal generating assets to answer to changes in demand and energy constrained resource output, the system of tomorrow will more likely rely upon price responsive demands and virtual power plants. Since hydrogen is anticipated to be a primary generating fuel of the future while also providing a large demand base for its production, it is reasonable to evaluate the potential performance for hydrogen-electric coordination issues.

Brewer, John↗

NASA NTRS1999

Application of Reconfigurable Avionics for the Bantam Launch Vehicle

The modern market is placing increasing pressure on launch costs. This is particularly true for small university science payloads, where the cost of the experiment itself is relatively low, and the launch frequency is potentially very high. It is the stated goal of the Bantam Program to dramatically reduce the costs of launching this class of payloads. This is a goal that will require that the avionics not only be reduced in production costs, but also in maintenance and operation costs, because the Bantam vehicle is envisioned as a reusable launch system. However, the costs of avionics is a relatively small fraction of the overall cost of launching a payload, and a simple reduction in the avionics costs will not immediately realize the necessary gains. Instead, to reduce the total system launch costs, it is also necessary to improve avionics performance. Only by reducing weight, volume, and power, while enhancing computational capability can the avionics be used to address the system-level cost reduction requirements. The National Aeronautics and Space Administration is currently pursuing technology development tasks, in order to support the Bantam requirements. One technology task is to develop a low-cost, high-performance reconfigurable avionics core unit. In addition to providing low cost and high performance, the use of reconfigurability will be used to explore the options of accommodating multiple launch configurations, and addressing such areas as redundancy management, single-event upset immunity, and low maintenance. This paper will address how emerging developments in reconfigurable avionics can be used to meet these challenges.

Wallace, Shawn↗

DOE OSTI2024

The hydrogen economy can reduce costs of climate change mitigation by up to 22%

In response to the urgent need to mitigate climate change via net-zero targets, many nations are renewing their interest in clean hydrogen as a net-zero energy carrier. Although clean hydrogen can be directly used in various sectors for deep decarbonization, the relatively low energy density and high production costs have raised doubts as to whether clean hydrogen development is worthwhile. Here, we improve on the GCAM model by including a more comprehensive and detailed representation of clean hydrogen production, distribution, and demand in all sectors of the global economy and simulate 25 scenarios to explore the cost-effectiveness of integrating clean hydrogen into the global energy system. We show that, due to costly technical obstacles, clean hydrogen can only provide 3%–9% of the 2050 global final energy use. Nevertheless, clean hydrogen deployment can reduce overall energy decarbonization costs by 15%–22%, mainly via powering “hard-to-electrify” sectors that would otherwise face high decarbonization expenditures. Our work provides practical references for cost-effective clean hydrogen planning.

08 HYDROGEN↗

DOE OSTI2024

Cost effectiveness of preemptive school closures to mitigate pandemic influenza outbreaks of differing severity in the United States

Background: Nonpharmaceutical interventions (NPIs) may be considered as part of national pandemic preparedness as a first line defense against influenza pandemics. Preemptive school closures (PSCs) are an NPI reserved for severe pandemics and are highly effective in slowing influenza spread but have unintended consequences. Methods: We used results of simulated PSC impacts for a 1957-like pandemic (i.e., an influenza pandemic with a high case fatality rate) to estimate population health impacts and quantify PSC costs at the national level using three geographical scales, four closure durations, and three dismissal decision criteria (i.e., the number of cases detected to trigger closures). At the Chicago regional level, we also used results from simulated 1957-like, 1968-like, and 2009-like pandemics. Our net estimated economic impacts resulted from educational productivity costs plus loss of income associated with providing childcare during closures after netting out productivity gains from averted influenza illness based on the number of cases and deaths for each mitigation strategy. Results: For the 1957-like, national-level model, estimated net PSC costs and averted cases ranged from $\$7.5$ billion (2016 USD) averting 14.5 million cases for two-week, community-level closures to $\$97$ billion averting 47 million cases for 12-week, county-level closures. We found that 2-week school-by-school PSCs had the lowest cost per discounted life-year gained compared to county-wide or school district–wide closures for both the national and Chicago regional-level analyses of all pandemics. The feasibility of spatiotemporally precise triggering is questionable for most locales. Theoretically, this would be an attractive early option to allow more time to assess transmissibility and severity of a novel influenza virus. However, we also found that county-wide PSCs of longer durations (8 to 12 weeks) could avert the most cases (31–47 million) and deaths (105,000–156,000); however, the net cost would be considerably greater ($\$88$-$\$103$ billion net of averted illness costs) for the national-level, 1957-like analysis. Conclusions: We found that the net costs per death averted ($\$180,000$-$\$4.2$ million) for the national-level, 1957-like scenarios were generally less than the range of values recommended for regulatory impact analyses ($\$4.6$ to 15.0 million). This suggests that the economic benefits of national-level PSC strategies could exceed the costs of these interventions during future pandemics with highly transmissible strains with high case fatality rates. In contrast, the PSC outcomes for regional models of the 1968-like and 2009-like pandemics were less likely to be cost effective; more targeted and shorter duration closures would be recommended for these pandemics.

60 APPLIED LIFE SCIENCES↗

NASA NTRS1978

High performance, high density hydrocarbon fuels

The fuels were selected from 77 original candidates on the basis of estimated merit index and cost effectiveness. The ten candidates consisted of 3 pure compounds, 4 chemical plant streams and 3 refinery streams. Critical physical and chemical properties of the candidate fuels were measured including heat of combustion, density, and viscosity as a function of temperature, freezing points, vapor pressure, boiling point, thermal stability. The best all around candidate was found to be a chemical plant olefin stream rich in dicyclopentadiene. This material has a high merit index and is available at low cost. Possible problem areas were identified as low temperature flow properties and thermal stability. An economic analysis was carried out to determine the production costs of top candidates. The chemical plant and refinery streams were all less than 44 cent/kg while the pure compounds were greater than 44 cent/kg. A literature survey was conducted on the state of the art of advanced hydrocarbon fuel technology as applied to high energy propellents. Several areas for additional research were identified.

Frankenfeld, J. W.↗

DOE OSTI2023

Natural fiber-derived gas diffusion layers for high performance, lower cost PEM fuel cells

The gas diffusion layer (GDL) is a critical component of proton exchange membrane fuel cells. GDL manufacture is dominated by the use of polyacrylonitrile (PAN) fibers, resulting in high production costs. Those costs contribute to the high cost of fuel cell stacks. Thus, reducing GDL manufacturing costs without sacrificing performance, should help reduce the overall cost of the fuel cell stack. Using inexpensive, natural fiber-based papers and fabric as substrates, here we examine the inherent performance these materials as GDLs, and the improvements enabled by the addition of a microporous layer, gas-phase hydrophobic treatment, and densification. The resulting GDLs achieve equivalent performance the commercial baseline GDL and demonstrate the potential of lower cost GDLs.

25 ENERGY STORAGE↗

DOE OSTI2023

Defining a compact dry cooler design to reduce LCOE contribution in a CSP facility

Concentrating solar power (CSP), when coupled with a supercritical carbon dioxide (sCO 2 ) power cycle and sensible heat storage, presents a renewable and clean alternative for utility-scale power generation. However, in order to be competitive in the current and future markets, CSP facilities must limit their levelized cost of electricity (LCOE) by minimizing capital costs and reducing operating costs over the lifetime of the plant. Targeting this goal, this study investigates the LCOE impact of the power cycle pre-cooler. This study considers a compact dry cooler with micro-channel technology on the CO 2 side and formed fin geometry on the air side, using directly-coupled centrifugal fans and a transition duct to improve air distribution across the fins as well as protect the fins from contaminants which may cause blockage, soiling, fouling, and damage. In an effort to better understand the dry cooler impact on LCOE, a sensitivity study was conducted using various combinations of end-to-end approach temperatures, air-side pressure drop values, CO 2 -side pressure drop values, fan types, cooler turndown control schemes, cooler module sizes, and design-point ambient temperatures. Furthemore, off-design cycle performance data was calculated for each dry cooler design using NPSS simulation software; cycle performance data were then input to System Advisor Model (SAM) along with the associated capital costs for LCOE prediction of a 100 MW system over a 30 year plant lifetime. Results of this study show the LCOE is most sensitive to air-side performance, followed by heat transfer effectiveness and capital cost. It was found that a power cycle with a mid- to high-performance dry cooler will produce the most competitive power-production costs. Designing at the extreme ends for approach temperature (or effectiveness), design-point ambient temperature, and compactness (footprint) produce higher LCOE values; mid-range values for these parameters balance performance, operating costs, and associated capital cost to optimize LCOE.

14 SOLAR ENERGY↗

NASA NTRS1992

Magnetic bearings: A key technology for advanced rocket engines?

For several years, active magnetic bearings (AMB) have demonstrated their capabilities in many fields, from industrial compressors to control wheel suspension for spacecraft. Despite this broad area, no significant advance has been observed in rocket propulsion turbomachinery, where size, efficiency, and cost are crucial design criteria. To this respect, Societe Europeenne de Propulsion (SEP) had funded for several years significant efforts to delineate the advantages and drawbacks of AMB applied to rocket propulsion systems. Objectives of this work, relative technological basis, and improvements are described and illustrated by advanced turbopump layouts. Profiting from the advantages of compact design in cryogenic environments, the designs show considerable improvements in engine life, performances, and reliability. However, these conclusions should still be tempered by high recurrent costs, mainly due to the space-rated electronics. Development work focused on this point and evolution of electronics show the possibility to decrease production costs by an order of magnitude.

Girault, J. PH.↗